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

Transcription

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

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

3 What is Contamination? ANY FOREIGN MATERIAL THAT ADVERSILY AFFECTS THE OPERATION OF YOUR EQUIPMENT. Wrong Oil Chemical

4 According to Vickers... The ROOT Cause of UP TO 80 % of Hydraulic Failures Are caused by CONTAMINATION

5 It Effects All Forms of Equipment... SKF Quote 1 Under special operating conditions, bearings can attain a much longer life than predicted by normal life calculation methods. These special conditions are when the rolling surfaces are effectively separated by a lubricant film and when the surface damage caused by contaminants is limited. In fact, under ideal conditions, it is possible to speak of infinite life. Vickers Quote 2 Proper selection and placement of contamination control devices in a system to attain the targeted cleanliness eliminates (the root cause of) up to 80% of hydraulic system failures. 1 SKF Bearing Maintenance Handbook 2 Vickers Guide to Systemic Contamination Control

6 Why Is Cleanliness So Important? Typical bearing application Oil Thickness is 0.1 to 3 Microns h Lubricant Load Zone Pressures Can Be Greater Than 100,000 PSI

7 Contamination Destroys Equipment 3 Micron Particle Abrasive Wear is the most common type of wear.

8 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/ lbs/yr 50 lbs/yr 2 Yr. Pump Life >14 Yr.Pump Life

9 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 15 µ 1µ What Size Part ic le Will Cause A Problem? 1 Micron = INCH

10 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.

11 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.

12 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

13 Water Is Harmful Too! Water is the SECOND Most Destructive Contaminant!!! Changes Oil Viscosity Rust & Corrosion Hydrogen Embrittlement Acids Pitting Causes Foaming Sludge & Sediment

14 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

15 Water, What is ok? ACCEPTABLE LEVELS: Typically below 250 PPM. It is normal to see levels of 150 to 250 PPM or % in SC You can see water at around 900 PPM

16 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

17 If We Can t See it, How Do We Know It s There? Use Oil Analysis with Particle Counts.

18 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 of the oil particles out

19 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

20 ISO Code Range Counts

21 ISO Cleanliness Code 20/19/16

22 ISO Cleanliness Comparison

23 OEM Recommended ISO Codes What is acceptable? There are definite standards set by each company. Here are some good examples.

24 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.

25 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.

26 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

27 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

28 Seal Your Systems Do not leave units open to the atmosphere.

29 Keep System Exteriors Clean Dirt is a great insulator. 130º F OK 164º F Oil Life Cut By 1/2

30 Use Adequate Breathers Typical breather caps only 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!

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

32 Use Adequate Breathers Apply the right kind of breather to the application Sealed Breat her Desic c ant Breat her Filt er Breat her

33 Seal The Systems and Your Containers Drum Open to the Elements Dip Stick Left Open to the Elements

34 Prevent Contamination At Each Handling Step Remember, new oil is usually not clean enough to meet sensitive equipment cleanliness requirements. Filter it in!

35 Proper Container Storage & Handling Water Surrounding the Bung will enter the drum through normal breathing. This occurs to sealed drums too!

36 Effects of Water on Sealed Drums

37 Proper Storage and Handling If it must be outside TILT DRUMS PLASTIC COVERS

38 Proper Storage and Handling Dispensing containers should be sealed too.

39 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.

40 Tag Lubrication Points and Dispensing Equipment Tag the equipment to help ensure that the right lubricant is in the right place.

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

42 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.

43 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 oil transfer

44 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

45 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 of 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.

46 Know Your Filters

47 Know Your Filters Example on the previous slide above: (Number of Particles Downstream Number of Particles Upstream) X 100 = % Efficiency ( ) =.5 x 100 = 50% Efficient ( ) =.995 X 100 = 99.5% Efficient

48 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.

49 External Site Glasses On Pumps Can Help Detect Problems

50 Provide Contamination Control Training Increases employee awareness and efficiency.

51 Reduce Your Costs Extend Lubricant and Equipment Life Through Contamination Control