3/15/2017. Oil Analysis: When the Oil Speaks, You Should Listen! Oil Analysis. Common Wear Metals Found in Oil. Common Wear Metals Found in Oil

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1 Oil Analysis Oil Analysis: When the Oil Speaks, You Should Listen! Michael Holloway, ALS Tribology Ken Hill, WearCheck Lubrication Services Session Number T16 Elemental Detects the amount and type of elements in the oil from component wear, contamination and various ingredients found in oil. Detects the physical presence of unwanted fluids (water, fuel, antifreeze) or particles (dirt, metal, etc ) in the oil and identifies oil by-products such as soot, nitration and oxidation. Tests viscosity and an oils ability to neutralize acids (TBN for engines) or increased acidity (TAN for CNG and nonengines). 1 4 Oil Analysis Can Extend Oil / Equipment Life Avoiding Catastrophic Failures Extending Oil Drain Intervals Decreasing Maintenance Time and Costs Scheduling Maintenance More Effectively Increasing Equipment Resale Value Providing Backup for Warranty Claims 2 Common Wear Metals Found in Oil METAL ENGINE TRANSMISSION DIFFERENTIAL PLANETARY TORQUE HYDRAULIC FINAL DRIVE GEAR BOX AIR CONVERTER POWER STEERING COMPRESSOR Aluminum (Al) Pistons Pumps Greases Impeller Pump/motor Oil pump Thrust Washers Rotors Clutches Pump bushings Turbine Housing Thrust washer Oil pump Pistons Pump Cylinder Greases Blocks Greases Housings Greases Block housing Oil pump bushings Blowers Thrust bearing Chrome (Cr) Rings Roller/taper Roller/taper Roller/taper Roller/taper Rods Roller/taper Roller/taper Rings Roller taper Spools Roller/taper Water Roller/taper treatment (Oil Liners cooler) Water Exhaust valves treatment (Oil Water cooler) treatment Chemicals Copper (Cu) Wrist pin Clutches Pump thrust Wear plates bushings Steering discs Plates Valve train Oil pumps (Where used) Pump pistons Wrist pin Bushings/thrust (Where used) Cylinder bushings Cam bushings Washers Guides (Near Oil cooler (Recip) failure) Oil coolers Oil cooler Governor Oil pump Oil additives 5 Problems Associated With Oils Include: Wear Metals Common Wear Metals Found in Oil METAL ENGINE TRANSMISSION DIFFERENTIAL PLANETARY TORQUE HYDRAULIC FINAL DRIVE GEAR BOX AIR CONVERTER POWER COMPRESSOR STEERING Iron (Fe) Cylinder Gears Gears Gears Housings Pump/motor Oil additives Oil additives Blocks Discs PTO Shafts vanes Gears Housings Shafts Shafts Gears Thrust Thrust Crankshaft Housings Pistons washers washers Wrist pins Brake bands Housings Cylinder bores Rings (Cast) Shift spools & rods Camshaft Pumps Valve train PTO Valves Oil pump Pump housing Liners Silicon (Si) Anti-foam Disc lining additives Defoamant Elastomeric Defoamant seals Octane improver Coolant leak Sodium (Na) Oil additive Oil additives Oil additive Oil additive Oil additive Oil additive Oil additive Coolant Coolant Road salt Coolant Road salt Road Salt Coolant Road salt Road Salt Tin (Sn) Pistons Thrust Pistons (Ovelay) washers Elemental 3 6 1

2 Common Additive Elements Found in Oil Element Function Barium Detergent / dispersant additive Boron Anti-wear additive, marker Calcium Detergent / dispersant additive, alkaline reserve Copper Anti-wear additive (Europe) Magnesium Detergent / dispersant additive, alkaline reserve Molybdenum Lubricity modifier, friction reducer Phosphorus Corrosion inhibitor, anti-wear additive, oxidation inhibitor, EP agent Silicon Anti-foaming additive Tin Anti-wear, friction reducing additive Zinc Anti-wear, anti-oxidant additive Elemental 7 Glycol Common Cause Cooling System Leak Ingression through crack or holes in cylinder sleeve, failed seals, gaskets, damaged cooler core, improperly torqued cylinder head Evidenced by increase in Sodium and/or Potassium levels 10 Water Common Cause Moisture Ingression through air breather, filter or cover into the system, cooling system leak Evidenced by either a steady or sudden increase in water level Water is the #1 cause of diesel engine failures (oil related) and #2 cause of industrial equipment failures. Fuel Dilution Common Cause Fuel is the #2 cause of diesel engine failures Fuel leaks dues to: Blow-by, faulty injector, or leaking fuel transfer pump seals Sampling timing If sample is collected after extensive idling, cold weather starting, frequent starting and/or short trip operation, then resampling properly will confirm if there is a true mechanical issue 8 11 Water Dissolved - Oil appears bright and clear. Emulsified- Very small droplets dispersed in oil. Oil viscosity may go UP (like mayonnaise). Tiny amounts of detergent engine oil can contaminate industrial oils. Soot Common Cause Retarded timing Late combustion will increase soot generation and fuel consumption correlates with an increase in viscosity Over-fueling Faulty injectors may cause soot to increase and would be evidenced by detection of fuel Poor air flow Incorrect air intake or exhaust leads to soot generation and requires visual confirmation Free - Large drops that readily settle out

3 Wear Scar diameter, mm 3/15/2017 Soot: Cause of Engine Wear? Combustion generated soot in the crankcases of diesel engines can significantly increase engine wear (valve train and liner). This is caused by the diesel soot adsorbing the anti-wear additive in the oil. Fred Rounds, G.M. Research Laboratories Wear increases with soot concentration This is the oil suction screen from the same Cat 3306 engine. Oxidation products in the form of crystals plugged the suction screen and caused lack of oil flow through the oil pump. Diesel Soot Concentration, wt% Ref: ASLE Paper 783-AM-7C-2, The Generation of Synthetic Diesel Engine Oil Soots for Wear Studies Oxidation Common Cause High temperatures Inherent reaction between oil and oxygen is greatly accelerated by heat Generally correlates with increase in viscosity and Acid Number (if measured) Remember that every 10 o C rise in sump operating temperature, over 80 o C, decreases the life of the oil by one half. TEMPERATURE C HOURS DAYS Nitration Common Cause High temperatures Reaction between oil and nitrogen at very high temperatures, typically seen in natural gas engines Generally correlates with increase in viscosity and Acid Number (if measured) Advanced timing Early combustion will increase nitration Bio-diesel use Without proper adjustment to timing, bio-diesels can produce more nitration than conventional diesel at same setting 17 This is a view of the inside of the engine block observed from the lower portion of the block. The interior of the block was coated with a dark brown to black deposit as a result of oil oxidation. Oil nitration causes light to dark brown deposits on cool parts of an engine such the piston skirts shown below

4 Oil nitration has created a brown sludge as observed on the top end of the engine head on this engine Acid Number Common Cause Extended service Normal operation results in a steady rise in Acid Number until oxidation inhibitor is depleted, then increase becomes exponential Can correlate with small increases in viscosity It is generally thought that a lubricant only begins to degrade after it has been put into service, but technically it begins to degrade immediately following blending Viscosity Causes for Change Mixing with another product Thinner oil, water, fuel, refrigerant and/or solvent ingression will cause viscosity to decrease Thicker oil or glycol will cause viscosity to increase Oxidation Aging, thermal abuse or water contamination will lead to excessive oxidation resulting in an increase Soot contamination Will increase viscosity in engine oils, however greater attention should be given to the 100 C viscosity Shearing Permanent shear will cause a decrease not common 20 Acid Number Considerations Trending Often the trend of the acid is of greater importance than the actual value Problems diluted Large volume reservoirs dilute changes in acid number Rule of Thumb?: When AN is double its new oil value, it is time to change the oil Exception: NGEO are ~1 new, require changing at 4-5 Exception: R&O oils are ~0.1 new, require changing at 1 23 Total Base Number & Total Acid Number Used to determine oil change intervals in gasoline, natural gas and diesel engines Titration Counts mg of KOH or HCL to bring 1gm sample to neutral More drops HCL = low TBN (for diesel or gasoline engines) or More drops KOH = high TAN (CNG, hydraulics, gearboxes) Both mean lower remaining oil life 21 Base Number Common Cause Extended service Normal operation results in a steady decrease in Base Number until oxidation inhibitor is depleted, then increase becomes exponential Can correlate with small increases in viscosity 24 4

5 Base Number Considerations High temperature Elevated operating temperatures will result in dramatic increase in acid production, thus lowering the Base Number Water content Elevate levels of water will contribute to greater acid production, thus lowering the Base Number Not for every application Base Number measures additive performance rather than by-products of oxidation, therefore the oil must contain a Base Number additive. Typically only diesel engine oils, some gasoline and natural gas engine oils. 25 Questions? Please complete the session evaluation on the CONEXPO CON/AGG Mobile App Go to Schedule and Select This Session 26 5

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