Service 3 On-Line Oil Monitoring V.S. Lab Oil Analysis – English

Service 3 On-Line Oil Monitoring V.S. Lab Oil Analysis – English

SCADA – Wireless Remote Control – Oil Monitoring System – Machine Condition Monitoring

OA-1 On-Line Oil Analyzer with IIOT4.0 Wireless Remote Monitoring & Remote Control Mini SCADA from OilPure is the On-Line oil testing device that reads oil contamination and additive depletion on a Real Time basis for 24 hours – 365 days. The OA-1 will determine the changes in lubricating properties and assimilate the Characteristic and Behavior of machine lubrication.

This data will reveal Oil Contamination Ingression Rate that allows us to design the proper preventive control of the oil contamination that disrupts the machine performance. While the conventional oil analysis from laboratory is merely a guess work on a periodic basis. As saying in Six Sigma, What get measured, get controlled.

On-Line Oil Analysis OA-1 Oil Analyzer is design to reads oil contamination with Centralized System from Multiple Point Oil Location from single machine or multiple machines.

Tribology 4.0 is IIOT4.0

  • Currently we are heading to Tribology 4.0 which the oil contamination control, oil oxidation level and oil additive depletion rate utilizes the Wireless SCADA with Centralized Control System to manage and monitor the changes of these variables. The study of these data changes allow us to better understand the Characteristic and Behavior of the Input Variances that lead us to the machine failures.
  • Data collecting is gathered in Data Logging format which yields into Big Data. Using Data Analytics to develop the line of defense in Interactive Proactive that is responsive to problematic occurrence autonomously. This new approach will become a systemic automated operation that will by-pass human error in the process.
  • It is the fact that human operator causes most maintenance and lubrication problems in the plant. This human factor must be avoided in such a way to improve efficiency and productivity. This autonomous system is described in the next slides of how the Tribology 4.0 should work for today industries.

On-Line Oil Analysis & Machine Condition Monitoring

  • On-Line Monitoring System will collect lubrication data and shows the changing data in Delta (∆) Value as well as displays in Trend Analysis while the equipment is running Full Time. We will not only, acknowledge the lubrication quality but also, witness the changes in lubrication quality describing machine performance. These lubricating data reveals the Root Cause of machine problem and help us diagnose the Variance Input. This data will help us to set a Line of Defense in Proactive Preventive Maintenance Plan to improve Machine Reliability.
  • Sending Oil Analysis to laboratory for testing is becoming obsoleted as it only detect lubrication quality at one point in time. One sampling for a month or 3 months provides inadequate data that can not represent the health of machine in the whole picture. So the result from lab Oil Analysis is just not enough to predict the real oil problems and find way to improve the process.

OA-1 On-Line Oil Analyzer

  • OA-1 Oil Analyzer with IIOT4.0 Capability:
    1. Communication Protocol is IIOT4.0 with Wireless Remote Control and Remote Monitoring System that can communicate like a Mini SCADA. User can dial into OA-1 at maximum 5 persons at a time.
    2. PLC Controller has the highest security Algorithms at 128 bit SSL Encription
    3. OA-1 Controller has a Built-in Server and is capable of communication with LAN Line CAT 5 and Mobile Router using Static IP Address SIMM Card for the internet outside connection.
    4. User can also dial the OA-1 to read the oil status from computer or mobile phone Browser with password and level of authority through WebMI Software.
    5. OA-1 Controller can communicate with other PLC controller by M2M Machine-To-Machine Network up to 199 PLC units
    6. User can access the real time of Particle Count, Water Content in ppm, and up to 10 locations of Oil Temperature Thermocouples. The Oil Oxidation Deterioration Curve and Oil Additive Depletion Curve become Parameters in the OA-1 Oil Analyzer that user can use his phone to view the current oil situation.
    7. Remote Control from Smart Phone Display will illustrate the same Display on PLC. User can use his finger to navigate the operation fro his phone as if he stands in front of the machine.
    8. Limit Alarm Signal on each sensor can send alarm messages by E-mail and SMS Text Messages to user smart phones as software program is set to do by OilPure.
    9. OA-1 Collects Historical Data in Data Logging in PLC controller. User can pull Oil Data Logging anytime in the past and stored in USB Drive which can be inserted in computer PC with Microsoft Excel. Historical Data will display in graphic trend in Excel Charts which user can import this chart to create a report to upper management. Oil Test data can in pdf files and kept in company CLOUD for Paperless Office.
    10. OA-1 can also send interactive signal, Autonomous Responsiveness to other output devices such as pump motor, fan, solenoid valves etc. for controlling purpose in the operation.
    11. Optional Mini SCADA, user can add more inputs such as Pressure Transmitter, Tachometer Sensor, Ultrasonic Level Sensor, Vibration Sensor, Cycle Time Counter etc. to OA-1 PLC controller digital and analog inputs to enhance the performance, not only On-Line Oil Analysis, but also an additional Machine Condition Monitoring System. These sensors will use OA-1 PLC controller to communicate as a Mini SCADA.

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  • OA-1 On-Line Oil Analyzer detects lubrication quality in Real Time and On-Line:
    1. PC1 = Particle Count Sensor reads data in ISO Code, NAS Class, SAE Class.
    2. OS1 = Oil Sensor detects Oil Oxidation & Additive Depletion in data curve and scale 1-10 from good to bad.
    3. MS1 = Moisture Sensor detects water content in ppm & % AW (Water Activity).
    4. TH1 = Monitor oil temperature read oil temperature in the lubricating system up to 10 points such as Bearing, Pump, Valve, Cylinder etc.which are heat sources causing oil breakdown.
    5. Remote alarms send to smart phones from PC1, OS1, MS1, high temperature & other monitoring devices etc.
    6. Mini SCADA for other machine condition.
    7. Data Logging Capability
    8. Dual points of Oil Monitoring between several oil reservoirs and oil pressure return line to determine Oil Contamination Ingression Rate.
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MS1 Moisture Sensor Monitoring Display

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Particle Count Monitoring Display

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Oil Oxidation Monitoring Display

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Oil Additive Depletion Monitoring Display

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Dual Location OA-1 Oil Monitoring – 1st Location from oil Reservoir – 2nd Location from Hydraulic Valve Manifold

  • OA-1 On-Line Oil Analyzer for Multiple Machines:
    • OA-1 Oil Analyzer is capable of reading the Multiple Point Oil Monitoring from hydraulic equipment as a Centralized Monitoring System.
    • OA-1 will read and record the oil contamination in real time every 24 hours and automatically switch to other hydraulic equipment on a periodic basis.
    • Central oil pipe can be plumbed in multiple Suction Lines and Discharge Lines with additional Transfer Pump and Solenoid Valves that will draw oil from equipment to OA-1 Oil Analyzer Unit for the real time oil analysis.
    • Oil analysis result can be kept in Data Logging all years round. The oil test data can be transfer into a  USB Drive and Downloaded the result into Microsoft Excel program in a graphic picture.
    • Oil contamination data can be transmitted through LAN Line or Dial in Browser from any smartphone.
    • The Alarm signal of oil contamination data can be forward to the operator who is responsible for the equipment maintenance to witness the Foreseeable Problems before the real catastrophes occur.
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Multiple Machine Location OA-1 Oil Monitoring on 4 Machines, OA-1 Rotates on Each Machine every 24 Hours.

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OA-1 Oil Analyzer Unit

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OA-1 Controller with Mobile Cellular Networking

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Mini SCADA Capability

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Machine Condition Monitoring can also work with OA-1 Software and Hardware by adding the sensor Inputs.

Misreading and Misinterpretation of Sending Oil Samples to Laboratory for Analysis

  • Oil Analysis Lab Report tries to make the test report look sophisticate and complex so user would have no idea what it means and how it affects his equipment. User has no clue in the test results.
  • Lab Technician doesn’t have adequate experiences in machinery problem and has never get involved or hand on working with the equipment. He just puts the oil samples in the equipment and print the number result entering to the test report. So he should not make good advice how to solve customer’s oil problems but fake it as if he is a voice of authority misguiding customer.
  • User has very little knowledge about oil analysis report and has a hard time understand complex test report. Usually it takes 7 years for employee involvement in Tribology to start to know the Oil Analysis and Oil Contamination Control and Lubrication Technology.
  • Most Oil Test Results are not accurate due to poor oil sample was taken from the wrong places.
  • Most Lab Equipment does not have the ISO 17025 Certification proofing quality control.
  • Most Lab Equipment has never been calibrated because it is very expensive to send lab equipment for 3 weeks to America for Calibration.
  • The Oil Analysis in the Lab is more of the Belief than the Science.
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Example of Error and Mistake from Oil Analysis from the Oil Testing Lab

The number from Wear Element from ICP shows in ppm (parts per million) between 0.1 – 6.7 ppm which considers to be very small amount while the Particle Count shows NAS 12 or ISO Code 22/22/19 in 2,262,480 count at 5-15 microns. This ICP and Particle Count is absolutely contradicting. ICP shows very small amount but Particle shoes extremely high.

If Particle Count is truly read at NAS 12 which means extremely high number, in reality, this hydraulic equipment would have blown up before the oil sample was sent to the lab.

This contradicting test result could come from the reading of ICP-AES on Wear Elements that is set to read elements at 25-50 microns level. The proper element reading from ICP should be lower than 10 microns in order to us the test data for analysis. The ICP should be set to read elements at 7-8 microns level. This contradicting test result could be from improper setting of the ICP, lack of proper device calibration, or device has been in service for a long time with the equipment has been ignored for maintenance and calibration for accuracy. This situation has caused the misunderstanding among the user and becomes “Blind leads the Blind”

  • Particle Count ISO Code 22/22/19 seems to be inaccurate reading number. At 6 microns (the middle number) should not be 22. It should be less than 22 such as 22/21/19 or 22/20/19. This misleading number described 2 sources of testing problems:
    1. Sensor Calibration Problem. This lab equipment has never been recalibrated for a long time. ISO Standard requires that Particle Count Calibration uses AC Fine Dust or AC Coarse Dust for calibration process. The reading of Calibrated Sensor will follow the same Particle Size Distribution Curve according to the AC Fine Dust or AC Coarse Dust Test. So the number should not be the same in the different micron level (4 microns/ 6 microns/ 16 microns).
    2. Cross Contamination Problem. The previous oil sample must be highly contaminated. So previous contamination has already been inside the sensor and lab technician did not clean the sensor port. This Cross Contamination allows the sensor to pick up additional number on the count so the reading could be 22/22/19 which is not real reading on this oil sample. The sensor cleaning process requires two different cleaning solvents; Hexane or Ether and Alcohol for lab standard with CAS # (not alcohol purchased from Big C store). Each solvent will require 3 times cleaning which takes about 20-30 minutes per cleaning procedure. This cleaning is a time consuming and cost extra money in cleaning materials. This cross contamination will affect the misleading number of Particle Count.

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