Shell IMAA Workshop Making Sense of Oil Analysis January 30, 2018 Tom Stuart Shell Lubricants Technical Advisor Greg Paluska Shell Lubricants Technical Team Lead East 04 October 2017 1
Why Oil Analysis? 1.0 2
Why Oil Analysis? Failure avoidance Improve lubrication and machine maintenance Monitor wear processes Allow maximum component service life Allow ma ximum oil service life Note: Oil Analysis cannot detect sudden failures. 3
Understanding Basic oil Analysis Oil Analysis provides information on: Fluid properties Equipment Condition Contamination 4
Improve: Using oil analysis data to provide valuable technical insight DATABASES CAN : REAL O EM EXAMPLE: Create insight into equipment and lubricants performance and conditions Detect problems before they result in failures and down time Save money and improve operations 14% 5% 9% 14% 25 20 15 10 5 0 Argentina Czech Republic Guinea Hungary Indonesia Netherland s Spain Utd.Arab Emir. 5% 5% 14% 5% 29% Incomplete Combustion Wear Metal Fuel Contamination Dirt/Wear Degraded Oil/Wear Degraded Oil/Dirt/Wear Degraded Oil Coolant Leak/Wear Coolant Leak Contamination 23 March 2016 5
Understanding Used Oil Analysis 2.0 6
Evaluating Fluid Analysis Test Data What s Needed: Sampling Consistency and Regularity ensures that trending will be relevant Proper test package selection provides the most revealing data to evaluate Knowledge about the equipment Knowledge about the fluid Knowledge about the tests employed Input and feedback from the Operator/ User 7
Basic Lubricant Tests & Metal Analysis Basic Tests: Appearance/ Color Acid Number Base Number Elemental Metals Analysis (ICP) Ferrography Analytical Flash Point (Cleveland Open Cup) Fuel Dilution Fuel Soot % Glycol Nitra tion Oxida tion Particle Count Pa rticle Qua ntifier Viscosity @ 40 o C Water by Crackle Water by Karl Fischer (Coulometric) 8
Viscosity Test Method Viscosity @ 40 C or 100 C: Measures a lubricant's resistance to flow (fluid thickness) at temperature and is considered a n oil's most importa nt physica l property. Depending on lube grade, viscosity is tested at 40 and/ or 100 Celsius. A set volume of lubrica nt to be tested is introduced by vacuum into specially designed Houillon tubes. After soaking at the required temperature, the oil is a llowed to flow. The time ta ken for the oil to pa ss indica ted ca libra tion points is automatically measured and the time in seconds is multiplied by the ca libra tion fa ctor for the appropriate tube to give the viscosity in cst or mm2/ s. 10
Water Test Method. 13
TAN Test Method Copyright of Shell of Shell Lubricants RESTRICTED 15
Elemental Analysis Test Method 17
Understanding oil analysis wear metals Lead (Pb) Source: Bearing overlay, oil additive in gear oils Nickel (Ni) Source: Valve stems & guides, ring inserts on pistons Silver (Ag) Source: Bearing cages, silver solder, turbocharger bearings, wrist pin bushings Iron (Fe) Source: Gears, rings, bearings, cylinder walls, rust, valve tra in, pistons Chromium (Cr) Source: Rings Aluminum (Al) Bushings, bearings, pistons, turbocharger, air compressor Tin (Sn) Source: Bearings Copper (Cu) Source: Bearings, bushings, radiators, oil coolers (new) 18
Understanding oil analysis additives Calcium (Ca) Source: Base additive to neutralize acids Molybdenum (Mo) Source: Piston rings, oil additive Ma gnesium (Mg) Source: Base additive to neutralize acids Boron (Bo) Source: Inhibitor additive, cooling system additive is bora te Zinc (Zn) Source: Anti-wear, EP and anti-oxidant additive Phosphorus (P) Source: Anti-wear, EP and anti-oxidant additive Ba rium (Ba ) Source: Detergent additive 19
Understanding oil analysis other elements Higher than 100ppm signals a coola nt lea k. Sodium: (Na) Source: Coola nt a dditive, externa l conta mina tion Potassium (K) Source: Coolant Silicon (Si) Source: External (dirt), Additive, silicon sealer 20
Particle count - optical laser test method 24
Proper Oil Sampling 3.0 25
Oil Condition Monitoring Sampling
Engine Oil Sample with Sample Probe Method (preferred) Run engine at low idle Remove dust cap. Insert probe into valve & collect 4 fl. oz. of flushing waste oil to clean the valve and ensure a representative live oil sample. Dispose of the flushing sample. Prepare sample bottle for actual sa mple collection a nd collect sample as above, keeping sample bottle lid in plastic bag to protect from airborne contaminants. Module #3 Construction.pptx 20 January, 2017 27
Engine Oil Sample with Thief Pump Module #3 Construction.pptx With engine off, remove dipstick, and measure and cut length of sample tubing equal to the length of the dipstick. Secure sample tubing into thief pump & insert other end of sample tubing into the oil through the dipstick tube, ma king sure not to let the tubing bottom out in the oil sump. Draw a vacuum with the sample thief pump and collect sample into sample bottle. When finished, cut sample tubing above the thief pump and push tubing through the bottle side of pump so the pump does not get conta mina ted with oil. 20 January, 2017 28
Final Drive Sample with Thief Pump Module #3 Construction.pptx Before drawing oil sample, mix oil in compartment by driving the unit back & forth. Pa rk ma chine so level line is para llel to the ground with the drain plug at bottom of compartment. Cut sa mple tubing so it extends to the middle of the final drive compartment, not to the bottom. Remove fill plug (slowly to vent pressure) and draw sample with thief pump as in previous slide. Do not sample from drains!! When finished, cut sample tubing above the thief pump and push tubing through the bottle side of pump so the pump does not get conta mina ted with oil. 20 January, 2017 29
The Future of Oil Analysis and Telematics: LubeAnalyst Sensors YOUR OIL S FINGERPRINT CHANGES AS IT DEGRADES EN ERGY (heat, pressure) + CHAN GES (fuel, wear, additive depletion) = Permanent changes to oil chemistry, polarity, that can be measured A REAL-TIME VIEW O F LUBRICAN T PERFO RMAN CE & EQ UIPMEN T RELIABILITY All applications Gearboxes, transmissions, engines, turbines, hydraulics, transformers A 24/ 7 view and call to action, working hand-in-hand with traditional oil analysis methods Patented, proven technology with excellent sensitivity March 12, 2018 30
Questions for the Team Bra vo Date Month 2016 31