Slide 1Technology Training that works
Oil and Particle Analysis
Oil and Particle Analysis is maturing into another effective technique.
When used in conjunction they provide a reliable source of machinery information.
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Oil Sampling Port Location
Primary location -
Typically located on a single return line just upstream of the sump or reservoir.
Secondary location -
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Oil Sampling Port Location
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Care while sampling is essential.
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Difficulties in getting a consistent sample.
Problems with sampling high-viscosity fluids.
Possibility of airborne contamination when drain is opened for sampling.
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Drain plug sampling from bottom can be erroneous.
Inward pilot tube is located at suitable location in the gearbox.
More consistent and representative than drop-tube.
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Sample valves are similar to a check valve.
Valve is normally closed until the sample port adapter is threaded or pushed on.
Sample ports have a dust cap with an O-ring for second stage leak protection.
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and take the sample.
the metal dust-cap.
Cleanliness - Sample Bottles
Cleanliness standards as per ISO 3722 and adopted for oil sampling bottles.
Clean : less than 100 particles, greater than 10 microns/ml
Super clean - less than 10 particles, more than 10 microns/ ml
Ultra clean - glass bottles washed and dried in “clean” environment.
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ISO 4406 - Particle Counting
ISO Particle Counting
code particle count
ISO Code = 19/10
ISO code includes a third range of 2 m and lesser
Size
Count
Scale
>5
3600
19
>15
7
10
SNR - Signal to Noise Ratio is defined as:
Recommended SNR is 10:1, but should not be less than 5:1
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Example of SNR
For example, an oil sample location calls for a target oil cleanliness level of ISO 19/16.
As per the ISO code (for the 10 micron size range) -
ISO 19/16 - 1200 particles > 10 m /ml
“Clean bottle” has less than 100 particles > 10 m / ml
Signal - 1200 particles > 10 m /ml
Noise - 100 particles > 10 m / ml
SNR = 12 : 1 - acceptable.
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PET (polyethylene terphthalate), HDPE (High Density Poly Ethylene) and glass.
PET and glass bottles are clear.
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Sample Bottles
HDPE are opaque and do not allow an instant visual examination of sample.
Glass bottles can provide extreme cleanliness, but require careful handling.
These are preferred in volume size of 4 oz.
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Sample Port Identification
Sampling ports must be labeled with corrosion resistant tags and contain:
Sample port I.D (identification)
Target cleanliness level (TCL)
TCL and SNR decide, whether “clean” or “super clean” sample bottles should be used.
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Particle counting
Primarily used for trending the accumulation of:
Small wear metals.
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Analyses smaller particles only, typically 5 m and lesser.
Larger particles, which are prime indicators of gross wear are not detected.
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Procedure -
Oil is electrically excited to the point where light is emitted.
Each element present in the burning oil emits a light of its own characteristic color and frequency.
The spectrometers translate the intensity of the colors into a computerized readout.
Presence of wear elements is compared with fresh oil and earlier samples to detect changes.
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Spectrometric Analysis
A typical report of a gear or hydraulic oil will have details of 9 elements.
A typical report of an automotive oil will have details of 12 elements.
These include Aluminum, Chromium, Copper, Iron, Lead, Magnesium, Molybdenum, Nickel, Silver, Silica, Tin, Zinc.
E.g. higher Lead could indicate wear of bearings, or presence of gasoline/oil additives.
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Spectrometric Analysis
The most common elements tracked by SA are iron, lead, tin and copper.
Coolant contamination can be detected by monitoring concentrations of sodium and boron.
Dirt is detected by tracking silicon.
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This drawback is overcome by techniques such as –
Rotating Disc Electrode method
Particle Counting
Particle Counting is a technique that is used in conjunction with wear metal analysis.
Excessive particulate contamination can be missed if Particle Counting is not a routine part of the OAP.
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Particle Counting
The information obtained is critical to determine if excessive wear or dirt entry is occurring.
Particle counting does not differentiate the composition of material present.
It requires clear oil samples.
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Particle Counting
Light from a solid-state laser is used to illuminate the sensing area of the flowing fluid. 
The light scattered by particulates passing through this intensive beam is collected at right angles to the laser beam.
This is then focused onto a photo detector.
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Particle Counting
All pulses over a pre-selected discrimination level are converted into digital form.
Once in digital format, the pulses can be counted and calculated to give an indication of the size of the particle (s).
Can track particles in the range b/w 5 m & 100 m.
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Wear Particle Analysis: Ferrography
Utilizes microscopic analysis to identify the composition of the material.
This method evaluates particle type, shape, size, and quantity.
Possible to identify wear related failures at an early stage, before collateral damage or failure occurs.
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Used in two ways:
Routine monitoring and trending of the solids content from the lubricant sample.
Observing and analyzing the type of wear from the shape of the particle.
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Routine Monitoring and Trending
Particle size, shape and quantity are indicative of the machinery condition.
A normal operating machine rarely expels particles greater than 10 microns in size.
However as deterioration sets in, the size and number of the particles also increase.
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Building a Ferrogram
Lubricant is first diluted with Trichloroethylene (TCE) or any other solvent.
It is then flown down a specially prepared low gradient inclined slide while passing across a bipolar magnetic field.
Ferrous particles line up in strings along the magnetic flux lines.
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After a Ferrogram is dry:
Microscopic examination of particles can indicate the wear mechanism and even external contaminants.
Upon heat treating the slide, the color and surface of particles can indicate the composition of particles.
Acid / Base reactions are used to identify non-ferrous particles.
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Ferrogram Analysis Chart prepared by Predict DLI, Cleveland Ohio, U.S.
Normal Rubbing Wear
Severe Sliding Wear
Ferrogram Analysis Chart prepared by Predict DLI, Cleveland Ohio, U.S.
Gear Wear
Bearing Wear
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Ferrogram Analysis Chart prepared by Predict DLI, Cleveland Ohio, U.S.
Black Oxide - Insufficient Lubrication
Corrosive Wear - Depletion of Additives
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Ferrogram Analysis Chart prepared by Predict DLI, Cleveland Ohio, U.S.
Aluminum Wear
Ferrogram Analysis Chart prepared by Predict DLI, Cleveland Ohio, U.S.
Fibers - Filter Media
Ferrogram Analysis Chart prepared by Predict DLI, Cleveland Ohio, U.S.
Case Hardened Low Alloy Steels
Lead Tin Babbit
Molybdenum Di Sulphide