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  • Who are Kittiwake and what the presenter will cover during the talk
  • This is THE BIG IMPACT slide to get your listeners interested with simple bold statements about Kittiwake and how you might be able to help
  • Our Systems A leading edge B2B e-commerce system for all transactions Guaranteed delivery performance from bases in the Europe and USA Monthly billing and online management reporting A paperless operating system with all production, stock control, delivery and quality information operating on a single SQL, Web enabled database. Company Qualifications Registered under ISO 9001 for all company activities UK Department of Transport approval as "Secure warehouse facility" for air freight 5 staff trained in handling of HAZMAT under IATA, IRD, IMDG codes. In house dedicated company training department Member of Sussex Enterprise & International Bunker Industry Association Experience with Fuel & Lube Oil Test Equipment A core business area is test equipment from simple go/no type tests to sophisticated electronics using mainly wet chemical test procedures. Our concern with consistent quality and delivery performance was sufficient to win the majority of the market for field test equipment over a five-year period. Much of our equipment carries US Military and NATO approvals. Experience in the Water Test Industry We provide sampling logistics for UK Sport, operating the Doping Control programme on behalf of the UK Government and supply duct water sampling equipment for the telecom industry. Supply of water test equipment is the latest business area for Kittiwake. Entry in to the market was achieved through design of leading edge Web enabled control equipment for low-pressure boiler systems. Autumn 2001 will see the launch of a major new initiative in this area with over 300 new product lines for on site testing of industrial waste and process water systems. Experience in Logistics Kittiwake laboratory logistics services are a key part of most marine used oil and fuel analysis services providing reassurance to over 26,000 deep-sea ships. We provide services to many land based programmes from oil analysis through to doping control. Distribution depots in Europe and the USA cover an 18 hour working day. B2B e-commerce facilities offer 24/7 world-wide ordering, tracking and reporting
  • Reduce downtime by predicting where problems may occur and acting before they do. Have a replacement part available, mechanic on hand and select when to stop the machine to minimise disruption.
  • Clear on screen instructions and simple operation make the PQM suitable for use by untrained staff. 5 samples per minute.
  • The PQA allows up to 144 oil samples to be loaded and can analyses them and produce results in under an hour. Manual, computer or robot control. Oil samples can be loaded and the PQA left unattended to produce results, freeing staff for other tasks Oil samples may be measured in bottles by using an adapter in the apateur of the measurement carousel. This adapter can accept bottles of different sizes. Bottles may be measured in an inverted position, provided their lids are leak proof.
  • Measurements taken successively without turning sensor off – sensor head purged of previous test sample with dried and filtered (0.2μm) compressed air. First peak is new oil Second peak – oxidise sample Third peak – heavily oxidised sample Forth peak – New oil mixed with water. 0.5% Water sample was lab simulated - turbomixed (high shear mixing) for 15 seconds shortly before measurement. Gear oil tested is a polyalphaolefin (PAO) synthetic. The shifts in sensor output are small (<0.5 Volt change), the sensor has a large operating range to cater for the responses from different oil types; the reading with a new gearbox oil may be 2 volts and a new hydraulic oil, 3.5 volts, for example. The outputs in the graph were in the raw state (pre-processing) and we would expect the final oil quality reading from the sensor to be scaled based on the sensor output voltage with new oil and the voltage with old, condemned oil.
  • This graph is data from Lubrigard system – earlier version of oil condition sensor. Dither on chart is due to: - Temperature instability of circuit and readings not always taken at constant temperature – cold days for example. And Digital (dither) output Resolution; a value equating 6.5 could be 6.49 one day or 6.51 another, output will be 6 or 7 respectively.
  • Graph: Linear and repeatable Two coils 1 Measurement one reference Correlates to standard Laboratory equipment Intricate shielding consisting of Outer shield to remove interference from Earths magnetic field, moving equipment etc. Inner shielding to separate sensor from electronics Patented shield around sample Ferrous and Non ferrous Explain Drawing
  • Graph: Linear and repeatable Two coils 1 Measurement one reference Correlates to standard Laboratory equipment Intricate shielding consisting of Outer shield to remove interference from Earths magnetic field, moving equipment etc. Inner shielding to separate sensor from electronics Patented shield around sample Ferrous and Non ferrous Explain Drawing
  • Ocm current

    1. 1. Presentation onAt 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-110018 www,kittiwake-india.com www.dantechengineers.com
    2. 2. Monitoring Innovation• 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
    3. 3. Oil Condition Monitoring - Two different objectivesLubricating Analysis Monitoring the lubricant  Condition of the lubricant  Viscosity, TAN, TBN, Water content, Insolubles Oil cleanliness as per ISO and NAS StandardsWear debris Analysis Monitoring the Machine  Quantity of wear particles in ppm  Monitoring and analysis of wear particles  Condition of the machine
    4. 4. 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
    5. 5. Lube Oil Condition MonitoringLube 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.
    6. 6. Where: Field or LaboratoryAll tests and testing started life in thelaboratoryMethods and Standardisation:ASTM/IP/ISO….DIN/GB/Gost etc.Methodology unsuitable for field useInstruments developed specifically forfield useQualitative or Quantitative
    7. 7. What parameters can you test in the fieldViscosityWaterTBNInsolublesTANParticlesFerrous Wear Debris
    8. 8. On Site Oil Condition Monitoring - Benefits 1. Saves Helps in Unscheduled diagnosing Down time problems 2. Allows quickly scheduling maintenance (Move from Helps take EmergencyOn Site Oil Oil Condition status to timelyCondition known when Normal ) maintenanceMonitoring needed 3. Generates Actions more amount of oil analysis Helps quick data for integration diagnostic or with other development RCM purposes. techniques
    9. 9. Fuel and Lube oil Lab.At site Lube oil monitoring OiOIL lOi
    10. 10. Lube Oil Test Kit - engines Viscotube M
    11. 11. What parameters can you test in the field MiniOTC OR Digi Insoluble (Optional) Range: 0-2.5% diesel engine lubes Test time: 2 minA combination of qualitative and quantitativemeasurements D HV
    12. 12. What parameters can you test in the field OTC – Oil Test CentreA Central Common consolewith:TBN,Water,TAN,Viscosity,Insoluble Cells and reagentsIn NATO approved boxIn industrial strolly
    13. 13. What parameters can you test in the fieldOil Test Cabinet •For Testing – Viscosity,TBN,Water,Insolubles, Oil Cleanliness,Compatibility,Density, Salt water,Pour point •On site testing will produce cost savings simple, rugged, reliable equipment Results are obtained quickly and accurately
    14. 14. 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 AnalyserThe Oil Analyser is comprised of three main components: •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 V
    15. 15. How to test and what results mean ViscosityDefined as cSt @ 40°C & 100°CControls oil film thickness and flow rateIncreased by oxidation and insolublesDecreased by shear down & fuel dilution 26.5 26.22 26Mineral, synthetic 25.5 25.32 25 Change-out limits: 24.5 24.36 24 23.5 23.44 -20% < New > +10 to 30% (Diesel), Viscosity cSt @ 40C 23 -10% < New > +25 to 50% (GT/Hyd) 22.5 22 0% 1% 2% 3% M HV
    16. 16. How to test and what results mean WaterAlways present in oils some systemscan run dryContamination from condensation,blow-by, leakage and adulteration 2500Causes corrosion, cavitation, 2000additive instabilityMineral and synthetic lubes & 1500hydraulics 1000 Field Lab 500 Change-out limits 0.3 - 0.5% (Diesels) 0 1000ppm (GT/Hyd) MD
    17. 17. How to test and what results mean TBNDepletion depends on oilconsumption, fuel sulphur andloadProblematic on low oilconsumption enginesLow TBN results in acid Exxon Lab 50 Exxon OTCcorrosion and fouling Shell LabDiesel only 40 Shell OTCChange-out limit 50 - 60% of 30new oil TBN 20 M D1 Dm 10 0 Paired Tests Field vs Lab
    18. 18. How to test and what results mean InsolublesAsh, oxidation products, wearmetals, asphaltines, carbonIngressed contaminants, dust etc.Causes increase in viscosity, wear,fouling of ring pack and underpiston crown. Blockage of aviationlube filters. 3Mineral and synthetic oils 2.5 Solids %w/w 2 Lab IP 316 Change-out limits: 1.5 typically 1.5 - 2.0 % w/w 1 (Diesels) 0.5 M 0
    19. 19. How to test and what results mean TAN  A function of additive chemistry and oxidation  Monitor by trend Figure 6 - Difference in TAN Measurements (NOAP minus OTC)  Measured by 1 Typical reject limits at 0.5 and 1.0 TAN neutralisation / colour 0.8 Difference in Results for TAN mg.KOH titration 0.6 0.4 M 0.2 32.5 MJOII 0 M1661 1 5 9 25 49 53 97 2 13 17 21 29 33 37 41 45 57 61 65 69 73 77 81 85 89 93 101 105 121 125 129 133 109 113 117 137 141 M2541.5 M1661 -0.2 1 Difference -0.40.5 Oil Sample 0 Paired Tests Field vs Lab Change-out limit + 1 (alert), + 2 (change) (GT / Hyd)
    20. 20. EZ OIL CLEAN CHECK Portable Oil Cleanliness Indicator A 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
    21. 21. EZ OIL CLEAN CHECKFeatures: 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
    22. 22. How to test and what results mean Particles in HydraulicsParticle counting and analysis usuallycarried in a laboratoryExpensive and complicatedFew low cost field solutionsHydraulic Particles Test KitDraws sample through 8micron filterComparison made with quality colouredreference chartGood field indication of pendingproblems
    23. 23. How to test and what results mean Ferrous Wear Debris Analex fdMplusMeasures ferrous wear metal debris inoil and grease without preparation ofthe sampleIndicates wear on ferrous metalcomponentsMeasures all debris including particles>5 micronLaboratory based ICP/AA does notmeasure these size particlesGives results in ppmUsed extensively for trendingFirst time available for field testing
    24. 24. fdMplus - Principle of OperationWhen the sample of oil containingferromagnetic debris is placed inthe sensor the balance between thecoils is altered.The resulting out-of-balance signalis amplified, filtered, and displayedas Total ppm as it is measuring thetotal mass of ferromagnetic debrisin the sample irrespective ofparticle size.
    25. 25. fdMplus - OperationThe sample is placed using suitablesupplied adaptor in:50ml Bottle10ml Syringe5ml Syringe5ml Test Tube4ml Grease PotsThe touch screen gives preciseinstructionsEach sample is uniquely numbered anddatedData is stored by equipment typeCan be viewed in tabular or graphicalformDownload to computer via RS232
    26. 26. lubMONITOR software 1. KITTIWAKE lubMONITOR®: Lube oil monitoring for OTC and miniOTC 2. 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.
    27. 27. Why On Line Sensors?Demand for a significant reductionin manpowerNeed for real time data – Laboratory testing takes time & often inconvenient – Off Line testing demands manpower & timeIntegrated part of RCM programme Reliability Centred Maintenance
    28. 28. What will the sensors monitor?Five Most Relevant Parameters:Oil Quality: TBN/TAN/Insolubles/Glycol/Water in oil quality units on a scale from 0-100Moisture: Up to saturation point 0-100% RHViscosity: For lube and hydraulic oilsFerrous Debris Sensor: All particles irrespective of size 0- 2000 micronsParticle Content Sensor : - Total particles/ minute Ferrous Particles – 40 - 2000 microns Non ferrous particles >130micron
    29. 29. Oil QualityOil 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 scaleTarget 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.
    30. 30. ANALEXrs Moisture SensorMeasures oil’s % RH –Relative Humidity – resultingfrom dissolved waterUses combination of thin filmcapacitance sensors andsmart algorithmsOil molecules penetrate apolymer coated sensor andthe dielectric property ismeasured
    31. 31. Total Ferrous Wear Debris MonitoringDetection of Metal Debris  Senses changes in magnetic flux as ferrous particles enter a magnetic field and losses when non ferrous conductive particles enterTechnology  Measures >5 micron (unlike ICP)  No radioactive source (unlike XRF)  Linear response  Independent of oil flow speedOutputs  CAN interface  4-20 mA, RS232, RS485  Radio link with built-in web server
    32. 32. Metallic Wear Debris Detection & Counting Online Wear Debris SensorDesigned to measureindividual ferrous and nonferrous particlesTotal no. of particles perminute and mass.Targeted at applicationswhere metal surfaces sheddebris which is taken away bythe oil flowTurbines, Bearings &Gearboxes
    33. 33. Online Wear Debris Sensor
    34. 34. Online Wear Debris Sensor
    35. 35. Online gear box /turbine monitoring system Particle Content Sensor Oil Condition Sensor Moisture Sensor Pump for circulating the Oil through sensors
    36. 36. On-Line Sensor Suite
    37. 37. Sensor Suite - Models AvailableStandard Options – Non-heated -Most Industrial use – Heated – Low Temperature applicationsSpecifications – 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 – IP65Interface Options – Analogue -4-20mA (4 loops) – Digital • RS232 • RS485 • Wireless LAN 802.11b • CAN
    38. 38. Acoustic Emission - Kittiwake Holroyd•We are specialists in Acoustic Emission Condition Monitoring for harshindustrial 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!
    39. 39. Uses of AECondition 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.
    40. 40. Basic principles of AE Source propa MHC sensor detection frequency Bac (100 kHz) kgr g n ation tio o un d ua Amplitude en Fric tion Att no i s &I mp act e so Sou rce s ur c es sensor A crystal in the sensor responds to the kHz as it 300 kHz 0 100 kHz 200 wave passes underneath it Frequency conditioning
    41. 41. Stop the Chain Reaction of Wear
    42. 42. Dynamic clearances example - Gear Pump Cut in Track Dynamic Clearance Tooth to side plate: 0.5 - 5 µm Tooth tip to case: 0.5 - 5 µm
    43. 43. 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!
    44. 44. Magnom™ - Features of the PatentedTechnologyThe Magnom™ comprises of a series of annular magnets and innovatively designed formed steel plates.The steel plates focus the magnet flux strength A
    45. 45. Magnom™ - Working ow Fl
    46. 46. Magnom™ – The BenefitsMagnom™ 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
    47. 47. Magnom™ - Oil Environments Only Units– Small to Medium Systems 1 Midi Module – 1 1/16” UNFMini Module - 3/8” BSP Small to Medium pressureSmall pressure line system line system Max Module – 1 5/8” UNFMax Working Pressure = 14 Bar Max Working Pressure = 120 Bar Small to medium pressure lineContaminant Capacity = 37g system Contaminant Capacity = 45gMax Temperature = 100 Deg C Max Working Pressure = 69 Max Temperature = 100 Deg C Bar g Contaminant Capacity = 80g Module unit – 1” 5” Clear Unit – 1” BSP* Max Temperature = 100 Deg C BSP Maximum Working Medium pressure Pressure = 12 Bar Check latest Datasheets for up to date line system Unit specifications & fluid Compatibility Contaminant Capacity = Max Working 200g Recommended for low pressure line Pressure = 140 side installation Bar Max Temperature = 80 Deg C Contaminant Capacity = 185g Max Temperature = 100 Deg C
    48. 48. Magnom™ - Oil Environments Only Units – Large Systems Process Filtration System Unit – 2” BSP or NPT Large pressure line system Max Working Pressure = 17 Bar Contaminant Capacity = 4000g Max Temperature = 100 Check latest Datasheets for up to date Deg C Unit specifications & fluid Compatibility
    49. 49. Magnom™- Mobile Hydraulic System UnitsOil 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
    50. 50. References
    51. 51. Thank you for listening Any Questions?
    52. 52. References