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CENT Condition Monitoring

May 2015

Equipment Life Cycle 
We all know that all equipment will fail and therefore its life is limited 
We do equipment maintenance to obtain:
- Better equipment life
- Better performance 

We also aspire for equipment to ‘fail safe’

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Maintenance Types Corrective / Breakdown  Where equipment is maintained after break down or failure  This maintenance is often most expensive because worn equipment can damage other parts and cause multiple damages Preventive  Where equipment is maintained before break down occurs Predictive     Observe the state of equipment by regular analysis Determines equipment’s health Done by Used Oil & Vibration Analysis Maintenance at right time 3 .

Benefits of PDM – Predictive Maintenance  Provides increased component operational life and availability  Allows for preemptive corrective actions  Results in decrease in equipment and / or process downtime  Lowers costs for parts and labor  Provides better product quality  Improves worker and environmental safety  Raises worker morale  Increases energy savings  Results in an estimated 8% to 12% cost savings over which might result from a predictive maintenance program 4 .

CENT as PdM Tool  Maintenance / Reliability  Managers require Condition-based Monitoring (CbM) tool for PdM  FUCHS offers CENT service for this purpose 5 .

Chemists  Available online  Available world-wide  No investment required by the customer 6 .CENT  A complete CbM program  Use Used Oil & Vibration Analysis  Supported by Engineers. Lubricant  Specialists.

World Wide Location UK Germany Poland France USA Spain Saudi Arabia India Tanzania South Africa Australia 7 .

Facilities Provided  Sample bottles  Sampling pumps  Courier services to collect the samples  Report within 24 hours after receiving  Technical support and training 8 .

Supported Industries  CENT can be used by all types of industries 9 .

Chemical Industry Refrigeration Systems Pumps Compressors Generators Turbines Hydraulic Systems Conveyor Systems 10 .

etc.) 11 .Used Oil Analysis  Analysis of used-oil samples taken at regular intervals - Identify wear components Identify contaminations Measure lubricant condition Monitor trends of wear and contamination Establish suitable drain intervals Equipment efficiency (filters. separators.

Final Drives  Turbines    Grease-packed Bearings Compressors  Machine Tools   12 .Preferred Method Application Electric Motors Oil Analysis Vibration    Gearboxes Hydraulic Systems  Engines  Transmissions.

Components – Complete Condition Monitoring Program  Sample Points  Sampling Intervals  Sampling Techniques  Analysis / Selection of tests and methods  Database  Report type. easily-understandable  Trend Analysis  Expert Comments 13 . speed.

Sample Point  Easy & Safe location  Should give representative sample  Avoid static condition  Avoid drain plugs  DO NOT change sample point 14 .

Sample Point Equipment Return Line Filter Pressure Filter Vent Filter Filler Pump Reservoir Suction Filter Dynamic Sampling Static Sampling Drain 15 .

dirty conditions / continuous operation Monthly / 250 hours Continuous running Monthly / 50 hours Intermittent running Every 2 months Engines – Mobile plant All conditions 10. light applications Light loading / normal temp (>50°C) / clean operating conditions Every 3-4 months Hydraulic – Automotive Wet.000 km / 250 hours Engines – Static plant All conditions 50-100 hours Gearbox – Automotive & Industrial Hydraulic – Industrial Air compressors 16 .Sampling Intervals Application Conditions Frequency Heavy loading / high temp (>65°C) / dirty conditions / continuous operations Monthly Light loading / normal temp (>50°C) / clean operating conditions Every 2-3 months Heavy loading / high temp (>65°C) / dirty conditions / continuous operations Monthly Hydraulic – Machine tools.

Sampling Intervals Alarm Limit Cautionary Limit 17 .

ISO 46 & below: 5-10 minutes  Conclusion: .Equipment is in normal operation . take sample within: . dry.ISO 220 & above: 20-30 minutes .Flush sample bottle .Label correctly .Area around the sample point to be clean .Syringes and tubes to be used only ONCE  Take sample when:  If equipment must be stopped for sampling.Seal the container .Drain some oil before taking sample .Oil should be well circulated and in turbulent flow 18 .ISO 68 to 150: 10-20 minutes . un-used sample container .Use clean.Sampling Techniques  Preparations: .Take at least 250ml .

Importance of Proper Sampling  Without a good sample the rest of the process is worthless  The error starts from taking the sample  Take care of the following: .Sample Point .Contamination .Label 19 .

Selection of Tests Equipment KV100 KV40 TBN TAN Water FTIR RDEAES Hydraulic System     Turbines     Compressors     Industrial Gears     Auto Gearboxes     Transmissions     Engines      20 .

P (Additive) 21 . Mo. Si. Fuel. Ni. Nit. Mg. Al.1mm % FTIR ppm ASTM D 6595 Flash Point Water IR Scan Sulf.Selection of Test Methods Test Units Method Kinematic Viscosity (KV) cSt ASTM D 445 Total Base Number (TBN) Mg KOH/g ASTM D 2896 Total Acid Number (TAN) Mg KOH/g ASTM D 664 °C ASTM D 92 ppm ASTM D 1744 A/0. Gly. Sb (White Metal). Li (Dirt Grease) Ca. Sn. Cu. Zn. Soot. Water RDE – Atomic Emission Spectroscopy Fe (Iron) Cr. Mn (Ferrous) Pb. Oxi.

Database  Database is required to maintain the following: - Equipment details Oil details Sample history Report history  Accessible to users and customers 22 .

Graphical report  The reports show: .Text report .CENT Report Formats  Two types of CENT reports .Expert comments 23 .Equipment.Test results and graphs . Sample Point and Oil Details .

Report Categories Green Triangle SATISFACTORY Amber Square CAUTION Red Circle ACTION 24 .

Interpretation of Results  Points to consider while interpreting: - Design & Operation of the Equipment Metallurgy of the components Awareness of Operating environment Awareness of likely contaminants Understanding of Oil chemistry and its working Monitoring of trends Establishment of relevant alarm levels 25 .

CENT Software  Maintains database  Secure Online Access  View and print reports and history  Label printing  Schedule samples  Feedback options 26 .

Secure Access to Reports For User ID and Password please contact Fuchs 27 .

Thank You .