CENT Condition Monitoring

May 2015

Equipment Life Cycle

� We all know that all equipment will fail and therefore its life is limited

� We do equipment maintenance to obtain:

- Better equipment life

- Better performance

� We also aspire for equipment to ‘fail safe’

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� We also aspire for equipment to ‘fail safe’

Maintenance Types

� Where equipment is maintained after break down or failure

� This maintenance is often most expensive because worn equipment can damage

other parts and cause multiple damages

� Where equipment is maintained before break down occurs

Corrective / Breakdown

Preventive

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� Where equipment is maintained before break down occurs

� Observe the state of equipment by regular analysis

� Determines equipment’s health

� Done by Used Oil & Vibration Analysis

� Maintenance at right time

Predictive

Benefits of PDM – Predictive Maintenance

� Provides increased component operational life and availability

� Allows for preemptive corrective actions

� Results in decrease in equipment and / or process downtime

� Lowers costs for parts and labor

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� Provides better product quality

� Improves worker and environmental safety

� Raises worker morale

� Increases energy savings

� Results in an estimated 8% to 12% cost savings over which might

result from a predictive maintenance program

CENT as PdM Tool

� Maintenance / Reliability

� Managers require Condition-based Monitoring (CbM) tool for PdM

� FUCHS offers CENT service for this purpose

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CENT

� A complete CbM program

� Use Used Oil & Vibration Analysis

� Supported by Engineers, Lubricant

� Specialists, Chemists

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� Available online

� Available world-wide

� No investment required by the customer

World Wide Location

USASpain

UK

France

Germany Poland

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South Africa

India

Australia

Saudi Arabia

Tanzania

Facilities Provided

� Sample bottles

� Sampling pumps

� Courier services to collect the samples

� Report within 24 hours after receiving

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� Technical support and training

� CENT can be used by all types of industries

Supported Industries

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Chemical Industry

Refrigeration Systems Pumps

Compressors Generators

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Turbines

Conveyor Systems

Hydraulic Systems

Used Oil Analysis

� Analysis of used-oil samples taken at regular intervals

- Identify wear components

- Identify contaminations

- Measure lubricant condition

- Monitor trends of wear and contamination

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- Monitor trends of wear and contamination

- Establish suitable drain intervals

- Equipment efficiency (filters, separators, etc.)

Preferred Method

Application Oil Analysis Vibration

Electric Motors � �

Gearboxes �

Hydraulic Systems �

Engines �

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Engines �

Transmissions, Final Drives �

Turbines � �

Grease-packed Bearings �

Compressors � �

Machine Tools �

Components – Complete Condition Monitoring

Program

� Sample Points

� Sampling Intervals

� Sampling Techniques

� Analysis / Selection of tests and methods

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� Database

� Report type, speed, easily-understandable

� Trend Analysis

� Expert Comments

Sample Point

� Easy & Safe location

� Should give representative sample

� Avoid static condition

� Avoid drain plugs

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� DO NOT change sample point

Sample Point

Equipment

Pressure

Filter

Return

Line Filter

Filler

Vent

Filter

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ReservoirPump

Suction

Filter

Filler Filter

DrainDynamic Sampling Static Sampling

Sampling Intervals

Application Conditions Frequency

Gearbox – Automotive &

Industrial

Heavy loading / high temp (>65°C) / dirty

conditions / continuous operationsMonthly

Light loading / normal temp (>50°C) / clean

operating conditionsEvery 2-3 months

Hydraulic – IndustrialHeavy loading / high temp (>65°C) / dirty

conditions / continuous operationsMonthly

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Hydraulic – Machine tools,

light applications

Light loading / normal temp (>50°C) / clean

operating conditionsEvery 3-4 months

Hydraulic – Automotive Wet, dirty conditions / continuous operation Monthly / 250 hours

Air compressorsContinuous running Monthly / 50 hours

Intermittent running Every 2 months

Engines – Mobile plant All conditions 10,000 km / 250 hours

Engines – Static plant All conditions 50-100 hours

Sampling Intervals

Alarm Limit

Cautionary Limit

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Sampling Techniques

� Preparations:

- Use clean, dry, un-used sample

container

- Area around the sample point to be

clean

- Flush sample bottle

� If equipment must be stopped for

sampling, take sample within:

- ISO 220 & above: 20-30 minutes

- ISO 68 to 150: 10-20 minutes

- ISO 46 & below: 5-10 minutes

� Conclusion:

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- Flush sample bottle

- Drain some oil before taking sample

- Syringes and tubes to be used only

ONCE

� Take sample when:

- Equipment is in normal operation

- Oil should be well circulated and in

turbulent flow

� Conclusion:

- Take at least 250ml

- Seal the container

- Label correctly

Importance of Proper Sampling

� Without a good sample the rest of the process is worthless

� The error starts from taking the sample

� Take care of the following:

- Sample Point

- Contamination

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- Contamination

- Label

Selection of Tests

Equipment KV100 KV40 TBN TAN Water FTIRRDE-

AES

Hydraulic System � � � �

Turbines � � � �

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Compressors � � � �

Industrial Gears � � � �

Auto Gearboxes � � � �

Transmissions � � � �

Engines � � � � �

Selection of Test Methods

Test Units Method

Kinematic Viscosity (KV) cSt ASTM D 445

Total Base Number (TBN) Mg KOH/g ASTM D 2896

Total Acid Number (TAN) Mg KOH/g ASTM D 664

Flash Point °C ASTM D 92

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Flash Point °C ASTM D 92

Water ppm ASTM D 1744

IR Scan

Sulf, Nit, Oxi, Soot, Fuel, Gly, Water

A/0.1mm

%

FTIR

RDE – Atomic Emission Spectroscopy

Fe (Iron)

Cr, Ni, Mo, Mn (Ferrous)

Pb, Cu, Sn, Sb (White Metal), Si, Al, Li (Dirt Grease)

Ca, Mg, Zn, P (Additive)

ppm ASTM D 6595

Database

� Database is required to maintain the following:

- Equipment details

- Oil details

- Sample history

- Report history

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- Report history

� Accessible to users and customers

CENT Report Formats

� Two types of CENT reports

- Text report

- Graphical report

� The reports show:

- Equipment, Sample Point and Oil Details

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- Equipment, Sample Point and Oil Details

- Test results and graphs

- Expert comments

Report Categories

Green Triangle

SATISFACTORY

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SATISFACTORY

Amber Square

CAUTION

Red Circle

ACTION

Interpretation of Results

� Points to consider while interpreting:

- Design & Operation of the Equipment

- Metallurgy of the components

- Awareness of Operating environment

- Awareness of likely contaminants

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- Awareness of likely contaminants

- Understanding of Oil chemistry and its working

- Monitoring of trends

- Establishment of relevant alarm levels

CENT Software

� Maintains database

� Secure Online Access

� View and print reports and history

� Label printing

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� Schedule samples

� Feedback options

Secure Access to Reports

For User ID and

Password please

contact Fuchs

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Thank You