Petroliance 12 2008

Vickers Quote2 Proper selection and placement of contamination control devices in a system to attain the targeted cleanliness eliminates the root cause of up to 80% of hydraulic syste

Introduction and Timing

Jeremiah JB Bacon C.L.S.

PetroLiance, LLC

Presentation should take about 1 hour.

What is Contamination?

ANY FOREIGN MATERIAL THAT

ADVERSILY AFFECTS THE

OPERATION OF YOUR EQUIPMENT.

Wrong Oil

Chemical

It Effects All Forms of Equipment

SKF Quote 1

Under special operating

conditions, bearings can attain

a much longer life

a much longer life than

predicted by normal life

calculation methods These

special conditions are when the

rolling surfaces are

effectively separated by a

lubricant film

lubricant film and when the

surface damage caused by

contaminants is limited

contaminants is limited In

fact, under ideal conditions, it

is possible to speak of infinite

life.

Vickers Quote2

Proper selection and placement

of contamination control devices

in a system to attain the targeted cleanliness eliminates (the root cause of) up to 80%

of hydraulic system failures.

1 SKF Bearing Maintenance Handbook

2 Vickers Guide to Systemic Contamination Control

Why Is Cleanliness So Important?

Typical bearing application

Contamination Destroys Equipment

3 Micron

Particle

Abrasive Wear is the most common type of wear.

The Life of a Typical Hydraulic Pump

The life of a typical hydraulic pump can be

predicted based on the amount of contamination that passes through the pump during its life.

What Size Particles Are We Talking About?

What size particle

can you see?

Contamination in a Hydraulic Piston Pump

What does it do?

The abrasive wear from the

particulate damages the

swashplate, piston shoe,

piston, cylinder wall,

cylinder block and valve

plate.

Particulate can clog the

piston shoe opening.

Contamination in a Servo Valve

What does it do?

The valve spools can have 1 micron clearances Particulate will damage the spool and cause

actuation problems due to internal leakage.

Abrasive Particulate Effects In Gears

Abrasive particles cause seals to erode and bearings to wear prematurely.

Shortens Rebuild/Replace Intervals

Increases Oil Consumption from Leaks

Increases Maintenance Costs

Water Is Harmful Too!

Water is the SECOND

Most Destructive

Contaminant!!!

Changes Oil Viscosity

Rust & Corrosion

What Water Contamination Can Do to a

Bearing

The Problem: Water causes Hydrogen

Embrittlement of the metal and premature fatigue.

Hydrogen

Embrittlement

Spalling from Embrittlement

Water, What is ok?

ACCEPTABLE

LEVELS: Typically below 250 PPM.

It is normal to see

levels of 150 to 250 PPM or 0.015

0.025 % in SC

You can see water

at around 900 PPM

If We Can t See it,

How Do We Know It s There?

If We Can t See it,

How Do We Know It s There?

Use Oil Analysis with Particle Counts.

ISO Particle Counts

It is important to understand what ISO

Particle Counts are.

What is it?

Quantitative analysis of oil to determine the

distribution of particle sizes in the oil

Why?

Try to keep oil at a cleanliness level to prevent

wear and failures

Targeted to remove clearance size particles out

of the oil

Filter Patch: ISO Rating of 20/17/15

Range or code

Greater Than 4 micron

Greater Than 6 micron

Greater Than 14 micron

We have to have some

ISO Code Range Counts

ISO Cleanliness Code 20/19/16

ISO Cleanliness Comparison

OEM Recommended ISO Codes

How Do We Control Contamination?

To control contamination, you ll need to assess just how contaminated your systems are.

Use Oil Analysis with Particle Counts to determine current system cleanliness levels.

Identify the most sensitive components on each

system.

Set system cleanliness goals base on those

sensitive components identified.

Document ISO cleanliness code and water content results for each system.

How Do We Control Contamination?

Once you have established how

contaminated your systems are, and what cleanliness level your system should be to maximize life;

Initiate a directive to work toward those goals by putting best practices in place.

Once your cleanliness goals are met, develop a maintenance plan to keep systems clean.

How Do We Control Contamination?

You will take care of most of the

contaminants if you will do 7 Things;

SEAL THE SYSTEMS

KEEP SYSTEM EXTERIORS CLEAN

USE ADEQUATE SYSTEM BREATHERS

STORE AND DISPENSE OIL PROPERLY

ROUTINELY USE OFF-LINE FILTRATION

INSPECT SYSTEMS AND MONITOR FOR OIL CONTAMINANTS REGULARLY

FIRST: SEAL THE SYSTEMS

You want your systems to get clean oil and keep it clean.

All of these can let in contamination:

Lack of a vent plug or cap left off

Poor breather

Poor seals on a cylinder

Dirty dispensing equipment

During maintenance equipment is exposed

Access plates and hatches Open piping

Open containers

Seal Your Systems

Do not leave

units open

to the

atmosphere.

Dirt is a great insulator.

Use Adequate Breathers

Typical breather caps

only protect from

Use Adequate Breathers

Mounting

breathers several

inches above the

unit will greatly

Use Adequate Breathers

Apply the right kind of breather to the

application

De s i c c a n t B r e a t h e r Fi l t e r B r e a t h e r

Se a l e d B r e a t h e r

Seal The Systems and Your

Prevent Contamination At Each Handling Step

Remember, new oil is usually not clean enough to

meet sensitive equipment

cleanliness requirements

Filter it in!

Proper Container Storage & Handling

Water Surrounding the Bung will enter the drum through normal breathing This

occurs to sealed drums too!

Effects of Water on Sealed Drums

TILT DRUMS PLASTIC COVERS

Proper Storage and Handling

If it must be outside

Proper Storage and Handling

Dispensing containers should be sealed too.

Mixing Different Oils is Contamination Too!

and color coded to

minimize lube cross

contamination.

Tag Lubrication Points and Dispensing Equipment

Tag the equipment

to help ensure that

the right lubricant

is in the right place.

Use Routine Filtration

Filter carts should be used to

clean oil in systems and storage containers routinely.

The easier it is to use the better Filter oil as it goes into a system.

Be careful filtering multi-grade

products Most filters designed

to clean oil can strip VI Improvers out

For Multi-grades use filters that are 10 micron and up.

Flush between product changes.

Using a single pump to

pump multiple product

families will ensure

cross contamination

Drum with desiccant breather

and adapter kit.

Use System Adapters Where Possible

Drum Adapters and Quick

Connects allow for quick,

easy connections for your

filter cart.

Install Quick Connects on

Systems to allow for quick

connections which makes

it easy to use the filter

cart

Use a Filter Cart with a

bypass system and Quick

Connect Couplings

Bypass allows for use as

system evacuation pump or

oil transfer

A Little About Filtration

Filter Rating Terminology

Nominal Rating - Rates size of pores in filter

(5 micron nominal)

Absolute - Gives Largest opening in media

Beta Ratio/%Efficiency - How many times through the filter before all particles of certain size are removed

Filter Sizes

Conventional System - 10 to 25 micron Absolute

N/C and Servo Systems - 3 to 5 micron Absolute

Know Your Filters

The Multipass Filter Performance Test, ISO

4572, is the most recognized standard for rating

the ability of a filter to efficiently control

contamination

The results of this test are reported as the ratio

of the number of particles greater than a

designated size upstream of the filter to the

number of particles greater than the same size downstream of the filter

This rating is the Beta Ratio.

Know Your Filters

Know Your Filters

Example on the previous slide above:

(Number of Particles Downstream ÷ Number

of Particles Upstream) X 100 = % Efficiency (100 ÷ 200) = 5 x 100 = 50% Efficient

(199 ÷ 200) = 995 X 100 = 99.5% Efficient

Seal the Systems, Look out for

Hose and pump trash;

Cap the end of hoses and pumps

Bad environments may require positive pressure (air padding).

Cap grease guns.

Clean grease fittings before use.

External Site Glasses On Pumps Can Help Detect Problems

Provide Contamination Control Training

Increases employee awareness and

efficiency.

Reduce Your Costs Extend Lubricant and Equipment

Life Through Contamination Control