Complete presentation

1. Presentation on
At Site / On Board Oil Analysis
by
Deepak Sharma
Director
Kittiwake Proactive Technologies P.Ltd.,
405, Ansals Majestic Tower 17,
Block G1,Vikaspuri Community centre,
N.Delhi-110018
www,kittiwake-india.com
www.dantechengineers.com

2. Monitoring Innovation
• On-site testing & analysis solutions for
fuel, oil & water condition monitoring
• Oil Sampling and Field Testing
• Laboratory & Field Wear Debris Analysis
• On-line Oil & Wear Debris Analysis
• Water Quality Field Testing
• Acoustic Emission CMS - Holroyd
• CEM systems - Procal
• Laboratory Logistics

3. Oil Condition Monitoring - Two different objectives
Lubricating Analysis Monitoring the lubricant
 Condition of the lubricant
 Viscosity, TAN, TBN, Water content, Insolubles
Oil cleanliness as per ISO and NAS Standards
Wear debris Analysis Monitoring the Machine
 Quantity of wear particles in ppm
 Monitoring and analysis of wear particles
 Condition of the machine

4. Lube Oil Condition Monitoring
Routine oil testing in a laboratory
though important has following limitations –
 Testing is usually done quarterly or higher intervals.
 Results usually take about a week to ten days to reach
the operator.
 Unable to capture the timing and magnitude of increase
in wear elements

5. Lube Oil Condition Monitoring
Lube Oil is the only component which “touches” all
the moving parts of an Equipment.
• Any deviation in the status of components
or operating parameters will affect the
lubricant parameters and its contents.
• Sudden variation in lube oil parameters
could reveal an impending failure.
• Immediate corrective measures could save
major downtime, provided………………………
…….Lube Oil Condition is
monitored in real time.

6. Where: Field or Laboratory
All tests and testing started life in the
laboratory
Methods and Standardisation:
ASTM/IP/ISO….DIN/GB/Gost etc.
Methodology unsuitable for field use
Instruments developed specifically for
field use
Qualitative or Quantitative

7. What parameters can you test in the field
Viscosity
Water
TBN
Insolubles
TAN
Particles
Ferrous Wear Debris

8. On Site Oil Condition Monitoring - Benefits
1. Saves
Helps in Unscheduled
diagnosing Down time
problems 2. Allows
quickly scheduling
maintenance
(Move from
Helps take Emergency
On Site Oil Oil Condition status to
timely
Condition known when Normal )
maintenance
Monitoring needed 3. Generates
Actions
more amount
of oil analysis
Helps quick data for
integration diagnostic or
with other development
RCM purposes.
techniques

9. Fuel and Lube oil Lab.
At site Lube oil monitoring
OiOIL lOi

10. Lube Oil Test Kit - engines
Viscotube
M

11. What parameters can you test in the field
MiniOTC
OR
Digi Insoluble
(Optional)
Range: 0-2.5%
diesel engine
lubes
Test time: 2 min
A combination of qualitative and quantitative
measurements D HV

12. What parameters can you test in the field
OTC – Oil Test Centre
A Central Common console
with:
TBN,Water,TAN,Viscosity,
Insoluble Cells and reagents
In NATO approved box
In industrial strolly

13. What parameters can you test in the field
Oil Test Cabinet •For Testing –
Viscosity,TBN,Water,Insolubles,
Oil
Cleanliness,Compatibility,Density,
Salt water,Pour point
•On site testing will produce cost
savings
simple, rugged, reliable
equipment
Results are obtained quickly and
accurately

14. Oil Analyser
The Oil Analyser is configured to comply with ASTM-D74181 Standard Practice and
the included software comes pre-loaded with the complete range of JOAP* and ASTM
approved methods used for the condition monitoring of in-service lubricants, including:
•Sulphate by-products
•Oxidation
•Nitration
•Phosphate Anti-wear
In addition, the following parameters are also calculated using ASTM defined test practices:
•Soot
•Water
•Antioxidant depletion
•Glycol contamination
As further methods are agreed upon within the ASTM, these can be easily added to the in-
built library within the Oil Analyser
The Oil Analyser is comprised of three main components:
•FTIR spectrometer with sampling system
•Portable computer with software
•Carrying case and accessories
Requires only 3 m sample and is easy to use and provides the user accurate and
reproducible results
V

15. How to test and what results mean
Viscosity
Defined as cSt @ 40°C & 100°C
Controls oil film thickness and flow rate
Increased by oxidation and insolubles
Decreased by shear down & fuel dilution 26.5
26.22
26
Mineral, synthetic
25.5
25.32
25
Change-out limits: 24.5 24.36
24
23.5 23.44
-20% < New > +10 to 30% (Diesel), Viscosity cSt @ 40C
23
-10% < New > +25 to 50% (GT/Hyd) 22.5
22
0% 1% 2% 3%
M HV

16. How to test and what results mean
Water
Always present in oils some systems
can run dry
Contamination from condensation,
blow-by, leakage and adulteration
2500
Causes corrosion, cavitation,
2000
additive instability
Mineral and synthetic lubes & 1500
hydraulics 1000
Field Lab
500
Change-out limits
0.3 - 0.5% (Diesels) 0
1000ppm (GT/Hyd)
MD

17. How to test and what results mean
TBN
Depletion depends on oil
consumption, fuel sulphur and
load
Problematic on low oil
consumption engines
Low TBN results in acid Exxon Lab
50 Exxon OTC
corrosion and fouling Shell Lab
Diesel only 40 Shell OTC
Change-out limit 50 - 60% of 30
new oil TBN 20
M D1 Dm 10
0
Paired Tests Field vs Lab

18. How to test and what results mean
Insolubles
Ash, oxidation products, wear
metals, asphaltines, carbon
Ingressed contaminants, dust etc.
Causes increase in viscosity, wear,
fouling of ring pack and under
piston crown. Blockage of aviation
lube filters. 3
Mineral and synthetic oils 2.5 Solids %w/w
2 Lab IP 316
Change-out limits:
1.5
typically 1.5 - 2.0 % w/w 1
(Diesels) 0.5
M 0

19. How to test and what results mean
TAN
 A function of additive
chemistry and oxidation
 Monitor by trend Figure 6 - Difference in TAN Measurements (NOAP minus OTC)
 Measured by 1
Typical reject limits at 0.5 and 1.0 TAN
neutralisation / colour
0.8
Difference in Results for TAN mg.KOH
titration
0.6
0.4
M 0.2
3
2.5 MJOII
0
M1661
1
5
9
25
49
53
97
2
13
17
21
29
33
37
41
45
57
61
65
69
73
77
81
85
89
93
101
105
121
125
129
133
109
113
117
137
141
M254
1.5 M1661 -0.2
1 Difference
-0.4
0.5
Oil Sample
0
Paired Tests Field vs Lab
Change-out limit + 1 (alert), + 2 (change) (GT / Hyd)

20. EZ OIL CLEAN CHECK
Portable Oil Cleanliness Indicator
A patented technology from IHS, Israel
A simple, cost effective and
yet accurate way of
knowing the ISO and NAS
cleanliness levels of
lubrication and
hydraulic oil

21. EZ OIL CLEAN CHECK
Features:
 Pore block technology – flow decay
 On line or bottle sample test
 Suitable for the field use
 Water or air bubbles in the sample do not affect
 Is equally effective for the dark oils
 Totally mechanical
 Small and lightweight
 Low and high pressure models ( 40psi – 3000psi )
 Upto 80 deg C and 150 cSt
 NAS 11 – NAS 5 ISO 22/20/17 – 16/14/10

22. How to test and what results mean
Particles in Hydraulics
Particle counting and analysis usually
carried in a laboratory
Expensive and complicated
Few low cost field solutions
Hydraulic Particles Test Kit
Draws sample through 8micron filter
Comparison made with quality coloured
reference chart
Good field indication of pending
problems

23. How to test and what results mean
Ferrous Wear Debris Analex
fdMplus
Measures ferrous wear metal debris in
oil and grease without preparation of
the sample
Indicates wear on ferrous metal
components
Measures all debris including particles
>5 micron
Laboratory based ICP/AA does not
measure these size particles
Gives results in ppm
Used extensively for trending
First time available for field testing

24. fdMplus - Principle of Operation
When the sample of oil containing
ferromagnetic debris is placed in
the sensor the balance between the
coils is altered.
The resulting out-of-balance signal
is amplified, filtered, and displayed
as Total ppm as it is measuring the
total mass of ferromagnetic debris
in the sample irrespective of
particle size.

25. fdMplus - Operation
The sample is placed using suitable
supplied adaptor in:
50ml Bottle
10ml Syringe
5ml Syringe
5ml Test Tube
4ml Grease Pots
The touch screen gives precise
instructions
Each sample is uniquely numbered and
dated
Data is stored by equipment type
Can be viewed in tabular or graphical
form
Download to computer via RS232

26. lubMONITOR software
1. KITTIWAKE lubMONITOR®:
Lube oil monitoring for OTC and miniOTC
2. ANALEX feMONITOR®:
Ferrous monitoring for fdM or fdM+
3. KITTIWAKE lubMONITOR® + ANALEX feMONITOR® :
Combined software for both Lube Oil and Ferrous
monitoring.
Features:
 Easy to view and set up hierarchical format : Plant–
Area – Machines.
 For OTC, miniOTCfdM+ and fdM data management,
monitoring trends, alarm setting of various measured
parameters, graphical representation of the measured
parameters for diagnosis (comparison of upto 2
machines )
 Tabular as well as graphical reports
 Email the reports directly through the software via
Outlook Express.
 Ways of transferring the data:
Transfer the data from OTC, fdM+ and fdM.
From file
Manual input
 Very useful to compare various parameters from the
similar machines for diagnosis.

27. Why On Line Sensors?
Demand for a significant reduction
in manpower
Need for real time data
– Laboratory testing takes time & often
inconvenient
– Off Line testing demands manpower & time
Integrated part of RCM programme
Reliability Centred Maintenance

28. What will the sensors monitor?
Five Most Relevant Parameters:
Oil Quality: TBN/TAN/Insolubles/Glycol/Water
in oil quality units on a scale from 0-100
Moisture: Up to saturation point
0-100% RH
Viscosity: For lube and hydraulic oils
Ferrous Debris Sensor: All particles irrespective of size
0- 2000 microns
Particle Content Sensor : - Total particles/ minute
Ferrous Particles – 40 - 2000 microns
Non ferrous particles >130micron

29. Oil Quality
Oil Quality: TBN/TAN/Insolubles/Glycol/Water
– Oil degrades with time for a variety of reasons
– Sensor permanently installed in oil flow
– Constantly monitoring quality and degradation
– Output as Oil Quality units (OQC) 0-100 scale
Target Applications
– Critical lubricated applications subject to rapid failure or high
change out costs.
– Medium & high speed marine diesels, gearboxes, bearings,
turbines, automobiles, off-road machines, compressors etc.

30. ANALEXrs Moisture Sensor
Measures oil’s % RH –
Relative Humidity – resulting
from dissolved water
Uses combination of thin film
capacitance sensors and
smart algorithms
Oil molecules penetrate a
polymer coated sensor and
the dielectric property is
measured

31. Total Ferrous Wear Debris Monitoring
Detection of Metal Debris
 Senses changes in magnetic flux as
ferrous particles enter a magnetic
field and losses when non ferrous
conductive particles enter
Technology
 Measures >5 micron (unlike ICP)
 No radioactive source (unlike XRF)
 Linear response
 Independent of oil flow speed
Outputs
 CAN interface
 4-20 mA, RS232, RS485
 Radio link with built-in web server

32. Metallic Wear Debris Detection & Counting
Online Wear Debris
Sensor
Designed to measure
individual ferrous and non
ferrous particles
Total no. of particles per
minute and mass.
Targeted at applications
where metal surfaces shed
debris which is taken away by
the oil flow
Turbines, Bearings &
Gearboxes

33. Online Wear Debris Sensor

34. Online Wear Debris Sensor

35. Online gear box /turbine monitoring system
Particle Content Sensor
Oil Condition Sensor
Moisture Sensor
Pump for circulating the
Oil through sensors

36. On-Line Sensor Suite

37. Sensor Suite - Models Available
Standard Options
– Non-heated -Most Industrial use
– Heated – Low Temperature applications
Specifications
– Measured Parameters
Ferrous debris: 0-2000ppm
Relative Humidity: 0-100%
Temperature: 0-100°C
Oil Condition: 0-100 OilQ
– Power 15-30 VDC
– 10Bar (145psi)
– Temperature: -20 to 80°C oil / -25-65°C Ambient
– IP65
Interface Options
– Analogue -4-20mA (4 loops)
– Digital
• RS232
• RS485
• Wireless LAN 802.11b
• CAN

38. Acoustic Emission - Kittiwake Holroyd
•We are specialists in Acoustic Emission Condition Monitoring for harsh
industrial and marine environments.
•Spun off from Rolls Royce in 1991, led by Trevor Holroyd.
Initial Machinery Health Checker (MHC) unit launched in 1993.
Continuous product evolution over the past 18 years.
• Acquired by Kittiwake in April 2011.
• Basically, Vibration Analysis made simple!

39. Uses of AE
Condition Monitoring
Measuring the health of rotating equipment.
Structural crack propagation. .
Non-Destructive Testing (NDT)
In-situ active crack propagation cracks in materials & structures.
Process control
Mixing, stirring & crystallisation.
Valve operation.

40. Basic principles of AE
Source
propa
MHC sensor detection frequency
Bac
(100 kHz)
kgr
g
n
ation
tio
o
un d
ua
Amplitude
en
Fric
tion
Att
no i s
&I
mp
act
e so
Sou
rce
s
ur c
es
sensor A crystal in the sensor responds to the kHz as it 300 kHz
0 100 kHz 200 wave
passes underneath it Frequency
conditioning

41. Stop the Chain Reaction of Wear

42. Dynamic clearances example - Gear Pump
Cut in Track
Dynamic Clearance Tooth to side plate: 0.5 - 5 µm
Tooth tip to case: 0.5 - 5 µm

43. Why remove fine ferrous debris?
Removal of particulate from 20 micron down to less than a micron is
absolutely key to arrest the wear process
The contaminant becomes lodged in dynamic clearances or it is
propelled around the system by the fluid it creates more wear and therefore
more contaminant, this is a ‘chain reaction of wear’
In any given system the hardest and sharpest debris is often the
FERROUS material – it is therefore absolutely key to stall the chain
reaction of wear by removing ferrous debris of all sizes – particularly
that of a similar size to the dynamic clearances
In fact, research has shown that much of the wear debris is never
created if the ferrous debris is removed early on…
MAGNOM™ technology reduces wear and
therefore failures!

44. Magnom™ - Features of the PatentedTechnology
The Magnom™ comprises of a series of annular magnets and innovatively designed formed steel plates.
The steel plates focus the magnet flux strength
A

45. Magnom™ - Working
ow
Fl

46. Magnom™ – The Benefits
Magnom™ is a field effect fluid conditioner that: -
Delivers MAJOR COST SAVINGS (Thousands of £ per annum)
and offering major environmental benefits: -
• By reducing the chain reaction of wear – Reducing the repair or
replacement of system critical parts i.e. pumps, valves, etc
• Extend existing filter life, if placed upstream
• Reducing system Downtime
• Increasing fluid and additive life
• Reducing disposal requirements – Filters & Fluid
• Enhancing overall system performance
Note!
• Benefits vary dependent on application – Specified
Separately

47. Magnom™ - Oil Environments Only Units
– Small to Medium Systems 1
Midi Module – 1 1/16” UNF
Mini Module - 3/8” BSP
Small to Medium pressure
Small pressure line system line system
Max Module – 1 5/8” UNF
Max Working Pressure = 14 Bar Max Working Pressure = 120
Bar Small to medium pressure line
Contaminant Capacity = 37g system
Contaminant Capacity = 45g
Max Temperature = 100 Deg C Max Working Pressure = 69
Max Temperature = 100 Deg C Bar g
Contaminant Capacity = 80g
Module unit – 1” 5” Clear Unit – 1” BSP* Max Temperature = 100 Deg C
BSP
Maximum Working
Medium pressure Pressure = 12 Bar Check latest Datasheets for up to date
line system Unit specifications & fluid Compatibility
Contaminant Capacity =
Max Working 200g Recommended for low pressure line
Pressure = 140 side installation
Bar Max Temperature = 80 Deg
C
Contaminant
Capacity = 185g
Max Temperature
= 100 Deg C

48. Magnom™ - Oil Environments Only Units – Large Systems
Process Filtration System
Unit – 2” BSP or NPT
Large pressure line system
Max Working Pressure =
17 Bar
Contaminant Capacity =
4000g
Max Temperature = 100
Check latest Datasheets for up to date
Deg C Unit specifications & fluid Compatibility

49. Magnom™- Mobile Hydraulic System Units
Oil Environments Only -
Mobile Hydraulic Pump Mate Unit
– 2” BSP
Installation of suction side of the
Pump (within sump)
Contaminant Holding Capacity =
200g
Maximum Temperature = 100
Deg C

50. References

51. Thank you for listening
Any Questions?

52. References