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Total Fluid ManagementPamapersada Nusantara

CONDITION MONITORING FUEL AND OIL FOR EFFECTIVE MAINTENANCE IN MINING HEAVY EQUIPMENTS

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Pamapersada Nusantara Total Fluid Management

Diskusi Ilmiah MASPI ke-10Jakarta, 14 April 2009


For most mechanical systems, the reliability engineer must define the lubricant as a critical component of the system because no shared-load system or spare exists for the function performed by the lubricant unless the host system is spared. Drew D. Troyer, "How to Lube Up Your FMEA Process". Practicing Oil Analysis Magazine. May 2000

PREFACE

LUBE FUNCTION

Lubricating Reduce friction Reduce wear Perform oil layer Transmission of power, hydraulics Cleaning Cooling Sealing Heat Transfer


Did you know that 8 out every 10 diesel engine failures are directly related to contaminated diesel fuel?

--Diesel Fuel Polishing Service July 2006

75-85% of hydraulic system failures are caused by contamination.

-- Hydraulics & Pneumatics June 1998-- Equipment Today August 1997


Likewise, a lubrication failure can produce significant secondary damage to other system components. Because of the lubricant’s critical nature, and the frequency with which mechanical failure is related to the lubricating system.

Drew D. Troyer, "How to Lube Up Your FMEA Process". Practicing Oil Analysis Magazine. May 2000

LUBE DEGRADATION

THERMAL BREAKDOWN Direct heat degradation of lubrication Overheating Oil Thinning

CHEMICAL BREAKDOWN Aging or Oxidation Oil Thickening

HYDROLYTIC BREAKDOWN Degradation by reaction of water Oil Thinning and milky

Contamination of the oil with solid or metal contaminant can accelerate the oxidation process.


Mark Barnes, Noria Corporation, "The Lowdown on Oil Breakdown". Practicing Oil Analysis Magazine. May 2003

The Three Common Methods of Hydrocarbon Oil Degradation


VISCOUS CYCLE OF THERMAL FAILURE

E.C. Fitch, Tribolics, Inc., "Temperature Stability". Machinery Lubrication Magazine. July 2002

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Lube Condition Monitoring System uses to minimize and control lube degradations within continuously monitoring the quality of fuel and oil.It offers significant advantages to planned equipment maintenance and make some identifications as predictive and proactive maintenance.

LUBE CONDITION MONITORING


Fluid Properties Analysis. Information on a lubricant’s physical and chemical properties such as viscosity, acid number, additives, etc.

Fluid Contamination Analysis. The presence of uninvited guests such as dirt, glycol, soot, fuel, water, etc.

Fluid Wear Debris Analysis. Concentration and characterization of wear metals suspended in used oil.

Lube service life extension has to confirm in laboratory studies, monitoring and analyze through the experience in the field.

There are three aspects of lube analyze are :

LUBE CONDITION MONITORING

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CONDITION MONITORING FUEL AND OIL IN MINING OPERATION


LUBE CONDITION MONITORING END to END

Supplier/ Transporter

Heavy Equipment

Main Tank/ Oil Storage Lube Truck

(WHAT – WHERE – WHEN – WHO - HOW)


LUBE CONDITION MONITORING END to END

- WHAT : Requirement Standard Lube Specification from OEM and Standard Properties

- WHERE : Sampling Point for Every Component and Lube Line Distribution

- WHEN : Periodically based on Component Type and New Lube

Incoming - WHO : Fuel and Oil Operator, Technical Mechanic, Lube Analyst - HOW : Periodically Sampling, Monitor, Analyze, Follow Up,

Feedback and Data Recording


Requirement Standard

Table 2: Oil Contamination Guidelines

PropertyGuideline

Viscosity change @ 100°C (ASTM-D445)

±1 SAE Viscosity grade or 5 cSt from the new oil

Fuel Dilution 5 %

Total base number (TBN) (ASTM D-4739)

2.5 number minimum or half new oil value or equal to TAN

Water content ASTM (D-95)

0.5 % maximum

Potential Contaminants:

Silicone (SI) 15 ppm increase over new oil

Sodium (Na) 20 ppm increase over new oil

Boron (B) 25 ppm increase over new oil

Potassium (K) 20 ppm increase over new oil

Cummins Engine Oil Recommendations


Requirement Standard (KOMATSU)


EquipmentFuel TruckMain TankTransporter

Fuel Sampling Point

CONTOH KASUS – WHAT HAPPENED WITH MAIN TANK?

Grafik Monitor Kebersihan

5

76

5

012345678

Transporter Main Tank Fuel Truck Equipment

Lokasi

Cle

an

line

ss

NA

S


Oil Sampling Point

Oil Engine

Hydraulic Oil

Differential Oil

Final Drive Oil


Sampling Periodically


LINE DISTRIBUTION

Supplier/ Transporter

Heavy Equipment

Main Tank/ Oil Storage Lube Truck


SUPPLIER/ TRANSPORTER

QUALITY Water suspecting Specific gravity Lube properties Cleanliness

QUANTITY Metering Seal

Fuel Test Properties


STORAGE/ MAIN TANK

GOOD INFRASTRUCTURE & CONDITION Pump Metering (Calibration) Strainer/ Filtration (correct beta ratio) Breather Remove water/ daily drain Space management ? Fast fill/ dry coupler adapter Bottom fill Floating suction Microbial inhibitor Safety Environment

Water In Lube Rises Contaminant

QUALITY Water content Microbial content Cleanliness (lab analyze) Lube properties (lab analyze)

Microbial Test


LUBE TRUCK/ SERVICE TRUCK

GOOD INFRASTRUCTURE & CONDITION Pump Metering (Calibration) Strainer/ Filtration (correct beta ratio) Breather Remove water/ daily drain Space management ? Fast fill/ dry coupler adapter Bottom fill Safety Environment

QUALITY Cleanliness (lab analyze) Lube properties (lab analyze)


EQUIPMENT USED OIL ANALYSIS

Periodic oil analysis can extend the life of equipment in excess of three times the normal or historic average. In addition, the cost of replacing equipment can be reduced by 50 percent or more. Opportunities for minimizing equipment failure, reducing the cost of analysis and extend the component lifetime. M. Williamson “First Line of Defense,” Issue of Lubricants World, May 2000


CATEGORIES OF OIL ANALYSIS TEST

Ashley Mayer Noria Corporation, "Using the Three Categories of Oil Analysis to Assist in Diagnosis". Practicing Oil Analysis Magazine. November 2006


SYSTEMATIC METHOD LUBE ANALYSIS INTERPRETATION, STEP BY STEP

1. Known sample and equipment conditions

No Equipment Component Type : Engine/ Transmission/

Hydraulic etc Component Hour Meter : Oil Hour Meter : 250/ 500/ 1000/ 2000 HM Oil Type : ISO VG, SAE Sample Date : 01/01/01 Name of Mechanic : Mr P Name of Company : PT. Sampling Location : Final Drive Left Side Additional Information :


2. Normalization

Terminology

• Baseline – This represents the original characteristics and properties of the new oil to be applied in the equipment (viscosity, AN, BN, additive content, oxidation stability, RPVOT for turbine oils). It is important to measure the baseline data from the beginning when implementing an oil analysis program.

• Caution Limits - Exceeding caution limits results in abnormal conditions and requires corrective actions.

• Critical Limits - Exceeding critical limits indicates a critical situation and requires immediate action.

• Goal-based Limits - These limits are set as predetermined values of properties (such as ISO code cleanliness, maximum water content, etc.).

• Aging Limits - These limits are a result of the oil’s normal aging process. For example: the highest permissible limit of acidity, oxidation or nitration; the lowest additive concentration, etc.

• Statistical Limits - These limits are statistically determined. Data average and standard deviation are obtained. Caution limit is set at an average of +/-1 standard deviation, and critical limit is set at an average of +/-2 standard deviations. Statistical limits may be applied to wear metals.

• Normalization - When collecting samples with different time intervals in reference to set frequency, it is easy to make mistakes and come to the wrong conclusions. Consider the following example: If the objective is to monitor iron wear every 500 hours and the data is 40 ppm (400 hours), 55 ppm (580 hours), 30 ppm (450 hours) and 68 ppm (500 hours), then the analyst observes which samples were taken at different time intervals Therefore, the data should be normalized in the following manner: For the first data, if during 400 hours the iron wear was 40 ppm, then what would the iron wear be in 500 hours? Answer: (40 ppm iron) (500 hours) / 400 hours = 50 ppm iron.


NORMALIZATION WEAR METAL (FROM KOMATSU)


Reff. On Site Analysis


3. Identification of oil properties

Identify and label each property measured by the categories for example: S for Properties, C for Contamination and D for Wear.

Viscosity (S) Acid Number (S) Water (C) Oil Cleanliness (C) Zinc (additive) (S) Silicon (both additive and contaminant) (S/C) Copper (wear metal) (D) Iron (wear metal) (D) Viscosity Index (S) Flash Point (S)


4. Baseline and last sample data analysis

Compare oil analysis results with baseline information. Refer to previous oil analysis results and review data of historical samples, then identify trends.


5. Setting limits

Based upon baseline data, determine caution and critical limits for each property. These will vary based on factors such as machine type and criticality. Write the calculated caution and critical limits next to each property.


6. Data qualification

Use the following terms to qualify the data.

Normal : when data value is less than or between caution limits. Trend data (B) : these values are between set limits but follow a particular trend (such as continuously decreasing or increasing, cyclic behavior, etc.). Problem/Abnormal (A) : these values are termed “pivots” and are used as reference points to qualify the report. Pivots are points that are out of critical limits


7. Partial conclusions

Note partial conclusions for each property

Properties - Viscosity (Normal), TBN (normal), additive content (normal), viscosity index (normal)

Contamination – Oxidation (Normal) Fuel (Normal), Soot (Normal) Water (Normal)

Wear - Abnormal, Cu out of limit


8. Pivot analysis, conclusions and recommendations

Upon completion, assemble all the notes together. If pivots (or trend data) indicate a relationship, analyze and summarize the findings. Avoid making early conclusions, and conduct a field investigation if necessary.


Additional Tool for Analyze and Recommendation


Puliyur Madhavan and Neal C. Werner, Pall Corporation, "Contamination Control for Extending Fluid Service Life". Practicing Oil Analysis Magazine. March 2005

Additional Tool for Analyze and Recommendation


MAINTENANCE CONCEPTCorrective Maintenance Action when failure occured.- High cost- Lost production

Preventive MaintenanceSchedule maintenance according to time - Over and under-maintained equipment- No root cause analysis

Perdictive Maintenance Condition-based maintenance. Consider the unique characteristics of each component- Increase production- Less overtime- Minor problem corrected early

Proactive MaintenanceCorrective action aimed at the root cause- Analyze and anticipate rather than react and repair- Reliability through oil analysis/ wear particle analysis- Reduce the number of breakdown failure

Predictive and proactive maintenance in industrial machinery is a proven strategy in extending equipment life and reducing downtime.


FOLLOW UP PROACTIVE MAINTENANCEBased on Conditioning Monitoring

HOSE CLEANING FOR HYDRAULIC SYSTEM

KIDNEY LOOP FOR DIFF OIL, F/D OIL, HYDRAULIC OIL,FUEL TANK TO REDUCE CONTAMINATION AND WEAR GENERATE

ADDITIONAL BY PASS FILTER TO REDUCE CONTAMINATION IN HYDRAULIC SYSTEM AND SOOT IN ENGINE


CONCLUSION

Lube analysis is a powerful tool condition monitoring and an important contributor to heavy equipment plant reliability.

This technology can be applied in both predictive maintenance and failure root cause investigation and is a keystone of

proactive maintenance.


TERIMA KASIH

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Optimized maspi pama april 2009 rev1 pomer point