International Council for Machinery Lubrication (ICML)
Brief Seminar Outline - Oil Analysis Level I
1994-1997 Condition Monitoring Savings – Baltimore Gas and Electric
Benefits from Excellence in Lubrication
Lubrication Fundamentals
Industry Rides on an Oil Film of About 10 Microns
Most Lubricating Oils Come From Petroleum (about 95%)
How Lubricant Oils are Formed
Base Stock Physical Properties
Mineral Oil Properties
Synthetic Lubricants are Man-Made Fluids Like Liquid Plastics
Molecular Comparison
Synthetic Lubricant Properties
Synthetic Lubricant Properties
Types of Lubrication Films
Sliding Contact Lubrication
Rolling Contact Lubrication
Oil Film Thicknesses In Machine Dynamic Clearances
Additives – What They Are
Wear and Friction Control Additives Form Chemical and Solid Lubrication Films
Anti-oxidants/Oxidation Inhibitors
How Anti-oxidants Alter Oil Life
Dispersants…Maximizing Particle “Hang Time”
Detergents
Corrosion Inhibitors
Viscosity Index Improvers
VI Improver Polymers – Viscosity and Shear Effects
Anti-foam Agents (Defoamants)
Roles of Base Oil and Additives
Are You Home Brewing Your Lubricants?
Oil Sampling – Sampling – The The Very Best Practices
Oil Sampling
Applications for Oil Sampling
In-service Oil Analysis
Options for Oil Sampling
Drain Plug Sampling
Tap Sampling – What’s Wrong…What’s Right
Drop-Tube Vacuum Pump Sampling
Tips to Effective Drop-Tube Vacuum Sampling
Where to Sample Crankcase Oil
Minimess Sampling Valves - Benefits
Minimess Sampling – Best Practice
Sample Valves Comparison
Live Zone Sampling
Options for Sampling From Pressurized Lines
Drain Line Oil Sampling Traps
Off-Line Sampling
Pathway Flushing
Minimum Line Flushing Requirements for Oil Sampling – 10x Flush Volume
Clean Oil Sampling Procedure
Sample Bottles
Study of Sample Bottle Cleanliness Levels
Primary and Secondary Sample Ports
Vibration Reading Comparison To Primary and Secondary Sample Ports
Secondary Sample Ports in a Single Component
Case Study: Paper Mill Calender Bearings
Primary Sampling – Wet Sump Circulating Systems
Primary Sampling – Dry Sump Circulating System
Sampling Points for a Forced Circulating Lube Oil System With Off-line Filtration
Sampling Points for a Hydraulic System With Return Line Filter
Six Options for Sampling Splash/Bath Lubricated Machines
Falk Splash Lubricated Gear box – Where Should you Sample?
Sampling Hard-to-Reach Machines
Microbore Sampling
Can You Find the Correct Sampling Locations?
Can You Find the Correct Sampling Locations?
Factors Influencing Oil Sampling Frequencies
Sample Frequency Generator
Sample Frequency Generator (continued)
Sample Frequency Generator (continued)
Case Study: Chevron – Chevron – Sample Sample Frequency Affects Failure Detection Efficiency
Summary: Oil Sampling “Best Practices”
Fluid Properties Analysis
1st Category of Oil Analysis: Fluid Properties Analysis
The Oil Aging Process…No, It Doesn’t Last Forever
Dual Course of Oxidation
Oxidation Root Causes
Common Oxidation Pointers
Two Common Measures for Viscosity
Measurement of Kinematic Viscosity
Common Laboratory Kinematic Viscometers
Onsite Viscometers
Kinematic Viscosity Conversions
What is Viscosity Index?
How Does Viscosity Index Impact an Oils Ability to Lubricate?
8600 cSt - Barely pumpable by a piston pump
860 cSt - Maximum start-up temperature for a vane pump to prevent cavitation
Mineral AW 32 (VI=95) 54 cSt
X 13 cSt
Synthetic AW 32 (VI=145)
Working Zone
C o
0 5
o
0 7 C
X X
The Causes of Oil Viscosity Changes
System Effects of Wrong Viscosity
What Temperature Should Viscosity be Measured and Trended at?
Viscosity Trends of Modern Diesel Crankcase Oils
How to Set Viscosity Limits
Case Study: Viscosity Trending of an ISO 68 Bearing Oil
How to Use Viscosity Analysis
Trending Acid and Base Numbers
Notes on Acid and Base Numbers
Use AN to Detect These Corrosive Acids
AN Trends with AW and R&O Oils
Variations in AN Trends by Oil Type
Notes on AN Monitoring
How to Monitor AN Trends
How BN Trends are Influenced
Trending BN’s with a Crankcase Oil
How to Monitor BN Trends
Fourier Transform Infrared Spectroscopy (FTIR)
How FTIR Works
Your Oil Analysis Report Might Show One or More of These FTIR Units
Using FTIR to Detect Common Base Oil Problems
Typical Absorption Wavenumbers (cm-1) for FTIR
Rotating Pressure Vessel Oxidation Test (RPVOT)*
Rotating Pressure Vessel Oxidation Test (RPVOT)*
*Formerly known as RBOT.
Case Studies: Trending an Oil’s RPVOT* Life
How to Monitor RPVOT* Trends
Cyclic-Voltammetry Tester for Measuring Antioxidant and RUL
Oil Analysis Oxidation Pointers
Varnish Formation
Ultracentrifuge (UC) – Detection of Carbon and Oxide Insolubles
Comparing Thermal and Oxidative Oil Failure
“Decomposition” Additive Depletion
“Separation” Additive Depletion
“Adsorptive” Additive Depletion
Mechanism of Depletion for Common Additive Types
How to Find Additive Depletion Data on an Oil Analysis Report
How to Use Elemental Analysis to Monitor Additive Depletion
Onsite Oil Condition Testers - Dielectric
Contamination Control and Proactive Maintenance
Contamination Control – Building Reliability
Damage Caused by Oil Contamination
The Silent Destruction of Rogue Particles
Particle Contamination: Both Cause and Effect of Wear
Case Study: Wear Debris Generation in 17 Hydraulic Machines
Three Ways to Measure the Life of a Machine
SKF Speaks Out on Contamination
National Research Council of Canada – What Causes Wear?
Maximize Investment
Understanding Particle Size and Particle Count
ISO Solid Contaminant Code
Other Current Standards for Particle Contamination
How Tough are Your Particles?
How Silt is Formed
How Silt Affects Bearings
Silt Degrades Hydraulic Valve Performance
How Particles Influence Engine Wear
Proactive Maintenance in Three Easy Steps
Conspicuous Charting is Key to Proactive Maintenance Success
Case Study: Nippon Steel
Case Study: Kawasaki Steel
Port of Tacoma Slashes Engine Rebuild Costs by 66% on 21 Straddle Carriers
BHP Decreases Failure Rate and Turns Up The Speed with Effective Lubrication Management
Case Study: General Motors
Step No. 1 - Set Target Cleanliness Levels
Typical Hydraulic Fluid Cleanliness Targets
Field Particle Counts – Averages of 25,000 Samples
Reliability Penalty Factor (RPF)
RPF (continued) Reliability Penalty Factor (RPF)
Machine I.D.: Date:
Safety Risks Upon Failure
Score
None
Low
Medium
High
0
1
4
8
Cost of Downtime Low
0
Hourly or Daily Downtime Costs (A) Medium High Extremely High
1
2
3 A x B
Typical Length of Downtime (B) Short
0
Long
1
2
3
4
RPF (continued)
Material and Labor Costs to Repair
Score
Low
Extremely High
0
1
2
3
4
5
Effectiveness of Early Warning Systems
Score
Highly Effective
0
Not Effective
1
2
3 Composite RPF Score
Reliability Penalty Factor = 10 Max
Contaminant Severity Factor (CSF) - Hydraulics
CSF - Hydraulics (continued)
Contaminant Severity Factor (CSF) - Hydraulics
Machine I.D.: Date:
Operating Pressure (psi)
Score
0 - 1,000
1001 - 2000
2001 - 3500
3501 - 5000
>5000
0
1
1.5
2
3
Valves
Score
Manual and Solenoid
0
Cartridge
Proportional
Servo
1
1.5
2
Pumps and Motors
Score
Gear
Vane
Fixed Piston
Variable Volume
0
1
1.5
2
CSF - Hydraulics (continued) Cyclic Loading
Score Frequency and Severity of Pressure Cycles Low Medium High
Constant Pressure
0.5
0
1
1.5
Varnish Potential
Score
Low
Medium
High
Extremely High
0
0.5
1
1.5
Water In Oil Contamination
Score
<100 PPM
<500 PPM
<1000 PPM
>1000 PPM
0
0.5
1
1.5
Particle Hardness/Abrasivity
Score
Low
Medium
High
0
0.5
2
Composite CSF Score
Contamination Severity Factor = 10 Max
Target Cleanliness Grid (TCG)
Contaminant Severity Factor (CSF) - Gearboxes
Contaminant Severity Factor (CSF) - Gearboxes
Contaminant Severity Factor (CSF) - Gearboxes
Life Extension Table New Cleanliness Level (ISO Code) 20/17 26/23 25/22
)
e d o C O SI (
s s e ni l n a el C e ni h c a M t r
n er u C
24/21 23/20 22/19 21/18 20/17
19/16
18/15
13/10
14/11
13/10
12/9
11/8
10/7
3.5
9
4
>10
5
>10
6
>10
7.5
>10
9
>10
>10
>10
>10
>10
>10
>10
>10
4
2.5
4.5
3
6
3.5
6.5
4
7.5
5
8.5
6.5
10
7
>10
9
>10
10
>10
>10
>10
>10
4
2.5
5
3
7
3.5
9
4
>10
5
>10
6
>10
7
>10
9
>10
>10
>10
>10
>10
>10
3
2
3.5
2.5
4.5
3
5
3.5
6.5
4
8
5
9
6
10
7.5
>10
9
>10
>10
>10
>10
3
2
4
2.5
6
3
7
4
9
5
>10
6
>10
7
>10
8
>10
10
>10
>10
>10
>10
2.5
1.5
3
2
4
2.5
5
3
6.5
4
7.5
5
8.5
6
9.5
7
>10
8
>10
10
>10
>10
2
1.5
3
2
4
2.5
5
3
7
3.5
9
4
>10
5
>10
6
>10
8
>10
9
>10
>10
1.7
1.3
2.3
1.5
3
2
3.7
2.5
5
3
6
3.5
7
4
8
5
10
6.5
>10
8.5
>10
10
1.6
1.3
2
1.6
3
2
4
2.5
5
3
7
3.5
8
4
>10
5
>10
6
>10
7
>10
>10
1.4
1.1
1.8
1.3
2.3
1.7
3
2
3.5
2.5
4.5
3
5.5
3.5
7
4
8
5
10
5.5
>10
8.5
1.3
1.2
1.5
1.5
2
1.7
3
2
4
2.5
5
3
7
3.5
9
4
>10
5
>10
7
>10
10
1.2
1.1
1.5
1.3
1.8
1.4
2.2
1.6
3
2
3.5
2.5
4.5
3
5
3.5
7
4
9
5.5
10
8
1.3
1.2
1.6
1.5
2
1.7
3
2
4
2.5
5
3
7
4
9
5
>10
7
>10
9
1.2
1.05
1.5
1.3
1.8
1.4
2.3
1.7
3
2
3.5
2.5
5
3
6
4
8
5.5
10
7
1.3
1.2
1.6
1.5
2
1.7
3
2
4
2.5
5
3
7
4
9
6
>10
8
1.2
1.1
1.5
1.3
1.8
1.5
2.2
1.7
3
2
3.5
2.5
5
3.5
7
4.5
9
6
1.3
1.2
1.6
1.5
2
1.7
3
2
4
2.5
5
3
7
4.5
>10
6
1.2
1.1
1.5
1.3
1.8
1.5
2.3
1.7
3
2
3.5
2.5
5.5
3.7
8
5
1.3
1.2
1.6
1.5
2
1.7
3
2
4
2.5
6
3
8
5
1.2
1.1
1.5
1.3
1.8
1.5
2.3
1.7
3
2
4
2.5
6
3.5
1.3
1.2
1.6
1.5
2
1.7
3
2
4
3.5
6
4
1.2
1.1
1.5
1.3
1.8
1.5
2.3
1.8
3.7
3
4.5
3.5
1.3
1.2
1.6
1.5
2
1.7
3
2
4
2.5
1.2
1.1
1.5
1.4
1.8
1.5
2.3
1.8
3
2.2
1.3
1.3
1.6
1.6
2
1.8
3
2
1.3
1.2
1.6
1.4
1.9
1.5
2.3
1.8
1.4
1.2
1.8
1.5
2.5
1.8
1.2
1.1
1.6
1.3
2
1.6
17/14
14/11
15/12
7
18/15
15/12
16/13
3
19/16
16/13
17/14
5
Hydraulics and Diesel Engines
Rolling Element Bearings
Journal Bearings and Turbo Machinery
Gear Boxes and Other
Clean Oil Helps You Detect Faults Earlier
Oil Pump or Dirt Pump?
Step No. 2 – Take Specific Actions to Achieve Targets
Where Does Particle Contamination Come From?
Case Study: How Clean Are New Oils?
Clean New Oil Management
Rack-Mount Lube Dispensing Station – Contamination Control
Lube Storage – Things to Avoid
Oil Cans and Top-up Containers – Things to Avoid
Take the Sump Management Self Exam
Tank and Sump Ventilation
Modernization of Vents and Breathers
New Tank Filter/Breather Hardware
Hatch Covers Need to be Sealed Tight
Shaft Seals…Oil Retention or Dirt Exclusion?
Controlling Hydraulic Cylinder Ingression
Filter Media Determines Filter Integrity
Make Sure Your Filters are Beta Rated
Filter Location Options
Portable Filtration
Offline Filters
Other Full Flow Filters
Crankcase Oil Contamination
Case Study – How Filtration Influences Oil Oxidation (AN) in Automatic Transmission Fluids
Step No. 3 – Monitoring and Controlling Particle Concentrations
Three Ways to Count and Size Particles
Automatic Optical Particle Counters (OPC)
How Optical Particle Counters Work
How Contaminants Appear to Optical Particle Counters
Procedure for Reducing Water Interferences with Optical Particle Counters
Onsite Optical Particle Counters
Pore Blockage Particle Counters – How They Work
Pore Blockage Particle Counting
Comparison of Optical to Pore Blockage
Particle Settling Can Alter Oil Analysis Results
Proper Particle Resuspension is Required Prior to:
How to Use Particle Counting in Oil Analysis
Water Contamination – The Scourge of Lubricating Oils
Water Contaminated Oil – States of Co-Existence
Controlling Water Ingression
Outdoor Drum Storage – Red Drum is Tilted for Water Drainage but What is Wrong?
Cleanout Hatch Shows Machine is a Rainmaker
Water Contamination – Contamination – Base Base Oil Effects
Water Contamination – Contamination – Additive Additive Effects
Water Contamination – Contamination – Machine Machine Effects
Effects of Water on Journal Bearings and Hydraulic Pumps
Water-Related Damage to Rolling Element Bearings
Water Contamination – Generator of Other Contaminants
Do Regular Walk-Around Visual Inspections for Water
How Low Should Moisture Limits (Targets) be Set?
Life Extension Table - Moisture New Moisture Level (ppm) 10,000
5,000
2,500
1,000
500
250
100
50
Rolling Rolling Rolling Rolling Rolling Rolling Rolling Rolling Element Journal Element Journal Element Journal Element Journal Element Journal Element Journal Element Journal Element Journal
)
m p p( l
e v e L er ut si o M t r
n er u C
50,000
2.3
1.6
3.3
1.9
4.8
2.3
7.8
2.9
11.2
3.5
16.2
4.3
26.2
5.5
37.8
6.7
25,000
1.6
1.3
2.3
1.6
3.3
1.9
5.4
2.4
7.8
2.9
11.2
3.5
18.2
4.6
26.2
5.5
1.4
1.2
2.0
1.5
3.3
1.9
4.8
2.3
6.9
2.8
11.2
3.5
16.2
4.3
1.4
1.2
2.3
1.6
3.3
1.9
4.8
2.3
7.8
2.9
11.2
3.5
1.6
1.3
2.3
1.6
3.3
1.9
5.4
2.4
7.8
2.9
1.4
1.2
2.0
1.5
3.3
1.9
4.8
2.3
1.4
1.2
2.3
1.6
3.3
1.9
1.5
1.3
2.3
1.6
1.4
1.2
10,000 5,000 2,500 1,000 500 250 100
Published Limits on Moisture
Be Aware of the Effects of Changing Oil Temperature
Measuring Water Concentrations
Crackle Test – A Sight and Sound Procedure
FTIR – Detection of Water in Oil
Measuring Water in Oil By Karl Fischer
Measuring Water in Oil Using Calcium Hydride Test Kits
Summary of Lab Test Method for Quantifying Water Content
How to Monitor Moisture
Water Removal Methods
Air Contamination: States of Co-Existence
Air Entrainment Problems Relate to Tank or Sump Design
Is There a Foam Problem Here? How About Air Entrainment?
Foam in Reservoir
When is Foam a Problem?
Air is the Primary Source of Oxygen in the Oxidative Degradation of an Oil
Glycol/Antifreeze Contamination in Engine Oil
Mechanism of “Oil Ball” Formation from Glycol (antifreeze) Contamination of Crankcase Oil
How to Detect Glycol in Crankcase Oil
Notes on Glycol
How to Use Elemental Analysis to Detect Glycol Contamination
High Soot Contamination in Engine Oil
Influence of Soot on Viscosity
Tests for High Soot Load
FTIR – Detection of Soot in Crankcase Oil
How to Monitor Soot Using FTIR
Fuel Contamination in Engine Oil (Fuel Dilution)
Tests for Fuel Contamination (Fuel Dilution)
Flash Point Test
How to Monitor Fuel Dilution Using Flash Point
Understanding and Analyzing Machine Wear
What Causes Changes in Wear Debris Concentrations
Dirt Causes Increased Wear and Oil Consumption
The Secret to Fault Detection and Analysis
Technologies Used to Analyze Wear Debris
Spectrometric Analysis of Wear Metals
Know Your Elements
How Spectrometric Elemental Analysis Works
Emission Spectrometer Anatomy
How Wear Particle Size Influences Spectrometric Analysis
The Progression of Mechanical Wear
Particle Size Sensitivities of Wear Particle Technologies
Rotrode Filter Improves Large Particle Measurement
RDE Spectroscopy Can Help Determine the Severity of a Wear Problem
Elemental Analysis by X-Ray Fluorescence Spectroscopy (XRF)
XRF is More Sensitive to Large Particles
XRF Applications and Benefits
Using SEM to Characterize Active Wear
Combining SEM with EDX (Energy Dispersive Xray) to Look at Component Metallurgy
Three Ferrous Density Testers
Direct Reading Ferrography
Using the Hall Effect to Determine Ferrous Particle Concentrations
Using Ferrous Particle Retardation
Using Exception Testing to Determine the Root Cause of an Active Wear Problem
Analytical Ferrography
Analytical Ferrography
Ferrographic Analysis – What it is Trying to Tell You?
*or ferrous particle count
1. Is There a Fault or Abnormal Wear?
2. If Yes to 1. Prepare Particles for Microscopic Examination (Analytical Ferrography)
Preparation of a Ferrogram
Procedure for Preparing a Filtergram
Field Filtergram (Patch) Makers
Ferrogram vs. Filtergram?
Microscopic Examination of Ferrogram
3. Where is the Abnormal Wear Coming From?
Localizing Problems with Oil Analysis
Heat Treated Ferrograms Helps Identify Metals
Characterizing Particle Composition by Visual Inspection
Look at Particle Metallurgy to Identify Source of Wear
Chemical Microscopy
4. What is Causing the Wear to Occur?
Shapes of Common Wear Particles
Examine Appearance of Particle to Identify Cause
Tips for Recognizing Common Problems
Abrasive Wear
Abrasive Wear Particles
Adhesive Wear
Adhesive Wear Particles
Surface Fatigue
Surface Fatigue Particles
Corrosive Wear
Corrosive Wear Particles
Spheres
Non-Ferrous Wear Particles
Friction Polymer Formation
Iron Oxide
5. How Severe or Threatening is it?
6. Can the Abnormal Wear be Arrested?
Ferrogram Particle Identification Guide
LaserNetTM Fines - Automated Wear Particle Morphology
Aspect Ratio Characterizes Wear Type
LaserNetTM Fines - Operational Principal
LaserNetTM Fines - Wear Particle Image Map
LNF Case Study - Gearbox Test Stand
LNF vs. Ferrography
Wear Particle Atlas on CD-ROM
Field Tests and Inspections
Simplify Oil Analysis…Use Easy Field Tests
Visual External Machinery Inspections
Routine Inspection of Sight Glasses is Oil Analysis
Visual Internal Machinery Inspections
Visual Inspection of Oil in a Sample Bottle
Using Oil Color as a Field Test
Using Oil Odor as a Field Test
Other Sensory Inspections
Field Test for Solid Contaminants
Simple Field Method for Preparing Patch
Field Test for Ferrous Particles
Field Test for Water Contamination – The Crackle Test
