231500267-06-Oil-Analysis

(1)

Oil Analysis

(2)

About POLARIS

Oil Analysis

Wear Debris Analysis

Data Interpretation/Alarm Limits

Sampling Methods

Information Technology

(3)

Significant Accomplishments

Since start-up in 1999:

•• Established customers in all 50

Established customers in all 50

states and over 15 countries

•• Total customer base of over 40,000

Total customer base of over 40,000

•• Reports available in 3 languages

Reports available in 3 languages

•• 300% growth rate over past 2 years

300% growth rate over past 2 years

•• Among top 25 fastest-growing

Among top 25 fastest-growing

privately-held companies in

Indianapolis for past 3 years

(4)

Industries Served

Power Generation

Transportation

Oil & Gas

Industrial

POLARIS

Laboratories

supports oil analysis

and reliability

maintenance

programming in a

wide variety of

industry applications.

Const/Mining

(5)

Facility Locations

Houston

Salt Lake City

• •Three locations

Three locations –

– 1

1 database

database

• •Accessible within 48

Accessible within 48

hours by ground

• •24-48 hour turnaround

24-48 hour turnaround

• •Local technical sales

Local technical sales

support

Indianapolis

(6)

One Lab Three Locations

BIG Advantages

••

Ship your sample to the

Ship your sample to the closest lab

closest lab

reducing transit time and cost

••

One phone number to call for

One phone number to call for entire program

entire program

••

Centralized Customer Service ensures a thorough

Centralized Customer Service ensures a thorough knowledge of

knowledge of

your program

••

Centralized Data Analysis ensures consistent commenting and

recommendations on all data from each of our

recommendations on all data from each of our laboratories

laboratories

••

One database secures data history even when samples are sent to

a different lab

(7)

Fluids Tested

Oil

••

Test for wear metals and contamination

••

Monitor fluid properties and suitability for

use

Fuel

••

Troubleshoot filter problems

••

Determine compliance with s

Determine compliance with supplier

upplier

specifications

Coolant

••

Detect corrosive chemicals

••

Monitor silicate levels

••

Determine compliance with OEM

antifreeze concentration

recommendations

POLARIS specializes in testing oil,

fuel, coolants and water-based fluids.

(8)

ISO 17025

A2LA Accreditation

••

Takes quality standard of

ISO 9000 to higher level

••

Ensures traceability back

to standard

••

Determines uncertainties

and repeatability

••

Is highest level of quality

attainable by a laboratory

backed by the most

stringent accrediting

body in the industry

ISO 9000

Guide 25

ISO 17025

ISO ISO 17025 17025 A2LA A2LA

(9)

About POLARIS

Oil Analysis

Wear Debris Analysis

Data Interpretation/Alarm Limits

Sampling Methods

Information Technology

(10)

OIL IS THE LIFEBLOOD

OF MANY SYSTEMS

•• Oil analysis is like a blood test

Oil analysis is like a blood test

–

– A sample is taken

A sample is taken

–

– Sample is documented

Sample is documented

–

– Sample is delivered to a lab

Sample is delivered to a lab

–

– Tests are performed

Tests are performed

–

– Results are interpreted

Results are interpreted

–

(11)

Oil Analysis Basics

(12)

WHY DO OIL ANALYSIS?

•• To monitor changes in lubricant properties

To monitor changes in lubricant properties

•• To identify contamination and its affect on

To identify contamination and its affect on

a lubricant properties

•• To determine type and severity of wear

To determine type and severity of wear

occurring

(13)

WHAT DOES OIL ANALYSIS TELL US?

•• Determine condition of the oil

Determine condition of the oil

−

Monitoring changes in the lubricant to determine if the oil is

suitable for continued use

•• Determine condition of the unit

Determine condition of the unit

–

– Analysis provides clues that can identify problems

Analysis provides clues that can identify problems so they can

so they can

be corrected before permanent damage occurs

–

– Evaluates wear data

Evaluates wear data

•• Determine effectiveness of maintenance

Determine effectiveness of maintenance

strategy

–

– Run to failure

Run to failure

–

(14)

MAINTENANCE STRATEGIES

Unplanned Maintenance

•• Run it to failure

Run it to failure

–

– Very high maintenance cost

Very high maintenance cost

–

– Short component life

Short component life

–

(15)

MAINTENANCE STRATEGIES

Preventive Maintenance

•• Interval-based Maintenance

Interval-based Maintenance

–

– Moderately high cost

Moderately high cost

–

– Short component life for unique equipment

Short component life for unique equipment

–

(16)

MAINTENANCE STRATEGIES

Predictive Maintenance

•• Condition-based and Planned

Condition-based and Planned

–

– Lowest overall cost

Lowest overall cost

–

– Considers unique component characteristics

Considers unique component characteristics

–

– Provides trending that can predict problems

Provides trending that can predict problems

and failures

–

– Increases component life

Increases component life

–

(17)

TESTING LUBRICANT PROPERTIES

•• Viscosity

Viscosity

•• Viscosity Index

Viscosity Index

•• TAN

TAN

•• TBN

TBN

•• Oxidation

Oxidation

•• Nitration

Nitration

•• Demulsibility

Demulsibility

•• Foaming

Foaming

•• Rust

Rust

•• Copper Corrosion

Copper Corrosion

•• RPVOT

RPVOT

•• Pour Point

Pour Point

•• Flash Point

Flash Point

•• Aniline Point

Aniline Point

(18)

VISCOSITY

•• Shear force/shear rate

Shear force/shear rate

•• Factors that affect

Factors that affect viscosi

viscosity

ty

•• Temperature/relatio

Temperature/relationship by

nship by grade

grade

•• Pressure

Pressure

•• Measurement

Measurement

•• Comparative classifications

Comparative classifications

•• Viscosity Index

Viscosity Index

Viscosity is a

lubricant’s resistance to flow at a

given temperature.

(19)

VISCOSITY

The force required to slide one object over another

when the two surfaces are fully separated by a fluid is

dependent on the fluid’s viscosity

Stationary Surface

Moving Surface

Sheared

Liquid

Shear Force (per area)

Viscosity =

Shear Rate (flow)

The higher a fluid’s

viscosity, the greater

the force (energy)

required to slide the

surfaces at a given

speed and gap

(20)

OPERATING

CONDITION

VISCOSITY

NEEDED

HIGHER LOAD

HIGHER

TEMPERATURE

INCREASED

SPEED

VISCOSITY SELECTION

(21)

TOTAL ACID NUMBER

•• Measures amount of both organic and

Measures amount of both organic and

inorganic acid present

•• Indicates oxidation or contamination from

Indicates oxidation or contamination from

other corrosives

•• ASTM D-664M reported as mg/KOH per/g of

ASTM D-664M reported as mg/KOH per/g of

sample

–

– Caution level >2X starting point of new oil

Caution level >2X starting point of new oil

–

(22)

TAN AND TBN BY TITRATION

(23)

OXIDATION

•• Breakdown of a lubricant due to age and operating

Breakdown of a lubricant due to age and operating

conditions

•• Prevents additives from performing

Prevents additives from performing properly

properly

•• Causes the formation of acids and increases viscosity

Causes the formation of acids and increases viscosity

•• Testing done by Infrared Analysis (FTIR)

Testing done by Infrared Analysis (FTIR)

•• Rep

Report

orted a

ed as a

s au’s

u’s/cm

/cm (ab

(absor

sorpti

ption u

on uni

nits p

ts per c

er cent

entime

imeter

ter))

–

– 25 condemnation level by CAT & Waukesha

25 condemnation level by CAT & Waukesha

–

(24)

NITRATION

•• In

Indi

dica

cate

tes

s ex

exce

cess

ssiv

ive “

e “b

blo

low

w--by” from cylinder walls and/or

by” from cylinder walls and/or

compression rings

•• Indicates presence of nitric acid, which speeds up oxidation

Indicates presence of nitric acid, which speeds up oxidation

•• Too much disparity between oxidation and

Too much disparity between oxidation and nitration points to

nitration points to

air-to-fuel ratio problems

•• As oxidation/nitration increases, so d

As oxidation/nitration increases, so does TAN and viscosity,

oes TAN and viscosity,

while total base number will decrease

•• Testing done by Infrared Analysis (FTIR)

Testing done by Infrared Analysis (FTIR)

•• Rep

Report

orted

ed as

as au’

au’s/cm

s/cm (Ab

(Absor

sorpti

ption

on uni

units

ts per

per cen

centim

timete

eter)

r)

–

– 25 condemnation level by CAT & Waukesha

25 condemnation level by CAT & Waukesha

–

(25)

FTIR - FUEL, SOOT,

OXIDATION, NITRATION

(26)

REPORTING MEASUREMENTS

Fu

Fue

el

l %

% So

Soot

ot %

% W

Wa

atte

er

r %

% Vi

Vis

s @

@ 4

40 0 Vi

Vis

s @

@ 1

10

00 0 A

AN

N BN

BN O

Ox

xi

i Ni

Nitt

Per Cent By

Volume

Viscosity In

Centistokes

_–

cSt

at Specified

Temperature

Neutralization

Number Expressed

In Mg/KOH/g

FT-IR Results

Expressed In

Absorbance Units

Per Centimeter

(27)

CONTAMINANT LIMITS

Oil

Silico

Oil

Silico

n

Sodium Potassiu

m

Fue

l %

Soot

%

Oxidatio

n

Nitration

Diesel

Engine

20

70

20

2

20

160

250

6

30

30 Transmission

Transmission

₂₀

₅₀

₂₀

N/A

_N/A

₂₅

_N/A

160

90

150

150 N/A

N/A

_N/A

₄₀

_N/A

Gear Box

₂₀

₇₅

₈₀

N/A

_N/A

₃₀

_N/A

256

307

180

180 N/A

N/A

_N/A

₅₀

_N/A

Hydraulic

₁₅

₂₅

₁₀

N/A

_N/A

₂₀

_N/A

65

(28)

METALS BY ELEMENTAL ANALYSIS

Wear Metals

_Contaminants

Lubricant

Additives

F

Fee

C

Crr

N

Ni

i A

Al

l C

Cu

u P

Pb

b S

Sn

n C

Cd

d A

Ag

g

T

Tii

V

S

Si

i N

Naa

K

M

Mo

o S

Sb

b M

Mn

n

Lii

L

B

B M

Mg

g C

Ca

a B

Ba

a P

P Z

Zn

n

1

13 3 0 0 0 0 1 1 2 2 0 0 0 0 0 0 0 0 0 0 0 0 3 3 3 3 0 0 0 0 0 0 0 0 0 0 5 5 0 0 2244449 9 0 0 1122660 0 11114444

Reported in concentrations of parts per million - ppm

Multi - Source

(29)

ICP SPECTROMETER

(30)

FLAGGING POINTS & ALARM

LIMITS

••

sample information YOU provide

the lab

••

OEM/equipment specifications

••

lubricant specifications

••

laboratory database of samples

with same criteria

••

s

stta

attiis

sttiic

ca

al a

l an

na

aly

lys

siis o

s of “

f “re

rea

al l

l liiffe

e””

laboratory data

Where do the numbers come from?

(31)

SETTING ALARM LIMITS

•• Statistics used to establish alarm limits for wear

Statistics used to establish alarm limits for wear

metal concentrations

•• Mean (average, indicated by x) and standard

Mean (average, indicated by x) and standard

deviation (the distance the spread of numbers

are from the mean, indicated by

are from the mean, indicated by σ

σ ) are

) are

determined for each population of elemental

concentrations

•• How many standard deviations from the mean (-

How many standard deviations from the mean

(-3 to +(-3) alarm limits will be set is based on

3 to +3) alarm limits will be set is based on

frequency distribution

(32)

ALARM LIM

ALARM LIMIT SPECIF

IT SPECIFICS

ICS

•• Base alarm limits on specific information

Base alarm limits on specific information

–

– Unit Type

Unit Type

•• Diesel Engine

Diesel Engine

•• Turbine

Turbine

•• Compressor

Compressor

–

– Reciprocating, Rotary Screw, Centrifugal

Reciprocating, Rotary Screw, Centrifugal

•• Gear System

Gear System

–

– Helical, Double Helical, Hypoid, Worm

Helical, Double Helical, Hypoid, Worm

•• Hydraulic System

Hydraulic System

•• Bearing

Bearing

–

– Babbitt, Roller, Spherical Roller, Needle

Babbitt, Roller, Spherical Roller, Needle

•• Pump

Pump

–

– Piston, Gear, Vane

Piston, Gear, Vane

–

(33)

Information Pyramid

Transmission

₂₁₇

PPM

Iron

Flagging

Point

(34)

Information Pyramid

Transmission

217

217 PPM

PPM

Iron

Flagging

Point

Automatic Tran

Automatic Transmission

smission

149

(35)

Information Pyramid

PPM

Iron

Flagging

Point

Transmission

217

217 Automatic Tran

Automatic Transmission

smission

149

149 Allison

Allison

171

(36)

Information Pyramid

PPM

Iron

Flagging

Point

Automatic Tr

Automatic Transmission

ansmission

₁₄₉

Transmission

217

217 Allison

Allison

₁₇₁

HT754CR

68 HT754CR

68

(37)

Transmission

217

217 Automatic

Automatic Transm

Transmission

ission

149

149 Allison

Allison

171

171 HT754CR

HT754CR

68

68 10µm

10µm

Fltr

₆₀

Information Pyramid

PPM

Iron

Flagging

Point

(38)

217

217 10µm

10µm

Fltr

52

52 Information Pyramid

Information Pyramid

Iron

PPM

Flagging

Point

Lack of

information

allows 165

ppm where

failure may

occur!!!

(39)

WEAR METAL LIMITS

Oil

Iron

Chrome

Chrome Nickel

Nickel

Aluminum

_Coppe

rr

Lea

d

Tin

Gas Turbines

₇

₁

₄

₆

₄

₃

35

5

7

20

24

28

30

30 Rotary Screw

Rotary Screw

Compressors

62

1

62

1

2

5

15

5

7

217

7

6

32

120

40

56

56 Injection

Injection

Molding

19

1

19

1

42

6

1

95

5

4

8

88

54

10

10 Roller Bearing

Roller Bearing

₁₄₁

₄

₂

₁₆

₂₆

₁₃

₇

493

14

493

14

8

59

208

104

56

(40)

DIESEL ENGINE LIMITS BY MFR

MFR

Iron

Chrome

Chrome Nickel

Nickel

Aluminum

_Coppe

rr

Lead Tin

Cummins

₆₀

₇

₄

₁₄

₂₁

₄₇

₅

390

46

20

98

147

353

40

40 CAT

CAT

₆₆

₆

₃

₉

₃₇

₂₄

₅

429

39

15

63

259

180

40

40 Navistar

Navistar

₇₇

₇

₃

₆

₁₇

₂₀

₅

501

46

15

42

1

119

19

150

40

40 Volvo

Volvo

₇₄

₆

₅

₁₃

₄₄

₁₆

₅

481

39

25

91

308

120

40

(41)

DIESEL ENGINE LIMITS BY MODEL

CA

CAT

T

Iron

Chrome

Chrome Nickel

Nickel

Aluminum

_Coppe

rr

Lead Tin

3406E

₄₃

₃

₅

₅₄

₅

₄

280

20

280

20

15

35

378

38

32

32 3304

3304

₄₉

₆

₃

₉

₃₈

₇

₅

319

39

319

39

15

63

266

53

40

40 3512B

3512B

₁₉

₃

₆

₄₃

₇

₃

124

20

124

20

15

42

301

53

24

24 3516

3516

₁₃

₃

₄

₄₈

₅

₃

85

20

15

28

336

38

24

(42)

TREND ANALYSIS

•• Oil Analysis works best when at least three samples

Oil Analysis works best when at least three samples

have been taken over a short period of time so that

trends can be

trends can be identified

identified

•• Result trends over a sufficient period of time

Result trends over a sufficient period of time are more

are more

useful than absolute numbers when trying to determine

what is occurring in a

what is occurring in a sampled machine.

sampled machine.

•• Trending and graphing offer an easy to read

Trending and graphing offer an easy to read

instantaneous analysis of the condition of the equipment,

condition of the lubricant, and level of contamination.

•• Never base a decision to tear down a machine on the

Never base a decision to tear down a machine on the

results of only one (1) oil analysis report

(43)

TREND ANALYSIS

•• Physical property trends help determine if the

Physical property trends help determine if the

best lubricant is being used

•• Trend analysis helps in

Trend analysis helps in scheduling regular

scheduling regular

maintenance such as oil and/or filter changes

•• Tr

Tren

end an

d anal

alys

ysis h

is hel

elps e

ps est

stab

ablilish “

sh “be

best

st

practices” maintenance procedures

(44)

TREND ANALYSIS

•• “T

“Top

oppi

ping o

ng off

ff” wi

” will s

ll ske

kew th

w the tr

e tren

end an

d and

d

should be noted when the sample is

submitted to the laboratory for processing

•• Note sump or

Note sump or reservoir capacity

reservoir capacity

•• Note if multiple components are lubricated

Note if multiple components are lubricated

from

from same

same sump,

sump, i.e.

i.e. motor

motor or

or turbine,

turbine,

gearbox, compressor

(45)

WHAT IS CONSIDERED

SIGNIFICANT CHANGE?

•• Wear Metals

Wear Metals

–

– an increase of 5 to 20 ppm - depending on the

an increase of 5 to 20 ppm - depending on the

metal and the unit type - or an increase of

100%, whichever is larger

•• Contaminant Metals

Contaminant Metals

–

– an increase of 5 to 10 ppm or an increase of

an increase of 5 to 10 ppm or an increase of

100%, whichever is larger

(46)

WHAT IS CONSIDERED

SIGNIFICANT CHANGE?

•• Water

Water

–

– an increase of 100%, or

an increase of 100%, or any increase that

any increase that

approaches the advisory levels of that

approaches the advisory levels of that sample

sample

point

•• Total Acid Number

Total Acid Number

–

– an increase of 0.1 for R&O oils

an increase of 0.1 for R&O oils

–

– an increase of 0.2 for AW oils

an increase of 0.2 for AW oils

–

(47)

WHAT IS CONSIDERED

SIGNIFICANT CHANGE?

•• Viscosity

Viscosity

–

– an increase or decrease of 5%

an increase or decrease of 5%

•• increases usually indicate lubricant degradation

increases usually indicate lubricant degradation

•• decreases indicate product

decreases indicate product contamination

contamination

•• Direct Read

Direct Read Ferrography

Ferrography

–

– a 50% increase of either DRS or DRL

a 50% increase of either DRS or DRL

•• ISO Particle Count

ISO Particle Count

–

– an increase of 2 classes in

an increase of 2 classes in any of the

any of the

reporting ranges (2/5/15 or 4/6/14)

(48)

HOW TO READ

OIL ANALYSIS REPORTS

••

Does the report suggest maintenance action?

–

– Yes

Yes

•• Consider all other available diagnostic information (vibration,

Consider all other available diagnostic information (vibration,

thermography, in-line sensors)

•• Act on the

Act on the recommen

recommendation or or

dation or order more

der more testing.

testing.

•• If lube change recommendation is due to contamination,

If lube change recommendation is due to contamination, ACT ON

ACT ON

RECOMMENDATION

to ensure fluid integrity

–

– No

No

•• Is re-sampling recommended?

Is re-sampling recommended?

–

– Yes

Yes

»

» Send se

Send second sa

cond sample im

mple immedi

mediately or at ha

ately or at half norm

lf normal sampl

al sample inter

e interval to

val to

verify results

1. Review highest severity

reports first

(49)

2. Review cautionary reports

•• Pay particular attention to cautionary data as it becomes

Pay particular attention to cautionary data as it becomes

more useful as more data

more useful as more data is acquired

is acquired –

– trends will

trends will

become easier to identify and appropriate actions to take

will appear clearer.

•• Sa

Samp

mple r

le res

esul

ults

ts ar

are “b

e “bor

orde

derl

rlin

ine”

e” - some wear and

- some wear and

contaminatio

contamination results may be

n results may be flagged but don’t

flagged but don’t

necessarily indicate failure mode or results are not

significan

significant enough to

t enough to warrant action.

warrant action.

HOW TO READ

OIL

(50)

3. Review normal reports

•• As time permi

As time permits, review norm

ts, review normal reports to learn w

al reports to learn what

hat

“normal” results are for each

“normal” results are for each unit sampled. Trends are

unit sampled. Trends are

then more easily recognized.

HOW TO READ

OIL

(51)

SAMPLE INFORMATION

Unit Type and ID

Unit Type and ID should give as much detail asshould give as much detail as possible.

possible. What kind ofWhat kind of compressor, gearbox,compressor, gearbox, engine, etc. influences flagging parameters and engine, etc. influences flagging parameters and depth of analysis. Different

depth of analysis. Different applicationsapplications and and metallurgies require different lubrication and have metallurgies require different lubrication and have great impact on how results are interpreted. great impact on how results are interpreted.

Manufacturer and Manufacturer and Model

Model can also can also identify metallurgies identify metallurgies involved as well as involved as well as the OEM’s standard the OEM’s standard maintenance maintenance guidelines and guidelines and possible wear possible wear patterns to expect. patterns to expect.

Lube Manufacturer, Type and Lube Manufacturer, Type and Grade

Grade identifies a lube’sidentifies a lube’s

properties and its viscosity and is properties and its viscosity and is critical in determining if the right critical in determining if the right lube is being used.

lube is being used.

Severity Status Levels: Severity Status Levels: 00——NormalNormal

11——Some items have violated initial flagging points yet are stillSome items have violated initial flagging points yet are still considered minor.

considered minor.

22—— A trend is developing. A trend is developing.

33——Simple maintenance and/or diagnostics are recommended.Simple maintenance and/or diagnostics are recommended. 44——Failure is eminent if maintenance not performed.Failure is eminent if maintenance not performed.

A

A Lab #Lab # is assigned to theis assigned to the sample upon entry for sample upon entry for processing and serves as a processing and serves as a reference number when reference number when communicating questions or communicating questions or Filter Types

Filter Types and theirand their Micron Ratings Micron Ratings areare important in analyzing important in analyzing particle count

particle count——thethe higher the micron higher the micron

Sump Capacity Sump Capacity identifies the total identifies the total volume of oil (in gallons) volume of oil (in gallons) in

in which wear which wear metalsmetals are suspended and is are suspended and is

Lube Time

Lube Time is how long theis how long the oil has been used.

oil has been used. UnitUnit Time

Time is the age of theis the age of the equipment and equipment and LubeLube Added

Added is how much oil hasis how much oil has

Make note of the difference Make note of the difference between the

between the Date SampledDate Sampled andand the

the Date ReceivedDate Received by the lab. by the lab. Turnaround issues may point to Turnaround issues may point to storing samples too long before storing samples too long before mailing or mail service problems. mailing or mail service problems.

(52)

UNDERSTANDING RESULTS

ELEMENTAL ANALYSIS

Combinations of these

Combinations of these Wear MetalsWear Metals cancan identify components within the machine that identify components within the machine that are wearing. Knowing what metals a unit is are wearing. Knowing what metals a unit is made of can greatly influence an analyst’s made of can greatly influence an analyst’s recommendations and determine the value recommendations and determine the value of elemental analysis.

of elemental analysis.

Knowledge of the environmental conditions under Knowledge of the environmental conditions under

Additive

Additive and and Multi-Source MetalsMulti-Source Metals may turn up in test results for a variety of may turn up in test results for a variety of reasons. Molybdenum, antimony and boron are additives in some oils. reasons. Molybdenum, antimony and boron are additives in some oils.

Magnesium, calcium and barium are often used in detergent/dispersant additives. Magnesium, calcium and barium are often used in detergent/dispersant additives. Phosphorous is used as an extreme pressure additive in gear oils. Phosphorous, Phosphorous is used as an extreme pressure additive in gear oils. Phosphorous, along with zinc, are used in anti-wear additives (ZDP).

(53)

TEST DATA

Depending on lube grade, Depending on lube grade, Viscosity

Viscosity is tested at 40° is tested at 40° and/or 100° C and reported in and/or 100° C and reported in centiStokes.

centiStokes.

Too much disparity between oxidation and nitration Too much disparity between oxidation and nitration can indicate air to fuel ratio problems. As

can indicate air to fuel ratio problems. As Oxidation/Nitration

Oxidation/Nitration increases, increases, TATANN will also will also increase and

increase and TBNTBN will begin to decrease. will begin to decrease. High

High Fuel DilutionFuel Dilution decreases unit decreases unit load capacity. Excessive

load capacity. Excessive SootSoot is a is a sign of reduced combustion sign of reduced combustion efficiency.

efficiency.

T

Totalotal AAcidcid NNumbers higher than that of new lubeumbers higher than that of new lube indicate oxidation or some type of contamination. indicate oxidation or some type of contamination.

The

The ISO CodeISO Code is an index number that represents a range of particles within a specificis an index number that represents a range of particles within a specific micron range, i.e. 4, 6, 14. Each class designates a range of measured particles per micron range, i.e. 4, 6, 14. Each class designates a range of measured particles per

(54)

UNDERSTANDING RESULTS

FLAGGING AND COMMENTING

125

125 ^^^^^

^^^^^

Numbers with

“carrots”“carrots”

printed below them denote

test results the analyst has

flagged

flagged because they

because they

exceed pre-set warning

parameters and warrant

closer examination or

require action.

(55)

Test Reports

••

Report 24 metals (wear,

contaminant, multi-source

& additive

••

10 graphs on every report

••

5 severity status levels

••

Flags clearly identifiable on

all reports

••

New lube reference

availability

••

Reports accessible by

internet, fax and paper

••

Report Particle Sizes and

ISO Code

(56)

About POLARIS

Oil Analysis

Wear Debris Analysis

Data Interpretation/Alarm Limits

Sampling Methods

Information Technology

(57)

SAMPLING

•• Objectives

Objectives

–

– Maximize data density

Maximize data density

–

– Minimize data disturbance

Minimize data disturbance

–

– Determine proper frequency

Determine proper frequency

•• Sampling Considerations

Sampling Considerations

–

– Sampling location

Sampling location

–

– Sampling hardware

Sampling hardware

–

– Sample bottle

Sample bottle

–

(58)

ACTIVE

ACTIVE ZONE SAM

ZONE SAMPLING

PLING

•• Sample from live fluid zones

Sample from live fluid zones

•• Sample from turbulent zones such as

Sample from turbulent zones such as

elbows

•• Sample downstream of bearings, gears,

Sample downstream of bearings, gears,

pumps, cylinders and actuators

•• Sample machine during typical working

Sample machine during typical working

conditions and at normal operating

temperature

(59)

ACTIVE Z

ACTIVE ZONE SAM

ONE SAMPLING

PLING

•• Do

Don’

n’t sa

t samp

mple

le fr

from

om de

dead p

ad pip

ipe l

e leg

egs or

s or

hoses

•• Do

Don’

n’t s

t sam

ampl

ple

e fr

from

om la

lami

mina

nar z

r zon

ones

es

•• Don

Don’t

’t sam

sample

ple aft

after

er fil

filte

ters o

rs or f

r from

rom sum

sumps

ps

•• Do

Don’

n’t sa

t samp

mple

le wh

when m

en mac

achi

hine i

ne is co

s cold o

ld orr

not operating

(60)

ACTIVE Z

(61)

SAMPLING PROCEDURES

•• Sampling Valve - Best

Sampling Valve - Best

•• Suction Pump - Second Best

Suction Pump - Second Best

•• Drain Plug - Least Best

Drain Plug - Least Best

(62)

SAMPLING DEVICES

Quick Draw

•• Used on systems with 4-100

Used on systems with 4-100

lbs. psi with a permanently

installed valve and a

disposable cap/needle/tube

assembly

(63)

SAMPLING DEVICES

Push Button Valve

•• Used on systems with 4-100 lbs. psi

Used on systems with 4-100 lbs. psi

and does not require tubing

Vacuum Pump

•• Used on non-pressurized systems

Used on non-pressurized systems –

–

pump is attached to sample jar,

tubing is inserted into pump and

then dipstick or reservoir halfway

then dipstick or reservoir halfway –

–

pump activated until jar ¾ full

(64)

BEST PRACTICES SUMMARY

•• Samples are taken at normal operating temperature

Samples are taken at normal operating temperature

from an active zone upstream of filters and

downstream of machine components

•• Sampling valves and devices are flushed and clean

Sampling valves and devices are flushed and clean

sample bottles are used at each sampling interval

•• Samples are taken at the proper frequency

Samples are taken at the proper frequency

•• Lube type, equipment ID and hours on the oil and the

Lube type, equipment ID and hours on the oil and the

machine are accurately recorded

•• Samples are forwarded immediately to the laboratory

Samples are forwarded immediately to the laboratory

via a trackable shipping service

(65)

THE IMPORTANCE OF TIME

•• Trend analysis is most effective when

Trend analysis is most effective when

sampling intervals are consistent.

•• Samples should be taken according to

Samples should be taken according to

schedule and shipped to the laboratory

immediately.

••

Turnaround issues can often be

attributed to the amount of

attributed to the amount of time that

time that

elapses from when the sample is taken

to the time it ships.

(66)

Why was Aluminum Flagged?

(67)

High

Viscosity

V

VAALLUUEES S EEXXPPRREESSSSEED D IIN N PPAARRTTS S PPEER R MMIILLLLIIOON N ((PPPPMM) ) BBY Y WWEEIIGGHHT T LLUUBBE E FFLLUUIID D DDAATTAA W

WEEAAR R MMEETTAALLS S CCOONNTTAAMMIINNAANNT T AADDDDIITTIIVVE E MMEETTAALLSS

LLUU BB EE IIRR OO NN CC HH RR OO MM IIUU MM MM OO LLYY BB DD EE NN UU MM AA LLUU MM IINN IIUU MM CC OO PP PP EE RR LLEE AA DD TTIINN NN IICC KK EE LL SS IILL IICC OO NN SS OO DD IIUU MM PP OO TTAA SS SS IIUU MM BB OO RR OO NN MM AA GG NN EE SS IIUU MM CC AA LLCC IIUU MM PP HH OO SS PP HH OO RR UU SS ZZIINNCC VV IISS @@ 1100 00 CC TTAANN 1 12 2 1 1 0 0 3 3 3 3 1 1 1 1 0 0 0 0 2 2 7 7 9 9 0 0 11441 1 77774 4 22221 1 1133..9 9 00..8866 750 750 1 14 4 2 2 0 0 4 4 5 5 1 1 0 0 0 0 3 3 2 2 2 2 3 3 0 0 22008 8 66335 5 22336 6 1144..1 1 22..66 790 790 1 15 5 2 2 0 0 3 3 6 6 2 2 2 2 0 0 5 5 2 2 3 3 3 3 0 0 22008 8 66335 5 22336 6 1166..2 2 22..66 720 720 1 15 5 2 2 1 1 3 3 6 6 3 3 2 2 0 0 5 5 3 3 4 4 4 4 0 0 22775 5 66115 5 22335 5 1166..8 8 33..22 750 750 CHG.

CHG. II--R R II--R R II--R R II--R R II--RR WAT

WATEER R HCHCARARB OXID B OXID NITNITR R GLGLYYCC

Y Y 11 777711 1188 2200 00 Y Y 11 772222 2222 2211 00 N N 11 778844 2222 2211 00 Y Y 11 775522 2222 2211 00

(68)

V

VAALLUUEES S EEXXPPRREESSSSEED D IIN N PPAARRTTS S PPEER R MMIILLLLIIOON N ((PPPPMM) ) BBY Y WWEEIIGGHHT T LLUUBBE E FFLLUUIID D DDAATTAA W

LLUU BB EE IIRR OO NN CC HH RR OO MM IIUU MM MM OO LLYY BB DD EE NN UU MM AA LLUU MM IINN IIUU MM CC OO PP PP EE RR LLEEAADD TTIINN NN IICC KK EE LL SS IILL IICC OO NN SS OO DD IIUU MM PP OO TTAA SS SS IIUU MM BB OO RR OO NN MM AA GG NN EE SS IIUU MM CC AA LLCC IIUU MM PP HH OO SS PP HH OO RR UU SS ZZIINNCC VV IISS @@ 1100 00 CC TTAANN 1 12 2 1 1 0 0 3 3 3 3 1 1 1 1 0 0 0 0 2 2 7 7 9 9 0 0 14141 1 77774 4 22221 1 1133..9 9 00..8866 750 750 1 14 4 2 2 0 0 4 4 5 5 1 1 0 0 0 0 3 3 2 2 2 2 3 3 0 0 20208 8 66335 5 22336 6 1144..1 1 22..66 790 790 1 15 5 2 2 0 0 3 3 6 6 2 2 2 2 0 0 5 5 2 2 3 3 3 3 0 0 20208 8 66335 5 22336 6 1144..2 2 22..66 720 720 1 15 5 2 2 0 0 3 3 6 6 3 3 2 2 0 0 770 0 3 3 4 4 4 4 0 0 22775 5 66115 5 22335 5 1144..8 8 22..66 750 750 CHG.

CHG. II--R R II--R R II--R R II--R R II--RR WAT

WATEER R HCHCARARB OXID B OXID NITNITR R GLGLYYCC

Y Y 11 777711 1188 2200 00 Y Y 11 772222 2222 2211 00 N N 11 778844 2222 2211 00

High Silicon

(69)

Iron Wear but why?

VALUES EXPRESSED IN PARTS PER MILLION (PPM) BY WEIGHT VALUES EXPRESSED IN PARTS PER MILLION (PPM) BY WEIGHT W

LLUU BB EE IIRR OO NN CC HH RR OO MM IIUU MM MM OO LLYY BB DD EE NN UU MM AA LLUU MM IINN IIUU MM CC OO PP PP EE RR LLEE AA DD TTIINN NN IICC KK EE LL SS IILL IICC OO NN SS OO DD IIUU MM PP OO TTAA SS SS IIUU MM BB OO RR OO NN MM AA GG NN EE SS IIUU MM CC AA LLCC IIUU MM PP HH OO SS PP HH OO RR UU SS 1 155 11 00 33 33 11 11 00 1010 22 77 22 00 114411 777744 750 750 2 211 88 00 44 55 11 00 00 1818 55 77 22 00 220088 663355 790 790 9 977 2211 00 33 66 22 22 00 3535 66 77 44 00 220088 663355 720 720 2 21111 3300 00 33 66 22 22 00 7788 55 88 33 00 227755 661155 750 750 CHG.

CHG. II--R R II--R R II--R R II--R R II--RR W WAATTEER HR HCCAARRB B OOXXIID D NNIITTR R GGLLYYCC Y Y 11 777711 1188 2200 00 Y Y 11 772222 2222 2211 00 N N 11 778844 2222 2233 00 Y Y 11 775522 2222 2222 00