How is oil analysis used for condition monitoring Services?
Oil analysis in Condition Monitoring Services
Condition monitoring services: Oil sensors come in various types. Some focus on the oil's dielectric constant, which changes as the oil degrades or becomes contaminated. (The dielectric constant of a substance reflects its ability to prevent the formation of an electric field in it.) Other oil sensors evaluate optical characteristics and compare them to model conditions to assess oil quality (a technique called transform infrared spectroscopy of Fourier). Still, others use magnetic fields to detect metal particles in the oil (a sign of wear). And still, others use X-ray emissions to detect the presence of foreign elements.
This oil analysis process is one of the methods Technomax performs in condition monitoring services in the UAE. Oil sensors must be placed on or near the resource to be monitored. The oil analysis sensors are not suitable for monitoring assets that are:
- Inaccessible (such as underground pumps)
- Remote or very spaced (such as offshore wind turbines)
- Located in hard to reach places
- Located in hazardous environments
They are located in harsh conditions such as hot strip steel plants where extreme temperatures can damage sensors and the resulting data stream.
Oil analysis performance during Condition monitoring services
Oil analysis can go beyond only revealing the condition of the lubricant during testing. Advanced oil analysis techniques are used to monitor the state of the equipment. Using these advanced techniques, equipment reliability is increased, and unexpected failures and downtime can be lowered. There are many types of abnormal wear that exist inside a machine.
However, there are only some primary sources of wear Problems related to the oil itself can contribute to wear as the lubricant degrades or becomes contaminated. Machine condition can also contribute to wear generation if a component is misaligned or improperly balanced. Misuse of equipment, such as overloading or accelerated heating conditions, can also lead to wear. Following are some examples of types of wear.
It is the result of contact of hard particles with internal components. These particles include a variety of wear metals. By using a filtration process can reduce abrasive wear, which, in turn, ensures the proper operation of vents, vents, and seals.
It occurs when two metal surfaces come into contact, allowing particles to separate from components. Insufficient lubrication or lubricant contamination usually causes this condition. Ensuring that the proper viscosity grade lubricant is used can reduce adhesive wear. Reducing oil contamination also helps eliminate adhesive wear.
It occurs when air or gas bubbles collapse. When internal components collapse against the surface, cracks, and holes can form. Controlling the foaming characteristics of the oil with the antifoam additive can help s to reduce the cavitation. Even random electrical current can cause corrosion. Corrosion from electrical current causes welding and wear surface corrosion. The presence of water can promote corrosive wear.
It occurs when an abrasive particle has encrusted a smooth surface. Equipment imbalance or misalignment can contribute to cutting wear. Proper filtration and equipment maintenance are essential to reduce cutting wear.
occurs when cracks develop on the component surface, allowing for the generation and removal of particles. The leading causes of fatigue wear include insufficient lubrication, lubricant contamination, and component fatigue.
It is caused by stress on the equipment. Subjecting the equipment to excessive speeds or loads can cause slip wear. Excess heat in an overload situation weakens the lubricant and can cause metal-to-metal contact. When a moving part comes into contact with a stationary position, sliding wear becomes an issue. Providing proper lubrication, filtration, and equipment maintenance can significantly reduce the wear inside the equipment.
By monitoring equipment conditions with oil analysis, a plant can identify various wear and take corrective action before a failure occurs. In many cases, oil analysis can identify problems with rotating equipment even before vibration analysis detects them.
When implementing oil analysis condition monitoring services, it is essential to select tests that will identify abnormal wear particles in the oil. When components within the equipment wear out, debris is generated. Placing the wear debris can establish the source of the problem. Here are some laboratory test examples that can help identify wear.
The spectrometric analysis is the most commonly used technology for the concentration of wear metals in condition monitoring services. The main objective of this technology is to determine the tendency for accumulation of slight wear metals and elemental additive constituents and to identify potential contaminants. This technology controls only the tiny particles present in the oil. Any large worn metal particles will not be detected or reported.
The particle count keeps track of all ranges of particles found in the sample. However, the particle count does not differentiate the composition of the materials present. Its main goal is to identify the number of particles in the model. Results are generally reported in specific size ranges per milliliter or per 100 milliliters of sample in that condition monitoring service.
In condition monitoring services, direct reading ferrography monitors and analyzes the relative concentration of ferrous wear particles and determines a ratio of large to small ferrous particles to provide information on the wear rate of the lubricated component. This method can be used as a tracking and trending tool, especially in systems that generate a high frequency of particles.
Analytical ferrography uses microscopic analysis in Condition monitoring services to identify the composition of the material present. This technology differentiates the type of material in the sample and determines the wear component from which it was generated. It is used to determine the characteristics of a machine by evaluating the type, size, concentration, distribution, and morphology of the particles.
This information helps determine the source and resolution of the problem. Every lab test has limitations. A well-balanced test package will correctly identify potential problems with the equipment. Many of the lab tests complement each other.
The purpose of Condition monitoring services (oil analysis program) should not be to check the condition of the lubricant. The actual maintenance savings with the use of oil analysis occur when equipment problems are detected. Initial wear, normal wear, and abnormal wear are the three wear stages in the equipment. Break-in wear occurs when starting a new component. It typically generates significant metal wear residue that is removed during the first two oil changes.
Normal wear occurs after the break-in phase. During this phase, the component stabilizes more. The proportion of wear metals increases with the use of the equipment and decreases when you add replacement oil or change the oil. Abnormal wear occurs due to some lubricant, machinery, or maintenance issues in Condition monitoring services. During this phase, wear metals increase considerably. Technomax provides best-in-class condition monitoring services in UAE.