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8/2/2019 Booklet - Basics of Oil Analysis[1]
1/20
I t s b e t t e r t o k n o w.
BASICS OF OIL ANALYSIS
4th Edi t ion
SOUTHWEST
12715 Rya l Dr.
Stard, TX 77477
800-248-7778
WEST
3401 Jack Nrthrp Ave.
Hawthrne, CA 90250
800-424-0099
MIDWEST
2450 Hassell Rd.
Hman Est., IL 60195
800-222-0071
MID CONTINENT
11350 Bluegrass Pkwy.
Luisville, KY 40299
800-491-6063
SOUTHEAST
3075 Crners N. Ct. NW
Nrcrss, GA 30071
800-241-6315
CORPORATE OFFICE
3401 Jack Nrthrp Ave.
Hawthrne, CA 90250
800-336-3637
Analysts, Inc. 2011 www.analystsinc.cm
8/2/2019 Booklet - Basics of Oil Analysis[1]
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1 | BASICS o oIL ANALYSIS BASICS o oIL ANALYSIS | 2
Tday, cmmercial il analysis serves a myriad industries. over the past
seven decades it has saved cuntless dllars in premature equipment ailure
and cmpany dwntime. It has becme the cus magazines, seminars, and
trade shws. And it is easily ne the mst eective and practive tls r
maintaining the physical integrity internal cmpnents. With ver 50 years
leadership and experience, Analysts has played a pineering rle in this
industrys develpment. We are prud ur legacy. Mrever, we are wrking
t create new innvatins and enhanced services in an ert t advance ur
industry and better serve ur clients in the years ahead.
Commitment to ou customes
As a sign ur cntinued cmmitment t ur custmers, we are pleased
t release the 4th editin ur Basics oil Analysis bk. This bk is
designed t help yu gain a better understanding the undamental cncepts
an il analysis prgram. It is ur hpe that all practitiners, whether nvice
r experts, can gain practical inrmatin rm this bk t imprve yur il
analysis prgram.
INTRODUCTION_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
The ith o an industy
The extensive histry il analysis makes it the ldest all cmmercial
practive-maintenance technlgies. over the past 75 years, il analysis has
helped diagnse the internal cnditins il-wetted cmpnents and their
lubricants in virtually every industry that invlves heavy machinery. While tdaysanalytical tls emply the mst advanced technlgies, early test methds
were shckingly simple. The rst diagnstic techniques merely invlved smelling
il in an attempt t detect the sur dr excess acid. other early tests
included inspecting il with the naked eye r visual signs cntaminants r
placing a sample drp n absrbent paper t detect cntaminant residue.
In 1960, Edward rgern brught a new level service t the industry by
unding Analysts, Incrprated the rst independent cmmercial labratry
t er cmplete il analysis diagnstic services t all areas business
and industry. Thus taking the rudimentary methds utilized in the eld and
incrprating mdern scientic testing t prvide critical insight r maintenance
departments acrss all industries.
A moden ea o luicant analysis
Present-day technlgy uses a cmbinatin physical and
chemical tests t mnitr lubricant and cmpnent cnditins.
These tests are established and reviewed by a number
agencies, including the Internatinal organizatin r
Standardizatin (ISo), the American Sciety r Testing and
Materials (ASTM), and the Sciety Autmtive Engineers (SAE). In additin,
a variety labratry and persnnel certicatins have emerged t ensure the
highest levels lab technician quality.
8/2/2019 Booklet - Basics of Oil Analysis[1]
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3 | BASICS o oIL ANALYSIS BASICS o oIL ANALYSIS | 4
OUTLINE FOR AN EFFECTIVE OIL ANALYSIS PROGRAM_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
1. Determine your primary objectivesoil analysis can be applied t equipment and lubricant utilizatin, maintenance
and management:
Utilization
Decrease unscheduled dwntime
Increase verall cmpnent liespan
Cntrl lube cnsumptin and il dispsal csts
Assist prduct selectin, cmparisn and vericatin
Maintenance
Identiy and measure lube cntaminatin alng with cmpnent wear r
targeted crrective actin
Reduce in-service ailures and eld repairs
Establish prper lubricant service intervals
Management
Imprve reliability, prduct quality and prductivity
Imprve cst cntrl r equipment, labr and materials
Eliminate needless inspectins r repairs
Cntrl spares and replacement csts
APPLYING OIL ANALYSIS
oil analysis is an integral part the maintenance plan r pwer generatin
and manuacturing plants, ver-the-rad trucking feets, -rad
cnstructin equipment, aircrat, rerigeratin systems, prcessing and
chemical plants. Any piece equipment that has a lubricating system is a
ptential candidate r il analysis.
A successul il analysis prgram requires an rganized and sustained
ert. N TPM (Ttal Prductive Maintenance), lean manuacturing r
Six Sigma initiative will reach its gal withut the prcesses t sustain
imprvement. Bth the user and the labratry must wrk clsely tgether
t lay the grundwrk r the prgram and achieve the desired results.
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2. Carefully consider your best choice for an oilanalysis provider
All il analysis labratries claim they are qualied. Althugh certicatins and
requirements that a qualied used-il analysis labratry must meet are nw
much mre dened than in the past, ne thing has nt changed: Yu, the il
analysis user, must chse which labratry best satises yur needs.
r example, Analysts has been eatured in numerus magazine articles,
advertisements, and ther published materials. These secnd pinins are
excellent surces reerence abut ur service. Hwever, the best guide t
chsing a labratry and srting between the many claims these cmpanies
make, is experience. Chances are, smene in yur eld is already using ne
r mre the labs yu are cnsidering. Talk with them. Theyll cnrm hw we
dene qualied.
Choose a well-estalished laoatoy
Analysts has been in cntinuus and evlving peratin since 1960 lngenugh t have develped cmplete, time-tested prcedures r purchasing,
analysis, reprting, client cntact and supprt. We er a wide selectin
sampling materials, including ur SureSample sampling cntainer, QSS
sampling valves, and ther supplies, and make sure that these materials are in
stck when yu need them. We prvide the additinal descriptive literature and
training assistance needed t enhance yur il analysis prgram.
Choose a well-equipped laoatoy
Each Analysts labratry is thrughly cmputerized, and mst ur mdern,
well-maintained instruments are autmated and directly interaced with the
labs inrmatin-management system. We adhere t published, prven testing
prcedures and use nly the highest quality chemicals. We encurage ur
clients t visit ur lab acilities t see this r themselves.
Choose a laoatoy with a well-tained, expeienced sta
Analysts service and technical persnnel are respected members the
reliability cmmunity. Mre ur sta members are STLE Certied Lubricatin
Specialists r oil Mnitring Analysts than all ur cmpetitrs cmbined! We
recgnize the specic technical requirements r yur applicatins and can
answer yur questins ully. We have an rganized apprach r establishing
yu as a client and can give yu sund, practical suggestins r vercming
any bstacle yu might encunter in establishing and maintaining yur Analysts
il analysis prgram.
Choose a laoatoy with ecognized quality contol
Analysts, Inc. has the strngest certied and registered ISo 17025 quality
prgram in cmmercial il analysis. By attaining the ISo 17025 certicatin,
Analysts demnstrates n a daily basis ur cmmitment t quality in every
aspect ur business. In additin, Ana lysts quality prgram meets the
requirements 10 CR 50, Appendix B the ederal specicatin r qualit y
prgrams in nuclear pwer plants. All ur data analysts have ne r mre the STLE CLS and oMA certicatins, and mst ur technical sta members
als hld these and ther credentials. With ur prgram dcumentatin,
training, prcedures and llw-up, Analysts is recgnized as the leader in quality
and service within the industry.
As you look at price, quality,
support and experience, dont
orget to evaluate the laboratory
instrumentation and methods.
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
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Examine example epots o eliale ecommendations and
easy-to-ead omat
Clearly stated results and recmmendatins are vital t the success
yur il analysis prgram. Analysts reprts are cncise and inrmative.
our recmmendatins are specic, cmplete and easy t understand.
The recmmendatins refect a real knwledge the perating and wear
characteristics the cmpnent sampled. Test results indicating the need r
a majr inspectin are duble-checked and veried prir t reprting t yu.
All ur sta data analysts and chemists are members pressinal and
technical scieties, and ur established psitin in the cmmercial il analysis
eld ensures ready access t lubricant and cmpnent manuacturers data.
Expect apid tunaound o analysis epots
Analysts, Inc. prvides an average turnarund time ne day r less r rutine
samples. over 80% the samples received are cmpleted the same day they
are received. We ntiy yu immediately i critical cnditins are detected, and
make yur reprts available nline instantly ater cmpletin. We prvide rush
handling i yu require an immediate respnse, and ater-hurs special penings
can be arranged in case emergency.
Look o specialized summay epots
T assist ur clients t manage and cntrl their il sampling prgram, we
will prvide any a series eight specially designed prgram-management
and summary reprts. These reprts cnslidate sampling activity t cmpile
inrmatin such as Critical Cnditin (Units), Cnditin Analysis Statistics,
Summarized Sampling Activity and Summarized Sample Cnditins. Thereprts are available n a mnthly basis.
Look o a ull ange o inomation management tools and options
Analysts maintains a cmprehensive website at www.analystsinc.cm. This
site als ers the ully web-based LoAMS (Lube oil Analysis Management
System), develped in respnse t tdays practive reliability management
needs. Thrugh LoAMS, yur entire il analysis prgram can be managed in
the clud. rm prgram setup t prgram administratin, LoAMS prvides
the user with easy-t-use eatures, such as reprt retrieval, equipment
management, label printing, graphing, user management, and much mre.
A samples transit time rom
sampler to lab is always the
largest part o the actual
turnaround o a sample.
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3. Build the foundation for your programrequently there is an assumptin that an il analysis prgram can be hurriedly
established simply by taking a ew samples and sending them t the nearest,
cheapest labratry. Nthing culd be urther rm the truth.
Sampling point suvey
Bere yu begin sampling, a necessary rst step is t identiy the systems yu
want t sample, and cllect relevant technical reerence inrmatin n thse
systems. Next, determine any histry perating r wear prblems, and the
criticality any particular system (the impact dwntime and repair upn yur
business prcess).
Selecting tests
Dierent cmbinatins physical and spectrchemical tests are used t measure
the prperties the lubricant and determine levels cntaminants and chemical
elements suspended in the lubricant. The applicatin and gals the il analysis
prgram help determine the number and type tests that shuld be perrmed.
The physical analysiscncentrates n measuring certain characteristics
the lubricant, including cntaminants and il breakdwn by-prducts, as well as
their general eect n the lubricant prperties. The spectrochemical analysis
identies and measures selected metallic elements present in the lubricant as
micrscpic particles. Test results are reprted in parts per millin (ppm) by
weight. The relative cncentratins these elements are used t mnitr wear
rates, detect cntaminants and determine additive levels.
Analysts has develped standardized packages which are cmbinatins
rutinely perrmed tests. These packages are designed t cver the general
testing needs brad industry classicatins such as pwer generatin,
manuacturing, cnstructin, mining, and ver-the-rad trucking. While these
packages meet mst prgrams needs and bjectives, yu can develp yur
wn custm test slates t meet yur prgrams gals. Analysts will assist yu
in selecting the prper cmbinatin tests prir t beginning yur sampling
prgram.
Pope sampling intevals
When beginning a rutine il analysis prgram, the usual practice is t sample
the entire grup units/cmpnents as part the criticality assessment t
establish initial baseline data and quickly spt any cmpnents with serius
prblems. once this prcess is cmplete, the client and labratry then agree
n an initial rutine-sampling interval. This interval is based n the resul ts
the preliminary wrk, cmpnent manuacturer guidelines, client maintenance
prcedures and service scheduling, and Analysts experience with similar
cmpnents and applicatins. once the prgram is ull y established, the rutine-
sampling interval may be adjusted.
obtaining a representative sample is ne the mst imprtant parts a
scheduled il analysis prgram. I a sample des nt represent the true cnditin
the lubricant and cmpnent at the time sampling, the reliability bth the
test results and their interpretatin is aected.
Once determined, routine-sampling intervals should remain as
constant as possible.
Oil Analysis labs vary as do the
tests they perorm. Choosinga lab should be based on
testing capabilities, service and
satisying your specifc needs.
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Otaining a epesentative sample
This is undubtedly ne the mst imprtant parts a scheduled il analysis
prgram. I a sample des nt represent the true cnditin the lubricant and
cmpnent at the time sampling, the reliability bth the test results and
their interpretatin is aected.
Sampling a component while it is running or within 30 minutes ater
shutdown gives the most representative sample. This ensures that wear
prducts and lubricant cntaminants are thrughly mixed with the lubricant
and that the heavier wear particles have nt settled ut.
Areas where lubricant ow is restricted or where contaminants and wear
products tend to settle or collect should be avoided as sampling points.
We recmmend the llwing sampling pints in rder preerence:
A petcck r ther sampling access installed prior t the il lter (using
Analysts QSS r similar valve)
An il-dipstick tube r ther service pening (using the SureSample
r avacuum pump)
The sump r reservir drain
The reservoir drain is oten the easiest sampling point, but it is so prone to
sampling error that we discourage it.
In special cases, samples may be taken rm lube lters. The lab shuld be
advised prir t testing i this ccurs.
once a prper sampling pint and methd is chsen r a particular
cmpnent, il samples rm that cmpnent shuld always be taken rm the
same pint with the same methd.
4. Establish consistent oil-analysis-baseline informationIn a busy peratins and maintenance schedule, n ne wants extra paperwrk
and recrd keeping. But, i an il analysis prgram is t urnish anything mre
than test data, the user must prvide supprting inrmatin n the machines,
cmpnents and lubricants in service.
Initial equipment registratin can be easily accmplished by urnishing the
labratry with a cnslidated equipment list based n yur sampling pint
survey, r by cmpleting an individual registratin rm r each sampled
system. In either case, the sampling pint ID and current perating data is sent
with each sample.
In cmpleting ur il analysis rms and sample-cntainer labels, the llwing
brie denitins are helpul:
Unit I.D. nume
A unique reerence number r an entire unctinal unit. Examples include a
cmpany asset r inventry identicatin r a vehicle serial number.
Component
The verall type il-wetted system such as engine, hydraulic, r gearbx
rm which the sample is taken. other designatins such as let, number
3, rear r an actual descriptin the cmpnents use such as an drive,
winch r swing are als needed r clear identicatin. our rms prvide
checkbxes r cmmn sampling psitins.
NoTE: In industrial applicatins the unit and cmpnent ten reer t thesame mechanical system. In this case, the descriptin the sampled system
will be recrded as the unit.
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Time since new o since last ovehaul
The perating hurs r miles since the sampled cmpartment was rst
put int service, r since the last verhaul r rebuild was perrmed. Since
nrmal wear rates change ver the lietime a cmpnent and break-in may
resemble abnrmal wear, this inrmatin is needed as an nging reerence
r interpretatin. This data may be btained directly rm an equipment r
cmpnent service meter, r rm general perating recrds.
Time since oil change
The number hurs r miles cmpnent use between the time the il was
last changed and the time the sample was taken. This inrmatin is essential t
time-based trending.
Oil type
The manuacturer, prduct name, and SAE r ISo viscsity grade r the il that
was sampled. Since a manuacturer may sell mre than ne blend the same
viscsity prduct, the cmplete name is very imprtant in determining which
testing reerence il t use.
Oil consumption o makeup oil
The amunt il added t maintain a crrect il-ll level in the sampled cmpnent.
Cmplete il changes shuld nt be reprted as makeup il r identied as new il.
A sample may nt be prcessed immediately i the client name, unit and
cmpnent identicatin, r sample date are nt prvided. I yu have sampled
a particular machine bere and d nt ensure that the unit and cmpnent
identicatins match what yu riginally prvided, testing may be delayed while
the needed inrmatin is established, r the results may nt be led crrectly
with ther samples rm that machine.
In additin t this must-prvide data r each sample, yu shuld reprt any recent
maintenance, changes in perrmance r unusual perating cnditins. I yu
sample at the same time that yu perrm ther rutine maintenance and servicing
activities, yu shuld als recrd that inrmatin and submit it with the sample.
Specic individuals shuld be assigned lng-term respnsibility r this pr tin the
prgram. I this is nt easible, then a particular department shuld be designated r
invlvement. once this respnsibility is established, a system recrd keeping and
crrect sample identicatin shuld then be develped and initiated.
Recording operating time on
oil is absolutely essential to
time-based trending the
most accurate way to pinpoint
abnormal wear conditions.
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5. Use the lab interpretation of the test data properlyour lab interpretatin typically separates the verall cmpnent and fuid
cnditin as related t the relative severity cntaminatin and wearint
ur main classicatins.
NOrMAL
Physical prperties the fuid are within acceptable limits, and n signs
excessive cntaminatin r wear are present.
MONITOr
Specic test results are utside acceptable ranges, but are nt yet serius
enugh t cnrm abnrmal cnditins r justiy diagnstic actin. Cautin is
advised. The initial stages an abnrmality ten shw the same pattern
results as temprary cnditins, such as extended usage r verlading.
AbNOrMAL
Lubricant physical prperties, cntaminatin, and/r cmpnent wear is clearly
unsatisactry, but nt critical. A cnrming resample shuld be submitted.
Additinal diagnstic prcedures may be needed t cnrm each cnditin.
Crrective actins are necessary t prevent reductin service lie r verall
lss perrmance.
CrITICAL
Lubricant physical prperties, cntaminatin and/r cmpnent wear is clearly
serius enugh t require immediate diagnstic and crrective actin t prevent
majr lng-term lss perrmance r cmpnent ailure. Increases in perating
hazard are likely. Shrt-term lss perrmance may already be present. Large-
scale repairs may be required. Yu may be advised t remve the unit/cmpnent
rm service until a cnrming resample is tested and ther diagnstics cnrm
that repairs are necessary.
These assessments are relative and are assigned using both trend
analysis and condemning limits.
When trend analysis is used (primarily in the case wear elements), threshld
values are develped t identiy the bundary areas between nrmal and
abnrmal results. r wear metals, these threshld values vary r dierent types
cmpnent, but are usually specic and cnsistent r each individual mdel
a given applicatin. The values d nt prvide sharp lines nrmal/abnrmal
interpretatins; instead, they indicate ranges increased likelihd that a prblem
has develped t a par ticular pint. Generally, the lubricant and cmpnent
cnditin can be cnsidered nrmal as lng as the wear, cntaminatin and
lubricant deteriratin levels remain within the established nrmal ranges.
Regardless the threshld values, any sharp increase in wear metals r majr
shit in physical prperties can signal the beginning prblems. Therere, the
threshld values cant be used as g/n-g criteria. A great deal cautin,
judgment, experience and client technical input must be used in applying
threshld values prperly.
Clients are cntacted immediately by telephne n all samples where ur
interpretatin detects a critical cnditin. urther, email cpies all critical r
abnrmal samples are dispatched upn cmpletin ur evaluatin. on these
reprts the lab will recmmend specic maintenance actins designed t crrect
nt nly the indicated prblems but als the causes these prblems.
Each reprt shuld be remved as sn as pssible r actin items. Analysis
cpies shuld be attached t wrk rders r instructins. Access t electrnic
versins the reprt(s) shuld be given t apprpriate persnnel.
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6. Provide the lab with proper feedbackThe interpretatin guidelines accuracy is veried by cmparing the labs
maintenance recmmendatins with actual cnditins cnrmed by inspectin.
In this way, the test interpretatins are cntinually rened by practical experience.
eedback rm the client includes:
Abnrmal lubricant r cmpnent cnditins that yu suspect are present
The ndings any inspectin perrmed as a result il analysis prgramrecmmendatins
Abnrmal machine cnditins discvered that were nt previusly indicated
by il analysis
Nticatin servicing and/r maintenance perrmed
Inrmatin cncerning perating envirnment r equipment
applicatin changes
These items may be nted n the sample inrmatin rm, recrded in LoAMS.
I the eedback is sent separately, please prvide the cmpnent reerence
number (n reprt, upper right crner, third line belw the Status Was blck).
7. Measure cost ef fectivenessThe ecnmic gals reducing perating expenses and increasing prt
margins have nt changed since Analysts was unded. Rutine il analysis
will help yu achieve substantial savings in maintenance and repair csts. The
prgram perates much like a medical checkup; i prblems are detected, they
can be crrected bere they develp int serius and hazardus cnditins
that are cstly t repair. When samples are reprted nrmal, then the immediate
value il analysis is a persnal peace mind rather than an ecnmic
return. As the number sampled pieces equipment increases, the nancial
benet il analysis als increases. Greater equipment availability and reliability
means mre prductin, less dwntime and increased prts.
The imprtance tracking the savings generated by yur il analysis prgram
cannt be ver emphasized. Manpwer, parts and tl expenses will all be
aected. Hwever, because a well-run il analysis prgram is deeply integrated
int a clients verall maintenance prgram, management must establish a
strng platrm results measurement and dcumentatin t see il analysissunique cntributin t prtability.
One simple way o measuring
program eectiveness is to
trend the number and type o
abnormal or critical conditions in
your machines over time.
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Oil analysis is both predictive and
proactive and is probably the
most cost-eective maintenancetechnique available.
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Althugh sme benets il analysis may nt shw clearly n the bttm line
because they represent cnditins that were prevented, many the ecnmic
savings rm il analysis can be calculated by cmparing:
Parts and labr expenses r cmpnent repair, verhaul, r replacement
Lss revenue during dwntime
Reductin in cnsumable items, such as lubricants r uels
Increase in prductivity
THE FIVE KEYS TO SUCCESSFUL OIL ANALYSISAs with any diagnstic methd, the user must share in the respnsibility r
success when using this well-established and widely accepted practive-
maintenance tl. T achieve verall success r yur il analys is prgram, use
these prven keys:
1. Clealy defned client goals and pogam equiements ensure
that the tests perrmed t the applicatin and that the service is being ullyutilized n an nging basis.
2. repesentative samples ensure that the true cnditin the lubricant
and cmpnent can be determined by reliable, accurate testing.
3. Fequent la/client contact prmtes accurate interpretatin and
leads t increased client cndence and interest in maintaining an active il
analysis prgram.
4. Complete sample inomation speeds prcessing and increases the
Data Analysts ability t ully interpret the test results.
5. Pompt epot eview ensures that abnrmal r critical cnditins are
recgnized and acted n in time t prevent damage r prductin lss.
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TESTS AND THEIR SIGNIFICANCE_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Withut a wrking knwledge il analysis tests and their signicance, the user
may be uncertain abut the value the service and hw each test interrelates
with the thers t prvide a useul, accurate picture internal-cmpnent
and lubricant cnditins. The llwing inrmatin is prvided as a general
rientatin t what Analysts cnsiders are the mst imprtant il analysis tests
r industrial and nnindustrial applicatins.
SPECTROCHEMICAL ANALYSISSelected metallic elements present as disslved slids and micrscpic
particles suspended in the fuid t be analyzed are identied and measured in
parts per millin by weight. The analyzed elements are gruped int three main
categries:
1. Wear MetalsRelative mtin between lubricated parts is always accmpanied by rictin
between the ppsing part suraces. Despite the act that these suraces are
usually cated with an il lm, rictin wears them away. Sme the particles
prduced as the parts wear are small enugh t remain suspended in the
circulating il. Since these wear prducts are cmpsed the same materials
as the suraces rm which they riginated, the level each wear metal
remaining in the used il indicates the relative wear rate the lubricated parts.
Five of the most common types of wear are:
Adhesive / ruing Wea
This type wear ccurs when the il lm des nt separate the rughest pints
the ppsing mving-part suraces, and they begin t tuch each ther.
Adhesive wear ccurs nrmally during bth break-in and rutine service as
the parts wear slightly t maintain alignment. I severe adhesin ccurs due t
lad, speed r temperature cnditins, scung and scring will result. Metal
may be trn the part suraces r transerred rm ne part t anther and
eventual seizure the aected parts is likely. In nrmal service, adhesive wear
is cntrlled with antiwear additives, which bnd t lubricated suraces and
reduce direct part-t-part cntact.
Aasive WeaAbrasive wear is a cutting r etching actin caused when either circulating hard
particles r hard-surace prjectins wear away ster suraces. Surces
abrasive particles identied by il analysis include cntaminants such as dirt
entering a cmpnent il system and metal particles rmed during wear.
Fatigue Wea
atigue wear ccurs when cyclic r repeated lad stresses cause cracking,
spalling, and pitting the cmpnent part suraces. This type wear is mre
cmmnly assciated with ball/rller element bearings and gears where the part
suraces rll past each ther.
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Coosive (Chemical) Wea
Crrsive r chemical wear results when chemical reactins cause crrsin
r xidatin part suraces and part mvement r fuid pressure disldges
material rm this surace layer. This type wear is assciated with rust-
prmting cnditins, crrsive cntaminants and excessively high levels
chemically active additives.
Cavitation Wea
Cavitatin wear ccurs when metal is remved rm parts by the shck
impact cllapsing cavitatin bubbles n the part suraces. Cavitatin itsel
is assciated with partial vacuums rmed in a liquid by sudden changes in
pressure and may be caused by vibratin, reduced r uneven liquid fw and
ther actrs invlving particular cmpnent-part shapes and mvements.
2. ContaminantsDepending upn the circumstances, many dierent substances may be classied
as cntaminants. Silicn, in the rm silicn dixide (sand), is ne the mst
cmmn cntaminants mnitred with spectrchemical analysis. Similarly,
grease cntaminatin in an il system may be indicated by increases in aluminum
r barium i the grease cntains metallic saps. Althugh the term cntaminatin
is cmmnly assciated with substances entering a cmpnents il system rm
an utside surce, wear metals themselves are als a rm cntaminant.
3. Additives
Additives are chemical cmpunds added t ils, uels, and clants t impart
specic benecial prperties t the nished prducts (examples include:
Anti-wear, anti-xidant, detergency, discrepancy). Additives create new fuid
prperties, enhance prperties already present and reduce the rate at which
undesirable changes take place in a fuid during service.
WEAR METALS AND CONTAMINANTS
SILICON Silicn is typically assciated with dirt cntaminatin.
This cntaminatin can result rm any cnditin that
allws dirt t enter a cmpnent il system.
other surces silicn include seals, il and clant
additives and greases.
IRON allying
element r cast
metal
Reciprocating engine: Gears and shats; blck; cylinder
liners; valve train; cnnecting rds, rings and il pump;
sme bearings; sme pistns; sme accessry systems.
Turbine engine: Gears and shats; bearings;
pumps; husings.
Transmission: Gears and shats; bearings; brakes and
disks; pumps and shit spls; PTo; husing.
Torque converter: Shats; bearings; sme husings.
Dierential: Shats and gears; bearings; husing.
Transaxle/fnal drive/reduction gearbox: Gears and
shats; bearings; husing.
Hydraulic: Rtrs, vanes, pistns, and rds; husing and
bres; gears and shats; valves.
Reciprocating and rotary compressors: Gears and
shats; case; valves; cylinder liners; crssheads; ringsand screws r turbines; bearings; sme il-cler tubing.
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COPPER
allying element
Reciprocating engine: Bearings; wrist pin and valve-
train bushings; ther bushings and thrust washers; il-
cler tubing. Als may be present as an il additive r a
crssver cntaminant rm a leaking transmissin seal.
Turbine engine: Sme main and accessry bearing
retainers; bushings and nuts; sme il-cntrl valves.
Transmission: Discs; bearings; bushings and thrustwashers; il-cler tubing.
Torque converter: Retainers and separatrs.
Dierential: Bearings; bushings, retainers,
and thrust washers.
Final drive/reduction gearbox: Bearings; bushings,
retainers, and thrust washers; il-cler tubing.
Transaxle/fnal drive/reduction gearbox: Gears andshats; bearings; husing.
Hydraulic: Bearings and bushings; swash plate cups;
valves; sme pistns; sme pump cylinders;
il-cler tubing.
Reciprocating and rotary compressors: Bearings;
bushings, thrust washers and retainers; il-cler tubing.
ALUMINUM
allying element
r cast metal
All components: Aluminum xides present in the
envirnment, typically assciated with silicn (dirt)
cntaminatin.
Reciprocating engine: Pistns; bearings; bushings;
blcks, main and accessry cases and husings; sme
il-cler tubing.
Turbine engine: Main and accessry case, husings;sme retainers; seals; bafes.
Transmission: Sme cases; bushings and retainers.
Torque converter: Impellers.
Final drive/reduction gearbox: Bearings; bushings,
retainers, and thrust washers; il-cler tubing.
Dierential: Bushings and thrust washers.
Final drive/reduction gearbox: Bushings and thrust
washers.
Hydraulic: Sme pump husings.
Reciprocating and rotary compressors: Case;
impellers, sme pistns and crssheads; retainers.
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CHROMIUM
allying element
r plating
Reciprocating engines: Liners and rings; shats; valve train.
Turbine engine: Bearings; shats and gears; seals.
Geared components (general): Bearings; shats; seals.
Hydraulic: Rds; valves.
Reciprocating and rotary compressors: Liners andrings; shats; valve train.
LEAD & TIN
ally r fashing
Reciprocating engines: Bearings; sme pistns,
bushings and thrust washers.
Final drive/reduction gearbox: Bearings; shats; seals.
Hydraulic: Pump thrust plate; bushings.
Reciprocating and rotary compressors:
Bearings; bushings.
Lead may still be ound (rarely) in industrial paints and primers.
Tin may be present as an oil additive, usually in conjunction with
lubricants containing molybdenum compounds.
NICKEL
allying element
r plating
Reciprocating engines: Gears and shats;
valve train; bearings.
Turbine engine: Gears and shats; bearings.
Geared components (general):
Gears and shats; bearings.
Hydraulic: Gears and shats, bearings.
SILVER plating;
tracer
General: Sme bearings and bushings;
il cler slder; seals.
Silver is also occasionally used as a physical tracer to indicate that
wear has progressed to a certain point. In this application, silver is
either plated directly onto a part surace or incorporated into a layer
under the surace. The wear condition o the part can then be related
to the amount o the tracer deposited in the oil. This usage is most
oten ound in aerospace applications.
MOLYBDENUM
ally r fashing
General: Typically und nly in certain aerspace and
heavy-duty cmmercial r industrial steels. May als be
present in uels as heavy crude residual material.
MAGNESIUM
allying element
General: Cases and husings.
TITANIUM
allying element
General: Sme shats, bearings, and gears. Typically
und nly in certain aerspace and heavy-duty
cmmercial r industrial steels.
ANTIMONY
allying element
General: Certain types jurnal-bearing verlays.
ZINC allying
element
General: Brass ttings (with cpper);
galvanized suraces.
VANADIUM
allying element
General: Typically und nly in certain aerspace and
heavy-duty cmmercial r industrial steels. May als be
present in uels as heavy crude residual material.
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ADDITIVESMst mdern lubricants and clants cntain rgan-metallic il additives.
Sme these additives are rmed rm cmpunds ne r mre the
same chemical elements used in cmpnent parts.
MOLYBDENUM General: Extreme pressure additive r slid lubricant in
specialty ils and greases; crrsin inhibitr in sme
cnventinal clants r supplemental additives.
MAGNESIUM General: Detergent, dispersant, alkalinity increaser.
SODIUM General: Crrsin inhibitr in ils and clants.
BORON General: Detergent, dispersant; anti-xidant in ils
and clants.
BARIUM General: Crrsin and rust inhibitrs; detergent;
anti-smke additive in uels.
PHOSPHORUS General: Anti-wear; cmbustin chamber depsit
reducer; crrsin inhibitr in clants.
POTASSIUM General: Crrsin inhibitr; trace element in uels;
als und as a mineral salt in sea water
(marine cling systems).
CALCIUM General: Detergent, dispersant, alkalinity increaser.
ZINC General: Anti-wear, anti-xidant, crrsin inhib itr.
PHYSICAL ANALYSISViscosity
Viscsity is a lubricants internal resistance t fw at a given temperature in
relatin t time, and is cnsidered t be the single mst imprtant physical
prperty a lubricant. Changes in viscsity indicate imprper servicing,
dilutin, cntaminatin r lubricant breakdwn in service. Viscsity is mstcmmnly determined with a kinematic methd and the results are reprted in
centistkes (cSt)*. In additin t the viscsity result, the crankcase il viscsity
class an engine lubricant may als be expressed as an SAE Grade.
*1 Centistoke (cSt)= 1 square millimeter per second
Wate
The presence water in a nn-water-base fuid indicates cntaminatin rm
an utside surce r rm cndensatin. Excessive levels water prmte
lubricant breakdwn and cmpnent part crrsin. Results are reprted in
percent (%) vlume. Water cntaminatin can be assessed with the crackle
test. In certain cmpnents and applicatins where water cntaminatin must
be kept extremely lw, the Karl ischer titratin methd is used t measure and
reprt water cntent in parts per millin (ppm).
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Fuel Soot y LEM
LEM is the acrnym r Light Extinctin Measurement, an Analysts, Inc.
patented prcess t determine uel st. LEM measures the uel st dispersed
in the il diesel engines. This is an indicatin
the cmbustin eciency the engine. An
excessive cncentratin st prmtes il
gelling and sludge in the engine, leading t
pr il circulatin. It is aected by uel-injectreciency, injectr timing, integrity the ring-
pistn seal, il cnsumptin and the lad n the engine. Results are reprted in
weight percent (%). LEM is the mst ecient and accurate methd t measure
uel st, widely specied by oEMs as the preerred measurement methd.
Fuel Dilution
uel dilutin indicates the relative amunt unburned diesel uel r gasline
present in an engine lubricant. This dilutin is assciated with imprperly
adjusted r malunctining uel system assemblies. Excessive uel dilutin
lwers lubricant lad-carrying capacities, prmtes lubricant breakdwn
and increases the risk re r explsin. uel dilutin is determined by gas
chrmatgraphy and is reprted in percent (%) vlume.
Glycol
Psitive test results indicate the presence ethylene glycl, mst cmmnly
assciated with engine-cling system leaks. Glycl cntaminatin prmtes
wear, crrsin, sludging, and lubricant breakdwn. I the analysis indicates that
clant additives r water cntaminatin is present in the il sample, additinal
chemical tests are used t cnrm ethylene glycl cntaminatin.
Inaed Analysis
When an rganic cmpund, such as lubricating il, is expsed t inrared light, the
substances present in the cmpund will absrb the light at specic wavelengths.
The amunt absrbance at a particular wavelength is related t bth the type
and quantity absrbing material. In this way, certain cntaminants and physical
changes in the lubricant can be directly measured as a mlecular spectrum. Glycl
(clant) cntaminatin, sulates, acid and base changes, and certain additives
may als be detected, alng with an extremely wide range rganic cmpunds.Inrared analysis is mst requently used in il analysis t mnitr:
Fuel Soot
The amunt uel st carbn suspended in the engine lubricant. Higher
values indicate reduced cmbustin eciency due t cnditins such as air
intake r exhaust restrictins, injectr malunctins r excessive idling. Test
results are reprted n an absrbance scale.
Oxidation
The chemical incrpratin xygen int and subsequent lss lubricant
perrmance due t aging, adverse r abnrmal perating cnditins r
internal verheating. Test results are reprted n an absrbance scale.
Nitration
The rganic nitrates rmed when cmbustin by-prducts enter the engine
il during nrmal service r as a result abnrmal blw-by past the
cmpressin rings. Test results are reprted n an absrbance scale.
Water
Water cntaminatin prduces a characteristic peak in mst ils, which can
be easily measured. Test results are reprted in % vlume.
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Neutalization Nume
Bth the acid cntent and the alkaline cntent a lubricant may be measured and
expressed as a neutralizatin number btained rm a wet chemical titratin:
Acid Number (AN, TAN)
Measures the ttal amunt acidic material present in the lubricant; multiple
methds have been develped t perrm this test. Generally, an increase
in AN abve that the new prduct indicates il xidatin, r mixing with a
mre acidic prduct r cntaminant. The results are expressed as a numeric
value crrespnding t the amunt the alkaline chemical ptassium
hydrxide required t neutralize the acid per ne gram sample.
Base Number (BN, TBN)
Measures the ttal alkaline cntent present in the lubricant; multiple methds
have been develped t perrm this test. Many the additives used in engine
ils cntain alkaline (basic) materials intended t neutralize the acid-rming
prcesses aging and uel cmbustin. A relatively high BN is assciated
with increased prtectin against ring and cylinder liner crrsin, and damage
t yellw metals, such as cpper and brnze. Abnrmal decreases in BN
indicate a reduced acid-neutralizing capacity and/r a depleted additive
package. The test rst determines the amunt acid required t neutralize
the alkaline cntent the sample. The nal result is then expressed as an
equivalent amunt alkaline ptassium hydrxide per gram sample.
Paticle Counting
This test uses instruments with special detectrs which cunt and size particles
present in the fuid. Results are reprted as numbers particles in a specic
size range per a given vlume sample.
Analysts uses tw dierent methds t perrm the particle cunt: the pre
blckage/fw decay methd, and the APC (autmated particle cunt), a laser-
based methd. Each has particular strengths and apprpriate applicatins.
r these methds, three size ranges represent the current ISo 4406 standard:
>4 micrns, >6 micrns and >14 micrns. Three additinal ranges (>21 micrns,
>38 micrns, and >70 micrns) cmplete the cunt where detailed sizing is
required by a particular standard r custmer requirement.
Results rm the particle cunt are then used t indicate fuid cleanliness via
ISo classicatin cdes. The ISo Class cde is expressed as three separate
numbers (r example, 20/15/12). The rst number represents the relative
cntaminatin level rm the rst size range, and the secnd and third rangesare similarly calculated. Abnrmal particle cntaminatin levels are assciated
with increased wear, peratinal prblems with clse tlerance cmpnents,
fuid cntaminatin r degradatin and lss lter eciency.
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Particle Counting Chart: Feogaphy
errgraphy is an analytical technique in which wear metals and cntaminant
particles are magnetically separated rm a lubricant and arranged accrding t size
and cmpsitin r urther examinatin. It is widely used in il analysis t determine
cmpnent cnditin thrugh direct examinatin wear metal particles.
There are three stages in a cmplete errgraphic analysis: (1) direct reading
(DR) errgraphy, (2) analytical errgraphy and (3) the errgram interpretatin
and reprt.
DR errgraphy precipitates the wear particles rm a sample and electrnically
determines the quantity large (ver 5 micrns) and small (1 t 2 micrns)
particles present in the sample. Wear calculatins rm these results indicate the
rate, intensity and severity wear ccurring in the sampled machine. In cases
where the DR errgraphy wear trends indicate an abnrmal r critical wear
cnditin, analytical errgraphy can reveal the specic wear type and prbable
surce the wear cnditin.
Analytical errgraphy uses the errgraph luid Analyzer t cncentrate n
direct micrscpic evaluatin the wear particles. A errgram slide is prepared
by drawing the il sample acrss a transparent glass r plastic plate in the
presence a strng magnetic eld. An experienced evaluatr then examines
the errgram t determine the cmpsitin and surces the particles and the
type wear present.
An analytical errgraphy reprt includes specic type and quantity
classicatins the metallic and nn-metallic debris present n the slide, a clr
phtmicrgraph the errgram, an assessment the sampled machines
verall-wear status and a detailed interpretatin the errgraphy results.
ISO CODE PartIClES/1m
30 10,000,000
29 5,000,000
28 2,500,000
27 1,300,000
26 640,000
25 320,00024 160,000
23 80,000
22 40,000
21 20,000
20 10,000
19 5,000
18 2,500
17 1,300
16 640
15 320
14 16013 80
12 40
11 20
10 10
9 5
8 2.5
7 1.3
6 0.64
5 0.32
4 0.16
3 0.082 0.04
1 0.02
0.9 0.01
0.8 0.005
0.7 0.0025
PartIClE COUNt PartIClE DIStrIBUtION
Old 4402ranges
> 2
> 5
> 15
> 25
> 50
> 100
> 4
> 6
> 14
> 21
> 38
> 70
> 4 to >70
> 6 to >70
> 14 to >70
31167
6650
316
= ISO 22/20/15
24517
6334
269
41
4
2
New 11171ranges
Total of ranges:RawCount
Changes in particle cunting calibratin and redened reprting
size ranges have cncerned many il analysis users because
the pssible eects n histrical trends and cleanliness target
guidelines. The new ranges have been chsen t maintain
cleanliness target pints and minimize the eect n cmparing
the current values t the testing histry. We all benet rm this
change: imprved instrument accuracy and repeatability means
superir quality results.
The ISo 4406 cde table is still in use, nly it nw reerences
the new ISo 11171 size ranges. Thi s table shws hw the
Cntaminatin Class reerence chart supprts bth sets
particle cunt ranges. The particle cunt results are reprted as
three cde numbers separated by a /, r example, 22/20/16.
The rst cde number crrespnds t ttal particles greater than
4 (r 2), the secnd number crrespnds t ttal particles
greater than 6 (r 5), and the third t ttal particles greater than14 (r 15). The cde is btained by crss-reerencing the chart.
Althugh the results themselves shit slightly in the new system,
n signicant shit in ISo cde number ccurs due t the changes
in the autmated particle cunter calibratin methd.
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QSA
Analysts has develped an innvative test Quantitative Spectrphtmetric
Analysis (QSA) t accurately determine a used lubricants likelihd t
prmte harmul sludge and varnish build-up. Based n the lubricant type
and the applicatin, the basic QSA rating allws a trained diagnstician t
determine the presence r likelihd internal sludge and varnish build-up.
There are numerus types insluble cntaminants und in lubricating
systems. Insluble cntaminants are thse materials that will nt disslve in
the il. The tw mst general classicatins insluble cntaminants are hard
cntaminants, such as dirt, debris and wear particles, and st cntaminants,
cmpsed the varius il degradatin by-prducts.
Varnish riginates rm these st cntaminants. It is a thin, insluble lm that
ver time depsits thrughut the internal suraces a lubricatin system.
The degradatin prcess accelerates as the lubricant underges cntinued
expsure t air, water, and high temperatures. The presence varnish in
hydraulic and lubricatin systems causes many serius prblems, including
but nt limited t the sticking varnish-cated cntrl valves. Als, nce the
varnish has rmed, it takes a majr investment in time and mney t clean up
an aected system.
Specialty Testing
Test slates r certain industrial systems, greases, uels, clants r ther
special investigatins, ten include nn-rutine r ASTM specicatin tests. A
cmprehensive verview these tests can be viewed n Analysts, Incs website
at: www.analystsinc.cm. our ully equipped labratries give us the widest
pssible testing capabilities, and we have specially designed analysis prgrams
r certain applicatins and fuids. Please cntact us r detailed inrmatin
related t yur specic needs. A list ur acilities and cntact inrmatin can
be und n the back cver.
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
NoTES
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