Your oil can be saved!! Even when water is mixed



Similar documents
Oil Analysis. It is important that the sampling be done in the following manner: 1.

PVS 185, 600, 1200, 1800, 2700 Series Portable Purification Systems

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

The Par-Gel Filter Water Removal Filter Elements

PVS Series - Models 185, 600, 1200, 1800 and 2700

RMF TANDEM 900 OFF-LINE FILTER SYSTEMS

Vacuum Dehydration Oil Purification System (VDOPS)

What is Oil Filtration By Dennis Morgan, Filtration Consultant and President of AMS Filtration April 8, 2008

Longer lifetime for hydraulic oil

Flushing and Cleaning the A/C System

MAINTENANCE PRODUCTS AND SERVICES S O S SM. Services

This chapter is devided into two sections:

S O SSM. Fluid Analysis Program. your equipment? The S O S Program was introduced by Caterpillar in 1971

petroleum technologies

Article published: May 2004,

Portable Purification Systems Models PVS 185, 600, 1200, 1800, 2700

Making the Most of SáOá SM Services

Cat S O SSM. Services. Understanding Your Results. Understanding Your: S O S Oil Reports S O S Oil Results S O S Coolant Reports S O S Coolant Results

OIL CONDITION MONITORING: AUTOMOTIVE ANALYSIS

S O SSM. Services. Cat. Management Guide. Accurate Analysis Improved Cost Control Optimized Performance

HOW THE CONTAMINATION IS MEASURED CONTAMINATION CLASSES ACCORDING TO ISO 4406:1999

ULTRA-FINE FILTRATION WITH WATER REMOVAL HELPING ALL TYPES OF HYDRAULIC INDUSTRIES

CONTAMINANT REMOVAL FROM CENTRIFUGAL SYSTEMS

What Can the OIL ANALYZERS Fluid Analysis Program Do For You?

World-Class Oil Sampling It is Possible

A New Membrane System for Efficient Removal of Water from Gear Oil Road to Commercialization

HIGH PERFORMANCE FILTERS AND ELEMENTS

Technical Training Guide Turbine Oil Condition Monitoring

Reliability. The Essentials of Eliminating Downtime of your Electric Motor. Asset Management? Or, Maintenance Management, Re-branded?

DIESEL FUEL CONDITIONING

NORMAN FILTER COMPANY PRODUCT OVERVIEW

Engine Lube and Hydraulic Oil Analysis Program OIL ANALYSIS

12 November 2008 *** I:\CIRC\MEPC\01\642.DOC INTERNATIONAL MARITIME ORGANIZATION 4 ALBERT EMBANKMENT LONDON SE1 7SR

Basic Hydraulics and Pneumatics

Lubrigard. A Guide To Lubrication Management

Cat S O SSM. Services. Reporting Particle Count by ISO Code. Management Guide. Two methods of reading particles

LEAP SM Oil Analysis Program Saves Money with Consistent, Accurate Monitoring

Chapter 7 Hydraulic System Troubleshooting

6.7L Diesel Fuel System Contamination Diagnosis and Service Procedure Job Aid (Revised March, 2012)

CSI Oil Analysis Options

Oil Analysis Program ISO 9001: 2008 Certified.

Particle Measurement Technology in Practice. From Theory to Application.

Clean hydraulics, oils and lubricants. Three ways to big savings & lean maintenance reliability by Howard C. Cooper, Amemco.net

Backup Fuel Oil System Decommissioning & Restoration Plan

High Vacuum Transformer Oil Purification Systems (HVTOPS) & Dielectric Oil Purification Systems (DOPS)

CSD WATER REMOVAL FILTERS FOR DIESEL

Medical Air Systems: Scroll

3/5/2015. Oil Analysis Tests. Lubricating Oils. Six Functions of Lubricating Oil

Equipment Performance Monitoring

Quiz On Information Learned From Chapter 1

FIXED DISPLACEMENT HYDRAULIC VANE PUMPS BQ SERIES

COURSE 1020 OIL ANALYSIS WHY ATTEND

Improving Diesel Engine Life:

When Dependability Counts Most

By-Pass Filters: Taking Your Fleet the Extra Mile

No grinding or welding operations should be done in the area where hydraulic components are being installed.

Subject: 2005 Air Conditioning Service Guidelines

FIXED DISPLACEMENT HYDRAULIC VANE PUMPS BQ SERIES

Trouble Shooting. Pump

Strong partners offer perfect solutions. Automatic filtration and maintenance of engine lubricating oil in diesel locomotives

Federal Wage System Job Grading Standards for Air Conditioning Equipment Operating, Table of Contents

Direct Fresh Air Free Cooling of Data Centres

National Competency Based Skill Training Refrigeration and Air-conditioning Mechanic Logbook

Atlas Copco Quality Air Solutions. Compressed Air Filters

FIXED DISPLACEMENT HYDRAULIC VANE PUMPS BQ SERIES

Guide to Contamination Standards ENGINEERING YOUR SUCCESS.

FS Lubricants. Oil Analysis Program

Kompressoren. Adsorption Dryer AD

Standard Hydraulic Piping Flushing Procedure

Equipment Breakdown. The extended property coverage you need for the equipment you rely on.

PROTECT YOUR ENGINES AND MACHINERY WITH ADVANCED USED OIL ANALYSIS SERVICES AND OPTIMISE YOUR OPERATIONAL RELIABILITY

An Overview of WearCheck Oil Analysis Services

Ultra Coolant. The Best Performance. The Best Cost. The Best Coolant.

David O. Ahrens, Commercial Marine Manager Caterpillar Engine Products Division

3620 W 11th Streetб Houston, TX Telephone: sales@kellogg-american.com Website:

Contamination Control for the Primary Metals Industry

ThermoStar Refrigeration Air Dryers

Understanding Oil Analysis: How It Can Improve Reliability of Wind Turbine Gearboxes Michael P. Barrett and Justin Stover

At Bently Nevada Corporation (BNC) we know one. Establishing a Lubricant Analysis Program. Joshua Hutton. John Kitchens.

DGA - Method in the Past and for the Future

What Boat Captains and Marine Surveyors Should Know about Oils and Oil Analysis

Nitration of Lubricating Oil and Benefits of Oil Analysis

Current state of plant Functioning as a peak and emergency centre. Statistics Accumulated operating hours:

Guide #5 Cleaning a Fuel Tank

Rexroth Hydraulic Pump A10VO Series User Manual

Elements Elements describe the essential outcomes.

Engine, Drive Train, and Hydraulic Repair Indicator Quick Reference Guide

AIR CONDITIONER GENERAL 1. SPECIFICATIONS AIR CONDITIONER REXTON

Eurovacuum EV Series. Single Stage Oil Sealed Rotary Vane Pump

Action Plan Template HVAC Page 1

Presented by Rory S. McLaren. SAFE by DESIGN

Refrigerant Charging Unit ICOGD. 020AH1000 Operating Manual. FR İ-COLD Rev. 00

NITROUS TRANSFER PUMP INSTRUCTIONS

PLP - TERMS AND CONDITIONS

TABLE OF CONTENT

Cryogenic Vacuum Pumps

Proper planning can prevent severe damage in the event of a failure.

On request of Akzo Nobel Dynamo Project Team we ve surveyed the energy efficiency of the compressed air system in the Barcelona Deco & A/AS plant.

Transcription:

OIL SAVER WATER REMOVAL IT IS NEVER TOO LATE!! With our service, you can save your oil and also save one third or half of your expenses for oil replacement. Your oil can be saved!! Even when water is mixed We can remove FREE WATER - Oil/water separation method EMULSIFIED WATER - Filter absorbing method DISSOLVED WATER - Vacuum Dehydration method For decades, it has been a task to save industrial lubricants and hydraulic oil costs. You know what consequences to expect if you don t change your engine oil regularly. The best possible way to save oil is by using it till its life span. However, when oil is accidentally mixed with water and changes to milkiness colour, no matter how new the oil is, it has to be changed. But why change when we can save it? We can remove water from oil, without removing any additive. Hydraulic Oil Transformation; before (left) and after our service (right). (Actual photo of samples taken from one of our customers) PROVIDING WATER REMOVAL SERVICE FROM OIL Water Damages Oil Catalyst of Oxidation Increasing Viscosity Foaming Encouraging Rust & Corrosion Generator of Other Contaminants in Oil Water can be mixed through Oil Cooler Humidity Steam Etc. MONEY BACK GUARANTEE Seeing is believing!! Try it whenever you need our service. We won t charge if you don t get what you expect!! EXCLUSIVE DISTRIBUTOR Petronas Reg No: L-613766-P MOF Reg No: 35702014335 MOF Kontraktor Bumiputra Reg No: BP077335-P AR DORROUN SDN. BHD. (CO. NO. 613766-P) Lot PT 11248, Taman Industri Paka 23100 Paka, Dungun, Terengganu Darul Iman, MALAYSIA Tel: +6(09) 827 1708 Fax: +6(09) 827 2708 email : sales.enquire@ar-dorroun.com.my web : www.ar-dorroun.com.my LubriCARE 11721 Norgrove Lane, Los Alamitos, California 90720 U.S.A. url : www.lubricare.net email : enquire@lubricare.net Copyright 2003 LubriCARE ALL RIGHTS RESERVED

INTRODUCTION...The AR Dorroun LubriCARE PdM AR Dorroun Sdn Bhd was founded in 2003 as an organization providing predictive maintenance (PdM) program and services. From its inception, it provides and also maintain a PdM known as LubriCARE that continually helping its customers by identifying various contaminants found in their lubricant samples. Most industrial hydraulic systems exist in unclean atmospheres and are frequently pushed for required production. Ensuring reliability in the equipment is critical. In preventing hydraulic system damage or equipment degradation, there are three important issues to consider: 1. Using a quality lubricant with good physical and chemical stability; 2. Implementing a good filtering process to maintain cleanliness levels; and 3. Maintaining a routine monitoring program to detect problems early. Implementing a good filtering process in a hydraulic system is essential. The majority (85%) of hydraulic system failures are a result of particulate contamination. Hydraulic systems are affected by small particles well as large ones. Particles are generated by a variety of sources including: wear metals, ingested dirt, debris and faulty components, such as seals or gaskets. AR Dorroun supports its clients with quick service coupled with accurate and concisely reported interpretation of data. Recommended actions are included with every sample submitted. Our LubriCARE software generates reports, charts, and graphs for convenient viewing, trending and comparison of data. We values a close customer relationship and strives to be aware of their individual needs. With clients in industries ranging from power generation to oil and gas production, AR Dorroun is well aware of the specialized requirements of individual plants. Accordingly, we will therefore tailor a customised LubriCARE PdM to fit these specific needs. We can assist in choosing a sampling frequency and an analysis package suitable for the different types of machinery in the plant. WHY LubriCARE? AR Dorroun Sdn Bhd s lube predictive maintenance program is known as LubriCARE. LubriCARE consists of a series on-site turbine oil remediation and reclamation and equipment reliability services aimed at reducing oil consumption and machine replacement costs and optimizing equipment availability. In order to achieve this, AR Dorroun Sdn. Bhd. also provides a pool of lubrication technical experts and competent engineers and technicians to undertake the LubriCARE Lube PdM Program. In the brief time that AR Dorroun Sdn. Bhd., has implemented LubriCARE Pdm to turbines at Petronas Gas Bhd. (GPPB), costly and unnecessary oil changes have been avoided and prevented more costly plant outages. AR Dorroun utilizes the application knowledge of LubriCARE Lube PdM Program and its pool of experts and engineer supervisors in determining just when to perform lubrication maintenance in order to maximize productivity and avoid machine or downtime. Information on the condition of each machine is matched against its importance in the overall production process. Machines that are critical to maintaining production, (e.g., turbines, compressors and pumps) are closely monitored to predict their performance. For instance, when lubricant sampling results reveal signs of degradation in a machine, AR Dorroun promptly deploys LubriCARE s pool of experts and technicians to assess and/or determine whether immediate on-line lube oil remediation is necessary to prevent a catastrophic failure or whether they can wait for a regularly scheduled shutdown to do off-line lube remediation thus avoiding costly plant outages. Copyright 2003 LubriCARE ALL RIGHTS RESERVED page 1

PURPOSE A vital support activity to the LubriCARE PdM is the Oil Condition Monitoring Program (OCM). The purpose of OCM is to identify lubricant components that indicate wear and tear of machine components caused by abrasion, adhesion and corrosion. Careful sampling, reliable testing and knowledgeable analysis of the test results are the basic elements of a solid program to determine whether the lube oil should be changed or its service life extended without the danger of machine breakdown or machine outage. The LubriCARE PdM can go far beyond simply telling you the condition of the lubricant itself. Our advanced oil analysis techniques are being used to monitor the condition of the equipment. By utilizing these advanced techniques, equipment reliability increases and unexpected failures and down time can be minimized. The purpose of an oil analysis program should not be to merely check the lubricant's condition. The real maintenance ringgits saved by utilizing oil analysis are going to be when equipment problems are detected. By utilizing LubriCARE oil analysis on a routine basis, a base line for each piece of equipment can be established. As the oil analysis data deviates from the established base line, abnormal wear modes can be identified. Once abnormal wear modes are identified corrective action can be planned. In short, implementation of LubriCARE PdM with analyses consistent with the goals of the program will significantly reduce maintenance costs and improve plant reliability and safety Increased reliability, availability, and the prevention of unanticipated failures and downtime are added benefits. BENEFITS This is the real measure of effectiveness. Our successful LubriCARE PdM prevents costly problems and has documentation to prove it. Dedicated advance oil analyses will identify potentially costly problems; undertake prompt measures to prevent these problems thus avoiding unnecessary oil changes and costly equipment shutdown. With the LubriCARE PdM, AR Dorroun aims to realize the following benefits: a) Increased machinery or equipment availability through planned shutdowns and scheduled minimal preventive or repair maintenance thus resulting in increased production. b) Reduce maintenance costs and improve plant reliability and safety Increased reliability, availability, and the prevention of unanticipated failures and downtime are added benefits. c) Savings in oil consumption through the on-line oil remediation program. In-service oils are monitored and its contaminants removed by the use of modern, state-of-the-art filtration and water removal equipment without the necessity of shutting down the gas or steam turbine. Savings often are achieved by adopting a plan of "as needed" replacement rather than changing oil periodically. If analysis shows a lubricant to be free of contamination, there's no need to replace it based on the OEM-recommended schedule. d) Established base line, so that abnormal wear modes can be identified. Once abnormal wear modes are identified corrective action can be planned. e) Savings in machinery spare parts because more serious breakdown and collateral damage of other vital spare parts are avoided. f) Savings in maintenance labor costs specifically repair maintenance labor costs, since serious lubrication-related breakdowns are avoided. g) Prolonged equipment or machinery life and reduced lubricant purchase and disposal costs. Copyright 2003 LubriCARE ALL RIGHTS RESERVED page 2

KEY ELEMENTS OF THE TOTAL TECHNICAL PACKAGE SUPPORT SERVICES a) OIL SAMPLING Sampling technique is the key to oil analysis. The sampling procedure can bias a sample to make it cleaner or dirtier depending on where or how the sample is taken. It is the goal of oil analysis to provide a representative insight into the actual condition of the oil and the condition of the piece of equipment. Some of the most common sampling ports are as follows: 1. Reservoir (using a vacuum gun & tubing from the center of the reservoir) 2. In-line sampling port 3. Before the filter 4. After the filter b) OIL ANALYSIS Oil analysis is the evaluation of the oil itself and any contamination that is present. The information derived from the following tests looks for different types of wear and contamination. Each test looks at a different aspect of the oil. The tests are as follows: i. Viscosity - The viscosity test measures the thickness of the oil. The oil is heated and run through the viscosity bath. The results are then compared to the new oil specification. This test is valuable in determining the condition of the oil and is an indicator of water contamination and oxidation. ii. Water Content (greater than 1%) - Water content above 1% is detected in the basic oil analysis. c) PARTICLE ANALYSIS A count of the number of particles present greater than given micron sizes per unit volume of fluid. The results reflect the solid contaminants present and are applied to assess fluid cleanliness and filtration efficiency. Cleanliness levels are also represented by the ISO 4406 classification system to classify the particles larger than 4-μm, 6-μm, and 14-μm per milliliter of fluid (for example: 18/16/14). Particle analysis is the second phase of oil analysis. This test evaluates the particulate from 5-100+ microns. Measurement of a typical oil Particle size X In micrometers 4µm 5120 6µm 89 10µm 43 14µm 22 20µm 2 50µm 04 No of particles Greater than X Size per ml OLD ISO R2/R5/R4, NEW ISO R4/R6/R14 Change of about 1 in first digit, Second two typical don t change ISO CLEANLINESS CODE R4/R6/R14 20/14/12 If only 2 range Numbers are used ISO*/14/12 No. 2.5 5 10 20 40 80 160 320 640 1280 2560 5120 10240 Range Code 8 9 10 11 12 13 14 15 16 17 18 19 20 Copyright 2003 LubriCARE ALL RIGHTS RESERVED page 3

The particle count is the single most important part of the report to measure the efficiency of system filtration. The particle count measures all particulate in the oil larger than 5 microns. Particulate include: dirt, carbon, metals, fiber, bug parts, etc. The particle count can be done using either laser or optical methods. The laser method reports the quantity, size and distribution of particulate but not what they are. The optical method gives a quantity, size, distribution and identification. A combination of these two methods is used in our particle analysis. Through the use of the two methods, we can provide the most representative analysis available. d) CONDITION MONITORING REPORTS After taking the lubes samples, we provide the laboratory with as much information about the equipment, lubrication types, environmental conditions, and maintenance practices as possible. Once we have received an oil analysis report from the laboratory, it is imperative to act quickly on any findings or recommendations. Keeping a close eye on the condition monitoring report can really ensure the maximum value for the company s investment in its equipment. e) DATA REPORTING FORMATS Three of the most common forms of data formats are: 1) ISO - International Standards Organization 2) NAS - National Aerospace Standards 3) SAE - Society of automotive Engineers SYSTEM PRINCIPLES, TECHNICAL CONFIGURATIONS & SPECIFICATION GENERAL INFORMATION Typical Fluid Cleanliness Level Requirements Component Servo control valves Proportional valves Vane and piston pumps/motors Directional and pressure control valves Gear pumps/motors Flow control valves cylinders New fluid ISO Cleanliness Level 16/14/11 17/15/12 18/16/13 18/16/13 19/17/14 20/18/15 20/18/15 Copyright 2003 LubriCARE ALL RIGHTS RESERVED page 4

Fluid cleanliness levels are a function of initial contamination levels, contamination ingression rates, reservoir size and filter element efficiency. From our experience with similar projects, We designed our LubriCARE Vacuum Dehydration Oil Purification Systems (VDOPS) to reduce overall operational and maintenance costs associated with contaminated hydraulic, lube, and dielectric oils. Our VDOPS are able to purify equipments contaminated oil while on or off-line. Our portable systems can be designed and used for oil transfer or kidney loop filtration, and they are equipped to effectively remove particulate, water, air, gasses, and acidity all at the same time. - Remove free, emulsified, and dissolved water by vacuum dehydration. - Remove dissolved air and entrained gasses by vacuum dehydration. - Remove particulate to meet or exceed ISO 14/12/10 specifications. - Flow rate from 1 to 500 GPM. - Achieve > 90 kv dielectric values for Dielectric oils. - Oils with high particle counts. - Oils with high water content. - Oils with high acid numbers. - Oils with low dielectric values. System Principles The Figure below, shows schematically the VDOPS operation. A vacuum pump creates a vacuum that draws fluid into the unit through an inline heater where the fluid is heated to 150 F (66 C). It then flows through dispersal elements that are located inside the vacuum tower. The contaminated oil flows through the pores of these elements where it is exposed to a vacuum, normally 25 Hg (635m Hg). The boiling point of water is below the 150 F fluid temperature at this vacuum. The water and dissolved gasses are boiled off and the fluid is dehydrated. An outlet pump removes the dry oil from the bottom of the vacuum chamber and pumps it through a high efficiency, high dust capacity, particulate filter (β >200) and back into the reservoir. LubriCARE Vacuum Dehydration Oil Purification System (VDOPS) Schematically Operation Flow Diagram Inlet Air Filter Vacuum Control Valve Vacuum Gauge Air Cooled Condser Absolute Rated Particulate Filter x= 200 High Level Switch Water Inlet Water Cooled Condser (Optional) Water Outlet Sample Port High Level Condensate Switch Variable Flow Diverter Valve Outlet Flow Oil Discharge Pump Low Flow Switch Low Watt Density Heater Condensate Tank Inlet Shutoff Inlet Flow Vacuum Pump Condensate Drain (Dry Seal Pump Only) Variable Flow Circuit Copyright 2003 LubriCARE ALL RIGHTS RESERVED page 5

PERFORMANCE TRACK RECORDS (Lube oil purification, filtration and flushing project using LubriCARE lube oil management system and analysis for gas turbines, gas compressors and pumps) PETRONAS GAS BERHAD GPP B Dec 2007 Dec 2007 Jan 2009 March 2009 March 2009 Project Description Lube Oil Purification Lube Oil Purification Lube Oil Purification Lube Oil Line Flushing Lube Oil Line Flushing PETRONAS GAS BERHAD CUFK Sept 2008 Project Description Replaced lube oil & perform lube oil purification on steam turbine Nov 2008 Lube Oil Line Flushing and Filtration Jan 2009 May 2009 May 2009 Aug 2009 Replaced lube oil & perform lube oil purification on steam turbine Perform lube oil purification on steam turbine, empty & refilling of lube oil Perform lube oil purification on steam turbine, empty & refilling of lube oil Perform lube oil purification on steam turbine, empty & refilling of lube oil POWERTEK BERHAD, Malacca August 2008 Project Description Perform lube oil filtration & purification on gas turbine more than 16 MW Copyright 2003 LubriCARE ALL RIGHTS RESERVED page 6

Copyright 2003 LubriCARE ALL RIGHTS RESERVED page 7

LEFT: BEFORE Water Concentration 1800 PPM RIGHT: AFTER Water Concentration 24 PPM LEFT: BEFORE Particulate ISO 21/20/18 (NAS 10) RIGHT: AFTER Particulate ISO 14/12/10 (NAS 4) LubriCARE 50 GPM Vacuum Dehydration Oil Purification System LubriCARE PORTABLE LUBE ANALYSIS INSTRUMENTATION (ONLINE/OFFLINE) LubriCARE 50 GPM HIGH FLOW PORTABLE FILTRATION SYSTEM LubriCARE Portable Filter Cart SYSTEM LubriCARE PORTABLE WATER TEST KIT For further information and to contact MOF Registed Company (Reg. No: 35702014335) AR DORROUN SDN. BHD. Lot PT 11248, Taman Industri Paka 23100 Paka, Dungun, Terengganu Darul Iman, MALAYSIA Tel: +60(9) 827 1708 Fax: +60(9) 827 2708 email : sales.enquire@ar-dorroun.com.my url : www.ar-dorroun.com.my Copyright 2003 LubriCARE ALL RIGHTS RESERVED page 9