booklet - basics of oil analysis[1]

8/2/2019 Booklet - Basics of Oil Analysis[1]

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I t s b e t t e r t o k n o w.

BASICS OF OIL ANALYSIS

4th Edi t ion

SOUTHWEST

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MID CONTINENT

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CORPORATE OFFICE

3401 Jack Nrthrp Ave.

Hawthrne, CA 90250

800-336-3637

Analysts, Inc. 2011 www.analystsinc.cm


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1 | BASICS o oIL ANALYSIS BASICS o oIL ANALYSIS | 2

Tday, cmmercial il analysis serves a myriad industries. over the past

seven decades it has saved cuntless dllars in premature equipment ailure

and cmpany dwntime. It has becme the cus magazines, seminars, and

trade shws. And it is easily ne the mst eective and practive tls r

maintaining the physical integrity internal cmpnents. With ver 50 years

leadership and experience, Analysts has played a pineering rle in this

industrys develpment. We are prud ur legacy. Mrever, we are wrking

t create new innvatins and enhanced services in an ert t advance ur

industry and better serve ur clients in the years ahead.

Commitment to ou customes

As a sign ur cntinued cmmitment t ur custmers, we are pleased

t release the 4th editin ur Basics oil Analysis bk. This bk is

designed t help yu gain a better understanding the undamental cncepts

an il analysis prgram. It is ur hpe that all practitiners, whether nvice

r experts, can gain practical inrmatin rm this bk t imprve yur il

analysis prgram.

INTRODUCTION_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

The ith o an industy

The extensive histry il analysis makes it the ldest all cmmercial

practive-maintenance technlgies. over the past 75 years, il analysis has

helped diagnse the internal cnditins il-wetted cmpnents and their

lubricants in virtually every industry that invlves heavy machinery. While tdaysanalytical tls emply the mst advanced technlgies, early test methds

were shckingly simple. The rst diagnstic techniques merely invlved smelling

il in an attempt t detect the sur dr excess acid. other early tests

included inspecting il with the naked eye r visual signs cntaminants r

placing a sample drp n absrbent paper t detect cntaminant residue.

In 1960, Edward rgern brught a new level service t the industry by

unding Analysts, Incrprated the rst independent cmmercial labratry

t er cmplete il analysis diagnstic services t all areas business

and industry. Thus taking the rudimentary methds utilized in the eld and

incrprating mdern scientic testing t prvide critical insight r maintenance

departments acrss all industries.

A moden ea o luicant analysis

Present-day technlgy uses a cmbinatin physical and

chemical tests t mnitr lubricant and cmpnent cnditins.

These tests are established and reviewed by a number

agencies, including the Internatinal organizatin r

Standardizatin (ISo), the American Sciety r Testing and

Materials (ASTM), and the Sciety Autmtive Engineers (SAE). In additin,

a variety labratry and persnnel certicatins have emerged t ensure the

highest levels lab technician quality.


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OUTLINE FOR AN EFFECTIVE OIL ANALYSIS PROGRAM_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

1. Determine your primary objectivesoil analysis can be applied t equipment and lubricant utilizatin, maintenance

and management:

Utilization

Decrease unscheduled dwntime

Increase verall cmpnent liespan

Cntrl lube cnsumptin and il dispsal csts

Assist prduct selectin, cmparisn and vericatin

Maintenance

Identiy and measure lube cntaminatin alng with cmpnent wear r

targeted crrective actin

Reduce in-service ailures and eld repairs

Establish prper lubricant service intervals

Management

Imprve reliability, prduct quality and prductivity

Imprve cst cntrl r equipment, labr and materials

Eliminate needless inspectins r repairs

Cntrl spares and replacement csts

APPLYING OIL ANALYSIS

oil analysis is an integral part the maintenance plan r pwer generatin

and manuacturing plants, ver-the-rad trucking feets, -rad

cnstructin equipment, aircrat, rerigeratin systems, prcessing and

chemical plants. Any piece equipment that has a lubricating system is a

ptential candidate r il analysis.

A successul il analysis prgram requires an rganized and sustained

ert. N TPM (Ttal Prductive Maintenance), lean manuacturing r

Six Sigma initiative will reach its gal withut the prcesses t sustain

imprvement. Bth the user and the labratry must wrk clsely tgether

t lay the grundwrk r the prgram and achieve the desired results.


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2. Carefully consider your best choice for an oilanalysis provider

All il analysis labratries claim they are qualied. Althugh certicatins and

requirements that a qualied used-il analysis labratry must meet are nw

much mre dened than in the past, ne thing has nt changed: Yu, the il

analysis user, must chse which labratry best satises yur needs.

r example, Analysts has been eatured in numerus magazine articles,

advertisements, and ther published materials. These secnd pinins are

excellent surces reerence abut ur service. Hwever, the best guide t

chsing a labratry and srting between the many claims these cmpanies

make, is experience. Chances are, smene in yur eld is already using ne

r mre the labs yu are cnsidering. Talk with them. Theyll cnrm hw we

dene qualied.

Choose a well-estalished laoatoy

Analysts has been in cntinuus and evlving peratin since 1960 lngenugh t have develped cmplete, time-tested prcedures r purchasing,

analysis, reprting, client cntact and supprt. We er a wide selectin

sampling materials, including ur SureSample sampling cntainer, QSS

sampling valves, and ther supplies, and make sure that these materials are in

stck when yu need them. We prvide the additinal descriptive literature and

training assistance needed t enhance yur il analysis prgram.

Choose a well-equipped laoatoy

Each Analysts labratry is thrughly cmputerized, and mst ur mdern,

well-maintained instruments are autmated and directly interaced with the

labs inrmatin-management system. We adhere t published, prven testing

prcedures and use nly the highest quality chemicals. We encurage ur

clients t visit ur lab acilities t see this r themselves.

Choose a laoatoy with a well-tained, expeienced sta

Analysts service and technical persnnel are respected members the

reliability cmmunity. Mre ur sta members are STLE Certied Lubricatin

Specialists r oil Mnitring Analysts than all ur cmpetitrs cmbined! We

recgnize the specic technical requirements r yur applicatins and can

answer yur questins ully. We have an rganized apprach r establishing

yu as a client and can give yu sund, practical suggestins r vercming

any bstacle yu might encunter in establishing and maintaining yur Analysts

il analysis prgram.

Choose a laoatoy with ecognized quality contol

Analysts, Inc. has the strngest certied and registered ISo 17025 quality

prgram in cmmercial il analysis. By attaining the ISo 17025 certicatin,

Analysts demnstrates n a daily basis ur cmmitment t quality in every

aspect ur business. In additin, Ana lysts quality prgram meets the

requirements 10 CR 50, Appendix B the ederal specicatin r qualit y

prgrams in nuclear pwer plants. All ur data analysts have ne r mre the STLE CLS and oMA certicatins, and mst ur technical sta members

als hld these and ther credentials. With ur prgram dcumentatin,

training, prcedures and llw-up, Analysts is recgnized as the leader in quality

and service within the industry.

As you look at price, quality,

support and experience, dont

orget to evaluate the laboratory

instrumentation and methods.

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Examine example epots o eliale ecommendations and

easy-to-ead omat

Clearly stated results and recmmendatins are vital t the success

yur il analysis prgram. Analysts reprts are cncise and inrmative.

our recmmendatins are specic, cmplete and easy t understand.

The recmmendatins refect a real knwledge the perating and wear

characteristics the cmpnent sampled. Test results indicating the need r

a majr inspectin are duble-checked and veried prir t reprting t yu.

All ur sta data analysts and chemists are members pressinal and

technical scieties, and ur established psitin in the cmmercial il analysis

eld ensures ready access t lubricant and cmpnent manuacturers data.

Expect apid tunaound o analysis epots

Analysts, Inc. prvides an average turnarund time ne day r less r rutine

samples. over 80% the samples received are cmpleted the same day they

are received. We ntiy yu immediately i critical cnditins are detected, and

make yur reprts available nline instantly ater cmpletin. We prvide rush

handling i yu require an immediate respnse, and ater-hurs special penings

can be arranged in case emergency.

Look o specialized summay epots

T assist ur clients t manage and cntrl their il sampling prgram, we

will prvide any a series eight specially designed prgram-management

and summary reprts. These reprts cnslidate sampling activity t cmpile

inrmatin such as Critical Cnditin (Units), Cnditin Analysis Statistics,

Summarized Sampling Activity and Summarized Sample Cnditins. Thereprts are available n a mnthly basis.

Look o a ull ange o inomation management tools and options

Analysts maintains a cmprehensive website at www.analystsinc.cm. This

site als ers the ully web-based LoAMS (Lube oil Analysis Management

System), develped in respnse t tdays practive reliability management

needs. Thrugh LoAMS, yur entire il analysis prgram can be managed in

the clud. rm prgram setup t prgram administratin, LoAMS prvides

the user with easy-t-use eatures, such as reprt retrieval, equipment

management, label printing, graphing, user management, and much mre.

A samples transit time rom

sampler to lab is always the

largest part o the actual

turnaround o a sample.

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http://www.analystsinc.com/http://www.analystsinc.com/


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3. Build the foundation for your programrequently there is an assumptin that an il analysis prgram can be hurriedly

established simply by taking a ew samples and sending them t the nearest,

cheapest labratry. Nthing culd be urther rm the truth.

Sampling point suvey

Bere yu begin sampling, a necessary rst step is t identiy the systems yu

want t sample, and cllect relevant technical reerence inrmatin n thse

systems. Next, determine any histry perating r wear prblems, and the

criticality any particular system (the impact dwntime and repair upn yur

business prcess).

Selecting tests

Dierent cmbinatins physical and spectrchemical tests are used t measure

the prperties the lubricant and determine levels cntaminants and chemical

elements suspended in the lubricant. The applicatin and gals the il analysis

prgram help determine the number and type tests that shuld be perrmed.

The physical analysiscncentrates n measuring certain characteristics

the lubricant, including cntaminants and il breakdwn by-prducts, as well as

their general eect n the lubricant prperties. The spectrochemical analysis

identies and measures selected metallic elements present in the lubricant as

micrscpic particles. Test results are reprted in parts per millin (ppm) by

weight. The relative cncentratins these elements are used t mnitr wear

rates, detect cntaminants and determine additive levels.

Analysts has develped standardized packages which are cmbinatins

rutinely perrmed tests. These packages are designed t cver the general

testing needs brad industry classicatins such as pwer generatin,

manuacturing, cnstructin, mining, and ver-the-rad trucking. While these

packages meet mst prgrams needs and bjectives, yu can develp yur

wn custm test slates t meet yur prgrams gals. Analysts will assist yu

in selecting the prper cmbinatin tests prir t beginning yur sampling

prgram.

Pope sampling intevals

When beginning a rutine il analysis prgram, the usual practice is t sample

the entire grup units/cmpnents as part the criticality assessment t

establish initial baseline data and quickly spt any cmpnents with serius

prblems. once this prcess is cmplete, the client and labratry then agree

n an initial rutine-sampling interval. This interval is based n the resul ts

the preliminary wrk, cmpnent manuacturer guidelines, client maintenance

prcedures and service scheduling, and Analysts experience with similar

cmpnents and applicatins. once the prgram is ull y established, the rutine-

sampling interval may be adjusted.

obtaining a representative sample is ne the mst imprtant parts a

scheduled il analysis prgram. I a sample des nt represent the true cnditin

the lubricant and cmpnent at the time sampling, the reliability bth the

test results and their interpretatin is aected.

Once determined, routine-sampling intervals should remain as

constant as possible.

Oil Analysis labs vary as do the

tests they perorm. Choosinga lab should be based on

testing capabilities, service and

satisying your specifc needs.

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Otaining a epesentative sample

This is undubtedly ne the mst imprtant parts a scheduled il analysis

prgram. I a sample des nt represent the true cnditin the lubricant and

cmpnent at the time sampling, the reliability bth the test results and

their interpretatin is aected.

Sampling a component while it is running or within 30 minutes ater

shutdown gives the most representative sample. This ensures that wear

prducts and lubricant cntaminants are thrughly mixed with the lubricant

and that the heavier wear particles have nt settled ut.

Areas where lubricant ow is restricted or where contaminants and wear

products tend to settle or collect should be avoided as sampling points.

We recmmend the llwing sampling pints in rder preerence:

A petcck r ther sampling access installed prior t the il lter (using

Analysts QSS r similar valve)

An il-dipstick tube r ther service pening (using the SureSample

r avacuum pump)

The sump r reservir drain

The reservoir drain is oten the easiest sampling point, but it is so prone to

sampling error that we discourage it.

In special cases, samples may be taken rm lube lters. The lab shuld be

advised prir t testing i this ccurs.

once a prper sampling pint and methd is chsen r a particular

cmpnent, il samples rm that cmpnent shuld always be taken rm the

same pint with the same methd.

4. Establish consistent oil-analysis-baseline informationIn a busy peratins and maintenance schedule, n ne wants extra paperwrk

and recrd keeping. But, i an il analysis prgram is t urnish anything mre

than test data, the user must prvide supprting inrmatin n the machines,

cmpnents and lubricants in service.

Initial equipment registratin can be easily accmplished by urnishing the

labratry with a cnslidated equipment list based n yur sampling pint

survey, r by cmpleting an individual registratin rm r each sampled

system. In either case, the sampling pint ID and current perating data is sent

with each sample.

In cmpleting ur il analysis rms and sample-cntainer labels, the llwing

brie denitins are helpul:

Unit I.D. nume

A unique reerence number r an entire unctinal unit. Examples include a

cmpany asset r inventry identicatin r a vehicle serial number.

Component

The verall type il-wetted system such as engine, hydraulic, r gearbx

rm which the sample is taken. other designatins such as let, number

3, rear r an actual descriptin the cmpnents use such as an drive,

winch r swing are als needed r clear identicatin. our rms prvide

checkbxes r cmmn sampling psitins.

NoTE: In industrial applicatins the unit and cmpnent ten reer t thesame mechanical system. In this case, the descriptin the sampled system

will be recrded as the unit.


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Time since new o since last ovehaul

The perating hurs r miles since the sampled cmpartment was rst

put int service, r since the last verhaul r rebuild was perrmed. Since

nrmal wear rates change ver the lietime a cmpnent and break-in may

resemble abnrmal wear, this inrmatin is needed as an nging reerence

r interpretatin. This data may be btained directly rm an equipment r

cmpnent service meter, r rm general perating recrds.

Time since oil change

The number hurs r miles cmpnent use between the time the il was

last changed and the time the sample was taken. This inrmatin is essential t

time-based trending.

Oil type

The manuacturer, prduct name, and SAE r ISo viscsity grade r the il that

was sampled. Since a manuacturer may sell mre than ne blend the same

viscsity prduct, the cmplete name is very imprtant in determining which

testing reerence il t use.

Oil consumption o makeup oil

The amunt il added t maintain a crrect il-ll level in the sampled cmpnent.

Cmplete il changes shuld nt be reprted as makeup il r identied as new il.

A sample may nt be prcessed immediately i the client name, unit and

cmpnent identicatin, r sample date are nt prvided. I yu have sampled

a particular machine bere and d nt ensure that the unit and cmpnent

identicatins match what yu riginally prvided, testing may be delayed while

the needed inrmatin is established, r the results may nt be led crrectly

with ther samples rm that machine.

In additin t this must-prvide data r each sample, yu shuld reprt any recent

maintenance, changes in perrmance r unusual perating cnditins. I yu

sample at the same time that yu perrm ther rutine maintenance and servicing

activities, yu shuld als recrd that inrmatin and submit it with the sample.

Specic individuals shuld be assigned lng-term respnsibility r this pr tin the

prgram. I this is nt easible, then a particular department shuld be designated r

invlvement. once this respnsibility is established, a system recrd keeping and

crrect sample identicatin shuld then be develped and initiated.

Recording operating time on

oil is absolutely essential to

time-based trending the

most accurate way to pinpoint

abnormal wear conditions.

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5. Use the lab interpretation of the test data properlyour lab interpretatin typically separates the verall cmpnent and fuid

cnditin as related t the relative severity cntaminatin and wearint

ur main classicatins.

NOrMAL

Physical prperties the fuid are within acceptable limits, and n signs

excessive cntaminatin r wear are present.

MONITOr

Specic test results are utside acceptable ranges, but are nt yet serius

enugh t cnrm abnrmal cnditins r justiy diagnstic actin. Cautin is

advised. The initial stages an abnrmality ten shw the same pattern

results as temprary cnditins, such as extended usage r verlading.

AbNOrMAL

Lubricant physical prperties, cntaminatin, and/r cmpnent wear is clearly

unsatisactry, but nt critical. A cnrming resample shuld be submitted.

Additinal diagnstic prcedures may be needed t cnrm each cnditin.

Crrective actins are necessary t prevent reductin service lie r verall

lss perrmance.

CrITICAL

Lubricant physical prperties, cntaminatin and/r cmpnent wear is clearly

serius enugh t require immediate diagnstic and crrective actin t prevent

majr lng-term lss perrmance r cmpnent ailure. Increases in perating

hazard are likely. Shrt-term lss perrmance may already be present. Large-

scale repairs may be required. Yu may be advised t remve the unit/cmpnent

rm service until a cnrming resample is tested and ther diagnstics cnrm

that repairs are necessary.

These assessments are relative and are assigned using both trend

analysis and condemning limits.

When trend analysis is used (primarily in the case wear elements), threshld

values are develped t identiy the bundary areas between nrmal and

abnrmal results. r wear metals, these threshld values vary r dierent types

cmpnent, but are usually specic and cnsistent r each individual mdel

a given applicatin. The values d nt prvide sharp lines nrmal/abnrmal

interpretatins; instead, they indicate ranges increased likelihd that a prblem

has develped t a par ticular pint. Generally, the lubricant and cmpnent

cnditin can be cnsidered nrmal as lng as the wear, cntaminatin and

lubricant deteriratin levels remain within the established nrmal ranges.

Regardless the threshld values, any sharp increase in wear metals r majr

shit in physical prperties can signal the beginning prblems. Therere, the

threshld values cant be used as g/n-g criteria. A great deal cautin,

judgment, experience and client technical input must be used in applying

threshld values prperly.

Clients are cntacted immediately by telephne n all samples where ur

interpretatin detects a critical cnditin. urther, email cpies all critical r

abnrmal samples are dispatched upn cmpletin ur evaluatin. on these

reprts the lab will recmmend specic maintenance actins designed t crrect

nt nly the indicated prblems but als the causes these prblems.

Each reprt shuld be remved as sn as pssible r actin items. Analysis

cpies shuld be attached t wrk rders r instructins. Access t electrnic

versins the reprt(s) shuld be given t apprpriate persnnel.


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6. Provide the lab with proper feedbackThe interpretatin guidelines accuracy is veried by cmparing the labs

maintenance recmmendatins with actual cnditins cnrmed by inspectin.

In this way, the test interpretatins are cntinually rened by practical experience.

eedback rm the client includes:

Abnrmal lubricant r cmpnent cnditins that yu suspect are present

The ndings any inspectin perrmed as a result il analysis prgramrecmmendatins

Abnrmal machine cnditins discvered that were nt previusly indicated

by il analysis

Nticatin servicing and/r maintenance perrmed

Inrmatin cncerning perating envirnment r equipment

applicatin changes

These items may be nted n the sample inrmatin rm, recrded in LoAMS.

I the eedback is sent separately, please prvide the cmpnent reerence

number (n reprt, upper right crner, third line belw the Status Was blck).

7. Measure cost ef fectivenessThe ecnmic gals reducing perating expenses and increasing prt

margins have nt changed since Analysts was unded. Rutine il analysis

will help yu achieve substantial savings in maintenance and repair csts. The

prgram perates much like a medical checkup; i prblems are detected, they

can be crrected bere they develp int serius and hazardus cnditins

that are cstly t repair. When samples are reprted nrmal, then the immediate

value il analysis is a persnal peace mind rather than an ecnmic

return. As the number sampled pieces equipment increases, the nancial

benet il analysis als increases. Greater equipment availability and reliability

means mre prductin, less dwntime and increased prts.

The imprtance tracking the savings generated by yur il analysis prgram

cannt be ver emphasized. Manpwer, parts and tl expenses will all be

aected. Hwever, because a well-run il analysis prgram is deeply integrated

int a clients verall maintenance prgram, management must establish a

strng platrm results measurement and dcumentatin t see il analysissunique cntributin t prtability.

One simple way o measuring

program eectiveness is to

trend the number and type o

abnormal or critical conditions in

your machines over time.

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Oil analysis is both predictive and

proactive and is probably the

most cost-eective maintenancetechnique available.

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Althugh sme benets il analysis may nt shw clearly n the bttm line

because they represent cnditins that were prevented, many the ecnmic

savings rm il analysis can be calculated by cmparing:

Parts and labr expenses r cmpnent repair, verhaul, r replacement

Lss revenue during dwntime

Reductin in cnsumable items, such as lubricants r uels

Increase in prductivity

THE FIVE KEYS TO SUCCESSFUL OIL ANALYSISAs with any diagnstic methd, the user must share in the respnsibility r

success when using this well-established and widely accepted practive-

maintenance tl. T achieve verall success r yur il analys is prgram, use

these prven keys:

1. Clealy defned client goals and pogam equiements ensure

that the tests perrmed t the applicatin and that the service is being ullyutilized n an nging basis.

2. repesentative samples ensure that the true cnditin the lubricant

and cmpnent can be determined by reliable, accurate testing.

3. Fequent la/client contact prmtes accurate interpretatin and

leads t increased client cndence and interest in maintaining an active il

analysis prgram.

4. Complete sample inomation speeds prcessing and increases the

Data Analysts ability t ully interpret the test results.

5. Pompt epot eview ensures that abnrmal r critical cnditins are

recgnized and acted n in time t prevent damage r prductin lss.


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TESTS AND THEIR SIGNIFICANCE_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Withut a wrking knwledge il analysis tests and their signicance, the user

may be uncertain abut the value the service and hw each test interrelates

with the thers t prvide a useul, accurate picture internal-cmpnent

and lubricant cnditins. The llwing inrmatin is prvided as a general

rientatin t what Analysts cnsiders are the mst imprtant il analysis tests

r industrial and nnindustrial applicatins.

SPECTROCHEMICAL ANALYSISSelected metallic elements present as disslved slids and micrscpic

particles suspended in the fuid t be analyzed are identied and measured in

parts per millin by weight. The analyzed elements are gruped int three main

categries:

1. Wear MetalsRelative mtin between lubricated parts is always accmpanied by rictin

between the ppsing part suraces. Despite the act that these suraces are

usually cated with an il lm, rictin wears them away. Sme the particles

prduced as the parts wear are small enugh t remain suspended in the

circulating il. Since these wear prducts are cmpsed the same materials

as the suraces rm which they riginated, the level each wear metal

remaining in the used il indicates the relative wear rate the lubricated parts.

Five of the most common types of wear are:

Adhesive / ruing Wea

This type wear ccurs when the il lm des nt separate the rughest pints

the ppsing mving-part suraces, and they begin t tuch each ther.

Adhesive wear ccurs nrmally during bth break-in and rutine service as

the parts wear slightly t maintain alignment. I severe adhesin ccurs due t

lad, speed r temperature cnditins, scung and scring will result. Metal

may be trn the part suraces r transerred rm ne part t anther and

eventual seizure the aected parts is likely. In nrmal service, adhesive wear

is cntrlled with antiwear additives, which bnd t lubricated suraces and

reduce direct part-t-part cntact.

Aasive WeaAbrasive wear is a cutting r etching actin caused when either circulating hard

particles r hard-surace prjectins wear away ster suraces. Surces

abrasive particles identied by il analysis include cntaminants such as dirt

entering a cmpnent il system and metal particles rmed during wear.

Fatigue Wea

atigue wear ccurs when cyclic r repeated lad stresses cause cracking,

spalling, and pitting the cmpnent part suraces. This type wear is mre

cmmnly assciated with ball/rller element bearings and gears where the part

suraces rll past each ther.


13/20


Coosive (Chemical) Wea

Crrsive r chemical wear results when chemical reactins cause crrsin

r xidatin part suraces and part mvement r fuid pressure disldges

material rm this surace layer. This type wear is assciated with rust-

prmting cnditins, crrsive cntaminants and excessively high levels

chemically active additives.

Cavitation Wea

Cavitatin wear ccurs when metal is remved rm parts by the shck

impact cllapsing cavitatin bubbles n the part suraces. Cavitatin itsel

is assciated with partial vacuums rmed in a liquid by sudden changes in

pressure and may be caused by vibratin, reduced r uneven liquid fw and

ther actrs invlving particular cmpnent-part shapes and mvements.

2. ContaminantsDepending upn the circumstances, many dierent substances may be classied

as cntaminants. Silicn, in the rm silicn dixide (sand), is ne the mst

cmmn cntaminants mnitred with spectrchemical analysis. Similarly,

grease cntaminatin in an il system may be indicated by increases in aluminum

r barium i the grease cntains metallic saps. Althugh the term cntaminatin

is cmmnly assciated with substances entering a cmpnents il system rm

an utside surce, wear metals themselves are als a rm cntaminant.

3. Additives

Additives are chemical cmpunds added t ils, uels, and clants t impart

specic benecial prperties t the nished prducts (examples include:

Anti-wear, anti-xidant, detergency, discrepancy). Additives create new fuid

prperties, enhance prperties already present and reduce the rate at which

undesirable changes take place in a fuid during service.

WEAR METALS AND CONTAMINANTS

SILICON Silicn is typically assciated with dirt cntaminatin.

This cntaminatin can result rm any cnditin that

allws dirt t enter a cmpnent il system.

other surces silicn include seals, il and clant

additives and greases.

IRON allying

element r cast

metal

Reciprocating engine: Gears and shats; blck; cylinder

liners; valve train; cnnecting rds, rings and il pump;

sme bearings; sme pistns; sme accessry systems.

Turbine engine: Gears and shats; bearings;

pumps; husings.

Transmission: Gears and shats; bearings; brakes and

disks; pumps and shit spls; PTo; husing.

Torque converter: Shats; bearings; sme husings.

Dierential: Shats and gears; bearings; husing.

Transaxle/fnal drive/reduction gearbox: Gears and

shats; bearings; husing.

Hydraulic: Rtrs, vanes, pistns, and rds; husing and

bres; gears and shats; valves.

Reciprocating and rotary compressors: Gears and

shats; case; valves; cylinder liners; crssheads; ringsand screws r turbines; bearings; sme il-cler tubing.


14/20


COPPER

allying element

Reciprocating engine: Bearings; wrist pin and valve-

train bushings; ther bushings and thrust washers; il-

cler tubing. Als may be present as an il additive r a

crssver cntaminant rm a leaking transmissin seal.

Turbine engine: Sme main and accessry bearing

retainers; bushings and nuts; sme il-cntrl valves.

Transmission: Discs; bearings; bushings and thrustwashers; il-cler tubing.

Torque converter: Retainers and separatrs.

Dierential: Bearings; bushings, retainers,

and thrust washers.

Final drive/reduction gearbox: Bearings; bushings,

retainers, and thrust washers; il-cler tubing.

Transaxle/fnal drive/reduction gearbox: Gears andshats; bearings; husing.

Hydraulic: Bearings and bushings; swash plate cups;

valves; sme pistns; sme pump cylinders;

il-cler tubing.

Reciprocating and rotary compressors: Bearings;

bushings, thrust washers and retainers; il-cler tubing.

ALUMINUM

allying element

r cast metal

All components: Aluminum xides present in the

envirnment, typically assciated with silicn (dirt)

cntaminatin.

Reciprocating engine: Pistns; bearings; bushings;

blcks, main and accessry cases and husings; sme

il-cler tubing.

Turbine engine: Main and accessry case, husings;sme retainers; seals; bafes.

Transmission: Sme cases; bushings and retainers.

Torque converter: Impellers.

Final drive/reduction gearbox: Bearings; bushings,

retainers, and thrust washers; il-cler tubing.

Dierential: Bushings and thrust washers.

Final drive/reduction gearbox: Bushings and thrust

washers.

Hydraulic: Sme pump husings.

Reciprocating and rotary compressors: Case;

impellers, sme pistns and crssheads; retainers.


15/20


CHROMIUM

allying element

r plating

Reciprocating engines: Liners and rings; shats; valve train.

Turbine engine: Bearings; shats and gears; seals.

Geared components (general): Bearings; shats; seals.

Hydraulic: Rds; valves.

Reciprocating and rotary compressors: Liners andrings; shats; valve train.

LEAD & TIN

ally r fashing

Reciprocating engines: Bearings; sme pistns,

bushings and thrust washers.

Final drive/reduction gearbox: Bearings; shats; seals.

Hydraulic: Pump thrust plate; bushings.

Reciprocating and rotary compressors:

Bearings; bushings.

Lead may still be ound (rarely) in industrial paints and primers.

Tin may be present as an oil additive, usually in conjunction with

lubricants containing molybdenum compounds.

NICKEL

allying element

r plating

Reciprocating engines: Gears and shats;

valve train; bearings.

Turbine engine: Gears and shats; bearings.

Geared components (general):

Gears and shats; bearings.

Hydraulic: Gears and shats, bearings.

SILVER plating;

tracer

General: Sme bearings and bushings;

il cler slder; seals.

Silver is also occasionally used as a physical tracer to indicate that

wear has progressed to a certain point. In this application, silver is

either plated directly onto a part surace or incorporated into a layer

under the surace. The wear condition o the part can then be related

to the amount o the tracer deposited in the oil. This usage is most

oten ound in aerospace applications.

MOLYBDENUM

ally r fashing

General: Typically und nly in certain aerspace and

heavy-duty cmmercial r industrial steels. May als be

present in uels as heavy crude residual material.

MAGNESIUM

allying element

General: Cases and husings.

TITANIUM

allying element

General: Sme shats, bearings, and gears. Typically

und nly in certain aerspace and heavy-duty

cmmercial r industrial steels.

ANTIMONY

allying element

General: Certain types jurnal-bearing verlays.

ZINC allying

element

General: Brass ttings (with cpper);

galvanized suraces.

VANADIUM

allying element

General: Typically und nly in certain aerspace and

heavy-duty cmmercial r industrial steels. May als be

present in uels as heavy crude residual material.


16/20


ADDITIVESMst mdern lubricants and clants cntain rgan-metallic il additives.

Sme these additives are rmed rm cmpunds ne r mre the

same chemical elements used in cmpnent parts.

MOLYBDENUM General: Extreme pressure additive r slid lubricant in

specialty ils and greases; crrsin inhibitr in sme

cnventinal clants r supplemental additives.

MAGNESIUM General: Detergent, dispersant, alkalinity increaser.

SODIUM General: Crrsin inhibitr in ils and clants.

BORON General: Detergent, dispersant; anti-xidant in ils

and clants.

BARIUM General: Crrsin and rust inhibitrs; detergent;

anti-smke additive in uels.

PHOSPHORUS General: Anti-wear; cmbustin chamber depsit

reducer; crrsin inhibitr in clants.

POTASSIUM General: Crrsin inhibitr; trace element in uels;

als und as a mineral salt in sea water

(marine cling systems).

CALCIUM General: Detergent, dispersant, alkalinity increaser.

ZINC General: Anti-wear, anti-xidant, crrsin inhib itr.

PHYSICAL ANALYSISViscosity

Viscsity is a lubricants internal resistance t fw at a given temperature in

relatin t time, and is cnsidered t be the single mst imprtant physical

prperty a lubricant. Changes in viscsity indicate imprper servicing,

dilutin, cntaminatin r lubricant breakdwn in service. Viscsity is mstcmmnly determined with a kinematic methd and the results are reprted in

centistkes (cSt)*. In additin t the viscsity result, the crankcase il viscsity

class an engine lubricant may als be expressed as an SAE Grade.

*1 Centistoke (cSt)= 1 square millimeter per second

Wate

The presence water in a nn-water-base fuid indicates cntaminatin rm

an utside surce r rm cndensatin. Excessive levels water prmte

lubricant breakdwn and cmpnent part crrsin. Results are reprted in

percent (%) vlume. Water cntaminatin can be assessed with the crackle

test. In certain cmpnents and applicatins where water cntaminatin must

be kept extremely lw, the Karl ischer titratin methd is used t measure and

reprt water cntent in parts per millin (ppm).


17/20


Fuel Soot y LEM

LEM is the acrnym r Light Extinctin Measurement, an Analysts, Inc.

patented prcess t determine uel st. LEM measures the uel st dispersed

in the il diesel engines. This is an indicatin

the cmbustin eciency the engine. An

excessive cncentratin st prmtes il

gelling and sludge in the engine, leading t

pr il circulatin. It is aected by uel-injectreciency, injectr timing, integrity the ring-

pistn seal, il cnsumptin and the lad n the engine. Results are reprted in

weight percent (%). LEM is the mst ecient and accurate methd t measure

uel st, widely specied by oEMs as the preerred measurement methd.

Fuel Dilution

uel dilutin indicates the relative amunt unburned diesel uel r gasline

present in an engine lubricant. This dilutin is assciated with imprperly

adjusted r malunctining uel system assemblies. Excessive uel dilutin

lwers lubricant lad-carrying capacities, prmtes lubricant breakdwn

and increases the risk re r explsin. uel dilutin is determined by gas

chrmatgraphy and is reprted in percent (%) vlume.

Glycol

Psitive test results indicate the presence ethylene glycl, mst cmmnly

assciated with engine-cling system leaks. Glycl cntaminatin prmtes

wear, crrsin, sludging, and lubricant breakdwn. I the analysis indicates that

clant additives r water cntaminatin is present in the il sample, additinal

chemical tests are used t cnrm ethylene glycl cntaminatin.

Inaed Analysis

When an rganic cmpund, such as lubricating il, is expsed t inrared light, the

substances present in the cmpund will absrb the light at specic wavelengths.

The amunt absrbance at a particular wavelength is related t bth the type

and quantity absrbing material. In this way, certain cntaminants and physical

changes in the lubricant can be directly measured as a mlecular spectrum. Glycl

(clant) cntaminatin, sulates, acid and base changes, and certain additives

may als be detected, alng with an extremely wide range rganic cmpunds.Inrared analysis is mst requently used in il analysis t mnitr:

Fuel Soot

The amunt uel st carbn suspended in the engine lubricant. Higher

values indicate reduced cmbustin eciency due t cnditins such as air

intake r exhaust restrictins, injectr malunctins r excessive idling. Test

results are reprted n an absrbance scale.

Oxidation

The chemical incrpratin xygen int and subsequent lss lubricant

perrmance due t aging, adverse r abnrmal perating cnditins r

internal verheating. Test results are reprted n an absrbance scale.

Nitration

The rganic nitrates rmed when cmbustin by-prducts enter the engine

il during nrmal service r as a result abnrmal blw-by past the

cmpressin rings. Test results are reprted n an absrbance scale.

Water

Water cntaminatin prduces a characteristic peak in mst ils, which can

be easily measured. Test results are reprted in % vlume.


18/20


Neutalization Nume

Bth the acid cntent and the alkaline cntent a lubricant may be measured and

expressed as a neutralizatin number btained rm a wet chemical titratin:

Acid Number (AN, TAN)

Measures the ttal amunt acidic material present in the lubricant; multiple

methds have been develped t perrm this test. Generally, an increase

in AN abve that the new prduct indicates il xidatin, r mixing with a

mre acidic prduct r cntaminant. The results are expressed as a numeric

value crrespnding t the amunt the alkaline chemical ptassium

hydrxide required t neutralize the acid per ne gram sample.

Base Number (BN, TBN)

Measures the ttal alkaline cntent present in the lubricant; multiple methds

have been develped t perrm this test. Many the additives used in engine

ils cntain alkaline (basic) materials intended t neutralize the acid-rming

prcesses aging and uel cmbustin. A relatively high BN is assciated

with increased prtectin against ring and cylinder liner crrsin, and damage

t yellw metals, such as cpper and brnze. Abnrmal decreases in BN

indicate a reduced acid-neutralizing capacity and/r a depleted additive

package. The test rst determines the amunt acid required t neutralize

the alkaline cntent the sample. The nal result is then expressed as an

equivalent amunt alkaline ptassium hydrxide per gram sample.

Paticle Counting

This test uses instruments with special detectrs which cunt and size particles

present in the fuid. Results are reprted as numbers particles in a specic

size range per a given vlume sample.

Analysts uses tw dierent methds t perrm the particle cunt: the pre

blckage/fw decay methd, and the APC (autmated particle cunt), a laser-

based methd. Each has particular strengths and apprpriate applicatins.

r these methds, three size ranges represent the current ISo 4406 standard:

>4 micrns, >6 micrns and >14 micrns. Three additinal ranges (>21 micrns,

>38 micrns, and >70 micrns) cmplete the cunt where detailed sizing is

required by a particular standard r custmer requirement.

Results rm the particle cunt are then used t indicate fuid cleanliness via

ISo classicatin cdes. The ISo Class cde is expressed as three separate

numbers (r example, 20/15/12). The rst number represents the relative

cntaminatin level rm the rst size range, and the secnd and third rangesare similarly calculated. Abnrmal particle cntaminatin levels are assciated

with increased wear, peratinal prblems with clse tlerance cmpnents,

fuid cntaminatin r degradatin and lss lter eciency.


19/20


Particle Counting Chart: Feogaphy

errgraphy is an analytical technique in which wear metals and cntaminant

particles are magnetically separated rm a lubricant and arranged accrding t size

and cmpsitin r urther examinatin. It is widely used in il analysis t determine

cmpnent cnditin thrugh direct examinatin wear metal particles.

There are three stages in a cmplete errgraphic analysis: (1) direct reading

(DR) errgraphy, (2) analytical errgraphy and (3) the errgram interpretatin

and reprt.

DR errgraphy precipitates the wear particles rm a sample and electrnically

determines the quantity large (ver 5 micrns) and small (1 t 2 micrns)

particles present in the sample. Wear calculatins rm these results indicate the

rate, intensity and severity wear ccurring in the sampled machine. In cases

where the DR errgraphy wear trends indicate an abnrmal r critical wear

cnditin, analytical errgraphy can reveal the specic wear type and prbable

surce the wear cnditin.

Analytical errgraphy uses the errgraph luid Analyzer t cncentrate n

direct micrscpic evaluatin the wear particles. A errgram slide is prepared

by drawing the il sample acrss a transparent glass r plastic plate in the

presence a strng magnetic eld. An experienced evaluatr then examines

the errgram t determine the cmpsitin and surces the particles and the

type wear present.

An analytical errgraphy reprt includes specic type and quantity

classicatins the metallic and nn-metallic debris present n the slide, a clr

phtmicrgraph the errgram, an assessment the sampled machines

verall-wear status and a detailed interpretatin the errgraphy results.

ISO CODE PartIClES/1m

30 10,000,000

29 5,000,000

28 2,500,000

27 1,300,000

26 640,000

25 320,00024 160,000

23 80,000

22 40,000

21 20,000

20 10,000

19 5,000

18 2,500

17 1,300

16 640

15 320

14 16013 80

12 40

11 20

10 10

9 5

8 2.5

7 1.3

6 0.64

5 0.32

4 0.16

3 0.082 0.04

1 0.02

0.9 0.01

0.8 0.005

0.7 0.0025

PartIClE COUNt PartIClE DIStrIBUtION

Old 4402ranges

> 2

> 5

> 15

> 25

> 50

> 100

> 4

> 6

> 14

> 21

> 38

> 70

> 4 to >70

> 6 to >70

> 14 to >70

31167

6650

316

= ISO 22/20/15

24517

6334

269

41

4

2

New 11171ranges

Total of ranges:RawCount

Changes in particle cunting calibratin and redened reprting

size ranges have cncerned many il analysis users because

the pssible eects n histrical trends and cleanliness target

guidelines. The new ranges have been chsen t maintain

cleanliness target pints and minimize the eect n cmparing

the current values t the testing histry. We all benet rm this

change: imprved instrument accuracy and repeatability means

superir quality results.

The ISo 4406 cde table is still in use, nly it nw reerences

the new ISo 11171 size ranges. Thi s table shws hw the

Cntaminatin Class reerence chart supprts bth sets

particle cunt ranges. The particle cunt results are reprted as

three cde numbers separated by a /, r example, 22/20/16.

The rst cde number crrespnds t ttal particles greater than

4 (r 2), the secnd number crrespnds t ttal particles

greater than 6 (r 5), and the third t ttal particles greater than14 (r 15). The cde is btained by crss-reerencing the chart.

Althugh the results themselves shit slightly in the new system,

n signicant shit in ISo cde number ccurs due t the changes

in the autmated particle cunter calibratin methd.


20/20


QSA

Analysts has develped an innvative test Quantitative Spectrphtmetric

Analysis (QSA) t accurately determine a used lubricants likelihd t

prmte harmul sludge and varnish build-up. Based n the lubricant type

and the applicatin, the basic QSA rating allws a trained diagnstician t

determine the presence r likelihd internal sludge and varnish build-up.

There are numerus types insluble cntaminants und in lubricating

systems. Insluble cntaminants are thse materials that will nt disslve in

the il. The tw mst general classicatins insluble cntaminants are hard

cntaminants, such as dirt, debris and wear particles, and st cntaminants,

cmpsed the varius il degradatin by-prducts.

Varnish riginates rm these st cntaminants. It is a thin, insluble lm that

ver time depsits thrughut the internal suraces a lubricatin system.

The degradatin prcess accelerates as the lubricant underges cntinued

expsure t air, water, and high temperatures. The presence varnish in

hydraulic and lubricatin systems causes many serius prblems, including

but nt limited t the sticking varnish-cated cntrl valves. Als, nce the

varnish has rmed, it takes a majr investment in time and mney t clean up

an aected system.

Specialty Testing

Test slates r certain industrial systems, greases, uels, clants r ther

special investigatins, ten include nn-rutine r ASTM specicatin tests. A

cmprehensive verview these tests can be viewed n Analysts, Incs website

at: www.analystsinc.cm. our ully equipped labratries give us the widest

pssible testing capabilities, and we have specially designed analysis prgrams

r certain applicatins and fuids. Please cntact us r detailed inrmatin

related t yur specic needs. A list ur acilities and cntact inrmatin can

be und n the back cver.

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

NoTES
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booklet - basics of oil analysis[1]

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