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Shell Global Solutions

FLUID PERFORMANCE
SOLUTIONS
CONTAMINATION CONTROL & RECLAMATION

Fluid
Performance
Solutions
Industrial FM - Key elements
Leakage
Reduction
ECM

Fluid
Performance
KPIs Reports Solutions

Benchmarking Best Data Input to


Practices LUBRIPLAN
Lubriplan
Work Orders Training
Lubrication
Product
& Coolant
Schedule Management
Waste
Management

Stock & Logistics


Management

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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions

Costs Associated with Equipment Failure are High

Proactive studies by the US Navy show that the cost of contamination


on marine and aviation equipment per operating hour exceeds 60
percent of the cost of fuel per hour on the same equipment

One third of all useable device produced energy is lost to friction and
wear = 2.5% of GNP
US Government Report on Tribology
Combined cost to industry of wear and corrosion estimated at 3-5% of
GDP
H Peter Jost, UK Department of Trade and Industry

Repair of machinery due to mechanical wear damage or failure


estimated at 7% GNP
Prof E. Rabinowicz, MIT
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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions

Benefits of Proactively Controlling Contamination are Dramatic

Steel Producer/Processor
90% reduction in tribological failures
50% reduction in bearing purchases
97% reduction in hydraulic component failures

Paper Manufacture4
90% reduction in bearing failures

BHRA study
10-50 x improvement in Mean Time Between Failures

Engine Manufacturer
Dramatic improvement in engine life

1980-1984 DTI Study : similar results for >3mm, >5mm (as above) & >15mm

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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions

Causes of Premature LOSS OFUSEFULNESS OF

Equipment Failure
MACHINERY

OBSOLESCENCE (15%) SURFACE DEGRADATRION (70%) ACCIDENTS (15%)

ABRASION
ADHESION
FATIGUE
MECHANICAL WEAR (50%) CORROSION (20%)
EROSION

WEAR FATIGUE
(THIN LUBRICANT FILM) (COMPONENT OVERLOAD)

CONTAMINANTS
INCORRECT ABRASION BY
OVERLOAD MISALIGNMENT CAUSE MICRO
LUBRICANT CONTAMINANTS
DISPLACES IMBALANCE STRESSES
LUBRICANT

Rabinowicz MIT 1984 - Reasons for Replacing Components


British Fluid Power Association 1991 - Guidelines to Contamination Control in Hydraulic Systems

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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions

Types and Causes of Machine Wear

Type of Wear Primary Cause Corrective Action

Particles move between Correct Lubrication; Improve


Abrasive Wear
adjacent moving surfaces Contamination Control of Particulates

Metal to metal contact - loss


Adhesive Wear Correct Lubrication; Correct Design
of lubricant film

Repeated stress on Correct Lubrication; Improve


Fatigue Wear
particulate damage surfaces Contamination Control of Particulates

Particles and high velocity Correct Lubrication; Improve


Erosive Wear
fluid 'rub' metal surfaces Contamination Control of Particulates

Water, chemicals & oxidation Correct Lubrication; Improve


Corrosive Wear
by-products Purification Control of Lubricant

Pall Europe UK ltd

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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions

Reasons for Equipment Problems

60% 22%

12%

6%
Contamination (Vk, Metals, Infra-Red, Particle Count , Millipore Sludge)
Abnormal Wear (Metals, Ferrography)
Oil Degradation (TAN, TBN, Vk, Infra-Red)
Oil Properties (Vk, TAN, TBN, Infra-Red, Foam, Rust)

Note the majority of problems (60%) are due to


contamination and poor filtration
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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions

Reasons for Equipment Problems

Particle Induced Non-Particle Induced


Sector
Abrasion Erosion Fatigue Ahesion Other Total
Pulp & Paper 217 93 13 36 23 382
Forestry 101 14 25 18 158
Mining 551 117 25 15 18 726
Agriculture 735 54 45 104 2 940
Transportation 799 202 240 85 1326
Power Gen 69 30 31 60 190
Total 2472 294 299 451 206 3722
66% 8% 8% 12% 6%
% of Total
82% 18%

National Research Council of Canada

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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions

Sources of Contamination in a
Hydraulic System :-

Manufacturing & Assembly Debris


Process Material & Internal Wear
External Environment &
Atmosphere
New Oil Change & Top up
Repair & Servicing Debris
~60% of external contamination enters
via the cylinder seals
105-1010 particles per minute > 10m

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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions

Solid Particle Ingression

Built In Ingested Generated

Service Manufacturing
Debris Debris Process Atmosphere Combustion Surfaces Oil

Repairs Burrs Compressed Breather Blow-by Mechanical De-sedimentation


air/gas ingestion wear
PMs Machining Soot Filter desorption
swarf Pulp Seal ingestion Corrosive wear
New filter Fly ash Additive
Weld spatter Pulverized coal Tank opening Cavitation precipitation
New oil Induction air
Abrasives Ore dust Rock dust Exfoliation Sludge
Dirty hose, Contaminated
fitting, Drill turnings Aggregates Mill scale fuel Hose fibers Oxide insolubles
components
Filings Cement Quarry dust Filter fibers Carbonization
Top-up
Dust Catalysts Foundry dust Break-in debris Coke
containers
Contaminated Clays Slag particles Elastomers
components
Molecular sieves Paint chips
Process
chemicals

Ingression All new particles entering a


lubricant, regardless of source. Noria UK

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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions

Abrasive Vibration
Wear & Noise

Poor Product High Operating Fix the Problem


Quality Temperature
but
Oxidation &
Destructive Pitting Cavitation Problem Recurs
& Spalling

Fix the Root Cause


Incorrect Oil & Imbalance &
Lubrication Misalignment
and
Chemical
Cleaners Problem Eliminated
Particles & Air & Moisture
Wear Debris Contamination
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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions

Attack the Root Causes of Component Failures with Contamination Control


Relative Degree of Failure Mechanism
Particulate Contamination

Moisture Contamination

Wrong or Degraded Lubricant

Failure Mechanism
Filtration Technology can
Misalignment
Proactively Reduce or Eliminate
some of the Major Root Causes & Imbalance
Frequency of Component Failures
High Temperatures

Component Failed
Others

Others
Root Cause
Others

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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions
0.004 Salt 100m

Industrial
Haze 90m

200 Mesh
Screen 75
Diameter in m

Pollen 60m

0.002 Fog 50m

Dust 40m 40
Human hair
30

15
Talc 10m
5
Bacteria 2m 1
Bearing Fine & coarse
lubrication film particle

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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions

Relative Pump
Improve Cleanliness Wear Rate
here produces large
Component Life
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Extension Factor
Millions of Cycles to Fatigue Failure

15
12

10

8 10

Improve Cleanliness here


6 produces marginal
Component Life Extension
Factor
4 5

5 10 15
10 20 30 40 50
Filter Rating (B>200) mm Filter Removal Rating mm
McPherson 1981 - Study based on Roller Bearing Life in Helicopter Gear Boxes NADC 1984 - Relative Wear Rates of
Hydraulic Components
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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions

Particle Generation Rate


Relationship of Wear Rates &
Component Failures to
Particulate & Moisture
Contamination over time Time
Wear rate (cc/hr)

0.1
1 10 100 1000 Particle Size (m)
Glantz 1993 - Contamination in Lubrication Systems for Bearings in Industrial Gearboxes
0.01
BFPA Recommended
Component/System Life (yrs)

Cleanliness Code
8
0.001
6 ISO Code 17/18
NAS Code 9
0.0001
1 10 4
Clearance /particle size
2
Watanabe 1985 - Evaluation of Wear Life of
Journal Bearings Lubricated by
Contaminated Oil 1000 2000 3000
Number of Particles / ml > 5m
Fitch 1991 - Pro-active Maintenance can Yield a Ten-fold Saving over Predictive/Preventative Maintenance

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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions

ISO 4406:1987 ISO 4406:1999 Dirt


Scale
No. of Particles/100ml No. of Particles/1ml (ISO-MTD)
No.
mg/l
24 8,000,000. 16,000,000. 80,000. 160,000. 80.
23 4,000,000. 8,000,000. 40,000. 80,000. 40.
22 2,000,000. 4,000,000. 20,000. 40,000. 20.
21 1,000,000. 2,000,000. 10,000. 20,000. 10.
20 500,000. 1,000,000. 5,000. 10,000. 5.
19 250,000. 500,000. 2,500. 5,000. 3.
18 130,000. 250,000. 1,300. 2,500. 1.
17 64,000. 130,000. 640. 1,300. 0.5
16 32,000. 64,000. 320. 640. 0.2
15 16,000. 32,000. 160. 320.
14 8,000. 16,000. 80. 160. 0.1
30 gm of particulate in
13 4,000. 8,000. 40. 80.
12 2,000. 4,000. 20. 40. 10,000 ltrs of lube oil
11 1,000. 2,000. 10. 20. equates to ISO Code 19
10 500. 1,000. 5. 10. 0.01
9 250. 500. 2.5 5.
8 130. 250. 1.3 2.5
7 64. 130. 0.64 1.3
6 32. 64. 0.32 0.64 0.001
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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions

Theoretical Life Extension Factor ?

Particulate Relative Pump


Filter Size (A) ISO Code (B)
Contamination (C) Life

25 micron
nominal
21/ 18 3100 kg 1.0
10 micron
nominal
19/ 16 820 kg 1.9
10 micron
absolute
16/ 13 95 kg 4.4
6 micron
absolute
14/ 11 24 kg 8.8
3 micron
absolute
12/ 9 6 kg 15.0

All figures are approximations. Component Wear Rate No. particles


/ 4000hrs (10 mm) / min.

Gear Pump 1.9 g/l ~180k


Vane Pump 6.3 g/l ~ 580k British Hydraulics Research Association
Piston Pump 1.7 g/l ~ 150k

Cylinder 0.5 g/cm2 ~2

Directional Valve 1.9 mg/l ~2

Component Contamination Generation


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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions

Relationship of Wear Rates & Component


Failures to Particulate & Moisture
Contamination over time
3.0

2.5

2.0
Most Laboratory Oil Analysis do not
Relative Bearing Life

Measure below 500 ppm or 0.05%


1.5

1.0

0.5

50 100 150 200 250 300 350

Moisture Content Level (ppm)

Fitch 1991 - Pro-active Maintenance can Yield a Ten-fold Saving over Predictive/Preventative Maintenance

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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions

Effects of water and particulate catalyst on oil oxidation

Run Particulate Water Hours Final


Catalyst Neutralisation
Number
1 None No 3500+ 0.17
2 None Yes 3500+ 0.90
3 Fe No 3500+ 0.65
4 Cu No 3000 0.89
5 Fe Yes 400 8.10
6 Cu Yes 100 11.20
Increase of 0.5 to 1.0 Neutralisation Value usually indicates significant oil deterioration

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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions

Characteristics which affect the oil and system degradation


due to gaseous contamination

Oxidation Accelerates Acid Formation and Oxidation


Aeration Foaming, Air Entrainment
Cavitation Pump Damage and/or Failure
System Response Reduced System Pressure, Erratic Response
Viscometrics Increases Oil Temperature
Drop Out Settling Time in Fluid Reservoir(s) & Dead Ends

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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions

Causes of Machine Failure


Machine - design, manufacture, assembly, shipping
Materials - inadequate material properties, wrong materials
used/combined
Manpower - inadequate training, incorrect operation, inexperience
Maintenance - lack of resource, incorrect timing, lack of quality controls
Types of Machine Failure
Wear-in Failures - during or immediately after commissioning
Incipient Failures - performance or condition gradually degraded
Misuse Failures - overloaded or used for task not designed for
Random Failures - under-designed components, deficient
lubrication
Wear-out Failures - component fatigue, design 21
Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions

Surface Treatment Surface Finish Residual Stress

Overloading
Material Hardness
Contamination Ingress
Manufacturing Material Combinations
Poor Lubrication
Deficiencies Material Properties
Overheating
Service Material
Conditions Deficiencies
Causes of
Failures
Maintenance Design
Procedures Deficiencies
Incorrect Training
Assembly System Tolerances
Improper Procedures
Procedures Component Clearances
Contamination Ingress
Design Strength
Wrong Replacement
Incorrect Shipping Assembly
Handling Damage Damage
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