Piedmont Chapter 14, Vibration Institute Meeting December 5, 2008 - - PowerPoint PPT Presentation

Piedmont Chapter 14, Vibration Institute Meeting December 5, 2008 Midlands Technical College West Columbia, SC

Introduction and Timing

Jeremiah JB Bacon C.L.S. PetroLiance, LLC Presentation should take about 1 hour.

What is Contamination?

ANY FOREIGN MATERIAL THAT ADVERSILY AFFECTS THE OPERATION OF YOUR EQUIPMENT. Wrong Oil Chemical

According to Vickers...

The ROOT Cause of UP TO 80 %

• f Hydraulic Failures

Are caused by CONTAMINATION

It Effects All Forms of Equipment....

SKF Quote SKF Quote

1

Under special operating conditions, bearings can attain bearings can attain a much longer life a much longer life than predicted by normal life calculation methods. These special conditions are when the rolling surfaces are rolling surfaces are effectively separated by a effectively separated by a lubricant film lubricant film and when the when the surface damage caused by surface damage caused by contaminants is limited contaminants is limited. In fact, under ideal conditions, it under ideal conditions, it is possible to speak of infinite is possible to speak of infinite life. life.

Vickers Quote Vickers Quote

2

Proper selection and placement

• f contamination control devices

in a system to attain the targeted cleanliness eliminates eliminates (the root cause of) up to 80% (the root cause of) up to 80%

• f hydraulic system failures.
• f hydraulic system failures.

1 SKF Bearing Maintenance Handbook 2 Vickers Guide to Systemic Contamination Control

Why Is Cleanliness So Important?

Typical bearing application

Lubricant

h

Load Zone Pressures Can Be Greater Than 100,000 PSI Oil Thickness is 0.1 to 3 Microns

Contamination Destroys Equipment

3 Micron Particle

Abrasive Wear is the most common type of wear.

The Life of a Typical Hydraulic Pump

The life of a typical hydraulic pump can be predicted based on the amount of contamination that passes through the pump during its life.

50 gpm Pump

ISO 21/18 ISO 14/11 1750 lbs/Yr

50 lbs/Yr

2 Yr. Pump Life >14 Yr.Pump Life

What Size Particles Are We Talking About?

What size particle can you see? Table Salt 100 µ Human Hair 70µ Lower Limit of site ~ 40 µ Flour 25 µ White Blood Cell 25 µ Red Blood Cell 8 µ

What Size Part ic le Will Cause A Problem ?

15 µ 1µ

1 Micron = .000039 INCH

Contamination in a Hydraulic Piston Pump

What does it do?

The abrasive wear from the particulate damages the swashplate, piston shoe, piston, cylinder wall, cylinder block and valve plate. Particulate can clog the piston shoe opening.

Contamination in a Servo Valve

What does it do? The valve spools can have 1 micron clearances. Particulate will damage the spool and cause actuation problems due to internal leakage.

Abrasive Particulate Effects In Gears

Abrasive particles cause seals to erode and bearings to wear prematurely.

Shortens Rebuild/Replace Intervals Increases Oil Consumption from Leaks Increases Maintenance Costs

Water Is Harmful Too!

Water is the SECOND Most Destructive Contaminant!!!

Changes Oil Viscosity Rust & Corrosion Hydrogen Embrittlement Acids Pitting Causes Foaming Sludge & Sediment

What Water Contamination Can Do to a Bearing

The Problem: Water causes Hydrogen Embrittlement of the metal and premature fatigue. Hydrogen Embrittlement Spalling from Embrittlement

Water, What is ok?

ACCEPTABLE LEVELS: Typically below 250 PPM.

It is normal to see levels of 150 to 250 PPM or 0.015 0.025 % in SC You can see water at around 900 PPM

If We Can t See it, How Do We Know It s There?

Heat Vibration Equipment Failures Sludge Cloudy Oil Residue Sticking Valves All ending up in

Premature Failures which equates to Production Loss & Money

If We Can t See it, How Do We Know It s There?

Use Oil Analysis with Particle Counts.

ISO Particle Counts

It is important to understand what ISO Particle Counts are. What is it?

Quantitative analysis of oil to determine the distribution of particle sizes in the oil

Why?

Try to keep oil at a cleanliness level to prevent wear and failures. Targeted to remove clearance size particles out

• f the oil

Filter Patch: ISO Rating of 20/17/15

Range or code

Greater Than 4 micron Greater Than 6 micron Greater Than 14 micron

We have to have some way of knowing it is there.... Oil Analysis ISO Particle Counts

Cleanliness Code 20/17/15 Filter Pad PC Scale:1Division =14 m

ISO Code Range Counts

ISO Cleanliness Code 20/19/16

ISO Cleanliness Comparison

OEM Recommended ISO Codes

What is acceptable? There are definite standards set by each company. Here are some good examples.

How Do We Control Contamination?

To control contamination, you ll need to assess just how contaminated your systems are. Use Oil Analysis with Particle Counts to determine current system cleanliness levels. Identify the most sensitive components on each system. Set system cleanliness goals base on those sensitive components identified. Document ISO cleanliness code and water content results for each system.

How Do We Control Contamination?

Once you have established how contaminated your systems are, and what cleanliness level your system should be to maximize life;

Initiate a directive to work toward those goals by putting best practices in place. Once your cleanliness goals are met, develop a maintenance plan to keep systems clean.

How Do We Control Contamination?

You will take care of most of the contaminants if you will do 7 Things;

SEAL THE SYSTEMS KEEP SYSTEM EXTERIORS CLEAN USE ADEQUATE SYSTEM BREATHERS STORE AND DISPENSE OIL PROPERLY ROUTINELY USE OFF-LINE FILTRATION INSPECT SYSTEMS AND MONITOR FOR OIL CONTAMINANTS REGULARLY

FIRST: SEAL THE SYSTEMS

You want your systems to get clean oil and keep it clean. All of these can let in contamination:

Lack of a vent plug or cap left off Poor breather Poor seals on a cylinder Dirty dispensing equipment During maintenance equipment is exposed Access plates and hatches Open piping Open containers

Seal Your Systems

Do not leave units open to the atmosphere.

130º F OK 164º F Oil Life Cut By 1/2 Keep System Exteriors Clean

Dirt is a great insulator.

Use Adequate Breathers

Typical breather caps

• nly protect from

large things. You need to be concerned with small particles.

Use breathers that are 5 microns or better. Help the breather by getting it out of the contamination, raise it!

Use Adequate Breathers

Mounting breathers several inches above the unit will greatly increase their effectiveness. Use desiccant breathers to fight condensation.

Use Adequate Breathers

Apply the right kind of breather to the application

Desic c ant Breat her Filt er Breat her Sealed Breat her

Seal The Systems and Your Containers

Drum Open to the Elements Dip Stick Left Open to the Elements

Prevent Contamination At Each Handling Step

Remember, new oil is usually not clean enough to meet sensitive equipment cleanliness requirements. Filter it in!

Proper Container Storage & Handling

Water Surrounding the Bung will enter the drum through normal breathing . This

• ccurs to sealed drums too!

Effects of Water on Sealed Drums

TILT DRUMS PLASTIC COVERS

Proper Storage and Handling

If it must be outside

Proper Storage and Handling

Dispensing containers should be sealed too.

Mixing Different Oils is Contamination Too!

Containers should be sealable. Containers should be utilized for single family lubricants to avoid cross contamination. Should be tagged and color coded to minimize lube cross contamination.

Tag Lubrication Points and Dispensing Equipment

Tag the equipment to help ensure that the right lubricant is in the right place.

Use Routine Filtration

Filter carts should be used to clean oil in systems and storage containers routinely. The easier it is to use the better. Filter oil as it goes into a system. Be careful filtering multi-grade

• products. Most filters designed

to clean oil can strip VI Improvers

• ut.

For Multi-grades use filters that are 10 micron and up. Flush between product changes.

Storage Containers

Use particulate breathers on bulk tanks, totes and drums. Utilize pumps for each product family. Using a single pump to pump multiple product families will ensure cross contamination.

Drum with desiccant breather and adapter kit.

Use System Adapters Where Possible

Drum Adapters and Quick Connects allow for quick, easy connections for your filter cart. Install Quick Connects on Systems to allow for quick connections which makes it easy to use the filter cart. Use a Filter Cart with a bypass system and Quick Connect Couplings

Bypass allows for use as system evacuation pump or

• il transfer

A Little About Filtration

Filter Rating Terminology

Nominal Rating - Rates size of pores in filter (5 micron nominal) Absolute - Gives Largest opening in media Beta Ratio/%Efficiency - How many times through the filter before all particles of certain size are removed

Filter Sizes

Conventional System - 10 to 25 micron Absolute N/C and Servo Systems - 3 to 5 micron Absolute

Know Your Filters

The Multipass Filter Performance Test, ISO 4572, is the most recognized standard for rating the ability of a filter to efficiently control contamination. The results of this test are reported as the ratio

• f the number of particles greater than a

designated size upstream of the filter to the number of particles greater than the same size downstream of the filter. This rating is the Beta Ratio.

Know Your Filters

Know Your Filters

Example on the previous slide above: (Number of Particles Downstream ÷ Number

• f Particles Upstream) X 100 = % Efficiency

(100 ÷ 200) = .5 x 100 = 50% Efficient (199 ÷ 200) = .995 X 100 = 99.5% Efficient

Seal the Systems, Look out for...

Hose and pump trash;

Cap the end of hoses and pumps

Bad environments may require positive pressure (air padding). Cap grease guns. Clean grease fittings before use.

External Site Glasses On Pumps Can Help Detect Problems

Provide Contamination Control Training

Increases employee awareness and efficiency.

Reduce Your Costs Extend Lubricant and Equipment Life Through Contamination Control