Bearings Contaminations Control

7/27/2019 Bearings Contaminations Control

1/51

Piedmont Chapter 14,Vibration Institute Meeting

December 5, 2008

Midlands Technical CollegeWest Columbia, SC


2/51

Introduction and Timing

Jeremiah JB Bacon C.L.S.

PetroLiance, LLC

Presentation should take about 1 hour.


3/51

What is Contamination?

ANY FOREIGN MATERIAL THATADVERSILY AFFECTS THEOPERATION OF YOUR EQUIPMENT.

Wrong OilChemical


4/51


5/51


6/51

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


7/51

Contamination Destroys Equipment

3 MicronParticle

Abrasive Wear is the most common type of wear.


8/51

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


9/51

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


10/51

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.


11/51

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.


12/51

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


13/51

Water Is Harmful Too!

Water is the SECONDMost DestructiveContaminant!!!

Changes Oil ViscosityRust & Corrosion

Hydrogen Embrittlement

Acids

Pitting

Causes Foaming

Sludge & Sediment


14/51

What Water Contamination Can Do to aBearing

The Problem: Water causes Hydrogen

Embrittlement of the metal and premature fatigue.

Hydrogen

Embrittlement

Spalling from

Embrittlement


15/51

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


16/51

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


17/51

If We Can t See it,How Do We Know It s There?

Use Oil Analysis with Particle Counts.


18/51

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


19/51

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


20/51

ISO Code Range Counts


21/51

ISO Cleanliness

Code 20/19/16


22/51

ISO Cleanliness Comparison


23/51

OEM Recommended ISO Codes

What is acceptable?

There are definite

standards set byeach company.

Here are some goodexamples.


24/51

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.


25/51


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.


26/51


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


27/51

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


28/51


29/51

130 FOK

164 F Oil Life Cut

By 1/2

Keep System Exteriors Clean

Dirt is a great insulator.


30/51

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!


31/51


Mountingbreathers severalinches above theunit will greatly

increase theireffectiveness.

Use desiccant

breathers to fightcondensation.


32/51


Apply the right kind of breather to theapplication

Desic c ant Breat her Fi l t er Breat herSealed Breather


33/51

Seal The Systems and YourContainers

Drum Open tothe Elements

Dip Stick Left Opento the Elements


34/51

Prevent Contamination At Each HandlingStep

Remember, new oil isusually not clean enough tomeet sensitive equipmentcleanliness requirements.

Filter it in!


35/51

Proper Container Storage & Handling

Water Surrounding the Bung will enter thedrum through normal breathing . This

occurs to sealed drums too!


36/51

Effects of Water on Sealed Drums


37/51

TILT DRUMS PLASTIC COVERS

Proper Storage and Handling

If it must be outside


38/51

Proper Storage and Handling

Dispensing containers should be sealed too.


39/51

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.


40/51

Tag Lubrication Points and DispensingEquipment

Tag the equipmentto help ensure thatthe right lubricant

is in the right place.


41/51

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.


42/51

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.


43/51

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


44/51

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


45/51

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.


46/51

Know Your Filters


47/51

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


48/51

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.


49/51

External Site Glasses On PumpsCan Help Detect Problems


50/51

Provide Contamination Control Training

Increases employee awareness andefficiency.


51/51

Reduce Your CostsExtend Lubricant and Equipment

Life ThroughContamination Control

Documents

Bearings Contaminations Control