extending equipment uptime and life through contamination ... · what is contamination control?...
TRANSCRIPT
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2018 GFX
San Diego, California
June 2018
Brian Redpath
Contamination Control
Extending Equipment Uptime and Life through Contamination Control
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Agenda
• Background on Contamination Control
• Contamination Control Basics • Dirt hurts & what’s a micron?
• Oil Oxidation
• Oil Sampling
• Particle Counting/ISO
• Kidney Looping
• Filtration
• CC Guides
• Success Stories
• Questions
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Caterpillar: Confidential Green
What is Contamination Control?
Contamination Control, or CC, is a “Proactive
Product Quality Based Initiative” aimed at
improved reliability through cleanliness design
and practices related to the fluids, parts, and
systems of Caterpillar equipment.
Reactive or Proactive?
Contamination Control
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Contamination Control – Plants Background/History
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Contamination Control...
Awareness
Just a few grains of dust – that light film on the funnel used to
fill the crankcase – the almost negligible amount that might
find its way past an improperly serviced crankcase breather.
Could such small quantities possibly have any appreciable
effect on the life of the engine? The answer is a very positive
YES!
In 1949, we had a basic
understanding of how
contaminants in oil affected
product reliability and durability.
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Even in the very early days of
diesel technology, we had a basic
understanding of how
contaminants in fuel affected
product reliability and durability.
Cover of the 1931 Operators’ Guide
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1931 Operators’ Guide CARE OF FUEL SYSTEM
The first paragraph on system
care from the 1931 operators
manual states that 90% of
Diesel troubles are due to dirt
or water in the fuel.
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Contamination Control – Plants Background/History
• Began Early to Mid 90’s
• Track-Type Tractor Division − Initiated with first time pass test rate
− Cleaned up manufacturing & assembly processes
− Developed commissioning (kidney looping) procedures
• Spread to machine & component plants worldwide
• Specifications & test methods developed − By 1999 all facilities focused on cleanliness
− Assembly reported 100% “Roll-Off” testing
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Contamination Control – Plants SUCCESS Formula
CLEAN Facilities
+ CLEAN Components
+ CLEAN Processes
+ CLEAN Fluids
= CLEAN Products
=> Satisfied Dealers & Customers!
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Contamination Control Implementation
• Contamination Control Basics
− Training
− Awareness
− Housekeeping
− Culture Change
• Implement Contamination Control:
− Clean Facilities
− Clean Components
− Clean Processes
− Clean Fluids
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Contamination Control Training…
Classroom
&
Hands On
Make it Initial & Ongoing
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Contamination Control Awareness…
Use these funnels to
put oil into your
machine or engine?
Would You…
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Contamination Control Awareness…
Would You…
Add this oil to your
machine or engine?
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Contamination Control Awareness…
Would You…
Use these bearings in
your equipment?
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Contamination Control Awareness…
Would You…
Install this oil filter on
your engine or machine
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Contamination Control Housekeeping…
Professional Image
Perception of Quality
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Contamination Control Culture Change…
Is this your current floor
cleaning method?
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Caterpillar: Confidential Green
Culture Change Albert Einstein
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Contamination Control Paradigm – Raise the Bar
• Current: Dirty greasy mechanic working in dirty greasy cluttered congested poorly lit shop.
• Now / Future: Technicians are technically competent professionals working in a clean organized well lit workshop diligently using robust processes.
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Contamination Control Culture Changed…
Alumbrera/Finning
NW Argentina
Nickel Rim
Canada
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Contamination Control Culture Changed…
Spence
Chile
Phu Bia Mining
Laos
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Caterpillar: Confidential Green
Culture Changed…
…Being Brilliant In The Basics
Contagem, Brazil
Asansol, India
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Caterpillar: Confidential Green
Culture Changed…
…Being Brilliant In The Basics
Lima, Peru
Dhaka, Bangladesh
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Caterpillar: Confidential Green
What Is Contamination?
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Caterpillar: Confidential Green
Mohs Mineral Brinell
10 Diamond
9 Corundum 667
8 Topaz 304
7 Quartz 178
6 Feldspar 147
5 Apatite 137
4 Fluorspar 64
3 Calcite 53
2 Gypsum 12
1 Talc 3
Iron Dust 5 Mohs
Bearing Metal Particles 6 - 7 Mohs
Silica Dust 7- 8 Mohs
Diamond Dust 10 Mohs
Copper Oxides 3.5 - 4 Mohs
Aluminum Oxide 9 Mohs
Fingernail 1 Mohs
Quarry Dust (limestone) 5 - 9 Mohs
How Tough Are Particulates?
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Caterpillar: Confidential Green
• Abrasion: Hard contaminates will cut
metals, creating new contaminates
• Fatigue: Contaminates will also fatigue
metals, especially at edges and wear
points, again creating new
contaminates
• Multiplication: It is estimated that each
particle creates 8 – 10 more particles
through abrasion and fatigue
Ref: Bosch Rexroth
The Multiplication of Contaminates
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Caterpillar: Confidential Green
Effects of Contamination on Oil Oxidation Rate
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Caterpillar: Confidential Green
62.8°C = 145°F
Ref: Arrhenius’s Law, Backe, STLE
Above 65°C (150°F) increasing the
temperature at which lubricant is stored by
10°C (18°F) doubles the oxidation rate, which
cuts the usable life of the oil in half.
Heat
Chemical – Oxidation Root Causes
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Caterpillar: Confidential Green
• Built-in
− Manufacturing & Assembly
• New Fluids
− New Fluid may NOT be Clean
• Introduced Contamination
− Pitted Rods
− Broken or Improper Breathers
− Worn Seals
• Service and Maintenance
− Open Systems
− Replacement Parts
− Work Practices
Contamination Sources
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Caterpillar: Confidential Green
The single greatest opportunity
for increasing component life
and lowering operating costs is
to effectively manage fluid
cleanliness.
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Caterpillar: Confidential Green
“Dirt You Can See”
• 40 Microns & Larger
• Weld Splatter
• Shot Blast
• Paint Chips
• Machine Chips
“Dirt You Can’t See”
• Under 40 Microns
• Wear Metals
• Silica
• Rocks
• Coal
• Dirt
Ref: Caterpillar
Two Types of Contamination
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Caterpillar: Confidential Green
1 Millionth of a Meter
1 Thousandth of a Millimeter
• 100 microns (µm) - grain of table salt
• 80 microns (µm) - diameter of a human hair
What is a Micron?
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Caterpillar: Confidential Green Ref: Caterpillar
Size Comparison Human Hair to a Micron
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Caterpillar: Confidential Green
MICRONS (µm)
Hydraulic
System Clearances
3
15 40
80
Smallest
Visible
to the Eye Human Hair
1 Fuel
Particles You Can’t See Are Harmful!
Ref: Caterpillar
Size Comparison
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Caterpillar: Confidential Green
• Cylinder Drift
• Jerky Steering
• Slower Performance
• Erratic Operation
• Shorter Service Intervals
• Higher Operating Costs
• Lost Productivity
Operating Effects of Contamination
“75-85% of hydraulic system failures are caused by contamination -- Hydraulics & Pneumatics, June 1998
-- Equipment Today, August 1997
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Caterpillar: Confidential Green
• Sampling Device Clean?
• Sample Hoses Clean?
• Dirty Towel Used - Probably?
• Working Conditions
− Work Bench Not Clean
Clutter
• Doors Open
• Sample Labeling Completed?
• Result!
• Bad Data In
• Bad Data Out!
• Poor Decisions
Oil Sampling The Right Way – NOT!
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Caterpillar: Confidential Green
• Two Methods
– Spectrographic Analysis
– Particle Counting
Microscopic (ISO 4407)
Automatic Optical (ISO 11500)
Automatic Pore Blockage (BS 3406)
“You Cannot Control What You Cannot Measure”
Ref: Caterpillar
How To Measure Contamination Particle Counting
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Caterpillar: Confidential Green
21/19/16
20/17/15
18/16/13
24/21/18
16/13/10
Ref: Caterpillar
Understanding Fluid Cleanliness How do we measure fluid contamination?
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Caterpillar: Confidential Green
1 Thousandth of a Liter
• 1 mL – This Bottle of Oil
• 330 mL – Bottle of Beer
• 960,000 mL – This AD60 Fuel Tank
Ref: Caterpillar
What is Milliliter (mL)?
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Caterpillar: Confidential Green
(International Organization for Standardization)
Ref: ISO, Caterpillar
ISO 4406 Cleanliness language
• Cleanliness Language ISO 4406
• Method For Coding The Level Of
Contamination By Solid Particles
• Groups by size and quantity
• Expresses Amount of Contaminant
in one mL of Fluid
• What does ISO 21/19/16 mean?
>4µm / >6µm / >14µm
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Caterpillar: Confidential Green Ref: ISO, Caterpillar
ISO 4406 Code ranges / Scale numbers
ISO 4406: 1999 (E) - ISO Contamination Code
Number of Particles per 1 ml
Scale
Number
More Than Up To and
Including
28 1,300,000 2,500,000
27 640,000 1,300,000
26 320,000 640,000
25 160,000 320,000
24 80,000 160,000
23 40,000 80,000
22 20,000 40,000
21 10,000 20,000
20 5,000 10,000
19 2,500 5,000
18 1,300 2,500
17 640 1,300
16 320 640
15 160 320
Chart cont…
Scale
Number
More Than Up To and
Including
14 80 160
13 40 80
12 20 40
11 10 20
10 5 10
9 2.5 5
8 1.3 2.5
7 0.64 1.3
6 0.32 0.64
5 0.16 0.32
4 0.08 0.16
3 0.04 0.08
2 0.02 0.04
1 0.01 0.02
0 0.00 0.01
Very
Dirty
Dirty
Clean
Clean
Very
Clean
Ultra
Clean
NOTE: Particle
count doubles
at each level
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Caterpillar: Confidential Green
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
2500000
1300000
640000
320000
160000
80000
40000
20000
10000
5000
2500
1300
640
320
160
80
40
20
10
5
2.5
1.3
0.64
0.32
0.16
0.08
0.04
0.02
0.01
0.00
≥4 ≥ 6 ≥ 14
Example:
Equal to or larger than 4µm = 11,343
Equal to or larger than 6µm = 4,257
Equal to or larger than 14µm = 548
ISO Code = / / 21 19 16 4µm / 6µm / 14µm
21
19
16
Ref: ISO, Caterpillar
Structure of ISO-Code: • Number of solid particles per
Milliliter of fluid
• Equal to or larger than these
specified sizes: 4µm / 6µm / 14µm
ISO 4406 Example
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Caterpillar: Confidential Green
Cart circulates oil through the
machine system / component
to filter out contaminants.
Kidney-loop Filtration
Proven to increase oil and
component life and reduce costs
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Caterpillar: Confidential Green
18,000hrs Total - 4000hr Oil Change
- w/Kidney Loop
- 50x photo
13,000hrs Total - 1200hr Oil Change
- No Kidney Loop
- 50x photo
Kidney-loop Filtration - Results
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Caterpillar: Confidential Green
18K hrs, 500 hr Kidney Loop, 6um Filtration
Kidney-loop Filtration - Wheel bearing
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Caterpillar: Confidential Green
• Spin-on / Cartridge
− Cellulose
− Synthetic
• Screens
• Magnets
• Centrifuges
Flow
Filter Types
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Caterpillar: Confidential Green
Cellulose
• Advantages
− Physically robust material
No backing screen needed
More media in same volume
− Inexpensive
• Disadvantages − Higher pressure drop for a given
efficiency
− Hard to make really fine element
Synthetic
• Advantages
− Lower initial pressure drop
Higher efficiency available
− Higher dirt retention capacity
per unit area
• Disadvantages
− Physically weaker material
Backing screen typically required
Less media in given volume
Less dirt retention for a given size
of filter
− More expensive
Filter Media Advantages / Disadvantages
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Caterpillar: Confidential Green Machinery Lubrication (10/2012)
Cellulose (Wood Pulp) Filter Media
Fiberglass Filter Media
Filter Media Visual differences
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Caterpillar: Confidential Green
Screens
• Advantages − Very low pressure drop
Long life
− Large dirt holding capacity
− Single pore size Blocks ALL contamination
larger than pore size
• Disadvantages − Expensive in small micron sizes
− Typically, not very good filter
− Limited real world dirt retention, cannot build cake
− Difficult to clean
Magnets
• Advantages
− Trap magnetic (iron) debris in
system
− Cleanable
• Disadvantages
− System can wash debris off easily
− Can be expensive
− Much debris not magnetic
Screens and Magnets Advantages / disadvantages
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CAT® Filter Ratings Efficiency vs micron sizes
The differences are basically the filter media used
Standard Advanced UHE
Air Filter - Engine Initial Efficiency Rating minimum 99.6% (SAE J726)
Not Available Not Applicable (99.9% efficient)
Breathers 50 µm absolute 10 -50 µm absolute < 10 µm absolute
Engine Oil Filters 30 -40 µm absolute 15 -30 µm absolute < 15 µm absolute
Fuel Filter >10 µm absolute 4 -10 µm absolute < 4 µm absolute
Fuel/Water Separator >20 µm absolute 10 -20 µabsolute < 10 µm absolute
Hydraulic Filter 27-40 µm absolute 10 -27 µabsolute < 10 µm absolute
Power Train Filter 27-40 µm absolute 10 -27 µm absolute < 10 µm absolute
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• Nominal Rated
− Media captures the majority of particulate at (60 - 98%) the rated pore size.
− Often stated as the micron size without an efficiency specification
− No industry standard
• Absolute Rated
− Largest particle that will pass through media or largest pore size
− No standard test to determine the value of the pore opening
− Efficiency typically rated at or higher than 98.6% at the micron size.
− Better way to understand effectiveness of the filter compared to Nominal
• Beta Rated
− Best method and most common
− Obtained from multipass testing – ISO 16889
− Number of particles greater that X microns upstream of the filter versus the
number of particles greater than X down stream of the filter.
Expressed as ((beta-1/beta) x 100
Filter Ratings Industry
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• Beta 10µ = 2
(Nominal Rating)
• Beta 22µ = 75
(Absolute Rating)
• Minimum Burst
800 PSI
5516 kPa
Filter Efficiency and Beta Ratings
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Nominal Absolute
Upstream Upstream Downstream Downstream
B10 = 2
2 1
Filter stops 1
Beta Ratio = 2/1 = 2
B22 = 75
75 1
Filter stops 74
Beta Ratio = 75/1 = 75
50% 98.67%
Filter Efficiency and Beta Ratings
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% Efficiency ß (Beta) % Efficiency ß (Beta)
100 Infinity 100.00 Infinity
90 10.00 99.9999 1,000,000
80 5.00 99.999 100,000
70 3.33 99.99 10,000
60 2.50 99.90 1,000
50 2.00 99.80 500
40 1.67 99.75 400
30 1.43 99.67 300
20 1.25 99.50 200
10 1.11 99.00 100
0 1.00 98.67 75
0.8%
Filter Efficiency and Beta Ratings
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• Most diesel engine clearances 2-22 µm
− Size most likely to damage engine parts
• Standard filtration lube 40 µm
• Finer filtration reduces abrasive engine
wear
− Wear reduced 50% with 30 µm filter
− Wear reduced 70% with 15 µm filter
Many CAT® machines systems / component
have a higher efficiency filter option
Correlating Lube Oil Filtration w/ Engine Wear
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Machinery life Extension Table
Oil ISO Cleanliness Target ISO
20/17 19/16 18/15 17/14 16/13 15/12 14/11 13/10 12/9 11/8 10/7 ISO 5 3 7 3.5 9 4 >10 5 >10 6 >10 7.5 >10 9 >10 >10 >10 >10 >10 >10 >10 >10 26/224 2.5 4.5 3 6 3.5 6.5 4 7.5 5 8.5 6.5 10 7 >10 9 >10 >10 >10 >10 >10 >10
4 2.5 5 3 7 3.5 9 4 >10 5 >10 6 >10 7 >10 9 >10 >10 >10 >10 >10 >10 25/2225/22
3 2 3.5 2.5 4.5 3 5 3.5 6.5 4 8 5 9 6 10 7.5 10 9 >10 >10 >10 >10 3 2 4 2.5 6 3 7 4 9 5 >10 6 >10 7 >10 8 >10 10 >10 >10 >10 >10 24/2124/21
2.5 1.5 3 2 4 2.5 5 3 6.5 4 7.5 5 8.5 6 9.5 7 >10 8 >10 >10 >10 >102 1.5 3 2 4 2.5 5 3 7 3.5 9 4 >10 5 >10 6 >10 8 >10 9 >10 >10 23/2023/20
1.7 1.3 2.3 1.5 3 2 3.7 2.5 5 3 6 3.5 7 4 8 5 10 6.5 >10 8.5 >10 101.6 1.3 2 1.5 3 2 4 2.5 5 3 7 3.5 8 4 >10 5 >10 6 >10 7 >10 >10 22/1922/19
1.4 1.1 1.8 1.3 2.3 1.7 3 2 3.5 2.5 4.5 3 5.5 3.5 7 4 8 5 10 5.5 >10 8.51.3 1.2 1.5 1.5 2 1.7 3 2 4 2.5 5 3 7 3.5 9 4 >10 5 >10 7 >10 10 21/1621/18
1.2 1.1 1.5 1.3 1.8 1.4 2.2 1.6 3 2 3.5 2.5 4.5 3 5 3.5 7 4 9 5.5 10 81.3 1.2 1.6 1.5 2 1.7 3 2 4 2.5 5 3 7 4 9 5 >10 7 >10 9 20/1720/17
1.2 1 1.5 1.3 1.8 1.4 2.3 1.7 3 2 3.5 2.5 5 3 6 4 8 5.5 10 71.3 1.2 1.5 1.5 2 1.7 3 2 4 2.5 5 3 7 4 9 6 >10 8 19/1619/16
1.2 1.1 1.5 1.3 1.8 1.5 2.2 1.7 3 2 3.5 2.5 5 3.5 7 4.5 9 61.3 1.2 1.6 1.5 2 1.7 3 2 4 2.5 5 3 7 4.5 >10 6 18/1518/15
1.2 1.1 1.5 1.3 1.8 1.5 2.3 1.7 3 2 3.5 2.5 5.5 3.7 8 51.3 1.2 1.6 1.5 2 1.7 3 2 4 2.5 6 3 8 5 17/1417/14
1.2 1.1 1.5 1.3 1.8 1.5 2.2 1.7 3 2 4 2.5 6 3.51.3 1.2 1.6 1.5 2 1.7 3 2 4 3.5 6 4 16/1316/13
Hydraulics & Rolling 1.2 1.1 1.5 1.3 1.8 1.5 2.3 1.8 3.7 3 4.5 3.5Diesel Engine Elem Bearings 1.3 1.2 1.6 1.5 2 1.7 3 2 4 2.5 15/1215/12
Joumal Bearings Gear Boxes & 1.2 1.1 1.5 1.4 1.8 1.5 2.3 1.8 3 2.2Turbo machinery Others 1.3 1.3 1.6 1.6 2 1.8 3 2 14/1114/11
1.3 1.2 1.6 1.4 1.9 1.5 2.3 1.81.4 1.2 1.8 1.5 2.5 1.8 13/10
1.2 1.1 1.6 1.3 2 1.6
Diesel engine oil at 20/17. If filtered clean and kept at 16/13 will promote an engine "Life Extension"
of 3 times nomal life. Gear box oil at 20/17. If filtered clean and kept at 13/10 will promote a gear
box "Life Extension" of 3 times nomal life.
Ref: Noria Corp
Yo
ur C
urre
nt C
lea
nlin
es
s P
artic
le C
ou
nt
Ref: Noria
Machinery Life Extension Table
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Example:
121 LPM (32 GPM) pump
working 8 hours / day
for 200 days
Contamination Control Example Dirt through a pump
How much difference will cleaning oil from
ISO -/21/18 to ISO -/18/15 to ISO -/16/13
really make?
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ISO -/21/18
ISO -/18/15
ISO -/16/13
630 lb / yr
79 lb / yr 20 lb / yr
Amount of “Dirt” Flowing
Amount of “Dirt” in Oil Through Pump in One Year
Contamination Control Example Dirt through a pump
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Half an aspirin!
160 mg
Visualizing Contamination
How much “dirt” can be present in a 208 liter (55 gallon) drum
of oil and still meet ISO -/16/13?
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Result:
Today’s Fluid Systems Are More Sensitive To Contamination
• Hydraulics
• Transmissions / Final drives
• Fuel systems
• Engines
Variable Displacement Pump*
Slipper-Port Plate Clearances from 1-25µm
Why Contamination Control? Advances in technology
Industry Trends:
• Electro-hydraulics
• Tighter Clearances
• Higher System Pressures
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CR 200 Injector
Why Contamination Control? Industry trends
FIE manufacturers’
Cleanliness Requirement
At
High Pressure Pump Inlet
ISO 12/9/6
FIE Manufacturer’s
Cleanliness Requirement
At
High Pressure Pump Inlet
ISO 12/9/6
Fuel Systems
• Common Rail Fuel System
• Higher Pressures: 30,000+ PSI (2000 bar)
• Tighter injector clearances
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CC GUIDES
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Implement Contamination Control
Procedures in the Work Shop
Cat® Dealer Contamination Control Compliance Guide Rev05
PEBJ0002-05 / PSBJ0002-05
English / Español
18 Sections
122 Standards
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14 Sections, 97 Standards
• Training
• Equipment Wash Facility
• Shop Attributes
• Shop Practices
• Remove And Install
• Tool Storage
• Parts Storage
• CRC or Reman Parts Return
• Hydraulic Hose Building / Rebuilding
• Bulk And Portable Fluid Storage
• Fuel Considerations
• Lube Truck
• Field Service Vehicle
• Fluid Analysis
Contamination Control Caterpillar Customer Compliance Guide
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Compliance Guide Process
Caps & plugs for hoses used
•Good – plastic or metal plugs and caps
•Acceptable - plastic taped over hose ends
•Not recommended - no caps used, rags stuffed
in holes or tape used to close open oil lines,
ports, etc.
Good = 8
Acceptable = 4 Not recommended = 0
Medium to high volume wash equipment
to remove heavy deposits of mud
• Good - machines are washed with high volume
water source such as a fire hose
• Acceptable - machines are washed with
medium pressure washer
• Not recommended - machines are washed with
“home owner” type pressure washer or low
pressure source such as a garden hoseGood = 8
Acceptable = 4 Not recommended = 0
Calculator Work Sheet
Standards
Contamination Control Caterpillar Customer Compliance Guide
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Start With Clean Tanks…
Bulk Tank Fluid Maintenance – Sampling
Enables fluid & tank condition
Fisher Scientific
(630) 259-4515
www.fishersci.com
USA Ph (800) 766-7000
Fax # (800) 926-1166
Petroleum Bacon Bomb Sampler
ASTM D 4057-95
14-209-D
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Customer spent $6,800 on a Track Loader
Fuel System Repair
Bulk Tank Sampling…
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Discuss the need for
clean fluid deliveries
A teaspoon of dirt in a fuel tank
can ruin an injector in 8 hours.
Supplier Requirements Must be part of the formal CC program
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Success
Stories
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793C Wheel Groups/Differentials
• Oil Drain Periods Extended
• Customer Savings =
• Year 1 (2001) = $110,000
• Over 3 years > $325,000
• Operating Cost Reduction - Wheel Groups Only
• $5.99/hour cost reduction
• 100 793Cs x $5.99/hr x 7000 hrs/yr
• Customer Savings = $ 4.2M/year
Batu Hijau Newmont - Indonesia
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Yanacocha Copper Mine Peru
• 52 OHTs
16 - 777D
27 - 785C
9 - 793C
• Availability increased > 4%
• Wheel Group/Diff life increased 50%
• Hydraulics/ Transmission life increased 30%
• Customer estimated his savings @ $800K
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La Herradura Gold Mine Mexico
2.23
1.120.94
0.75
8592
1235011491
13580
0
0.5
1
1.5
2
2.5
FD 1999 FD 2000 FD 2001 FD 2002
Average
$/H
r.
0
2000
4000
6000
8000
10000
12000
14000
16000
Hrs
.
0.29
0.14
13580
8592
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
Dif. 1999 Dif. 2002
Component
$/H
r.
0
2000
4000
6000
8000
10000
12000
14000
16000
Hrs
.
0.97
0.75
13034
12816
0.00
0.20
0.40
0.60
0.80
1.00
1.20
T 1999 T 2002
Transmissions
$/H
r.
12700
12750
12800
12850
12900
12950
13000
13050
13100
Hrs
.
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Customer Implementation - Results
Benchmarking Site Goals
• Lower Warranty Cost
• Lower Owning & Operating Cost
• Extend Oil Life
• Extend Component Life
All Goals were achieved – All Sites
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If optimum component life is
not achieved is this a
premature failure?
Closing Thought?