ocm current

Presentation on

At Site / On Board Oil Analysis

by

Deepak Sharma

Director

Kittiwake Proactive Technologies P.Ltd.,

405, Ansals Majestic Tower 17,

Block G1,Vikaspuri Community centre,

N.Delhi-110018www,kittiwake-india.com

www.dantechengineers.com

http://www.dantechengineers.com/

• On-site testing & analysis solutions for fuel, oil & water condition monitoring

• Oil Sampling and Field Testing

• Laboratory & Field Wear Debris Analysis

• On-line Oil & Wear Debris Analysis

• Water Quality Field Testing

• Acoustic Emission CMS - Holroyd

• CEM systems - Procal

• Laboratory Logistics

Monitoring Innovation

Oil Condition Monitoring - Two different objectivesTwo different objectives

Lubricating AnalysisLubricating Analysis Monitoring the lubricantMonitoring the lubricant Condition of the lubricantCondition of the lubricant Viscosity, TAN, TBN, Water content, InsolublesViscosity, TAN, TBN, Water content, Insolubles

Wear debris AnalysisWear debris Analysis

Monitoring and analysis of wear particlesMonitoring and analysis of wear particles Condition of the machineCondition of the machine

Quantity of wear particles in ppmQuantity of wear particles in ppm

Monitoring the MachineMonitoring the Machine

Oil cleanliness as per ISO and NAS StandardsOil cleanliness as per ISO and NAS Standards

Lube Oil Condition Monitoring

Routine oil testing in a laboratory though important has following limitations –

Testing is usually done quarterly or higher intervals.

Results usually take about a week to ten days to reach the operator.

Unable to capture the timing and magnitude of increase in wear elements

Lube Oil Condition Monitoring

Lube Oil is the only component which “touches” all the moving parts of an Equipment.

• Any deviation in the status of components or operating parameters will affect the lubricant parameters and its contents.

• Sudden variation in lube oil parameters could reveal an impending failure.

• Immediate corrective measures could save major downtime, provided………………………

…….Lube Oil Condition is monitored in real time.

Where: Field or Laboratory

All tests and testing started life in the laboratory

Methods and Standardisation: ASTM/IP/ISO….DIN/GB/Gost etc.

Methodology unsuitable for field use

Instruments developed specifically for field use

Qualitative or Quantitative

What parameters can you test in the field

Viscosity

Water

TBN

Insolubles

TAN

Particles

Ferrous Wear Debris

On Site Oil Condition Monitoring - Benefits

On Site Oil Condition

Monitoring

Oil Condition known when

needed

Helps take timely

maintenance Actions

Helps in diagnosing problems quickly

Helps quick integration with other

RCM techniques

1. Saves Unscheduled Down time

2. Allows scheduling maintenance (Move from Emergency status to Normal )

3. Generates more amount of oil analysis data for diagnostic or development purposes.

Fuel and Lube oil Lab.OiOIL lOi At site Lube oil monitoring

Lube Oil Test Kit - engines

Viscotube

M

A combination of qualitative and quantitative measurements D

Digi Insoluble (Optional)Range: 0-2.5% diesel engine lubesTest time: 2 min

OR

MiniOTC


HV


OTC – Oil Test Centre

A Central Common console

with:

TBN,Water,TAN,Viscosity,

Insoluble Cells and reagents

In NATO approved box

In industrial strolly


•For Testing – Viscosity,TBN,Water,Insolubles, Oil Cleanliness,Compatibility,Density,

Salt water,Pour point

•On site testing will produce cost savings

simple, rugged, reliable equipmentResults are obtained quickly and accurately

Oil Test Cabinet

Oil Analyser

The Oil Analyser is configured to comply with ASTM-D74181 Standard Practice and the included software comes pre-loaded with the complete range of JOAP* and ASTM approved methods used for the condition monitoring of in-service lubricants, including:

•Sulphate by-products•Oxidation•Nitration•Phosphate Anti-wear

In addition, the following parameters are also calculated using ASTM defined test practices:

•Soot•Water•Antioxidant depletion•Glycol contamination

As further methods are agreed upon within the ASTM, these can be easily added to the in-built library within the Oil Analyser

•FTIR spectrometer with sampling system•Portable computer with software•Carrying case and accessories

Requires only 3 m sample and is easy to use and provides the user accurate and reproducible results

The Oil Analyser is comprised of three main components:

V

How to test and what results mean

Viscosity

Defined as cSt @ 40°C & 100°C

Controls oil film thickness and flow rate

Increased by oxidation and insolubles

Decreased by shear down & fuel dilution

Mineral, synthetic

Change-out limits:

-20% < New > +10 to 30% (Diesel), -10% < New > +25 to 50% (GT/Hyd)

M HV

26.22

25.32

24.36

23.44

22

22.5

23

23.5

24

24.5

25

25.5

26

26.5

0% 1% 2% 3%

Viscosity cSt @ 40C


Water

Always present in oils some systems can run dry

Contamination from condensation, blow-by, leakage and adulteration

Causes corrosion, cavitation,

additive instability

Mineral and synthetic lubes & hydraulics

Change-out limits0.3 - 0.5% (Diesels)

1000ppm (GT/Hyd) M D

0

500

1000

1500

2000

2500

Field Lab


TBNDepletion depends on oil consumption, fuel sulphur and load

Problematic on low oil consumption engines

Low TBN results in acid corrosion and fouling

Diesel only

Change-out limit 50 - 60% of new oil TBN

M D1 Dm

0

10

20

30

40

50

Paired Tests Field vs Lab

Exxon LabExxon OTCShell LabShell OTC


Insolubles

Ash, oxidation products, wear metals, asphaltines, carbon

Ingressed contaminants, dust etc.

Causes increase in viscosity, wear, fouling of ring pack and under piston crown. Blockage of aviation lube filters.

Mineral and synthetic oils

Change-out limits:

typically 1.5 - 2.0 % w/w

(Diesels)

M 00.5

11.5

22.5

3Solids %w/w

Lab IP 316


Figure 6 - Difference in TAN Measurements (NOAP minus OTC)

-0.4

-0.2

0

0.2

0.4

0.6

0.8

1

1 5 9

13 17 21 25 29 33 37 41 45 49 53 57 61 65 69 73 77 81 85 89 93 97

101

105

109

113

117

121

125

129

133

137

141

Oil Sample

Diff

eren

ce in

Res

ults

for

TAN

mg

.KO

H

Difference

Typical reject limits at 0.5 and 1.0 TAN

Change-out limit + 1 (alert), + 2 (change) (GT / Hyd)

TAN A function of additive chemistry and oxidation Monitor by trend Measured by neutralisation / colour titration M

0

0.5

1

1.5

2

2.5

3

Paired Tests Field vs Lab

MJOII

M1661

M254

M1661

EZ OIL CLEAN CHECK

Portable Oil Cleanliness IndicatorA patented technology from IHS, Israel

A simple, cost effective and yet accurate way of

knowing the ISO and NAS cleanliness levels of

lubrication and hydraulic oil

Features: Pore block technology – flow decay On line or bottle sample test Suitable for the field use Water or air bubbles in the sample do not affect Is equally effective for the dark oils Totally mechanical Small and lightweight Low and high pressure models ( 40psi – 3000psi ) Upto 80 deg C and 150 cSt NAS 11 – NAS 5 ISO 22/20/17 – 16/14/10

EZ OIL CLEAN CHECK


Particles in Hydraulics

Particle counting and analysis usually carried in a laboratory

Expensive and complicated

Few low cost field solutions

Hydraulic Particles Test Kit

Draws sample through 8micron filter

Comparison made with quality coloured reference chart

Good field indication of pending problems


Ferrous Wear Debris Analex fdMplus

Measures ferrous wear metal debris in oil and grease without preparation of the sample

Indicates wear on ferrous metal components

Measures all debris including particles >5 micron

Laboratory based ICP/AA does not measure these size particles

Gives results in ppm

Used extensively for trendingFirst time available for field testing

fdMplus - Principle of Operation

When the sample of oil containing ferromagnetic debris is placed in the sensor the balance between the coils is altered.

The resulting out-of-balance signal is amplified, filtered, and displayed as Total ppm as it is measuring the total mass of ferromagnetic debris in the sample irrespective of particle size.

fdMplus - Operation

The sample is placed using suitable supplied adaptor in:50ml Bottle

10ml Syringe

5ml Syringe

5ml Test Tube

4ml Grease Pots

The touch screen gives precise instructions

Each sample is uniquely numbered and dated

Data is stored by equipment type

Can be viewed in tabular or graphical form

Download to computer via RS232

lubMONITOR software

1. KITTIWAKE lubMONITOR®: Lube oil monitoring for OTC and miniOTC2. ANALEX feMONITOR®: Ferrous monitoring for fdM or fdM+ 3. KITTIWAKE lubMONITOR® + ANALEX feMONITOR® : Combined software for both Lube Oil and Ferrous monitoring.

Features: Easy to view and set up hierarchical format : Plant–

Area – Machines. For OTC, miniOTCfdM+ and fdM data management, monitoring trends, alarm setting of various measured

parameters, graphical representation of the measured parameters for diagnosis (comparison of upto 2 machines )

Tabular as well as graphical reports

Email the reports directly through the software via Outlook Express.

Ways of transferring the data: Transfer the data from OTC, fdM+ and fdM. From file Manual input

Very useful to compare various parameters from the similar machines for diagnosis.

Why On Line Sensors?

Demand for a significant reduction in manpower

Need for real time data– Laboratory testing takes time & often

inconvenient

– Off Line testing demands manpower & time

Integrated part of RCM programmeReliability Centred Maintenance

What will the sensors monitor?

Five Most Relevant Parameters:

Oil Quality: TBN/TAN/Insolubles/Glycol/Water

in oil quality units on a scale from 0-100

Moisture: Up to saturation point

0-100% RH

Viscosity: For lube and hydraulic oils

Ferrous Debris Sensor: All particles irrespective of size

0- 2000 microns

Particle Content Sensor : - Total particles/ minute

Ferrous Particles – 40 - 2000 microns

Non ferrous particles >130micron

Oil Quality

Oil Quality: TBN/TAN/Insolubles/Glycol/Water– Oil degrades with time for a variety of reasons

– Sensor permanently installed in oil flow

– Constantly monitoring quality and degradation

– Output as Oil Quality units (OQC) 0-100 scale

Target Applications

– Critical lubricated applications subject to rapid failure or high change out costs.

– Medium & high speed marine diesels, gearboxes, bearings, turbines, automobiles, off-road machines, compressors etc.

ANALEXrs Moisture Sensor

Measures oil’s % RH – Relative Humidity – resulting from dissolved water

Uses combination of thin film capacitance sensors and smart algorithms

Oil molecules penetrate a polymer coated sensor and the dielectric property is measured

Total Ferrous Wear Debris Monitoring

Detection of Metal Debris Senses changes in magnetic flux as

ferrous particles enter a magnetic field and losses when non ferrous conductive particles enter

Technology Measures >5 micron (unlike ICP) No radioactive source (unlike XRF) Linear response Independent of oil flow speed

Outputs CAN interface 4-20 mA, RS232, RS485 Radio link with built-in web server

Metallic Wear Debris Detection & Counting

Online Wear Debris Sensor

Designed to measure individual ferrous and non ferrous particles

Total no. of particles per minute and mass.

Targeted at applications where metal surfaces shed debris which is taken away by the oil flow

Turbines, Bearings & Gearboxes

Online Wear Debris Sensor

Online gear box /turbine monitoring system

Particle Content Sensor

Oil Condition Sensor

Moisture Sensor

Pump for circulating the

Oil through sensors

On-Line Sensor Suite

Sensor Suite - Models Available

Standard Options– Non-heated -Most Industrial use

– Heated – Low Temperature applications

Specifications– Measured Parameters

Ferrous debris: 0-2000ppm

Relative Humidity: 0-100%

Temperature: 0-100°C

Oil Condition: 0-100 OilQ– Power 15-30 VDC– 10Bar (145psi)– Temperature: -20 to 80°C oil / -25-65°C Ambient– IP65

Interface Options– Analogue -4-20mA (4 loops)– Digital

• RS232• RS485• Wireless LAN 802.11b• CAN

•We are specialists in Acoustic Emission Condition Monitoring for harsh industrial and marine environments.

•Spun off from Rolls Royce in 1991, led by Trevor Holroyd.

Initial Machinery Health Checker (MHC) unit launched in 1993.

Continuous product evolution over the past 18 years.• Acquired by Kittiwake in April 2011.

• Basically, Vibration Analysis made simple!

Acoustic Emission - Kittiwake Holroyd

Condition Monitoring

Measuring the health of rotating equipment. Structural crack propagation. .

Non-Destructive Testing (NDT)

In-situ active crack propagation cracks in materials & structures.

Process control

Mixing, stirring & crystallisation. Valve operation.

Uses of AE

pro

pagatio

n

sensor

conditioning

A crystal in the sensor responds to the wave as itpasses underneath it

Am

plit

ud

eFrequency

Backg

round n

oise

source

s

Friction & Impact Sources

0 100 kHz 200 kHz 300 kHz

MHC sensor detection frequency(100 kHz)

Att

enua

tion

Basic principles of AE

Source

Stop the Chain Reaction of Wear

Dynamic Clearance Tooth to side plate: 0.5 - 5 µm Tooth tip to case: 0.5 - 5 µm

Dynamic clearances example - Gear Pump

Cut in Track

Why remove fine ferrous debris?

Removal of particulate from 20 micron down to less than a micron is absolutely key to arrest the wear process

The contaminant becomes lodged in dynamic clearances or it is propelled around the system by the fluid it creates more wear and therefore more contaminant, this is a ‘chain reaction of wear’

In any given system the hardest and sharpest debris is often the FERROUS material – it is therefore absolutely key to stall the chain reaction of wear by removing ferrous debris of all sizes – particularly that of a similar size to the dynamic clearances

In fact, research has shown that much of the wear debris is never created if the ferrous debris is removed early on…

MAGNOM™ technology reduces wear and therefore failures!

Magnom™ - Features of the PatentedTechnology

The Magnom™ comprises of a series of annular magnets and innovatively designed formed steel plates.

The steel plates focus the magnet flux strength

A

Flow

Magnom™ - Working

Magnom™ is a field effect fluid conditioner that: -

Delivers MAJOR COST SAVINGS (Thousands of £ per annum) and offering major environmental benefits: -

• By reducing the chain reaction of wear – Reducing the repair or replacement of system critical parts i.e. pumps, valves, etc

• Extend existing filter life, if placed upstream• Reducing system Downtime • Increasing fluid and additive life• Reducing disposal requirements – Filters & Fluid • Enhancing overall system performance

Note!• Benefits vary dependent on application – Specified

Separately

Magnom™ – The Benefits

Magnom™ - Oil Environments Only Units – Small to Medium Systems 1

Mini Module - 3/8” BSP

Small pressure line system

Max Working Pressure = 14 Bar

Contaminant Capacity = 37g

Max Temperature = 100 Deg C

Module unit – 1” BSP

Medium pressure line system




Midi Module – 1 1/16” UNF

Small to Medium pressure line system




Check latest Datasheets for up to date Unit specifications & fluid Compatibility

Recommended for low pressure line side installation

Max Module – 1 5/8” UNF

Small to medium pressure line system

Max Working Pressure = 69 Bar g


Max Temperature = 100 Deg C5” Clear Unit – 1” BSP*

Maximum Working Pressure = 12 Bar



Magnom™ - Oil Environments Only Units – Large Systems

Process Filtration System Unit – 2” BSP or NPT

Large pressure line system




Check latest Datasheets for up to date Unit specifications & fluid Compatibility

Magnom™- Mobile Hydraulic System Units Oil Environments Only -

Mobile Hydraulic Pump Mate Unit – 2” BSP

Installation of suction side of the Pump (within sump)

Contaminant Holding Capacity = 200g

Maximum Temperature = 100 Deg C

References

Thank you for listening

Any Questions?

References

ocm current

Business

lube oil lab

lube oil parameterscould

new oil tbn

insolubles oil cleanliness

ccontrols oil film thickness

test practices

testing viscosity

lubricant condition