APPLICATION PAPER ‘Changing the woy the wore partons montennoee Case Histories and Cost Savings: Using In-Shop Oil Analysis For Industrial Plant Applications Ray Garvey eer ‘This paper documents several Where do the savings come from? such as wrong lube, or in rare examples of cost savings through in-shop lube oil analysis for indus- trial plant applications. Ci industrial applications including Pumps, presses, gearboxes, motors, and compressors have been selected for case study. One theme of this particular paper is to. show how people are successfully using in-shop oil analysis, often in conjunction with laboratory oil ‘analysis and vibration analysis pro- grams. Cost savings in each of the ‘case studies Is the result of either extended oil change through con: dition monitoring of the lube, oF from maintenance cost avoidance ‘and production uptime, resulting from carly detection and correc- tion of lube contamination and mechanical wear problems. Introduction: ‘Analysis of used lube oils isa sim- pple and cost effective method ta Tearn about 1)the quality of the be, 2) passible contamination of the lube system. and 3) the pro- ‘aressive degradation of ail wetted surfaces. A variety of tests can be done using in-shop, on-site, and off-site methods, given a consistent ‘il sampling progeam. Typical industrial plants report annual sav- ings of S277,000as a direct result of oil analysis’. Gil analysis saves money several Ways. Condition based oil analysis will invariably save money when compared to calendar based oil analysis for industrial equipment. This is because those changing oil based on hours or days are elther doing it too soon oF too late, Too soon, ifthe oil has significant remaining useful life, Too late if the oils already degraded or contaminated. By monitoring for contaminants in the oil, one can find and fix prob lems before they can cause dam- age. The most common contami= nants in industrial lubricants are ier, coolant, and process materi: als. Wher these gjet into the lube we things must be done, First, the ingress of contaminants must be stapped. Second, the lube must be filtered, desiccated, or changed. Condition based oll change and contamination monitoring are proactive maintenance actions. ‘They gu directly to the root cause ofmany machinery problems, An Skx report shows that 50% of all bearing failures are the result of poor lubrication or contamination’. Its important to point out that when the plant maintenance staff pays particular attention to the Condition of lubricants, they will surely notice common problems instances, no lube at all, ‘Savings also result from early [problem detection thraugh wear ‘particle analysis. This is-a predic ‘ive maintenance action. Its fare- casting machine stoppage due to progressive failure of mechanical components. Oil analysis and vibration analysis complement each other well. The oil can con- ‘firm certain problems detected ‘through vibration. It can also give advanced warning, Some report ax ‘much as six month earlicr indica- tion of wear related problems using oil analysis. For engines, ‘compressors, crushers, pulveriz- ‘ers, presses, and gearboxes, oll analysis may be the more informa- live predictive maintenance tech- nique due to their complex vibra- tion sigmatures in some of these ‘mechanical systems. “Minimizing unscheduled prodve- ion downtime is the first abjective ‘of any predictive maintenance pro- gram, Wear particle analysis sup= ports this objective with early indi- cation of component failure, the type of damage taking place (cor- rosion, abrasion, fatigue, or other), and information about possible problem locations. COMPUTATIONAL SYSTEMS INCORPORATED # 1Case Histories and Cost Savings: Using In-Shop Oil Analysis, in-Shop, On-Site, and Off-Site Lube Analysis Keeping in mind that the objective for doing oll analysis is to deter- mine the present condition of the lube, contaminants in the lube, andl ‘wear particles in the lube, there are multiple ways lube oil samples can be tested. Samples can be analyzed in-shop using ficld-portable analyz ers, oF on-site using laboratory analyzers, or offsite using con- tracted lab services or a combina- tion of these three. In-shop oll analysis has the advan- tage of giving immediate feedback to the people whe know the most ‘about the machinery. Te strength of this approach is that oil analysis is being done by those who are motivated to find the problem and who are capable of fixing machin- ery problems. In each of the case studies reported in this paper, the OilView* Model 5100, was used for in-shop habe oil analysis. The sum= mary ofits detectability limits are given in Table 1. On-site oF contracted tab oll analysis offers more sophisticated tools and greater knowledge of lube oil technology. It hax penal ties assnciated with the nced for information transfer between lab and maintenance personnel regarding both machinery and ube analysis results. The appropriate mix of these three approaches to oil analysis is differ- ent for each plant situation. For ‘most, the solution is not one or another, but is a combination of al, Typically, the most critical equip. ment in the plant will be monitored using on-site o contracted lab ser vices. In-shop analyzers may be used to monitor this same eq} ment, Another effective use of shop lube analysis tools is to moni- tor the non-critical applications that make up the remaining 70% to 90% of the plant equipment. ‘This is how E.l. DuPont and Duke Power are successfully using beth in-shop and contracted lab ser vices for oil analysis programs. At E.l, DuPont in Louisville, Kon- tucky, Keith Mosier uses both in- shop oil analysis and-contracted lat services. In-shop lube analysis enables him to find and fix contami- nation, particularly water and coolant in the oil. It alse gives imme- jate indication oF confirmation of wear problems. It complements his vibration analysis program. ‘At Duke Qeonee Nuctear Station, Gary Sweet and Marc Snyder use both in-shop analysis and contract- ed lab services. They use the shop tools as the first line of test- ing, relying on the contracted lab for more in-depth analysis on selected samples. Lubricant suppliers or fiter suppl ers may perform “free” oil anal service by providing sample bottles or mailers (o their customers. Commercial oil labs typically charge $15 to $50 per sample for their services. In-shop ol analyzers require-sn initial investment, recur- ring consumable expense (this may be negligible), and labor expense. One needs to consider when set- ting up oF expanding an oll analy’- sis program that the higher cost options typically include wear par- ticle analyses needed for effective machinery condition monitoring. Regardless which method or com- bination of methods is selected for analyzing the oil itis of little value lunless the resuits are received, understood, and acted upon by the plant maintenance staff. A success- ful lube analysis program needs to provide information about Iube quality, lube contamination, and mechanical wear that will be used to increase production up-time and reduce maintenance expense, 2 + COMPUTATIONAL SYSTEMS INCORPORATEDCase Histories and Cost Savings: Using In-Shop Oil Analysis Table 1. OilView* Model $100 Detection Limits? rapt | tn ete Mira Detectable Ln Oxidation Lic Most Lubvicanes <<10% by FTIR (OL, Cont Sot Cor Hew duty diesel (01% by TGA Lube System Coetanination Ot, Com, 0.005%; (OL and Cond 0.006% C- ‘Water a5 Hydrate lee <0.2% (04, Cor, Can 196 5% (LC Water Geie Hemvy Buty Diese veplts; Water droplet formation begins shen lubricant ples ative s saturated. 1, Cor, Soe Tine One a nM 60.2% 104, Corona 215%, ‘Water ae thelbearing at the atend of a ae : marine drive shat) ae Poly Alkalene Glycol synthetic ‘Water OL Cor bricant use i B-1a 2.04% (OL, Coo refrigerant compressor) i OL. Cor, Poly Eater tnymtbesclbvicare used Obi (Cont) 0.085 (OL). 0.32% (Cor) aa Cont, tC in R134a roigerantcompreson:) —— Oé4% (LC-Droples) Feeflooinaied Uther tynithetc ‘Water OL Cor Jbricant used iv hard vacua 0.02% (Cor) 0.05% 100, pues) Giyeot OL Cor Heavy Buty Diese 2% “Mechanical Wear i Fe.Cont, a 1 pp >5p et <30 pom >5p (Cont <1 ppm uc 40) (UC-Ferous) Googe Cont LC all 50 pp +54 (Cort) <1 pct 0p 1C-Nonter) Tio oat, UC al 50 porn 25 (Cont) 40p ALC-Nonfer 50 ppm >5p (Cort instead of afectng the -cantaminate inde, it may cause 2 cortecion Lead Cont all incex response due to chemical ouistion of the lead particles. The process of-oxidation makes ‘them elecrically noncoesuctive) “OL" the OilLife™ index,, “Cor” the corrosion index, “Cont” the contaminant index, “LCT qualitative “lange ferrous” or “large: non-ferrous" or “droplets, “Fe the Ferrous index. COMPUTATIONAL SYSTEMS INCORPORATED © 3‘Case Histories and Cost Savings: Using In-Shop Oil Analysis ‘Case Histories The following case histories are ‘examples of common instances ‘where maintenance costs have been avoided through the use of in-shop and lab-service type oil analyses. Pumps icroclectronics Division sis program is credited with saving $79,000 by early detec- tion of contamination with water ‘or coolant er process materials in 25-vacuum pumps. ‘One pump selected for example is dwards single-stage rotary cal vacuum pump. il sample was taken from the bottom drain after 15 minutes of ‘operation, Normally this pump ‘operates for 5 to 15 minute inter: vals, 10 times per day. The pump ‘evacuates a high vacuum chamber used in metal evaporation process- es. These problems were detected using OilView* Model 5100 in-shop oil analyzer, which provided the following output The alarming result was due to coolant contamination, Given this analysis, the pump was repaired at a cost of $1,000. Left undetected, the pump would have failed. A replacement pump would cost $16,000". Therefore. the savings for Presses 1g Plant in i in-shop oi nalysis to find impending failures in two of their 1000-ton Hamilton presses, Press 16-3 had two broken rockers Figure 1. Rocker arm from Hampton Press. below and a photograph of the racker is shown in Figure 1. Had the press continued to be run with ‘out immediate maintenance, a dan {ger to the press operator could have occurred as well as costly expense to the company Press 16-4 had a sheared stud sup- porting the rocker arm. Again, the this vane pump equaled $15,000. and four worn out link bushings. Gi) analysis history report shown The oll analysis was the indication below was the only indication of of these mechanical failures. The ear catastrophic falure oll data history report is shown ‘Machine: Pump 1 - Rotary vane mechanical pump Point: Point 1 ~ Bottom Drain eff vacuum pump : Covrosion Contaminant Semple Dale | Ollie nex ee Ferrousindex —LamgeContam Vise anovn | 00 00 00 00 NONE NA HAAN 7593 M3 ‘CRITICAL CRITICAL Fane NYA ‘Sample taken from bortom drain after 15 minutes of aperation. Critical! 4. © COMPUTATIONAL SYSTEMS INCORPORATEDCase Histories and Cost Savings: Using In-Shop Oil Analysis ‘Chrysler reported that without oil analysis a problem like this is not ee ee ee ies known until the table drops. Both Gait ant Dresses were repained quickly Press 16-4 was repaired within 2+ hours, the other took about ‘3 weeks to be repaired. Several — ‘months of lost production was avoided by detecting these incipi- HEH mene ati cent problems. Figure 2 shows the trend plot for OilView* data col- Sais ‘stots fracas S| ‘each of these two cases is estimat- ted between $50,000 to $1,000,000. a : PO Ree eee ee nee ae eA Figure 2. 16-4 OilView* Data, Machine: 16-3 — Hamilton 1000 T Press Point; Lube tie Corrosion Contam Ferrous Lange pee eS tedex rank tndex tex Coram, Nee EMAR-93 26 oo 97 400 Fane 20 o3.UNs a7 oo uz sao F 0 oN 109 oo 19. 20 f De raves a 9 30120 ' 20 Broken rockers! link bushings worn outt Machine: 164 - Hamilton 1900 T Press Point: Lube oti Comosion ——-Contami- «Ferrous Lage SevteDee [Bewsee tex ave tndex lode Conta, bse 2AR.93 2? at na 220 F 20 oon pr oo o36.0 1086.0 Fane ao Broken rocker sand placed reUNe3 194 04 187 1830 Fan 20 rrauess 127 oa tas 700 F 220 COMPUTATIONAL SYSTEMS INCORPORATED + 5Case Histories and Cost Savings: Using In-Shop Oil Analysis Grinding Rolls ‘St. John's River Power Park (SIRPPI typically sends off 140 oil ‘samples a month for complete: predictive analysis (e.g. ferro graphic wear particle analysi ‘This has been a very successful program for them, In adaition to using contracted lab snalysis, SURPP uses in-shop inalysis to monitor the degra ion, contamination, and wear tak- ing place, particularly on the co: pulverizer Grinding Rolls. Each pulerizer has three bearings which operate in a harsh environ- ment with elevated temperature. coal dust, and other abrasives. ‘There is no way to take vibration 6 pull oll samples while the equip- ment is operating. The brief inter= val while pulverizers are opened for service is the only time avail- able to pull a sample, get the results, and decide what mainte- nance actions are needed. Prior to implementing in-shop oil analysis. SIRPP overhauled approximately 27 Grinding Rolls er year at a cost of $19,000 each, “We started our oil testing pro- the Mode! 5100 Oil Analyzer, in February 1993. As. part of our testing program, we continued sending oil samples to an outside testing lab to-quantify the OilView readings. We have now collated enough data to s alarm limits and start trendii Grinding Roll oil samples... By using the Model 5100 OilView Analyzer, within minutes a deci- sion can be made an the replace ment of Pulverizer Grinding Rolls. Since February, we have not replaced a single Roll, nor have we had unexpected failures.’” Figure 3 shows histograms and alarm limits for these Grinding Rolls When tested using the Model $100, the 3 » 15 10 5 O85 510 1015 1520 2025 2530 303s 3540 Ferrous ten Wace “ F r 2» » 0 10 1015 15:29 25 Bao Was 340 ‘Contarninant tres Vahoes 0 40 %0 20 10 0 510 WAS 15.20 2025 2530 1035 1540 Corrosion Index Values Figure 3. Histogramyof statistical dita collected on SIRPP Grinding Rolls. © COMPUTATIONAL SYSTEMS INCORPORATED.Case Histories and Cost Savings: Using In-Shop Oil Analysis Gearboxes Gearboxes can be a challenge for even the mast experience vibration analyst, Gear mesh, numerous bearings, modulation, and bulky housings may impede immediate Identification of gear or bearing defect when using vibration analy: sis alone. These applications are particularly well suited for wear particle analysis. Two gearbox case histories are presented. The first is a double reduction gearbox. The second is single reduction. Basic American Foods in Moses Lake, Washington used both vibra- tion and oil analysis to determine that an old Jones-Maxi-Power int Double Reduction Helical Speed Reducer was failing (100 hp, 1730 mM, final output is 45 PM, unit ‘operates.24 hours: per day, 365 days per year, temperature is 90°F), A gearbox was generating very large ferrous and nonferrous wear particles as shown below. This result prompted visual inspection of the gears. Severe sliding and rolling wear had badly worn ene side of the gears. In spite of this severe stiding wear on the gear tecth, Basic American Faodis was able to get an additional 18 months service out of the gear- bax before replacing it. They did. this by reversing the direction of rotation of the gears. By detecting Machine: GB 1 - Helical speed reducer gearbox and addressing the wear problem, 2 replacement gearbox was able to bbe ordered with normal delivery. “The single reduction gearbox caso is also from a food processing company. In this case. predictive maintenance surveys revealed a trend of increasing vibration at a sgear mesh frequency of 26X the output shall running speed". Requests for visual inspection of ¢ gear condition were made on two occasions. Gear condition was reported as “goad for a gearset that was 40+ years old,” Oil cond: jon analysis, performed by the oi vendor on a quarterly basis, did not indicate any cause for alarm. After detecting a large increase it vibration amplitude, an oil sample was analyzed using the OilView* Model 5100, The sample showed high ferrous and large ferrous ‘content, Investigation revealed that the “free” oil services provid- ‘ed by the oil supplier revealed tha! the sampling was designed to test for the oil condition only. not for wear particles. Based.on ine combined vibration and OilView results, a more thor= ‘ough inspection was recommend- ‘ed. This included rolling the shafts to visually inspect each tooth. Again, the report indicated no ‘excessive gear tooth wear or dam: age. During subsequent question: Point: Point 1 « Sump of gearbox: ing of the maintenance repairmen, the only negative comment was that the input sha seemed to have “3 lot of play in the bearings.” Since the bearings were tapered roller bearings, any visually detectable looseness is abnormal The gearbox was overhauled dur- ing the Christmas outage. While no damage to the bearings was found, excessive clearance betwoen the bearing outer race and the bearing housing was noted. The bearing housing was Welded and re-machined to repair the damaged caused by bearing outer race looseness. The increased vibration was attributed to-the loss of proper backlash. The iron in the oil sample was not from ear tooth wear but was a result of wear on the bearing housing In January, Uhe vibration ampti- tude at gear mesh frequency was: reduced after the overhaul. How- ever, by February the spectrum and the OilView* data both showed marked increase. This prompted another visual inspec- tion of the gearbox. Inspection easily identified that the gear, which is held in place on the shaft by a wedge key, had moved load (since much ef the tooth was not carrying any load). and the Sample Oltide Comosion ‘Contam Feros Lope Date Indes Index ant Index levies Comm, — aawars? | 00 oo 00 00 NONE NA 25-APRID 00 oo a2 190 FANF NIA COMPUTATIONAL SYSTEMS INCORPORATED * 7Case Mi and Cast Savings: Using In-Shap Oil Analysis establishment of a new wear pat- tern, This resulted in the increase in iron wear particles in the oll. ‘After the gear was repositioned, vibration levels returned to near the baseline amplitude In this case history, oil analysis was used twice in conjunction with vibration analysis to prevent passi- ble damage to-a gear set. Since replacement gears were nat avi able, a catastrophic failure would have resulted in a lengthy plant production outage. ‘The cost savings for this single reduction gearbox is conservati ly $83,200 assuming avoidance of three-day outage for this raw material production line (S600/hr x 72 hn). A four-day or longer outage ‘could have cost several §100,000 because stockpile product from this line would not be available to support two injection molder pro- ‘duction lines. Adeitional savings resulted from planned procure- ‘ment (50,000). rather than emer- ‘gency procurement thigher cost), of @ Used, replacement gearbox Electric Motors Two cases of electric motors are reported. The first is a grease hub cated 60 HP electric motor driving an air handler. The second is an il lubricated 3000 HP electric motor driving a crusher, ‘Vibration monitoring (sce Figure 4) of the grease lubricated, 60 HP, air handler motor pointed to a likely inboard bearing problem. In less ‘than an hour, a grease sample was extracted and mixed 1:3 with light mineral oll for analysis on the Model $100. This ail analysis showed extreme wear: a ferrous index af 46.0 with large ferrous particles was detected. ‘The Facilities Maintenance person responsible for this air handler was told thal the inboard bearing was bad and would fail soon. An hour Figure 4, Vibvation tena pls for G0-HP air handler motor. later the motor failed! The interval for vibratian/grease monitoring af this particular application was evi- dently longer than the time for a failure mode te propagate 10 destruction. ‘The second motor case study invelved a 3000 HP electric motor used to drive a crusher. This appli- cation was sampled monthly from October January. The Model $100 data are reported below. ‘The steadily increasing Ferrous: Index from 0.0 to 10.0 raises con cem. Then in January, the pres- ence of Large Ferrous particles (arger than 40 um) becomes quite alarming. Cok tally, motor damage prompted a complete rebuild, Unfortunately, it was net possible to examine the bearings before rebuild. 8 + COMPUTATIONAL SYSTEMS INCORPORATED Compressors Compressors, like gearboxes, are applications in which oil analysis: can be particularly helpful to the vibration analyst. Whether the compresser is a rotary or recipro- machine, mechanical com- plexities and qeometric arrange- ‘ment can limil conclusive vibration analysis. The #10 refrigeration compressor from E.1. DuPont Louisville Works was selected for this case study", Vibration analysis of this centrifu- gal compressor had indicated a low amplitude subharmonic vibra- tion. The mechanic collecting the oil sample observed very small brass color particles in the oll ter. “Tne Model $100 in-shop analysis indicated the presence of water (Contaminant Index = 27.4) and large contaminants, “droplets.” Since no reference oil was used, the Model 5100 was not able to evaluate the Corrosion or OilLife™Case Histories and Cost Savings: Using, In-Shop Oil Analysis Indexes). The oil lab analysis classi- ficd the sample as “abnormal” duc to high water, total acid umber, and increased levels of iran and copper gencrally associated with shafl and bearing wear. Production needs required the continued operation of this unit ‘After four months, the Model 5100 ‘showed that while the large con! minant indication remained alarm- ing (this time due to the presence of large non-ferrous particles), the water had been driven away. It also showed that the Ferrous Index increased from 0.0 to 6.8. When the #10 compressor was shut down and inspected, it was found that the compressor oll pump gears, one of which is brass and the ‘There was also some looseness in the seals allowing water to get in the oil. The subharmonic vibration ‘was confirmed as a gear defect induced vibration—and the fre= ‘quency matched the calculated hunting tooth vibration. This was ‘estimated at $53,000 maintenance cost and production loss avoidance. Extended Oil Change Intervals A major northeast manufacturing company selected a portion of the plant which included 400 machines for oil analysis. These machines Included gearboxes (40%), com- pressors, pumps, motors, fans. and process machinery. Preventive maintenance practices require quarterly oil change on all these Which is not at the end of its useful life, Conservatively projecting one quarter per year life extension from switching to condition based oil change. they expect $54,000 per year savings on just this group of machines. This docs not take into account savings fram proactive ar predictive maintenance actions resulting from findings or from the long term value of environmental impact avoidance. IBM Microelectronics Division in Hopewell Junction, NY, reported ‘$20,000 savings in consumables alone for the first three quarters of 199311. This savings was achieved through monitoring 135 points and realizing average ail life extension of 05 years. Additional savings are realized through reduced labor ther Is steel, were badly pitted. &PPlications. They believe that this ou 2 ss practice is disearding some and disposal costs. ‘Machine: Crusher - 3000 HP Motor Point: Point 4 = n-tine tap before filter Sompie tie ey ie ae Dose Inde Index enter tex Coctam, nom | oo ao 00 oo NONE ua prov | sa 19 13 se NONE ni norcoa | 47 10 13 +0 \NONE Na mann a9 oa 4 100 F NA Machine: COMP #10 R : Point: 751123700! = 10 Refrig Machine sample ‘oie Covsien Coma Reve Lowe ae Date ine inde anion bale Conte. - vawavez | Na NA ara 00 D ee vests: | NA NA 00 oa ne NA (COMPUTATIONAL SYSTEMS INCORPORATED + 9Case Histories and Cost Savings: Using In-Shop Oil Analysis Conclusion ‘The life of the machinery is In the lube. The quality and performance of that lube becomes critical to long term operatien for expensive industrial systems. Most of the tools used by the predictive main- tenance team in a plant are intend ed to bring the loads for a mechanical system within design imits. These tools include vibra. mn analysis, balancing, align- ment, electric motor monitoring, and others. ‘Oil analysis is a very important tool to address the fluid that supports those loads. By testing that fluid, ‘one gains critical information about the functionality of that fluid, about contamination of the system, and about wear and other machinery ‘damage that is taking place. ‘Armed with this information the maintenance team can take appro- priate actions to remove root caus ¢s of failure before damage can occur (e.g. oil change, seal repair, etc.) and 6 monitor the progressive degradation of a hidden mechani- cal component, thereby predicting \wisen it wil fail. ‘The maintenance staff now have access to in-shop, on-site, or con: tracted off-site analysis of used lube oils. Techniques have become quite simple and aceurate. Savings are substantial, et al, The Reliability- Based Maintenance Strategy: A Vision for Improving Industrial Productivity, Industry Report, page 6. 1992 7, Rycalts, SKF Effective Bearing Monitoring, Effective Enhanced ‘Techniques for Early Detection, Monitoring, Trending. and Diagno- sis of Bearing Damage, SKF Condi- tion Monitoring Utrecht, undated. * R, Garvey, Correlation of OilView Models $100 and 51FW with Stan- dard Analytical Parameters for Lubricants, International Confer- ence on Condition Monitoring. Swansea, UK. 1994, “J, Medita, [BM Microelectronics Division, East Fishkill Facility, lopewell Junction, NY, January 12, 1993, “Terry Aikins and Ed Gossman, Chrysler Stamping Plant, Warren, ‘ML. September 14, 1992. “D.E. Bryant, Congratulations to Terry, Warren Stamping, the 9 Mile Bet, Volume 5, Issue 5, UAW Locals 869, 412 and 889, page 2. Septem- ber-October 1983. ' Randy Blake, St Johns River Power Park, Letter to CSI, *R. Garvey and T. Spettel, In-Shop Oil Analysis, a New Tool for the Vibration Analyst. Vibration Insti tute. June 1953, * J. Medita, IBM Microelectronics Division, East Fishkill Facility, ‘October 28, 1993. " K. Mosier, Experience Using Oit ‘Analysis to Identify Machinery Degradation, 1993 CSI User Con- ference, Louisville, KY. September 1998, ® J. Meditz, IBM Microelectronics Division, East Fishkill Facility ‘October 28, 1993. 10 + COMPUTATIONAL SYSTEMS INCORPORATED