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FLUID PERFORMANCE
SOLUTIONS
CONTAMINATION CONTROL & RECLAMATION
Fluid
Performance
Solutions
Industrial FM - Key elements
Leakage
Reduction
ECM
Fluid
Performance
KPIs Reports Solutions
2
Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions
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
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
Equipment Failure
MACHINERY
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
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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions
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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions
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)
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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions
Sources of Contamination in a
Hydraulic System :-
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Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions
Service Manufacturing
Debris Debris Process Atmosphere Combustion Surfaces Oil
10
Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions
Abrasive Vibration
Wear & Noise
Moisture Contamination
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
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
14
Extension Factor
Millions of Cycles to Fatigue Failure
15
12
10
8 10
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
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
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
2.5
2.0
Most Laboratory Oil Analysis do not
Relative Bearing Life
1.0
0.5
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
19
Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions
20
Fluid Performance Solutions Fluid
Performance
Fluid Contamination Control & Reclamation Solutions
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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