Oil Analysis OIL... your engine’s lifeblood... can reveal its internal condition……
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Transcript of Oil Analysis OIL... your engine’s lifeblood... can reveal its internal condition……
Oil Analysis
OIL . . . your engine’s lifeblood . . . can reveal its internal condition……
What Oil Analysis
Oil analysis is a quick, nondestructive way to gauge the health of an engine by looking at what's in the oil. It is as like as medical blood test, where we can know about our diseases from our blood.
Oil Analysis Blood Test
• Friction control --- Separates moving surfaces• Wear control --- Reduces abrasive wear• Corrosion control --- Protects surfaces from
corrosive substance• Temp control --- Absorbs and transfer heat• Contamination control --- Transport particles and other contaminants to
filters/separators• Power transmission --- In hydraulics, transmits force
and motion
Functions of Lubricants
Oil Analysis seeks to provide answers for…
Change Filter?Change Oil?Tear Down?
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Cost justification for industrial oil analysis
Documented case histories and cost savings on-site oil analysis to monitor a wide range of industrial machinery. Realistic Return on Investment: 500%+
Defer maintenanceProactive CONTAMINATION CONTROLKeeping oil clean, dry, and fit for use
Reduce oil consumptionLESS OIL USED
“Test it, don’t change it”
Eliminate reactive maintenanceTrend FAILURE PROGRESS
Predictive vibration & oil analysis
All Test of Your Oil
1. Elemental Analysis (Spectral Analysis) 2. Particle count, 3. Particle Shape Analysis 4. Parts per million (PPM) distribution , 5. ISO codes and ASTM standard 6. Ferrography 7. Oil Chemistry ( Dielectric, TBN, TAN, Oxydation,
Nitration, Sulfations, Soot etc.)8. Water-in-oil, 9. Viscosity 10.Wear Debris Analysis (WDA)
Wear Metals and Possible SourcesEngine Bearing Gear Transmission Hydraulic
System
Heat Exchanger
Compressor Turbine
Iron
Cylinder Liners, Piston Rings, Valve train, Crankshaft, rocker arms, spring gears, lock washers, nuts,
pins, connecting rods, Engine Blocks, Oil
pump
Rolling element Bearings: rollers
(tungsten alloyed steel), raceways and
cages, Journal Bearings:
Journal shaft, bearing Shoe backing
Locking keys
Bull gears, pinions, case
hardened teeth, locking
pins
Gears, bearings, Brake bands, clutch, shift spools, pumps, power take off (PTO)
Pump, motor, vanes, pump
housing, cylinder bores and rods,
servo valves, pistons
Rotary Screw, lobes, vanes, connecting rods, rocker arm,
bearings, cylinders, housing, shafts, roller bearings (see above)
oil pump, piston rings
Reduction gear, shaft, bearings,
piping, case
Copper
Valve train bushing, Wrist pin bushing, Cam bushings, Oil
Cooler core, Thrust washers, governor,
connecting rods bearings, valve gear train thrust buttons
Rolling element Bearings: alloyed element in cages, Journal Bearings:
journal bearing pads, slinger rings,
Locking keys
Bushings, thrust washers
Clutches, steering discs, bearings
Pump thrust plates, bushings,
cylinder gland guides, pump
pistons, oil coolers
Cooler tubes, baffles, plates
bearings, cylinder guides, wear plates,
thrust washers, bearings (see above) oil pump, oil coolers,
thermostats, separator filters
Bearings (see bearing section) piping, coolers
Tin
Valve train bushing, Wrist pin bushing, Cam bushings, Oil
Cooler core, Thrust washers, governor,
connecting rods bearings, valve gear train thrust buttons
Rolling element Bearings: alloyed element in cages, Journal Bearings:
journal bearing pads (babbited)
Bushings Clutches, steering discs, bearings
Pump thrust plates, bushings, Can be a residue from catalyst in
some oils (Quinto lubric series)
bearings, separator filters
Bearings (see bearing
section) piping, coolers
Aluminum
Engine blocks, pistons, blowers, Oil pump bushings, bearings
(some) Cam bushings(some) , Oil
coolers (some)
Rolling element Bearings: alloyed element in cages, Locking keys
Bushings, thrust washers, grease contamination
Bushings, clutches Cylinder gland (some) pump,
motor pistons, oil coolers.
Aluminum complex grease contaminant
Cooler tubes, baffles, plates
Housing, bearings, cylinder guides, wear
plates, thrust washers, bearings (see above), oil pump, oil coolers
Bearings(see above) piping, coolersEHC Systems: Residue from synthetic media (alumina) filters
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Wear Metals and Possible Sources (Cont.)
Engine Bearing Gear Trans-mission Hydraulic System
Heat Exchanger
Compressor Turbine
Chrome Rings, Liners, exhaust valves, zinc chromate from cooling system inhibitor
Rolling element Bearings: alloyed /coated element in rollers, tapers
Bearings(some), shaft coatings, some special gears are chrome plated
Bearings, water treatment
Cylinder liners, rods, spools
Housing, bearings, cylinder guides, wear plates, thrust washers, bearings (see above), oil pump, oil coolers
Shaft coating (some) bearings
Lead Main Bearings, connecting rod bearings.Lead can be present as a contaminant from Gasoline (Leaded gas) (Octane improver, anti-knock compound)
Rolling element Bearings: alloyed element in cages, Journal Bearings: Major alloying element in Babbitt bearings, alloying elements
Bearings, can also be red lead paint flakes from gear case walls
Bearings Bearings Bearings
Silicon Engine blocks (alloying element with aluminum parts), ingested dirt from breathers, external sources. Can also be from defoamant additive in lubricant
Rolling element Bearings: alloyed element with aluminum in cages
Bushings, thrust washer, silicone sealant, defoamant additive
Brake shoes, clutch plates, ingested dirt
Elastomeric seals (some) pump, motor pistons, oil coolers
Ingested dirt, silicone sealant, bearings, cooler (alloyed with aluminum)
Ingested dirt, silicone sealant, defoamant additive
Silver Bearings (alloying element) wrist pins, turbochargers (EMD railroad engines)
Bearings, oil coolers
Baffle & tube solder
Nickel Valves, Valve guides, Cylinder liners, Bearings. Can also be from heavy fuel contamination
Rolling element Bearings: alloyed element in rollers, races
Alloying element for tool steel gears
Bearings, servo valve plating pumps, pistons
Bearings Bearings, shaft, reduction gears
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Other Wear Metals and Metallic Additives
Element Possible Sources in Additives
SodiumCorrosion inhibitor additive, also indicates coolant leak into oil, can also be road Salt, Sea water, Ingested Dirt
BoronCorrosion Inhibitor additive, Antiwear/Antioxidant additive, can indicate coolant leak, grease contamination
Magnesium Detergent/dispersive additive, can also be alloying element in steels
CalciumDetergent/dispersant additive, Alkaline reserve additive for high sulfur fueled engines, can be grease contamination,
Molybdenum Solid/liquid antiwear additive, alloy in bearing and piston rings
Barium Corrosion inhibitors, Detergents, Rust inhibitors
ZincAnti-wear, Corrosion inhibitors, Anti-oxidants, alloying element for bearings, thrust washers, galvanized cases
Phosphorus Anti-wear, Corrosion inhibitors, Anti-oxidants additives, EP additives
Element Possible Wear Sources
TitaniumWear metal for aircraft engines, bearings, Can also be contaminant from paint (titanium dioxide)
Vanadium Fuel Contaminant, can also be alloying element for steel
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Ferrography
Optical Particle Counting Techniques
Readout & ControlReadout & Control
Laser
View Volume
PhotoDiode
Laser Beam
Light BlockingLight Blocking
Oil Flow
Readout & ControlReadout & Control
Light ScatteringLight Scattering
Laser
Scattered Light
Lens
PhotoDiode
Laser Beam Trap
Oil Flow
Laser
Oil Flow
Direct ImagingDirect Imaging
CCDLens Display
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Particle Counting Classifications• The count is compared to known standards
• ISO 4406 • NAS 1638(out of service, but still widely quoted)• AS 4059• MIL-STD-1264• and many other internal industry methods
• Two types of counting method • Cumulative• Differential
MOST POPULAR
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Particle Counting Reporting Codes
• A particle counting code is simply an arbitrary number given for a sample that represents a particle count range for a given size range
• In ISO 4406, code increases when the particle population is ~ doubled from the previous range
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Engine Hydraulic Synthetic Gas Turbine
Compressor/ transmission
Gear/Turbine
Water (ppm)
Oxidation (abs/mm2)
TAN (mg KOH/g)
TBN (mg KOH/g)
Alien fluid (%)
Anti-Oxidant Additive (%)
Anti-wear Additive (%)
Nitration (abs/mm2)
Sulfation (abs/mm2)
Soot (%)
Glycol (%)
FT-IR Oil Analyzer
Wear Debris Analysis
PLATELETS:Two dimensional particles produced by metal to metal sliding.
SPHERICAL:Produced by bearing fatigue or by lubrication failure resulting in local overheating.
SPIRALS:Similar in appearance to machining swarf, and are produced by a harder surface abrading into a softer
CHUNCKY:Produced by a fatigue mechanism
WDA Images
Sliding Wear
• Severe sliding wear commences when the wear surface stresses become excessive due to load and/or speed.
• Many sliding wear particles have surface striations as a result of sliding.
• Severe sliding wear starts with particles greater than 15 µm.
Catastrophic Sliding WearSevere Sliding with Lubrication StarvationSevere Sliding Wear
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Three Body Abrasive Wear
“Soft” Surface
“Hard”Surface
Hard abrasive contamination
Cutting wear particle
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Surface Damage due to Hard Particles
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Spheres
Spheres generated from an extraneous source such as a welding or grinding process. These spheres are much larger than those generated by bearing fatigue.
Spheres generated by a fatiguing bearing < 5 microns20