LUBRICATION OF MACHINE

ELEMENTS

PREVENTIVE AND PREDECTIVE MAINTENANCE

Dr Mohamad Ali Ahmad

4. Preventive and Predictive
Maintenance
i. Lubricant Testing and Performance Analysis
ii. Ferro Graphic
iii. Fourier Transform Infra Red (FTIR)
iv. Spectrography

2
 Preventive & Predictive
Maintenance Practices

What Is It? What are the Benefits?

What are the Risks?
 Maintenance Definition
British Standard Glossary of terms
(3811:1993) defined maintenance as:

The combination of all technical and

administrative actions, including supervision
actions, intended to retain an item in, or
restore it to, a state in which it can perform a
required function.

4
 Maintenance Definition

Maintenance is a set of organised activities

that are carried out in order to keep an item in
its best operational condition with minimum
cost acquired.

5
 Maintenance Activities

Activities of maintenance function could be

either repair or replacement activities, which
are necessary for an item to reach its
acceptable productivity condition and these
activities, should be carried out with a
minimum possible cost.

6
 Maintenance History

1. In the period of pre-World War II, people thought of

maintenance as an added cost to the plant which did
not increase the value of finished product.

Therefore, the maintenance at that era was restricted

to fixing the unit when it breaks because it was the
cheapest alternative

7
 Maintenance History

2. During and after World War II at the time when the

advances of engineering and scientific technology
developed, people developed other types of
maintenance, which were much cheaper such as
preventive maintenance.

In addition, people in this era classified

maintenance as a function of the production system.

8
 Maintenance History

-Term terotechnology
introduced.
-Recognition of need to
present equipment failures.
-Models for preventive
maintenance developed.
Development of
Maintenance

-Increased awareness of:

-Environment
-Safety
-Quality
Fix the equipment when it -Need for reliable equipment.
breaks -Reduction in costs.

Time

Pre-World War II Post-World War II 1980 Onwards

Figure 1: Maintenance History

9
 Maintenance History
3. Nowadays, increased awareness of such issues as
environment safety, quality of product and services
makes maintenance one of the most important
functions that contribute to the success of the
industry.

World-class companies are in continuous need of a

very well organised maintenance programme to
compete world-wide.

10
 Maintenance Objectives
Maintenance objectives should be consistent with and
subordinate to production goals.
The relation between maintenance objectives and production
goals is reflected in the action of keeping production machines
and facilities in the best possible condition.
Maximising production or increasing facilities availability at
the lowest cost and at the highest quality and safety standards.
Reducing breakdowns and emergency shutdowns.
Optimising resources utilisation.
Reducing downtime.
Improving spares stock control.

11
Maintenance Objectives
PLANT

M
Maximising Production
A Reduce Breakdowns
I
N
Minimising Energy Usage T Reduce Downtime
E
N
Optimising Useful Life of Improving Equipment
Equipment A Efficiency
N
Providing Budgetary C Improving Inventory
Control E Control

Optimising Resources Implementing Cost

Utilisation Reduction

Figure 2: Maintenance Objectives

12
 Maintenance Objectives

Improving equipment efficiency and reducing scrap

rate.
Minimising energy usage.
Optimising the useful life of equipment.
Providing reliable cost and budgetary control.
Identifying and implementing cost reductions.

13
 Types of Maintenance

Preventive Maintenance (PM)

Predictive Maintenance (PDM)

14
Q= What is Preventive Maintenance?
Preventive Maintenance is the care and
understanding of your assets basic needs, while
in routine service.

Preventive Maintenance can also be described

as the scheduling tool or action plan for
managing the anticipated life expectation of
any asset.

15
 Preventive Maintenance
British Standard 3811:1993 Glossary of terms
defined preventive maintenance as:

The maintenance carried out at

predetermined intervals or according to
prescribed criteria and intended to reduce the
probability of failure or the degradation of the
functioning and the effects limited.

16
 Preventive Maintenance
The factors that affect the efficiency of this type of
maintenance:

1. The need for an adequate number of staff in the

maintenance department in order to perform this type of
maintenance.
2. The right choice of production equipment and machinery
that is suitable for the working environment and that can
tolerate the workload of this environment.
3. The required staff qualifications and skills, which can be
gained through training.
4. The support and commitment from executive management
to the PM programme.
5. The proper planning and scheduling of PM programme.
6. The ability to properly apply the PM programme.

17
 Preventive Maintenance
Researchers subdivided preventive maintenance into different kinds
according to the nature of its activities:

Routine maintenance which includes those maintenance activities that

are repetitive and periodic in nature such as lubrication, cleaning, and
small adjustment.
Running maintenance which includes those maintenance activities that
are carried out while the machine or equipment is running and they
represent those activities that are performed before the actual preventive
maintenance activities take place.
Opportunity maintenance which is a set of maintenance activities that
are performed on a machine or a facility when an unplanned opportunity
exists during the period of performing planned maintenance activities to
other machines or facilities.
Window maintenance which is a set of activities that are carried out
when a machine or equipment is not required for a definite period of time.
Shutdown preventive maintenance, which is a set of preventive
maintenance activities that are carried out when the production line is in
total stoppage situation.

18
Q= What is Predictive Maintenance
Predictive Maintenance is the action taken to
prevent damage resulting from component
failure as a result of normal and predictable
wear.

Predictive Maintenance can also be described

as predetermined obsolescence or planned life
cycle expectation.

19
 Predictive Maintenance
It is classified into two kinds according to the
methods of detecting the signs of failure:
Condition-based predictive maintenance;
depends on continuous or periodic condition
monitoring equipment to detect the signs of
failure.
Statistical-based predictive maintenance;
depends on statistical data from the
meticulous recording of the stoppages of the
in-plant items and components in order to
develop models for predicting failures.
20
Q= What are the Benefits of Preventive
& Predictive Maintenance?
Extended Natural Life Cycle Expectation
Reduced overall Maintenance costs
Predictable Maintenance Budget
Reduced down time for repairs
Reduced Unscheduled Repairs
Predictable and reliable equipment utilization.

21
Q= What are the Risks associated with
poorly maintained equipment?
Poor Safety Record!
Increased Maintenance Costs.
The expected repair costs associated with poorly
maintained equipment usually results in an
escalation factor of two times or greater the rate of
normally maintained assets.
Extensive unplanned down time due to unexpected
repairs.

22
Counter Measures
Develop a Scope of Work (Right Quality)
Understand what is it you want to achieve
Identify the basic needs of the asset
Establish normal wear characteristics and
identify the life cycle in current utilization.
Develop a process to adjust for the changing
needs of each asset.
Track Progress and adjust as necessary

23
 Maintenance Strategy
Learn & understand wear patterns, causes and
costs associated with wear at different stages of
component life cycle.
Develop a strategy for your Preventive
Maintenance program (When & Where) will your
equipment be maintained.
Develop a risk assessment strategy. (What do
you do when your maintenance plan is
interrupted?)

24
 Maintenance Tools

Shop selection (Preferred shops) Select the

right shops and communicate your
maintenance strategy (Right Quality)
KPIs (Key Performance Indicators) develop a
set of measures as a way to keep track of
your assets condition.
KPIs are a form of risk assessment that will
allow you to make key decisions at regular
intervals.

25
Preventive/Predictive Maintenance
Q= What is it?
A= Preventive Maintenance is the tool to
keep your assets in near new condition.
A= Predictive Maintenance is the
understanding of wear associated with the
asset lifecycle.
A= It is your opportunity to manage your
asset base in a responsible, reliable and
fiscally responsible manner.

26
Preventive/Predictive Maintenance
Q= What are the Benefits?

A= Increased Asset Life Cycle expectation

B= Predictability

C= Piece of Mind in knowing you have a

clean, safe, reliable and cost effective asset
base.

27
Preventive/Predictive Maintenance
Q= What is the Risk?

A= You will have peace of mind in knowing

you are utilizing Best Practices with your
Assets.

A= You will have reduced exposure to

unplanned mechanical events.

28
Lubricant testing and Performance
Analysis
What is Lubricant Testing??
Why you need Lubricant Testing
How you run Lubricant Testing??
What is Performance Analysis??

29
Lubricant Testing

Important factor purpose of the tests

Some reason of test:-
1. It is work well in particular piece of equipment
2. It is will survive in particular conditions (heat,humidity)
3. safe to use/toxicity/flammable
4. Meets specification??
5. To check if it is same lubricant from previous
6. Legal purpose

30
Lubricant Testing

Category of test:-
1. Functional test designed to show how the lubricant
performs it function as lubricant, or one of it secondary
functions as a hydraulic fluid, coolant or corrosive
preventive.
2. Chemical Test measuring chemical property (acidity,
concentration)
3. Physical Test physical properties

31
 Functional Test
Service trial to predict lubricants and bearing
behavior at unusual condition.
Factor cause Service trial unsatisfactory:-
1. Duration of the trial
2. Insufficient control (environmental conditions)
3. Difficulty of monitoring
4. Cost

Alternative laboratory test

Advantages of laboratory test
1. Operating condition varies and control
2. Measurable instrument
3. Fast result
32
 Functional Test
Common lubricant test machine:-

33
 Functional Test
Other functional test:-

34
 Chemical and Physical Test
Oxidation test choose appropriate tests
Thermal stability all into 3 basic groups
1. Breakdown of structure at high temperature
2. Measure the extent which volatile component evaporate
3. Tendency of oil to breakdown chemically
Flammability
Composition
Contamination
Viscosity and consistency
Other physical tests

35
 Performance Analysis
Girdhar and Scheffer [2004], signified that oil analysis
is not only a tool to analyze the condition of a lubricant
but it is also used to monitor the condition of
equipment.
Macian et.al [2003] stated that oil analysis is an
advanced techniques and has been widely used around
the world as a suitable method of reducing maintenance
costs, improving reliability and productivity
Three types of oil analysis techniques which are
concentration analysis, wear particles analysis and
lubricant degradation analysis.
36
 Performance Analysis
The concentration analysis is measures the amount of
wear on wear particles present in the lubricant.
The wear debris analysis deals with examination of
the shape, size, number, composition, and other
characteristics of the wear particles so as to identify the
wear state.
Lubricant degradation analysis is used to analyse
physical and chemical characteristics of lubricant and
determine the state of lubricant.
All of these types of oil analysis can be conducted in
field or laboratory
37
 4.2 Ferro Graphic
In the late 1960s, United States military aircraft use
ferromagnetic chip detector technology and
spectroscopy to detect the failures in rolling element
bearings found in aircraft.
by using these technologies, they were only capable of
detect larger particles.
more sophisticated method needed for detecting smaller
wear particles to avoid more bearing damages.
later collaborated with Westcott in early 1970s,
produced the first ferrograph as shown.

38
4.2 Ferro Graphic

39
 4.2 Ferro Graphic
After years of research,
analytical ferrography
have been developed
followed by direct
reading ferrography.
Ferrographic technique
then became the Duplex Ferrograph

fundamental tool of oil

analysis and reliability
maintenance.

40
 4.2 Ferro Graphic
The ferrograph is a laboratory-based instrument which
commonly provides two wear monitoring techniques which is
Analytical Ferrography (AF) and Direct Read Ferrograph
(DRF).
Both instruments used a strong magnetic field to separate wear
debris from an oil sample and then the wear debris patterns
visually examined for further analysis.
There is different between these two techniques.
AF - the wear debris pattern is examine and compared to the
standard chart. (Please refer on wear atlas in lab)
DRF - larger and smaller are plotted to characterized wear using
severity of wear index

41
 4.2 Ferro Graphic
The Wear Particles Atlas is a guide to wear particle identification
containing photographs of typical wear particles found in used
lubricating oil, illustrative case histories, and operational
procedures for wear debris analysis.

Cast iron at 1000X Steel wear at 400X

Abrasive wear 400X

42
Corrosive wear 1000X
 4.2 Ferro Graphic
The ferrographic analysis, used as a tool to detect
failures by analyzing the particles found in the
lubricants since size particles below 50m in filtering
elements.

43
4.3 Fourier Transform Infra Red (FTIR)

44
4.3 FT-IR
analytical techniques used by scientists
mostly in organic and inorganic fields.
To determine the chemical functional
groups in the sample.
Different functional groups absorb
characteristic frequencies of IR radiation
Infrared refers to a section of the
electromagnetic spectrum between the visible
at high frequencies regions and microwave
region at low frequencies
45
4.3 FT-IR
Electromagnetic spectrum can be considered
as waves or particles that move and travelling
at the speed of light which having
wavenumbers between 13,000 to 10 cm1, or
wavelengths from 0.78 to 1000 m
These waves differing from each other in the
length and frequency as illustrated in Figure..

46
4.3 FT-IR

: The electromagnetic spectrum

47
4.3 FT-IR
In IR spectroscopy, an infrared radiation is
absorbed by organic molecules then
converted into energy. When the radiant
energy matches the energy of chemical
bonds of molecular vibration, the absorption
occurs.
Major vibrational modes -

48
4.3 FT-IR
The IR regions of the electromagnetic
spectrum

The IR spectrum plotted as transmission and absorbance 49

4.3 FT-IR
Characteristic Group Absorption
Alkanes 2850-2960/1350-1470
Alkenes 3020-3080/675-1000
Alkynes 3300
Mononuclear Aromatics 1500/ 700
Alcohols And Phenols 3350
Acetals 1150
Ethers 1180-970
Carbonyl Compound 3200-2500
Acid Chlorides 1790
Anhydrides 1800
Amides 1640-1590
Amines 830-770/3180-2000
Nitriles 2300
Carbodiimides 1580-1370
Nitro Compound 1590-1570
Sulphur Compound 2600
Thiocarbonyl Group 975
Halogen Compound 1380-1220/760-640
Silicon Compound 980-910
Phosphorus Compound 1100-900 50
4.3 FT-IR
Basic Component

FTIR spectroscopy can accept a wide range

of sample types such as gases, liquids, and
solids

51
4.3 FT-IR
Characteristics Absorption
Group (approx. cm-1)
Soot 2000
Oxidation (carbon) 1700
Nitration 1630
Sulfation 1150
Water 3400
Diesel fuel 800
Gasoline 750
Antifreeze (glycol) 880
Antiwear additive 960

Concentration of functional Group

52
4.3 FT-IR
Bond Type Absorption region (cm-1)
C-O 1300 - 800
C-C 1300 - 800
C-N 1250 - 1000
C=C 1900 - 1500
C=O 1850 - 1600
C=C 2150 - 2100
C=N 2240 - 2280
C-D 2250 - 2080
C-H 3000 - 2850
O-H 3800 - 2700
IR Absorption Regions
53
4.4 Spectrography
https://www.youtube.com/watch?v=J-
wao0O0_qM
Spectrometric analysis is one of the main
techniques used in particle analysis.

54
 4.4 Spectrography
technique is based on the principles of atomic
physics.
an atom emits or absorbs light of a certain
wavelength within the ultraviolet and visible
region of the energy spectrum when there is an
upset in the energy balance within its atomic
structure.
Each element present in the burning oil emits a
light of characteristic colour and frequency.

55
 4.4 Spectrography
Spectrometers translate the intensity of the
colours into a computerized readout.
The results of a spectrometric analysis are
typically reported in ppm (parts per million).
The main focus of this analysis is to trend the
accumulation of small particles of wear metals
and elemental constituents of additives, as well
as to identify the possible introduction of
contaminants.

56
 4.4 Spectrography
Wear Elements Probable Origin
Piston, bearings, blower/turbo charges, pump vanes, thrust washers and bearings,
Aluminum
blocks, oil pump bushings, housing clutches, impellers, rotors
Rings, roller-tapper bearing, liners, exhaust valves, coolant, rods, spools, gears,
Chromium
shafts, anti-friction bearings
Bearings, thrust washers, bushings, oil coolers, oil additives, wrist-pin bushings, cam
Copper bushings, valve-train bushings, governor, oil pump, steering disc, pump thrust plates
and piston, injector shields, wet clutches
Cylinders, crankshafts, valve train, piston rinfs, clutch, pistons, rings, gears, bearings,
Iron liners, shafts, plates, blocks, camshafts, pumps, shift spools, cylinder bores and rods,
piping and components of circulating oil systems
Lead Bearings, gasoline additives, oil additives
Magnesium Oil detergent, oil alkaline reserve
Molybdenum Oil additive, friction modifier
Nickel alloy, gear plating, valve guides and ring bands, shafts, anti-friction bearings
Silver Wrist-pin bushings, anti-friction bearings, silver solder
Tin Bearings, piston plating, alloy of bronze (cooper/tin), bushings
Silica (Silicon) Ingested dirt and sand, gasket sealant, oil anti-foam additives, anti freeze additive

Anti-wear oil additive (zinc-dialkyl-dithio-phosphate), galvanized parts in circulating

Zinc
oil systems

57
4.4 Spectrography

Barium (Ba) detergent or dispersant additive

Boron (B) extreme-pressure additive
Calcium (Ca) detergent or dispersant additive
Copper (Cu) anti-wear additive
Lead (Pb) anti-wear additive
Magnesium (Mg) detergent or dispersant additive
Molybdenum (Mo) friction modifier
Phosphorus (P) corrosion inhibitor, anti-wear additive
Silicon (Si) anti-foaming additive
Sodium (Na) detergent or dispersant additive
Zinc (Zn) anti-wear or anti-oxidant additive

Elements contained within additives

58
4.4 Spectrography
Oil Spectrometric Diagnosis Validation of
sampling analysis (data analysis) the diagnosis

Spectrometric oil analysis procedures

59
 4.4 Spectrography
two methods using the spectrometric analysis
which are emission spectrometry (AES) and
atomic absorption spectrometry(ABS)
Both have the same operations but different in
sample application. Emission spectrometry is
based on high voltage excitation of 15kV and
atomic absorption spectrometry relies on oxy-
acetylene flame to atomize the metallic elements.
The wave-length of the light absorbed by the
elements in the sample is detected and measured
by the spectrometer.
60
4.4 Spectrography

61