Oil Analysis Lessons Learned Chad Norris Refrigeration Engineer Wells 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
Why Oil Analysis? 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.
Oil Analysis Methods Internal CSI 5200 Minilab External 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.
Oil Analysis Methods Pro/Cons Internal - Pros Fast turnaround of data. On-site staff can become experts at their equipment. Utilize other Predictive Technologies together more effectively. Internal Cons Lack of specialized equipment.
Oil Analysis Methods Pro/Cons External - Pros Overall lubrication expertise. Specialized equipment to solve difficult issues. External Cons Cost pay per sample by amount of testing. Slow turnaround time. May be difficult to integrate data to database.
CSI 5200 Minilab(Internal) Laser Particle Counter Ferrous and Water Analyzer WDA Microscope Dielectric Strength Analyzer Data sent to Oilview Software Digital Viscometer Reports WDA Patch Maker
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 Analysis Operational Conditions (Temp, Press., Flow) Spiral #2 lower operating temps than design Appearance (Milky, Sludge, Debris) Obvious water and contaminant entrapment Color (Darker) Degradation caused by contaminants and heat Odor (Burnt, Rotten) Thermal degradation, microbial contamination
Oil Analysis Reports (Cont.) Quantitative Particle Count ISO Code for 2, 5, and 15 micron size Water Contamination % Viscosity Centistokes at 40C Dielectric Strength Chemical properties of reference oil compared to sample (additive package depletion and oxidation) Ferrous Index Ferrous 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 lubrication Abrasive wear contamination with abrasive particles Fatigue wear overloaded bearings Fretting wear vibration induced particles Degradation Residues - sludge or varnish, red and black oxides Process 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.
Oil Analysis Findings (Cont.) 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.
Oil Analysis Findings (Cont.) 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 Analysis Findings (Cont.) 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 Equipment SMRP Society of Maintenance and Reliability Professionals Insight Services www.testoil.com
Oil Analysis Questions?