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How to manage an onsite oil analysis programme

How to manage an onsite oil analysis programme

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Le price training presentation Le price training presentation Presentation Transcript

  • www.kittiwake.com sales@kittiwake.com How to manage an Onsite Oil Analysis Programme Zainudin Yahya Managing Director CbM Solutions Sdn. Bhd. August 2013
  • Who are Parker Kittiwake? Parker Kittiwake are one of the world’s leading asset protection experts We manufacture products that allow our customers to monitor and manage the following: Lubrication Fuel Gas Machinery Marine Water Our key customers are leaders in the following application spaces: Marine, Industrial, Renewable Energy, Offshore, Power, Food Manufacturing Kittiwake are trusted and used by the majority of the major companies in our key application areas to provide products to monitor and manage their assets
  • Kittiwake’s Credentials 1992 to 2012 - 20 years of successful industry experience. Strong financial growth over this period. ~ $20m Turnover for 2011. > 500 product lines > 1,000 global customers ~ 90 staff. Offices in UK, USA, Germany, India and Malaysia. Quality Assurance: ISO 9001:2008 Strong, continued, organic growth over the past 20 years, enhanced by acquisitions, offering added value for our customers Acoustic Emissions Gas Fuel & Lube
  • Certified solutions to give representative samples for analysis Oil Sampling Simple to use No operator/sample contact Major UOA programme logistics Fuel Sampling In-line, continuous sampling LR Type approved IMO MARPOL Annex VI compliant Oil and Fuel Sampling Obtaining a representative sample is one of the most important aspects of any scheduled oil analysis programme.
  • Lube Test Kits On-Site condition based monitoring - high specification & exact results. DIGI Kits (6 Parameters) Simple to use Economical Rugged EasySHIP – non hazardous option Analysis Laboratories (8 Parameters) High specification Laboratory accuracy levels Tested for harsh environments In use globally with oil companies, engine OEMs, international navies, shipping companies, offshore contractors, power generators, etc.
  • Marine Water Test Kits Helping customers to comply with current and forthcoming legislation requirements Marine hygiene & potable water test kits Full Compliance with ILO 178 (1996) & ILO MLC (2006) Sewage effluent test kits Full Compliance with MARPOL Annex IV, V, 26 Cooling & boiler water test kits Offer real time analysis User friendly with full instructions provided Avoids costly laboratory analysis Training available for fleet purchases
  • Laboratory/Field based equipment for ultimate accuracy and repeatability pqL Total ferrous (ANALEX fdMPlus) Ferrography Oil test centre FTIR Density meter Heated viscometer Compatibility tester Flashpoint tester Cloud point tester Particle counter (Through Parker) Laboratory/Field Test Equipment Trusted by Oil Testing Laboratories Worldwide Including Caterpillar, ExxonMobil, BP, Shell, Castrol, ITS Caleb Brett, Wearcheck, etc.
  • Real-time Machinery Condition Monitoring There is an increasing desire to move from on-site to on-line analysis Kittiwakes offerings remove the “man” between machine and ultimate reliability On-line Sensors Total ferrous debris Metallic Wear Debris Oil condition Moisture Total water / insolubles Exhaust Emissions (Kittiwake Procal) Acoustic Emissions (Kittiwake Holroyd) Under Development Online Viscosity sensor •Real-time measurements From multiple locations Flexible In/Output options
  • Kittiwakes Online Sensors Effective trending relies upon the provision of regular and accurate information Real time monitoring provides: Ultimate reliability Removes sampling errors Web Visibility Empowers fast and informed decisions Kittiwakes sensor range Total Ferrous Metallic Wear Debris Oil Condition Moisture Online Viscosity (under development) Sensor suite – containing combinations of the above sensors Kittiwakes MWDS is the most sensitive Metallic Wear Debris Sensor available in the market today
  • Holroyd - Acoustic Emissions (AE) AE monitoring provides: Early indication of machine degradation Monitors: Fast and Slow speed (>0.25 rpm) Bearings, motors, pumps, gearboxes Complementary to oil analysis to provide an overall condition monitoring solution Holroyd sensor range: MHC – Machinery Health Check Online modules SetPoint SloPoint Smart Sensors DM1/SM1 Sigma Wireless Ultraspan Specialists in acoustic emissions sensors and systems
  • 25 years in the emissions industry, over 2800 installed analysers in 41 countries, > 120 million device hours. Continuous Emissions Monitoring In-situ IR and UV exhaust gas monitoring Multiple gases analysed within a single unit (up to 6 of: SOx, NOx, N2O, CO, CO2, NH4, C2H6, C2H4, HCl, HF, CH4, C3H8, H2O). Global Approvals: ATEX/IEC (Hazardous areas) MCERTS (Europe) US EPA 40 CFR Part 60 and 75 (US) MED 2008/67/EC (Marine)
  • Application Specific Condition Monitoring
  • World Class R & D Highly qualified R&D team (13 BEng/BSc, 4 MEng, 5 PhD’s) covering: Electronics Mechanical Design Software Chemistry Physics Research and utilise novel technologies Develop and improve existing products Extended product life cycles Joint customer partnerships >10% of turnover invested back into R&D
  • Kittiwake’s Global Presence
  • The Kittiwake group of companies Kittiwake - Serving your needs on a global basis.
  • Shell Co-brand Shell Analex Alert Ferrous Debris Monitor For marine market
  • Wartsila Co-brand Wartsila Power Plant Test Cabinet Fuels & Lubricant test kits For power plant market
  • Why condition monitoring is important? Detection Range = 15X Time Detection Range = X Time Ref.: B.T. Kuhnell, Director of The Center For Machine Condition Monitoring, Monash UniversityVarnishing in Turbine Bearing Wear Debris Analysis Vibration Analysis
  • Why Oil Analysis? Contamination Oil Condition Machine condition
  • Why do we do it? NOTE 1. QA/QC 2. Troubleshoot problems 3. Identify potential failure 4. Extend oil service life 5. Proof of performance 6. Monitor equipments wear and tear 7. Preventive maintenance 8. Save money
  • What does it takes? NOTE 1. People 2. Time 3. Equipments 4. Money 5. Know – how 6. Long Term Commitments 7. Continuity
  • Why onsite? •Viscosity, Water, TBN, Insolubles, TAN, Particles, Metal Analysis, Additive content, RPVOT etc. •Take time, 48hrs – 1 month •> 3 manhour, >USD10 of manpower cost/test • >USD50/test, or included in lubricant cost •80% of sample are OK •Spoon feed information Viscosity, Water, TBN, Insolubles, TAN, Particles, Ferrous Wear Debris Fast less than 30 mins 0.5 manhour Low cost per test Easy to re-confirm alarming sample 80% saving on lab oil analysis Ownership of the data Easy to start!!!
  • Onsite Oil Test Matrix Test Engine Oil Industrial Remarks Viscosity @ 100 oC @ 40 oC Water in Oil R R Typically below 2000ppm. Acid / Base Number BN AN Insolubles / Soot Soot Insolubles Particle counts R Especially clean oils Oxidation O R Especially long-life lubricants Antioxidant depletion O R Especially long-life lubricants Sulphation O O When exposed to Sulphur Nitration O O When exposed to Nitrogen Phosphate Anti-wear depletion O O Especially AW type oil Ferrous Concentration R R Especially gear oil Flash Point O O Once viscosity dropped significantly. Glycol/Diesel O O Especially when suspected
  • Oil Test Centre Viscosity @ 40oC – 15 – 500cSt within +/- 2cSt – compute @ 100oC given density & VI Water in Oil (WIO) – 0 – 2.5% or 0 – 6000ppm or 0 – 3000ppm – +/- 0.1 or 100ppm – EasySHIP version Total Base Number (TBN) – 0 – 50 TBN within +/-10% of fresh TBN Total Acid Number (TAN) – 0 – 6 mgKOH within +/-0.2mgKOH Insolubles – 0 – 3.5% w/w within +/-0.1% w/w
  • Clean Oil Particle Test Visual indication of cleanliness Easy reference chart given Easy to use
  • Analex Alert Ferrous Debris Monitor+ Ferrous Mass in Oil / Grease / Scrapedown Ferrous as leading indicator of wear Range 0- 2000ppm All range of particle size incl. > 5 microns Wear Particle Size Being Generated .1 1 10 100 1,000 Microns Catastrophic Failure Advanced Failure Mode Onset of Severe Wear Mode Slow Wear WearParticleConcentration
  • Flash Point Test • Indication of the level of flammability of the sample in the presence of:- – Oxygen – Source of Ignition (Fire/Spark) • Typical condemning limit for lubricant is <180degC
  • The Kittiwake FTIR 3 Oil Analyser ASTM Compliant and field deployable, all in a small, portable instrument Measures: Sulphation – TO ASTM D7415-09 Oxidation – To ASTM D7414-09 Nitration – To ASTM D7624-10 Phosphate Antiwear – To ASTM D7412-09 Soot – To ASTM E2412-10 Water – To ASTM E2412-10 Ethyl Glycol Coolant – To ASTM E2412-10 Antioxidant depletion – To ASTM E2412-10 Diesel Fuel Contamination As new ASTM methods become adopted, these can be added to the instrument.
  • 29 iCount BS+ 8 channels of particle sizes User selectable standard (ISO 1999, NAS, AS4059, ISO11171,DEF91-91, GOST, NAVAIR) User programmable flush volume User programmable test cycle
  • Onsite Oil Analysis Master Plan Identify Equipment With Alarming Result/Trend Verify Result Resampling? Retesting? Take action Compile result REVIEW OK? Equipments List to Monitor High Impact High Probability Set Frequency & Parameter Of Testing Evaluate Implementation Cost & Benefits ROI OK? APPROVAL? Identify Sampling Points & Methods Identify Personnel Set Training Program Deploy Monitoring Equipments PREPARED? Brief on Objectives & Plan of Onsite Oil Analysis Train on Sampling & Onsite Testing Train on Result & Interpretation Discuss on Possible Responses TRAINED? Take sample Onsite Testing Get Result Trend & Compare with Baseline Inteprete IMPLEMENTED?
  • Equipment Typical Service Life Recommended Sampling & Intervals Remarks Compressor 2,000 running hours Fresh, 0 hrs and every 500 running hours Gas Turbine 3 – 10 years depending on severity From drums, from storage tanks, 0 hrs, 24 hrs and every 500 hrs 1. Follow recommended flushing procedures prior to installing a new oil charge 2. Increased frequency for severe turbine or oil approaching the end of their service life Steam Turbine 5 – 20 years depending on severity From drums, from storage tanks, 0 hrs, 24 hrs and every 3 months Hydraulic System 2,000 running hours Fresh, 0 hrs and every 500 running hours Industrial Gear 2,000 running hours Fresh, 0 hrs and every 500 running hours Or 300 hours for high speed and 1,000 low speed. Frequency of Sampling – less frequent or more?
  • NOTE 1. Representative sample 2. Return line 3. Dipstick tube 4. Oil sump 5. Drum / supplier’s packaging Where to take sample?
  • NOTE 1. Locate the sampling point. 2. Prepare the sampling gun and bottles. 3. Make sure the hose reach the mid-point. 4. Make sure it is safe to take oil sample. 5. Take sample as soon as possible. 6. Ensure the sampling gun is upright. 7. Pump the first charge to flush the hose. 8. Replace the sampling bottle with the fresh one. 9. Then start pumping until the bottle is ¾ full. 10. Unscrew the bottle from the sampling gun. 11. Close the bottle properly ensuring the inner cap seal is intact. 12. Fill up the details required on the sample tag ID. How to take sample?
  • Good Practices Do’s 1. Separate pump for coolant and oil 2. Flushed sampling valves, sampling devices and use clean bottles 3. Running Hours / Mileage recorded 4. Samples forwarded immediately to lab 5. Dedicated personnel
  • Diesel Engine Oil Analysis Type Fuel Viscosity Insolubles TBN Water Flash Point Change Maximum Change/Min Maximum Minimum Automotive Distillate + / - 25% 2% -60% / 1 0.5% 180° High Speed Distillate + / - 20% 2% -50% / 2 0.3% 180° Medium Speed Distillate +20% -10% 2.5% -50% / 5 0.2% 180° Medium Speed Residual +20% -10% 2.5% -50% / 10 0.2% 180° Fuel Dilution has reduced oil thickness resulting in wear of the bearing and journal.
  • Hydraulic Oil Analysis Viscosity (cSt at 40°C) Exceeds limit < +/- 10% Viscosity increase is more common than decrease. It should be noted and checked at more frequent intervals. Check that the correct grade of oil is used for top-up. Water (%) Satisfactory 0.05% - 0.15% Upper limit should be checked against manufacturers’ data. Some oils cannot tolerate water - BEWARE. Data not applicable to water or phosphate ester-based hydraulic fluids. Borderline 0.15% - 0.2% Exceeds limit > 0.20% TAN Exceeds limit + 0.6 of fresh TAN should always be monitored by trend as the TAN of some oils can fall from new then rise again as the oil ages. Particulates Refer to manufacturer s data Hydraulic systems can be extremely sensitive to wear from particulate contamination and great care should be taken to ensure all filters are in good condition and no dirt enters via top- up oil or tank vents. Failure due to acidic-erosion
  • Natural Gas Engine Oil Analysis Engine Type Viscosity Insolubles TBN TAN Water Flash Point Natural Gas 100° +25% 1.0% 2 2.5 0.3% 180° Lean Burn 40° +50% Rise from New Failure due to water contamination
  • Turbine Oil Analysis Viscosity (cSt at 40°C) Exceeds limit < +/- 10% nom Viscosity increase is more common than decrease. It should be noted and checked at more frequent intervals. Check that the correct grade of oil is used for top-up. Water (%) Satisfactor y 0.05% - 0.15% Upper limit should be checked against manufacturers’ data. Some oils, especially synthetic oils, cannot tolerate water - BEWARE. Water contamination may lead to hydrolysis of synthetic oils and rapid TAN increase. Exceed 0.20% TAN Exceed Change +/- 0.4 from nominal TAN should always be monitored by trend as the TAN of some oils can fall from new then rise again as the oil ages. Lubricant varnishing
  • Compressor Oil Analysis Viscosity (cSt at 40°C) Satisfactory < +/- 15% A viscosity increase is more common than decrease. It should be noted and checked at more frequent intervals. Check that the correct grade of oil is used for top-up. Borderline nom >15- 20% Water (%) Satisfactory 0.05% - 0.10% Water can enter the oil via the compressor cylinders; always check that inter-cooler drains are operated effectively. Refrigeration oils cannot tolerate water at all. Exceeds limit > 0.10% Insolubles (%) Exceeds limit > 0.10% Formed by carbon from oxidised oil, high insolubles will rapidly foul air delivery valves and particles contaminants & wear metals. TAN (mg.KOH) Exceeds limit +/- 1.0 TAN should always be monitored by trend as the TAN of some oils can fall from new then rise again as the oil ages. Abrasive wear due to insolubles
  • Gear Oil Analysis Viscosity (cSt at 40°C) OK < +/- 15% Viscosity increase is more common than decrease. It should be noted and checked at more frequent intervals. Check that the correct grade of oil is used for top-up. Exceed >+/-20% Water (%) OK 0.05% - 0.15% Upper limit should be checked against manufacturers’ data. Some oils cannot tolerate water - BEWARE. Steam turbine gearbox oils are often more tolerant of water than most. Synthetic oils can be less tolerant than most. Exceed > 0.20% TAN OK Refer to manufactu rers limits. TAN should always be monitored by trend as the TAN of some oils can fall from new then rise again as the oil ages. Ferrous OK Refer to manufactu rers limits. Iron (ppm) should always be monitored by trend as compared to normal, as wearing rate is dependent on operational conditions.
  • Trending, Cross-referencing & Alarms Allow to extrapolate internal trend Allow to forecast internal trend X-Refering to other parameters to confirm hyphothesis X-Refering to other equipment data to identify normal level Simplify localise decision making Traffic Light Green = OK & Continue Amber = Retest & Report Red = Change Oil / Further Inspection
  • Further Analysis Laboratory Wear Metal Analysis through XRF / AAS / ICP Identify other wear metals other than Ferrous Identifying which components is wearing Not able to detect metal of > 5 microns Ferrography Identify shape & sizes of wearing component Identify the cause of wear Confirming the stage of wear
  • Summary • Oil Analysis provide earlier detection of failure as compared to vibration analysis • Oil analysis provide 70% of mechanical failure detection • Early detection of contamination will reduce failure rate • Early detection of failure will reduce cost of rectifications
  • Salamat Po •Any Questions? •www.kittiwake.com •zainudin@cbmsolutions.com.my
  • www.kittiwake.com sales@kittiwake.com World Class Asset Protection