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

Maintenance Types
Corrective / Breakdown

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

Preventive

Where equipment is maintained before break down occurs

Predictive

Observe the state of equipment by regular analysis

Determines equipments health
Done by Used Oil & Vibration Analysis
Maintenance at right time

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

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
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CENT as PdM Tool

Maintenance / Reliability

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

FUCHS offers CENT service for this purpose

CENT

A complete CbM program

Use Used Oil & Vibration Analysis

Supported by Engineers, Lubricant

Specialists, Chemists

Available online

Available world-wide

No investment required by the customer

World Wide Location

UK

Germany

Poland

France
USA

Spain

Saudi Arabia
India

Tanzania
South Africa
Australia

Facilities Provided

Sample bottles

Sampling pumps

Courier services to collect the samples

Report within 24 hours after receiving

Technical support and training

Supported Industries

CENT can be used by all types of industries

Chemical Industry
Refrigeration Systems

Pumps

Compressors

Generators

Turbines

Hydraulic Systems

Conveyor Systems

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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
Establish suitable drain intervals
Equipment efficiency (filters, separators, etc.)

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Preferred Method

Application
Electric Motors

Oil Analysis

Vibration

Gearboxes
Hydraulic Systems

Engines

Transmissions, Final Drives

Turbines

Grease-packed Bearings
Compressors

Machine Tools

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Components Complete Condition Monitoring

Program

Sample Points

Sampling Intervals

Sampling Techniques

Analysis / Selection of tests and methods

Database

Report type, speed, easily-understandable

Trend Analysis

Expert Comments

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Sample Point

Easy & Safe location

Should give representative sample

Avoid static condition

Avoid drain plugs

DO NOT change sample point

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Sample Point
Equipment
Return
Line Filter
Pressure
Filter

Vent
Filter

Filler

Pump

Reservoir
Suction
Filter

Dynamic Sampling

Static Sampling

Drain
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Sampling Intervals
Application

Conditions

Frequency

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

conditions / continuous operations

Monthly

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

operating conditions

Every 2-3 months

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

conditions / continuous operations

Monthly

Hydraulic Machine tools,

light applications

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

operating conditions

Every 3-4 months

Hydraulic Automotive

Wet, dirty conditions / continuous operation

Monthly / 250 hours

Continuous 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

Gearbox Automotive &

Industrial

Hydraulic Industrial

Air compressors

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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
- Drain some oil before taking sample
- Syringes and tubes to be used only
ONCE

Take sample when:

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:
- Take at least 250ml
- Seal the container
- Label correctly

- Equipment is in normal operation

- Oil should be well circulated and in
turbulent flow

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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
- Label

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Selection of Tests

Equipment

KV100

KV40

TBN

TAN

Water

FTIR

RDEAES

Hydraulic System

Turbines

Compressors

Industrial Gears

Auto Gearboxes

Transmissions

Engines

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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

ASTM D 92

ppm

ASTM D 1744

A/0.1mm
%

FTIR

ppm

ASTM D 6595

Flash Point
Water
IR Scan
Sulf, Nit, Oxi, Soot, Fuel, Gly, Water
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)

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Database

Database is required to maintain the following:
-

Equipment details
Oil details
Sample history
Report history

Accessible to users and customers

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CENT Report Formats

Two types of CENT reports
- Text report
- Graphical report

The reports show:

- Equipment, Sample Point and Oil Details
- Test results and graphs
- Expert comments

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Report Categories

Green Triangle
SATISFACTORY
Amber Square
CAUTION
Red Circle
ACTION

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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
Understanding of Oil chemistry and its working
Monitoring of trends
Establishment of relevant alarm levels

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CENT Software

Maintains database

Secure Online Access

View and print reports and history

Label printing

Schedule samples

Feedback options

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Secure Access to Reports

For User ID and
Password please
contact Fuchs

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Thank You