maximize equipment life with lubricant condition management
TRANSCRIPT
Organized by:
Optimize Equipment Life with Lubricant Condition Management
Jarrod Potteiger
Education Services Manager
Des-Case Corporation
© 2012 Des-Case Corp.
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Des-Case Confidential
© 2010 Des-Case Corp. Slide XXXX
What is Precision Lubrication?
Using better or more expensive lubricants is not precision
lubrication.
Increasing lubrication PM frequencies is not precision lubrication.
Precision lubrication requires a holistic approach including lubricant
specifications, education, contamination control, PM optimization,
proper storage and handling, condition monitoring, etc.
Doing lubrication the right way is almost always easier than doing it
the wrong way.
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What Causes Machines to Fail?
Ref: MIT, E. Rabinowicz
70% of loss of machine life is dueto loss of surface material
Loss of Usefulness
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What Causes Surface Degradation?
Ref: MIT, E. Rabinowicz
Surface Degradation
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What Causes Machines to Wear?
Ref: NRCC, STLE
Primary Wear Mechanisms
82% of mechanical
wear is caused by
particle contamination
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The value of Contamination Control
Before After
Standard OEM
filtration
Standard OEM/
3 um bypass
filtration
ISO Code (6/14 um) 19/16 15/12
Mean Time to rebuild 14,500 hrs 52,000 hrs
Annual Rebuild Cost $151,000 $42,000
Savings/year $109,000
Upfront Cost $900
Ongoing Cost $200/year
• CAT 980F (3406 diesel engine)• Installed a 6 um cellulose depth media
filter in by-pass after the full flow filter, taking 10% of the oil flow
• Monitored oil analysis to determine engine health and fluid cleanliness
Results:
3.5x life extension
Annualized savings/year estimated to be approximately $100K
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Des-Case Confidential
Auto Manufacturing Case Study
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Principle Strategy• Education
• Contamination Control
• Storage and Handling
• PM Optimization
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Automotive Press Case Study
0
10000
20000
30000
40000
50000
60000
70000
80000
1 2 3 4 5 6 7
Par
ticl
e C
on
cen
trat
ion
(P
arti
cle
s/m
L) =
/>4
mic
ron
Sample Number
93%-97% reduction in particle
contamination
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Automotive Press Case Study con’t
A Line B Line C Line D Line E Line
3 yearaverage
2012 YTD
Do
wn
tim
e (M
inu
tes)
Downtime54% reduction in
downtime
6 7 8 9 10
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What is contamination?
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Dirt & other Particles
Water Air Wear Debris
FuelOther
LubricantsCoolant Detergents
and other Chemicals
Anything that doesn’t belong in the oil
Damage Caused by Contaminant Type
Direct Machine Wear
Damage to Lubricant
Indirect Damage
Particle Contamination
•Abrasion•Erosion•Fatigue•Valve Stiction (silt
lock)
•Oxidation•Particle Scrubbing•Viscosity Increase
•Varnish / Deposits•Corrosive attack• Increased aeration
Moisture Contamination
•Corrosion•Cavitation erosion
•Oxidation•Hydrolysis•Water Washing•Viscosity Increase
•Varnish / Deposits•Corrosive attack• Increase Aeration•Exacerbates all
wear mechanisms due to loss of film strength
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Common Effects of Contamination
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How Big is a Micron?
0.001” = 25.4 microns 1” = 25,400 microns
Human Hair
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How New Oil Gets Dirty
Refinery / Blend Plant
National Distribution
Regional DistributionLocal Distributor
By the time oil arrives at your site, it is already too dirty for most
equipment.
Poor storage and transfer methods add to the contamination.
Dirty accessories compound the problem.
Not using the proper breathers allow more contaminants to enter
the oil.
DeliveryISO 19/17/15
StorageISO 20/18/16
DispensingISO 21/19/17
In ServiceISO 22/20/18
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Contamination Control Strategy
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Set Targets Measure ResultsTake Action
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Machine Type Particle Level Target Moisture Level Target
Hydraulics1500-
2500psi
With servo valves 15/13/11 125 ppm
With proportional valves
16/14/12 150 ppm
Variable volumepiston pump
17/15/12 150 ppm
With cartridge valves or fixed piston pump
17/16/13 150 ppm
With vane pump 18/16/14 150 ppm
Gearbox 19/16/13 300 ppm
Paper Machine 18/14/11 200 ppm
Steam Turbine 18/14/11 100 ppm
Pumps 17/14/12 150 ppm
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How Clean / Dry should oil be?
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Contamination Control Methods
Contamination Exclusion• Filter new oil
• Use good quality breathers
• Use sound application methods
• Upgrade seals
• Use hydraulic cylinder rod boots
• Utilize non-invasive inspection / sampling methods
• Use sound flushing practice for new or recently serviced equipment
• Practice good parts management
Contamination Removal• Upgrade system filters
• Permanent off-line filtration
• Portable off-line filtration
• Vacuum dehydration
• Centrifugal separators
• Water absorbing filters
• Coalescing filters
• Air stripping
• Electrostatic / BCA filters
• System flushing
Studies show it costs about 10 times more to remove contamination than it does to exclude it.
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Particle Effects on Component Life
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Tested Particle Count24/20/13
New Target Count17/15/12
Anticipated Life Extension = 4X
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Particle and Moisture Exclusion
Head space managementQuality sealsFilter new oilPassive shieldingGood parts storageUse quality oil transfer equipment
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Headspace Management
Controlling the condition of the air in the headspace above the oil is one of the most cost effective ways to prevent contamination.
Methods for headspace management
Desiccant breathersHybrid breatherMechanical filtersNitrogen purgeConditioned air purgeExpansion chambers
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How Do We Rate Filter Performance?
The Beta Rating is the ratio of particles, at a given size, upstream of the filter Vs. downstream of the filter.
© 2010 Des-Case Corp.
100 particles in (5 microns or greater)1 particle out (5 microns or greater)
= β5 ≥ 100
Efficiency = (β-1) x 100% (100-1) x 100% = 99%β 100
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Filter Media Type / Design
Micro-glass Fibers Pleated Cellulose Fibers
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Portable Offline Filtration Units
Portable offline filtration is one of the most useful tools in your lubrication arsenal.
Uses for filter carts
Offline DecontaminationFlushing during commissioningOil transfersDispensing to top up containersFlushing hoses / other equipmentPower flushing small systemsPeriodic decontamination
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Portable Filtration Effectiveness
New oil Unfiltered in-service oil
Filtered in-service oil, 180 mins 12 um
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Portable Filtration Effectiveness Cont’d
Before Filtration100x Magnification
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Portable Filtration Effectiveness Cont’d
After Filtration
100x Magnification
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Water Removal – Vacuum Dehydrator
Removes all free and emulsified water and up to 90% of dissolved water by lowering pressure and boiling the water at a safe temperature for the oil.
Very effective for removing all water from the oil. Poorly designed units can be difficult to maintain.
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Water Removal – Polymer Absorbent Filters
Removes free and emulsified water using a polymer absorbent.
Very cost effective for removing water from small sumps where larger, more expensive options are not feasible.
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Problem:A large refinery was experiencing pump failures at a rate of 351/year
Solution:Deployed new lubricant storage and handling, equipment tagging and operator lead reliability
Results:
• Pump failures dropped from 351 to 276 in 1 year• Estimated annualized savings of $935,000• Reduction in lubricant purchases of $50,000• 5-year Net Present Value (NPV) savings of $3M at
an Internal Rate of Return (IRR) of 196%
The Value of Precision Lubrication – Storage & Handling
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Essential Components for World-Class Storage and Dispensation Systems
Separate fluid handling for each product
Filtration….Filtration….FiltrationQuality tank breathers
Product tagging to preventcross-contamination
Climate control
Quality assurance procedures includingnew oil testing
Oil Storage and Dispensing
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