Documentos de Académico
Documentos de Profesional
Documentos de Cultura
ANALISIS Y MONITOREO DE
LUBRICANTES COMO ESTRATEGIA DE
CONFIABILIDAD
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129
EL ACEITE NO ES UN VINO
El aceite se oxida
( envejece)
El aceite se
contamina.
Los aditivos se
degradan
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9Nunca se deteriore
9Resista la oxidacin
9Resista el agua
9Resista la contaminacin
9Sea fcil de conseguir
9Sea fcil de aplicar
9Nunca se cambie
9Sea econmico
9No Contamine
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Aceite oxidado.
Picado
destructivo
Cavitacin
Reparar
Reemplazar
Rebabas
Desgaste
abrasivo
Reconstruir
Remover
Ruido
Alta
temperatura
Aceite
equivocado
Desbalance
Polvo y partculas
Contaminacin
por aire
Conclusin: Repeticin
de los problemas
Desalineamiento
Agua
Calor
Humedad
Productos
Qumicos
Est fro
Esta alineado y balanceado.
Esta bien lubricado.
Conclusin: problem a
eliminado
Derechos Reservados, Mxico 2003 Tomado de NORIA LTD
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Inicio de
falla
Deteccin
de la falla
Estrategia
Correctiva
Estrategia
Proactiva
Estrategia
Preventiva
Ocurrencia
de falla
Tiempo
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133
Aire
Lubricante
Degradado
Otros,
Combustible,
anticongelante
Desbalanceoyy
Desbalanceo
Desalineacin
Desalineacin
Defecto
Defectoen
en
Materiales
Materiales
Condiciones
Condicionesde
de
operacin
operacinfuera
fuera
de
dediseo
diseo
Otros
Otros
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134
Lubricante inadecuado
Practicas de lubricacin inapropiadas
Extensin en exceso de la vida til del
lubricante.
Contaminacin del lubricante
Aplicaciones especiales en
circunstancias extremas o difciles.
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Aceite nuevo
Aceite usado
Viscosidad - V1
Viscosidad V2
Acidez Ac1
Acidez Ac2
Aditivos Ad1
Aditivos Ad2
Partculas Pa1
Partculas Pa2
Agua Ag1
Agua Ag2
Metales M1
Metales M2
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136
PRINCIPALES FUENTES DE
CONTAMINACIN
1) Partculas
provenientes de la
construccin y
componentes de la
mquina
3) Ingreso de partculas
externas:
Respiraderos
Sellos
4) Contaminantes
Introducidos en el
mantenimiento:
2) Componentes
generados:
Ensamble
Ensamble y
desensamble
Operacin normal
Aceite
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Los rodamientos podran tener una vida infinita cuando las partculas
ms grandes que la pelcula lubricante sean
removidasSKF
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138
Noria Latinoamericana
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139
TECNICO
Analizar la condicin del lubricante
Analizar el origen y nivel de contaminantes
Analizar la condicin del equipo
ECONOMICO
Establecer medidas preventivas y correctivas
en mantenimiento
Establecer informacin objetiva para
documentar y proyectar ahorros.
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DEGRADACION (irreversible)
CONTAMINACION (* reversible)
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Aceites de
motor
Aceites
Industriales
Aceites industriales en
ambientes severos
+ 20 %
+ 10 %
+7%
Precaucin
( superior)
+ 20 %
+5%
+4%
Crtico
( inferior)
-5%
-5%
-5 %
Precaucin
( inferior)
- 10 %
- 10 %
- 10 %
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143
EFECTOS DE LA TEMPERATURA EN
LUBRICACIN.
Alta temperatura
Acorta la vida del lubricante.
Se incrementa la frecuencia de lubricacin.
Cada 10 C de incremento de temperatura en un equipo sobre la de diseo,
reduce la vida til del lubricante a la mitad.
Condiciones normales de operacin en lubricacin: 50 a 60 C
Operaciones entre 60 y 80 C, incrementan la frecuencia de relubricacin en
un equipo y se deber considerar la aplicacin de un lubricante sinttico.
Por arriba de 80C se deber aplicar un lubricante sinttico.
Baja temperatura
Formacin de slidos (ceras) por debajo de 15C.
Se incrementa la viscosidad.
Considere el uso de lubricantes sintticos
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Por
Descomposicin
Por Separacin
Se rompen molecularmente
Por Hidrlisis (ataque del agua)
Asentamiento y precipitacin
En Filtracin
Evaporacin y Centrifugacin
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En sitio
En laboratorio externo, resultados va e-mail
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Cambio de la
viscosidad
(incremento)
Formacin de
lacas y lodos en
depsitos.
Olor a quemado
Oscurecimiento
del aceite
Incremento de la
acidez (TAN)
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152
Lodos, espesamiento,
barniz
Espuma y aire
Reduce la resistencia
de pelcula, desgaste
Reduce las
propiedades aislantes
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153
LMITES DE CONTAMINACIN
CON AGUA
Existen diversos criterios rangos de peligrosidad para la
contaminacin con agua, los siguientes son guas
establecidos por estndares internacionales, sin embargo se
sugiere consultar con su fabricante:
Hidrulicos y Turbinas : 200 700 ppm ( 0.02 0.07 % )
Engranajes y Circulacin : 200 1000 ppm ( 0.02 - 0.10 % )
Transformadores : 30 50 ppm ( 0.003 0.005 % )
Aceites de motor : 1000 2000 ppm ( 0.1 0.2 % )
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157
METALES DE DESGASTE
El anlisis de los metales de
desgaste proporciona una valiosa
ayuda para identificar el origen del
desgaste y su severidad.
Cada elemento de una mquina
tiene una metalurgia especfica.
Se recomienda obtener los lmites
de metales de desgaste
recomendados en el aceite con el
fabricante.
Se deben de establecer limites de
juicio para identificar problemas
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158
ANLISIS ESPECTROMTRICO.
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160
PARTCULAS Y DESGASTE
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Polvo de talco 10
micrones
1,000,000 micrones
igual a 1 metro
Glbulo Blanco 20
micrones
Cabello humano
80 micrones
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163
CARGA
1) Ingreso de partculas
CARGA
CARGA
CARGA
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165
Los rodamientos podran tener una vida infinita cuando las partculas
ms grandes que la pelcula lubricante sean
removidasSKF
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Contaminacin...
80%
2%
Partes defectuosas,
errores humanos)
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169
SUCIEDAD EN UN SISTEMA
El trmino limpieza de un lubricante, est basados en
el nmero y tamao de las partculas presentes en un
sistema.
Las partculas en tamao, se expresan en micrones
Las partculas en cantidad se expresan en partes por
milln (ppm).
La norma ISO 4406 establece rangos de valores crticos
entre la cantidad y tamao de partculas presentes en
un sistema.
El tamao de las partculas que provocan los mayores
daos fluctan entre 4, 6 y 14 micrones.
Aplicando la norma ISO 4406, los usuarios de
maquinaria pueden establecer y medir los limites
permisibles de partculas en un sistema, para
compararlos con los niveles establecidos por los
fabricantes del equipo.
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RANGOS
R / R/ R
4
14
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Ejemplo
ISO 18 / 16 / 13
CONTEO DE PARTICULAS
Ejemplo de conteo ( aprox 1 ppm)
Conteo
Ta mao e n
Micrones
1
2
5
10
15
20
50
75
100
pa rtculas > e n
tamao-ml
1752
1396
517
144
55
25
1.3
0.27
0.08
LIMITE
MENOR
0.01
0.02
0.04
0.08
0.16
0.32
0.64
1.3
2.5
5
10
20
40
80
160
320
640
1,300
2,500
5,000
10,000
20,000
40,000
80,000
LIMITE
MAYOR
0.02
0.04
0.08
0.16
0.32
0.64
1.3
2.5
5
10
20
40
80
160
320
640
1,300
2,500
5,000
10,000
20,000
40,000
80,000
160,000
*
Aceites
nuevos
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Aceite
nuevo
Aceite nuevo
mas
contaminantes
internos
Aceite con
Filtrado
convencional
Aceite con
Filtracin
Adecuada (alta
eficiencia)
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Aceite
nuevo
22/20/18
Aceite con
Filtrado
convencional
20/18/16
Aceite con
Filtracin de alta
eficiencia
14/12/9
23/22/20
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12/9
Hidrulicos
Muy
limpio
14/11
16/13
Limpio
Turbinas
Rodamientos
antifriccin
Chumaceras
Muy
limpio
24/21 26/23
Sucio
Sucio
Sucio
Limpio
Muy
limpio
22/19
Limpio
Limpio
Muy Limpio
limpio
Muy
limpio
20/17
Sucio
Muy
limpio
Engranes
Motores
18/15
Sucio
Limpio
Sucio
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Comentarios:
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Comentarios:
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Mantenga sus
lubricantes:
Limpios, Secos y
Frios
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Diagnstico
Fe
Cr
Al
Cu
Visc.
ppm
15
10
5
30
150
Diagnstico
Estado del aceite
Estado de la
mquina
Contaminacin
Informe a la
gerencia,
Estudio de
costos
Toma de
medidas
preventivas
Reporte de
tendencias
Establezca lmites
Anlisis estadstico
Compare con
estndares
Analice las
tendencias
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180