Preventing Equipment Failures with Real Time Oil Condition Monitoring

Introduction

With the commitment and investment by the Government in renewable energy and the continuing changes to the energy mix actually produced due to tighter controls and legislation, flexible and reliable peak capacity has never played a more critical role in ensuring that the lights quite literally “Do Not Go Out” .

Real Time Oil Monitoring

The life blood of any engine is the hydrocarbon or synthetic based oils which provides the essential lubrication to ensure trouble free operation. As over 80% of all equipment failures are due in some form to lubrication issues and the use of more diverse fuel types such as Methane is further putting pressure on all operators to regularly monitor and maintain this fluid to ensure efficient running and reduce the significant risk of engine failure. That is why the measurement and monitoring of the Quality of the oil for ongoing performance and reliability is paramount.

It is essential that both suppliers and operators of industrial equipment which relies on oil for lubrication and/or operation, ensure that the oil is correctly specified and maintained in the optimal condition for reliable and cost effective operation. Commercial expectations are also placing greater pressure on OEM’s to supply extended warranties whilst operators are constantly looking for effective cost savings

Traditional offline oil sampling techniques are widely used within industry for the purpose of oil monitoring, there is the risk that the condition of the machine and/or lubricant could become seriously contaminated or otherwise affected at a point just after or at least between sampling times. To reduce this problem a risk assessment program is usually carried out to establish the ideal frequency of monitoring any given equipment. However, this ideal frequency of monitoring could prove difficult to justify both financially and practically in case where safety of sampling is an issue or the equipment is in remote locations, such as isolated pumping stations, a wind turbine etc.

To overcome this problem and reduce the risk further it follows that an accurate Real Time Oil monitoring solution would deliver significant advantages in such cases. Historically the challenge has been that the available technology has been proven to be unreliable and intensive to the key changes in the oil condition and has therefore failed to deliver a commercial base on which to deploy such technology. However with the advent of the patented Tan Delta Oil Quality Sensor , a revolutionary broad spectrum sensor which accurately and reliably monitors all of the key factors within the oil in Real Time, the ability to realise a significant return on investment has now become a reality.

The Tan Delta Oil Quality Sensor is based on a variant of the dielectric properties of the oil, the sensor uses patented technology based on dielectric loss factor (Tan Delta), which is far more sensitive indicator of oil condition than Permittivity alone (often known as dielectric constant). For most oils, the loss factor will vary from perhaps 0.005 (fresh oil) to 0.1 when contaminated, a dynamic range of 20:1. This is compared with just 0.8:1 for dielectric constant (which changes typically from 2.3 to 2.9), and therefore it is evident that Tan Delta is many times more sensitive than traditionally understood and used dielectric constant.

Figure 1 shows the data produced in the laboratory from oil samples taken from a Gas Engine running on Methane fitted with the Tan Delta Oil Quality Sensor. Clearly there are direct relationships with the oil sensor readings and the typically measured oil condition-monitoring laboratory data.

Table 2 shows the above results in detail. The analyses show a fall in TBN, a rise in TAN and a rise in oxidation resulting in the laboratory recommending a caution value where appropriate. The data shown is Table 2 confirms that the oil sensor reliably tracked the oil Condition

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Sensor Technology

The Tan Delta Oil Quality Sensor uses patented technology to accurately monitor the various changes which take place as oil ages and degrades. Every single oil which is available on the market today has a unique chemical makeup, this is as a result of the different base oil and the individual additive package which has been utilized. The Tan Delta Oil Quality Sensor can easily be configured for the specific oil which is being used, the sensor knows what this oil looks like when it is clean and therefore accurately report any changes which take place.

The sensor works by introducing a very high frequency AC voltage into the fluid to precisely measure the oil’s ability to store energy (Capacitance) and the oil’s ability to conduct current (Conductance).

As an oil ages and/or get contaminated the amount of polar molecules with the oil increase dramatically and by combining the measurement factors (patent method) we can assess the amount of change (damage) which has occurred.

To see how we can assist you in saving money, please call Lourens Janse Van Rensburg on +27 (0) 79 512 8027 or alternatively via email, lourens-cisindustrial@outloo.com. Or visit our website:https://cisindustrialservices.com

Plant Uptime • Plant Safety • Asset Reliability

 

Preventing Equipment Failures with Real Time Oil Condition Monitoring

Introduction

With the commitment and investment by the Government in renewable energy and the continuing changes to the energy mix actually produced due to tighter controls and legislation, flexible and reliable peak capacity has never played a more critical role in ensuring that the lights quite literally “Do Not Go Out” .

Real Time Oil Monitoring

The life blood of any engine is the hydrocarbon or synthetic based oils which provides the essential lubrication to ensure trouble free operation. As over 80% of all equipment failures are due in some form to lubrication issues and the use of more diverse fuel types such as Methane is further putting pressure on all operators to regularly monitor and maintain this fluid to ensure efficient running and reduce the significant risk of engine failure. That is why the measurement and monitoring of the Quality of the oil for ongoing performance and reliability is paramount.

It is essential that both suppliers and operators of industrial equipment which relies on oil for lubrication and/or operation, ensure that the oil is correctly specified and maintained in the optimal condition for reliable and cost effective operation. Commercial expectations are also placing greater pressure on OEM’s to supply extended warranties whilst operators are constantly looking for effective cost savings

Traditional offline oil sampling techniques are widely used within industry for the purpose of oil monitoring, there is the risk that the condition of the machine and/or lubricant could become seriously contaminated or otherwise affected at a point just after or at least between sampling times. To reduce this problem a risk assessment program is usually carried out to establish the ideal frequency of monitoring any given equipment. However, this ideal frequency of monitoring could prove difficult to justify both financially and practically in case where safety of sampling is an issue or the equipment is in remote locations, such as isolated pumping stations, a wind turbine etc.

To overcome this problem and reduce the risk further it follows that an accurate Real Time Oil monitoring solution would deliver significant advantages in such cases. Historically the challenge has been that the available technology has been proven to be unreliable and intensive to the key changes in the oil condition and has therefore failed to deliver a commercial base on which to deploy such technology. However with the advent of the patented Tan Delta Oil Quality Sensor , a revolutionary broad spectrum sensor which accurately and reliably monitors all of the key factors within the oil in Real Time, the ability to realise a significant return on investment has now become a reality.

The Tan Delta Oil Quality Sensor is based on a variant of the dielectric properties of the oil, the sensor uses patented technology based on dielectric loss factor (Tan Delta), which is far more sensitive indicator of oil condition than Permittivity alone (often known as dielectric constant). For most oils, the loss factor will vary from perhaps 0.005 (fresh oil) to 0.1 when contaminated, a dynamic range of 20:1. This is compared with just 0.8:1 for dielectric constant (which changes typically from 2.3 to 2.9), and therefore it is evident that Tan Delta is many times more sensitive than traditionally understood and used dielectric constant.

Figure 1 shows the data produced in the laboratory from oil samples taken from a Gas Engine running on Methane fitted with the Tan Delta Oil Quality Sensor. Clearly there are direct relationships with the oil sensor readings and the typically measured oil condition-monitoring laboratory data.

Table 2 shows the above results in detail. The analyses show a fall in TBN, a rise in TAN and a rise in oxidation resulting in the laboratory recommending a caution value where appropriate. The data shown is Table 2 confirms that the oil sensor reliably tracked the oil Condition

undefined

Sensor Technology

The Tan Delta Oil Quality Sensor uses patented technology to accurately monitor the various changes which take place as oil ages and degrades. Every single oil which is available on the market today has a unique chemical makeup, this is as a result of the different base oil and the individual additive package which has been utilized. The Tan Delta Oil Quality Sensor can easily be configured for the specific oil which is being used, the sensor knows what this oil looks like when it is clean and therefore accurately report any changes which take place.

The sensor works by introducing a very high frequency AC voltage into the fluid to precisely measure the oil’s ability to store energy (Capacitance) and the oil’s ability to conduct current (Conductance).

As an oil ages and/or get contaminated the amount of polar molecules with the oil increase dramatically and by combining the measurement factors (patent method) we can assess the amount of change (damage) which has occurred.

To see how we can assist you in saving money, please call Lourens Janse Van Rensburg on +27 (0) 79 512 8027 or alternatively via email, lourens-cisindustrial@outloo.com. Or visit our website:https://cisindustrialservices.com

Plant Uptime • Plant Safety • Asset Reliability

 

Accurate Real Time Monitoring

Tan Delta Oil Quality Sensor (OQSx)

The Oil Quality Sensor (OQSx) is your ideal solution for accurate real time oil condition monitoring. Quickly and easily installed, the OQSx detects all wear and contamination elements to an exceptionally high sensitivity level and provides an accurate statement of your oil condition second by second – in any oil type and in any application.

Accurate

The OQSx accurately reports the precise condition of any oil in real time and is certified to a sensitivity of 15ppm.

ATEX Certified

The OQSx Ex II is fully certified, ATEX approval to BS EN 60079-0: 2012 and BS EN 60079-11:2013 x ic IIA T3 Gc.

Applications

Heavy Mobile Mining Equipment; Continuous Miners, Dump Trucks, Shovels, Drills. Transformers, Gearbox, Compressors, Engines, Hydraulics.

CIS Industrial Services (Pty) Ltd – Plant Uptime, Plant Safety, Asset Reliability.

For more information, please contact Lourens Janse Van Rensburg via mobile +27 (0) 79 512 8027 or alternatively via email: Lourens-cisindustrial@outlook.com.

Data Trending… Optimising Your Maintenance Strategy

Simply gathering information from sensors and systems is not enough to yield the benefits of predictive maintenance.

The ability to collect and then analyse data can be crucial to predicting impending failure.

By investing in an Oil Quality Sensors to influence these maintenance practices, you can  have the benefit of:

  1. Reduce overall maintenance cost by 30%
  2. Reduce sampling cost by up to 80%
  3. Reduce oil purchases and disposal cost by 20%
  4. Increase equipment availability by 5%
  5. and, rule out human induced contamination.

To see how we can assist you in saving money, please call Lourens Janse Van Rensburg on +27 (0) 79 512 8027 or alternatively via email, lourens-cisindustrial@outloo.com. Or visit our website:https://cisindustrialservices.com

Future-Proofing Asset Monitoring at Port…

The infrastructure-heavy operation at seaport, marine and inter-modal terminals, face increasing demand for efficient and cost-effective operation. Advanced equipment and technology underpins port performance, and productivity hinges upon robust asset management.

The majority of port infrastructure (including Container Cranes, Straddle Carriers, Shiploaders and Hoppers) have a useful economic life of up to 50 years, however an increasing portfolio of ageing and expensive assets over time leads to an increase in exposure to business risk. Research suggests that issues resulting from the application of inadequate or incorrect maintenance procedures cause roughly 25% of the total cost of equipment damage and that satisfying short-term operational needs can lead to major asset downtime due to unplanned maintenance and catastrophic failure. 

Increasing global trade is increasing the demand for more infrastructure to combat port congestion problems. Subsequently there has been an increasing industry focus on equipment lifecycle management, and real-time condition monitoring and maintenance strategies as part of a wider approach to the managing of an entire portfolio of assets. 

Oil condition monitoring plays a fundamental role in total asset management. Accurate, high quality oil condition analysis provides a deep insight into the health and status of port equipment. Contamination can quickly lead to oil losing its lubrication properties and equipment damage. Small unseen issues, which if left to develop will cause a major breakdown, are reflected in changes in oil condition, and as oil condition degrades with use, you can pin-point the exact time for maintenance, extending intervals without risk.

Tan Delta sensors were fitted to the primary hydraulic systems of Container Cranes in a busy South African port. An operator panel was installed in each, providing a simple traffic light condition status, whilst live data was streamed back to the maintenance centre. The data enabled the port to extend the intervals between servicing thus reducing direct operating costs, also providing reassurance that in the event of an unexpected issue, an alert would be provided, and action taken in a planned and controlled manner before any equipment damage had occurred. 

“Since the installation we have seen a significant reduction of 32% in our oil consumption. We were replacing our oil prematurely and have since been able to streamline our maintenance across the whole port. With a total project payback of 6 months this technology forms a crucial part of our asset management strategy, and has helped provide complete visibility, tracking and actionable predictive insights across the port”. – Port Operations Manager, South Africa.

Would you like to see how we can save you money?

Contact, Lourens Janse Van Rensburg on +27 (0) 79 512 8027 or alternatively,

lourens-cisindustrial@outlook.com

CIS Industrial Services (Pty) Ltd – Plant Uptime, Plant Safety, Asset Reliability!

Interrupted production can be costly!

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The IIot Motor Diagnostic System – Cracked Rotor Bar Defect

Interrupted production can be costly. Loss of production hours, output as well as the cost to repair mechanical faults or major machine breakdowns can severely impact production and maintenance budgets.

The IIot Motor Diagnostic System allows plant owners to prevent unplanned mechanical breakdowns through fault detection alerts enabling maintenance teams to act proactively.

The IIot Motor Diagnostic System installed at an international rubber and tyre manufacturer on a rubber-mixing mill saved the company many hours of unscheduled downtime and hundreds of thousands in production revenue.

The Roll Milling Machine applies a mechanical process to blend the ingredients into a homogeneous substance. Internal mixers fitted with two counter-rotating rotors in a large housing shear the rubber charge along with the additives.

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The IIot Motor Diagnostic System identified an existing Coupling/Bearing problem in the Roll Milling Machine. The system also flagged an immediate alert related to the Rotor Bar parameter.

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The trend visibly reflects how the Rotor Bar error advanced. Vibration measurements verified the presence of broken rotor bars, already identified by The IIot Motor Diagnostic System.

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The IIot Motor Diagnostic System in this instance demonstrated its ability to detect developing Rotor Bar faults, alerting the maintenance team. The necessary predictive and preventative maintenance actions were taken, resulting in no production loss recorded.

Can you imagine the impact on the production and maintenance budget if this fault were not detected?

CIS Industrial Services (Pty) Ltd – Plant Uptime, Plant Safety, Asset Reliability!

Asset Management and Energy Efficiency Toolkit

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Asset Management Toolkit (AMT), is an Asset Management and Energy Efficiency Toolkit, which use three-phase voltage and current signals to diagnose existing electrical and mechanical problems.

Check-Up for Motor Driven Equipment – routine check-up and early diagnosis of equipment prevents catastrophic damages and helps to reduce energy consumption and operating costs.

HOW IT WORKS

Asset Management Toolkit (AMT) is equipped with a computer, which is optional as the client can also supply their own PC, meeting the required specifications if preferred, fully functional AES software for AMT Toolkit hardware, current transformers, and cables.
Asset Management Toolkit (AMT) is connected to motor cables using clamp-on current sensors and voltage cables. It collects data from motor driven systems and also has the ability to measure equipment driven by the motor, for example, a gearbox, and saves it to an SQL database. At the end of the testing period, the toolkit generates a condition assessment report, which indicates existing faults of the system, time to failure information, recommended corrective actions, and effects of these faults on energy efficiency.

Fault Coverage

  • Loose foundation/components
  • Unbalance/misalignment/coupling
  • Transmission faults
  • Driven equipment faults
  • Bearing faults
  • Rotor faults
  • Stator/insulation faults
  • Voltage unbalance
  • Current unbalance
  • Internal and external electrical faults

Process Faults

  • High energy consumption
  • Low efficiency
  • Cavitation in pumps
  • Flow turbulence in fans, blowers
  • Filter and heat exchanger fouling
  • Lubrication
  • Oversize/undersize motors

Parameters

  • RMS values of three phase voltages and currents
  • Frequency
  • Power factor
  • Active power
  • Reactive power
  • Total Harmonic Distortion
  • Harmonics up to 13th
  • Voltage and current balances

WHAT ARE THE KEY BENEFITS OF THE ASSET MANAGEMENT AND ENERGY EFFICIENCY TOOLKIT?

  • Immediate payback by corrective action
  • Instant condition assessment report
  • Advanced analysis and reporting
  • No sensors on motor or equipment
  • Improved efficiency and reliability of plant and processes
  • Increased machine availability

Software Features

  • Classification of data into companies and motors
  • Instant Condition Assessment Report
  • Instant PSD download for frequency spectrum analyses
  • Instant voltage-current waveform download

Current Transformers included in the Asset Management Toolkit (AMT)

  • 4 sets split-core current transformers
  • 400/5A, 300/5A, 200/5A, and 100/5A, Class 1
  • Frequency range 50/60 Hz
  • System rated voltage 0.72/3kV
  • Isolation voltage 3kV (1 minute)
  • Continuous current 1.2xrated current

Immediate Payback

Taking corrective action for existing equipment faults will eliminate unplanned downtime, improve energy efficiency, reduce maintenance cost and extend equipment lifetime.

Energy Consumption

Motor-driven systems consume 66% of the electrical energy in an industrial plant. Any improvement can yield a considerable amount of energy saving.

Operations and Maintenance

It has been estimated that Operations and Maintenance programs targeting energy efficiency can save up to 20% on energy bills without a significant capital investment. From small to large sites, these savings can represent thousands to hundreds-of-thousands of Rand each year, and many can be achieved with minimal cash outlays.

SECTORS

Asset Management Toolkit (AMT), can be used in all industrial sectors ranging from; Oil & Gas, Energy, Cement, Metal, Pharmaceutical, Automotive, Water, Transportation, Food & Beverages, Building and more.

APPLICATIONS

Applications typically range from; compressors, fans, pumps, conveyors, generators to motor driven equipment.

DIMENSIONS

The Asset Management Toolkit (AMT) is compact in size, 550x310x190mm, and the unit comes in a handy protective dust and waterproof case.

CIS Industrial Services (Pty) Ltd – Plant Uptime, Plant Safety, Asset Reliability!