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A-1
Obsolete
15%
Surfaces Degrade
70%
Corrosion
20%
Accident
15%
Wear
50%
Caused by
Abrasive Wear
Adhesive Wear
Fatigue Wear
Caused by
Caused by
Caused by
abrasive particles-in-oil
dirt, secondary wear,
process contamination...
inadequate lubrication
low visc, no oil, high temp,
excess load, slow speed...
misalignment, imbalance,
improper fit/assembly,
secondary damage...
A-2
Vibration monitoring
Oil monitoring
A-3
Vibration monitoring
A-4
Ex t reme
B ad
W e ar
Marg in al
Fa ir
W e ar - Ex t reme
C on t amin at ion - G o od
C he mis try - G ood
Th is is a d oz er cran kc ase o il. N ot ice
t he larg e w e ar part icles .
G oo d
C he ck - B re at h er, Sh op Mic , Mech an ic al
A ct ion - N o t if y mec ha nic
Es t ima t ed t ot a l wa t er con t en t 0 .00 00 %
In Solut ion 0% +Emu ls if ied 0%
+F ree 0% = 10 0%
C on t amin at ion
C he mis try
Extreme
Bad
Marginal
Wear - Good
Contamination- Extreme
Chem istry - Extreme
Fair
Good
Wear
Extreme
Bad
Marginal
W ear - Good
Cont aminat ion - Good
Chemistry - Good
Fair
Good
Check - None
A ction - None
Estimat ed tot al w at er content 0.0000%
In Solution 0% +Emulsif ied 0%
+Free 0% = 100%
W ear
Chemistry
Contamination
Chem istry
Oil condition
monitoring
A-5
A-6
P-F Curve
Method, Tools & Technology
conditional
incipient
impending
precipitous
catastrophic
Time
PDM
A-7
TAHAPAN KEGAGALAN
Conditional
Incipient
Impending
Precipitous
Catastrophic
End of Life
Kegagalan yang
tidak bisa dikelola
(unmanageable
failures)
A-8
Equipment Maintenance
Strategies
A-9
Technology Owners
PdM
To Control
Room
Vibration
Pressure
Motor
Current
Lube Oil
GateCycle
Thermography
Performance
Monitoring
A-10
Tribology
Definisi: the study of surfaces in relative motion
Menyangkut:
Friksi, Lubrikasi, dan Keausan
Tribology
Keausan mesin berarti:
Perawatan,
Penggantian, &
Terganggunya proses produksi.
A-12
A-14
A-15
A-16
Off-site
Oleh pihak ketiga
fluid analysis laboratory.
A-17
Database
"Oil routes"
bersifat proaktif,
Melibatkan root cause
failure analysis dan
contamination control.
A-20
A-21
Procurement Practices
Menjamin kualitas lubricants, Filters,
dan Breathers
Menjalin kerjasama dengan
penyalur pelumas dan filter
A-22
A-23
Trivektor
Wear
Contamination
- Particle Counting
- Water
Chemistry
- Oksidasi (AN/BN)
- Viscositas
- FTIR (aditif)
A-24
Trivector example
ABRAS W E AR - Ab rasive W ear Exampl e
P3 - Mo bil DT E hydrauli c f lui d
Samp le Date: 21-FE B- 93
Extreme
Bad
M arg inal
Fair
W ear
W ear - Bad
Co nt aminatio n - E xtreme
Ch emistry - G oo d
Bad seal leaking co ol an t in to hydraul ics
Saw ab rasive w ear particles on g rid 100x
G oo d
Ch eck - Vi sco sit y, Breath er, Co nt aminatio n, Sh op M ic, Mech an ical
Actio n - Remove Con tamin ant s ( w ater? )
Estimat ed tot al w ater co ntent 2.5089%
In So lu tio n 1% + Emul sifi ed 72%
+ F ree 27% = 100%
Co nt aminatio n
Ch emistry
A-25
A-26
On-site
Langkah Pertama
Lihat,
Cium,
Sentuh, dan
Pikirkan
A-28
Lihat!
A-31
Pengujian konvensional
A-32
Pengujian Konvensional
Isu :
Tidak ada perencanaan tentang:
Alarm level
Tindak lanjut
Menunggu hasil
Data pasif.
A-33
Oil Analysis
Program
6. Data dibandingkan
dengan teknologi PdM
yg lain
C
4. Penyimpanan dan Analisis data
dengan komputer
3. Kirim sampel bermasalah
ke Laboratorium
5. Teknisi terlatih mengerti data
A-34
dan batas alarm
Roots Blower
Parameter
ISO 4
ISO 6
Nominal
K/p Wear Factors
Value
K = Wear Coefficient
22
p = Penetration Hardness
22
ISO 14
121
0.1
22,052
0.01
Count > 6
20,628
0.001
Count > 14
13,631
0.0001
0.00001
Count > 22
7,250
Count > 4
Count > 40
449
Count > 54
14.5
PPM by Vol
116.2
1st Peak
24
2nd Peak
40
New
sand
paper
Used
sand
paper
Dry
Fine
abrasive
particles
Silico
n
Large
Ferrous
Particle
s
Course
abrasive
particles
Journal
Bearing
Sliding
on
Oil Film
Lubricated
Roller Bearing
A-35
Salah pelumas
Temperatur tinggi
dilusi
Gross water
Kontaminasi air
Beban tinggi
Statik
Dinamik
Sliding, metal-to-metal
contact
Gesekan yang hebat
menyebabkan
temperatur tinggi
seperti terlihat pada
partikel aus.
Melted
Smeared
Black oxides
Tempered
Slow speed
A-36
Design
Life 100%
75%
50%
25%
0%
100%
Design
Load
200%
300%
400%
500%
A-37
Bearing Life
200%
150%
100%
50%
0%
0.0%
0.1%
0.2%
0.3%
0.4%
0.5%
Percent Water-in-Oil
A-38
Greasing
Contamination Control
Training
Oil Analysis
A-39
A-40
Incoming inspection
SAE
Starburst
Dielectric
Viscosity
ISO code (optional)
Moisture (optional)
A-41
Solvents destroy
viscosity
Burn or dispose
properly
A-42
A-44
Lubricant Management
A-45
Lubrication Management
A-46
Lubrication System
A-47
A-48
Vanguard
680
Silogram 85
Way 100
OMALA
100
Texaco
Rando HD 68
Texaco
Meropa 150
Texaco
Meropa 320
Texaco
Vanguard 680
Pocket
Reference Guide
Template
Lube
Con 663
Rando
32
Texaco
Rando HD 32
Meropa
220
Tribol
290
Tribol
22
Silogram
85/140 SAP
Texaco Way
100 Oil
Ucon 300
ATF-210
Texaco
Meropa 220
A-49
A-50
A-51
A-52
Engine breather of
turbocharged engine
A-53
Jadi.
Melakukan Kontrol untuk kontaminasi
air dan partikel padatan,
Terbukti dapat memperpanjang umur
mesin.
A-54
Analisis Pelumas
Analisis pelumas dengan tujuan
perawatan dapat dibandingkan dengan
analisa darah untuk tujuan medis.
A-55
Pertanyaan???
Metoda pengujian apa yang perlu dilakukan
untuk jenis mesin tertentu?
Instrumen apa yang dipakai?
Apa tujuannya?
A-56
Apa tujuannya?
Mengetahui kondisi pelumas
Mengetahui Tingkat Kebersihan (tingkat
kontaminasi) pada sistem pelumasan
tersebut
Mengetahui kesehatan dari Mesin yang
dilumasi.
A-57
Hydraulic
Transformer
Gear and
Roller
Bearing
Journal
Wear
Fe, Pb, Sn, Cu wear is mostly oxide
and mostly <5 micron size.
Concentration in direct proportion to
soot and oxidation and inversely
proportional to TBN. Steady
increase in wear concentration
between oil changes.
Any wear is an abnormal condition.
Abrasive wear results from dust and
corrosive wear from moisture. Seal
wear from contamination or fit.
Wear due to arcing generates
dissolved gases in oil.
Contamination
Soot, dust, and
coolant
contamination.
Chemistry
Combustion gases
consume TBN,
contaminants
consume detergent
additives, hot surfaces
oxidize oil.
High temperatures
oxidize oil and
produce acidity.
Water
contamination.
Prolonged arcing,
moisture, and heat
may oxidize oil.
Moisture, heat, and air
entrainment may
oxidize oil.
A-58
UNSUR
KEMUNGKINAN SUMBER
Aluminum(Al)
Barium (Ba)
Detergen/Aditif dispersan
Boron (B)
Cadmium (Cd)
Coating on metal
Chromium (Cr)
Bearings, rings, rollers, liner, exhaust valves, seals, shafts, coolant treatment
Copper (Cu)
Iron (Fe)
Blocks, bearing, pumps, liner, gears, piston, rings, discs, shaft, valve, screws
Lead (Pb)
Bearing, additive
Magnesium (Mg)
Detergen/Aditif dispersan
Molybdenum(Mo)
Nickel (Ni)
Phosphor (P)
Antiwear additive
Silicon (Si)
Silver (Ag)
Sodium (Na)
Tin (Sn)
Titanium (Ti)
Vanadium (V)
Valve, coating
Zinc (Zn)
Antiwear/Inhibitor additive
A-59
A-60
A-61
Aplikasi -- gearbox:
Mechanical wear, dimana partikel
geram hasil keausan bisa berukuran
10 100 mikron
Penggumpalan zat aditif: Anti-wear,
anti-oxidant, dan anti-scuff additive,
Oil oxidation,
Naiknya tingkat keasaman,
Air dan kontaminan lainnya.
A-62
Contamination Of Oils
Particle count
Particle size
distribution
ppm < 6 micron
ppm 6 to 14 micron
ppm >14 micron
Water-in-oil
Glycol (engine)
Soot (diesel engine)
Spectrometals
Sodium (Na)
Boron (B)
Silicon (Si) < 5
micron
Physical/Chemical Tests
Viscosity
Viscosity Index
Specific Gravity
Flash Point
Pour Point
Dielectric
OR
OR
Okay
Spectrometric
TAN
For Additives
TBN
Zn, P, Ca, Mg
Oxidation
Color
Physical/chemical tests
measure oil chemistry, not
contamination or wear
A-64
What is measured?
Wear Parameters
Iron particles > 5 microns
Iron particles >> 60 microns
Other metals >> 60 microns
Microscopic particle
examination
Contamination Parameters
ISO counts at 8 different sizes
Non-ferrous contaminants
Water or other corrosive fluid
Imiscible fluid droplets in oil
Chemistry Parameters
Deteriorated lubricant
Physical property of lubricant
ISO viscosity grade
Significance
Recent abnormal wear
Abrasive wear indication
Abrasive wear indication
Wear severity and root cause
A-65
Pengujian yang
dilakukan salah
Partikel yang lebih besar
tidak terihat
Pengambilan sample
salah
What can
I see?
Training
Wear
Sampling
Contamination Chemistry
Testing
A-66
A-67
Oil Sampling
Sample yang baik
Desintas data maksimal
Data disturbance minimal
Frekuensi yang sesuai
Pertimbangan saat mengambil sampel oli
Lokasi sampel
Alat yang digunakan untuk mengambil sample
Botol tempat sampel
Prosedur pengambilan sampel
A-68
Oil Sampling
Sampling di zona aktif
Agitated - mixed
Flowing
Hot
After machinery
Before filter
Before dilution
Away from walls
Before settling
Clean procedures
Machine
Ideal Place
to Sample
Oil Supply
A-69
A-70
A-71
Metode Sampling
Sampling Port
- Minimess Port
Sampling Probe
- Low Pressure Hose
- Vacuum Pump
- Pitot Tube
A-72
A-73
A-74
A-75