Understanding the root cause of the symptoms that are observed on your machinery?

It is observed across the spectrum that whenever we see issues/symptoms like:

Oxidized oil

Destructive pitting

Excessive vibration

Abrasive wear

Cavitation

Machinery abnormal noise

Wear debris generation

High running temperature

We usually believe in either Repairing, Replacing, Rebuilding and Removing the affected component. However, it only subsides the symptoms temporarily. This approach is called the 4-R approach and it weeds out the issue from the surface and not at the root level and hence the problem reoccurs. Call +91 7030901266 for Mechanical Maintenance & Oil Check.

However, we should aim at studying these symptoms and work on the root causes. Some of the very frequent root causes that cause the above-mentioned symptoms are:

Misalignment

Wrong oil usage

Moisture

Machinery part imbalance

Particle contamination

Air contamination

Hence, we should aim at 5I approach i.e. It’s clean, It’s Cool, It’s dry, It’s aligned and balanced, It’s well oiled. This approach keeps the machine healthy and eliminates the problem.

Technology -

Stage Wise Mechanical Filtration

The first stage is the largest micron rating, i.e. 50 micron or 25 microns. Second stage could be a medium-sized micron rating, maybe 10 or 16 or 20 microns and the final one, polishing filter stage, could be 6, 3 or 1 micron. The decision of micron rating depends on the kind of oil, level of dirt present in the oil and the application where this equipment is used.

Low Vacuum Dehydration

This technique is used for removal of moisture content from the oil, which is present in three forms:

Dissolved

Emulsified

Free form

The technology evolves around the fact that water boiling point is 100℃, when the vapour pressure above the water surface is atmospheric pressure. But when we reduce the vapour pressure to a vacuum condition say 750 torr, it's evident that the boiling point of water reduces from 100℃ to 60℃.

Electrostatic Fluid Cleaning

This calls for electrostatically charged electrodes inside a water bath.

It is a known fact that all foreign particles carry some charge. While we create positive and negative electrodes on the oil bath, the foreign particles which are negatively charged would be attracted towards the positive charged electrode and vice-versa. Thereby, after some interval of oil passage the particles would be attracted towards the respective oppositely charged electrode and a separation of particles happen.

Nitrogen Blanketing

This technique talks about the creation of an inert gas blanket in the header space of oil tanks.It has been seen that the header space of oil tanks, especially in the coastal areas, is full of humid air. This humidity is the biggest concern for oil oxidation and degradation. Hence, dry inert gas blanketing technology enables us to create a dry environment in the header space of these tanks. Having an inert gas ensures absence of oxygen, which would be the key element for oxidation and oil degradation.This technique has enabled a number of governing systems, lube oil systems in the coastal regions and they help them to reduce the problems of oil oxidation and degradation.

Tan Reduction By Ion Exchange

This is a technology which is used for reduction of TAN (Total Acid Number) value in the oil. TAN value is an indication of total acidity formed in the oil, which leads to an understanding of oil degradation.If we analyze the oil chemistry, there would be an understanding that oil degrades and forms carbonic acids and carboxylic acid groups. These lead to a condition where the oil is no more lubricating and it loses its basic properties. Hence, it is very important to maintain the TAN value within manufacturer subscribed limits.

In case you are unable to understand the root cause of the symptoms that are observed on your machinery contact Minimac Systems Pvt. Ltd.