OMA 201
Seminar Content
1. Introduction:
- History of Oil analysis
- Condition based maintenance
- Types of problems detectable through Oil Analysis
2. Oil Sampling:
- Steps for representative sampling
o Planning a sample ID data base of sampling points
o Strategy and considerations
o Accessories for sampling
o Procedures documentation
o Contamination control during sampling
o Sampling location
- Test selection
- Sample intervals: consider the application
3. Contamination and wear debris:
- Surface Damage Classification
o Types of wear
- Abrasion
- Fatigue
- Corrosion
- Adhesion
- Delamination
- Erosion
- Cavitation
- Lubricant Degradation and Contamination
o Effect of contamination on oxidation
- Tests for contamination
- Glycol, coolant additives, soot, fuel, water, visual screening, abrasives, contaminants ingression
- Tests for oil degradation and limits determinations
o Viscosity, oxidation, nitration, sulfation, acidity(AN), alkalinity(BN), additive depletion
- Wear debris generation
- Tests for solid and wear debris
o Elemental spectrometry
o Fluorescence spectrometry
o Ferrous Particle Screening
o Qualitative ferrography
o Particle counting
o OEM and oil company limits
o Filter analysis
- Analytical Ferrography
o Contaminants from machinery operation
o Wear modes
o Wear debris generation
o Influences on oil film integrity and additives
4. Lubricant Applications and Contamination Effects:
- Internal combustion engines
- Hydraulic turbines
- Steam turbines
- Gas engines
- Screw compressors
- Reciprocating, centrifugal and refrigeration compressors
- Vacuum pumps
- Hydraulic systems and fluid cleanliness targets
- Gears
- Plain (sleeve) bearings
- Roller bearings
- Effect of cleanliness on component life
- Practical considerations during machine operation
o Abnormal wear debris, solid particles contamination, additive depletion, oxidation stability, water/glycol contamination, fuel dilution, soot loading, wrong oil make up, thermal degradation, corrosive condition, alkalinity reserve depletion, micro-dieseling, cavitation and erosion.
5. Offsite - Onsite - Online testing:
- Oil analysis evolution
- Field test parameters
- Portable Infrared Spectrometer
- Tests results evaluation
- Online sensors
o Oil condition sensor
o Moisture sensor
o Total ferrous debris sensor
o Particle content sensor
o Sensor suite
- Operating parameters
- Interface options for sensors
- Strategies
- Examples
6. Current technologies:
- Reliability-Centered Knowledge
o Reliability-Centered Knowledge Base
o Analyzing Maintenance Data
o Condition Based Maintenance (CBM)
o Reliability-Centered Maintenance (RCM)
- Oil analysis input to RCM
- Failure Mode Effect Analysis (FMEA)
- Maintenance strategies
- Integration of technologies for Condition Monitoring
o Thermography
o Acoustics
o Vibration analysis
o Oil analysis
- Integration examples
- Reliability concept for maintenance
- Software
o Laboratory information management system (LIMS)
o Automated diagnostics for oil analysis results (Intelligent Agent)
7. Interpretation Workshop:
- Data Rating
o Statistics
o Limits
1. Used lube tolerances
2. Awareness of sample integrity issues
3. Awareness of test precision and repeatability
o Trends and Nuances
o Combinations
- Applying Commentary
o Mobile Equipment
1. On-Road
2. Off-Road
o Industrial
o Railroad
o Marine
o Oil & Gas
8. The Bottom Line:
- Program logistics and implementation
o Goals and expectations
o Machinery/Components to be involved, and at what level
o Funding
o On site audit and deliverables
o Timing
o Training
- Lubricants reception, storage and distribution
- Selling the program and motivating the players
- Selecting/Monitoring lube vendors
o Quality and safety
o Product performance and technical support
o Oil reclamation and recycling
o Documentation of procedures and activities
- Implementing an Effective Oil Analysis Program
o Ongoing review – Continuous Improvement
o Take and Confirm Corrective Action
- Return on Investment (ROI), the underlying reason
o Costs
- Sampling and program management
- Component failure or damage
o Return
- Increased uptime and production
- Secondary damage prevention
- Motivation
- Using results to drive maintenance
- Equipment longevity
- Root Cause Analysis (RCA)
- Interactive round table and conclusion