Advanced Oil Analysis

Transcription

1 Advanced Oil Analysis

2 Advanced Oil Analysis OCTOBER 2014 LAKESIDE USERS GROUP FORUM 2

3 Agenda Most Common Failure Modes How to Use Lubricant Performance Technologies How Does Each Technology Work? What Readings are Abnormal and What do they Indicate Specific Failure Analysis Case Studies Demonstration of new Portable Technologies

4 About Spectro Scientific Founded in 1981 Headquartered Chelmsford, MA, USA Privately owned by SFW Capital Partners Acquired Emerson CSI oil analysis business in 2012 Acquired Wilks Enterprise in 2013 Changed to Spectro Scientific April ,000 square ft. facility housing R&D, manufacturing, sales, marketing and G&A functions ISO 9001:2008 certified 70+ international representatives for sales and service in over 100 countries

5 Serves Oil Labs and End Users Root Cause Analysis Commercial/Industrial Oil Labs End User Predictive Maintenance

6 Representative Customers & Markets

7 Agenda Most Common Failure Modes How to Use Lubricant Performance Technologies How Does Each Technology Work? What Readings are Abnormal and what do they Indicate Specific Failure Analysis Case Studies Demonstration of new Portable Technologies

8 Overview of Oil Analysis The Two Pillars of Condition Monitoring 2014 Spectro Scientific CONFIDENTIAL

9 Mechanical causes of machine failure- oil wetted components 70% of equipment downtime is due to surface degradation - Corrosion and Wear ROOT CAUSES MECHANISM CAUSES 20% CORROSION water or other corrosive fluids chemically attacks and weakens metal surfaces Water in oil, degraded oil, process contamination, coolant, condensation ABRASION 3 Body Cutting damage from abrasive particles between two moving surfaces Abrasive particles in oil, dirt, secondary wear, process contamination 50% wear ADHESION Damage from metal surfaces dragging over each other Inadequate lubrication low viscosity oil or no oil, high temperature, excess load, slow machine speed FATIGUE Damage from micro cracks caused by cyclic loading Misalignment, imbalance, improper fit or assembly, secondary damage ASLE Bearing Workshop, Rabinowicz, 1981

10 Complementary: Vibration & Lubrication Analysis Proactive maintenance Extends life & prevents failure Reduce dynamic loads to extend machinery life & reduce fatigue Misalignment, imbalance, resonance, looseness and incorrect assembly cause mechanical damage % life remaining Proactive Onset of failure Dust and other particles cause abrasion Water and other fluids cause corrosion Inadequate lubrication causes adhesion ~ 90% of component life in proactive period Eliminate root causes with proactive maintenance. No damage= long component life Operating hours 2014 Spectro Scientific CONFIDENTIAL

11 Complementary Techniques: Vibration and Lubricant Analysis Predictive maintenance When failure has begun onset Predictive Detection of incipient/initial damage Monitor and trend from onset to predict failure % remaining life ~ 10% of component life in Predictive period` Operating hours failure Identify defects with vibration analysis (overall method and advanced analysis techniques such as PeakVue ) Monitor and trend key oil analysis parameters critical to machinery health to establish alarm levels Eliminate root causes with proactive maintenance. No damage= long component life 2014 Spectro Scientific CONFIDENTIAL

12 Agenda Most Common Failure Modes How to Use Lubricant Performance Technologies How Does Each Technology Work? What Readings are Abnormal and what do they Indicate Specific Failure Analysis Case Studies Demonstration of new Portable Technologies

13 Comprehensive Lubricant Analysis Program Is it The Right Lube? Viscosity, additives Is the Lube Still Clean? No dirt, dust Is it still dry? Water, liquids Is it still fit for use? Viscosity, oil chemistry Is the machine still OK? Free of abnormal wear debris How best to address these?

14 Overview of Oil Analysis The Two Pillars of Condition Monitoring 2014 Spectro Scientific CONFIDENTIAL

15 What the Data Means Individual Data Points Somewhat Useful Better to use Trend Information More useful Shows Failure Progression Easier to spot on a Graph Absolute Warnings vs. Relative Warnings If Failure is Rapid, Relative Warning Much Better 2014 Spectro Scientific CONFIDENTIAL

16 Wear Debris Analysis- Key Technology Debris in the system Normal or Abnormal? How Debris is Formed is Your key to Root Cause Analysis Particle Count, Size and Shape is Key that Unlocks Door 2014 Spectro Scientific CONFIDENTIAL

17 Break-In of a Wear Surface Typical surface finish Schematic view of grinding marks from surface finishing. Plastic Deformation Ridges on the wear surface are flattened and form cornices which break away and form long flat particles

18 Severe sliding wear commences when the wear surface stresses become excessive due to load and/or speed. Many sliding wear particles have surface striations as a result of sliding. Severe sliding wear starts with particles greater than 15 µm. Sliding Wear Severe Sliding Wear Severe Sliding with Lubrication Starvation Catastrophic Sliding Wear

19 Three Body Abrasive Wear Cutting wear particle Hard Surface Soft Surface Hard abrasive contamination

20 Surface Damage due to Hard Particles

21 Rolling Element Bearing Failures Cracks initiated in subsurface by high shear stress Surface initiated cracks propagate at acute angles to the surface

22 The Fatigue Process Fatigue of bearing components occurs due to cyclic stressing between rollers and raceways. High stresses are generated underneath the raceway. Maximum stresses are at some distance below the race way surface. Cracking can initiate at inclusions and propagate until it finally breaks out at the surface causing spalling. The edges of the spall act as stress risers causing further removal of material at the spall. A repaired spall can also propagate subsurface cracking and eventually flake out adjacent to the initial repaired area.

23 Rolling Fatigue Fatigue spall particles originate as material removed as a pit opens up. The fatigue spall particles start at approximately 10 µm and are flat platelets with a major dimension to thickness ratio of 10:1. Fatigue spall particles have a smooth surface and a random, irregular shaped circumference.

24 Rolling Contact Fatigue Particles Increased Mag Irregularly shaped fatigue spall particle with a smooth heavily pitted surface Thin laminar fatigue particle < 1 micron thick Increased Mag Rolling element fatigue spall particles smooth surfaces and irregular contours Laminar fatigue particle with holes

25 Spheres Spheres generated from an extraneous source such as a welding or grinding process. These spheres are much larger than those generated by bearing fatigue. Spheres generated by a fatiguing bearing < 5 microns

26 Combined Rolling and Sliding (Gear Systems) Pitch line Pitch line Pitch Circle Pitch Circle Scuffing / Scoring (Increasing Sliding Component) Fatigue pitting Gear systems combine both rolling and sliding. At the pitch line, the contact is rolling so the particles will be similar to rolling contact fatigue particles. The contact has an increasing sliding component as the root or tip is approached. The particles will show signs of sliding such as striations and a greater ratio of major dimension to thickness.

27 Fatigue Particles - Combined Rolling & Sliding Pitch Line Fatigue Wear (Rolling) Irregularly shaped smooth surface fatigue particle. Root / Tip Sliding Wear (Scuffing) Fatigue chunk Individual Scuffing wear particles showing signs of oxidation.

28 Wear Particle Wear Mode Association

29 Wear Particle Summary Wear Particle Type Results from Particle Shape, Size & Appearance Surface Damage Root Cause Benign Sliding (Normal Rubbing) Normal sliding wear Exfoliation Laminar platelets, 0.5 to 5 µm MD, 0.15 to 1 µm thick MD:T Ratio: 10:1 Smooth & shiny Polishing, Smoothing Normal operation, Buildup over time. Severe Sliding (Adhesive Wear) Sliding contact, high loading, asperity welding, boundary/mixed film lubrication Chunky particles, 15 to 100 µm MD,.15 to 1 µm thick MD:T Ratio: 10:1 Surface striations (scratches), defined, jagged edges) Scoring, Scuffing, gouging Higher than designed load, Lubricant additive failure/incorrect type Oxidative Sliding Red Oxides (Fe 2 O 3 ) Oxidative Sliding Black Oxides (Fe 3 O 4 ) Exfoliation Corrosion under wet conditions Sliding wear under high temperature conditions Platelet, 5 to 50 µm MD, orange to brown color Pebble/chunk, 5 to 50 µm MD:T :10:1 Black, pebble like appearance Gouging, Exfoliation Gouging, Scoring, Blue Tempering Water in oil, Lubrication Starvation Oxidative Sliding Dark Metalloxides Partially oxidized ferrous wear Various sizes dependant on wear process, dark/gray appearance As above Abrasive Wear (Cutting wear) Contaminant particles of high hardness (3 body abrasion) Sliding surfaces (two body abrasion) Long strips, 2 to 5 µm wide, 25 to 100 µm long Long strips 0.25 to 5 µm wide, 5 to 25 µm long Scoring, furrowing Grooving As above Sand/dirt in fluid Poor filters Sand/dirt in fluid, Misalignment

30 Wear Particle Summary (Cont.) Wear Particle Type Results from Particle Shape & size Surface Damage Root Cause Fatigue Cyclic loading, rolling contact, subsurface fatigue Fatigue spall particles, 10 to 100 µm MD, MD:T Ratio: 10:1 Laminar platelets 20 to 50 µm MD, MD:T :30:1 (rolling fatigue wear) Spherical Particles.5 to 5 µm diameter Spherical Particles (other than fatigue generated) Cavitation Erosion Electrical Discharge Stray Currents Spherical Particles 5 to 15 µm diameter Spalling Pitting, Brinelling Frosting Pitting, Scoring Welding Corrosion Oxidation, acidic attack Sediment, 0.1 to 1 µm diameter Pitting, Pickling Polishing (some gears) Fluid Contamination, Subsurface inclusions, (poor metallurgy) Cyclic loading above design Excessive turbulence, soft foot on pump, Poorly grounded equipment Welding bead ingression Fluid degradation, seal failure cylinder blowby

31 Wear Particle-Progression to Failure Wear Particle Concentration (WPC) Benign Wear Onset of Severe Wear Mode Advanced Failure Mode Catastrophic Failure Large particles are the most indicative of progression to advanced failure. Some failure modes generate only large wear particles ,000 Wear Particle Size in µm (micrometers)

32 Closed loop lubricating system Simplified Oil Flow Path Machine Sampling Valve Particles are lost by the following mechanisms Filtration Settling Dissolution Impaction & Adhesion Magnetic Separation Filter Pump Sump

33 Behavior of particles in closed loop lubricating system Concentration in Parts per Million Large Particles (exponential rise) Dynamic Equilibrium Condition the concentration is Inversely proportional to removal rate Fine & Dissolved Particles Operating Time in Hours

34 Idealized Wear Metal Concentration Rates Break-in Wear Normal Wear Abnormal Wear Just a Few Large Particles May Indicate a Problem Concentration In ppm Spectrometric Data For certain mechanical systems, such as rolling element bearings in military aircraft, 10 or 20 large wear particles may indicate incipient failure These would account for less than 1 ppm if they came from 1 ml of sample LaserNet Data Operating Time in Hours

35 Why Contamination Control is Important Keep it out Incoming oil Breather, cover, seals Secondary wear Filter it out Circulating Off-line Drain it out Bleed off bottom Oil change Measure It Set Targets Measure Cleanliness Save Time and Money

36 Wear Metal Analysis Elemental Composition of Debris Fingerprints the debris Trace to source Useful in Root Cause Analysis Fast Easy 2014 Spectro Scientific CONFIDENTIAL

37 Wear Metals and Possible Sources Engine Bearing Gear Transmission Hydraulic System Heat Exchanger Compressor Turbine Iron Cylinder Liners, Piston Rings, Valve train, Crankshaft, rocker arms, spring gears, lock washers, nuts, pins, connecting rods, Engine Blocks, Oil pump Rolling element Bearings: rollers (tungsten alloyed steel), raceways and cages, Journal Bearings: Journal shaft, bearing Shoe backing Locking keys Bull gears, pinions, case hardened teeth, locking pins Gears, bearings, Brake bands, clutch, shift spools, pumps, power take off (PTO) Pump, motor, vanes, pump housing, cylinder bores and rods, servo valves, pistons Rotary Screw, lobes, vanes, connecting rods, rocker arm, bearings, cylinders, housing, shafts, roller bearings (see above) oil pump, piston rings Reduction gear, shaft, bearings, piping, case Copper Valve train bushing, Wrist pin bushing, Cam bushings, Oil Cooler core, Thrust washers, governor, connecting rods bearings, valve gear train thrust buttons Rolling element Bearings: alloyed element in cages, Journal Bearings: journal bearing pads, slinger rings, Locking keys Bushings, thrust washers Clutches, steering discs, bearings Pump thrust plates, bushings, cylinder gland guides, pump pistons, oil coolers Cooler tubes, baffles, plates bearings, cylinder guides, wear plates, thrust washers, bearings (see above) oil pump, oil coolers, thermostats, separator filters Bearings (see bearing section) piping, coolers Tin Valve train bushing, Wrist pin bushing, Cam bushings, Oil Cooler core, Thrust washers, governor, connecting rods bearings, valve gear train thrust buttons Rolling element Bearings: alloyed element in cages, Journal Bearings: journal bearing pads (babbited) Bushings Clutches, steering discs, bearings Pump thrust plates, bushings, Can be a residue from catalyst in some oils (Quinto lubric series) bearings, separator filters Bearings (see bearing section) piping, coolers Aluminum Engine blocks, pistons, blowers, Oil pump bushings, bearings (some) Cam bushings(some), Oil coolers (some) Rolling element Bearings: alloyed element in cages, Locking keys Bushings, thrust washers, grease contamination Bushings, clutches Cylinder gland (some) pump, motor pistons, oil coolers. Aluminum complex grease contaminant Cooler tubes, baffles, plates Housing, bearings, cylinder guides, wear plates, thrust washers, bearings (see above), oil pump, oil coolers Bearings(see above) piping, coolers EHC Systems: Residue from synthetic media (alumina) filters

38 Wear Metals and Possible Sources (Cont.) Engine Bearing Gear Trans-mission Hydraulic System Heat Exchanger Compressor Turbine Chrome Lead Rings, Liners, exhaust valves, zinc chromate from cooling system inhibitor Main Bearings, connecting rod bearings. Lead can be present as a contaminant from Gasoline (Leaded gas) (Octane improver, anti-knock compound) Rolling element Bearings: alloyed /coated element in rollers, tapers Rolling element Bearings: alloyed element in cages, Journal Bearings: Major alloying element in Babbitt bearings, alloying elements Bearings(some), shaft coatings, some special gears are chrome plated Bearings, can also be red lead paint flakes from gear case walls Bearings, water treatment Cylinder liners, rods, spools Housing, bearings, cylinder guides, wear plates, thrust washers, bearings (see above), oil pump, oil coolers Bearings Bearings Bearings Shaft coating (some) bearings Silicon Engine blocks (alloying element with aluminum parts), ingested dirt from breathers, external sources. Can also be from defoamant additive in lubricant Rolling element Bearings: alloyed element with aluminum in cages Bushings, thrust washer, silicone sealant, defoamant additive Brake shoes, clutch plates, ingested dirt Elastomeric seals (some) pump, motor pistons, oil coolers Ingested dirt, silicone sealant, bearings, cooler (alloyed with aluminum) Ingested dirt, silicone sealant, defoamant additive Silver Bearings (alloying element) wrist pins, turbochargers (EMD railroad engines) Bearings, oil coolers Baffle & tube solder Nickel Valves, Valve guides, Cylinder liners, Bearings. Can also be from heavy fuel contamination Rolling element Bearings: alloyed element in rollers, races Alloying element for tool steel gears Bearings, servo valve plating pumps, pistons Bearings Bearings, shaft, reduction gears

39 Other Wear Metals and Metallic Additives Element Possible Wear Sources Titanium Vanadium Wear metal for aircraft engines, bearings, Can also be contaminant from paint (titanium dioxide) Fuel Contaminant, can also be alloying element for steel Element Sodium Boron Magnesium Calcium Molybdenum Barium Zinc Phosphorus Possible Sources in Additives Corrosion inhibitor additive, also indicates coolant leak into oil, can also be road Salt, Sea water, Ingested Dirt Corrosion Inhibitor additive, Antiwear/Antioxidant additive, can indicate coolant leak, grease contamination Detergent/dispersive additive, can also be alloying element in steels Detergent/dispersant additive, Alkaline reserve additive for high sulfur fueled engines, can be grease contamination, Solid/liquid antiwear additive, alloy in bearing and piston rings Corrosion inhibitors, Detergents, Rust inhibitors Anti-wear, Corrosion inhibitors, Anti-oxidants, alloying element for bearings, thrust washers, galvanized cases Anti-wear, Corrosion inhibitors, Anti-oxidants additives, EP additives

40 Summary - Standard Elements in Oils Wear Metals Contaminant or Wear Metal Oil Additive Contaminant or Additive Coolant or Additive iron aluminum chromium copper lead tin nickel silver vanadium potassium zinc phosphorous calcium magnesium barium molybdenum silicon sodium boron

41 Lubricant Condition Analyzers Handheld IR Spectrometer (FluidScan) Kinematic Viscometer Fuel Dilution Meter

42 Agenda Most Common Failure Modes How to Use Lubricant Performance Technologies How Does Each Technology Work? What Readings are Abnormal and what do they Indicate Specific Failure Analysis Case Studies Demonstration of new Portable Technologies

43 How Atomic Emission Spectroscopy Works Take an Ordinary Flame, put pure Copper into the flame The Flame changes color (That s Emission Spectroscopy)

44 Wear (Elemental) Metal Analysis Techniques Scanning Electron Microscopy Atomic Absorption Spectrometry X Ray Fluorescence Atomic Emission Spectrometers (AES) Inductively Coupled Plasma (ICP) Rotating Disc Electrode (RDE)

45 SEM/EDXRF Definitive Analysis Tool 1000 to 5000 X typically used for debris analysis SEM is employed to image the particles, Xray fluorescence is captured for particle identification Can determine size, shape, elemental alloy content Expensive-used for failure analysis

46 Atomic Absorption Spectrometers Reference Beam Grating Hollow Cathode Lamp Monochromator Chopper Burner Half-Silvered Mirror Readout & Control Oil Sample

47 X-ray Fluorescence Spectrometers Excellent tool for determination of elemental concentration and alloy ratios Best employed when wear debris is concentrated, such as in filter debris Not practical for routine laboratory work EDXRF filter analysis emerging as a tool for field-based oil analysis Oil Sample Detector Signal Filter Detector Emitted Radiation Readout & Control X-ray Tube

48 Inductively Coupled Plasma (ICP) Technique TCP/IP Interface TCP/IP Readout & Control CCD Readout Instrument Controller MHz RF Generator Plasma Torch Optical Plasma Interface (OPI) RF Load Coil Argon Supply Optical System (CIROS) OilSample Peristaltic Pump Spray Chamber

49 Atomic Emission Spectrometers (RDE) Graphite Rod and Disc Electrodes Grating Exit Slits CCD Oil Sample & Holder Excitation Source Fiber Optic Cable Entrance Slit Readout & Control A/D Converter

50 CCD Optics

51 Comparison of RDE and ICP RDE ICP Target Fluid Lube, fuels, coolant, water Different type of fluids Key Features No Solvent Tolerate extreme working conditions Simple to operate Low detection limit Low cost of operation with mid to high sample volume Sample Preparation None Yes Automation Available Yes Yes Detection Efficiency Particle Size < 10 m Particle Size < 5 m Utility Requirement No Special utility requirement May require Argon gas Solvent Best Use Case Remote area mining sites, power plants Good for low to mid volume small labs Commercial lab with stable power Mid to high volume

52 Particle Analysis Particle Analysis Ferrography Optical Particle Counters (Laser) Direct Imaging Particle Analyzers

53 Ferrography Thistle Tube Ferrogram Top View Oil Sample Ferrous Particles Lineup in Direction of Magnetic Flux Ferrogram Side View Magnet Drain

54 Particle Deposition Pattern on a Ferrogram Ferromagnetic particles line up in strings with longest dimension in direction of magnetic field Non ferrous particles deposit randomly along the length of the ferrogram Largest magnetic particles deposited at the entry region 60 mm Non-Wetting Barrier 24 mm Ferrous Particles Near Exit are Submicroscopic Non Ferrous & Weakly Magnetic Debris Deposited Randomly Entry Region

55 Ferrography - An Aluminum Wear Particle Aluminum particles are non magnetic and very reflective. They will be distributed randomly down the Ferrogram. If many particles are presented, they maybe confirmed to be aluminum by putting a drop of base such as Potassium Hydroxide (KOH) onto the Ferrogram. A strong base will dissolve aluminum, but leave any other common metal unaffected. A crystalline residue will be left after reaction with the base solution

56 Ferrography - A Copper Alloy Wear Particle Copper is the only common wear metal with a yellowish appearance. Heat treatment may cause a variety of temper colors to form, including blue, white and gray.

57 Particle Counting A measure of the cleanliness of a fluid Count all particulate, regardless of composition, shape Classify according to size and quantity Compare to established contamination patterns Particle counting mainly applicable to very clean lube systems that DO NOT generate a lot of normal wear particles Hydraulics, Gears, Aero Turbines Close fitting parts with tight tolerances can easily become jammed or damaged larger abrasive particles can cause additional wear between surfaces Sources of contamination are mainly through ingress of dirt through faulty air filters, breather valves and open covers etc. Particle Counting is therefore the preferred method of monitoring dirt contamination

58 Particle Counting Classifications The count is compared to known standards ISO 4406 NAS 1638(out of use, but still widely quoted) AS 4059 MIL-STD-1264 Many other internal industry methods Two types of counting methods Cumulative Differential MOST POPULAR

59 Flow Decay Technique Pore Blockage Contaminated fluid passes through a screen of defined pore size and spacing under constant flow or constant pressure Pressure across the screen increases (Constant Flow) or flow decays (Constant Pressure) as it blocks up

60 Optical Particle Counting Techniques Oil Flow Oil Flow Laser View Volume Photo Diode Laser Beam Readout & Control Laser Scattered Light Lens Photo Diode Readout & Control Laser Beam Trap Light Blocking Light Scattering Oil Flow Laser Lens CCD Display Direct Imaging

61 LNF Particle Analyzer Sam pled Flu id Flow Lens 4x M a g TV R ate C a mer a Ima ge P r o ces s ing Sh a p e C lass if icat ion Las er Diod e We a r D eb ris Direct Imaging Particle Analyzer Particle size distribution Particle shape map Fluid Condition Viscosity Water and Soot content

62 Q200 Solution to Heavily Contaminated Samples Large CCD area = NO coincidence effect at high particle concentrations

63 Q200 solution to true particle size Each pixel represents 2.5 um (factory calibrated) 1.6mm 1.2mm 2.5 m 2.5 m

64 Particle Shape Analysis Severe Wear long with straight edges Fatigue Wear equiaxed with irregular edges Cutting Wear curved and curly Non-metallic partially transparent Water Droplets index of refraction Fibers long, curved, partially transparent Cutting Wear Fatigue Wear Sliding Wear Non-metallic

65 Q200 to Free Water % Measurement Q200 Measures Free Water in ppm Water Droplet Air Bubble

66 Q200 solution to Dark Oils Sample Fluid Flow Lens 4x Mag TV Rate Camera Image Processing Shape Classification Laser Diode Wear Debris Q200 uses high powered laser w/ Automatic Gain Control (AGC)

67 LNF with Ferrous particle counter A B B A

68 Contamination and Wear monitoring Model Particle count Contamination (non-metal) Wear (metals) Measurement Capabilities -> Particle Count, & Codes Dirt & Sand Water & Air Bubble Correction Wear Particle Classify Ferrous content Fe particle count & distribution Q210 Particle Counter Q220 Particle Counter & Wear classifier Q230 Particle Counter & Wear classifier & Magnetometer Solution for Contamination Control and abnormal Wear 68

69 Q200 Solution to Automation 2 ASP Systems At Fluid Life lab Canada ASP Automatic Sample Processor

70 Lubricant Condition Analyzer Fluidscan handheld IR oil analyzer Viscometer Fuel Dilution Meter

71 Infrared spectroscopy for oil analysis

72 FluidScan IR Spectrometer Measures Critical Oil Chemistry Parameters ASTM D7889

73 FluidScan - A Versatile Instrument FTIR New Oil Identification Used Oil Degradation KF Titrator Water Contaminatio n TAN/TB N Titrator TAN or TBN Oil Reference Library Limits for used oil

74 Extensive Reference Oil Library Engine Hydraulic Synthetic Gas Turbine Compressor/ transmission Gear/Turbine Water (ppm) Oxidation (abs/mm2) TAN (mg KOH/g) TBN (mg KOH/g) Alien fluid (%) Anti-Oxidant Additive (%) Anti-wear Additive (%) Nitration (abs/mm2) Sulfation (abs/mm2) Soot (%) Glycol (%) 60+ Brands, 540+ oils, 30+ fine tuned calibration algorithms and growing Synthetic, Mineral Fluid, Biodiesels, etc. Comprehensive oil match algorithm to expand new oil library in the field

75 High Correlation to Lab Methods TAN correlation to titration method Chemical Titration vs. FluidScan In-Service MIL Oils Water correlation to KF titration method 6 TAN (mgkoh/g) by Titration R 2 = TAN (mgkoh/g) - FluidScan 2014 Spectro Scientific CONFIDENTIAL

76 Route-Based Oil Monitoring Create Route in Oilview LIMS module Export Route to Flash Drive (route data includes Alarm Limits for each Area/Equipment/Point ) Import Route to Fluidscan from Flash Drive 2014 Spectro Scientific CONFIDENTIAL

77 Q1100 Features No Solvents or Hazmat waste Portable Small sample volume (one drop of oil) QUANTITATIVE Results in about a minute Data management Alert/alarm levels built-in, (no manual logging needed) Export data to spread sheet for Statistical & Trend analysis 2014 Spectro Scientific CONFIDENTIAL 77

78 Traffic Light Simplicity Results Highlighted: Green /Yellow/Red (per OilView alarm set) Quantitative Measurements PPM Water TAN Oxidation Nitration Sulfation Glycol AW Depletion Soot TBN 2014 Spectro Scientific CONFIDENTIAL

79 Record Observations and Notes Observations selected in Fluidscan will populate the Oilview screens Notes feature allows free-form notes to be typed in 2014 Spectro Scientific CONFIDENTIAL

80 Fluidscan is a Perfect Solution for Optimizing Fleet Oil Change Intervals Condition based oil changes Improve Predictive Maintenance Effectiveness Easy On Site Oil Condition Monitor

81 Q3000 Portable Kinematic Viscometer True Kinematic Viscosity (Constant Temp) No Training Extremely Low Fluid Volume (3 drops) C No Solvents Needed!

82 Operating Principle -Q3000 Two parallel plates separated by a small gap Fluid flows between plates Flow velocity dominated by viscosity and gravity Simple relationship between flow time and viscosity

83 Fuel Dilution- A Hidden Danger Excessive Unburned Fuel in a Crankcase or Reservoir (Sump) Typical sources : Leaking fuel injectors Excessive Idling Clogged air filters Degraded seals and gaskets Daily concern for engine owners 14% of engine samples sent for oil analysis are alarmed due to fuel dilution 2014 Spectro Scientific CONFIDENTIAL 83

84 Current solutions for testing fuel dilution In the lab Gas Chromatography Pensky-Martens Flash Point Tester Viscometer FTIR In the field Viscometer Blotter test Flash point tester Spectro Fuel Dilution Meter 2014 Spectro Scientific CONFIDENTIAL 84

85 How a SAW sensor works Henry s Law SAW Sensor Ref:images: Ivanov, Advanced sensors for multifunctional applications tms.org/jom 2014 Spectro Scientific CONFIDENTIAL 85

86 Q6000 Fuel Dilution Meter Next Generation Fuel Sniffer DIRECT READING in Percent Dilution No Flames or Ignition Sources! Accuracy 0.2%, range 0-15 Percent Multiple Calibrations Diesel in oil Gasoline in oil JP 8 in hydraulic oil MIL 7808 Only 20 seconds per sample USB Connection for Data Transfer Rechargeable-Battery Powered Full color touchscreen NO SOLVENTS 2014 Spectro Scientific CONFIDENTIAL 86

87 Portable fluid condition combos Oxidation, nitration, sulfation Acid Number, Base Number Dissolved water, Glycol, soot Foreign fluid Fuel Dilution Viscosity

88 5200 Trivector Minilab Wear particles Viscosity Water Particle Count with Size Distribution Large wear debris Wear Debris Analysis Oil Chemistry (% change dielectric) Oil Chemistry Oil Contamination OilView Software

89 Q5800 EFAS Portable Solvent Free All in one carry case 2014 Spectro Scientific CONFIDENTIAL 89

90 Understanding the FPQ/XRF output Results will AGREE with Ferrography for Abnormal Wear CORRELATE to RDE Spectroscopy for wear conditions where both large and small wear particles are trending to failure WILL NOT Detect dissolved material /additive elements quantitatively If there is large debris present, Q5800 will catch it 2014 Spectro Scientific CONFIDENTIAL

91 Q5800 detects abnormalities Element Result (ppm) Al 0 Si 0 Ti 0 Cr 0 Fe 0.32 Ni 0.15 Cu 5.34 Zn 0 Pb 0 Mo 0 Ag 0 Sn 0 FPQ Particle Count > 4 micron: (ISO 22) 2014 Spectro Scientific CONFIDENTIAL Wear Debris on filtergram patch reveals severe, recently generated copper sliding wear justifying an inspection of gearbox

92 How To Select The Right Test Equipment Know What You Need to Measure Viscosity Oil Chemistry Fuel Dilution Wear Metals Particle Size, Count and Shape Soot Content Know Why it is Important to Your Operation What will happen if you DON T know these values Determine the Best Technology for Each Measurement Select Appropriate Tools Don t Overdo It!

93 Agenda Most Common Failure Modes How to Use Lubricant Performance Technologies How Does Each Technology Work? What Readings are Abnormal and what do they Indicate Specific Failure Analysis Case Studies Demonstration of new Portable Technologies

94 Machine condition monitoring technologies Oil Analysis Alignment Vibration Analysis Ultrasound Condition Monitoring Technologies Infrared Thermography Oil condition monitoring is part of a comprehensive Predictive Maintenance program. Motor Circuit Evaluation

95 Oil analysis provides actionable information Trivector TM Wear Particles in oil from normal and abnormal machinery wear Contamination Dust/dirt accelerates wear Water, glycol Process fluids Chemistry Oil degradation Additives & Physical: Viscosity Change filter? Dry oil? Change oil? Tear Down? Let s address each of these Trivector is a trademark of Emerson CSI

96 On-site Oil Analysis Levels Scheduled Avoid Mix-up Ensure Cleanliness Scheduled Exception based Trending and Screening Root Cause Analysis Oil Analysis Lab On-site Analysis

97 Contamination in Oil Cause Water Oil Oxidation Sand/Dirt - From Environment Worn Wiper Seals Poor or Ineffective Filters Machine Burrs Effect Wear-Abrasive and fatigue wear initiator Intermittent Failure Plugging/Silt Locking Pressure Overshoots Leakage

98 Condition Monitoring = Trend Analysis Drain Oil Test Test Warning Limit Equipme nt Us e Hours /Miles Required Action Projected trend Recommended Action be taken Norm al Re sult Variability Regular Oil Analysis is needed for an effective maintenance program. Oil Analysis results are plotted against operational hours. Actions needed based on the trending report Alert: Serious problem detected, Inspect ASAP Caution: An abnormality is present, Correct problem when possible Normal: No corrective action necessary

99 Statistical limit setting: Turbine Oil Ferrous Index Ray Garvey - Use statistical evaluation to check alarm limits for machine lubricants.

100 Statistical limit setting: Turbine Oil Particle Count ISO Code Ray Garvey - Use statistical evaluation to check alarm limits for machine lubricants.

101 Agenda Most Common Failure Modes How to Use Lubricant Performance Technologies How Does Each Technology Work? What Readings are Abnormal and what do they Indicate Specific Failure Analysis Case Studies Demonstration of new Portable Technologies

102 Cost justification for industrial oil analysis Documented case histories and cost savings on-site oil analysis to monitor a wide range of industrial machinery. Realistic Return on Investment: 500%+ Reduce oil consumption LESS OIL USED Test it, don t change it Defer maintenance Proactive CONTAMINATION CONTROL Keeping oil clean, dry, and fit for use Eliminate reactive maintenance Trend FAILURE PROGRESS Predictive vibration & oil analysis

103 Refinery lubrication & oil analysis program Measurable results: 30% less failures Savings of $2.1M/year at $6,500/incident average cost Year 1 Year 2 Year 3 Year 4

104 Turbo Pump Premature Failures Particle Analysis Showed high percentage of Sliding Wear Diagnosis was loss of Hydrodynamic Lubrication Increased Viscosity of Turbo pump lube Sliding Wear particles disappeared on next test. Refinery - Turbo Pumps 2014 Spectro Scientific CONFIDENTIAL

105 Mining- Haul Truck Glycol Found in Crankcase Oil Indicates Coolant problem Found and Replaced Oil Cooler Then Fount Tin and Lead in Crankcase oil Indicates failure of bearings Inspection revealed all Main & Connecting Rod Bearings Wiped Clean Repair = $50,000 New Engine would have been $400,000

106 Oil analysis program justification: Gearbox failure caused 27 hour production outage. Results: Assembly plant $1.6 Million savings in 28 months 2 month payback period 738% ROI based on 20% IRR Improve Lubrication Quality Reduced Machinery Wear Extended Oil Change Intervals Reduced Oil Disposal Cost Reduced Oil Sample Cost Simple Cost Avoidance Methods

107 Stamping plant Stamping plant Discovered impending failures in two 1000-ton presses Press 16-3: two broken rockers and four worn out link bushings Press 16-4: had a sheared stud supporting the rocker arm In both cases Oil analysis was the only indication of these near catastrophic failures. Continued operation would have been catastrophic. Avoided danger to the press operator, and costly expense to the company.

108 Problem Presses - Stamping Plant Results allowed both presses to be repaired quickly. Press 16-3 took about 3 weeks to repair the broken rocker arm. The sheared stud on press 16-4 was repaired within 24 hours. Several months of lost production was avoided by detecting these incipient problems. Savings in each case is estimated at $50,000 in avoided maintenance and $1,000,000 in lost production. Without oil analysis problems like these are not known until the table drops, said Terry Aikens, Predictive Maintenance Engineer, Warren Stamping Plant, and at that point, it takes several months to repair.

109 Coal-fired Power Plant- Grinding Rolls 140 lab samples per month Also on-site oil analysis, particularly on Coal Pulverizer Grinding Rolls. Pulverizer operates in harsh environment Elevated temperature Coal dust Other abrasives

110 Coal-fired Power Plant-Grinding Rolls Before in house oil analysis, Plant overhauled 27 grinding rolls per year. $10,000/overhaul. On-site analysis used to find the 20% needing maintenance. Savings documented > $230,000 per year on grinding rolls alone. We started our on-site oil testing program within minutes a decision can be made on the replacement of Pulverizer Grinding Rolls..Since beginning, we have not replaced a single roll, nor have we had unexpected failures. Randy Blake

111 Paper Mill Test-it, don t change it Debarking drum gearboxes. $480/ Oil Change $140 for 35 gallons of lubricant $240 for 2 mechanics working 6 hours to complete the oil change $50 to dispose of used oil $50 to restock On site testing - Immediate results Oil is healthy, clean, and fit for continued service. Cost for labor of materials for on-site test <$15 each. Actual expenses: $15. Actual savings $480. ROI = 3,200% Additional savings: Avoided risk to personnel injuries Avoided possible new insult to machinery Avoided opportunity cost-6 hours Personnel, tools, and machinery

112 Semiconductor Manufacturer Test-it, don t change it Oil changed 2 X/Yr. on 135 rotary vane pumps, per OEM guidelines Annual savings calculated to switch to condition based oil change = $20,000 Achieved PLUS collateral savings of $79,000/year Several otherwise unknown Machinery Health problems detected while testing oil quality Problem with $16,000 pump, repair cost $1000. Savings $15,000 4:1 rule suggested by collateral savings experience. Similar savings achieved at two other plants. Total savings= $99,000 in first year, sustained for several years. After five years only ½ pumps needed oil change Largely associated with collateral savings repairs requiring oil change.

113 Other Cost Avoidance Examples Potable Water Plant- Reduced Oil usage by $35,000/yr Waste Water Treatment Plant- Reduced testing from ½ day to 90 minutes Municipality- Saved 2,000 Hydraulic Tank oil replacement Fleet Manger Saved $9,300 in 6 months on 67 car and light truck fleet Railroad- Saves Locomotives 2014 Spectro Scientific CONFIDENTIAL

114 Remote Site Fluid Analysis Users need answers NOW Answers NOW are more valuable than later Users cannot WAIT for Commercial Lab test results Need to act before results returned Sometimes it just too LATE User s of high value, mobile assets need real-time portable CBM

115 The importance of NOW

116 Offshore Drilling Equipment downtime very expensive Long delay for results Prohibitive cost of setting up full lab on each rig Capital Staff Training 116

117 The Value of Getting Answers Now? Sample at the asset Go/No go on fluid quality and contamination Detect severe wear if present Recheck there and then Reduce logistics trail 117

118 Current Oil Analysis Programs Equipment Operator Oil Lab Pass Critical Equipment (10% of equipment pool) Periodic Sample 1 Resample Transport Test Fail Mx Action? Yes Database No Perform Mx Action Essential Equipment (Everything else) Perform Mx Action 2 1. Routine samples are taken at prescribed intervals or samples sent based on certain events (e.g., metal chunks in sump). 2. Fluids and filters are changed at prescribed intervals. No routine oil analysis done. 11

119 Expeditionary Fluid Analysis LIMS CMMS Field Lab Sample Periodic/Unscheduled Q5800 Test Pass Sample for lab3 Transport Test Pass Critical and Essential Equipment Yes Fail Change Fluid/ parts 2? No Fail Mx Action? No Yes Perform Mx Action 1. EFAS checks are performed at prescribed intervals. 2. May also require extra maintenance action(s). 3. Samples are taken at prescribed intervals or when EFAS device results dictate.

120 Extending Oil Analysis in the field Phase III Lubricant and Machine Condition Complete Integration Wear Debris Analysis Capability Phase I: Fluid Analyzer Physical properties Cross Contamination Degradation & Water Flip-Top sampling Phase II- Lubricant Condition Add Kinematic Viscosity Combo Kit Q5800 Fluidscan Combo Kit?

121 Q5800 EFAS Portable Solvent Free All in one carry case 2014 Spectro Scientific CONFIDENTIAL 121

122 Integrated Solutions Portable Bench Top Root Cause Analysis On Site Screening Mission Critical Military Aerospace Mining Marine Fleet Railway Automobile Offshore drilling Marine OEM Field Service High Volume Lab Commercial Lab Mining Military Industrial Plants Food Paper & Pulp Cement Power

123 Summary On site oil analysis To maintain critical and important assets Justified and documented ROI Surface degradation and wear particles Majority of machinery failures Must be closely monitored Spectro Scientific/Lakeside Provider of total solutions In service oil analysis Condition based predictive and proactive maintenance

124 Additional Learning - Reliability Links Machinery Health Management Training PlantWeb University MHM Video Tutorials Solve & Support Suggested Emerson Courses 2069 Fundamentals of Vibration 2068 Introduction to AMS Suite Machinery Health Manager 2074 Intermediate AMS Machinery Health Manager 2083 Oilview for AMS Machinery Manager 2088 CSI Online Prediction Operation and Maintenance

125 Solve & Support PeakVue & Machinery Health Manager Software Date: December 8th - 11th Time: 8:00am - 4:00pm Cost: $ Location: Lakeside Process Controls Head Office, 2475 Hogan Drive, Mississauga, ON

126 Thank You Fast. Simple. Accurate Spectro Scientific CONFIDENTIAL 126