Conditions' Monitoring in Ambito Navale Mediante le Analisi del Lubrificante in Esercizio - Mecoil
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XVII Convegno di Tribologia
“Attrito, Usura e Lubrificazione in Campo Marino
Applicazioni e Sfide Tecnologiche”
Conditions’ Monitoring in Ambito Navale
Mediante le Analisi del Lubrificante in Esercizio
Giuseppe Adriani – Ilaria Marsili Libelli
5 Maggio 2016 - Napoli
50 Anni di Tribologia Circa 50 anni fa nasceva la “Tribologia” una scienza in cui sono confluite diverse tecniche derivate dallo studio di tutti i fenomeni legati all’usura. Tra i sistemi preposti al controllo dell’usura, le procedure di lubrificazione svolgono un ruolo primario. Di seguito la notizia ricavata dal comunicato della Società di Tribologia: The 9 March 2016 sees the 50th anniversary of the publication of the ground breaking report “Lubrication (Tribology) Education and Research”. This report, commonly referred to as the “Jost Report”, described the findings of a committee, chaired by Prof H Peter Jost and organized on behalf of the UK government. It also coined the word “tribology” for the first time and outlined dramatic financial savings that could be gained through the correct application of tribological principles, leading to global development and in- tegration of inter-disciplinary studies in friction, wear and lubrication to form the subject of tribology as it is known and understood in 2016.
COMPANY'S GROWTH AND DEVELOPMENT
Mecoil has been giving full support to
predictive maintenance strategies since 1990.
Oil analysis for machines’ health assessment became vital part of
any Predictive/Proactive Maintenance Program
DIAGNOSTIC POWER OF OIL ANALYSIS
An industrial plant is like an organism, so take care for its good health!
IN SERVICE OIL ANALISYS
LUBE OIL QUALITY
EFFICIENT MANAGEMENT
OF MAINTENANCE PLANTS’ LIFE
OPTIMIZATION
IMPROVING THE ENTIRE COMPANY PRODUCTION
PROCESS
MECOIL SERVICE: la risposta per ogni applicazione!
Mecoil assists customers with tailored chemical & physical oil test packages
recommending the most appropriate analysis
Engine Standard Standard e Clean Gas
for diesel and for industial for eolic gear for for gas
gasoline engine and vehicle box hydraulic engine
gear box system
Simple Plus Deep Fuel Diatermico
for for compressor for compressor for for
aviation system system, gasoline diathermic oil
centrifugal sample
compressor
UCVD: OUR PATENTED SYSTEM FOR OIL SAMPLING
UCVD Ultra Clean Vacuum Device
Il campionamento di olio non mai stato così semplice, pulito e veloce!
QUICK • draws any practical viscosity in seconds
EASY • hands-free sampling, no other device is required
CLEAN • pre-charged vacuum allows a high cleanliness level
SURE • no possible cross-contamination
SAFE • no oil spills, keeps oil away from the user and the environment
MECOIL REPORT and TREND ANALYSIS
Mecoil report for in-depth analysis
• Evaluation of hidden problems such as varnish tendecy
• Representative imagines of most important contaminations
• Automatic recognition of main wear and contamination modes
STRENGHT OF OIL ANALYSIS
• Elimination of machine unplanned
downtime
Operative • Better machinery utilization
advantages • Oil life extension
• Better control of contamination cause
• Increase of plant useful life
• Reduction of the plant costs:
• spare parts
• repairs
Economic • labor
advantages • provides more than 25% cost advantage compared
to direct reactive maintenance costs
• Most cost-effective policy for asset conservation
Supportiamo il cliente nelle scelte strategiche per una maggior efficienza gestionale
Come invecchia l’olio lubrificante?
Causes of Oil Aging
Fe
Temperature Catalysts
Stress (Metal Particles) Shear Stress Aeration Water
Aging Mechanisms
+
+
Oxidation Polymerization Cracking Hydrolysis Evaporation
Which Alter Fluid Properties
Density Acid Content
Physical Viscosity Chemical Sludge
And Decrease Useful Life
Sludge Corrosion and Wear
Cause prime dell’ossidazione
These root causes when occurring together will have a marked effect on the lubricant aging
process. Two of these root causes are detectable by routine oil analysis.
Heat Water
Temperature Relative No. of
°C °F Oil Changes
Water in oil can
80 180 16 increase oil
70 160 8 degradation rate
by more than 10
60 140 4
times
50 125 2
40 105 1
Acid Level
Air Metal Particles Metal Catalyst
(AN)
%AIR Acid Number
None 0.17
0 0.1
Iron 0.65
3 0.15
Copper 0.89
6 0.25
Copper and
9 0.5 11.2
Water
12 0.6Dual Course of Oxidation
La degrazione ossidativa è un fenomeno As Oxidation Progresses...
irreversibile, autocatalitico, in cui sono
coinvolti prodotti lubrificanti in ambiente • Long-chain molecules are produced,
ricco di ossigeno. which leads to sludge, tars and varnish.
• Acids are produced, which leads
to corrosion.
ACIDS CORROSION
Increasing AN
Increasing Viscosity
OXIDATION Soluble Insoluble
Long-Chain Long-Chain Sludge,
Molecules Molecules Tars,
VarnishLa percezione dello stato di ossidazione dell’olio
Foul Odor Darkening
FIELD
LAB
FTIR Oxidation
(infrared spectroscopy)
AN Increase
Viscosity IncreaseDifferenze tra degradazione termica ed ossidativa
Indicazioni
ossidazione volatilità
Incremento della viscosità
Formazione di morchia
Varnish
Colore scuro
Incremento densità
cracking
Decremento viscosità
Coking
Grease-like suspensions
Azoto
Incremento dell’ acidità
Contaminazione da acqua
Elevata concentrazione di metalli
Esaurimento di additivi
Odore pungente
Incremento costante dielettrica
L’olio è
degradato da L’olio è
calore e degradato dal
ossigeno calore
Degradazione ossidativa Degradazione termicaCause e caratteristiche di degradazione del lubrificante
Adiabatic Compression
Carbonization
Hot
compressed
air bubble Hydrolysis
• Aerazione del lubrificante
• Scariche elettrostatiche
• Degradazione termica della base
• Contaminazione da antigelo Oil
• Coagulazione del soot
• Degradazione ossidativa della base
+
• Idrolisi (esteri) Additive
• Stoccaggio prolungato a basse T Reactions
• Nitrazione
• Contatto con superfici clade (coking)
• Perdite di efficienza della Oxidation
combustione e blowby
• Combustibili altamente aromatici
• Solfatazione (fuel, H2S, etc.)
• Incompatibilità tra additivi
• Incompatibilità tra basi olio
Temperature
Stress
An Upset Lubricant Up CloseIl fenomeno delle Varnish come conseguenza
dell’invecchiamento dell’olio
Una nuova sfida diagnostica!
Hydrocarbon
(oil)
Progressive removal Oxidized New
of oxide insolubles Aged but
Primary Oxidation Oil Oil serviceable - spot
Products and ring darker
Oil Change Color Gauge Increased Oxidation but uniform
throughout
Mildly oxidized
High-Molecular- oil - dark in
Weight Products center with
lighter color oil
outward
Varnish and Sludge Severely oxidized
from Oxide 1 2 3 4 5 6 7 Watery oil - dark center
Insolubles (sludge) with
OK CHANGE OIL
distinct outer ring
Use glass or PET plastic bottlesLacche e Morchie in conseguenza della precipitazione degli additivi
Mixing Oil Brands,
Products and Retrofit
Precipitant
Chemical Contamination
Additive
Additives Is Risky
Filter Centrifuge
New Oil Used Oil
Residue Residue
(ppm) (ppm)
(ppm) (ppm) 20% 20%
Calcium 1,490 991 105,500 >18,000 Unknown Company
Phosphorus 714 817 3100 310 Oil A Oil
Zinc 882 691 45,100 6,422
Sodium 22 47 2,330 592
Caustic contaminant (sodium
hydroxide)reacts with oil to form sodium
carboxylate soaps
60% Synlube
Where Dead Additives Ended Up ...
On Filters Centrifuge Sediment Bottom Sediment On Bearing SurfacesEsaurimento degli additivi per Decomposizione
Neutralizzazione
Acido + Base Sale + Acqua Modificazione irreversibile degli additivi
Detergente
Rottura Ossidazione
ZDDP Idroperossidi e
Polimeri
Fenolo radicali liberi
Idrolisi Degradazione termica
ZDDP Fosfati Fosfuri
ZDDP + Acqua + Calore S-P EP additivi Calore
Solfati solfuri
Acido solforico + Solfuro di
idrogenoEsaurimento degli additivi per “separazione” massiva
Condensazione e decantazione –
Gli additivi possono separarsi o venire
Gli additivi diventano insolubili e
separati dall’olio, come fenomeno massivo.
decantano
Evaporazione –
Deidratatori sottovuoto
possono rimuovere
Filtrazione – additivi volatili*
Gli additivi solidi o
condensati vengono filtrati Additivi
solidi
Centrifugazione –
Adsorbimento di Gli additivi più pesanti
aggregati– possono separarsi per
La separazione per centrifugazione*
adsorbimento rimuove le additivi
molecole polari Fullers Earth
*In funzione di condizioni variabili
come tipo di olio e temperatura.Esaurimento degli additivi per Adsorbimento Intrappolamento Contatto per Sfregamento Le particelle Gli addittivi EP e AW polari formano intrappolano gli un film d’olio sulla superficie additivi e li portano ai metallica e di conseguenza sono filtri o li trascinano sul soggetti ad un progressivo fondo esaurimento Adsorbimento Dilavamento superficiale L’acqua, essendo Gli additivi polari polare, trascina gli aderiscono alle superfici additivi sul fondo del della macchina serbatoio
Lubrificanti fatti in casa?
Mescolare diverse • Potenziali rischi del lubrificante “fatto in casa”
marche o tipi di olio e
• Precipitazione degli additivi
aggiungere additivi
aftermarket è rischioso • Perdita di proprietà antiusura
• Perdita della proprietà demulsiva
• Riduzione della stabilità all’ ossidazione
• Instabilità allo stoccaggio
Come analizzare il lubrificante “fatto in casa”
• Normalizzare le baselines dopo il blending
• Ripetere il test ad alta frequenza per tre campioni
consecutivi
20% Test di compatibilità:
Olio sconosciuto 20% Oilo “A”
• Olio: 50/50, 90/10, 10/90, filtrabilità,
sedimentazione, colore, RPVOT, stoccaggio, forza-
film, demulsività.
60% Synlube Vedi ASTM D7155
Alcune associazioni di additivi sono: • Grasso: 75:25, 25:75, consistenza, punto di goccia,
resistenza allo stress, ASTM D6185
Sinergiche Antagoniste
• Ammine e fenoli antiossidanti • Disperdenti e additivi EP/AW 1 Litro di olio motore ha abbastanza
disperdenti per annullare la
• Alcune combinazioni AW/EP • Inibitori della corrosione e EP/AW demulsività di 6000 Litri di olio turbina
Neutre • Modificatori d’attrito ed EPIncompatibility of Lubricant Mixing
Class A Class B Class C
Oils Containing Oils Containing Oils Not
Acidic Additives Alkaline Additives Containing Either
• Mixing within class: May be
Aviation Hydraulic Fluids Automatic Transmission Fluid Aero Engine Oils chemically compatible although
there is risk of diluted
Clarity Paper Machine Oils Delo 400 Cyloils Aviation Engine Oils
performance
Uncompounded
Cylinder Oils W Delo Cyloils • Mixing between classes:
Cylinder Oils
Gear Compounds EP Delo 400 Multigrade 1. Don’t mix A with B
Delo Gear Lubricants
Lubricating Oils FM Delo 100 Motor Oils 2. Oils from C can be mixed
Quenching Oil 70 with A or B but with risk of
Machine Oils R&O Symbol Diesel Engine Oils Delo 6170
Refrigeration Oils WF diluted performance
Machine Oils R&O Drive Train Fluids HD
• Flushing
Ultra Gear Lubricants
Marine Oils E Hydraulic Oils AW
1. Flush when switching
Utility Oils LVI
Paper Machine Oil N Industrial Oils EP between A and B
Utility Oils HVI 2. No flushing required when
RPM Universal Gear Lubricants Journal Bearing Oil
switching from A or B to C
Synthetic Compressor Oils Tegra Machine Oils AW
• When in doubt perform
Synthetic Gear Lubricants Tegra Paper Machine Oils D compatibility testing such as
Turbine Oil Symbol 2190 TEP RPM Gear Oils ASTM D7155 or D6185
Turbine Oils GST Supreme Motor Oils
All Oils Chevron BrandHow lubricant Properties Change (Irreparably)
Storage In-service
Mixed Lubricants Contamination Mechanical Shear
(Static Conditions) Environment
Base Oil Incompatibility: • Oxidation Oxidation Minimal risk under • Oxidation
• Sludge • Physical (continuous normal storage • Thermal
• Varnish properties agitation of conditions degradation
• Viscosity change • Hydrolysis pro-oxidants; • Chemically
• Thermal water, metal reactive machine
• Oxidation stability
degradation particles and air) surfaces
• Radiation
• Process gases
Additives Incompatibility: • Oxidation VI Improver Gravitational • Filtration
• Neutralization • Stripping and and pour point separation of (separation)
• Impaired washing depressant organometallic • Surface activity
performance • Accelerated shear down and insoluble • Evaporation
• Sludge and normal depletion additives • Separation
varnish • Miscellaneous
chemical
reaction
Thickener Incompatibility: • Change in Change in • Separation • Centrifugal
(Grease) • Change in consistency consistency • Thixotropy separation
consistency • Separation • Thermal
• Separation • Wash out separationApplication: TWO-STROKE MARINE DIESEL ENGINES
Two-stroke marine diesel engines
MCL oil inlet
cylinder lubrication
Marine Cylinder Lubricating (MCL) oil is
injected between cylinder lining and
piston.
– Flows through the cylinders once,
then discharged as waste oil
System Oil
– Recirculated to lubricate all other
moving parts.
Over 95% of these vessels are powered by two-stroke engines made by:
• Wärtsilä
• MAN DieselProblems on marine vessel
“Cold Corrosion” is a very
aggressive corrosive attack on
“Slow steaming” the engine cylinder linings
This results in “cold corrosion” if engine running high sulfur fuels at low
cylinder lubrication is not managed well load
Premature failure of cylinder liners and piston
rings due to cylinder scuffing (under
lubrication) and cylinder scaling (over
lubrication)
New sulfur emissions requirements
drive vessels to carry two fuel types
Each fuel needs a different lubricant with
different Base Number (BN) to compensate for
the different Sulfur levels in the fuelLUBRIFICANT MAINTENANCE ON BOARD
Shore-based Offices
Fleet Manager/Marine Superintendent
• Concern with vessel operating costs
• Compliance with Insurance requirements
• Must adhere to OEM recommendations
Shipboard
Chief Engineer Mechanic/Ship’s mate
• Follows OEM recommendations • Ease of use for crew
• Knowledgeable about oil analysis • Fast measurement, data logging
• Will ask about iron corrosion • < 30 crew members maintain all
shipboard systemsLIMITATION OF EXISTING MONITORING APPROACHES
Shore based Labs On-board Shaker kits
• Transit delay • Products are time consuming to
• Results come after the damage use, 10 minutes per test
is done
• Wet chemistry require HAZMAT
reagents
Existing approaches do not • Results obtained are operator
provide accurate, economical or sensitive
fast BN measurement • High consumables costCONDITION MONITORING ON-SITE&ON-LINE
On-site, off-line Off-site, off-line
(manual detection of temperature, (traditional oil analysis)
pressure, vibration)
Off-site analysis,
On-site, intranet on-line reports
(signal digitization and
automation of its transfer)
No real time service
(delay in delivery)
Dedicated tool - expensive
On-site On-line Real-Time
• Engine real-time monitoring
• Simultaneously control of several systems
• Trend of the health machine
• Rapid and punctual maintenance serviceFLUIDSCAN® Q1200 SERIES
a partnership of Spectro Scientific and Wärtsilä Services
• innovative approach to a critical test that must be performed
New approach onboard
Specific • Daily test for BN (Base Number) in Marine Cylinder Lubricant
• The software can store up to 5000 measurement results export
Database these results by .csv file
Measuring corrosive iron is UNNECESSARY if you properly control residual
cylinder oil BN and never let it fall below 15 (Wärtsilä recommended limit).FLUIDSCAN® Q1200 SERIES
Easy to use!
• Uses just one drop of oil to test
• Results in less than 1 minute
• After test, just wipe clean, no
solvents required
• Provides immediate, actionable data
• Pre-defined labels simplifies record
keeping
• Minimal training requiredSailing toward on-line monitoring
Miscellaneous
CPU: ARM11 @ 800Mhz
Memory: 8 GB SD
Software web upgradeable
Set-up via web page
Case: Pelican 1150
• Power Requirements Power consumption: 12 Watts Protection Grade: IP65
Weight: 1.620 kg (3.6 lbs)
• System I / O 8 connectors (CanBus, ModBus, RS485, RS232, analogic or output), 1 Dimensions: 232 x 192 x 111 mm
connector 5-pin version: to extend (9.1 x 7.6 x 4.4 in)
• Communication ports 1 USB port, 1 Ethernet port Data is collected from each sensor every 2 minutesUNA SFIDA CULTURALE!
Via delle Panche, 140 - 50141 FIRENZE
Tel. +39 055 6120.567/486 - Fax +39 055 6120.375
Mail: info@mecoil.net
Visit our website
www.mecoil.net
to keep in touch with mainteniance news and additional materials!Puoi anche leggere
