Predictive and Preventive Maintenance Control

June, 2012
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©2012 Moog

22
Predictive and Preventive Maintenance
The technique involves :

 Monitoring oil contamination

• Solid contamination
• Water contamination
• Gaseous contamination

 Monitoring chemical properties changes within the oil

• Viscosity
• Oxidation
• Thermal Degradation
• Oil Additives depletion (i.e anti-oxidation agent, anti-foaming agent,
demulsifier agent)

 Using appropriate filters and filtration solutions

 Implement corrective actions before damaged beyond recovery

3
Solid Contamination Class

Recommended cleanliness class of the fluid

for normal operation : ISO 4406 < 14/11 (New
ISO4406 )
for longer life operation : ISO 4406 < 13/10
(New ISO4406)

4
 Oil - Contamination Class

NAS 5 ISO 14/11 for present hydraulic systems required

5
 Oil - Contamination Class

NAS 7 ISO 15/13 fresh oil, delivered in tanker (truck)

6
 Oil - Contamination Class

NAS 9 ISO 18/15 fresh oil, delivered in mini-container

7
 Oil - Contamination Class

NAS 12 ISO 21/18 fresh oil, delivered in drums

8
Filter Selection

Absolute rating (pore size): diameter of the largest hard particle

that will pass through.

Beta (Filtration) Ratio: Average number of particles upstream of the

filter compare to the number downstream.
X = number of upstream particles X microns and larger
number of downstream particles X microns and larger

9
 Effect of Cleanliness on Reliability
• Results of DTI survey 1984.

30

25
ISO CODE

20

15 >3um

>5um
10
>15um
5

MEAN TIME BETWEEN FAILURES (hours)

10
Filter Locations
M 3 Low Pressure
"Duplex" style Filter System
Re-Circulation w/Bypass & Dirt Alarms
Pump
5

3
Low Press. "Typical" M O O G
Filter Heat Servo or Proportional
Exchanger Valve!

Ambient Air
Exchange
3 System
Relief

T T2

B
4 100 Suction
Reservoir

A
Filter

P
Breather / 2 System
Filter 1 Load
3 Low Press.

X Y
2a
Main

U S
Pump 15 High Press.
M "Last Chance"
Filter

3
Low Press.
Filter
M
Facility "New"
Reservoir Oil

Transfer
Pump
Recommended Filtration Schematic 11
12
 Sources of Contamination

Contamination Sources

Built In Ingested Generated Maintenance

Manufacturing Process Atmosphere Combustion Surfaces Fluid Service Debris

Debris Compressed Breather Blow-by Mechanical De-sedimentation Repairs
Burrs air/gas ingestion Soot wear Filter desorption PM’s
Machining swarf Pulp Seal ingestion Fly ash Corrosive wear Additive New filter
Weld spatter Pulverized coal Tank opening Induction air Cavitation precipitation New oil
Abrasives Ore dust Rock dust Contaminated Exfoliation Sludge Dirty hose, fitting,
Drill turnings Aggregates Mill scale fuel Hose fibres Oxide insolubles components
Filings Cement Quarry dust Filter fibres Carbonisation Top-up containers
Dust Catalysts Foundry dust Break-in debris Coke Wrong fluid
Contaminated Clays Slag particles Elastomers Aeration
components Process Paint chips
chemicals

13
Consequences of solid contamination

• increased leakage

• jamming of moving part

• breakdown of components

14
 Contamination - Silting

This phenomenon occurs with any spool type valve. If we hold a spool in
a fixed position with high pressure across the lands, there is a gradual
build up of fine ‘silt’ particles that can lock the spool within 5-10 minutes.

15
 Consequences of liquid contamination

• Corrosion
• Decrease of dynamic viscosity
• decrease of lubrication film
• friction of part surfaces => heat
Corrosion in pipe air space • reduction of oil lifetime
due to moisture condensation
• Alteration of oil condition
• generation of acid oil-ageing products
• speed up oil ageing
• generation of vanish / sludge

Rust particles in oil tank 16

Type of Water Formation

• Water can be present in two forms:

- Free (emulsified or droplets)
- Dissolved (below saturation) saturation curve
• Solubility of water in oil depend on :
- Temperature 200

Water Concentration (PPM)

- Oil type
150
Free Water
100

Dissolved Water
50

25 50 75
Oil Temperature (°C)
17
Liquid Contamination Levels
• The level of contamination is usually measured as a % by volume. It
may also be expressed as parts per million (ppm), 1% = 10,000
ppm.
• In the case of water contamination, it may also be given as %
saturation (100% saturation is the point at which free water begins
to form in the fluid). This figure is dependant on fluid properties such
as type, temperature, etc.

18
Liquid Contamination Levels

• To minimise the corrosive effects of ‘free water’, water concentration

in oil should be kept as far below the oil saturation level as possible.
• Typical oil saturation levels are:
– Hydraulic fluid: 200 - 500 ppm (0.02 - 0.05%)
– Lubrication oil: 200 - 750 ppm (0.02 - 0.075%)
– Transformer oil: 30 - 50 ppm (0.003 - 0.005%)
• If using percentage saturation measurements:
- Caution > 75% saturation (at operating temperature)
- Critical > 90% saturation (at operating temperature)

19
Consequences of gaseous contamination

• Foaming
• Slow system response with erratic action
• A reduction in system stiffness
• Higher fluid temperatures
• Pump damage due to cavitation
• Inability to develop full system pressure
• Acceleration of oil oxidation

20
Type of Gaseous Formation

Various forms of air contamination in fluid :

- Dissolved air causes oxidation &
accelerates additive depletion.
- Entrained (10-3 to 1 mm bubbles); cause
oil compressibility, poor heat transfer,
film strength failure, oxidation, cavitation
& varnishing.
- Free (trapped air pockets); cause
hydraulic compressibility, corrosion,
vapor lock & loss of system controls.
- Foam (> 1 mm bubbles); has a similar
effect to Free air.

21
Cavitation Erosion
Vapour bubbles form in low pressure areas of the fluid. When these
reach a higher pressure area they collapse. This generates pressure
waves which cause erosion and fatigue damage when they strike
component surfaces.
Also results in adiabatic heating, fluid degradation, high acidity in
phosphate esters.
Component Surface Wear Particles

Low Oil High

Pressure Pressure

Pressure Wave Collapsing 22

Bubble
Consequences of gaseous contamination

Servovalve
hunting or oscillate during initial start up. However the air remained trapped is
very unlikely.

Servoactuator
Hunting is highly related to dissolved air inside the servoactuator due to dead
oil volume trapped inside the actuator chamber.

23
 Oil Effects Temperature

Vicious Cycle of Thermal Failure

Other Effects
• Oxidation
• Thermal degradation
• Varnishing
• Hydrolysis

A useful rule of thumb is:

“Every 10ºC rise in temperature
above 60ºC, oil life is halved.”
24
Effect of Heat on Oil
Carbon Formation
Black carbon particles can be the result of severe overheating of the fluid. Sub-
micron sized particles of carbon can be formed from dieseling of the fluid.
Dieseling formed by the pressure from main pump and the excessive air in the
fluid and/or too high vacuum on the suction side that allows the formation of
free air bubbles. Temperatures in the wall of the air bubble being compressed
can reportedly reach hundreds of degrees so that some fluid degradation is
likely.

Metal Content
Can come from anything in the system. For example mineral such as
magnesium, calcium, zinc, iron, copper, iron and sodium may be from
purification media or synthetic absorbents material. In can also come from
piping, tank surface, oil etc. High Magnesium, calcium and sodium can lead to
formation of soap and/or gel. 25
Effect of Heat on Oil

SITUATION WHY SLUDGE?

FILTER CLOGGING  ADDITIVE DEPLETION
 LOW QUALITY ADDITIVES
SERVO VALVE STICKING
 DUST+Zn+WATER

CAUSES COLOR CHANGE  SLUDGE FORMATION

SLUDGE IN HYDRAULIC OIL

PROPERTIES OF OIL

26
 Effects on Servovalve

AFSA ball worn out

Nozzle-flapper type
due to contamination

Flow gain
Flow

Signal

27
Effects on Servovalve
Scratches on bushing inner surface

Flapper

Nozzle
(x2)

Bushing and Spool Assembly (BSA)

Qleakage [L/min]
Scratches on the spool surface

Null leakage
Under lap
Flow Zero lap

Flow gain Over lap

Signal
0
Spool stroke
X [mm]
28
Effects on Servovalve & Servoactuator

29
 What causes Varnish ?

Two most common causes of varnish are :

• Oil Degradation by Oxidation :
• A chemical deterioration of the fluid that
occurs in the presence of oxygen.

• Oil Degradation by Thermal :

• A similar process that occurs without
oxygen present.

HEAT

Both degradation process are accelerated by several factors

30
Electro-static Spark in Turbine Reservoir

Electrostatic sparking in Turbine Oil Reservoir

31
 Electro-static Discharge Residue

• High temperature sparks create varnish particles that have a

recognizable shape – Like a sphere or ball
• This varnish gel will fall out or precipitate with known solvents and
can be separated with simple gravimetric patch filtrations

Filtered From the Oil Filtered From the Oil Removed From Filter Core

32
Electro-static Discharge in Mechanical Filter

Electrostatic Discharge at filter

Last Chance Filter

33
How do we minimize wear?

34
How do we minimize wear?

• Conduct weekly/monthly oil analysis on the oil (particle count, metal

contents, water content etc) to determine the condition.

• Use good filters in the 5 to 10 micron range with high Beta Ratios
(ßx1000)

• Follow OEM recommendations

• Periodically inspect the tank and filters for sign of contaminant or

chemical reaction.

35
Laboratory Tests Needed To Monitor EHC Fluid

Test Name Method Information

Particle Count ARP 598 Particle Size And Distribution
Water Content ASTM D - 1744 Amount Of Water In Parts Per Million
Total Acid Number ASTM D - 664 TAN - Measures Oxidation Of Fluid
Chlorine Content X-RAY Checks For Solvent Contamination
Mineral Oil GE METHOD Checks For Fluid Contamination
Specific Gravity ASTM D - 1298 Checks For Fluid Contamination
Viscosity ASTM D - 445 Fluid Quality And Contamination
Spectroanalysis SPECTROMETER Fine Wear Particles And Additives
Color ASTM D - 1500 Oxidation And /Or Contamination
DC Resistivity ASTM D - 1169 Resistance or Conductance of Fluid
AC Conductivity ASTM D - 1125 Conductance of the Fluid

36
Suggested Schedule for Oil Analysis

37
 Suggested Parameter Limits
Parameter Proposed Limits Remarks
Viscosity +/-5% of new oil Check for water contamination
TAN 0.2mg KOH/g Check for hydrolysis
RPVOT <25% Check for vanish
Resistivity >5Gohm@cm Check for electrokinetic wear
Water <500ppm Check for hydrolysis or oxidation
Chlorine <100ppm Check for solvents
Flash Point 1ºC drop from new oil Check for thermal degradation
ISO4406 16/14/11 (NAS 1638 Class 5)
Cleanliness Check for solid contamination
or better
Foam Seq 1 exceeds 300/11 Check for gaseous contamination

Metals Magnesium, Calcium, Sodium Check for soap or gel formation

-40 to 130ºC oil & max 80ºC ambient

temperature
Temperature
Max 50ºC max ambient temperature
for Intrinsically Safe
RPVOT – Rotating Pressure Vessel Oxidation Test TAN – Total Acid Number 38
How often should I change the oil?

Oil change frequency really depends :

• Filtration quality is high
• Oil temperature
• Water contents => Moisture condensation
• Oil degradation and chemical properties changes

Conduct oil sampling analysis on a periodical

Where the hydraulic power unit is dedicated to the servovalve alone, it may be
several years before an oil change is necessary. This assumes a normal
makeup rate of 10-15% per year.

Where the servovalve is fed from a larger power unit servicing other functions a
more frequent change will be necessary.

If the tank volume is topped by more than 10%, flushing of the system must be
repeated.

39
How often should the fullers earth be changed?
Depend on the oil degradation.
• Chlorine content > 150ppm
• Water content > 1000ppm
• Acid number >0.1 mgKOH/g
Typically 3 times a year.

40
Actions to prolong the Operating Life

• Maintain the oil condition (Particle and chemical control) – by User

• Regular Overhaul the servovalves – by Moog

• Regular Overhaul the component within the system (pump, cooler,

other hydraulic component, piping, tank etc) – by user or OEM

• Control the operating conditions ( Temperature, environmental,

pressure etc) – by User

• Improve the system design (cooling, filtration design) – User or OEM

• Practices good handling procedures - User

41