extending equipment uptime and life through contamination ... · what is contamination control?...

2018 GFX

San Diego, California

June 2018

Brian Redpath

Contamination Control

[email protected]

Extending Equipment Uptime and Life through Contamination Control

Agenda

• Background on Contamination Control

• Contamination Control Basics • Dirt hurts & what’s a micron?

• Oil Oxidation

• Oil Sampling

• Particle Counting/ISO

• Kidney Looping

• Filtration

• CC Guides

• Success Stories

• Questions

Caterpillar: Confidential Green

What is Contamination Control?

Contamination Control, or CC, is a “Proactive

Product Quality Based Initiative” aimed at

improved reliability through cleanliness design

and practices related to the fluids, parts, and

systems of Caterpillar equipment.

Reactive or Proactive?


Contamination Control – Plants Background/History

Contamination Control...

Awareness

Just a few grains of dust – that light film on the funnel used to

fill the crankcase – the almost negligible amount that might

find its way past an improperly serviced crankcase breather.

Could such small quantities possibly have any appreciable

effect on the life of the engine? The answer is a very positive

YES!

In 1949, we had a basic

understanding of how

contaminants in oil affected

product reliability and durability.

Even in the very early days of

diesel technology, we had a basic

understanding of how

contaminants in fuel affected

product reliability and durability.

Cover of the 1931 Operators’ Guide

1931 Operators’ Guide CARE OF FUEL SYSTEM

The first paragraph on system

care from the 1931 operators

manual states that 90% of

Diesel troubles are due to dirt

or water in the fuel.

Contamination Control – Plants Background/History

• Began Early to Mid 90’s

• Track-Type Tractor Division − Initiated with first time pass test rate

− Cleaned up manufacturing & assembly processes

− Developed commissioning (kidney looping) procedures

• Spread to machine & component plants worldwide

• Specifications & test methods developed − By 1999 all facilities focused on cleanliness

− Assembly reported 100% “Roll-Off” testing

Contamination Control – Plants SUCCESS Formula

CLEAN Facilities

+ CLEAN Components

+ CLEAN Processes

+ CLEAN Fluids

= CLEAN Products

=> Satisfied Dealers & Customers!

Contamination Control Implementation

• Contamination Control Basics

− Training

− Awareness

− Housekeeping

− Culture Change

• Implement Contamination Control:

− Clean Facilities

− Clean Components

− Clean Processes

− Clean Fluids

Contamination Control Training…

Classroom

&

Hands On

Make it Initial & Ongoing

Contamination Control Awareness…

Use these funnels to

put oil into your

machine or engine?

Would You…


Would You…

Add this oil to your

machine or engine?


Would You…

Use these bearings in

your equipment?


Would You…

Install this oil filter on

your engine or machine

Contamination Control Housekeeping…

Professional Image

Perception of Quality

Contamination Control Culture Change…

Is this your current floor

cleaning method?


Culture Change Albert Einstein

Contamination Control Paradigm – Raise the Bar

• Current: Dirty greasy mechanic working in dirty greasy cluttered congested poorly lit shop.

• Now / Future: Technicians are technically competent professionals working in a clean organized well lit workshop diligently using robust processes.

Contamination Control Culture Changed…

Alumbrera/Finning

NW Argentina

Nickel Rim

Canada

Contamination Control Culture Changed…

Spence

Chile

Phu Bia Mining

Laos


Culture Changed…

…Being Brilliant In The Basics

Contagem, Brazil

Asansol, India


Culture Changed…

…Being Brilliant In The Basics

Lima, Peru

Dhaka, Bangladesh


What Is Contamination?


Mohs Mineral Brinell

10 Diamond

9 Corundum 667

8 Topaz 304

7 Quartz 178

6 Feldspar 147

5 Apatite 137

4 Fluorspar 64

3 Calcite 53

2 Gypsum 12

1 Talc 3

Iron Dust 5 Mohs

Bearing Metal Particles 6 - 7 Mohs

Silica Dust 7- 8 Mohs

Diamond Dust 10 Mohs

Copper Oxides 3.5 - 4 Mohs

Aluminum Oxide 9 Mohs

Fingernail 1 Mohs

Quarry Dust (limestone) 5 - 9 Mohs

How Tough Are Particulates?


• Abrasion: Hard contaminates will cut

metals, creating new contaminates

• Fatigue: Contaminates will also fatigue

metals, especially at edges and wear

points, again creating new

contaminates

• Multiplication: It is estimated that each

particle creates 8 – 10 more particles

through abrasion and fatigue

Ref: Bosch Rexroth

The Multiplication of Contaminates


Effects of Contamination on Oil Oxidation Rate


62.8°C = 145°F

Ref: Arrhenius’s Law, Backe, STLE

Above 65°C (150°F) increasing the

temperature at which lubricant is stored by

10°C (18°F) doubles the oxidation rate, which

cuts the usable life of the oil in half.

Heat

Chemical – Oxidation Root Causes


• Built-in

− Manufacturing & Assembly

• New Fluids

− New Fluid may NOT be Clean

• Introduced Contamination

− Pitted Rods

− Broken or Improper Breathers

− Worn Seals

• Service and Maintenance

− Open Systems

− Replacement Parts

− Work Practices

Contamination Sources


The single greatest opportunity

for increasing component life

and lowering operating costs is

to effectively manage fluid

cleanliness.


“Dirt You Can See”

• 40 Microns & Larger

• Weld Splatter

• Shot Blast

• Paint Chips

• Machine Chips

“Dirt You Can’t See”

• Under 40 Microns

• Wear Metals

• Silica

• Rocks

• Coal

• Dirt

Ref: Caterpillar

Two Types of Contamination


1 Millionth of a Meter

1 Thousandth of a Millimeter

• 100 microns (µm) - grain of table salt

• 80 microns (µm) - diameter of a human hair

What is a Micron?

Caterpillar: Confidential Green Ref: Caterpillar

Size Comparison Human Hair to a Micron


MICRONS (µm)

Hydraulic

System Clearances

3

15 40

80

Smallest

Visible

to the Eye Human Hair

1 Fuel

Particles You Can’t See Are Harmful!

Ref: Caterpillar

Size Comparison


• Cylinder Drift

• Jerky Steering

• Slower Performance

• Erratic Operation

• Shorter Service Intervals

• Higher Operating Costs

• Lost Productivity

Operating Effects of Contamination

“75-85% of hydraulic system failures are caused by contamination -- Hydraulics & Pneumatics, June 1998

-- Equipment Today, August 1997


• Sampling Device Clean?

• Sample Hoses Clean?

• Dirty Towel Used - Probably?

• Working Conditions

− Work Bench Not Clean

Clutter

• Doors Open

• Sample Labeling Completed?

• Result!

• Bad Data In

• Bad Data Out!

• Poor Decisions

Oil Sampling The Right Way – NOT!


• Two Methods

– Spectrographic Analysis

– Particle Counting

Microscopic (ISO 4407)

Automatic Optical (ISO 11500)

Automatic Pore Blockage (BS 3406)

“You Cannot Control What You Cannot Measure”

Ref: Caterpillar

How To Measure Contamination Particle Counting


21/19/16

20/17/15

18/16/13

24/21/18

16/13/10

Ref: Caterpillar

Understanding Fluid Cleanliness How do we measure fluid contamination?


1 Thousandth of a Liter

• 1 mL – This Bottle of Oil

• 330 mL – Bottle of Beer

• 960,000 mL – This AD60 Fuel Tank

Ref: Caterpillar

What is Milliliter (mL)?


(International Organization for Standardization)

Ref: ISO, Caterpillar

ISO 4406 Cleanliness language

• Cleanliness Language ISO 4406

• Method For Coding The Level Of

Contamination By Solid Particles

• Groups by size and quantity

• Expresses Amount of Contaminant

in one mL of Fluid

• What does ISO 21/19/16 mean?

>4µm / >6µm / >14µm

Caterpillar: Confidential Green Ref: ISO, Caterpillar

ISO 4406 Code ranges / Scale numbers

ISO 4406: 1999 (E) - ISO Contamination Code

Number of Particles per 1 ml

Scale

Number

More Than Up To and

Including

28 1,300,000 2,500,000

27 640,000 1,300,000

26 320,000 640,000

25 160,000 320,000

24 80,000 160,000

23 40,000 80,000

22 20,000 40,000

21 10,000 20,000

20 5,000 10,000

19 2,500 5,000

18 1,300 2,500

17 640 1,300

16 320 640

15 160 320

Chart cont…

Scale

Number

More Than Up To and

Including

14 80 160

13 40 80

12 20 40

11 10 20

10 5 10

9 2.5 5

8 1.3 2.5

7 0.64 1.3

6 0.32 0.64

5 0.16 0.32

4 0.08 0.16

3 0.04 0.08

2 0.02 0.04

1 0.01 0.02

0 0.00 0.01

Very

Dirty

Dirty

Clean

Clean

Very

Clean

Ultra

Clean

NOTE: Particle

count doubles

at each level


28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

0

2500000

1300000

640000

320000

160000

80000

40000

20000

10000

5000

2500

1300

640

320

160

80

40

20

10

5

2.5

1.3

0.64

0.32

0.16

0.08

0.04

0.02

0.01

0.00

≥4 ≥ 6 ≥ 14

Example:

Equal to or larger than 4µm = 11,343

Equal to or larger than 6µm = 4,257

Equal to or larger than 14µm = 548

ISO Code = / / 21 19 16 4µm / 6µm / 14µm

21

19

16

Ref: ISO, Caterpillar

Structure of ISO-Code: • Number of solid particles per

Milliliter of fluid

• Equal to or larger than these

specified sizes: 4µm / 6µm / 14µm

ISO 4406 Example


Cart circulates oil through the

machine system / component

to filter out contaminants.

Kidney-loop Filtration

Proven to increase oil and

component life and reduce costs


18,000hrs Total - 4000hr Oil Change

- w/Kidney Loop

- 50x photo

13,000hrs Total - 1200hr Oil Change

- No Kidney Loop

- 50x photo

Kidney-loop Filtration - Results


18K hrs, 500 hr Kidney Loop, 6um Filtration

Kidney-loop Filtration - Wheel bearing


• Spin-on / Cartridge

− Cellulose

− Synthetic

• Screens

• Magnets

• Centrifuges

Flow

Filter Types


Cellulose

• Advantages

− Physically robust material

No backing screen needed

More media in same volume

− Inexpensive

• Disadvantages − Higher pressure drop for a given

efficiency

− Hard to make really fine element

Synthetic

• Advantages

− Lower initial pressure drop

Higher efficiency available

− Higher dirt retention capacity

per unit area

• Disadvantages

− Physically weaker material

Backing screen typically required

Less media in given volume

Less dirt retention for a given size

of filter

− More expensive

Filter Media Advantages / Disadvantages

Caterpillar: Confidential Green Machinery Lubrication (10/2012)

Cellulose (Wood Pulp) Filter Media

Fiberglass Filter Media

Filter Media Visual differences


Screens

• Advantages − Very low pressure drop

Long life

− Large dirt holding capacity

− Single pore size Blocks ALL contamination

larger than pore size

• Disadvantages − Expensive in small micron sizes

− Typically, not very good filter

− Limited real world dirt retention, cannot build cake

− Difficult to clean

Magnets

• Advantages

− Trap magnetic (iron) debris in

system

− Cleanable

• Disadvantages

− System can wash debris off easily

− Can be expensive

− Much debris not magnetic

Screens and Magnets Advantages / disadvantages


CAT® Filter Ratings Efficiency vs micron sizes

The differences are basically the filter media used

Standard Advanced UHE

Air Filter - Engine Initial Efficiency Rating minimum 99.6% (SAE J726)

Not Available Not Applicable (99.9% efficient)

Breathers 50 µm absolute 10 -50 µm absolute < 10 µm absolute

Engine Oil Filters 30 -40 µm absolute 15 -30 µm absolute < 15 µm absolute

Fuel Filter >10 µm absolute 4 -10 µm absolute < 4 µm absolute

Fuel/Water Separator >20 µm absolute 10 -20 µabsolute < 10 µm absolute

Hydraulic Filter 27-40 µm absolute 10 -27 µabsolute < 10 µm absolute

Power Train Filter 27-40 µm absolute 10 -27 µm absolute < 10 µm absolute


• Nominal Rated

− Media captures the majority of particulate at (60 - 98%) the rated pore size.

− Often stated as the micron size without an efficiency specification

− No industry standard

• Absolute Rated

− Largest particle that will pass through media or largest pore size

− No standard test to determine the value of the pore opening

− Efficiency typically rated at or higher than 98.6% at the micron size.

− Better way to understand effectiveness of the filter compared to Nominal

• Beta Rated

− Best method and most common

− Obtained from multipass testing – ISO 16889

− Number of particles greater that X microns upstream of the filter versus the

number of particles greater than X down stream of the filter.

Expressed as ((beta-1/beta) x 100

Filter Ratings Industry


• Beta 10µ = 2

(Nominal Rating)

• Beta 22µ = 75

(Absolute Rating)

• Minimum Burst

800 PSI

5516 kPa

Filter Efficiency and Beta Ratings


Nominal Absolute

Upstream Upstream Downstream Downstream

B10 = 2

2 1

Filter stops 1

Beta Ratio = 2/1 = 2

B22 = 75

75 1

Filter stops 74

Beta Ratio = 75/1 = 75

50% 98.67%



% Efficiency ß (Beta) % Efficiency ß (Beta)

100 Infinity 100.00 Infinity

90 10.00 99.9999 1,000,000

80 5.00 99.999 100,000

70 3.33 99.99 10,000

60 2.50 99.90 1,000

50 2.00 99.80 500

40 1.67 99.75 400

30 1.43 99.67 300

20 1.25 99.50 200

10 1.11 99.00 100

0 1.00 98.67 75

0.8%


Caterpillar: Confidential Green Ref: SAE Technical Paper 881825

• Most diesel engine clearances 2-22 µm

− Size most likely to damage engine parts

• Standard filtration lube 40 µm

• Finer filtration reduces abrasive engine

wear

− Wear reduced 50% with 30 µm filter

− Wear reduced 70% with 15 µm filter

Many CAT® machines systems / component

have a higher efficiency filter option

Correlating Lube Oil Filtration w/ Engine Wear


Machinery life Extension Table

Oil ISO Cleanliness Target ISO

20/17 19/16 18/15 17/14 16/13 15/12 14/11 13/10 12/9 11/8 10/7 ISO 5 3 7 3.5 9 4 >10 5 >10 6 >10 7.5 >10 9 >10 >10 >10 >10 >10 >10 >10 >10 26/224 2.5 4.5 3 6 3.5 6.5 4 7.5 5 8.5 6.5 10 7 >10 9 >10 >10 >10 >10 >10 >10

4 2.5 5 3 7 3.5 9 4 >10 5 >10 6 >10 7 >10 9 >10 >10 >10 >10 >10 >10 25/2225/22

3 2 3.5 2.5 4.5 3 5 3.5 6.5 4 8 5 9 6 10 7.5 10 9 >10 >10 >10 >10 3 2 4 2.5 6 3 7 4 9 5 >10 6 >10 7 >10 8 >10 10 >10 >10 >10 >10 24/2124/21

2.5 1.5 3 2 4 2.5 5 3 6.5 4 7.5 5 8.5 6 9.5 7 >10 8 >10 >10 >10 >102 1.5 3 2 4 2.5 5 3 7 3.5 9 4 >10 5 >10 6 >10 8 >10 9 >10 >10 23/2023/20

1.7 1.3 2.3 1.5 3 2 3.7 2.5 5 3 6 3.5 7 4 8 5 10 6.5 >10 8.5 >10 101.6 1.3 2 1.5 3 2 4 2.5 5 3 7 3.5 8 4 >10 5 >10 6 >10 7 >10 >10 22/1922/19

1.4 1.1 1.8 1.3 2.3 1.7 3 2 3.5 2.5 4.5 3 5.5 3.5 7 4 8 5 10 5.5 >10 8.51.3 1.2 1.5 1.5 2 1.7 3 2 4 2.5 5 3 7 3.5 9 4 >10 5 >10 7 >10 10 21/1621/18

1.2 1.1 1.5 1.3 1.8 1.4 2.2 1.6 3 2 3.5 2.5 4.5 3 5 3.5 7 4 9 5.5 10 81.3 1.2 1.6 1.5 2 1.7 3 2 4 2.5 5 3 7 4 9 5 >10 7 >10 9 20/1720/17

1.2 1 1.5 1.3 1.8 1.4 2.3 1.7 3 2 3.5 2.5 5 3 6 4 8 5.5 10 71.3 1.2 1.5 1.5 2 1.7 3 2 4 2.5 5 3 7 4 9 6 >10 8 19/1619/16

1.2 1.1 1.5 1.3 1.8 1.5 2.2 1.7 3 2 3.5 2.5 5 3.5 7 4.5 9 61.3 1.2 1.6 1.5 2 1.7 3 2 4 2.5 5 3 7 4.5 >10 6 18/1518/15

1.2 1.1 1.5 1.3 1.8 1.5 2.3 1.7 3 2 3.5 2.5 5.5 3.7 8 51.3 1.2 1.6 1.5 2 1.7 3 2 4 2.5 6 3 8 5 17/1417/14

1.2 1.1 1.5 1.3 1.8 1.5 2.2 1.7 3 2 4 2.5 6 3.51.3 1.2 1.6 1.5 2 1.7 3 2 4 3.5 6 4 16/1316/13

Hydraulics & Rolling 1.2 1.1 1.5 1.3 1.8 1.5 2.3 1.8 3.7 3 4.5 3.5Diesel Engine Elem Bearings 1.3 1.2 1.6 1.5 2 1.7 3 2 4 2.5 15/1215/12

Joumal Bearings Gear Boxes & 1.2 1.1 1.5 1.4 1.8 1.5 2.3 1.8 3 2.2Turbo machinery Others 1.3 1.3 1.6 1.6 2 1.8 3 2 14/1114/11

1.3 1.2 1.6 1.4 1.9 1.5 2.3 1.81.4 1.2 1.8 1.5 2.5 1.8 13/10

1.2 1.1 1.6 1.3 2 1.6

Diesel engine oil at 20/17. If filtered clean and kept at 16/13 will promote an engine "Life Extension"

of 3 times nomal life. Gear box oil at 20/17. If filtered clean and kept at 13/10 will promote a gear

box "Life Extension" of 3 times nomal life.

Ref: Noria Corp

Yo

ur C

urre

nt C

lea

nlin

es

s P

artic

le C

ou

nt

Ref: Noria

Machinery Life Extension Table


Example:

121 LPM (32 GPM) pump

working 8 hours / day

for 200 days

Contamination Control Example Dirt through a pump

How much difference will cleaning oil from

ISO -/21/18 to ISO -/18/15 to ISO -/16/13

really make?


ISO -/21/18

ISO -/18/15

ISO -/16/13

630 lb / yr

79 lb / yr 20 lb / yr

Amount of “Dirt” Flowing

Amount of “Dirt” in Oil Through Pump in One Year

Contamination Control Example Dirt through a pump


Half an aspirin!

160 mg

Visualizing Contamination

How much “dirt” can be present in a 208 liter (55 gallon) drum

of oil and still meet ISO -/16/13?


Result:

Today’s Fluid Systems Are More Sensitive To Contamination

• Hydraulics

• Transmissions / Final drives

• Fuel systems

• Engines

Variable Displacement Pump*

Slipper-Port Plate Clearances from 1-25µm

Why Contamination Control? Advances in technology

Industry Trends:

• Electro-hydraulics

• Tighter Clearances

• Higher System Pressures


CR 200 Injector

Why Contamination Control? Industry trends

FIE manufacturers’

Cleanliness Requirement

At

High Pressure Pump Inlet

ISO 12/9/6

FIE Manufacturer’s

Cleanliness Requirement

At

High Pressure Pump Inlet

ISO 12/9/6

Fuel Systems

• Common Rail Fuel System

• Higher Pressures: 30,000+ PSI (2000 bar)

• Tighter injector clearances


CC GUIDES


Implement Contamination Control

Procedures in the Work Shop

Cat® Dealer Contamination Control Compliance Guide Rev05

PEBJ0002-05 / PSBJ0002-05

English / Español

18 Sections

122 Standards


14 Sections, 97 Standards

• Training

• Equipment Wash Facility

• Shop Attributes

• Shop Practices

• Remove And Install

• Tool Storage

• Parts Storage

• CRC or Reman Parts Return

• Hydraulic Hose Building / Rebuilding

• Bulk And Portable Fluid Storage

• Fuel Considerations

• Lube Truck

• Field Service Vehicle

• Fluid Analysis

Contamination Control Caterpillar Customer Compliance Guide


Compliance Guide Process

Caps & plugs for hoses used

•Good – plastic or metal plugs and caps

•Acceptable - plastic taped over hose ends

•Not recommended - no caps used, rags stuffed

in holes or tape used to close open oil lines,

ports, etc.

Good = 8

Acceptable = 4 Not recommended = 0

Medium to high volume wash equipment

to remove heavy deposits of mud

• Good - machines are washed with high volume

water source such as a fire hose

• Acceptable - machines are washed with

medium pressure washer

• Not recommended - machines are washed with

“home owner” type pressure washer or low

pressure source such as a garden hoseGood = 8

Acceptable = 4 Not recommended = 0

Calculator Work Sheet

Standards

Contamination Control Caterpillar Customer Compliance Guide


Start With Clean Tanks…

Bulk Tank Fluid Maintenance – Sampling

Enables fluid & tank condition

Fisher Scientific

(630) 259-4515

www.fishersci.com

USA Ph (800) 766-7000

Fax # (800) 926-1166

Petroleum Bacon Bomb Sampler

ASTM D 4057-95

14-209-D

http://www.fishersci.com/


Customer spent $6,800 on a Track Loader

Fuel System Repair

Bulk Tank Sampling…


Discuss the need for

clean fluid deliveries

A teaspoon of dirt in a fuel tank

can ruin an injector in 8 hours.

Supplier Requirements Must be part of the formal CC program


Success

Stories


793C Wheel Groups/Differentials

• Oil Drain Periods Extended

• Customer Savings =

• Year 1 (2001) = $110,000

• Over 3 years > $325,000

• Operating Cost Reduction - Wheel Groups Only

• $5.99/hour cost reduction

• 100 793Cs x $5.99/hr x 7000 hrs/yr

• Customer Savings = $ 4.2M/year

Batu Hijau Newmont - Indonesia


Yanacocha Copper Mine Peru

• 52 OHTs

16 - 777D

27 - 785C

9 - 793C

• Availability increased > 4%

• Wheel Group/Diff life increased 50%

• Hydraulics/ Transmission life increased 30%

• Customer estimated his savings @ $800K


La Herradura Gold Mine Mexico

2.23

1.120.94

0.75

8592

1235011491

13580

0

0.5

1

1.5

2

2.5

FD 1999 FD 2000 FD 2001 FD 2002

Average

$/H

r.

0

2000

4000

6000

8000

10000

12000

14000

16000

Hrs

.

0.29

0.14

13580

8592

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

Dif. 1999 Dif. 2002

Component

$/H

r.

0

2000

4000

6000

8000

10000

12000

14000

16000

Hrs

.

0.97

0.75

13034

12816

0.00

0.20

0.40

0.60

0.80

1.00

1.20

T 1999 T 2002

Transmissions

$/H

r.

12700

12750

12800

12850

12900

12950

13000

13050

13100

Hrs

.


Customer Implementation - Results

Benchmarking Site Goals

• Lower Warranty Cost

• Lower Owning & Operating Cost

• Extend Oil Life

• Extend Component Life

All Goals were achieved – All Sites


If optimum component life is

not achieved is this a

premature failure?

Closing Thought?


Brian Redpath


[email protected]

QUESTIONS

extending equipment uptime and life through contamination ... · what is contamination control?...

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