Fundamentals of Oil Analysis - PDF Free Download

IRC RESEARCH AND TECHNOLOGY FORUM Wednesday May 6, 2015 Thursday May 7, 2015 Madison, WI 53706 University of Wisconsin-Madison Pyle Center 702 Langdon St. University of Wisconsin-Madison Fundamentals of Oil Analysis Tim Vann / WearCheck USA Cary, North Carolina

WearCheck USA 501 Madison Ave Cary, North Carolina 27513

WearCheck International Group Worldwide Leaders WearCheck is the world-wide leader in oil analysis. Since 1966 WearCheck has been providing condition-monitoring services to all sectors of industry. With operations in 10 countries, the company employs about 1,000 people and processes over 1 million samples per year.

Maintenance Strategies Reactive Maintenance replace components when they fail Fix and repair components upon failure. Preventive Maintenance replace components before we expect them to fail Fix and repair components before their anticipated failure date. Predictive Maintenance perform corrective maintenance when condition monitoring detects problems Condition-Monitoring for detecting potential failures to control maintenance actions. Proactive Maintenance prevent maintenance problems by identifying and correcting root causes Prevent the situations that cause premature component failure. Reduce overall maintenance costs. 2015 WearCheck International. All rights reserved. Terms of use.

The Role of Oil Analysis Predictive Maintenance Monitor for abnormal wear modes Determination of proper oil change interval Detect environmental and process contamination Proactive Maintenance Evaluate filtration upgrades Evaluate lubricant type and brand changes Evaluate effectiveness of maintenance improvements Confirmation of maintenance activities Root cause failure analysis 2015 WearCheck International. All rights reserved. Terms of use.

Equipment Failure Cycle Ingress of contaminants and other oil contamination increases rate of fluid degradation. Contamination and poor fluid quality cause increased wear. Eventual equipment failure is inevitable. Oil analysis detects contamination and fluid degradation before these conditions cause equipment failure. 2015 WearCheck International. All rights reserved. Terms of use.

Managing an Oil Analysis Program An Effectively Managed Oil Analysis Program Will Provide effective maintenance scheduling Minimize unscheduled downtime Extend equipment life Reduce maintenance costs Minimize installation errors Verify warranty and service claims Determine optimum oil drain intervals (ODI) Improve equipment reliability 2015 WearCheck International. All rights reserved. Terms of use.

Lubricant and Fluid Analysis

Material Services

Sample information form instructions 12345678 < Ticket Stub to be kept for customer records. Each sample has a unique identifier for tracking purposes and is called a SIF number, or Sample Information Form number. E.g.. For this example form, the tracking number, or SIF number is WCI2 12345678. Complete contact information for first time customer or Customer Code assigned at time of initial sampling should always be present for each sample. On initial sampling for a unit, unique unit identifier and unit information should be as completely filled out as possible, especially component and oil types. On repeat samples for units previously tested, only unit ID and component type need to be indicated. Sample date, current time on unit, oil and filter should always be indicated, as well as whether oil and/or filter were changed at time of sampling. 12345678 Comment section is to be used for any concerns about unit or special attention customer wants to be given to a particular test.

Vacuum pumps Material Services Tubing Gauge plugs Sampling Hose

Oil Analysis Tests

Testing Includes ICP Analysis ASTM D5185 Viscosity @ 40 C ASTM D445 Determines the parts per million (ppm) of all wear metals (Fe, Cr, Ni, Pb, Cu ), contaminants (Si, Na, K.), and additives (Ca, P, Zn, Mg, Mo ). Determine the viscosity of the oil at 40 C to determine if oil is still within specification. High viscosity can indicate oxidation, low viscosity can indicate contamination, improper make-up oil. TAN ASTM D974 Determines overall acidity (TAN) or remaining alkalinity Single best test to determine change-out interval. WEARCHECK Advanced Most industrial clients utilize the IND II oil WC sample IND kit. 2+PC Sample Kits Visual Screen In-house method Particle Count ISO 4406:1999 A inspection of both the oil color/clarity and the bottom of the sample bottle are taken, and any level of contamination, visual oil problems or visible wear debris of the oil is recorded. Determine cleanliness levels of oil. High particle count levels can indicate gross contaminant ingress, wear, filter by-pass or all of these issues. LMA-18 KF ASTM D6304 Determines level of moisture or water contamination in the oil.

Detecting Spectrometric Analysis (ICP)

Detecting Kinematic Viscosity (KV) Acid Number (TAN)

KV - Kinematic Viscosity @ 40 C ASTM D445 Viscosity refers to the oil's flow characteristic. Under normal operating conditions, oil viscosity (thickness) increases gradually because lighter base oil fractions evaporate while the contaminant and degradation product levels build-up. Viscosity measurement will determine the extent to which the oil has become contaminated and/or degraded. Detect incorrect oil make-up/contamination Detect severe oil oxidation Viscosity is deemed abnormal when it has decreased by 10% or increased by 20% of the baseline value. Example We see the correlation between the marked increase in TAN (indicating severe oxidation) and the subsequent increase in viscosity (in this case from 105 to 174 cst. (sample is from a compressor using Mobil Delvac 1. The compressor shows high copper and aluminum wear.) 2015 WearCheck International. All rights reserved. Terms of use.

Detecting Particles Process Contamination Improper Oil Make-up Dirt Water

Cleanliness of New Oil View through the bung hole of a barrel of new hydraulic oil. Typical 18/13 New oil is guaranteed to be new, not clean In some situations the oil you are throwing out is cleaner that the oil you are putting in Oil cleanliness is not vendor specific Ref: WearCheck New oil filtered on 0.8µm PDF at 100X magn.

How is Oil Cleanliness Measured? Particle count (1 ml of fluid) Particle Size Classification (2, 5, 15, 25, 50, 100µm) (4, 6, 14, 21, 38, 71µm) Cleanliness Code (ISO 4406:1999 ) Ref: WearCheck

Effect of Cleanliness on Component Life Component life is dependent on the cleanliness of the lubricating fluid. The cleanliness of any lubricant is dependent on oil handling practices, top up procedures and the quality of both air breather and oil filtration. Cleaner Oil = Longer Component Life Ref: Pall

Material Services Vacuum pumps Sample Kits Tubing Gauge plugs Fast sampler

Contamination Dirt Source Environmental (Dust, Dirt) Cause Faulty air filtration, seals, air breathers Symptom Gouging of metal surfaces

Dirt Entrainment ICP Spectrometric Analysis Silicon (or Silica, Dirt) next to oxygen is one of nature's most prolific elements and the single greatest cause of oil contamination, component wear damage and potential failure. Believe it or not, most of the dirt in engines enters via poorly maintained air intake systems and faulty air cleaners. In other components, dirt can enter (and does) almost anywhere there is a loose clamp, damaged gasket and seals, breather tubes, ill fitting dust covers, loose or missing bolts, filler caps and inspection plates, damaged housings...the list is almost endless. Silica contamination can "dust" and engine all by itself, but when combined with other contaminants such as fuel, glycol, and water, equally disastrous results can be expected. Damaged Air Filter and/or Air Cleaner Poorly Maintained Air Intake System Figure ICP-1 Example In Figure ICP-1 the severe silica (Si) level indicates dirt ingress. The resulting severe iron (Fe) and Aluminum (Al) levels are as a direct result of abrasive wear from the dirt particles to the cylinder assembly.

Contamination Water Source Condensation, Environmental, Combustion Cause Leaking seals, air breathers with no dessicator Symptom Rusting and corrosive etching Sludge, oil line plugging Scale deposits

Effect of Moisture on Component Life Component life is dependent on the dryness of the lubricating fluid. Dryer Oil = Longer Component Life Rolling Element Bearings Journal Bearings Ref: SKF, OSU

Keep it Clean and Dry Portable Filter Cart Desiccating Air Breathers

Accomplished via coordination with WearCheck Canada Software www.oilanalysis.net

www.oilanalysis.net Conquer your biggest maintenance challenges: Different sites, different departments, different responsibilities? Collaborate in one common maintenance workplace. Different maintenance systems, different maintenance databases? A common maintenance workspace. Overload of oil analysis data, poorly organized program, no follow up? A system to track your oil analysis program. WebCheck is a maintenance extranet that uses analytical and collaborative tools to consolidate individuals, management groups, the entire organization and OEM maintenance extranets. With your maintenance information centralized the result is better maintenance decisions. From the inception of your Oil Analysis program, effective management is essential to ensure you realize the full potential from your program and reap the maximum return on your maintenance investment. WebCheck ensures that you have the knowledge and tools available at your fingertips to manage your program at each stage of the Oil Analysis Cycle.

Review Reports Receive Notification of Completed Samples E-Mail Notification Completed OA results Once several samples from a batch of samples submitted to the laboratory have been completed the Client is notified by e-mail. The E-mail informs the Client of which samples have been completed, what the status of those samples are as well as which samples are still awaiting completion. Clients can modify settings for which samples they receive e-mail notification on.

Sample Reports

Review Reports IND 2 Sample Report Unit Information Including make, model, s/n Test kit used Recommendation Summary and any necessary corrective actions required. Contamination Dirt, Water, Particle Count (ISO Code) Identifies any abnormal contaminants present in the oil. Quick Sample Status Unit Identification Sample Information Sample, Recieved Date Sample Number Time on oil, filter, component Abnormal Limits Target ISO Cleanliness Level Wear Wear metals in parts per million (ppm) Determines if equipment is wearing Abnormally. Oil Condition Oil additive levels in ppm Viscosity @ 40 C Total Acid Number (AN) Determines if oil is suitable for continued use. New oil baseline CUSANY [WCALAB] 00123456 Report Identification 2015 WearCheck International. All rights reserved. Terms of use.

Review Reports IND 2 Sample Report (back) Ferrous Wear Metal Graph All ferrous wear metals charted on a log graph showing up to 25 samples chronologically. Allows for the visual identification of wear of alloyed components. Particle Count Graph A chart of the current particle levels in an easy to read format showing the current particle levels against the ISO level. The chart also shows the target level. Babbitt Wear Metal Graph All non-ferrous wear metals charted on a log graph showing up to 25 samples chronologically. Allows for the visual identification of wear of alloyed components. Viscosity Graph Trend of the viscosity in cst showing both upper and lower limits. TAN Graph Trend of the TAN level of the oil showing both the base and typical levels of the base oil. CUSANY [WCALAB] 00123456 Pg. 2 ATTN: JOHN DOE ABC MANUFACTURING LTD. 123 INDUSTRIAL DRIVE STEELTOWN, NY 10023 (212)555-1234 FAX (212)555-2345 Customer contact info 2015 WearCheck International. All rights reserved. Terms of use.

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