Oil Analysis – Lessons Learned Chad Norris Refrigeration Engineer Wells’ Dairy, Inc.
Oil Analysis – Lessons LearnedChad Norris
Refrigeration EngineerWells’ Dairy, Inc.
Oil Analysis – Lessons Learned
Oil Analysis Methods – Internal vs. External
Oil Analysis Reports – What info do I need?
Wear Debris Analysis – Valuable tool for root cause analysis
Oil Analysis Findings – Share-out of our experiences
Lubricant Storage – Oil cleanliness starts with storage practices
Lubrication Training – Procedures and management of an oil analysis program
Lubrication References – “Experts” in lubrication
What equipment could or should have oil analysis performed?
Any rotating equipment that has an oil volume allowing a sample to be retrieved. (Compressors, pumps, gearboxes,…)Why is oil analysis an important part of Mechanical Integrity?
Predictable method to prevent catastrophic failure of rotating equipment from lubricant related problems.
Why Oil Analysis?
Oil Analysis Methods
Internal – CSI 5200 MinilabExternal – Send samples to contracted outside agency for analysis and receive feedback in the form of a report.Lubricant / Equipment Suppliers – Some provide this service. Be wary, this is like having the fox guard the hen-house.
Internal - ProsFast turnaround of data.On-site staff can become experts at their equipment.Utilize other Predictive Technologies together more effectively.
Internal – ConsLack of specialized equipment.
Oil Analysis Methods Pro/Cons
External - ProsOverall lubrication expertise.Specialized equipment to solve difficult issues.
External – ConsCost – pay per sample by amount of testing.Slow turnaround time.May be difficult to integrate data to database.
Oil Analysis Methods Pro/Cons
CSI 5200 Minilab(Internal)
Digital Viscometer
Laser Particle Counter
Ferrous and Water Analyzer
Dielectric Strength Analyzer
WDA Microscope
WDA Patch Maker
Data sent to Oilview Software
Reports
Oilview Database
Company Database By:Plant (SICP, NICP, RR,….)
Equipment/Area Type (Production, Air, Ammonia,….)
Sample Point (SC21, SC23,……..)All 5200 Minilab tests and WDA microscope photos automatically stored for each sample point.Prints Labels for sample bottles with lab# for ID.
Oil Analysis Reports
Qualitative AnalysisOperational Conditions (Temp, Press., Flow)
Spiral #2 lower operating temps than designAppearance (Milky, Sludge, Debris)
Obvious water and contaminant entrapmentColor (Darker)
Degradation caused by contaminants and heatOdor (Burnt, Rotten)
Thermal degradation, microbial contamination
Oil Analysis Reports (Cont.)
QuantitativeParticle Count
ISO Code for 2, 5, and 15 micron sizeWater Contamination %Viscosity
Centistokes at 40CDielectric Strength
Chemical properties of reference oil compared to sample (additive package depletion and oxidation)
Ferrous IndexFerrous debris count and density
Oil Analysis Reports (Cont.)
Wear Debris Analysis
Microscopic Analysis of Wear Debris Particles characterized by wear process:
Boundary lube wear – inadequate lubricationAbrasive wear – contamination with abrasive particlesFatigue wear – overloaded bearingsFretting wear – vibration induced particlesDegradation Residues - sludge or varnish, red and black oxidesProcess contaminants – fibers, dusts, and organic compounds
Wear Debris Analysis (Cont.)
What is the purpose of Wear Debris Analysis?To detect potential failures before they occur.To determine the root cause of failures after they occur.To detect abnormal machine or lubricant conditions.
Wear Debris Analysis (Cont.)Examples
Oil Analysis Findings
Contamination will decrease with better filtration methods.
Oil Analysis Findings (Cont.)
Contamination will decrease with proper filter changes.
Oil Analysis Findings (Cont.)
This chart from Noria, shows a study of industrial rotating equipment life. Doubling the life of
equipment is expected if oil cleanliness can be improved from ISO 22/19 to ISO 17/14.
Oil Analysis Findings (Cont.)
Synthetic Ammonia Compressor oil can be used for a very long time with proper filtration and operating temperature. (>50,000 hrs). May require spiking with new oil to prevent additive depletion.Removal of contaminant may also remove additives.
Oil Analysis Findings (Cont.)
Oil viscosity can be increased or decreased by water depending on the additive package. Oil analysis results are only as good as the sampling procedure.Utilize other predictive maintenance technologies along with oil analysis (vibration analysis, thermography, ultrasonics – grease).
Oil Analysis Findings -Greases
Greases are not fully tested but suspect greases can be emulsified and have ferrous wear test and WDA performed.Procedures in place to ensure grease compatibility and application.
Oil / Grease Storage
New oil is not necessarily clean oil (>ISO 21/20/19). High cost to purchase “clean oil” from suppliers.Dedicate a clean, dry, air conditioned room.Sampling on new oil containers.Label and have procedure in place for different lubricants.Filter lubricants before adding to equipment.
Oil Storage (Cont.)
Training
Suggest all facilities have those taking samples and responsible for the oil storage and usage take Level I training.Suggest that individuals that are responsible for reading/interpreting oil analysis reports be Level II trained.
References
Compressor/Motor Manufactures – specs.Noria – training, procedures, applications, publications.Emerson Process – Analysis EquipmentSMRP –Society of Maintenance and Reliability ProfessionalsInsight Services – www.testoil.com
Oil Analysis
Questions?