Fluid Analysis for Mobile Equipment : Condition Monitoring and Maintenance / edited by Diego Navarro, Blaine Ballentine, and Michael D. Holloway.

Format:

Book

Contributor:

Navarro, Diego, editor.

Ballentine, Blaine, editor.

Holloway, Michael D., 1963- editor.

Language:

English

Subjects (All):

Fluid dynamics.

Physical Description:

1 online resource (481 pages)

Place of Publication:

South Norwalk, Connecticut : Industrial Press, Inc., [2024]

Summary:

Welcome to the wonderful, practical world of fluid analysis utilization. There are plenty of labs around the world processing millions of oil, coolant, and fuel samples every year. Most of them do very professional work, however, the data received from them usually fall into two main categories: 1). The information is incomplete for a true machine health assessment, or; 2). At the user's end, nobody is acting on the information at a level that would allow good, proactive maintenance activity. The sad truth is that very few companies make use of the valuable information contained in fluids. This work, Fluid Analysis for Mobile Equipment, supports all activity around fluid analysis so managers can lay a more solid foundation for maintenance. It serves as a major contribution to both the science and art of fluid analysis, and is destined to become the cornerstone of every successful condition-based maintenance program. The examples and recommendations will have direct application to implement a true predictive maintenance program. More than 100 examples come from real-life cases, and reflect what many fleet managers encounter in their daily challenges.

Contents:

Cover (Fluid Analysis For Mobile Equipment: Condition Monitoring and Maintenance)

Title Page

Copyright

Contents

Foreword

Introduction

Acknowledgments

Chapter 1 Condition-Based Maintenance

Wear No Matter What!

Wear: Does Size Matter?

Wear: Does Technology Matter?

Do We Really Control Wear?

Maintenance Paradigms

None of These Creates Equipment- aving Opportunities

Types of Maintenance

Flaws of Scheduled Maintenance and RAF

Basic Principles of CBM

How Can We Listen Better?

How Can We See Better?

Oil Analysis

Coolant Analysis

Fuel Analysis

The Unseen World

Maintenance Is a Matter of Visibility

When Do the Diagnostics Take Place?

Looking at Wear with CBM Eyes

The Performance-Failure Curve

CBM versus Scheduled Maintenance: Cultural Differences

Impact of CBM on Operating Costs

Inspections

Operator

Telematics

Fluid Sensors

Managing the Data

Machine Health Correlations

Root-Cause Analysis and Failure Scene Investigation

Most Popular RCA Methodologies

Conclusion

Chapter 2 Lubrication

Lubrication Fundamentals

Tribology

Lubricant Functions

Petroleum

API Base Oil Groups

Solvency

Viscosity

Viscosity Index

SAE J300 Specification and the Introduction of Additives

SAE J300 Standard for Temperature and Viscosity

Gear Lube Viscosity

ISO Viscosity Grades

API Diesel Engine Categories

Gasoline Engine Oil Classifications

Oil Breakdown

Contaminants and Filtration

Types of Lubrication

Hydrodynamic Lubrication Example

Boundary and Dynamic Lubrication

Herztian Forces

Elastohydrodynamic Lubrication

Additives and Their Functions

Foam Inhibitors

Additive Antioxidant Synergies

Zinc Dialkyl Dithiophosphate and Tricresyl Phosphate

Dispersants and Detergents

Additives versus Load.

Additive Synergies versus Temperature

Additives Fight for Surface

Water and Rust Inhibitors

Dispersants for Soot

Copper Passivators

Etching versus Physical Erosion

Friction Modifiers

How Additives Show Up in Oil Analysis

Lubricants and Additives Used in Mobile Equipment

Typical Signatures of Various Lubricants

Hydraulic Fluids

Multi-Viscosity Fluids

Tractor Fluid and Automatic Transmission Fluid Signatures

Gear Oils Signatures

Engine Oil Signatures

Viscosity Decline at 40°C

Physical Properties

Lubricant Compatibility

Where Lubrication Happens

Lubricant Optimization

Lubricant Storage

Greases

Grease Classification

Grease Temperature Performance

Grease Colors

Performance Specifications for Automotive Use(Mobile Equipment Included)

NLGI High-Performance Grease Specifications for Mobile Equipment (2021)

HPM Core

HPM + WR (Water Resistance)

HPM+CR (Saltwater Corrosion Resistance)

HPM+LT (Low Temperature)

HPM+HL (High Load)

Grease Selection

Grease Compatibility

Choosing the Best Option for a Fleet

Example of a Greasing Lubrication Decision

Greases for High-Load and High-Shock Applications

Automatic Lubricators

Chapter 3 Contamination

What Is Contamination?

What Are Those Contaminants?

Particle Sizes and Visibility

Filtration

Heat and Air

Things to Look for during a Visual Inspection of a Machine

Metals as Catalysts

Static Current

Water Content: Parts per Million and Percentage of Saturation

Visibility of Water

Visibility of Particles

Wear Metals and Contaminant Sources

Measuring and Counting

Particle Counts Can Hide Something Else

Cleanliness versus Life of Components: British Hydrodynamics

Particle Counts for Engines

Soot in Engines

Cleaning Soot in Engines.

Micropatch and Microscope: Creating the Patch

ISO Code Visibility: Quantitative Code Catalog

Oil Pump or Dirt Pump?

Component Tolerances

Internally Generated Contamination

Chapter 4 Hydraulic Cleaning Procedures

Where Does the Debris Collect After a Failure?

Intelligent Filter Caddies

How Much of the Old Fluid Remains in the System after Flushing?

Identifying Type of Contamination and Cleaning Procedures in Hydraulic Systems: Case Discussion

The Machine Shows Dirty Fluid and High Particle Counts

The Hydraulic System Is Contaminated with Water

The Fluid Is Oxidized or Has a High TAN

The Hydraulic System Shows Mixed Fluid

A Component Is Wearing Out Slowly,and the Fluid Is Showing Growing Metal Readings

A Component Has Failed and Has Contaminatedthe Whole System (Machine Is Not Operable)

The System Is Contaminated with Varnish

The System Shows Blackened Fluid

Chapter 5 Oil Sampling

Sampling Methods

Sampling Valve Method

Vacuum Pump Method

Bottle Types

Submitting Samples

The Laboratory

Sampling Points

Sampling Valve Installation

Sampling Valve Dead Ends

Chapter 6 Lubricant Testing

Oil and Fluid Testing

Wear Metals (ICP AES Spectrometer ASTM D5185, D6595 [RDE])

Viscosity Tests (ASTM D445/D727)

Water Content Tests (Karl Fischer ASTM D6304/E203)

Alternative Methods of Measuring Water Content (ASTM D2412)

Soot: Shimadzu Attenuated Total Reflection (ATR) Method(IR/ASTM D77844)

Glycol by Sodium and Potassium Readings

Engine Oil Fuel Dilution

Particle Counts (ISO 11500)

Total Base Number (TBN) Test (ASTM D2896 and D4739)

Oxidation (ASTM 943, D5846, D8048 FTIR[Fast Fourier Transform Infrared] Spectroscopy)

Nitration (ASTM D943)

Sulfation (ASTM D7415)

PQ Index (ASTM D8184)

Grease Testing.

ASTM Grease Testing Methods

Grease Thief Tests

Chapter 7 Oil Analysis Basics

Oil Analysis Interpretation Knowledge Fundamentals

Why We Need Oil Analysis

What Can We Measure with Oil Analysis?

Oil Analysis Formats

Horizontal versus Vertical Displays

Required Information

What Should We Test in Engines?

1. Dirt

2. Glycol

3. Viscosity

4. Soot

5. Fuel

6. TBN and TAN

7. Metals

8. Additives

9. Oxidation

10. Sulfation and Nitration

11. Lab Comments

12. Oil Type, Brand, and Hours of Operation

Oil Analysis for Hydraulics

1. Particle Counts

2. Dirt

3. Moisture

4. Wrong Fluid/Mixes

5. Metals

6. Acidity

7. Degradation, Aging

8. Temperature Records

9. Fluid Changed

10. Total Hours and Fluid Hours

Oil Analysis for Power Shift Transmissions and Gearboxes

2. Moisture

3. TAN

4. Fluid Signature

5. Oxidation

6. Viscosity Changes

8. PQ Index

9. Particle Counts

10. Comment Box

11. Fluid Changed

12. Information on Type of Fluid and Hours

Oil Analysis for Axles and Final Drives

2. Water

3. Friction Modifier/TAN

4. Additive Signature

6. Viscosity

7. Metal Generation

9. Oil Hours Information

10. Comments from the Lab

Lab Website and Results

Some Rules Can Help

Elements for a Good Oil Analysis Interpretation

Logic Flow Path for High Viscosity on a Diesel Engine

Logic Flow Path for High Copper in Hydraulics Example

Maintenance Applications

Chapter 8 Wear Tables and Standard Deviations

What Are Wear Tables?

Why Do We Need Wear Tables?

How Do We Calculate Wear Tables?

What Is Standard Deviation?

Types of Standard Deviations

Which Standard Deviation Is More Appropriate for an Equipment Fleet?.

Population Standard Deviation

Sample Standard Deviation

Parametric Bell Curve

Example Applied to a Fleet

Parametric Curve and Cumulative Curve

Nonparametric Curve for High Reference Values

Nonparametric Curve for Zero Reference Values

Measurements Handled without Standard Deviations

Mean or Median Values?

Why Do We Need So Many Wear Tables?

Geography and Utilization

Can We Use Wear Tables from One Country in Another Country?

Collecting Information

Using Excel to Calculate Standard Deviations

Cleaning the Data

Normalizing Time-Dependent Elements

Establishing Abnormal and Critical Values

Wear Tables for Harsh Applications

Minor Metals and Contaminants

Metals Not Typically Used by Mobile Equipment

Handling of Potassium (K) and Sodium (Na)

Example of a Wear Table

Example of a Wear Table for ElementsThat Do Not Need Standard Deviations

Table for Particle Counts, PQ Index, TBN,TAN, and Viscosity Changes

Chapter 9 Hydraulic Fluid Analysis

Keeping the Balance

Basic Cleanliness Levels

Testing

Hydraulic Contamination Sources

Wear Thresholds

Case Discussion

1. Dirt and High Particle Counts in a Large Production Bulldozerwith Combined Hydraulics/Hydrostatics

2. Silt Accumulation in a Production Hydrostatic Bulldozer withCombined Hydraulics and Hydrostatics

3. Water Contamination in a Construction-Sized Excavator

4. High Particle Counts: Gelling and Mixingin a Construction Excavator

5. High Copper Production (Etching) in a Hydrostatic Crawler

6. High Copper Generation (Progressive Component Failure)in a Large Production Excavator

7. High Iron Particle Production in a Medium-Sized Excavator

8. Fluid Oxidation and Thermal Records in a Medium-SizedExcavator

9. Operation with Bypass Filtration in a Large Production Excavator.

10. Hydraulic Fluid Foaming in a Construction-Sized Excavator.

Notes:

Description based on print version record.

Includes bibliographical references and index.

ISBN:

0-8311-9637-8