Oil Analysis Study Guide g2780

7/27/2019 Oil Analysis Study Guide g2780

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Oil Analysis FundamentalsA Technical Introduction to Oil Analysis | Presented by AMSOIL INC.

Dealer Training Series



Table of ContentsOil Analysis

What is Oil Analysis? ......................................................................................................... ....... 5Advantages of Oil Analysis ....................................................................................................... 5Oil Analysis as a Sales Tool ....................................................................................................... 6Determining if Oil Analysis is Warranted ................................................................................. 7Oil Analysis Intervals ........................................................................................................ ........ 8AMSOIL Sucon Gun ................................................................................................................ 9Required Informaon for Proper Analysis ............................................................................. 10Choosing a Test Laboratory .................................................................................................... 11Methods for Evaluang Oil Integrity ...................................................................................... 13Parts Per Million (PPM) per Mile/Hour .................................................................................. 15Trending ...................................................................................................................... ........... 16Types of Elements ............................................................................................................. ..... 17OIL ANALYZERS INC. Test Methods ......................................................................................... 18Addional Tests ................................................................................................................... ... 20New Tesng Services Off ered by OAI ..................................................................................... 20Basic Diesel Fuel Tesng ........................................................................................................ 21Diesel Fuel Contaminaon ..................................................................................................... 21Cold-Weather Diesel Fuel Tesng .......................................................................................... 21

Premium Cold-Weather Diesel Fuel Tes

ng ........................................................................... 21Parcle Count Reporng and ISO Regulaons ....................................................................... 22Compleng the OIL ANALYZERS INC. Registraon Form ........................................................ 24Understanding the OIL ANALYZERS INC. Oil Analysis Report ................................................. 26

AppendixOIL ANALYZERS INC. Suggested Intervals for Industrial Applicaons ..................................... 30ISO Cleanliness Code .......................................................................................................... .... 31Severity Levels ....................................................................................................................... 32Generic Physical Properes Chart .......................................................................................... 32Generic Contaminant Levels Chart ........................................................................................ 32Generic Condemning Limits for Gasoline Crankcase Chart .................................................... 33Generic Condemning Limits for Diesel Crankcase Chart ........................................................ 33

Generic Condemning Limits for Automac Transmissions Chart ........................................... 34Generic Condemning Limits for Manual Transmissions Charts .............................................. 34Generic Condemning Limits for Diff erenals Chart .............................................................. 35SAE J-300 Engine Oil Viscosity Classificaon Chart ................................................................ 36Addive Metals Sources Chart ............................................................................................... 37Wear Metals Sources Chart ................................................................................................... 38Contaminaon Metals Sources Chart .................................................................................... 40Mul-Source Metals Sources Chart ....................................................................................... 41ISO 3348 Viscosity Table ........................................................................................................ 42


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Introduction to Oil Analysis: Section 1Oil Analysis

Introduction

This course is an introducon to the analysis of used lubricang fluids.It provides insight into the basic principles and test methodologies usedwithin this field. It is ideal for those who service or maintain mechanicalequipment and those who market AMSOIL products.

Section Objectives

Aer studying Secon 1, you should understand and be able to explain thefollowing terms and concepts:

1. How oil analysis is conducted2. Three main categories of oil analysis3. Oil analysis as preventave maintenance4. Benefits of a roune oil analysis schedule5. How oil analysis can be applied as a sales tool6. Negave aspects of too frequent oil changes

7. Typical oil analysis intervals as well as the interval schedule for morecrical applicaons

8. Significance of equipment age when determining an oil’s integrity9. Four element types that are measured by oil analysis10. Two methods for evaluang an oil’s integrity11. The significance of trending

Section Keywords

The following keywords will be explained in this secon. Pay parcularaenon to their meanings as these concepts will serve as building blocksfor future lessons.

Addive ElementsElement Level versus Time on OilContaminantsContaminant ElementsMul-Source ElementsOil AnalysisParts Per Million per Mile/HrRepeatabilityReproducibilityTrendingWear Debris


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What is Oil Analysis?

The basic funcon of oil analysis is to ensure the fundamentalperformance of the lubricang fluid and equipment. It is the process of analyzing a lubricant’s chemical and physical properes in order to detectlubricant or equipment issues before major problems develop. Oil analysisserves as a valuable preventave maintenance tool, allowing an accuratescienfic look at the lubricant’s service condion as well as the condionof the operang equipment.

The four primary areas of focus include physical fluid properes,contaminaon, addive metals and wear debris. The addive metalscategory focuses on chemical properes of the oil and compares them tobaseline metals previously established for the oil.

Fluid contaminaon assesses concentraons of solid parcles, such asdirt and dust, and other contaminants, including water and coolant.Contaminants are any parcle or foreign maer within the oil that inhibitits performance. Solid contaminants can compromise metal surfaces,leading to premature equipment failure. Water and coolant contaminaonalso break down lubricants and cause accelerated wear due to lack of lubricaon.

Wear debris relates specifically to the internal condion of the equipment.The number of wear parcles, as well as their size and shape, can give an

accurate picture of the machine’s condion. The test methods used toexamine these properes will be discussed in detail later in this course.

Advantages of Oil Analysis

Oil analysis provides users with informaon regarding a piece of equipment. When conducted as part of a roune preventavemaintenance program, trending values provide important informaonabout the condion of the equipment and off er clues to impendingfailures. This informaon provides the opportunity to be proacvewith service maintenance, providing scheduling and budget-planning

What is Oil Analysis?

Advantages of Oi Analysis

Figure 1.1Oil analysis has a number of useful functions and is able to determine baseline fluid properties

FuncƟons of Oil Analysis

1. Ensure the performancequality of the oil

2. Idenfy potenal equipment

or oil deficiencies beforea mechanical breakdownoccurs

3. Provide the informaonfor users to be proacƟ ve about oil and equipmentmaintenance, rather thanreacve



convenience for the operator. Unexpected failures that occur on theroad or during normal operaon are likely to be costlier than scheduledmaintenance procedures.

The eff ecveness of equipment maintenance procedures and serviceintervals can also be verified through oil analysis. Maintenance performedtoo frequently off ers lile to no benefit and increases operaonal costsunnecessarily, while maintenance intervals that are too infrequentcan result in expensive equipment failures. Oil analysis allows users to

be proacve instead of reacve, providing the opportunity to reduceoperaonal expenses and downme.

An overlooked but invaluable benefit from roune oil analysis is the peaceof mind from knowing that the equipment and lubricant are in soundoperang condion. When an equipment owner/operator is concernedabout the integrity of the equipment, oil analysis is an economical,accessible and scienfically accurate method to address those concerns.

Although there is a cost to oil analysis, it is important to consider the valueit can provide. For example, the cost to outright replace the engine in aclass 8 truck at today’s prices could be tens of thousands of dollars, whilethe cost for an oil analysis program is significantly less.

Oil Analysis as a Sales Tool

Oil analysis can be an eff ecve sales tool to build credibility in the eyes of the consumer looking for hard data to back up product claims. It can alsobe used to demonstrate advantages off ered by one product over another.Oil analysis is a resource for diagnosc invesgaons and provides a soundbasis for correcve acon.

Oil analysis can be used to verify the extended drain interval performanceof AMSOIL synthec oils. Most consumers are accustomed to oil drainintervals of 3,000 - 6,000 miles – a noon that persists in consumers’minds. Because of this, convincing them to try extended drain intervalscan be challenging. Oil analysis can be the tool that provides proof of safeoperang condions and improved performance.

Prove Extended Drain Intervals are SafeMany vehicle owners are resistant to extending the intervals betweenoil changes. The resistance is understandable considering that vehiclemanufacturers and many oil companies have been prescribing relavelyfrequent oil drain intervals for a long me.

Oil analysis can be used to validate that AMSOIL synthec motor oil is

Oil Analysis as aSales Tool

1. Prove the safety of extended drain intervals while usingAMSOIL synthec motor oils

2. Validate the improved performance of AMSOILsynthec motor oils over the compeon

3. Provide the hard data to back up product claims

Figure 1.2Oil analysis can be used as a sales tool



capable of lubricang and protecng against wear, sludge and depositslonger than convenonal oils.

Increase Equipment ReliabilityUnexpected breakdowns cost more than scheduled maintenance. By takingadvantage of oil analysis, owners can get a clear picture of the equipment’soperang state, whether engine components are wearing at an acceptablerate or are showing signs of accelerated deterioraon. By using thisinformaon, appropriate measures can be taken to repair troublesome

components before an unexpected and costly failure occurs.

Normalize Equipment Operation with Trending DataDeveloping wear trends that are characterisc to a parcular piece of equipment permits precise recommendaons based on the assessment of the lubricant and equipment.

Enhance Equipment Resale Value by Exhibiting Component IntegrityOil analysis records can be used to show potenal buyers that a piece of equipment is in good condion. If mechanical repairs are necessary, pastrepair records can corroborate proper maintenance measures were taken.

Reduce Un-Needed Maintenance and Oil WasteAMSOIL has an ongoing condion-monitoring service that is managedat AMSOIL headquarters. Oil analysis has frequently shown that AMSOILsynthec motor oil is suitable for use beyond the general guidelines,helping to reduce oil waste, maximize oil installaon costs and minimizeroune maintenance.

Determining if Oil Analysis is Warranted

Determining if a piece of equipment would benefit from oil analysisrequires review of the following areas:

1. Equipment AgeTypically, newer equipment provides more payback than equipmentnearing the end of its life expectancy.

2. Value of Equipment/DownƟmeThe value of equipment, in terms of replacement cost and/oroperaonal loss while the equipment cannot be operated, should beconsidered when determining the value of an oil analysis program.

3. Cost of Analysis vs. Cost to Replace OilPerforming oil analysis on a small reservoir may not be cost-eff ecve inall situaons; however, replacing the oil in a 100-gallon reservoir costssignificantly more than oil analysis.

4. Customer Concerns The peace of mind that comes from knowing whether a problemexists or not is many mes worth the investment, even with smallerreservoirs.

Determining if Oil Analysis isWarranted



Oil Analysis Intervals

When should oil analysis be performed? The answer depends on theequipment, the frequency at which it is used and service severity.Typically, oil analysis is performed at prescribed intervals. This intervalschedule allows a baseline to be established to assist analyzers in isolangequipment failures. Oil analysis baselines establish typical values for wearmetals and fluid characteriscs for a parcular piece of equipment. Asmore data points are collected, a more accurate baseline is established,

and deviaons from the norm are more easily disnguished.

The suggested intervals shown in Figure 1.3 are for convenonal (non-synthec) oils only. When using AMSOIL synthec motor oils, theAMSOIL recommended interval should be followed. For instance, if therecommended oil drain interval for an AMSOIL product is 3x the OriginalEquipment Manufacturer (OEM) drain interval (e.g. 7000 miles), theAMSOIL product may be used for 21,000 miles. To extend the oil’s servicebeyond the 3x OEM recommendaon, oil analysis should be conducted. If oil analysis determines the oil is suitable for connued use, the oil shouldbe tested at the intervals recommended in Figure 1.3.

Oil analysis is also appropriate when problems occur or there are quesonsor concerns regarding the operaon of the equipment. For example, itcan reveal excessive fuel diluon from fuel injector problems or excessivecoolant in the oil from a water pump leak.

Obtaining an Oil Sample

Proper procedures need to be followed to ensure accurate results andproper delivery of the sample to the tesng laboratory. OIL ANALYZERSINC. recommends the following safeguards be taken when collecng an oilsample.

Oil Analysis Intervals

Obtaining an OilSample

Figure 1.3Lubrication interval and method chart



1. Collect a 4 – 8 oz. sample of oil (2 – 4 oz. absolute minimum).

2. Place in a clean and unbreakable container. Sampling kits are availablethrough the AMSOIL online store. The complete oil analysis tesng kitincludes all of the tesng materials, registraon card and postage.

3. Samples should be collected at or near operang temperatures.

4. Collect the sample from an area that represents the overall system:

typically from the center of the reservoir.

5. Seal and package the sample bole appropriately.

There are three common methods for collecng an oil sample. Allmaterials necessary for obtaining an oil sample are available through theAMSOIL online store.

To find the oil analysis kits online, select the Services tab in the mainnavigaon bar located at the top of the AMSOIL website. Select Oil AnalysisServices from the drop-down menu to see the full list of oil analysisproducts from OIL ANALYZERS INC.

AMSOIL Suction Gun

A new sample bole is aachedto one end of the gun and anew secon of sampling hoseis aached to the pump fing.It is important that cleancollecng materials are usedat each collecon to avoidcontaminaon.

The hose is inserted into theequipment reservoir via a filleror dip-sck tube. Care must betaken to avoid inserng the hosedeeper than the center of thereservoir. Pulling the plungeron the gun creates a vacuum

within the sample bole and draws the oil inside. It is not necessary orrecommended to fill the bole completely because this could cause oil tobe drawn into the gun itself and contaminate future samples. To preventcontaminaon, never reuse sampling boles or secons of the hose.

Sampling PortThe second method uses an exisng sampling port on the equipmentwhich requires the equipment be operang to collect the sample. Openthe sampling valve and allow a small amount of oil to flush contaminantsfrom the valve. Place the sampling bole under the valve and obtain thesample. Ensure the sampling valve is securely closed once the samplingprocess is complete.

Reservoir Drain PlugThe third method uses the equipment’s reservoir drain plug which requires

AMSOIL Suction

Gun

Figure 1.4AMSOIL sampling gun



0

il Analysis Fundamentals

oil to be drained from the plug for a few moments so contaminants thathave seled around the drain are flushed out. Place the sample bole inthe oil stream and collect the sample. Using the reservoir drain plug is theleast desirable method for obtaining an oil sample because the boomof the reservoir contains elevated amounts of contaminants. It should beused only when the other opons are unavailable.

Mobile Sampling LocationsAppropriate sampling locaons for automobiles, light- and heavy-dutytrucks and over-the-road trucks include the oil dipsck tube, the reservoirdrain plug or petcock valve if one has been installed. While oil samples canbe taken from the oil filter, this method is the least preferred due to thehigh amounts of contaminants retained in the filter.

Industrial Sampling LocationsCommon sampling locaons include the oil reservoir, oil filter, samplingport and filtraon mount. If excess wear is detected in industrialapplicaons, samples can be taken immediately before or aer parcularcomponents, such as pumps or valves, to help isolate which component isproducing excess wear elements.

Required Information for Proper Analysis

A great deal of analycal data is generated when oil analysis isperformed. Proper interpretaon of that data requires complete andaccurate informaon be provided by the customer to ensure properrecommendaons are made. If accurate or complete informaon is notprovided to the laboratory, vital clues will be missed, and subsequently,

Figure 1.6Sampling locations diagram

RequiredInformation for Proper Analysis

Figure 1.5Drain plug and sampling port



interpretaons and recommendaons won’t reflect this cricalinformaon. For instance, if a customer only supplied the informaon“truck” for Manufacturer/Model, valuable data developed on the specificcomponent will not be used in the interpretaon of results.

Laboratories generally provide a submission form to be completed by thecustomer and returned with the fluid sample. Diff erent informaon maybe requested by diff erent oil analysis laboratories; however, most labs willrequire the following:

1. Proper idenficaon of the equipment/componentName, make, model, year manufactured

2. Proper idenficaon of the lubricant being usedBrand name, type of product, viscosity grade

3. Miles or me accumulated on the equipment since new or rebuilt4. Date the oil sample was taken5. Date the fluid and fluid filters were last changed6. Indicaon that prior analysis has been conducted for the equipment (to

allow for accurate interpretaon)7. Indicaon that recent maintenance has been conducted on the

equipment

Choosing a Test LaboratoryThere are numerous laboratoriesthroughout North America that arecapable of performing oil analysis.Listed below are several factors toconsider when making a decisionabout which laboratory to use.

Tests ConductedThere are a wide variety of testsand test methodologies available.Laboratories must provide tesngthat is appropriate for parcularapplicaons and concerns,

especially when dealing with synthec oil. Keep in mind that there can beseveral test methods available to obtain data in a specific area. Each testhas its own natural level of variability.

CostThe actual cost of an analysis can vary significantly. Generally, the greaterthe number of tests run on an oil sample, the greater the cost. Make sureto get the sample kit that provides all the informaon required for theparcular analysis.

Turnaround TimeThis refers to how rapidly the tests will be conducted and how quicklythe informaon will be forwarded to the customer, which can be cricaldepending upon the applicaon. OIL ANALYZERS INC. provides a 24 - 48hour turnaround me for most tesng.

Receiving Test ResultsOIL ANALYZERS INC. results are communicated via mail, fax or email, inaddion to viewing through a computer database. OIL ANALYZERS will

Choosing a TestLaboratory



2


contact customers immediately if a serious situaon has been noted.

Understandable InterpretationThe raw analycal data generated through oil analysis can off er lile tothose not trained in the field. OIL ANALYZERS INC. reviews the test resultsand provides understandable recommendaons and direcon to thecustomer.

Understanding of Synthetic Oil

Not all oil analysis laboratories are equipped to test synthec oils, whichcontain base oils that can produce misleading test results when testedby laboratories unfamiliar with these products. Make sure the tesnglaboratory is capable of accurately tesng synthecs.

Analysis Results and InterpretationElement analysis is important to determine acceptable concentraonlevels. Contaminant levels should always be zero in new fluids, but mayshow up as a few parts per million based on cleanliness of the sump/reservoir or test equipment being used. Addives should generallycorrespond to those levels found in the new or unused sample of oil beingtested.

Acceptable wear levels for wear elements can vary for the followingreasons:

1. Idencal equipment can create diff erent wear rates

2. How equipment is used aff ects wear ratesA car subjected to connuous stop-and-go driving experiences greaterwear than a car operated connually at highway speeds.

3. Age of the equipmentInternal wear is significantly higher during equipment break-in

4. Length of me the oil has been in service

5. Lubricant quality

It is important to know the equipment’s age when determining whether ornot wear metal levels have become excessive. The Equipment Age/Rate of Wear graph, Figure 1.7, shows the typical rate of wear that occurs over thelife-span of a piece of equipment.

The rate of wear is high while new components are breaking in or seang

themselves. Once this has occurred the rate of wear stabilizes and remainsstable over the majority of the equipment’s life. As equipment nearsthe end of its life, or in the event of a failure, the rate of wear increasessignificantly. In order to properly interpret oil analysis data, it is importantto know where a piece of equipment falls on this curve at the me the oilsample was taken.

Knowing the length of me a fluid has been in service is also crical toproperly interpreng the level of a wear element. The Comparave Wearexamples in Figure 1.8 show wear levels and concentraons of commonwear elements. Note that the levels of wear elements are significantly



higher in sample B. One might inially conclude that the vehicle in sampleB is wearing faster than the vehicle represented in sample A.

A closer look reveals that in sample B, the oil has been in service five meslonger than sample A. Therefore, the rate of wear is the same between thetwo vehicles because the concentraon of wear elements in sample B isapproximately five mes greater than in sample A.

The concentraon of wear elements is proporonal to the length of methe oil has been in service. If the normal wear concentraon of iron in avehicle with a recommended drain interval of 6,000 miles is 25 parts permillion (ppm), it’s expected that at 3,000 miles, the concentraon of ironshould be roughly 12.5 ppm. At 12,000 miles, iron levels should be atapproximately 50 ppm, indicang normal wear.

Figure 1.7Wear rates as related to equipment life span

Figure 1.8Comparative wear metals example



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Methods for Evaluating Oil Integrity

When assessing the condion of the test oil, laboratories use similarequipment for comparave purposes. Discussed below are the twocommon methods for determining wear rates. The first, Element Levelvs. Time on Oil, is a comparave method using proporonal values. Thesecond method is the Parts per Million per Mile/Hour, which determinesthe amount of wear generated in a single mile or hour of operaon.

Element Levels vs. Time on OilThe Element Level vs. Time on Oil method for evaluang the oil’s integrityrequires an evaluaon of wear rate over me on the oil.

Using the example of the vehicle with a recommended 6,000-mile oildrain and typical iron wear-metal concentraon of 25 ppm, calculangthe ancipated iron concentraons for the life of the vehicle is relavelysimple. The projected iron wear-metal concentraons for this vehicle aregraphed in Figure 1.9, shown in blue and labeled “Projected.” Actual wearconcentraons are shown in red and labeled “Actual.”

As shown, inially the iron wear-metal concentraons for the actual

vehicle were only marginally higher than typical values. But, at 6,000 milesthe iron levels rose significantly higher than projected.

Figure 1.9Iron wear levels; projected vs. actual wear-metal levels*This chart does not include a break-in period

Methods for Evaluating OilIntegrity



ApplicationCalculating with Element Level vs. Time on Oil

Vehicle A has a recommended drain interval of 5,000 miles. Typical ironwear-metal concentraƟons for the recommended drain interval are 20 ppm.

Vehicle B has a recommended drain interval of 6,000 miles. Typical iron wear-metal concentraƟons for the recommended drain interval are 30 ppm.

Q1. What would the expected iron concentraon be for vehicle A at 15,000miles?

Q2. At 7,500 miles the owner of vehicle A was concerned about the operaonof the vehicle and decided to have an oil analysis performed. Iron wear-metal concentraon levels at 7,500 miles were 42 ppm. What does this valueindicate?

Q3. What would the expected iron concentraons be for vehicle B at 15,000miles?

Parts Per Million (PPM) per Mile/Hour

An alternate method for determining the condion of the test oil isto calculate the amount of wear generated in a single mile or hour of operaon. This is known as the Parts Per Million per Mile/Hour value.This is the preferred method when comparing wear rates because itnormalizes for miles/hours so it can be compared versus other equipmentand lubricants. Values derived in this manner may be accurately comparedregardless of the miles or hours of service on the oil.

To calculate the amount of wear generated in single mile or hour, the milesor hours are divided by the element concentraon.

If the wear-metal concentraon of iron was 25 ppm at 6,000 miles, thePPM/Mile calculaon would be:

25 ÷ 6,000 = 0.0042

In other words, 0.0042 parcles of iron are suspended per million parclesof oil in every mile driven. For this example, the value 0.0042 ppm canbe considered a reasonable baseline value for iron wear in this vehicle.Concentraon values lower than the baseline would indicate safe wearlevels of iron. Values greater than the baseline would indicate wearoccurring within the system, where correcve acon may be needed and

Parts Per Million(PPM) per Mile/Hour



6


further invesgaon is warranted.

Using the ppm/mile method and the original example, we now need onlyto compare one figure from each scenario. A higher number than thebaseline indicates accelerated wear. A number lower than the baselinesuggests a reduced rate of wear. This is a more analycal way to compareand interpret wear rates.

Note: The same can be done for equipment that is serviced according to

me or fuel consumpon. Use the same formula but replace miles witheither hours or gallons.

ApplicationCalculating with Parts per Million per Mile/Hour

Vehicle A has a recommended drain interval of 5,000 miles. Typical ironconcentraƟons for the recommended drain interval are 20 ppm.

Vehicle B has a recommended drain interval of 6,000 miles. Typical ironconcentraƟons for the recommended drain interval are 30 ppm.

Q1. Determine the baseline values for vehicle A and vehicle B using the ppm/mile method.

Q2. Vehicle A was tested at 12,000 miles, iron concentraons were 42 ppm.Vehicle B was tested at 18,000 miles, iron concentraons were 63 ppm. Whichvehicle is wearing faster?

Q3. Vehicle A was tested at 20,000 miles, iron concentraons were 81 ppm.What is the ppm/mile value? Is this level of wear acceptable?

Trending

Trending or trend analysis is the most accurate way to assess the condionof an oil or machine and involves a data set of three or more variables.Variables represent the instances the oil sample was taken and in orderto have a trend of oil analysis established, oil would have to be sampledat least three mes. While manufacturers publish general guidelines forwear rates and condemnaon limits, they can oen be ambiguous orle to interpretaon. Trending provides the most accurate method fordetermining normal values for interpreng oil analysis results and makingrecommendaons.

Trending



Trending allows analyzers to look for abrupt changes over me. At leastthree samples must be on record for a trend to be determined. In thecase where there is an inadequate amount of data, wear rates provide aguideline. For machines with a trend report, significant changes within thereport will aid in determining potenal problem areas.

Commonly, manufacturers provide wear-rate guidelines to serve as ageneral oil-quality-indicaon tool; however, interpretaon can be difficultwhen thresholds between normal, abnormal and crical are only digitsapart.

Types of Elements

Oil analysis is performed to determine both fluid and machine integrity bymeasuring the elements found in the three main categories: physical fluidproperes, fluid contaminants and wear-debris. It’s important to note thata fourth category does exist: mul-source elements.

Wear-Debris/Wear-Metal Elements

Unlike fluid properes or contaminants, wear-debris relates directly to thecondion of the machine. Wear-debris/wear-metals are those elementsthat are introduced into the oil due to the wearing down of machinecomponents. Most commonly these components are made of metal,which is why they are oen referred to as wear metals. The term weardebris is used interchangeably with wear metals and includes materialssuch as molybdenum, that also may be incorporated into machinesystems. Combinaons of wear debris can idenfy components within themachine that are wearing. For a proper analysis of wear-debris/metals,the component materials incorporated into the parcular system must beknown.

Results from wear-debris tesng can indicate if components in the systemare operang in a normal state, are nearing failure or have already reacheda failure state. This is accomplished not only by assessing the type of debris/metals present, but also by looking at their relave concentraon inthe sample, which can be indicave of specific component failures.

Figure 1.10Significant changes in test results can be more accurately and readily located with trend analysis

Types of Elements



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Contaminant Elements

Contaminant elements are those found in the environment naturally,such as dirt, dust and water. But, they can also come from other systemswithin the machine, like leaks from the coolant system. The presence of contaminants in the lubricant suggests the integrity of that system hasbeen compromised and warrants further examinaon or repair.

Additive Elements

Addi Ɵ ve elements are those that have been added to the oil to impartparcular characteriscs needed for a specific applicaon. A measure of addive elements can provide the necessary informaon to determine if the oil is sll chemically able to perform its job. For example, the addivecalcium (Ca) is used as a detergent; if oil analysis showed calcium levels tobe too low, it would be correct to surmise that the oil will not be able toadequately prevent sludge and deposits.

Multi-Source Elements

Mul Ɵ -source elements can be wear debris, an addive or contaminant, orany combinaon of the three. Molybdenum (Mo) is a common extreme-pressure (EP) addive, but is also incorporated in some piston ring designs.So, while some elements originate directly from wear, others have mulplesources. This is why it is important that a thorough report of componentdata is provided to oil analysis laboratories, as they off er important cluesto the source of elements.

OIL ANALYZERS INC. Test Methods

A number of test methods are required to determine oil properesand contaminant levels, as no single test can generate all the neededinformaon. Each method has its own variables and level of accuracy.Procedures and equipment also vary depending upon which laboratory isused and can also result in variaon. Slight discrepancies can be seen evenin single oil samples tested mulple mes at the same laboratory using thesame test methodology.

Because of the inherent varia

on between laboratories, it is stronglyrecommended that a customer have all of their tests conducted with thesame laboratory to establish an accurate trend analysis. Comparing the testresults from two laboratories would not be the best comparison becauseof the inherent diff erences. The margin of accuracy is much wider acrossdiff erent laboratories and is significantly reduced by using one laboratory,meaning greater precision for diagnoscs and recommendaons.

The test methods used by OIL ANALYZERS INC. are listed below, along withtheir repeatability and reproducibility variables. Repeatability is the abilityof a test to be reproduced within the same laboratory. Reproducibility is

OIL ANALYZERS

INC. Test Methods

Figure 1.11Environmental elements such as dirt, dust and water can be detectedby oil analysis.



the variability in test results when a sample is run at a diff erent laboratory.As Figure 1.12 shows, many tests have a wide margin for repeatability.For those tests, the range of reproducibility is even wider, meaning thatif a parcular test is conducted at mulple laboratories, there is moreopportunity for inaccuracy.

To ensure tests and trend reports represent accurate and meaningful data,it is important to have the analysis performed at one laboratory. This willreduce the margin of inaccuracy and reduce the likelihood of generanginaccurate trend reports.

The following is a list of common tests conducted by OIL ANALYZERS INC.to determine the condion of the oil.

Emission Spectroscopy by ICPThis test is most oen included in oil analysis and is designed to test forwear parcles and addives. It detects parcles that are 4 – 9 microns and

reports elements in parts per million. Parcles larger than 9 microns willnot be detected.

Fourier Transform Infrared Spectroscopy (FTIR)This test assesses levels of soot, sulfates, oxidaon, nitro-oxidaon, glycol,fuel and water contaminaons.

ViscosityThis test measures a lubricant’s resistance to flow at a given temperatureand is considered the most important physical property.

Figure 1.12

Repeatability and reproducibility for test methods used by OIL ANALYZERS INC.



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TBNThe TBN test measures the oil’s ability to neutralize harmful acids.

TANTAN represents the amount of acid present in the oil. High test valuesindicate a depleon of the TBN addive system, which can result in acidbuildup.

Oxidation

The oxidaon test measures the breakdown of a lubricant due to age andoperang condions.

NitrationThis test indicates the presence of nitric acid which can be caused byexcessive “blow-by” from cylinder walls and/or compression rings wearingand can speed up oxidaon.

Soot by FTIR or Wilks Soot MeterThis test measures the concentraon of soot and is reported in percentof volume. Soot is a sign of reduced combuson efficiency. When sootagglomerates, it reaches a crical parcle size and becomes abrasive,

thereby increasing the rate of wear.

Fuel Dilution – Parker Elmer Gas Chromatography (GC)This test measures the amount of raw, unburned fuel that ends up in thecrankcase.

Water – Water by CrackleThis test esmates the percent of water volume in oil. It only reports andesmates up to 0.5 percent. Beyond 0.5 percent, the test is very subjecve,so the Karl Fischer method is used above this level.

Water – Water by Karl Fischer

This test relies on chemical reacons and electric current to measure theamount of water in the oil sample.

Additional Tests

SAE Grade (Viscosity)The SAE Grade test converts kinemac viscosity to SAE viscosity grade.

Filtration Patch TestThis test quanfies parcles of contaminants that exceed a pre-determinedsize.

Particle CountThis test determines ISO cleanliness levels.

ISO Cleanliness CodeThis test indicates the level of cleanliness using a universal scale of a newor used sample of oil.

New Testing Services Ofered by OAI

Coolant TestingThis test is conducted by elemental analysis by ICP. It detects up to

Additional Tests

New TestingServices Offered byOAI



17 elements that can be present in used coolant due to corrosion,contaminaon or addives.

pHThe pH test measures the coolant’s acidity or alkalinity.

Antireeze Percent (Ethylene or Propylene Glycol)This test indicates the level of anfreeze and water in the system.

Freeze PointThe Freeze Point Test determines the temperature at which coolantsolidifies.

Boil PointThis test indicates which temperature a coolant will boil at sea level.

NitriteThe Nitrite Test determines if the an-corrosive addives in the coolant areat the proper concentraons.

SCA Number (Supplement Coolant Additive)

This test determines the level of coolant addive required for adequateliner ping protecon in a diesel engine convenonal coolant.

Specifc ConductanceThe Specific Conductance Test measures the coolant’s ability to resistcarrying an electrical current between dissimilar metals.

Total HardnessThis test monitors calcium carbonate and magnesium carbonateconcentraons in the coolant.

Visual Inspection

The coolant sample is physically observed by a technician forcharacteriscs that may indicate contaminaon: foaming, indicaon of contaminaon by odor, microbial growth, etc.

Basic Diesel Fuel Testing

Cetane IndexThis test measures the fuel’s ignion quality.

DistillationThe composion of the diesel fuel is analyzed for its disllaoncharacteriscs; it indicates the fuel’s volality and potenal for forming

explosive vapors and deposits during engine operaon.

API GravityThis test measures the fuel’s density or weight per volume.

Diesel Fuel Contamination

WaterThis test measures the water concentraon in fuel, which can causecorrosion, wear, bacterial growth and premature fuel filter clogging.

Basic Diesel FuelTesting

Diesel FuelContamination



2


Aerobic BacteriaThe Aerobic Bacteria Test measures the amount of bacteria present, whichcan develop from improper storage and water contaminaon.

Cold-Weather Diesel Fuel Testing

Cloud PointThe Cloud Point Test determines the temperature at which wax crystalsfirst appear in the fuel.

Pour PointThe Pour Point Test determines the lowest temperature at which the fuelwill pour.

Premium Cold-Weather Diesel Fuel Testing

Cold Filter Plug PointThis test measures the temperature at which wax crystals form in the fueland the extent that they plug fuel filters.

Particle Count Reporting and ISO Regulations

The ISO developed a universal system for represenng parcleconcentraons within a sample. The classificaon is used to determineoil cleanliness by idenfying the amount and size of parcles found in asystem. This informaon can be important when making recommendaonsfor equipment that exhibits sensivity to small parcles like hydraulic andcertain gear and turbine applicaons.

Parcle count is the measurement of all parcles that have accumulatedwithin a system, including those metallic and non-metallic, fibers,dirt, water, bacteria and any other kind of debris. It is most usefulin determining fluid system cleanliness in filtered systems including

hydraulics, turbines, compressors, auto/power-shi transmissions,recirculaon systems and filtered gear systems with a fluid viscosity of lessthan ISO 320.

The current ISO parcle counts are determined at three size scales:> 4 microns, > 6 microns, and > 14 microns per one milliliter of fluid.

Figure 1.13Suggested cleanliness levels

Cold-Weather DieselFuelTesting

Premium Cold-Weather FuelTesting

Particle CountReporting and ISORegulations



Figure 1.14ISO cleanliness code system. Represents number of particles per 1 mlof fluid

ISO parcle counts are reported using this scale, and are reported asfollows: 16/15/9. This result indicates that in one ml of fluid, there were 16parcles larger than 4 microns in size/15 parcles larger than 6 microns insize/9 parcles larger than 14 microns in size.

Figure 1.13 lists suggested cleanliness levels for general applicaons.



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Completing the OIL ANALYZERS INC. Registration Form

A great deal of analycal data is generated when oil analysis is performed.In order for that data to be properly interpreted, certain informaon mustalso be provided by the customer. Complete and accurate registraonforms will ensure proper interpretaon of test results.

Informaon required by OIL ANALYZERS INC. includes:

A Complete the Component Registraon Form when subming a sample for the firstme or when subming a change to a component that is already registered withOIL ANALYZERS INC. Provide complete and accurate informaon to ensure you willreceive accurate recommendaons from OAI. Only steps B - D are necessary whensending in subsequent samples for components already registered with OAI.

B Complete the OIL ANALYZERS sample label and affix it to the sample jar. Do notaach it to the black mailing canister. For Lube Time, enter the number of miles onthe oil. For Unit Time, enter the number of miles on the vehicle. Leave the ACCT#field blank; OAI will assign an account number.

C Mailing labels are provided for the convenience of customers with non-postage-paid kids. Choose the mailing label for the laboratory nearest you and affix it to themailing package. Postage pre-paid kits are pre-labeled for mailing.

D Retain the Tracking Number Stub for your records.

1 Carefully complete the Customer Informaon secon.

2 Complete the Unit ID informaon. Indicate the vehicle’s year, make and model in theSecondary ID field.(e.g. VIN number, Serial number or John’s Truck)

This is your opportunity to give your vehicle a unique ID. This is especially helpful for thosewho test mulple vehicles or those who manage a fleet of vehicles.

3 Complete the Unit Type secon to the best of your ability.(e.g. Engines, Mobile Gear/Bearing System, Transmission, etc.)

4 Provide complete Unit Manufacturer and Unit Model informaon.(e.g. CAT, Cummins, GM; CI5, 5.9L, Duramax, or Allison 1000, Ford Torqueshi transmission)

Proper idenficaon of equipment will ensure accurate tesng for specific metallurgies.NOTE: OAI needs component manufacturer and model informaon, not vehiclemanufacturer informaon.

5 Choose the best descripon of the operang environment of the equipment.

An accurate descripon of the environment will help to determine possible exposure tocertain contaminants.

6 Provide informaon regarding the lubricant currently installed, including the brand,

product name or code and viscosity. Complete this secon to the best of your ability.(e.g. AMSOIL Synthec Motor Oil (ASL), SAE 5W30)

7 Include informaon in the Special Comments or Problems secon that you feel isimportant, but is not listed in the Component Registraon Form.

8 Write in the Unit ID (designated in step 2) on the Tracking Number Slip and retain foryour records.

Before shipping:• Ensure the OIL ANALYZERS label is affixed to the sample bole.• Remove the Tracking Number Stub and retain for your records.• Verify you have included the Component Registraon Form.

Completing the OILANALYZERS INC.Registration Form



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Understanding the OIL ANALYZERS INC. Oil Analysis Report

1. Company/Personal informaon is found in the upper right-hand cornerof the reportCompany/Name, telephone number and address are included

2. Vehicle informaon is found in the upper-le hand cornerPrimary and secondary IDs are included, unit type, and unit applicaon

3. Account number and dates the sample was received, sampled areincluded

4. Tracking number and other vital unit informaon are included such aslubricant type and filter informaon

5. Severity rang is given, as well as laboratory number, laboratorylocaon and the analyst’s inials

6. Metal concentraons are reported for the unitResults are color-coded by severity level for easy and quickidenficaon

7. Addional crical test results are reportedSoot content, fuel diluon, water content, oxidaon levels, nitraonlevels, Total Base Number and Total Acid Number are included

1

2

3

4

5

6

7

Normal

Oil is suitable for connued use.

Normal

Oil is suitable for connued use. Observe trends in future tests.

Elevated

Oil is suitable for connued use. Re-sample oil at half thenormal level.

Abnormal

Replace oil filter and top off system with fresh make-up oil andre-sample at half the normal interval or change oil.

CriƟcal

Change oil and filters if not done when oil sample was

taken.

Understanding theOIL ANALYZERSINC. Oil AnalysisReport



Figure 1.16OIL ANALYZERS INC. Oil Analysis Report



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Oil Analysis Review Questions

1. What is the basic funcon of oil analysis?

2. What informaon can be gleaned from oil analysis trending values?

3. How can oil analysis benefit customers in the area of preventavemaintenance?

4. Name three consideraons that should be evaluated when

determining if oil analysis is warranted.

5. Give an example of when it would be appropriate to conduct oilanalysis at half the recommended drain interval.

6. Oil samples should be collected __________ or __________operang temperatures.

7. Collect oil samples from the top of the oil reservoir.

True or False

8. How can a troublesome component be discerned in industrialequipment?

9. Why is complete informaon necessary for accurate interpretaonsof data to be performed?

10. Oil analysis should find addive levels that __________ with a newor unused sample.

11. What are the two methods for evaluang oil’s integrity?

12. What method is the most eff ecve for making comparisons whenassessing the condion of oil?

13. Equipment wear-debris/wear-metal values relate directly to the

condi

on of the oil.True or False

14. What do equipment wear-debris/wear-metal concentraon valuesindicate?

15. What are mul-source elements?

16. Why is it recommended to conduct oil analysis with one laboratory?

17. What quality of oil is an indicator of motor oil’s ability to neutralizeacids?

18. Name two eff ects fuel diluon has on a lubricant.

19. List three important details about oil that laboratories need to knowto create an accurate analysis report.



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AppendixOIL ANALYZERS INC. Suggested Intervals for Industrial Applications



ISO Cleanliness Code



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Normal use. “Oil is suitable for connued use. Observe fortrends in future tests.”

Elevated use. “Oil is suitable for connued use. Re-sampleat half the normal interval”

Crical use. “Change oil and filters if not done when oilsample was taken.”

Abnormal use. “Replace oil filter and top off system withfresh make-up oil and re-sample at half the normal intervalor change oil.”

Severity Levels **

** The informaon contained in these charts is for reference purposes only. It is based on carefullyanalyzed market averages collected by an oil analysis laboratory. This informaon should not beused to evaluate specific equipment and/or oil analysis results.

Generic Physical Properties Chart **

Generic Contaminant Levels Chart **



Generic Condemning Limits for Gasoline Crankcase Chart **

Generic Condemning Limits for Diesel Crankcase Chart **




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Generic Condemning Limits for Manual Transmissions Charts **

Generic Condemning Limits for Automatic Transmissions Chart **




Generic Condemning Limits or Diferentials Chart **




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SAE J-300 Engine Oil Viscosity Classifcation Chart



Additive Metals Sources Chart



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Wear Metals Sources Chart



Contamination Metals Sources Chart



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Multi-Source Metals Sources Chart



ISO 3348 Viscosity Table



Notes

Oil Analysis Study Guide g2780

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