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