oil analysis lab

Oil Analysis – Lessons LearnedChad Norris

Refrigeration EngineerWells’ Dairy, Inc.

Oil Analysis – Lessons Learned

Oil Analysis Methods – Internal vs. External

Oil Analysis Reports – What info do I need?

Wear Debris Analysis – Valuable tool for root cause analysis

Oil Analysis Findings – Share-out of our experiences

Lubricant Storage – Oil cleanliness starts with storage practices

Lubrication Training – Procedures and management of an oil analysis program

Lubrication References – “Experts” in lubrication

What equipment could or should have oil analysis performed?

Any rotating equipment that has an oil volume allowing a sample to be retrieved. (Compressors, pumps, gearboxes,…)Why is oil analysis an important part of Mechanical Integrity?

Predictable method to prevent catastrophic failure of rotating equipment from lubricant related problems.

Why Oil Analysis?

Oil Analysis Methods

Internal – CSI 5200 MinilabExternal – Send samples to contracted outside agency for analysis and receive feedback in the form of a report.Lubricant / Equipment Suppliers – Some provide this service. Be wary, this is like having the fox guard the hen-house.

Internal - ProsFast turnaround of data.On-site staff can become experts at their equipment.Utilize other Predictive Technologies together more effectively.

Internal – ConsLack of specialized equipment.

Oil Analysis Methods Pro/Cons

External - ProsOverall lubrication expertise.Specialized equipment to solve difficult issues.

External – ConsCost – pay per sample by amount of testing.Slow turnaround time.May be difficult to integrate data to database.

Oil Analysis Methods Pro/Cons

CSI 5200 Minilab(Internal)

Digital Viscometer

Laser Particle Counter

Ferrous and Water Analyzer

Dielectric Strength Analyzer

WDA Microscope

WDA Patch Maker

Data sent to Oilview Software

Reports

Oilview Database

Company Database By:Plant (SICP, NICP, RR,….)

Equipment/Area Type (Production, Air, Ammonia,….)

Sample Point (SC21, SC23,……..)All 5200 Minilab tests and WDA microscope photos automatically stored for each sample point.Prints Labels for sample bottles with lab# for ID.

Oil Analysis Reports

Qualitative AnalysisOperational Conditions (Temp, Press., Flow)

Spiral #2 lower operating temps than designAppearance (Milky, Sludge, Debris)

Obvious water and contaminant entrapmentColor (Darker)

Degradation caused by contaminants and heatOdor (Burnt, Rotten)

Thermal degradation, microbial contamination

Oil Analysis Reports (Cont.)

QuantitativeParticle Count

ISO Code for 2, 5, and 15 micron sizeWater Contamination %Viscosity

Centistokes at 40CDielectric Strength

Chemical properties of reference oil compared to sample (additive package depletion and oxidation)

Ferrous IndexFerrous debris count and density

Oil Analysis Reports (Cont.)

Wear Debris Analysis

Microscopic Analysis of Wear Debris Particles characterized by wear process:

Boundary lube wear – inadequate lubricationAbrasive wear – contamination with abrasive particlesFatigue wear – overloaded bearingsFretting wear – vibration induced particlesDegradation Residues - sludge or varnish, red and black oxidesProcess contaminants – fibers, dusts, and organic compounds

Wear Debris Analysis (Cont.)

What is the purpose of Wear Debris Analysis?To detect potential failures before they occur.To determine the root cause of failures after they occur.To detect abnormal machine or lubricant conditions.

Wear Debris Analysis (Cont.)Examples

Oil Analysis Findings

Contamination will decrease with better filtration methods.

Oil Analysis Findings (Cont.)

Contamination will decrease with proper filter changes.


This chart from Noria, shows a study of industrial rotating equipment life. Doubling the life of

equipment is expected if oil cleanliness can be improved from ISO 22/19 to ISO 17/14.


Synthetic Ammonia Compressor oil can be used for a very long time with proper filtration and operating temperature. (>50,000 hrs). May require spiking with new oil to prevent additive depletion.Removal of contaminant may also remove additives.


Oil viscosity can be increased or decreased by water depending on the additive package. Oil analysis results are only as good as the sampling procedure.Utilize other predictive maintenance technologies along with oil analysis (vibration analysis, thermography, ultrasonics – grease).

Oil Analysis Findings -Greases

Greases are not fully tested but suspect greases can be emulsified and have ferrous wear test and WDA performed.Procedures in place to ensure grease compatibility and application.

Oil / Grease Storage

New oil is not necessarily clean oil (>ISO 21/20/19). High cost to purchase “clean oil” from suppliers.Dedicate a clean, dry, air conditioned room.Sampling on new oil containers.Label and have procedure in place for different lubricants.Filter lubricants before adding to equipment.

Oil Storage (Cont.)

Training

Suggest all facilities have those taking samples and responsible for the oil storage and usage take Level I training.Suggest that individuals that are responsible for reading/interpreting oil analysis reports be Level II trained.

References

Compressor/Motor Manufactures – specs.Noria – training, procedures, applications, publications.Emerson Process – Analysis EquipmentSMRP –Society of Maintenance and Reliability ProfessionalsInsight Services – www.testoil.com

Oil Analysis

Questions?

oil analysis lab

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