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