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Oil Analysis
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Analysis of used oil is analogous to a laboratory medical analysis with a blood test. Like blood, lubricating oil contains a good deal of information about the envelope in which it is circulating. Wear of metallic parts, for example, produces a lot of minute particles, which are carried by the lubricant. These small metal particles can give information about the machine elements that are wearing, and can be detected by various methods, for example, Atomic Emission Spectrometry. Determination of larger particles can be done using optical or electronic microscopy, or ferrography.
InfraRed Imaging Solutions Inc. (IRIS) partnered with Wear Check Canada and Wear Check USA for an accurate and complete analysis of your used oil. Several methods are used to analyze oil condition and contamination. These include spectrometry, viscosity analysis, dilution analysis, water detection, Acid Number assessment, Base Number assessment, particle counting, and microscopy. Oils undergo destructive changes in property when subjected to oxygen, combustion gasses and high temperatures. Viscosity change, as well as additive depletion and oxidation occur to degrade the oil. The causes of oil contamination are many, and can be classified according to source. Thus there is contamination coming from outside the system - dust (silica); liquids (mixture with other oils, water, other contaminated oil). The second is in open systems - chains, cables, gears in contact with dust, water, and so on. The third is in closed systems. The critical factor in oil analysis is the interpretation of the oil analysis results. A diagnostician interprets the oil test results and produces a concise summary of the equipment, and oil condition.
THE BENEFITS OF OIL ANALYSIS PROGRAM FOR INDUSTRIAL EQUIPMENT:
• Reduction in unscheduled downtime
• Effective maintenance scheduling
• Improved equipment reliability
• Reduction in maintenance costs
• Determination of optimum oil service intervals
• Minimization of installation errors
• Verification of warranty claims
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Sampling Practice Recommendations |
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Industrial Plants |
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Category |
Component |
Test Kit |
Interval |
Comments |
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Turbines |
Natural Gas |
IND 3 |
3 mon / 1500 hr |
Test kit includes ferrography to monitor for rapid system
failures (e.g. rolling element bearings), particle counting to
monitor fluid cleanliness, and TAN to monitor fluid degradation. |
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Steam |
IND 3 |
3 mon / 1500 hr |
" |
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Blowers |
Blower |
IND 3 |
1 mon / 500 hr |
" |
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Hydraulics |
Hydraulic System |
IND 2 |
1 mon / 500 hr |
Test kit includes particle counting to monitor fluid
cleanliness, and TAN to monitor fluid degradation. |
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Extruder |
IND 2 |
1 mon / 500 hr |
" |
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Press |
IND 2 |
1 mon / 500 hr |
" |
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Compressors |
Refrigeration Comp. |
IND 2 |
1 mon / 500 hr |
Includes Karl Fischer to monitor fluid cleanliness levels, and
TAN to monitor fluid degradation. |
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Chillers |
IND 2 |
1 mon / 500 hr |
Includes Karl Fischer to monitor fluid cleanliness levels, and
TAN to monitor fluid degradation. |
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Air and Gas Comp. |
IND 2 |
1 mon / 500 hr |
Includes Karl Fischer to monitor fluid cleanliness levels, and
TAN to monitor fluid degradation. |
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Gears |
Gearbox |
IND 1 |
1 mon / 500 hr |
Routine analysis kit. |
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Worm Gear |
IND 1 |
1 mon / 500 hr |
Routine analysis kit. |
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Bevel Gear |
IND 1 |
1 mon / 500 hr |
Routine analysis kit. |
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Reduction Gear |
IND 1 |
1 mon / 500 hr |
Routine analysis kit. |
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Differential |
IND 1 |
1 mon / 500 hr |
Routine analysis kit. |
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Final Drive |
IND 1 |
1 mon / 500 hr |
Routine analysis kit. |
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Gear Extruder |
IND 2 |
1 mon / 500 hr |
Includes particle count to monitor fluid cleanliness levels,
and TAN to monitor fluid degradation. |
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Engines |
Diesel Generators |
IND 1 |
1 mon / 500 hr |
Routine analysis kit. |
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Fluids |
New Unused Oil |
IND 1 |
every oil shipment |
Establish baseline for your oil. |
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Thermal Oil |
IND 2 |
3 mon / 1500 hr |
Test kit includes flash point. |
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Special
Sampling Considerations |
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Follow up on abnormal samples |
IND 3 |
WearCheck advises that ferrographic analysis be performed with
resamples on equipment that tested abnormal. Filter analysis
allows the diagnostician to locate and detect major wear
situations. |
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Extended oil drain intervals |
IND 2 |
Any equipment that is undergoing extended oil drain interval
testing should use MOB 2 test kits. These kits include TAN
testing to monitor the degradation of the oil, as well as the
build up of acids in the oil. Oils with high TAN levels
generally experience oil thickening, sludging, improper oil
flow, and corrosion of components. |
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Critical Systems |
IND 3 |
IND 3 kits include the most comprehensive battery of tests to
monitor the oil condition, wear condition, and contamination
levels of the system. |
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