Contamination Control and

Proactive Maintenance
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 Outline

Damage Caused by Oil Contamination

Effect of Incorrectness ISO Code Target
Proactive Maintenance Steps to Control
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Contamination
Contamination Control Program
Water Effect and Foam Problem
 Tiga Katagori Utama Analisa Oli
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 Trivektor
Wear
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Contamination Chemistry
 Water and Bearing Life
Based on 100% Life at 0.01% Water
250
% Bearing Life

200

150

100

50

0
0 0.1 0.2 0.3 0.4 0.5
Percent Water
Reference:Timken Bearing Company
 Lube Tips: Visual Crackle Test
The crackle-test is a simple test to identify the
presence of free and emulsified water in that is
suspended oil. This is the water that is the most
harmful to the machine and oil.
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The method is as follows:

Achieve surface temperature on a hot plate of 300

degrees F (135 degrees C). Always use the same

temperature.
Violently agitate oil sample to achieve homogenous

suspension of water in oil.

Using a clean dropper, place a drop of oil on the
hot plate
 Visual Crackle Observation
If no crackling or vapor bubbles are produced
after a few seconds, no free or emulsified
water is present.
If very small bubbles (0.5 mm) are produced
but disappear quickly; approximately 0.05-
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0.1% water is present.

If bubbles approximately 2 mm are
produced, gather to center of oil spot,
enlarge to about 4 mm, then disappear,
approximately 0.1 to 0.2% water is present.
For moisture levels above 0.2%, bubbles
may start out about 2-3 mm then grow to 4
mm, with the process repeating once or
twice. For even higher moisture levels violent
bubbling and audible crackling may result.
 Visual Crackle Test: Limitation

The method is non-quantitative.

Hot plate temperatures above 300 degrees F induce rapid
scintillation that may be undetectable.
The method does not measure the presence of chemically
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dissolved water.
Applicable Standards: None
Interferences: Refrigerants and other low boiling-point
suspensions may interfere. Different base stocks, viscosities,
and additives will exhibit varying results. Certain synthetics,
such as esters, may not produce scintillation.
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Source and Control of Contamination
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Damage Caused by Oil Contamination
 The Silent Destruction of Rogue Particles
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 The Silent Destruction of Rogue Particles
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 Proactive Maintenance Steps to Control
Contamination
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 Step 1 Target
Set Target Cleanliness Levels
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 Efek Pemilihan ISO Code yang tidak tepat
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 Efek Pemilihan ISO Code yang tidak tepat
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Dengan mengunakan ISO 21/18, sistem hidraulic ini memompa 136

karung (ukuran + 25 kg) kotoran setiap tahun
Dengan menggunakan ISO 14/11, hanya 1 karung (ukuran + 25kg)
kotoran setiap tahunnya yang melewati pompa
 Step 2 Tindakan
Ambil tindakan spesifik untuk mencapai target
Cegah partikel masuk ke dalam sistem
Oli baru
Ventilasi dan breather
Seals
Servis dan pembentukan debris
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Filter dumping
Keluarkan kotoran secepatnya
Gunakan filter yang tepat pada sistem sirkulasi
Mesin yang lain gunakan filter portable
Manajemen sump dan reservoir yang baik
Penggantian filter secara periodik
Biaya mencegah masuknya 1 gram kotoran hanya sekitar 10% dari
biaya yang harus kita keluarkan jika kotoran tersebut sudah masuk ke
sistem oli.
Biaya dari filter berkinerja tinggi pada umur mesin umumnya lebih
murah daripada filter yang murah tetapi efisiensinnya rendah
 Darimana partikel kontaminan berasal
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Lubricant Management
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Lubricant Management
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Lubrication Management
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Lubrication Management
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Lubrication System
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Lubrication System
 Contamination Control Program
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 Step 3 - Monitoring and Controlling Particles
Concentration

Why?
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How?
 Optical Particle Counter (OPC)
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 Pore Blockage Particle Counter
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 Particle Counting in Oil Analysis
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Water Contamination
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Efek Air
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Efek Air
Measuring Water in Oil by Karl Fischer
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Foam Problem
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Questions and Comments?