Trend Health Check & Monitoring Program - in-depth fluid condition analysis at laboratory

Transcription

1 Trend Health Check & Monitoring Program - in-depth fluid condition analysis at laboratory A thorough monitoring program is essential for an efficient preventive maintenance of your system. Our program detects even the smallest changes in the health of your system at a very early stage, which will enable you to take action before the changes causes interruptions within the production. We Complete the Circle 1. On-site Oil Sampling: A ssistance w ith representative oil sampling in accordance to standards: ISO 4021, ISO 4407, ISO 3722, NAS 1638 and AS In-depth Analysis at Laboratory: Execution of a wide range of both routine and special analysis tests. Read more about the content of different analysis packages on the following pages. 3. Trend Analysis & Trouble Shooting: Test results are saved in a database enabling us to perform trendanalyses for each unique system. Any deviations from the normal trend curve will immediately be identified and followed up by a trouble shooting process in order to identify, what is causing these divergent test results. 4. Recommenced Action Plan: Co nsultation of recommended further actions, which will spare you for unnecessary shutdowns and production loss. 5. On-site Execution of Recommended Actions: Not only do we recommend a problem solving action plan and use differentiating technologies. We also offer to complete the circle by executing the agreed actions and hereby eliminate those trouble making factors in your system. One-Stop-Service Program 5. On-Site execution of recommended actions 4. Recommended action plan 3. Trend analysis & trouble shooting 1. On-Site oil sampling 2. In-Depth analysis at laboratory

2 With increasing costs and tighter deadlines, the need for effective maintenance strategies is greater than ever before. Optimise your maintenance program with Ocean Teams Contamination Monitoring Program. Like a blood sample, a small amount of oil can show signs of contamination, degradation and/or wear and tear. In machinery the oil sample will carry small particles of metallic debris, which can give indications of any wear patterns, which may be occurring within the system. Using state of the art instruments we can determine the composition and concentration of these metallic particles and indicate which part of the machinery is wearing at abnormal rates. Information generated from an oil analysis can be used for prediction of a potential problem with the oil or machinery before it becomes critical and long before it becomes evident to the maintenance engineer. This enables you to plan an efficient and optimal preventive maintenance of your system saving you for costly downtime and minimise your maintenance and repair costs. Analysis for all Applications All mechanical equipment will benefit from a fluid condition monitoring program. Our laboratory is accredited to UKAS ISO17025 and has more than 30 years of experience in analysing samples from all types of lubricated systems including: Engines diesel, petrol and gas powered Hydraulic systems Gearboxes Compressors Turbines gas and steam Heat transfer systems Circulating oils Transmissions Transformers Cooling Waters Analytical services: Greases Fuels Coolants Ferrography Product formulations Chemical and microscopy examination: Sludge/deposits Metal debris Filters What Analyses do We Offer? Our testing ranges from basic contamination checks to full-blown system oil condition analysis, whereby we perform lubricant condition checks to ascertain whether your system oil is fit for further use. Our routine testing program includes among others analysis of wear metals, ISO 4406 particle count, viscosity and colour. Beside our routine testing program, we offer a range of additional tests, which is especially recommended to be

3 performed at least twice a year on in-service turbine oils: Foaming sequence: ASTM D892 Demulsification number: IP 19 Emulsibility: ASTM D1401 Rust prevention characteristics: IP 135 A&B Air release: IP313 Oxidation stability (RPVOT): ASTM D2272 Acid number: ASTM D664 Varnish potential: ultra-centrifuge method and patch colourimetry Water content: Karl Fischer method Flash point closed cup: ASTM D93 The content of each of the analysis packages is outlined in the table at the following pages. For further information about the different additional tests, take a look at the below Technical Insight Box. We have divided our analysis program into 3 different standard packages. TECHINICAL INSIGHT Explanation of Turbine Oil Analyses Methods Why are the additional oil analysis tests important to the optimization of your maintenance program? Following a short explanation of the different additional tests within our Turbine Health check Service Program: Foaming Sequence: The foaming characteristics of turbine oil can be analysed at the lab by blowing air through the oil and measuring the amount of foam generated. Too much foam can strongly affect a lubricants ability to perform and can be derived from contamination of the oil, excessive agitation, or cavitation. Emulsibility: In steam turbine applications it is inevitable that the lubricating oil will come into contact with water; therefore it is vital that the oil s ability to shed water is monitored. Oil that sheds water quickly will continue to perform in a desired way than oil that continues to hold in the water and therefore will lose lubrication and oxida-tion resistance capabilities. Rust Prevention: All turbine oils will contain additives that will help inhibit rust. Rust particles can cause abnormal increases in wear metals within the lubricated system and increase the rate of oxidation. Air Release: The air release properties of oils need to be monitored to ensure that the in-service oil continues to have the ability to detrain entrained air. Too much air in lubricating oils can lead to increased oxidation of the oil and reduced film strength properties. Oxidation Stability: Over time turbine oils will oxidise. Monitoring the amount of oxidation resistance is critical to ascertain the remaining use-ful life of the oil. Using the RPVOT test enables the laboratory to make a comparison against an unused RPVOT level to determine the oils condition. Acid Number: Abnormal increases in an oil s acid levels may indicate severe oxidation or over-heating of the oil. These acids can corrode metallic components. Varnish Potential: Varnish found within lubricat-ed systems can affect operating temperatures, clearances and increase component wear, it is usually derived from oxidised oil by-products or additives. It can be analysed by colourimetric testing or the Ultra-Centrifuge test. Ultracentrifuge Test: This test measures the amount of insoluble material and oxidised material present within the sample. The test gives results of 1 through to 8, with the higher number showing higher levels of insoluble material present. This insoluble material can indicate possible varnish potential problems and oils with a result higher than 4 should be monitored closely Water Content: The amount of water present in turbine oil will reflect the potential for rust formation and reduction in oxidation resistance. Therefore it is vital that these water concentra-tions are monitored and kept at low levels. Water can also cause sludge formation and affect the oil s viscosity.

4 Routine Lubrication Oil Analysis Our Routine Lubrication Oil Analysis Service is a prepaid service. This means that you buy the standard bottles upfront. The bottle comes in a pre-addressed mailing tube with a submission sheet and the cost of the analysis is included in the initial upfront payment. Duration of test: 5 working days. Tests performed: See table below. Olieanalysis Standard - Standard bottle type 250 ml Variants Diesel Gearbox/ Hydraulic Trans- Air Circ Fridga Diesel- Engine pumpe mission Compressor Oil Compressor Fuel Viscosity at 40 C (cst) (based on IP71)* Viscosity at 100 C (cst) (based on IP71)* Wear metals and contami-nation (ppm) (based on ASTM D5185)* Appearance Water (%) Water KF (ppm) (based on ASTM D6304)* Ferrous Debris ISO cleanliness code (based on BS EN ISO 4406)* Soot % Fuel Dilution & Flash Point Glykol Glycol Total Acid Number (based on IP139)* Total Base Number (based on IP276)* Foam sequence 1 Water separation Air release Rust test RPVOT Varnish Potential by MPC RULER *Accredited to UKAS ISO17025 = By Oil Analysis Advance kit 1 selects one of these three Olieanalysis Advance kit 1 Standard bottle type 250 ml Olieanalysis Advance kit 2 Standard bottle type ml

5 Online Trending and Web Site Access The test results are send as pdf attachment to specified addresses. Further we offer client specific passwords enabling customers to access their complete historical database of all sample results and reports from a single secure website. Results are uploaded daily and the first page check allows you to view the status of recently uploaded results. Results can be split by location for users who sample from multiple sites, and sample reports can be searched by many parameters including equipment make, model serial number or oil grade. As well as viewing all samples submitted online, other aspects of our oil analysis services can be accessed, including: Online trending Creation of individual unit or multiple plant sampling schedule Ordering sample kits the lab Print sample bottle labels Does your Oil Analysis tell the Truth? The reliability of an oil analysis is very much dependent on how the oil sample is extracted from the system and how it is treated afterwards. To secure reliable test results Ocean Team offers our assistance with representative oil sample extractions in accordance with ISO 4021, ISO 4407, ISO 3722, NAS 1638 and AS Misleading results from oil analyses can result in inefficient and/or insufficient maintenance of your systems. A reliable contamination monitoring program secures the most optimal maintenance of your systems. For further information contact us at: Tel ots@oceanteam.eu