Lubrication monitoring

Wear Debris Analysis When machine surfaces wear, they generate metallic particles that enter the lubricant. Monitoring and analyzing the generated debris enables analysts to detect and evaluate abnormal conditions to assist in directing needed maintenance activities. 

Improved sensors allow computer monitoring of the system for safety and protection of the equipment from damage. Sensors include lubrication-flow monitors and alarms, bearing-temperature sensors, belt scales, rotation sensors, and proximity sensors to detect ore level under the crusher. The latter prevent jamming of the output with too high an ore level, and protect the conveyor from impact of lumps with too low an ore level. Motion detectors assure that the conveyor is moving. Control applied to crusher systems including conveyors can facilitate use of mobile crushers in quarries and mines, since these can be controlled remotely by computer with reduced labor. 

Hot running Preventive maintenance bearings., Monitor bearings temperature Purging and sealing to keep solvents out, if solvent (even vapor) exposure is possible Use improved bearing lubricant CCPS G-29... 

Check for pre-lubrication/grease and its monitoring attachment (provided in large machines). 

The gas turbine is a complex system. A typical control system with hierarchic levels of automation is shown in Figure 19-3. The control system at the plant level consists of a D-CS system, which in many new installations is connected to a condition monitoring system and an optimization system. The D-CS system is what is considered to be a plant level system and is connected to the three machine level systems. It can, in some cases, also be connected to functional level systems such as lubrication systems and fuel handling systems. In those cases, it would give a signal of readiness from those systems to the machine level systems. The condition monitoring system... 

This chapter will cover some of the more common accessory items for compressors such as the lubrication system, gears, coupling, instrumentation, vibration monitoring, and process control. The subject is broad and far-reaching. It is hoped that, for the first-time user, this discussion will be a good introduction and, for the veteran, it may offer another perspective on the subject. 

The rod drop monitor is recommended for all non-lubricated compressor applications, because there is no lubricant to act as a buffer to prevent piston-to-cylinder contact on the loss of the wear band. Lubricated com pressors handling gases with traces of water or gas components that can degrade the local lubricant are candidates. Hydrogen compressors should be considered for monitors because hydrogen is a difficult gas in it sc It and may contain trace quantities of water. While sweet gas compressor-, as are found in pipeline service, would normally not be considered a problem, the rod drop monitor may be used to signal a loss of lubricant anti the compressor can be shutdown before damage can occur. 

Mechanical testing of the non-lubricated helical-lobe compressors is modified from the previously described lest. For example, API 619 only requires a two-hour mechanical run. The procedures and monitoring requirements are generally the same as previously described. A run comparable to the overspeed run is the heat run. The compressor is run on air at the maximum allowable speed, and the discharge temperature is allowed to stabilize at a value 20°F higher than the rated discharge temperature. The compressor is then run for 30 minutes. 

The first method used for wear particle analysis is routine monitoring and trending of the solids content of machine lubricant. In simple terms the quantity, composition and size of particulate matter in the lubricating oil is indicative of the mechanical condition of the machine. A normal machine will contain low levels of solids with a size less than 10 microns. As the machine s condition degrades, the number and size of particulate matter will increase. 

Condition monitoring is an established technique which has been used by capital-intensive or high-risk industries to protect their investment. The concept has developed radically in recent years largely due to advances in computerization, which offer greater scope for sophisticated techniques. These fall into three types of monitoring vibration, performance and wear debris. The last monitors particulate debris in a fluid such as lubricating oil, caused by the deterioration of a component. 

In the area of process monitoring TLC has been used for the study of the thermal decomposition of zinc di-isopropyl dithiophosphate (antiwear additive in lubricating oils) [458]. TLC analysis has been reported as a quality control tool for analysis of dispersing agents (alkylsalicylates, thioalkylphenolates), AOs (dithiophosphates, dialkyldithiophosphates) and their intermediates in lubricating oil (UV detection,... 

CE is also potentially a useful alternative analytical tool for monitoring of chemicals (dyes, flame retardants and lubricants) involved in various steps of the textile fibre manufacturing process. In this area, CE compares favourably with existing techniques. CZE-MSn was used for the analysis of sulfonated azo dyes [942]. A variety of fluorescent analytes including thiazole orange dyes have been characterised by CE-FLNS [943]. 

Marino MP, Placek DG. 1994. Phosphate Esters. In CRC Handbook of Lubrication and Tribology Volume III Monitoring, Materials, Synthetic Lubricants, and Applications, ed. E. Richard Booser. Boca Raton CRC Press, Inc. 269-286. 

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