PREDICT offers used oil services to PdM users requiring lubricant
monitoring. The used oil test programs may be included in conjunction with our
ferrography program or used as a stand alone tool. Various tests are offered to determine
viscosity properties, additive package quality, and identification and severity of
contamination. We offer customized programs that will cover any and all of your wear
particle/used oil analysis needs.
Identification
Test Description
Purpose of Test
Machine Specific
Analysis
Results from the following tests are reviewed by your Machine
Condition Analyst and recommendations for your equipment is given with supporting data on
each report.
Both Lubricant Condition & Equipment Condition are analyzed based
on specific characteristics of your equipment, previous component performance, and test
data.
Elemental Analysis
Elemental analysis is performed in accordance with atomic emission
spectroscopy (AES). A specific volume of lubricant is energized using an electrical arc.
The light frequencies and intensities are measured and reported in parts per million of
various elements.
Elemental analysis is useful for identifying contamination, confirming
additive content, and indicating system wear. The following elements are analyzed: Fe, Cr,
Al, Pb, Sn, Cu, Ag, Ni, Na, V, Cd, Ti, Mo, Ca, Ba, P, Zn, B, K, Mg, and Si.
Water by Karl Fischer
(ASTM D-4928)
Results from the following tests are reviewed by your Machine
Condition Analyst and recommendations for your equipment is given with supporting data on
each report.
Quantification of water contamination - water in a lubricant not only
promotes corrosion and oxidation, but also may form an emulsion having the appearance of a
soft sludge.
Total Acid Number
(ASTM D664)
TAN is determined by titration of a known substance, such as KOH in
order to determine an unknown quantity. Weighed samples are titrated using an automatic
titration system
TAN of a used lubricant is one measure of its degree of degradation by
oxidation.
Total Base Number
(ASTM D4739)
TBN is determined by titration of a known substance, such as HCl, in
order to determine an unknown quantity. Weighed samples are titrated using an automatic
titration system.
TBN of a used lubricant is a measurement of its ability to neutralize
the acid using basic buffers.
Infrared Analysis
FT-IR
The infrared absorption spectrum of a lubricant furnishes a means of
fingerprinting organic compounds and functional groups. Test results are trended and
quantitative and qualitative determinations can be made.
Infrared analysis is often used for identifying additives and their
concentrations, reaction products, and contamination by organic materials in used
lubricants. Oxidation (carboxylic acids and esters), nitrate esters, water, soot, and
glycol can be quantified.
Crackle
Eye Dropper test of lubricant on a hot plate heated to 100° C to
determine presence of water. Detection can be made of water concentration > 800 ppm
This screening test is used by the analysts to check for water
contamination and determination of whether more sensitive testing is required to determine
more exact concentration.
Viscosity
(Kinematic/Oil Bath
ASTM D445/446)
ASTM test uses a constant temperature bath. The efflux time is
measured between two points. The viscosity is computed by using a calibration constant and
the efflux time. Viscosity is reported in centiStokes (cSt) at 40ºC or 100ºC.
Viscosity is the single most important property of a lubricant. A
reduction usually indicates that the system has been contaminated with a solvent or
refrigerant fluid. A significant increase normally is traced to mixture with a high
viscosity product, contamination, or oil oxidation. Normal measurement range for 40ºC is
+30% and -20% and for 100ºC is +20% and -10%.
Fuel Dilution of Diesel Lubricants
(ASTM D3524-90)
Gas Chromatograph
The sample is mixed with a specific amount of an internal standard.
One microliter of the mixture is injected into a 10 meter HP-1 WCOT capillary column,
heated at a specified rate, detected via a Flame Ionizing Detector, and the results (in
percentages/peak area) are displayed in a report generated from the computer software
Some fuel dilution of the engine oil may take place during normal
operation. However, excessive fuel dilution (> 5%) is of concern in terms of possible
performance problems. Immediate effects of high fuel dilution are decreased lubricant
viscosity resulting in increased wear.
Flash Point
(ASTM D92)
The lubricant sample temperature is raised at a constant rate as the
flash point is approached. At specified intervals, a small test flame is passed across the
cup containing the sample. The lowest temperature at which application of the test flame
causes the vapors above the surface of the liquid to ignite is taken as the flash point.
Flash Point indicates the presence of highly volatile and flammable
materials in a relatively nonvolatile or nonflammable material. Example: an abnormally low
flash point on a test specimen of engine oil can indicate fuel contamination.
Rotating Bomb Oxidation Test
(ASTM D2272)
The test lubricant, water, and a copper catalyst coil contained in a
covered glass container, are placed in a bomb equipped with a pressure gage. The bomb is
charged with oxygen to a pressure of 620 kPa, placed in a constant-temperature oil bath
set at 150°C, and rotated axially at 100 rpm at an angle of 30° from the horizontal. The
number of minutes required to reach a specific drop in gage pressure is the oxidation
stability of the test sample.
Test is used to assess the remaining oxidation test life of in-service
lubricants.
Demulsibility
(ASTM D1401-96)
40 ml of sample and 40 ml of distilled water are stirred for 5 min. at
54°C in a graduated cylinder. The time required for the separation of the emulsion thus
formed is recorded or volumes of water, oil, and emulsion remaining after 30 minutes.
Test provides a guide for determining the water separation
characteristics of oils subject to water contamination and turbulence.
Pour Point
(ASTM D97)
After preliminary heating, the petroleum sample is cooled at a
specified rate and examined at intervals of 3ºC for flow characteristics. The lowest
temperature at which movement of the specimen is observed is recorded as the pour point.
Determination of the lowest temperature at which a petroleum product
may be used if fluidity is necessary to the application.
%Sulfur
(ASTM D4294-90)
A petroleum sample is placed in the beam emitted from an X-ray source.
The resultant excited characteristic X radiation is measured, and the accumulated count is
compared with counts from previously prepared calibration samples to obtain the sulfur
concentration in mass %.
The degree of sulfur concentrations in a petroleum product may be used
to qualify the product's processing characteristics or compliance with environmental
regulations.
Particle Count
(ASTM D4406)
As particles in the lube flow pass a laser, the laser light is blocked
allowing individual particles to be counted and sized. The resulting data is a
distribution of the concentration of particles in various size ranges.
Since all contaminants in the oil are counted as particles, the
particle count includes wear particles, soot, dirt, and other contaminates. This test
provides information on lubricant cleanliness.
Foam Test
(ASTM D892-95)
Sequence I, II, III
A defined volume of air is forced through a set volume of sample
lubricant at a specified temperature. The resulting volume of foam is measured
Determination of the foaming characteristics of lubricating oils at
specified temperatures. Means of empirically rating the foam tendency and the stability of
the foam.
Cone Penetration of
Lubricating Grease
(ASTM D 217)
A measured amount of grease sample is placed under a cone apparatus.
The cone is attached to a gauge that measures from 85-475. The cone is dropped into the
grease sample from a specified height and time. The measured amount that the cone
penetrates into the grease is dropping point.
This test measures the consistency of grease. Harder grease will have
a low NLGI rating number such as 00 or 1. Most industrial greases penetrate in the 265-295
ranges and have a NLGI rating of 2.
Dropping Point of Lubricating Greases
(ASTM D566)
A grease sample is heated in the dropping point apparatus. The point
where the grease starts separating and the oil drops out of the apparatus is the dropping
point. The temperature is measured in degrees Celsius.
This test is a determination of the maximum operating temperature of
grease.
% Sediment in Lubricating Oils
An oil sample is well shaken and dissolved in a solvent at a 1:1
ratio. The solvent: oil mixture is well shaken and 100 mls of sample is poured into two
centrifuge tubes. The tubes are placed in the centrifuge at opposite ends and spun for 30
minutes. The sediment collected on the bottom is calculated and multiplied by two to give
the total percentage of sediment in the oil.
This test is an excellent determination of sediments suspended in
lubricating oil. Excessive amounts of sediments can impede oil capability
FERROGRAPHY & OIL
ANALYSIS
Ferrographic wear particle analysis is a
machine condition analysis technology that is applied to lubricated equipment. It provides
an accurate insight into the condition of a machine's lubricated components by examining
particles suspended in the lubricant.
By trending the size, concentration, shape, and composition
of particles contained in systematically collected lubricant samples, abnormal
wear-related conditions can be identified at an early stage.
Wear particle analysis complements vibration analysis
by providing, in many cases, much earlier fault detection and is less susceptible to the
limitationsimposed by slowly rotating
or reciprocating equipment. PREDICT acquired ferrographic wear
particle analysis technologies in the early 1980's and has been the primary developer of
this condition monitoring tool. Currently, we operate the world's largest commercial
ferrography laboratory. Our systems and procedures have evolved over time, not merely
keeping pace with technology, but driving it.
What you can't see can hurt your machinery. Large wear particles (of 10 microns or larger)
abraded or broken from critical wear components, cannot be detected by standard,
spectrographic used oil analysis. Used oil analysis gives you vitally important
information about the condition of the lubricant within your equipment, but tells you
nothing about the particles that are indicative ofimminent component failure. During the
past 20 years, PREDICT professional analysts have analyzed abnormal wear particles in more
than 22,000 individual machine components. We have correlated particle size,
concentration, shape, and material composition to machinery wear related problems. This
depth of knowledge in the science of ferrography provides your condition monitoring team
the expertise to ensure your condition monitoring success.
Case Study:
On February 13, 1997, PREDICT received
a sample from The Aristech Chemical Corporation in Haverhill, Ohio. This was taken
from the Inboard Bearing on a Air Compressor Motor. The Direct Reading levels increased
significantly, from 117 to 1,132. Ferrographic Analysis revealed very large white
nonferrous metal wear particles. These particles measured up to 180 microns in size, and
after heat treatment of the slide, it was determined that they were composed of a lead/tin
babbitt. Water was also detected in the oil and excessive quantities of contaminants were
present. The equipment was rated CRITICAL and this information was immediately conveyed to
the General Foreman at the plant. Shortly afterwards an inspection was performed on the
motor and it was discovered that the sleeve bearing was badly worn. The analysis provided
to this customer resulted in a total cost savings of $11,800.
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