Initial Report Review
Initial Report Review The ability to interpret the results of oil analysis is vital to guiding significant decisions about preventive maintenance activities. Having someone in your organization who can pick up a report and interpret it in the context of the environment is absolutely essential. This is a skill which can easily be developed with a minimal investment in training and certification. This article addresses the basics of oil analysis and interpreting the resulting reports. Once an analysis is complete, it is important to review the report and interpret the accompanying data. Based on the report, you can determine whether action is needed. The report does not always pinpoint specific problems, but does provide a starting point for analysis. Reports should be easy to review. Each test should be clearly identified, and in general, the information should be organized in a spreadsheet with numbers indicating test results. When you look at your reports, make sure they are just that, your reports. Be certain the report includes: Your Name
Machine MFG
Lube Type
Machine Type
Your report should clearly state your Machine and Lubricant Condition. Your lab should have a rating system that notifies you of Normal, Marginal and Critical levels. Your report should also include your own Customer Notes. These notes are important to help complete the overall picture of the equipment. The analyst will consider your notes to assess the machine condition. Finally, the Analyst Summary will help you gauge the criticality of the problem and provide you with a suggested course of action. Machine Condition
Customer Notes
Lubricant Condition
Analyst Comments
Machine Condition:
CRITICAL
Lubricant Condition:
CRITICAL B ID FAN BEARING LUBE OIL
Anal ys is Repor t
Lube Type:
Conoco AW 46
Received:
6/30/2012 12:00:00AM
Machine MFG:
AIR PROD INC
Report:
5/4/12 4:43:00PM
Machine MOD:
B175A
Sample No:
19 ‐ 1 ‐ 4 ‐ 4
Machine Type:
Anti‐Friction Bearing
Analyst:
MM
Problems: *** HIGH IRON. *** HIGH LEAD. ***HIGH WATER CONTENT. ***EXCESSIVE PARTICLE COUNT.
ATTN: Jack Boilerman Lake Rd Plant 20338 Progress Drive Strongsville, OH 44149
Customer Notes: Mach Hours: 2016 * Lube Hours: 2016 Filter Change 1/5/2012
Analyst Comments: Water content at .689% (6890 ppm) is likely the result of condensation or water ingression. Water contamination can lead to oil degradation, corrosion and reduction in load carrying capacity. If specific source of moisture cannot be located, inspect or install desiccant breathers. The particulate contamination exceeds our limits for a bearing (19/17/16). High particulate contamination will lead to abrasive wear and damage internal components. Reducing particle levels will significantly extend component life. Fluid contamination is a possible contributor to www.TESTOIL.com Page 1 elevated wear metals.
Checking Resistance to Flow: Viscosity
Checking Resistance to Flow: Viscosity This test measures a lubricant’s viscosity (resistance to flow at a specific temperature). An oil’s viscosity is considered its most important property. This test can quickly detect the addition of a wrong oil. In fact, it’s the best standard for measuring oil serviceability. If a lubricant doesn’t have the proper viscosity, it can’t perform its functions properly. If the viscosity isn’t correct for the load, the oil film can’t be established at the friction point. Heat and contamination aren’t carried away at the proper rates, and the oil can’t adequately protect the component. A lubricant with the improper viscosity can lead to overheating, accelerated wear, and, ultimately, the failure of the component. Viscosity Limits
Industrial oils are identified by their ISO viscosity grade (VG). The ISO VG refers to the oil’s kinematic viscosity at 40°C. To be categorized at a certain ISO grade, an oil’s (either new or used) viscosity must fall within plus or minus 10 percent of the grade. So for an oil to be classified as ISO 100, the viscosity must fall within 90 to 110 cSt. If an oil’s viscosity is within plus or minus 10 percent of its ISO grade, it’s considered normal. If the oil’s viscosity is greater than plus or minus 10 percent and less than plus or minus 20 percent, then it’s considered marginal. Viscosity greater than plus or minus 20 percent from grade is critical.
An increase in viscosity may indicate: Increasing suspended solid material such as wear particles, contamination, or soot Additions of a higher viscosity oil Lubricant oxidation Water contamination
A decrease in viscosity may indicate: Contamination from fuels or process fluid Additions of a lower viscosity oil Additive shear
Kinematic Oil Viscosity in Centistokes ISO VG ISO VG 2 ISO VG 3 ISO VG 5 ISO VG 7 ISO VG 10 ISO VG 15 ISO VG 22 ISO VG 2 ISO VG 32
Mid Point KV 40° C ‐ mm2s 1 2.2 3.2 4.6 6.8 10 15 22 32 46
Limits, KV 40° C
Min.
Max.
1.98 2.88 4.14 6.12 9 13.5 19.8 28.8 41.4
2.4 3.52 5.06 7.48 11 16.5 24.2 35.2 50.6
ISO VG ISO VG 100 ISO VG 150 ISO VG 220 ISO VG 320 ISO VG 460 ISO VG 680 ISO VG 1000 ISO VG 1500 ISO VG 2200
Mid Point KV 40° C ‐ mm2s 1 100 150 220 320 460 680 1000 1500 2200
Limits, KV 40° C
Min.
Max.
90 135 198 288 414 612 900 1350 1980
110 165 242 352 506 748 1100 1650 2420
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Page 2
Let's interpret this report with high viscosity Lube Type: Mobil Mobil Gear 634 Machine Type: Industrial Gear
Lab No Oil Chng / Mach / Lube
Reference
8/27/2010
6/18/2010
5/14/2010
4/26/2010
884169
639886 N/N/C
620613 N/N/C
607160 N/N /C
601898 N/N/C
Let's interpret this report with high viscosity Lube Type: Mobil Mobil Gear 634 Machine Type: Industrial Gear
Reference
8/27/2010
Lab No 884169 639886 Oil Chng / Mach / Lube N/N/C SPECTROSCOPIC ANAYLSIS (ppm) ASTM D 5185 Iron 2 Copper 0 Lead 0 Aluminum 1 Tin 1 Nickel 0 Chromium 0 Titanium 0 Vanadium 0 Silver 0 Silicon 12 Boron 1 Calcium 0 Magnesium 0 Phosphorus 369 Zinc 0 Barium 0 Molybdenum 0 Sodium 2 Potassium 0 VISCOSITY (centistokes) ASTM D 445 Vis 40 437.9
6/18/2010
5/14/2010
4/26/2010
620613 N/N/C
607160 N/N /C
601898 N/N/C
7 0 0 0 1 0 0 0 0 0 4 15 44 4 387 50 0 0 0 2
21 0 0 0 5 0 0 0 0 0 6 10 43 1 389 25 0 0 1 0
26 0 0 3 3 0 0 0 0 0 10 21 132 3 338 58 0 0 2 2
30 0 1 2 0 0 1 0 0 0 8 21 142 5 368 70 1 0 8 4
327.3
230.3
220.0
220.3
26/25/21 502842 195556 14914 653 40
22/21/ 17 36420 14163 1080 47 2
26/25/21 502842 195556 14914 653 40
PARTICLE COUNT (particles per ml) ISO 4406:99
ISO Code >4 Micron >6 Micron >14 Micron >50 Micron >100 Micron
18/17/13 2191 852 65 2 0
27/24/20 999999 99999 9999 99 9
As you review this report the first thing you should look at is the reference column. The reference level for the viscosity of this oil is at 437.9ppm, and on the first three tests the viscosity is in the 200 cSt range. Remember what we said about viscosity limits: If the oil’s viscosity is outside of plus or minus 10 percent (marginal) or plus or minus 20 percent (critical), then it’s considered to be in alarm. With this in mind we know the lubricant in this equipment is at a critical viscosity level. But something changes in August 2010. The viscosity increases 100 cSt from the previous results. This remains below the specification and remains in alarm, but from this we see that there was an addition of fluid (or this is not the intended use fluid) to bring the viscosity up to specification. Also if you notice that while the viscosity has increased so has the level of zinc. As we look at the reference area we notice that zinc should not be in this lubricant and we can conclude that this is another product that has been put in and not the 634 gear oil we were expecting. The recommendation for this equipment would be a proper flush and to refill with the correct lubricant.
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Measuring Metals: Elemental Spectroscopy
Page 3
Measuring Metals: Elemental Spectroscopy Analyzing the oil analysis report involves understanding the concentration of expected and unexpected elements in your oil. Some elements are picked up as the oil circulates and splashes off different components and surfaces of the machine. Additionally, contaminants can enter the machine during manufacturing, routine service, faulty seals, poor breathers or open hatches. No matter how the contaminants enter the oil, they are carried along within the oil and can cause metal wear. Elemental spectroscopy determines the concentration of wear metals, contaminant metals, and additive metals in a lubricant. When the predominant source of additive elements in used lubricating oils is the additive package, significant differences between the concentrations of the additive elements and their respective specifications can indicate that the incorrect oil is being used. The concentrations of wear metals can be indicative of abnormal wear if there are baseline concentration data for comparison. A marked increase in boron, sodium, or potassium levels can be indicative of contamination as a result of coolant leakage in the equipment. Limits should be based on trends, all machines are different. For example, if you have two identical machines in different places, depending on the maintenance practices load and duty cycles these two machines can have vastly different elemental spectroscopy results and both could be considered normal put off totally different particles and be fine. Trending is really important for judging a machine's health. Use your best judgment when thinking about operational conditions. Has anything changed? Have you been running the machine longer? Have you been putting more load on it? Or is it a new machine just breaking in.
Wear Metal Limits
Limits should be based on trends
Operational conditions can effect where metal levels
Sudden increases indicate problems
Oil changes, breaking periods, loading
OEM recommendations
Before you think the machine is faulty think about all of these things. OEM recommendations are sometimes good but all machines are different and you'll never get exactly what the OEM recommendation says depending on what you do the machine.
Spectroscopy cannot measure particles larger than roughly seven microns, which leaves this test blind to larger solid particles. As with any type of testing, spectroscopy is subject to inherent variance (natural inconsistency).
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Let's interpret this report with wear particles Lube Type: CONOCO Multipurpose R&O 68 Machine Type: Plain Bearing
Lab No.
Reference 609348
8/12/2010 639281
6/21/2010 624653
12/26/2008 485474
10/6/2007 377712
Let's interpret this report with wear particles Lube Type: CONOCO Multipurpose R&O 68 Machine Type: Plain Bearing
Reference 8/12/2010 Lab No. 609348 639281 Oil Chng / Mach / Lube N/ C/ M SPECTROSCOPIC ANAYLSIS (ppm) ASTM D 5185 Iron Copper Lead Aluminum Tin Nickel Chromium Titanium Vanadium Silver Silicon Boron Calcium Magnesium Phosphorus Zinc Barium Molybdenum Sodium Potassium
0 0 0 0 0 0 0 0 0 0 0 0 0 0 17 0 0 0 0 0
260 155 30 2 3729 1 1 0 0 0 4 0 118 0 201 0 0 0 0 0
6/21/2010 624653 N/ C/ M 45 49 7 2 722 0 0 0 0 0 5 0 44 0 82 3 0 0 0 0
12/26/2008 485474 N/ N/ M 29 2 1 1 26 0 0 0 0 0 4 1 1 0 3 2 1 0 0 8
10/6/2007 377712 N/ C/ M 39 39 17 2 531 0 0 0 0 0 4 0 3 0 34 18 0 0 4 3
First, if you are ever looking at a report for any kind of a plain bearing you should always look at the copper and tin levels. There are thin layers of copper and tin between the shaft and the housing, so if you start to see the numbers climbing up, be aware that this could indicate a wear problem. In reviewing the report above we see that in 2007 the copper level is at 39 ppm, which alone can indicate a problem, but the real clue here is the tin, which is at 531 ppm. This is a critical level. After receiving these results, the machine operator changed the oil and continued to use the machine. A year later the machine was tested again and the results are marginal. These results gave the machine operator confidence that his equipment was healthy and he stopped regular testing. You should be aware that changing oil may have flushed away the wear material which in turned temporarily masked the problem. The machine was not tested again until June 2010. You can see that the tin was elevated to 722ppm and the copper also shows a significant increase. This machine was probably making all kinds of noise alerting the operator to the problem, but it was too late. Soon after the June testing the machine failed. The results shown in August 2010 were from the failed equipment. You can see the tin levels are through the roof, as are the copper and Iron. These results tell us that severe damage has occurred to this plain bearing.
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Stay On The Look Out For Contaminants
Page 5
Stay On The Look Out For Contaminants Oil contamination causes approximately 80% of all oil system failures. Contamination takes the form of insoluble materials such as metals, dust particles, sand and rubber. The smallest particles, those below 2 µm, and better known as silt, resin or oxidation deposits are often responsible for defects. Many of these contaminants influence equipment reliability and lifetime. When talking about contaminants, the objective is to detect the presence of foreign components and to ask “What are they? Where did they come from (built‐in, generated, ingressed, introduced)? How can I prevent further entry or generation?” Contaminants act as a catalyst for wear. This generated wear debris further acts as a catalyst for additional component wear. If the cycle is not broken, wear accelerates and downgraded serviceability results.
Typical contaminants are: Silicon (Si) o Airborne Dust & Dirt, Defoamant Additive Boron (B) o Anti Corrosion in Coolants
Potassium Coolant Additive o Sodium Detergent Additive, Coolant Additive o
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Page 6
Let's interpret this report with contamination Lube Type: SAFETY KLEEN AW 46 Machine Type: Hydraulic System
Lab No
Reference 349585
9/8/2010 642792
9/28/2009 551484
2/9/2009 494182
8/24/2008 449544
Let's interpret this report with contamination Lube Type: SAFETY KLEEN AW 46 Machine Type: Hydraulic System
Lab No Oil Chng / Mach / Lube
Reference 349585
9/8/2010 642792 N/N/M
9/28/2009 551484 N/M/C
2/9/2009 494182 N /N/C
8/24/2008 449544 N/N/C
0 5 1 0 1 0 0 0 0 0 1 0 126 3 385 433 0 0 1 0
0 0 0 0 1 0 0 0 0 0 0 0 82 0 296 370 0 0 1 3
0 0 1 0 0 0 0 0 0 0 3 0 65 0 300 363 0 0 3 3
SPECTROSCOPIC ANALYSIS (ppm) ASTM D 5185
Iron Copper Lead Aluminum Tin Nickel Chromium Titanium Vanadium Silver Silicon Boron Calcium Magnesium Phosphorus Zinc Barium Molybdenum Sodium Potassium
0 0 0 0 0 0 0 0 0 0 0 1 49 0 312 424 0 0 0 4
1 1 5 0 1 0 0 0 0 0 68 0 50 0 382 450 0 0 1 6
Pay attention closely to the silicon levels for this Hydraulic System. Several of the test show the silicon at low levels, but on the September 2010 test the silicon is at 68ppm. This could be contributed to airborne dust, however in this case we have a sample of new oil. Now if we look at the past samples which have no history of high silicon levels we now ask the question “Where did this come from?” Being new incoming oil and considering that there has never been an issue like this before, the only variable that is different is the fact that this is incoming oil. With that said, we can conclude that there appears to be a contamination issue with our incoming batch of oil. It would be best to resample. This is a good example of the importance of testing incoming oil ‐ not only to be sure it is the correct lubricant, but also to check cleanliness, and in this case the presence of contamination.
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Monitor Additive Levels
Page 7
Monitor Additive Levels Oil additives are chemical compounds that improve the lubricant performance of base oil. Without many of these additives the oil would become contaminated, break down, leak out, or not properly protect parts at all operating temperatures. Some of the most important additives include those used for viscosity and lubricity, contaminant control, for the control of chemical breakdown, and for seal conditioning. Some additives permit lubricants to perform better under severe conditions, such as extreme pressures and temperatures and high levels of contamination. These precious additives can be depleted during use and monitoring this depletion can provide an early warning of impending lubricant failure. Monitoring additive levels is important not only to assess the health of the lubricant, but it also may provide clues related to specific degradation mechanisms.
Typical additives are: Magnesium (Mg) Detergent Additive o Barium (Ba) o Rust & Corrosion Inhibitor Calcium (Ca) o Detergent/Dispersant Additive
Zinc (Zn) Anti‐wear Additive o Phosphorus (P) o Anti‐Wear Additive, EP Gear Additive Molybdenum (Mo) Extreme Pressure Additive o
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Let's interpret this report with additive issues Lube Type: QUAKER QUINTOLUBRIC 888‐68 Machine Type: Hydraulic System
Lab No
Reference 641386
9/1/2010 641039
7/28/2010 631381
6/14/2010 614442
4/25/2010 601224
Let's interpret this report with additive issues Lube Type: QUAKER QUINTOLUBRIC 888‐68 Machine Type: Hydraulic System
Reference 641386
9/1/2010 Lab No 641039 Oil Chng / Mach / Lube N/N/C SPECTROSCOPIC ANALYSIS (ppm) ASTM D 5185 Iron Copper Lead Aluminum Tin Nickel Chromium Titanium Vanadium Silver Silicon Boron Calcium Magnesium Phosphorus Zinc Barium Molybdenum Sodium Potassium
0 0 0 0 340 0 0 0 0 0 6 0 2 0 205 4 0 0 5 0 VISCOSITY (centistokes) ASTM D 445
2 4 3 1 0 0 0 0 0 0 152 0 35 0 515 397 0 0 0 0
Vis 40 SINGLE COMPONENT TESTS
44.3
69.4
7/28/2010 631381 N/N/N
FLASH POINT D92 °C
6/14/2010 614442 N/ U/U
4/25/2010 601224 N/N/N
1 2 1 0 285 0 0 0 0 0 6 3 5 0 626 28 0 0 3 0
1 1 2 0 330 0 0 0 0 0 5 2 5 0 690 30 0 0 4 0
63.1
63.6 276.00
The first thing you need to know about this report is that Quintolubric is a fire resistant lubricant and it contains tin as an additive. On this particular report you can see that in April 2010 the tin matches closely with the reference oil at 330ppm. The phosphorus level is also high, but the viscosity looks good, so the lubricant is flagged as normal. In June 2010 the Flash Point was tested to ensure the oil was maintaining its fire resistant quality. The levels are within specification. The September 2010 is where we see an issue. The first red flag is that there is no tin showing in the lubricant. In reviewing the other elements, we see the high levels of phosphorous and zinc are the real issue. These levels of phosphorous and zinc give the indication that this is a hydraulic oil not Quintolubric. The concern here is that another oil could have been added to this machine, and the results indicate it is not a fire resistant oil.
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Quantifying the Amount of Water:
Page 9
Quantifying the Amount of Water: Karl Fischer Water Test The Karl Fischer coulometric moisture test is a series of chemical reactions discovered in 1935 by German chemist Karl Fischer. This method analyzes water in the microgram or part‐per‐ million range. This test is very accurate, to .001 percent. Water determination by Karl Fischer is defined in ASTM D 6304. Low levels of water are typically the result of condensation. Higher levels can indicate a source of water ingress. Water can enter a system through seals, breathers, hatches, and fill caps. Internal leaks from heat exchangers and water jackets are other potential sources.
Click on the image to watch a short video about the Karl Fischer Test
When free water is present in oil, it poses a serious threat to the equipment. Water is a very poor lubricant and promotes rust and corrosion to the components. Dissolved water in an oil promotes oil oxidation and reduces the load handling ability of the oil. Water contamination can also cause the oil’s additive package to precipitate. Water in any form causes accelerated wear, increased friction, and high operating temperatures. If left unchecked, water can lead to premature component failure. In most systems, water should not exceed 500ppm.
Common sources of water:
External contamination Breathers, Seals, Reservoir covers o Internal leaks Heat exchangers, Water jackets o Condensation
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Page 10
Let's interpret these two reports with water issues Lube Type: SULLAIR SULLUBE Machine Type: COMPRESSOR
Lab No Oil Chng / Mach / Lube
Reference 752001
8/12/2010 636637 N/N/C
3/19/2010 586192 N/N/N
10/24/2008 463401 N/N /N
9/5/2008 453020 N/N/N
Let's interpret these two reports with water issues Lube Type: SULLAIR SULLUBE Machine Type: COMPRESSOR
Lab No Oil Chng / Mach / Lube SINGLE COMPONENT TESTS Acid # m KOH/ Water %
Reference 752001
8/12/2010 636637 N/N/C
3/19/2010 586192 N/N/N
10/24/2008 463401 N/N /N
0.01
1.65 0.842
0.70 NEG
0.71 NEG
9/5/2008 453020 N/N/N 0.95 NEG
This report shows that the water levels have been negative across the board up until the August 2010 test. At .842%, this is a critical water limit. In addition, the acid number has increased, which is a direct result of the increase in water and it tells us that the oil has started to oxidize. The machine operator needs to quickly find the source of water and fix the problem prior to properly flushing and refilling. Lube Type: SHELL MORLINA SD 6680 Machine Type: UNKNOWN
Lab No Oil Chng / Mach / Lube DEMULSIBILITY
Reference 629766
8/16/2010 637151 N/N/C
Demulsibility 40‐38‐ 2 (25) VISCOSITY (centistokes) ASTM D 445
7/12/2010 627463 N/N/C
6/7/2010 613168 N/N /C
5/17/2010 607203 N/N/C
0‐ 8 ‐72 (60)
Vis 40 SINGLE COMPONENT TESTS
700.2
1071.4
959.0
1053.8
1222.0
Acid # mg KOH/g Water %
0.01
1.65 0.842
0.70 NEG
0.71 NEG
0.95 NEG
Shell Morlina oils are rust and oxidation inhibited lubricating oils that provide excellent lubrication in MORGOIL® bearing and steel mill circulating systems. They are designed to have appropriate viscosity/temperature characteristics, low foaming tendencies and excellent water separation properties. With that in mind, the first thing you want to look at in this report is the failed demulsibility* results from the July 2010 test. When you see something like this the next thing you should look at is the viscosity. The reference oil shows the normal levels for this oil to be at 700cSt, and if you scan all the test results, the viscosity has been well above the critical alarm limit. This lubricant's inability to separate from water and introduction of a water source are the reasons for this high viscosity. With the water at .842%, the oil is no longer doing its job and you can assume that the machine parts are not properly lubricated. *Demulsibility can be tested using ASTM D1401. During this test, a graduated cylinder containing a volume of oil and a volume of distilled water is placed in a constant temperature bath. The contents are stirred together for five minutes. The volumes of oil, water, and emulsion are recorded at five minute intervals until 3 milliliters or less of emulsion remains or until a time limit is reached. A sample is considered to have failed the test if more than 3 milliliters of emulsion remains when the time limit is reached. Less viscous oils (lower than 80 cSt) are expected to separate within 30 minutes. More viscous oils (greater than 80 cSt) are expected to separate within 60 minutes. In other words, the faster the separation, the better the demulsibility.
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Looking at Chemical Composition: FT IR
Page 11
Looking at Chemical Composition: FT‐IR Molecular analysis of lubricants and hydraulic fluids by FT‐IR spectroscopy produces direct information on molecular species of interest, including additives, fluid breakdown products, and external contamination. It compares infrared spectra of used oil to a baseline spectrum. The differences in IR spectra are quantified. Levels of the following oil degradation are reported:
Oxidation: At elevated temperatures, oil exposed to oxygen from the air oxidizes to form a variety of compounds. The majority of these are carbonyl‐containing compounds, such as carboxylic acid. Nitration: This level shows the reaction of oil components with nitrogen oxides. Soot: This measurement is the level of partially burned fuel in oil; it’s relevant for diesel engines. Glycol: A positive measurement here may indicate a coolant leak.
Let's interpret this report with oxidation Lube Type: ALCOA ML 686 Machine Type: INDUSTRIAL GEAR
Reference 571957
6/3/2009 521406 N/N/C
5/7/2009 512706 N/N/C
4/1/2009 504404 N/N/C
Vis 40 429.9 724.6 FTIR SPECTROSCOPY (indexing numbers) JOAP Method
715.7
686.7
628.1
Anti Wear Nitration Other Fluid Oxidation SINGLE COMPONENT TESTS
Lab No Oil Chng / Mach / Lube VISCOSITY (centistokes) ASTM D 445
Acid # mg KOH/g Water %
7/6/2009 528488 N/N/C
8 3 22 1
20 13 52 85
19 13 51 83
19 12 53 79
19 12 53 73
0.11
13.86 NEG
5.33 NEG
2.41 NEG
0.56 NEG
If you look at the FTIR for the reference oil the oxidation level is at 1, but the past tests show it in the 70 and 80 ranges. These are dangerous levels. There are a few things that you can consider here. The machine operator may have replaced the oil with a synthetic version, which typically have higher oxidation levels. However, let's continue reviewing the results to find more clues. You can see that the acid is fairly high. The viscosity will give us another clue, The reference for viscosity is at 429.9cSt, but the history of test results show the oil in the 700 range. We can now assume without a doubt that this oil is degrading at a rapid pace.
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Determine Oil's Serviceability: Acid Number
Page 12
Determine Oil's Serviceability: Acid Number Acid Number (AN) is an indicator of oil serviceability. It is useful in monitoring acid buildup in oils due to depletion of antioxidants. Oil oxidation causes acidic byproducts to form. High acid levels can indicate excessive oil oxidation or depletion of the oil additives and can lead to corrosion of the internal components. By monitoring the acid level, the oil can be changed before any damage occurs. An oil analyst is looking for a sudden increase. When your oil is flagged for high acid levels, it indicates accelerated oil oxidation, and you should change the oil as soon as possible. If any of the remaining highly acidic oil is left, it can have a catalyst effect and quickly ruin the new oil.
AN is measured by titration using ASTM D‐664 or D‐974. Both methods involve diluting the oil sample and adding incremental amounts of an alkaline solution until a neutral endpoint is achieved. The AN of a new oil will vary based on the base oil additive package. An R&O oil will usually have a very low AN, around 0.03. An AW or EP oil will have a slightly higher value, typically around 0.5. Engine oils commonly have a higher AN, in the neighborhood of 1.5.
Let's interpret these reports with acid issues Lube Type: NTL CLEARLUBE RS 32‐F Machine Type: SCREW COMPRESSOR
Reference 81983
10/13/2005 265015 N/M/C
8/9/2005 258380 N /N/N
6/23/2005 252985 N/N/N
Vis 40 31.5 33.0 FTIR SPECTROSCOPY (indexing numbers) JOAP Method
45.7
32.3
32.0
Anti Wear Nitration Other Fluid Oxidation SINGLE COMPONENT TESTS
9 3 117 22
17 5 105 67
7 3 120 8
7 3 121 7
2.52
5.00 0.044
0.50
0.44
Lab No Oil Chng / Mach / Lube VISCOSITY (centistokes) ASTM D 445
7 2 122 3
Acid # mg KOH/g Water %
10/22/2005 266426 Y/N/M
If you look at the acid number for this oil it started in June 2005 at .44 and got up to 5.0 by October. We know that the oil was changed at this time, but when the oil was tested again just 9 days later, the acid number is still high. This leads us to believe that even though the oil was changed, it is likely that the machine was not properly flushed, so the old oil contaminated the new oil. If a proper flush was done along with the oil change we would be less likely to see these test results.
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Gauging Particle Count
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Gauging Particle Count The concentration of wear particles in oil is a key indicator of potential component problems. Therefore, oil analysis must be capable of measuring a wide range of wear particles and contaminant particles. Some types of wear produce particles that are extremely small. Other types of wear produce larger particles that can be visually observed in the oil. Particulates of any size have the propensity to cause serious damage if allowed to enter the lubricating oil. Particle count analysis is conducted on a representative sample of the fluid in a system. The particle count test provides the quantity and micron size of the various solid contaminants in the fluid. The actual particle count and subsequent ISO Cleanliness Code are compared to the target code for the system. If the actual cleanliness level of a system is worse than the desired target, corrective action is recommended. Particle count is reported in six size ranges: 1. 2. 3. 4. 5. 6.
ISO 4406 Chart Range
Greater than 4 Greater than 6 Greater than 14 Greater than 25 Greater than 50 Greater than 100
Number of Particles Per 100 MI
Number
More than
Up to and including
24
8,000,000
16,000,000
23
4,000,000
8,000,000
22
2,000,000
4,000,000
21
1,000,000
2,000,000
Different mechanical systems have distinct levels of cleanliness that are required for optimum life and minimum component wear. Contaminants in a system accelerate wear, reduce efficiency, increase operating costs and can cause significant downtime.
20
500,000
1,000,000
19
250,000
500,000
18
130,000
250,000
17
64,000
130,000
16
32,000
64,000
Typically, new fluids are not clean fluids. Bulk lubricants from blending plants can range from 19/17/15 to 17/14/13, while sealed drum lubricants can have cleanliness codes as high as 22/21/19. In contrast, highly filtered fluids may have a code of 16/14/11 or lower.
15
16,000
32,000
14
8,000
16,000
13
4,000
8,000
12
2,000
4,000
11
1,000
2,000
10
500
1,000
9
250
500
8
130
250
7
64
130
6
32
64
ISO Cleanliness Code
ISO cleanliness codes are then assigned for particles in 4, 6, and 14 micron ranges. The results are reported by three numbers with a slash between them. The lower the numbers in the ISO Cleanliness Code, the cleaner the fluid.
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Let's interpret these reports with high particle count Lube Type: MOBIL SHC 626 Machine Type: PLAIN BEARING
LabNo
Reference 621848
9/9/2010 642889
5/19/2010 607906
3/19/2010 585735
12/28/2009 567207
Let's interpret these reports with high particle count Lube Type: MOBIL SHC 626 Machine Type: PLAIN BEARING
Reference 621848
9/9/2010 LabNo 642889 Oil Chng / Mach / Lube N/ N/ C SPECTROSCOPIC ANALYSIS (ppm) ASTM D 5185
Iron 0 4 Copper 0 0 Lead 0 0 Aluminum 1 0 Tin 0 0 Nickel 0 0 Chromium 0 0 Titanium 0 0 Vanadium 0 0 Silver 0 0 Silicon 19 4 Boron 0 1 Calcium 0 0 Magnesium 1 0 Phosphorus 932 879 Zinc 0 0 Barium 0 0 Molybdenum 0 0 Sodium 3 0 Potassium 0 0 PARTICLE COUNT (particles per ml) ISO 4406:99 ISOCode >4Micron >6Micron >14Micron >50Micron >100Micron
16/14/11 413 160 12 0 0
21/20/16 14362 5585 426 18 1
5/19/2010 607906 N/ N/ N 1 0 0 0 0 0 0 0 0 0 5 0 0 0 896 0 0 0 0 0
20/18/15 5603 2179 166 7 0
3/19/2010 585735 N/ N/ N 0 0 0 0 1 0 0 0 0 0 6 0 1 0 844 0 0 0 0 0
20/ 19/15 7776 3024 230 10 0
12/28/2009 567207 N/ N/ M 4 1 0 0 0 0 0 0 0 0 3 0 0 0 865 0 0 0 0 0
21/19/15 10255 3988 304 13 0
If you look at the particle count section of the report you will see that the 4 micron level is at 10,000+ in December 2009 and increases to 14,000 by September 2010. Though the particle count is high, there is no evidence of an extreme problem because the spectroscopic analysis doesn't show any wear problems. We can assume that the high particle count can be fixed with a filter change or the addition of a filtration system.
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Ferrous Wear Concentration
Page 15
Ferrous Wear Concentration In some cases, a particle count isn’t an effective test because the sample is inherently dirty and filtering the oil may not be plausible. A particle count indicates that the sample is extremely dirty, but it do not give any indication of ferrous wear. This test gives a direct measure of the amount of ferrous wear metals present in a sample.
Let's interpret these reports with high ferrous wear concentration Lube Type: MOBIL MOBIL GEAR 630 Machine Type: INDUSTRIAL GEAR
LabNo Oil Chng / Mach / Lube
Reference 397924
8/27/2010 639875 N/ M/ N
5/14/2010 607150 N/ M/ N
3/23/2010 586961 N/ N/ M
12/14/2009 564456 N/ N/ M
SPECTROSCOPIC ANALYSIS (ppm) ASTM D 5185
Iron 0 Copper 0 Lead 0 Aluminum 0 Tin 0 Nickel 0 Chromium 0 Titanium 0 Vanadium 0 Silver 0 Silicon 0 Boron 6 Calcium 6 Magnesium 0 Phosphorus 232 Zinc 4 Barium 0 Molybdenum 0 Sodium 0 Potassium 1 FERROUS WEAR CONCENTRATION (ppm) Concentration
80 0 0 4 5 2 0 0 0 0 17 18 50 5 232 39 0 0 1 0
603.00
67 0 0 3 5 1 0 0 0 0 21 18 54 5 240 40 0 0 0 4
336.00
15 0 0 1 2 0 0 0 0 0 4 12 86 55 309 97 1 0 0 12
19.00
13 0 0 1 0 0 0 0 0 1 7 13 91 56 285 102 1 0 2 0
21.00
This report is showing a Ferrous Wear issue in May 2010. You can also see that there was a sharp increase in the Iron at this time. Though these iron levels are not bad for a gear box, you never want to see major jumps like this, especially in a two month time period. This should alert your lab to take a closer look at the oil under a microscope using a test called Analytical Ferrography (AF). www.TESTOIL.com
Analytical Ferrography
Page 16
Analytical Ferrography Analytical Ferrography allows an analyst to visually examine wear particles present in a sample and determine the severity of wear on the unit. The wear particles are classified according to size, shape, and metallurgy. The analyst can evaluate the concentration, size, shape, composition, and condition of the particles, which indicates where and how they were generated. Particles are categorized based on these characteristics, and conclusions can be drawn regarding the wear rate and health of the component that the sample was drawn from. Trace RubbingWear
3
Light
Moderate Heavy 3
3
3
3
Rolling Contact
Max.
5‐
Particle
Ferrous White Non‐Ferrous
Sliding Wear
Rolling/Sliding Wear CuttingWear Chunks Spheres
Corrosion DarkMetallicOxides RedOxides
2 1
Dust/Dirt
3
OtherContaminants OxidationBy‐Products
Observations: Analytical Ferrography did not detect abnormal particles for this sample. Microns
200x
Wear debris and dust/dirt.
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Microns
500x
Wear debris and dust/dirt.
Page 17
