Maximize Equipment Life with Lubricant Condition Management

Organized by:

Optimize Equipment Life with Lubricant Condition Management

Jarrod Potteiger

Education Services Manager

Des-Case Corporation

© 2012 Des-Case Corp.

2

Des-Case Confidential

© 2010 Des-Case Corp. Slide XXXX

What is Precision Lubrication?

Using better or more expensive lubricants is not precision

lubrication.

Increasing lubrication PM frequencies is not precision lubrication.

Precision lubrication requires a holistic approach including lubricant

specifications, education, contamination control, PM optimization,

proper storage and handling, condition monitoring, etc.

Doing lubrication the right way is almost always easier than doing it

the wrong way.


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What Causes Machines to Fail?

Ref: MIT, E. Rabinowicz

70% of loss of machine life is dueto loss of surface material

Loss of Usefulness



4

What Causes Surface Degradation?

Ref: MIT, E. Rabinowicz

Surface Degradation



5

What Causes Machines to Wear?

Ref: NRCC, STLE

Primary Wear Mechanisms

82% of mechanical

wear is caused by

particle contamination



The value of Contamination Control

Before After

Standard OEM

filtration

Standard OEM/

3 um bypass

filtration

ISO Code (6/14 um) 19/16 15/12

Mean Time to rebuild 14,500 hrs 52,000 hrs

Annual Rebuild Cost $151,000 $42,000

Savings/year $109,000

Upfront Cost $900

Ongoing Cost $200/year

• CAT 980F (3406 diesel engine)• Installed a 6 um cellulose depth media

filter in by-pass after the full flow filter, taking 10% of the oil flow

• Monitored oil analysis to determine engine health and fluid cleanliness

Results:

3.5x life extension

Annualized savings/year estimated to be approximately $100K


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Auto Manufacturing Case Study

© 2010 Des-Case Corp. Slide rw bmp 14

Principle Strategy• Education

• Contamination Control

• Storage and Handling

• PM Optimization


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Automotive Press Case Study

0

10000

20000

30000

40000

50000

60000

70000

80000

1 2 3 4 5 6 7

Par

ticl

e C

on

cen

trat

ion

(P

arti

cle

s/m

L) =

/>4

mic

ron

Sample Number

93%-97% reduction in particle

contamination



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Automotive Press Case Study con’t

A Line B Line C Line D Line E Line

3 yearaverage

2012 YTD

Do

wn

tim

e (M

inu

tes)

Downtime54% reduction in

downtime

6 7 8 9 10


What is contamination?

© 2010 Des-Case Corp. Slide CCT 40

Dirt & other Particles

Water Air Wear Debris

FuelOther

LubricantsCoolant Detergents

and other Chemicals

Anything that doesn’t belong in the oil

Damage Caused by Contaminant Type

Direct Machine Wear

Damage to Lubricant

Indirect Damage

Particle Contamination

•Abrasion•Erosion•Fatigue•Valve Stiction (silt

lock)

•Oxidation•Particle Scrubbing•Viscosity Increase

•Varnish / Deposits•Corrosive attack• Increased aeration

Moisture Contamination

•Corrosion•Cavitation erosion

•Oxidation•Hydrolysis•Water Washing•Viscosity Increase

•Varnish / Deposits•Corrosive attack• Increase Aeration•Exacerbates all

wear mechanisms due to loss of film strength


Common Effects of Contamination

© 2010 Des-Case Corp. Slide 0000

How Big is a Micron?

0.001” = 25.4 microns 1” = 25,400 microns

Human Hair


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How New Oil Gets Dirty

Refinery / Blend Plant

National Distribution

Regional DistributionLocal Distributor

By the time oil arrives at your site, it is already too dirty for most

equipment.

Poor storage and transfer methods add to the contamination.

Dirty accessories compound the problem.

Not using the proper breathers allow more contaminants to enter

the oil.

DeliveryISO 19/17/15

StorageISO 20/18/16

DispensingISO 21/19/17

In ServiceISO 22/20/18



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Contamination Control Strategy

3


Set Targets Measure ResultsTake Action


15 15

Machine Type Particle Level Target Moisture Level Target

Hydraulics1500-

2500psi

With servo valves 15/13/11 125 ppm

With proportional valves

16/14/12 150 ppm

Variable volumepiston pump

17/15/12 150 ppm

With cartridge valves or fixed piston pump

17/16/13 150 ppm

With vane pump 18/16/14 150 ppm

Gearbox 19/16/13 300 ppm

Paper Machine 18/14/11 200 ppm

Steam Turbine 18/14/11 100 ppm

Pumps 17/14/12 150 ppm


How Clean / Dry should oil be?


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Contamination Control Methods

Contamination Exclusion• Filter new oil

• Use good quality breathers

• Use sound application methods

• Upgrade seals

• Use hydraulic cylinder rod boots

• Utilize non-invasive inspection / sampling methods

• Use sound flushing practice for new or recently serviced equipment

• Practice good parts management

Contamination Removal• Upgrade system filters

• Permanent off-line filtration

• Portable off-line filtration

• Vacuum dehydration

• Centrifugal separators

• Water absorbing filters

• Coalescing filters

• Air stripping

• Electrostatic / BCA filters

• System flushing

Studies show it costs about 10 times more to remove contamination than it does to exclude it.



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Particle Effects on Component Life


Tested Particle Count24/20/13

New Target Count17/15/12

Anticipated Life Extension = 4X


Effects of water on bearing life


Particle and Moisture Exclusion

Head space managementQuality sealsFilter new oilPassive shieldingGood parts storageUse quality oil transfer equipment


Headspace Management

Controlling the condition of the air in the headspace above the oil is one of the most cost effective ways to prevent contamination.

Methods for headspace management

Desiccant breathersHybrid breatherMechanical filtersNitrogen purgeConditioned air purgeExpansion chambers

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How Do We Rate Filter Performance?

The Beta Rating is the ratio of particles, at a given size, upstream of the filter Vs. downstream of the filter.


100 particles in (5 microns or greater)1 particle out (5 microns or greater)

= β5 ≥ 100

Efficiency = (β-1) x 100% (100-1) x 100% = 99%β 100


Filter Media Type / Design

Micro-glass Fibers Pleated Cellulose Fibers


Portable Offline Filtration Units

Portable offline filtration is one of the most useful tools in your lubrication arsenal.

Uses for filter carts

Offline DecontaminationFlushing during commissioningOil transfersDispensing to top up containersFlushing hoses / other equipmentPower flushing small systemsPeriodic decontamination


Portable Filtration Effectiveness

New oil Unfiltered in-service oil

Filtered in-service oil, 180 mins 12 um


Portable Filtration Effectiveness Cont’d

Before Filtration100x Magnification


Portable Filtration Effectiveness Cont’d

After Filtration

100x Magnification


Water Removal – Vacuum Dehydrator

Removes all free and emulsified water and up to 90% of dissolved water by lowering pressure and boiling the water at a safe temperature for the oil.

Very effective for removing all water from the oil. Poorly designed units can be difficult to maintain.


Water Removal – Polymer Absorbent Filters

Removes free and emulsified water using a polymer absorbent.

Very cost effective for removing water from small sumps where larger, more expensive options are not feasible.


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Problem:A large refinery was experiencing pump failures at a rate of 351/year

Solution:Deployed new lubricant storage and handling, equipment tagging and operator lead reliability

Results:

• Pump failures dropped from 351 to 276 in 1 year• Estimated annualized savings of $935,000• Reduction in lubricant purchases of $50,000• 5-year Net Present Value (NPV) savings of $3M at

an Internal Rate of Return (IRR) of 196%

The Value of Precision Lubrication – Storage & Handling



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Des-Case Confidential30

Essential Components for World-Class Storage and Dispensation Systems

Separate fluid handling for each product

Filtration….Filtration….FiltrationQuality tank breathers

Product tagging to preventcross-contamination

Climate control

Quality assurance procedures includingnew oil testing

Oil Storage and Dispensing



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Essential Modifications to Maintain Cleanliness



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Gearbox Modifications


High Quality Breather

ISO ‘B’ QuickDisconnect

Sample Valve /Liquid Level / QC

Engineering

Maximize Equipment Life with Lubricant Condition Management