Oil Analysis

About POLARIS
Oil Analysis
Wear Debris Analysis
Data Interpretation/Alarm Limits
Sampling Methods
Information Technology

Significant Accomplishments
Since start-up in 1999:
Established customers in all 50
states and over 15 countries
Total customer base of over 40,000
Reports available in 3 languages
300% growth rate over past 2 years
Among top 25 fastest-growing
privately-held companies in
Indianapolis for past 3 years
3

Industries Served
Transportation

Power Generation

Oil & Gas

POLARIS
Laboratories
supports oil analysis
and reliability
maintenance
programming in a
wide variety of
industry applications.

Marine

Const/Mining

Industrial
4

Facility Locations
Indianapolis

Salt Lake City

Three locations 1
database
Accessible within 48
hours by ground

24-48 hour turnaround

Houston

Local technical sales

support
5

One Lab Three Locations

BIG Advantages
Ship your sample to the closest lab reducing transit time and cost
One phone number to call for entire program
Centralized Customer Service ensures a thorough knowledge of
your program
Centralized Data Analysis ensures consistent commenting and
recommendations on all data from each of our laboratories
One database secures data history even when samples are sent to
a different lab
Redundancy for disaster recovery
6

Fluids Tested

POLARIS specializes in testing oil,

fuel, coolants and water-based fluids.

Oil
Test for wear metals and contamination
Monitor fluid properties and suitability for
use
Fuel
Troubleshoot filter problems
Determine compliance with supplier
specifications
Coolant
Detect corrosive chemicals
Monitor silicate levels
Determine compliance with OEM
antifreeze concentration
recommendations
7

ISO 17025
A2LA Accreditation
Takes quality standard of
ISO 9000 to higher level
Ensures traceability back
to standard
Determines uncertainties
and repeatability
Is highest level of quality
attainable by a laboratory
backed by the most
stringent accrediting
body in the industry

ISO
17025
A2LA

ISO 17025

Guide 25

ISO 9000
8

About POLARIS
Oil Analysis
Wear Debris Analysis
Data Interpretation/Alarm Limits
Sampling Methods
Information Technology

OIL IS THE LIFEBLOOD

OF MANY SYSTEMS
Oil analysis is like a blood test

A sample is taken
Sample is documented
Sample is delivered to a lab
Tests are performed
Results are interpreted
Diagnostic report is issued

10

Oil Analysis Basics

11

WHY DO OIL ANALYSIS?

To monitor changes in lubricant properties
To identify contamination and its affect on
a lubricant properties
To determine type and severity of wear
occurring

12

WHAT DOES OIL ANALYSIS TELL US?

Determine condition of the oil
Monitoring changes in the lubricant to determine if the oil is
suitable for continued use

Determine condition of the unit

Analysis provides clues that can identify problems so they can
be corrected before permanent damage occurs
Evaluates wear data

Determine effectiveness of maintenance

strategy
Run to failure
Preventive
Predictive
13

MAINTENANCE STRATEGIES
Unplanned Maintenance
Run it to failure
Very high maintenance cost
Short component life
No historical data or root cause analysis

14

MAINTENANCE STRATEGIES
Preventive Maintenance
Interval-based Maintenance
Moderately high cost
Short component life for unique equipment
No root cause analysis

15

MAINTENANCE STRATEGIES
Predictive Maintenance
Condition-based and Planned
Lowest overall cost
Considers unique component characteristics
Provides trending that can predict problems
and failures
Increases component life
Maintenance guided by root cause analysis
16

TESTING LUBRICANT PROPERTIES

Viscosity
Viscosity Index
TAN
TBN
Oxidation
Nitration
Demulsibility

Foaming
Rust
Copper Corrosion
RPVOT
Pour Point
Flash Point
Aniline Point

17

VISCOSITY
Viscosity is a lubricants resistance to flow at a
given temperature.

Shear force/shear rate

Factors that affect viscosity
Temperature/relationship by grade
Pressure
Measurement
Comparative classifications
Viscosity Index

18

VISCOSITY
The force required to slide one object over another
when the two surfaces are fully separated by a fluid is
dependent on the fluids viscosity
Moving Surface

Sheared
Liquid

Stationary Surface

Viscosity =

The higher a fluids

viscosity, the greater
the force (energy)
required to slide the
surfaces at a given
speed and gap
Shear Force (per area)
Shear Rate (flow)
19

VISCOSITY SELECTION
OPERATING
CONDITION

VISCOSITY
NEEDED

HIGHER LOAD
HIGHER
TEMPERATURE
INCREASED
SPEED
20

TOTAL ACID NUMBER

Measures amount of both organic and
inorganic acid present
Indicates oxidation or contamination from
other corrosives
ASTM D-664M reported as mg/KOH per/g of
sample
Caution level >2X starting point of new oil
Severe level >4X starting point of new oil

21

TAN AND TBN BY TITRATION

22

OXIDATION
Breakdown of a lubricant due to age and operating
conditions
Prevents additives from performing properly
Causes the formation of acids and increases viscosity

Testing done by Infrared Analysis (FTIR)

Reported as aus/cm (absorption units per centimeter)
25 condemnation level by CAT & Waukesha
>30 is severe and will lead to corrosive wear

23

NITRATION
Indicates excessive blow-by from cylinder walls and/or
compression rings
Indicates presence of nitric acid, which speeds up oxidation
Too much disparity between oxidation and nitration points to
air-to-fuel ratio problems
As oxidation/nitration increases, so does TAN and viscosity,
while total base number will decrease
Testing done by Infrared Analysis (FTIR)

Reported as aus/cm (Absorption units per centimeter)

25 condemnation level by CAT & Waukesha
>30 is severe and will lead to corrosive wear
24

FTIR - FUEL, SOOT,

OXIDATION, NITRATION

25

REPORTING MEASUREMENTS
Neutralization
Number Expressed
In Mg/KOH/g

Per Cent By
Volume

Viscosity In
Centistokes cSt
at Specified
Temperature

Fuel % Soot % Water % Vis @ 40 Vis @ 100 AN

FT-IR Results
Expressed In
Absorbance Units
Per Centimeter

BN Oxi Nit

26

CONTAMINANT LIMITS
Oil

Silico
n

Sodium

Potassiu
m

Fue
l%

Soot
%

Diesel
Engine

20

70

20

20

20

160

250

250

30

30

20

50

20

N/A

N/A

25

N/A

160

90

150

N/A

N/A

40

N/A

20

75

80

N/A

N/A

30

N/A

256

307

180

N/A

N/A

50

N/A

15

25

10

N/A

N/A

20

N/A

65

114

78

N/A

N/A

35

N/A

20

50

20

N/A

0.5

20

20

160

175

165

N/A

1.1

25

27
25

Transmission

Gear Box

Hydraulic

Natural Gas
Engine

Oxidatio Nitration
n

METALS BY ELEMENTAL ANALYSIS

Wear Metals

Fe
13

Cr Ni
0

Al
1

Contaminants

Cu Pb Sn Cd Ag
2

Ti

Si

Na

Lubricant
Additives

Multi - Source

K Mo Sb Mn

Li

Mg Ca Ba
0

2449

Zn

1260

1144

Reported in concentrations of parts per million - ppm

*Refer to POLARIS Wear Metals Map
28

ICP SPECTROMETER

29

FLAGGING POINTS & ALARM

LIMITS
Where do the numbers come from?
sample information YOU provide
the lab
OEM/equipment specifications
lubricant specifications
laboratory database of samples
with same criteria
statistical analysis of real life
laboratory data

30

SETTING ALARM LIMITS

Statistics used to establish alarm limits for wear
metal concentrations
Mean (average, indicated by x) and standard
deviation (the distance the spread of numbers
are from the mean, indicated by ) are
determined for each population of elemental
concentrations

How many standard deviations from the mean (3 to +3) alarm limits will be set is based on
frequency distribution
31

ALARM LIMIT SPECIFICS

Base alarm limits on specific information
Unit Type
Diesel Engine
Turbine
Compressor
Reciprocating, Rotary Screw, Centrifugal

Gear System
Helical, Double Helical, Hypoid, Worm

Hydraulic System
Bearing
Babbitt, Roller, Spherical Roller, Needle

Pump
Piston, Gear, Vane

Unit Manufacturer
Unit Model Number
32

Information Pyramid
Transmission

217

PPM
Iron
Flagging
Point

33

Information Pyramid
Transmission

Automatic Transmission

217

149

PPM
Iron
Flagging
Point

34

Information Pyramid
Transmission

217

Automatic Transmission
149

Allison

171

PPM
Iron
Flagging
Point

35

Information Pyramid
Transmission
217

Automatic Transmission

Allison

HT754CR

171

68

149

PPM
Iron
Flagging
Point

36

Information Pyramid
Transmission

217

Automatic Transmission

149
PPM

Allison

171

Iron
Flagging

HT754CR

68

Point

10m
Fltr

60

37

Information Pyramid
217
Lack of
information
allows 165
ppm where
failure may
occur!!!

Iron
PPM
Flagging
Point

10m
Fltr

52

38

WEAR METAL LIMITS

Chrome Nickel Aluminum Coppe
r

Oil

Iron

Gas Turbines

35

62

217

Injection
Molding
Roller Bearing

Rotary Screw
Compressors

Sleeve
Bearing

Lea
d

Tin

20

24

28

30

15

32

120

40

56

19

42

95

88

54

10

141

16

26

13

493

14

59

208

104

56

40

16

26

20

44

1379

47

208

160

39
352

DIESEL ENGINE LIMITS BY MFR

Chrome Nickel Aluminum Coppe Lead
r

MFR

Iron

Cummins

60

14

21

47

390

46

20

98

147

353

40

66

37

24

429

39

15

63

259

180

40

77

17

20

501

46

15

42

119

150

40

74

13

44

16

481

39

25

91

308

120

40

92

61

14

598

39

25

56

427

105

4040

CAT

Navistar

Volvo

Mack

Tin

DIESEL ENGINE LIMITS BY MODEL

Chrome Nickel Aluminum Coppe Lead
r

CAT

Iron

3406E

43

54

280

20

15

35

378

38

32

49

38

319

39

15

63

266

53

40

19

43

124

20

15

42

301

53

24

13

48

85

20

15

28

336

38

24

57

100

371

26

15

42

700

53

5441

3304

3512B

3516

C15

Tin

TREND ANALYSIS
Oil Analysis works best when at least three samples
have been taken over a short period of time so that
trends can be identified
Result trends over a sufficient period of time are more
useful than absolute numbers when trying to determine
what is occurring in a sampled machine.
Trending and graphing offer an easy to read
instantaneous analysis of the condition of the equipment,
condition of the lubricant, and level of contamination.
Never base a decision to tear down a machine on the
results of only one (1) oil analysis report
Refer to Interpreting Data Map
42

TREND ANALYSIS
Physical property trends help determine if the
best lubricant is being used
Trend analysis helps in scheduling regular
maintenance such as oil and/or filter changes
Trend analysis helps establish best
practices maintenance procedures

43

TREND ANALYSIS
Topping off will skew the trend and
should be noted when the sample is
submitted to the laboratory for processing
Note sump or reservoir capacity
Note if multiple components are lubricated
from same sump, i.e. motor or turbine,
gearbox, compressor

44

WHAT IS CONSIDERED
SIGNIFICANT CHANGE?
Wear Metals
an increase of 5 to 20 ppm - depending on the
metal and the unit type - or an increase of
100%, whichever is larger

Contaminant Metals
an increase of 5 to 10 ppm or an increase of
100%, whichever is larger

45

WHAT IS CONSIDERED
SIGNIFICANT CHANGE?
Water
an increase of 100%, or any increase that
approaches the advisory levels of that sample
point

Total Acid Number

an increase of 0.1 for R&O oils
an increase of 0.2 for AW oils
an increase of 0.3 for EP oils
46

WHAT IS CONSIDERED
SIGNIFICANT CHANGE?

Viscosity

an increase or decrease of 5%
increases usually indicate lubricant degradation
decreases indicate product contamination

Direct Read Ferrography

a 50% increase of either DRS or DRL

ISO Particle Count

an increase of 2 classes in any of the
reporting ranges (2/5/15 or 4/6/14)
47

HOW TO READ
OIL ANALYSIS REPORTS
1. Review highest severity
reports first
Does the report suggest maintenance action?
Yes
Consider all other available diagnostic information (vibration,
thermography, in-line sensors)
Act on the recommendation or order more testing.
If lube change recommendation is due to contamination, ACT ON
RECOMMENDATION to ensure fluid integrity

No
Is re-sampling recommended?
Yes
Send second sample immediately or at half normal sample interval to
verify results
No
Monitor unit vitals and sample at normal interval

48

HOW TO READ
OIL ANALYSIS REPORTS
2. Review cautionary reports
Pay particular attention to cautionary data as it becomes
more useful as more data is acquired trends will
become easier to identify and appropriate actions to take
will appear clearer.
Sample results are borderline - some wear and
contamination results may be flagged but dont
necessarily indicate failure mode or results are not
significant enough to warrant action.

49

HOW TO READ
OIL ANALYSIS REPORTS
3. Review normal reports
As time permits, review normal reports to learn what
normal results are for each unit sampled. Trends are
then more easily recognized.

50

SAMPLE INFORMATION

Severity Status Levels:

0Normal
1Some items have violated initial flagging points yet are still
considered minor.
2A trend is developing.
3Simple maintenance and/or diagnostics are recommended.
4Failure is eminent if maintenance not performed.

Unit Type and ID should give as much detail as

possible. What kind of compressor, gearbox,
engine, etc. influences flagging parameters and
depth of analysis. Different applications and
metallurgies require different lubrication and have
great impact on how results are interpreted.

Manufacturer and
Model can also
identify metallurgies
involved as well as
the OEMs standard
maintenance
guidelines and
possible wear
patterns to expect.

Lube Manufacturer, Type and

Grade identifies a lubes
properties and its viscosity and is
critical in determining if the right
lube is being used.

Make note of the difference

between the Date Sampled and
the Date Received by the lab.
Turnaround issues may point to
storing samples too long before
mailing or mail service problems.

Filter Types and their

Micron Ratings are
important in analyzing
particle countthe
higher the micron
rating, the higher the
particle count results.

Sump Capacity
identifies the total
volume of oil (in gallons)
in which wear metals
are suspended and is
critical to trending wear
metal concentrations.

Lube Time is how long the

oil has been used. Unit
Time is the age of the
equipment and Lube
Added is how much oil has
been added since the last
sample was taken.

A Lab # is assigned to the

sample upon entry for
processing and serves as a
reference number when
communicating questions or
concerns with the laboratory.

51

UNDERSTANDING RESULTS
ELEMENTAL ANALYSIS
Combinations of these Wear Metals can
identify components within the machine that
are wearing. Knowing what metals a unit is
made of can greatly influence an analysts
recommendations and determine the value
of elemental analysis.

Knowledge of the environmental conditions under

which a unit operates can explain varying levels of
Contaminant Metals. Excessive levels of dust and
dirt can be abrasive and accelerate wear.

Additive and Multi-Source Metals may turn up in test results for a variety of
reasons. Molybdenum, antimony and boron are additives in some oils.
Magnesium, calcium and barium are often used in detergent/dispersant additives.
Phosphorous is used as an extreme pressure additive in gear oils. Phosphorous,
along with zinc, are used in anti-wear additives (ZDP).

52

TEST DATA
High Fuel Dilution decreases unit
load capacity. Excessive Soot is a
sign of reduced combustion
efficiency.

Depending on lube grade,

Viscosity is tested at 40
and/or 100 C and reported in
centiStokes.

Total Acid Numbers higher than that of new lube

indicate oxidation or some type of contamination.
When TAN and Total Base Number approach the
same number, the lube should be changed or
sweetened, meaning more lube should be added.

Too much disparity between oxidation and nitration

can indicate air to fuel ratio problems. As
Oxidation/Nitration increases, TAN will also
increase and TBN will begin to decrease.

The ISO Code is an index number that represents a range of particles within a specific
micron range, i.e. 4, 6, 14. Each class designates a range of measured particles per
one ml of sample. The particle count is a cumulative range between 4 and 6 microns.
This test is valuable in determining large particle wear in filtered systems.

53

UNDERSTANDING RESULTS
FLAGGING AND COMMENTING

125
^^^^^
Numbers with carrots
printed below them denote
test results the analyst has
flagged because they
exceed pre-set warning
parameters and warrant
closer examination or
require action.

54

Test Reports
Report 24 metals (wear,
contaminant, multi-source
& additive
10 graphs on every report
5 severity status levels
Flags clearly identifiable on
all reports
New lube reference
availability
Reports accessible by
internet, fax and paper
Report Particle Sizes and
ISO Code
55

About POLARIS
Oil Analysis
Wear Debris Analysis
Data Interpretation/Alarm Limits
Sampling Methods
Information Technology

56

SAMPLING
Objectives
Maximize data density
Minimize data disturbance
Determine proper frequency

Sampling Considerations

Sampling location
Sampling hardware
Sample bottle
Sample procedure
57

ACTIVE ZONE SAMPLING

Sample from live fluid zones
Sample from turbulent zones such as
elbows
Sample downstream of bearings, gears,
pumps, cylinders and actuators

Sample machine during typical working

conditions and at normal operating
temperature
58

ACTIVE ZONE SAMPLING

Dont sample from dead pipe legs or
hoses
Dont sample from laminar zones
Dont sample after filters or from sumps
Dont sample when machine is cold or
not operating

59

ACTIVE ZONE SAMPLING

60

SAMPLING PROCEDURES

Sampling Valve - Best

Suction Pump - Second Best
Drain Plug - Least Best
Dip Method - Not Recommended

61

SAMPLING DEVICES
Quick Draw
Used on systems with 4-100
lbs. psi with a permanently
installed valve and a
disposable cap/needle/tube
assembly

62

SAMPLING DEVICES
Push Button Valve
Used on systems with 4-100 lbs. psi
and does not require tubing

Vacuum Pump
Used on non-pressurized systems
pump is attached to sample jar,
tubing is inserted into pump and
then dipstick or reservoir halfway
pump activated until jar full
63

BEST PRACTICES SUMMARY

Samples are taken at normal operating temperature
from an active zone upstream of filters and
downstream of machine components
Sampling valves and devices are flushed and clean
sample bottles are used at each sampling interval
Samples are taken at the proper frequency
Lube type, equipment ID and hours on the oil and the
machine are accurately recorded
Samples are forwarded immediately to the laboratory
via a trackable shipping service
64

THE IMPORTANCE OF TIME

Trend analysis is most effective when
sampling intervals are consistent.
Samples should be taken according to
schedule and shipped to the laboratory
immediately.
Turnaround issues can often be
attributed to the amount of time that
elapses from when the sample is taken
to the time it ships.
65

Why was Aluminum Flagged?

66

High Viscosity
VALUES EXPRESSED IN PARTS PER MILLION (PPM) BY WEIGHT
WEAR METALS

LUBE FLUID DATA

CONTAMINANT

ADDITIVE METALS

IRON

CHROMIUM

MOLYBDENUM

ALUMINIUM

COPPER

LEAD

TIN

NICKEL

SILICON

SODIUM

POTASSIUM

BORON

MAGNESIUM

CALCIUM

PHOSPHORUS

ZINC

VIS @ 100 C

TAN

LUBE

12

141

774

221

13.9

0.86

14

208

635

236

14.1

2.6

15

208

635

236

16.2

2.6

15

275

615

235

16.8

3.2

I-R
NITR
20
21
21
21

I-R
GLYC
0
0
0
0

750
790
720
750
CHG.
Y
Y
N
Y

I-R
I-R
I-R
WATER HCARB OXID
1
771
18
1
722
22
1
784
22
1
752
22

67

High Silicon
VALUES EXPRESSED IN PARTS PER MILLION (PPM) BY WEIGHT
WEAR METALS

LUBE FLUID DATA

CONTAMINANT

ADDITIVE METALS

IRON

CHROMIUM

MOLYBDENUM

ALUMINIUM

COPPER

LEAD

TIN

NICKEL

SILICON

SODIUM

POTASSIUM

BORON

MAGNESIUM

CALCIUM

PHOSPHORUS

ZINC

VIS @ 100 C

TAN

LUBE

12

141

774

221

13.9

0.86

14

208

635

236

14.1

2.6

15

208

635

236

14.2

2.6

15

70

275

615

235

14.8

2.6

I-R
NITR
20
21
21
21

I-R
GLYC
0
0
0
0

750
790
720
750
CHG.
Y
Y
N
Y

I-R
I-R
I-R
WATER HCARB OXID
1
771
18
1
722
22
1
784
22
1
752
22

68

Iron Wear but why?

VALUES EXPRESSED IN PARTS PER MILLION (PPM) BY WEIGHT
WEAR METALS

CONTAMINANT

ADDITIVE METALS

IRON

CHROMIUM

MOLYBDENUM

ALUMINIUM

COPPER

LEAD

TIN

NICKEL

SILICON

SODIUM

POTASSIUM

BORON

MAGNESIUM

CALCIUM

PHOSPHORUS

LUBE

15

10

141

774

21

18

208

635

97

21

35

208

635

211

30

78

275

615

I-R
WATER
1
1
1
1

I-R
HCARB
771
722
784
752

I-R
OXID
18
22
22
22

I-R
NITR
20
21
23
22

I-R
GLYC
0
0
0
0

750
790
720
750
CHG.
Y
Y
N
Y

69

Any
Questions?

70