Jarrod Potteiger Descase LE
Designing Your C Contamination i i Control C l Program Jarrod Potteiger Des-Case Corporation
What Causes Machines to Fail? Loss of Usefulness 15% 15%
Surface Degradation Obsolescence
70%
Accidents
70% of loss of machine life is due to loss of surface material
2 © 2010 Des‐Case Corp.
Slide CCT 3
What Causes Machines to Fail? Mechanical Wear Breakdown Corrosive Wear
Mechanical Wear h l
21%
79%
Ref: MIT, E. Rabinowicz Ref: MIT E Rabinowicz
3 © 2010 Des‐Case Corp.
Slide CCT 4
What Causes Machines to Wear? Primary Wear Mechanisms
66%
12%
8%
8%
3 body Abrasion Adhesion y
Erosion
Fatigue g
4% Other
2% Frettingg
82% of mechanical wear is caused by particle contamination 4 © 2010 Des‐Case Corp.
Slide CCT 5
Contamination Control Gets Results • Nippon Steel reduces hydraulic pump replacements by 80% and bearing failures by 50% with contamination control. • Kawasaki Steel eliminates 96% of hydraulic component failure with offline filtration. • Port of Tacoma extends engine life by 300% with improved fil i filtration practices. i • GM / SAE study shows 8x engine life improvement with 5 micron filtration when compared to 40 micron filtration 5‐micron filtration when compared to 40‐micron filtration The primary action taken in all of these cases was the use of high‐quality filters and breathers. 5 © 2010 Des‐Case Corp.
Slide CCT ?
Contamination Control
© 2010 Des‐Case Corp.
Slide CCT 39
Common Sources of Contamination • • • •
New Oil: New oil is typically far too dirty to meet common machine cleanliness targets. Ambient Air: All sumps breath. This is a primary source for particles and moisture. Built In: Poor maintenance practices and part management lead to gross oil contamination. Machine Born: Wear debris is also contamination.
7 © 2010 Des‐Case Corp.
Slide CCT 41
Common Effects of Contamination Damage Caused by Direct Machine C t i Contaminant t Type T W Wear
Particle Contamination
Moisture Contamination
Damage to L bi t Lubricant
Indirect Damage
Abrasion Erosion Fatigue Valve stiction (silt lock)
Oxidation Particle scrubbing Viscosity increase
Varnish/deposits Corrosive attack Increased aeration
Corrosion Cavitation erosion
Oxidation Hydrolisis Water washing Viscosity increase
Varnish/deposits Corrosive attack Increase aeration Exacerbates all wear mechanisms due to loss of film strength
8 © 2010 Des‐Case Corp.
Slide CCT 42
Contamination Control Strategy Set Targets
1 Take Action
2 Measure Results
3 9 © 2010 Des‐Case Corp.
Slide CCT 43
How Clean / Dry Should Oil Be? Particle Level Target
Moisture Level Target
With servo valves
15/13/11
125 ppm
With proportional valves
16/14/12
150 ppm
Variable volume piston 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 9/ 6/ 3
300 ppm 300 ppm
Paper Machine
18/14/11
200 ppm
Steam Turbine
18/14/11
100 ppm
Pumps
17/14/12
150 ppm
Machine Type
Hydraulics H d li 1500‐ 2500psi
10 © 2010 Des‐Case Corp.
Slide CCT 45
ISO Cleanliness Codes The ISO contamination code states the average concentration in particles per mL for particles in particles per mL for particles in the following sizes: 4 micron and larger 6 micron and larger 14 micron and larger l Example: 18/16/13 Example: 18/16/13
© 2010 Des‐Case Corp.
Slide CCT 44
The ISO code describes the averag Dirt in 55 gallon (208 Liter) drum of oil = ISO 18/16/13 of oil = ISO 18/16/13 = ½ Teaspoon
Contamination Control Methods • Contamination Exclusion Contamination Exclusion Filter new oil Use good, quality breathers Use sound application methods Use sound application methods Upgrade seals Use hydraulic cylinder rod boots Utilize non invasive inspection / Utilize non‐invasive inspection / sampling methods – Use sound flushing practice for new or recently serviced equipment or recently serviced equipment – Practice good parts management – – – – – –
• Contamination Removal Contamination Removal • • • • • • • • • •
Upgrade system filters Permanent offline filtration Portable offline filtration offline filtration Vacuum dehydration Centrifugal separators W t Water‐absorbing filters b bi filt Coalescing filters Air stripping El t t ti / BCA filters Electrostatic / BCA filt System flushing
12 © 2010 Des‐Case Corp.
Head Space Management The best way to prevent airborne contamination in the average system is the use of high‐quality breathers with fine mechanical filtration as well as moisture removal capabilities removal capabilities. Hybrid breathers are typically the best typically the best value for systems that do not undergo significant volumetric change. 13 © 2010 Des‐Case Corp.
Cost Effective Contamination Removal
Offline filtration, whether portable or whether portable or permanent, is the most cost‐effective way to remove particles and achieve a high level of cleanliness.
14 © 2010 Des‐Case Corp.
How Good Are Your Filters?
The Beta Rating is the ratio of particles, at a The Beta Rating is the ratio of particles, at a given size, upstream of the filter vs. downstream of the filter.
15 © 2010 Des‐Case Corp.
How Do We Achieve Targets?
Old
New
Add permanent or portable offline filtration
Replace traditional breather Replace traditional breather with high‐quality desiccant breathers
Filter new oil
16 © 2010 Des‐Case Corp.
Storage, Handling and Application of New Oil f
17 © 2010 Des‐Case Corp.
Slide CCT 31
Oil Storage and Dispensing Essential Components for World‐Class World Class Storage and Storage and Dispensation Systems Separate fluid handling for each product fl d h dl f h d Filtration, filtration, filtration Quality tank breathers Product tagging to prevent cross‐contamination i i Climate control Quality assurance procedures including new oil testing
18 © 2010 Des‐Case Corp.
Slide CCT 32
Bulk Storage
19 © 2010 Des‐Case Corp.
Slide CCT 34
Intermediate Bulk Containers
20 © 2010 Des‐Case Corp.
Slide CCT 54
World‐Class Application Methods Not only should new oil be filtered before use, it must also be delivered and applied to machinery in a way that prevents further machinery in a way that prevents further contamination.
When possible, oil should be applied directly to the machine sump via filter cart. Additionally, the sump should be fitted with the sump should be fitted with quick‐connect fittings to facilitate the contamination‐free transfer. Lubricant top‐up containers should be plastic, sealable, marked for product type and stored in a clean environment. stored in a clean environment.
21 © 2010 Des‐Case Corp.
Slide CCT 33
Drum Dispensing
22 © 2010 Des‐Case Corp.
Slide CCT 36
Top Up Containers High‐Quality Top‐Up High‐Quality Top‐Up Containers Should Be: Made of plastic Marked for product type Sealable Cleaned periodically Filled with pre‐filtered oil Stored off the floor in a reasonably Stored off the floor in a reasonably clean manner
23 © 2010 Des‐Case Corp.
Slide CCT 38
Measuring Contamination Important Things to Important Things to Remember Reliable particle counts require good sampling Make sure the test methods are appropriate Make sure the test methods are appropriate relative to the targets Targets are never set in stone
24 © 2010 Des‐Case Corp.
Slide CCT 38
Effective Contamination Control D l th P Develop the Process Measure Correctly Review / Refine Targets and Methods Measure the Results
25 © 2010 Des‐Case Corp.
Questions
© 2010 Des‐Case Corp.
Slide
What Causes Machines to Fail? Loss of Usefulness 15% 15%
Surface Degradation Obsolescence
70%
Accidents
70% of loss of machine life is due to loss of surface material
2 © 2010 Des‐Case Corp.
Slide CCT 3
What Causes Machines to Fail? Mechanical Wear Breakdown Corrosive Wear
Mechanical Wear h l
21%
79%
Ref: MIT, E. Rabinowicz Ref: MIT E Rabinowicz
3 © 2010 Des‐Case Corp.
Slide CCT 4
What Causes Machines to Wear? Primary Wear Mechanisms
66%
12%
8%
8%
3 body Abrasion Adhesion y
Erosion
Fatigue g
4% Other
2% Frettingg
82% of mechanical wear is caused by particle contamination 4 © 2010 Des‐Case Corp.
Slide CCT 5
Contamination Control Gets Results • Nippon Steel reduces hydraulic pump replacements by 80% and bearing failures by 50% with contamination control. • Kawasaki Steel eliminates 96% of hydraulic component failure with offline filtration. • Port of Tacoma extends engine life by 300% with improved fil i filtration practices. i • GM / SAE study shows 8x engine life improvement with 5 micron filtration when compared to 40 micron filtration 5‐micron filtration when compared to 40‐micron filtration The primary action taken in all of these cases was the use of high‐quality filters and breathers. 5 © 2010 Des‐Case Corp.
Slide CCT ?
Contamination Control
© 2010 Des‐Case Corp.
Slide CCT 39
Common Sources of Contamination • • • •
New Oil: New oil is typically far too dirty to meet common machine cleanliness targets. Ambient Air: All sumps breath. This is a primary source for particles and moisture. Built In: Poor maintenance practices and part management lead to gross oil contamination. Machine Born: Wear debris is also contamination.
7 © 2010 Des‐Case Corp.
Slide CCT 41
Common Effects of Contamination Damage Caused by Direct Machine C t i Contaminant t Type T W Wear
Particle Contamination
Moisture Contamination
Damage to L bi t Lubricant
Indirect Damage
Abrasion Erosion Fatigue Valve stiction (silt lock)
Oxidation Particle scrubbing Viscosity increase
Varnish/deposits Corrosive attack Increased aeration
Corrosion Cavitation erosion
Oxidation Hydrolisis Water washing Viscosity increase
Varnish/deposits Corrosive attack Increase aeration Exacerbates all wear mechanisms due to loss of film strength
8 © 2010 Des‐Case Corp.
Slide CCT 42
Contamination Control Strategy Set Targets
1 Take Action
2 Measure Results
3 9 © 2010 Des‐Case Corp.
Slide CCT 43
How Clean / Dry Should Oil Be? Particle Level Target
Moisture Level Target
With servo valves
15/13/11
125 ppm
With proportional valves
16/14/12
150 ppm
Variable volume piston 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 9/ 6/ 3
300 ppm 300 ppm
Paper Machine
18/14/11
200 ppm
Steam Turbine
18/14/11
100 ppm
Pumps
17/14/12
150 ppm
Machine Type
Hydraulics H d li 1500‐ 2500psi
10 © 2010 Des‐Case Corp.
Slide CCT 45
ISO Cleanliness Codes The ISO contamination code states the average concentration in particles per mL for particles in particles per mL for particles in the following sizes: 4 micron and larger 6 micron and larger 14 micron and larger l Example: 18/16/13 Example: 18/16/13
© 2010 Des‐Case Corp.
Slide CCT 44
The ISO code describes the averag Dirt in 55 gallon (208 Liter) drum of oil = ISO 18/16/13 of oil = ISO 18/16/13 = ½ Teaspoon
Contamination Control Methods • Contamination Exclusion Contamination Exclusion Filter new oil Use good, quality breathers Use sound application methods Use sound application methods Upgrade seals Use hydraulic cylinder rod boots Utilize non invasive inspection / Utilize non‐invasive inspection / sampling methods – Use sound flushing practice for new or recently serviced equipment or recently serviced equipment – Practice good parts management – – – – – –
• Contamination Removal Contamination Removal • • • • • • • • • •
Upgrade system filters Permanent offline filtration Portable offline filtration offline filtration Vacuum dehydration Centrifugal separators W t Water‐absorbing filters b bi filt Coalescing filters Air stripping El t t ti / BCA filters Electrostatic / BCA filt System flushing
12 © 2010 Des‐Case Corp.
Head Space Management The best way to prevent airborne contamination in the average system is the use of high‐quality breathers with fine mechanical filtration as well as moisture removal capabilities removal capabilities. Hybrid breathers are typically the best typically the best value for systems that do not undergo significant volumetric change. 13 © 2010 Des‐Case Corp.
Cost Effective Contamination Removal
Offline filtration, whether portable or whether portable or permanent, is the most cost‐effective way to remove particles and achieve a high level of cleanliness.
14 © 2010 Des‐Case Corp.
How Good Are Your Filters?
The Beta Rating is the ratio of particles, at a The Beta Rating is the ratio of particles, at a given size, upstream of the filter vs. downstream of the filter.
15 © 2010 Des‐Case Corp.
How Do We Achieve Targets?
Old
New
Add permanent or portable offline filtration
Replace traditional breather Replace traditional breather with high‐quality desiccant breathers
Filter new oil
16 © 2010 Des‐Case Corp.
Storage, Handling and Application of New Oil f
17 © 2010 Des‐Case Corp.
Slide CCT 31
Oil Storage and Dispensing Essential Components for World‐Class World Class Storage and Storage and Dispensation Systems Separate fluid handling for each product fl d h dl f h d Filtration, filtration, filtration Quality tank breathers Product tagging to prevent cross‐contamination i i Climate control Quality assurance procedures including new oil testing
18 © 2010 Des‐Case Corp.
Slide CCT 32
Bulk Storage
19 © 2010 Des‐Case Corp.
Slide CCT 34
Intermediate Bulk Containers
20 © 2010 Des‐Case Corp.
Slide CCT 54
World‐Class Application Methods Not only should new oil be filtered before use, it must also be delivered and applied to machinery in a way that prevents further machinery in a way that prevents further contamination.
When possible, oil should be applied directly to the machine sump via filter cart. Additionally, the sump should be fitted with the sump should be fitted with quick‐connect fittings to facilitate the contamination‐free transfer. Lubricant top‐up containers should be plastic, sealable, marked for product type and stored in a clean environment. stored in a clean environment.
21 © 2010 Des‐Case Corp.
Slide CCT 33
Drum Dispensing
22 © 2010 Des‐Case Corp.
Slide CCT 36
Top Up Containers High‐Quality Top‐Up High‐Quality Top‐Up Containers Should Be: Made of plastic Marked for product type Sealable Cleaned periodically Filled with pre‐filtered oil Stored off the floor in a reasonably Stored off the floor in a reasonably clean manner
23 © 2010 Des‐Case Corp.
Slide CCT 38
Measuring Contamination Important Things to Important Things to Remember Reliable particle counts require good sampling Make sure the test methods are appropriate Make sure the test methods are appropriate relative to the targets Targets are never set in stone
24 © 2010 Des‐Case Corp.
Slide CCT 38
Effective Contamination Control D l th P Develop the Process Measure Correctly Review / Refine Targets and Methods Measure the Results
25 © 2010 Des‐Case Corp.
Questions
© 2010 Des‐Case Corp.
Slide
