Clean_Oil_Guide 油品清洁指南.doc

Clean Oil 油品清洁Guide 指南ADDING ENERGY 为您增添动力100 micrometres 100微米Grain of salt 盐粒40 micrometres 40微米Naked eye visibility 肉眼可见3 micrometres 3微米OIL 油2 micrometres 2微米Bacteria 细菌8 micrometres 8微米Coal dust 煤尘70 micrometres 70微米Human hair 人的毛发25 micrometres 25微米Pollen 花粉Clean Oil Guide 油品清洁指南Second Edition 2003 第二版 2003Published by: 版权所属：C.C.Jensen A/S C.C.Jensen 公司Svendborg, Denmark. 斯芬博格市, 丹麦Layout: 设计：Novatesa, s.l. Novatesa, s.l.Barcelona, Spain. 巴塞罗那, 西班牙Revision layout, print: 修订, 印刷：SvendborgTryk, SvendborgTryk,Denmark. 丹麦Sources: 来源:“Chemistry in electrical apparatuses” 电子仪器化学Lars ArvidsonVsteras PetroleumKemi AB西西延森Lars ArvidsonVsteras PetroleumKemi AB西西延森Contents目录0 Introduction0 介绍1 Wear and tear in oil systems1 油质系统中的磨损2 Oil sampling2 油品取样Where to take an oil sample何处取得油样How to take an oil sample如何取得油样3 Oil sample analysis3 油样分析ISO standardsISO 标准NAS classesNAS 分级Evaluation of particle count颗粒数量的评估Frequency of analysis分析的频率4 Oil cleaning methods4 油品清洁方法Filter types过滤器的类型The surface filter表面型过滤器The depth filter深度型过滤器5 Basic filtration definitions5 过滤的基本定义Nominal filtration标准过滤精度Absolute filtration绝对过滤精度x valuex值Dirt capacity纳污容量By-pass旁路6 Installation methods6 安装方式Off-line filtration离线过滤Full-flow完全流量7 Economy7 经济性8 Ordering a filtration system8 定购一套过滤系统9 Handling of oil and oil systems9 油品及油质系统的处理New oil in containers容器里的新油Oil in the system系统中的油品10 Recommendations for buying oil10 关于购买油品的建议Oil test certificates and test sampling油品的检测证书及测试取样Claims我们的权益Sampling取样Page页码2 Introduction2 介绍3 Wear and tear in oil systems3 油质系统中的磨损4 Oil sampling4 油品取样8 Oil sample analysis8 油样分析12 Oil cleaning methods12 油的清洁方式16 Basic filtration definitions16 过滤的基本定义18 Installation methods18 安装方式20 Economy20 经济性21 Ordering a filtration system21 订购一套过滤系统22 Handling of oil and oil systems22 油品及油质系统的处理23 Recommendations for buying oil23 关于购买油品的建议Page headerIntroduction介绍Maintenance is the largest single controllable expense in a manufacturing plant. 对一个从事制造生产的工厂或企业来说，设备维护的开销是最大的一笔独立支出并可控制的费用。With as many as 80% of all machine failures related to contamination in the oil, pro-active methods are saving industries considerable costs every year.80%的机械故障是由油品的污染所引起的，提前做好预防措施就可以节省这笔可观的开支。This booklet offers an introduction to the problems with insufficient oil cleanliness, the causes and the remedy of the problems. 这本小册子介绍了由于油品清洁度问题引起的故障，以及故障的原因和补救的方法。All the information presented is generally known and accepted. 这里所有提到的信息都广为人知并被认同。It was compiled and published by people within the company C.C. Jensen A/S. 本指南是由西西延森公司的人员编辑及出版的。We invite you to take advantage of the experience we have gathered over the past 50 years with oil maintenance within various types of industrial and marine applications. 我们真诚地邀请您参考和利用我们这50年来在船舶业以及其他各行业中积累的油品保养应用的经验。The perfect oil cleaning system will control the level of all types of contamination. 这个完美的油品清洁系统将能够控制各种类型污染的等级。For further information, we recommend that you visit www.cjc.dk or , where you can also order a CJC Oil Sampling Kit including materials and instructions for sampling your oil.如需要更详尽的内容及信息，请访问我们的网站www.cjc.dk 或 ，您同时也可以在线订购CJC油样提取工具包，其中包含如何进行油样提取的说明。Wear and tear in oil systems油系统中的磨损Any machine using oil for power transmission or lubrication will be affected by the condition of the oil.任何使用油进行动力传输或润滑的机器都会受到油品状况的影响。The oil comes into contact with all the other components in the system and should be considered the most important.油会与系统中的其它所有部件接触，因此油品应该受到最大的重视。Contamination in the oil is anything that should not be there, like solids and chemicals.任何污染物，包括固体或化学产物，都不应该出现在油品里。Mechanical Wear机械磨损Solid particles typically cause 50% of all failures and multiply by destroying the surface of even very hard metal.设备的各种失效故障中有50%是由于固体颗粒引起的，这种磨损还会因为设备元件表面被破坏而加剧，哪怕是材质非常坚硬的金属。 The most harmful particles are the ones trapped in the dynamic tolerance like in bearings (figure 1).最有害的颗粒是那些在集中在动态配合的位置上（例如轴承处）的颗粒。（图1）Fig. 1图1Roller滚子Oilgroove 油沟 1m： 1微米 5m： 5微米Force压力Source: 来源：Vsteras PetroleumKemi ABChemical Wear化学磨损Chemical contamination includes w，ater and oxidation products and certain metals (e.g. copper).化学污染物包括水份、氧化物和某些金属（例如铜）。Water typically accounts for 20% of mechanical failures. 水是最典型的化学污染物,20%的机械故障是由水所引起.It reduces the lubricity of the oil and results in corrosion and erosion leading to spalding (figure 2).水份降低了油的润滑性能，导致了部件的腐蚀和局部的碎裂。（图2）Fig. 2 图2Furthermore, it acts as a catalyst in the oxidation of the oil, just as copper does.此外，某些化学污染物在油品的氧化过程中，还充当了催化剂的角色，例如铜。Oxidation products form a sticky layer onmetal surfaces and is often referred to as varnish.氧化产物形成的粘性膜覆盖在金属的表面，常被认为是涂层。Hard particles of all sizes get caught in the sticky layer,creating a sandpaper like, grinding surface.各种尺寸的硬质颗粒集中在这种粘性膜上，会象砂纸一样磨损着金属的表面。Oil sampling油品取样The purpose of oil sampling is to achieve the highest level of machine performance and reliability at the lowest possible cost.为了在尽可能少花费的同时，使机械的性能表现和可靠性达到最高水平，我们需要先对油品取样。The initial samples serve to establish benchmarks and to identifythe machines with critical levels. 最初的油样用于建立基准和认定评估的等级。The routine sampling is done to document that goals are met and can also provide indication of abnormal wear that needs to be addressed.常规取样是用于证明（过滤的）目标已达到，同时也能在出现需要引起注意的非常规磨损时，提供警示。 The quality of analysis results depends first on correct sampling and handling of the sample, secondly on the quality of the laboratory performing the analysis.分析结论的质量首先取决于正确的取样和样本的处理，其次是实验室的分析的能力。The importance of the knowledge about where and how to take a sample is paramount and requires special attention.何处取样和如何取样至关重要，请特别注意。Where to take an oil sample何处取油品样本Referring to figure 3 derive the oil from a preferably upwards pointing pipe with continuous and ample flow to produce arepresentative sample. 参见图3，在油管的上部某点取样，这里油的流动持续且充分，可以取得具有代表性的样品。Sampling points fitted on the lower perimeter of a pipe tend to allow depositing of particles in the sampling valve.如果在油管的低处取样，会使颗粒的沉淀物进入取样阀。Fig. 3: 图3： Pipe cross section with sampling valves取样阀位置示意图（油管的横截面方向）Source: 来源： Vsteras PetroleumKemi ABCorrect 正确Wrong 错误The best sampling point is between the pump and the filter housing of an off-line filter, which is normally the worst contaminated part of the oil system. 最佳的取样点在泵和离线过滤器的过滤室之间，这里通常是整个油质系统中污染最严重的地方。A satisfying result from such a sample is the best guarantee. 如果来自污染最严重处的油样都有令人满意的测试结果，那么这将是对油系统清洁度最好的保证。If no off-line filter system is installed a vacuum type sampling pump is a valid option. 如果没有安装离线过滤系统，那么也可以使用真空取样泵。In such case the sample should be drawn 10 cm (4 inches) off the lowest part of the tank (see page 7).这种情况下，样本需要在离油箱底部10cm（4英寸）的位置抽取（见第7页）。How to take an oil sample- between the pump and the filter如何取油样在泵和过滤器之间To take an oil sample, the following is required: a 200 mL particle free glass bottle a cloth a five litre (1 1/2 US gallon), open oil container取样要求：一只容量200ml的无颗粒污染的玻璃瓶一块布一只容量5公升（1 1/2 美制加仑），开口的油品容器Please read the following instructions carefully before takingthe oil sample.在取油样之前，请仔细阅读以下介绍。Fig. 4: Oil sampling图四：提取油样Sump油箱Off-line Filter离线过滤器Steps 1-3 步骤1-3Steps 4-5 步骤4-5Step 6 步骤61. Place the oil container beneath the sampling valve2. Open and close the valve five times and leave it open.3. Flush the pipe by draining one litre (one US quart) intothe container.4. Open the sample bottle.5. Place the bottle under the oil flow without touchingthe sampling valve6. Fill the bottle approximately 80% full.7. Place the cap on the bottle immediately after takingthe sample.8. Close the sampling valve.9. All samples must be clearly marked with number, place ofsampling, date and oil type/make (see below example).1 将油品容器放在取样阀下2 开启、关闭阀5次，再使之处于开启状态3 排出1公升油到容器，以冲洗油管4 打开取样瓶5 使用取样瓶接油，不要触摸取样阀。6 将取样瓶填充至80左右7 取样完毕后，立即用瓶盖封口8 关闭取样阀9 所有的油样都必须清晰标注（数字、取样地、日期和油品类型及构成），如下图所示，日期：样品号：事件号：温度：油的品牌：油品型号：运行时间：过滤型号：过滤压力：滤芯型号：用户名称：地点：机器：备注： If certified clean sample bottles are not available you may usesample bottles that are not certified, performing the followingmethod.如果没有被鉴定过的干净的取样瓶，那么你就使用一个干净的瓶子，按如下方法操作：1-2. As above3. Empty the content into the container.4. Perform this procedure three times.Continue with points 5 to 9 as above12项，同上3清空取样容器4如此操作三次59项，同上。Samples should only be collected with the machine operatingat normal working temperature. 应该在机器正常工作的温度下收集样本。When sampling for particle counting the method is very important. 当取样是为计算颗粒时，取样的方法非常重要。Remember that you can never make a sample any better (cleaner) than the oil in the system, but it is easy to make it worse请记住，决不可能使样本比系统中的油品更好（更清洁），但使它更差（更脏）是很容易的。 using a manual vacuum pump 使用手动真空泵Follow the instructions that came with the pump kit.遵守以下泵的使用要求。The illustrations below show the CJC oil sampling kit.以下图片，展示了CJC的油品取样工具。Fig. 5: 图5：Oil sampling with a vacuum pump.用真空泵提取油样Sump 油箱Vacuum pump 真空泵Steps 1 步骤1Step 2 步骤2Step 3 步骤3Try to lower the free end of the plastic tube to one third above the bottom of the tank in the center of the tank or, if relevant, above the lowest point of the tank. 将塑胶管的自由端放到油箱底部以上约三分之一高度处（相对油箱 的最低点）Be careful not to touch the walls or the bottom of the reservoir with the tube.注意不要让管触碰到油箱壁或底部。When you have sealed the bottle, make sure that the label is filled in with all the information as per example on page 6.当你密封好取样瓶后，请确认标签已经填写完毕（如第6页图片所示）。Oil sample analysis油品样本分析As a minimum an oil analysis should include:作为油样分析，最少应包含： A particle count 颗粒数量 Water content in ppm水份含量（ppm，百万分之） Viscosity 粘性 Acidity level酸性等级If the oil additive content is of interest a spectral analysis should be included.如果需要了解油品添加剂，则需要作光谱分析。This test is best carried out by the oil supplier as they have the detailed knowledge of the initial additivation of the oil.这类测试最好能由油品的供应商执行，因为他们了解油品的原始添加剂。It is recommended that the initial tests are performed by an independent laboratory with special knowledge on lubricants.推荐：初步的测试交由具有润滑品专业知识的独立实验室进行。Fig. 6: 图6：Particle analysis颗粒物分析Source: 来源：Filtrex Services BV, Holland Filtrex Services BV,荷兰Particle counting 颗粒物计数每100ml颗粒物数量2微米3136505微米8721115微米8137Colour test filter disc滤片颜色测试I.greyI级.灰色ISO 440619/17/14Paticles identification颗粒鉴定黑色金属：70焊屑： 亮色金属：10锈：5沙粒：纤维：5合成物：5铜：51 DIV=15 MICRON1刻度=15微米ISO StandardsISO标准The ISO 4406/2000 classification of particle contents was introduced to facilitate comparisons in particle counting.ISO 4406/2000 颗粒物等级标准被引入，用于颗粒物的比较。Sudden break down in an oil system is often caused by large particles (14 m) in the oil while slower, progressive faults,e.g. wear and tear, are caused by the smaller particles(4-6 m).油质系统的突然崩溃通常是由系统中的大颗粒(14 m)引起，而缓慢的、累积性的故障，例如磨损，则是由更小的颗粒(4-6 微米)所引起This is one of the explanations why the particle reference sizes were set to 4 m, 6 m and 14 m in ISO 4406/2000. 这也是之所以在ISO 4406/2000标准中，将颗粒按4微米, 6微米和14微米分类的原因。A typical sample from a wind turbine gearbox, for example, contains in every 100 mL of oil:以风力涡轮机的齿轮箱中取得的一个典型油品样本为例，每100ml油品中含有:450,000 particles 4 micron120,000 particles 6 micron14,000 particles 14 micron450,000个颗粒4微米120,000 个颗粒 6 微米14,000 个颗粒 14 微米Fig. 7: 图7：Contamination classes according to the new ISO 4406/2000 standard.依据新ISO 4406/2000标准的污染等级。More than多于Till 最多Class等级Max：number of particles per 100ml fluid after their size rangesMax：每100毫升液体中超过其颗粒范围的颗粒数量。Introduced in the ISO classification table (on the right), this oil sample has a contamination class of 19/17/14.根据ISO标准的表格，此油样的污染物等级是19/17/14。NAS ClassesNAS 等级NAS 1628 is a American standard that translates approximatelyinto ISO Codes. NAS 1628是一个美国的标准，可以近似的转化为ISO代码。The difference is that the NAS gives a more detailed breakdown of the different particle sizes.不同之处在于NAS给出了更为细致颗粒尺寸分类。Fig. 8: 图8：NAS 1628Size 尺寸Classes NAS 1628NAS 1628等级Evaluation of particle count颗粒数量的评估The obtained ISO code is an indication of the cleanliness of the oil in the gearbox and can be verified in the contamination charts shown below.ISO代码可以标示出齿轮箱内油品清洁度，并且能在以下的污染物表格中对应查询。Fig. 9a: 图9a：Contamination guide for hydraulic and lube oil systems对于液压和润滑油质系统的污染程度说明ISO Code ISO 代码Description 描述Suitable for 适合于Very clean oil 非常清洁的油All oil systems 所有油系统Clean oil 清洁的油Servo & high pressure hydraulics 伺服或高压液压Light contaminated oil 轻度污染的油Standard hydraulic and lube oil systems 标准的液压或润滑系统New oil 新油Medium to low pressure systems 中低压系统Very contaminated oil 污染严重的油Not suitable for oil systems 不宜使用Fig. 9b: 图9b：Contamination guide for gears对于齿轮的污染程度说明ISO Code ISO代码Description 描述Suitable for 适用于Improvement Factor 改进因数Very clean oil 非常清洁的油 All systems 所有系统Clean oil 清洁的油Critical gear system 要求严格的齿轮系统 Light contaminated oil 轻度污染的油Standard gear systems 标准齿轮系统New oil 新油Non critical gear systems 要求不很严格的齿轮系统Very contaminated oil 严重污染的油Not suitable for gear systems 不适用于齿轮系统Oil sample analysis油样分析Fig. 10: 图10：Test membranes together with microscopic photographs of various contamination levels显微镜下不同污染等级的测试膜片。For every oil-filled system, a cleanliness goal should be specified. This is the basic requirement to insure reliability at the lowest possible cost.对于每个油系统，都会有一个指定的清洁度。这是以最低成本保证系统可靠性的基本要求。Frequency of analysis分析的频率In the implementation phase of a condition monitoring system, analyses must be made frequently at least every six months in order to establish a knowledge data base.在情况检测系统的执行阶段，需要经常做分析（至少每6个月1次），以建立起一个认识数据库。Every oil system should have a log where analysis results are registered, The logbook must also contain information about oil type, oil changes, break-downs, targeted ISO class code and oil analysis results.每个油质系统都应该有一个日志，用于记载分析结果。日志记录上应该包含油品类型，油品变化，故障，ISO等级以及油品分析结果。Oil cleaningmethods油品清洁方法Several oil cleaning methodsare available:几种油品的清洁方法：Fig. 11: Oil cleaning methods图11：油品的清洁方法Method 方法Cleaning action 清理作用Conventional surface filter 常规的表面型过滤器Reduce the content of solid particles.减少固体颗粒物含量Cellulose-based depth filter 纤维基的深度型过滤器Reduce the content of solid particles, water and resin. 减少固体颗粒，水份和树脂的含量。Electrostatic filters 静电过滤器Reduce the content of polar contaminants. 减少有极性的污染物的含量Centrifugal separator 离心分离器 Reduce the content of particles with a density higher than that of oil.减少密度大于油的颗粒含量Vacuum filter 真空过滤器Reduce the content of air and water. 减少空气和水份的含量All the above technologies are commercially available.以上所有的技术都在进行商业应用。The surface filter and the depth filter however, are often preferred due to their superior efficiency and economy.选择表面型过滤器和深度型过滤器，源于它们更胜一筹的效率和经济性。Both these cleaning techniques work best under constant conditions, i.e. steady flow and pressure. 在连续稳定的状态下（稳定的流量和压力），这两种过滤会达到最好的工作状态。The depth filter is often placed in a separate off-line circuit and with such stable conditions; it retains the majority of contaminants in the oil.深度型过滤器通常被安装在独立的离线回路中，并保持稳定的状态。它截留了油中的大部分污染。The surface filter could be installed in an oil cooling circuit or as a full-flow emergency filter in the pressure (upstream) line of the oil system.表面型过滤器一般被安装在油的冷却回路中，或者作为主回路中的紧急过滤器，安装在油质系统的压力回路中。Filter types过滤器类型The Depth Filter is like a maze where the oil passes through several layers of cellulose. 深度型过滤器如曲径一般，油通过它时，需要经过多层的纤维。The largest particles are retained on the outside of the element whereas the smaller particles enter the element and are retained within the filter material, ensuring a high dirt holding capacity.最大的颗粒将会被截留在滤芯的外层，而更小的颗粒将会进入滤芯，被截留在滤芯内部，这样就保证了很高的纳污容量。Using a cellulose element also enables removal of water (absorption) and oxidation residuals; resins/varnish (adsorption).使用纤维素的滤芯还能起到去除水份（吸收），氧化残留物和树脂或漆（吸收）的作用。This type of filter can also be installed in a by-pass circuit, using the pressure of the system pump.这种类型的过滤器也能被安装在旁路回路中（使用系统泵的压力）。The Surface Filters of conventional designs have relatively thin layers of filter media, allowing high flows through the element.常规设计的表面型过滤器，采用相对薄的滤材，允许大流量通过滤芯。The filter element is pleated in order to increase the surface area and reduce the pressure drop. 这种滤芯通常是褶状的，以增加表面积，减少压力损耗。The filter is capable of removing solid particles only and as it utilizes only the surface area, it has a restricted dirt holding capacity.这种过滤器只能去除固体颗粒，而且因为它只能利用表面，所以纳污容量有限。See illustrations on pages 14 & 15.请参看14&15页插图。Modern oil systems often combine the two cleaning systems, where the depth filter removes the contamination a