Application example: Eight-channel particle counter vs. Triple code contamination monitor
In a Finnish paper mill, the operating fluid of a roller bearing was monitored simultaneously with two measuring instruments for four months: on one side a contamination monitor comprising 3 size channels and on the other side a particle counter equipped with 8 size channels. As per ISO 4406, the contamination monitor provided information on the particles in the 3 size channels > 4 µm(c), > 6 µm(c) and > 14 µm(c), whereas the automatic particle counters reported on the contamination level in 8 size channels between > 4 and > 70 µm(c).
numbers in the size channel > 70 µm(c). A further examination revealed that mechanical components of the roller bearing had been badly damaged. The bearing had to be exchanged. If the machine abrasion had not been detected on time, a severe and costly machine failure or complete down times would have been the consequence.
The use of an automatic particle counter hence had been crucial in this application example. Only because of the differentiation of particle numbers in eight size channels and in particular in the channel > 70 µm(c) was it possible to clearly show the real degree of contamination. The high number of larger particles casted light on abrasion and provided insight on a failure in the system (i.e. a defective bearing in this case). If such abrasive particles are detected on time, proactive and preventive maintenance operations can be undertaken to repair the failure and to limit the down times.
Condition monitoring of lubricating oil systems requires an early detection of failures, so that they can be quickly repaired and so that consequential damages can be prevented. The application example from real life proved that a differentiated particle analysis of at least 8 size channels is required to detect abrasive particles. A contamination monitor reporting triple codes as per ISO 4406 does not provide any information on the real size distribution of larger particle sizes. Contamination monitors cannot detect these large particles and hence are not adequate for the condition monitoring of lubricating oil systems. A real online particle counter with 8 or more size channels is more suitable for early detection of bearing failures, as it provides information on the particle size distribution also for larger particle sizes.
Unlike a contamination monitor, an automatic particle counter is able to provide information on abrasive particles. In a Finnish paper mill, the use of an automatic particle counter with 8 size channels revealed that mechanical components of the roller bearing were badly damaged. An exchange of the roller bearing limited further losses. (Picture: PAMAS)
The comparison of measuring results showed that the triple code as per ISO 4406 did not suffice to identify the quality of the lubricating oil sample. During the complete measuring interval, the contamination monitor declared the oil to be clean with low triple codes as per ISO 4406. The automatic particle counter with its 8 size channels however reported alarmingly high particle
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Equipped with 8 or more size channels, automatic particle counters are able to detect bearing failures in lubricating oil systems at an early stage. With the aid of particle counting, contamination-related damages can be prevented. (Picture: PAMAS)
LUBE MAGAZINE NO.136 DECEMBER 2016
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