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7/27/2019 Bearings Contaminations Control
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Piedmont Chapter 14,Vibration Institute Meeting
December 5, 2008
Midlands Technical CollegeWest Columbia, SC
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Introduction and Timing
Jeremiah JB Bacon C.L.S.
PetroLiance, LLC
Presentation should take about 1 hour.
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What is Contamination?
ANY FOREIGN MATERIAL THATADVERSILY AFFECTS THEOPERATION OF YOUR EQUIPMENT.
Wrong OilChemical
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Why Is Cleanliness So Important?
Typical bearing application
Lubricanth
Load Zone Pressures Can BeGreater Than 100,000 PSI
Oil Thickness is0.1 to 3 Microns
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Contamination Destroys Equipment
3 MicronParticle
Abrasive Wear is the most common type of wear.
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The Life of a Typical Hydraulic Pump
The life of a typical hydraulic pump can bepredicted based on the amount of contaminationthat passes through the pump during its life.
50 gpm Pump
ISO 21/18 ISO 14/11
1750 lbs/Yr 50 lbs/Yr
2 Yr. Pump Life >14 Yr.Pump Life
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What Size Particles Are We Talking About?
What size particlecan you see?
Table Salt 100
Human Hair 70
Lower Limit of site~ 40
Flour 25
White Blood Cell25
Red Blood Cell 8
What Size Part icle Wil lCause A Problem?
15
1
1 Micron = .000039 INCH
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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.
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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.
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Abrasive Particulate Effects In Gears
Abrasive particles cause seals to erodeand bearings to wear prematurely.
Shortens Rebuild/Replace IntervalsIncreases Oil Consumption from Leaks
Increases Maintenance Costs
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Water Is Harmful Too!
Water is the SECONDMost DestructiveContaminant!!!
Changes Oil ViscosityRust & Corrosion
Hydrogen Embrittlement
Acids
Pitting
Causes Foaming
Sludge & Sediment
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What Water Contamination Can Do to aBearing
The Problem: Water causes Hydrogen
Embrittlement of the metal and premature fatigue.
Hydrogen
Embrittlement
Spalling from
Embrittlement
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Water, What is ok?
ACCEPTABLELEVELS: Typicallybelow 250 PPM.
It is normal to seelevels of 150 to 250PPM or 0.0150.025 % in SC
You can see waterat around 900 PPM
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If We Can t See it,How Do We Know It s There?
Heat
Vibration
Equipment Failures
Sludge
Cloudy Oil
Residue
Sticking ValvesAll ending up in Premature Failures whichequates to Production Loss & Money
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If We Can t See it,How Do We Know It s There?
Use Oil Analysis with Particle Counts.
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ISO Particle Counts
It is important to understand what ISOParticle Counts are.
What is it?
Quantitative analysis of oil to determine thedistribution 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 outof the oil
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Filter Patch: ISO Rating of 20/17/15
Range or codeGreater Than 4 micron
Greater Than 6 micron
Greater Than 14 micron
We have to have someway of knowing it isthere....
Oil Analysis ISOParticle Counts
Cleanliness Code 20/17/15
Filter Pad PC Scale:1Division =14 m
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ISO Code Range Counts
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ISO Cleanliness
Code 20/19/16
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ISO Cleanliness Comparison
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OEM Recommended ISO Codes
What is acceptable?
There are definite
standards set byeach company.
Here are some goodexamples.
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How Do We Control Contamination?
To control contamination, you ll need to assess justhow contaminated your systems are.
Use Oil Analysis with Particle Counts to determine
current system cleanliness levels.Identify the most sensitive components on eachsystem.
Set system cleanliness goals base on thosesensitive components identified.
Document ISO cleanliness code and water contentresults for each system.
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How Do We Control Contamination?
Once you have established howcontaminated your systems are, and whatcleanliness level your system should be to
maximize life;Initiate a directive to work toward those goals byputting best practices in place.
Once your cleanliness goals are met, develop a
maintenance plan to keep systems clean.
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How Do We Control Contamination?
You will take care of most of thecontaminants if you will do 7 Things;
SEAL THE SYSTEMS
KEEP SYSTEM EXTERIORS CLEANUSE ADEQUATE SYSTEM BREATHERS
STORE AND DISPENSE OIL PROPERLY
ROUTINELY USE OFF-LINE FILTRATION
INSPECT SYSTEMS AND MONITOR FOR OILCONTAMINANTS REGULARLY
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FIRST: SEAL THE SYSTEMS
You want your systems to get clean oil andkeep 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 hatchesOpen piping
Open containers
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130 FOK
164 F Oil Life Cut
By 1/2
Keep System Exteriors Clean
Dirt is a great insulator.
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Use Adequate Breathers
Typical breather capsonly protect fromlarge things.
You need to beconcerned with smallparticles.
Use breathers that are5 microns or better.
Help the breather bygetting it out of the
contamination, raise it!
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Use Adequate Breathers
Mountingbreathers severalinches above theunit will greatly
increase theireffectiveness.
Use desiccant
breathers to fightcondensation.
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Use Adequate Breathers
Apply the right kind of breather to theapplication
Desic c ant Breat her Fi l t er Breat herSealed Breather
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Seal The Systems and YourContainers
Drum Open tothe Elements
Dip Stick Left Opento the Elements
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Prevent Contamination At Each HandlingStep
Remember, new oil isusually not clean enough tomeet sensitive equipmentcleanliness requirements.
Filter it in!
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Proper Container Storage & Handling
Water Surrounding the Bung will enter thedrum through normal breathing . This
occurs to sealed drums too!
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Effects of Water on Sealed Drums
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TILT DRUMS PLASTIC COVERS
Proper Storage and Handling
If it must be outside
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Proper Storage and Handling
Dispensing containers should be sealed too.
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Mixing Different Oils is Contamination Too!
Containers should besealable.
Containers should beutilized for single
family lubricants toavoid crosscontamination.
Should be tagged
and color coded tominimize lube crosscontamination.
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Tag Lubrication Points and DispensingEquipment
Tag the equipmentto help ensure thatthe right lubricant
is in the right place.
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Use Routine Filtration
Filter carts should be used toclean oil in systems and storagecontainers routinely.
The easier it is to use the better.
Filter oil as it goes into a system.Be careful filtering multi-gradeproducts. Most filters designedto clean oil can strip VI Improversout.
For Multi-grades use filters thatare 10 micron and up.
Flush between product changes.
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Storage Containers
Use particulatebreathers on bulktanks, totes anddrums.
Utilize pumps for eachproduct family.
Using a single pump topump multiple product
families will ensurecross contamination.
Drum with desiccant breatherand adapter kit.
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Use System Adapters Where Possible
Drum Adapters and QuickConnects allow for quick,easy connections for yourfilter cart.
Install Quick Connects on
Systems to allow for quickconnections which makesit easy to use the filtercart.
Use a Filter Cart with a
bypass system and QuickConnect CouplingsBypass allows for use assystem evacuation pump oroil transfer
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A Little About Filtration
Filter Rating Terminology
Nominal Rating - Rates size of pores in filter(5 micron nominal)
Absolute - Gives Largest opening in mediaBeta Ratio/%Efficiency - How many times through thefilter before all particles of certain size are removed
Filter Sizes
Conventional System - 10 to 25 micron AbsoluteN/C and Servo Systems - 3 to 5 micron Absolute
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Know Your Filters
The Multipass Filter Performance Test, ISO4572, is the most recognized standard for ratingthe ability of a filter to efficiently control
contamination.The results of this test are reported as the ratioof the number of particles greater than adesignated size upstream of the filter to thenumber of particles greater than the same size
downstream of the filter.This rating is the Beta Ratio.
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Know Your Filters
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Know Your Filters
Example on the previous slide above:
(Number of Particles Downstream Numberof Particles Upstream) X 100 = % Efficiency
(100 200) = .5 x 100 = 50% Efficient
(199 200) = .995 X 100 = 99.5% Efficient
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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.
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External Site Glasses On PumpsCan Help Detect Problems
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Provide Contamination Control Training
Increases employee awareness andefficiency.
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Reduce Your CostsExtend Lubricant and Equipment
Life ThroughContamination Control