Brief introduction to oil analysis

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By the end of this presentation you will be ableISO cleanness code for the oil Read to
Know about the oil types Familiar with some chemical properties of the Click to edit Master subtitle style oil Familiar with contamination type of the oil Familiar with sample point do and do not

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Predictive maintenance (PdM)

Predictive maintenance techniques help determines the

condition of equipment in order to predict when maintenance should be performed. This approach Offers cost savings over routine or time-based because tasks are performed only when warranted. The main value of Predicted Maintenance is to allow scheduling of corrective maintenance Prevent unexpected equipment failures. The key is "the right information in the right time". By knowing which equipment that needs maintenance, the maintenance work can be better planned (spare parts, people )and what would had been "unplanned stops" are transformed to shorter and less "planned stops" thus increasing plant availability.
increased plant safety, less accidents with negative impact

on environment, optimized spare parts handling 3/29/12

Technologies applied in Pdm

vibration and sound measurement analysis Click to edit Master subtitle style

thermal image oil analysis motor current signature also ultra sonic and non destructive test

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Maintenance Identify and measure lube contamination and component wear Eliminate unnecessary overhauls or inspections Reduce in service failures and field repairs Establish proper lubricant service intervals Management Improve cost assessment and control for equipment, labor and materials

What we need from our oil

Prevent wear(anti wear additives) Reduce friction and coolant for surface Be stable wide temperature range

temperatures Maintain viscosity throughout service interval To keep internal components clean To prevent rust(rust inhibitor) To maintain high levels of effectiveness throughout service life
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Oil classification types

Mineral oils
Manufactured from crude oil containing

many impurities; it has to be distilled to separate it into Gases, fuel liquids, lubricant fractions and heavier components such as asphalt Further processing of the lubricant removes additional impurities

Synthetic oils
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 As a rule of thumb Oil

consider to be contaminated when chemical properties are changed from OEM standard or the base line measurements
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physical and chemical properties of the oil

Viscosity is a lubricant's internal

resistance to flow at a given temperature in relation to time, and is considered to be the single most important physical property of a lubricant. Changes in viscosity indicate improper servicing, dilution, contamination or lubricant breakdown in service. Viscosity is usually determined with a kinematic method and
Industrial lubricating oils are generally

measured at 40 C reported in 3/29/12 centistokes (cSt) like ISO VG 32 mens

DIELECTRIC STRENGTH
This test measures an oil's ability to

withstand an electric current without failing. Oil is placed in the gap between two electrodes and an increasingly higher voltage is applied to the oil until an arc forms across the gap In large transformers, the circulating oil is formulated to act as an insulator. The relative insulating capacity of the transformer oil is indicated by the dielectric strength. Generally, small amounts of water, dirt, or metal will 3/29/12

FERROGRAPHY
Ferrography is an analytical technique in

which wear metals and contaminant particles are magnetically separated from a lubricant and arranged according to size and composition for further examination. It is widely used in oil analysis to determine component condition through direct examination of wear metal particles.
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Total Acid Number (TAN)

Measures the total amount of acidic

material present in the lubricant. Generally, an increase in TAN above that of the new product indicates oil oxidation or contamination with an acidic product units
milligrams of potassium-hydroxide per
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gram of sample, or mg/Gm or mg/KOH gr

New fresh oil will start around 0,2

1. Wear metals 2. Contaminants 3. Additives

Oil sample analysis grouped in three main categories

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Wear metals
Adhesive wear
Excessive load, low speed and/or reductions in fluid

viscosity can reduce the oil film thickness to a point where metal-to-metal contact occurs. Surface asperates are "cold welded" together and particles are sheared off as surfaces move.

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Wear metals
Abrasive wear
Abrasive wear occurs when a harder material is rubbing
against a softer material. Abrasive wear is a primary wear mechanism. Particles enter the clearance space between two moving surfaces, and act like cutting tools to remove material from the surfaces. The particle sizes causing the most damage are those equal to and slightly larger than the clearance space

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Wear metals
Fatigue wear Fatigue wear of a material is caused by a cycling
loading during friction, spalling, and pitting of the component part Surfaces.

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Wear is controlled with antiwear additives, which coat the lubricated surfaces and reduce direct part to part contact.

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Contaminants
Depending upon the circumstances,

many different substances may be classified as contaminants. Silicon, in the form of Silicon dioxide (sand) is one of the most common contaminants What about other types of contamination? As destructive as particulate contamination can be, there are other contaminants that also contribute to oil 3/29/12 degradation and premature machine

effect of water contamination

Water alone is a significant factor in

lubricant degradation. When combined with iron or copper particles, water becomes even more powerful in attacking lubricant base-stocks and additives. The adverse effects of water in oil include: Lubricant breakdown, through oxidation and additive break down. Changes in viscosity, affecting the ability of a lubricant to maintain the film 3/29/12 thickness necessary to protect the

Example show water content level and bearing life

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As a rule of thumb water concentration should not exceed 300 PPM.

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Other CONTAMINENT source

SOURCES 1-Aluminium Pistons, bearings 2- Copper Bearings, bushings, washers etc. 3- Iron Piston rings, ball and roller bearings

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3. Additives
Additives are chemical compounds

added to oils, fuels, and coolants to impart specific beneficial properties Additives create new fluid properties, enhance properties already present and reduce the rate at which undesirable changes take place in a fluid during service undesirable changes take place in a fluid during service. 3/29/12 MOLYBDENUM

How is oil cleanliness quantified?

ISO 4406 establishes the relationship

between particle counts and cleanliness ,This international standard uses a code system to quantify contaminant levels by particle size in micrometers (m). Using ISO 4406, a machine owner/operator can set simple limits for excessive contamination levels, based on quantifiable cleanliness measurements.
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ISO 4406

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EXAMPLE
ISO 4406 Rating -- 16/13/11 16 = range of number of particles >

4 13 = range of number of particles > 6 11 = range of number of particles > 14

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How clean does your oil need to

Machine/element

ISO Target
Roller bearing

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Journal bearing

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Industrial gearbox
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Determine the proper sampling point and method do and do not.

Do Sample from live fluid zones Turbulent

zones such as Elbows if applicable Downstream of system(Bearings, gears) if applicable Sample while machine isRunning Sample under typical working conditions
Do not Dead legs 3/29/12 Laminar flows

Sample report
1

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