OIL ANALYSIS. Types of oils and lubricants Mineral (or white) oils are the main group of the produced lubricants in the world (more than 90%). Biolubricants. - презентация

1 OIL ANALYSIS

2 Types of oils and lubricants Mineral (or white) oils are the main group of the produced lubricants in the world (more than 90%). Biolubricants are made from vegetable oils and other renewable sources. Synthetic oils are produced from different chemical compounds. Mineral (or white) oilsBiolubricants Synthetic oils

3 Oil. What is it? BASE OILADDITIVES READY LUBRICANT Additives suppliers ImproveCharacterictics of base oils MineralSinteticvegetable Oil retinery

4 Mineral oil – a petroleum derivative Main disadvantage is the viscosity to change large with temperature. Paraffinic oils Naphthenic oilsAromatic oils

5 SYNTHETIC OIL is a result of chemical synthesis Polyalphaolefins (PAO) Polyalkaline glycol (PAG) Polyol ester Small molecules combine to form … large molecules (by synthesis)

6 Oxidation stability of mineral and synthetic oils More stable Less stable Synthetic oil Naphthenic oil Aromatic oil Mineral oil Synthetic oil

7 Additives are chemical compounds that improve the lubricant performance of base oil (or oil "base stock"). Additives comprise from 0,1% up to 30% by weight of some oils. They used to change a base oil: To expand base oil properties. To remove undesirable oil properties. To add new properties.

8 Oil application Engine oil; Transmission fluids; Hydraulic oils; Gear oils; Compressor oils ; Steam and gas turbine oils Crosshead cylinder oils etc.

9 Purpose of an oil analysis program Oil condition monitoring; Equipment condition monitoring; Oil contamination and wear metals monitoring.

10 What is the result of oil analysis? Determination of oil degradation, Detection of oil contamination, Determination of increased wear, Prevention of potential machine failures, Maintenance intervals optimization, Unnecessary repairs reduction. Oil analysis of diesel engine diagnostic on a regular basis allows to reduce maintenance costs per 25% !

11 Benefits of oil analysis Diagnostics is conducted without disassembling and visible inspection; To identify potential problems before a major repair is necessary; It is not required delivery of diagnostic equipment to the working place of machinery; To reduce the frequency of oil changes and increase the resale value of your used equipment.

12 Proper oil sampling – the basis of oil analysis program IMPORTANT Place of sampling Sampling procedure Used accessories and techniques Accompanying information

13 Types of liquid flow Laminar (or streamline) flow occurs when a fluid flows in parallel layers, with no disruption between the layers. Turbulence flow is a flow regime characterized by chaotic property changes. This includes low momentum diffusion, high momentum convection, and rapid variation of pressure and velocity in space and time. Mixed flow - intermediate model where elements of both turbulent and laminar flow regimes coexist.

14 Reynolds number The Reynolds number (Re) is a dimensionless quantity that is used to help predict similar flow patterns in different fluid flow situations. The Reynolds number is defined as the ratio of inertial forces to viscous forces and consequently quantifies the relative importance of these two types of forces for given flow conditions. It is also used to characterize different flow regimes within a similar fluid, such as laminar or turbulent flow. Re=ρνL/µ (1) where ρ is the density of the fluid, ν is the mean velocity of the fluid, L is characteristic travelled length, µ is the dynamic viscosity of the fluid.

15 Choice of sample points YTurbulent zones such as elbows NoDead legs YDownstream of system (bearings, gears) NoLaminar flows YSample while machine is running NoAfter filters YSample under typical working conditions NoMachine cold/ not operating YSample from live fluid zones No

16 Sampling methods for machinery Oil Drain Method Vacuum Pump Sampling Sample Valve Method

17 Oil Drain Method Pros Only a sample bottle is required (and maybe a first aid kit if you spill hot oil all over your hands). Cons The health hazard of burning ones hand while trying to take an oil sample that may be at an operating temperature as high as 100 °C. The high likelihood of unrepresentative data due to contamination by sump bottom sediment. A greater likelihood of the sample being taken cold to avoid the hazard of working with hot oil.

18 Oil Drain Method (procedure) Be sure the oil is at normal operating temperature. Clean the drain plug and surrounding area to avoid contaminating the sample. Allow a sufficient amount of oil to flow from the drain to flush the inside of the reservoir near the drain plug. A quart is usually sufficient or about one half the capacity of the sump. While the oil is flowing, tip the sample bottle into the flow of oil and pull it out when the oil is within ½ inch from the top. Be sure the wasted oil is utilized by ecological way.

19 Vacuum Pump Sampling Pros This is a simple and low cost way to draw a sample of oil. The same pump can be used to sample different components. The flow of oil can be easily controlled. It requires no external modification to the component. Cons The tube that is directed into the dipstick port can be difficult to control. The tubes final resting place can be hard to predict, resulting in samples being taken from different locations within the sump. There is always the risk of the tube actually going all the way to the bottom of the sump where debris and sediment can be picked up. The possibility of cross contamination of sampling tubes with another oil that has been sampled at the same time. The drop-tube method is intrusive. The intrusion introduces the risk of contamination while the machine is being exposed to the environment.

20 Be sure the oil is at normal operating temperature. Insert the sample tubing through the top of the vacuum pump until it extends approximately ½ below the body of the pump and tightened the compression nut sufficiently to secure the tubing in the pump. Screw the sample bottle into the pump. Do not stick the cap in your pocket or allow it to become contaminated! Placing the lid in a plastic bag or our mailing container will protect it from becoming contaminated. Insert the sample tubing into the sump as described above. If inserting the tubing through a dipstick, only insert the tubing to the same depth as the dipstick. KEEPING THE GUN AND BOTTLE IN AN UPRIGHT POSITION pull the plunger back a few times until oil begins to flow into the bottle. When the oil reaches the shoulder of the sample bottle (just below the threads), break the vacuum by pressing the button on the front of the gun (or unscrew the bottle to break the vacuum). Vacuum Pump Basics Notes Remember that it is a good idea to throw away the first two samples when sampling through dipsticks to insure any contamination that might have entered the tubing as it traveled down the dipstick does not become part of the sample.

21 Vacuum Pump Sampling (procedure)

22 Sample Valve Method Pros More consistent and representative results as the machine has to be running and the sample will always be taken from the same location. Cons Requires mechanical modification of equipment if the valve has to be retrofitted.

23 Sample Valve Method (procedure) Be sure the oil is at normal operating temperature. Wipe the exterior of the sample valve and surrounding area clean prior to sampling. Flush the sample valve by allowing four to eight ounces of oil to flow before taking the sample. Insert the sample bottle in the flow while depressing (or opening) the valve to avoid adding wear from the valve into the sample (especially petcocks and ball valves).

24 Sampling best practices in a dusty environment Place sealed bottle in a clean zip-lock bag and seal. Prior to sampling remove the cap without opening the bag. Thread the bottle on to the sampling device without opening the bag. Puncture with the sampling tube. Recap the bottle after taking the sample without opening the bag. Remove the sealed (capped) bottle from the bag, label if needed and dispose of the bag. Zip lock Bottle Sample Lid

25 General rules of sampling Take samples while the equipment is running and at normal operating temperature and load if possible. If this is not possible, samples should be taken as soon after shutdown as possible. Samples taken from equipment that has been inactive for long periods are not representative. Take samples from the same point and using the same procedure each time. This will help insure repeatability. Dont sample directly after an oil change or after a large quantity of make-up oil has been added. Take samples from flowing lines between the lubricated device and before the oil filter wherever possible. This sample will be the most representative of the actual wear condition. Clean around the sample point and flush an adequate quantity of oil through the sample piping to insure a representative sample. Use the sampling materials supplied. They are clean and hold the proper quantity for the required analysis. Dont use water or soft drink bottles, jelly or baby food jars. If samples are taken using a vacuum pump, use new hose for every sample to avoid cross contamination between sample points. It is also advisable to flush the hose by filling the sample bottle two times and discarding the oil then use the third filling as your actual sample. This process will flush any debris that may have entered the sample hose as it traveled down the dipstick tube and also rinses the sample bottle. Attention! Never sample very hot oil in to the plastic bottle so the bottle can melt or deform. Use glass bottles for sampling.

26 PropertyWhat does it mean? ViscosityReduction – fuel in the oil; Increase – oil oxidation, oil contamination by insoluble substance. TBNMeasures the amount of active additive left in a sample of oil. Can aid the user in determining how much reserve additive the oil has left to neutralize acids. The lower the TBN reading, the less active additive the oil has left. TANIs used to find out the amount of acidic components present within the oil, i.e. the acidic concentration. Water contentIs an indicator of a leak in the cooling system. What oil properties are analyzed?

27 PropertyWhat does it mean? Wear metals (Fe, Cu, Pb, Al, Cr, Zn) The indicators of excessive wear and contamination. Silicon contentThe indicator of external oil contamination of abrasive particles. Glycol in oilThe indicator of exhaust gaskets or cracks.

28 What oil properties are analyzed? PropertyWhat does it mean? Fuel in oilGlaze on the inner surfaces; dirty injector; the supply of air to the combustion chamber is limited; idling the engine for a long period of time. Soot contentThe indicator of fuel air mixture problems and problems with air supply and injectors.

29 Wear indicators of engine components Engine componentsMarker BearingsLead + Tin (Cuprum/Aluminum) Bushings/InsertsLead + Ferrum Camshaft and valve block Ferrum. But the concentration of other elements is regular. CrankshaftFerrum + Lead + Tin + (Cuprum/Aluminum) CylindersFerrum + Chrome and/or Aluminum PistonAluminum + fuel or dirt Air filterSilicium Cylinder block/ Intake manifold Antifreeze or Sodium/Potassium Piston ringChrome + fuel or dirt

30 Oil analysis methods Standard laboratory methods (titration, sedimentation etc.) IR spectroscopy Elemental analysis (AAS, XFA, potentiometry) Ferrography Express analysis (dielectric constant, blotter spot test etc.)

31 Express analysis BALTECH-5000 – oil analyzer BALTECH-5300 – oil analysis mini lab Blotter Spot Test DISADVANTAGES There is no correlation with more popular parameters very often. BALTECH-5000BALTECH-5300

32 Mini laboratory BALTECH OA-5000 Application Oil condition monitoring in order to definite if the oil is possible to use further or not.

33 Types of analyzed oils Engine oils Gear oils Lubricating oils

34 Content of BALTECH AO-5000 Oil analyzer BALTECH AO-5000 Chromatographic paper filters Mechanical pipette with tips Cleaning kit (napkins and solvent) Sample pump (delivered only as part of maximum configuration ) Operation manual BALTECH AO-5000 Blotter spot test manual Transportation case

35 Oil analyzer BALTECH OA-5000 A portable device that provides instant information on oil condition, which in many cases eliminates the necessity to perform long – term laboratory tests. The analysis takes only 2 minutes!

36 Analytical tests Instant detection of change in oil condition caused by Water content Fuel content Oxidation Metal particles Reduction of detergent - dispersant additives

37 Oil analyzer BALTECH OA-5000 (theory of operation) Oil analyzer BALTECH OA-5000 measures changes in oil dielectric constant. By comparing the measurements obtained from used and unused oils of the same brand and type, the oil analyzer BALTECH OA – 5000 determines the degree of change in the condition of the oil.

38 What is dielectric constant? A dielectric constant is a fundamental property of a material, along with: boiling point, melting point, viscosity, and refractive index. A dielectric constant measures the interaction of an oscillating electric field (that is an electric field that oscillates between positive and negative values at a certain AC frequency) with a molecule. A dielectric constant is a dimensionless number. Oil contamination (water, metal particles etc.) settling to the sensor of the analyzer cause the change of dielectric constant on the sensor/oil border. So dielectric change is directly related to the degradation and the contamination level of the oil and will allow the user to achieve optimised intervals between oil changes and detect increased mechanical wear and loss of the oils lubricating properties.

39 Minilaboratory BALTECH OA-5000 (features) Replace the long laboratory tests Hand held and user friendly Numerical read-out to facilitate trending Test takes just only 2 minutes Save the last calibration in the instruments memory Possibility to make a blotter spot test

40 Oil analyzer BALTECH OA-5000 (front panel) 1.Display 2.Digital window 3.Sample sensor 4.Test button 5.Cal button 6.ON/OFF, HI/LO switch

41 Oil analyzer BALTECH OA-5000 (back panel) Battery cover

42 Interpretation of the reading The red and green areas are designed as an indicator of the condition of an engine oil. Within the green band the oil is deemed acceptable and within the red area the oil should be changed and checked again after a short running period to ensure no mechanical problems are present. Users should use BALTECH OA-5000 to monitor the change in the oils properties and build up a picture of oil degradation based on their experience and own operating criteria. Individual thresholds of acceptability can be marked on the units scale.

43 Blotter Spot Test The test is based on the established procedure of paper chromatography and involves placing a couple of drops of used oil on common blotter paper. Analytical tests: Oxidation Contamination Detergent - dispersant additives

44 Blotter Spot Test (interpretation) C – Center Zone - Area where the original oil drop was initially deposited; A – Aureole Zone - Rings formed outside of central zone; D – Diffusion Zone - Area of diffusion of medium to small size particles; T – Translucent Zone - End of the chromatogram (base oil and diesel fuel). C A D T

45 Blotter Spot Test (interpretation) Center Zone Color:What does it mean? Light brown Brown or grey Deep brown Black Able to work Not able to work Evaluation of detergent - dispersant additives: What does it mean? ED=1-(d²/D²)*ED > 0,3 Able to work ED < 0,3 Not able to work * - where d – mean value of center zone, mm. D – mean value of diffusion zone, mm.

46 Blotter Spot Test (examples) 1.Practically new oil, used in the engine only 50 hours. 2.The same oil, used about 100 hours. 3.Dirty oil but available to use so the working characteristics have been saved. 4.и 5. The oil lost the most part of its detergent - dispersant additives. It should be changed. 6.The oil is bad quality. It shouldnt be used more.

47 Portable kinematic viscometer 3000/3050 Battery operated Solvent- free and easy to clean Temperature Controlled 40 Degree C ± 0.1 Limited waste / sample 60 microliter required (3 Drops) Can enter viscosity measurement into Fluidscan and export to Oilview

48 Innovative technology 3000/3050 This viscometer operates as a Hele- Shaw cell, where Stokes flow is present between two parallel plates. The distance between plates is necessarily small relative to the width and height of the plates. The optical detection method, where LEDs positioned on the one side of the microchannel and respective photodiodes on the other side are not obstructed by side walls, is also advantageous.

49 Technical specification 3000/3050 Viscometer 3000Viscometer 3050 Standard Analytical range, cSt, at 40 °C Accuracy, %±3 of measured value ±3 of measured value over cSt ±5 of measured value for viscosity > 350 cSt V100 viscosity calculation from VI index input noyes

50 IR spectroscopy ANALYTICAL TESTS Water, Oxidation, Nitration, Sulfation, Glycol, Soot, TAN, TBN, Anti-oxidant depletion. DISADVANTAGES Complexity in use Can be used only in laboratory Lambert-Beer law T=I/I 0 =10 - ɛ ·l·c A=-lgT= ɛ ·l·c

51 Portable Infrared analyzer FluidScan Q1100 ANALYTICAL TESTS Water, TAN, TBN, Oxidation, Nitration, Sulfation, Soot, Glycol, Antiwear/antioxidant depletion, Incorrect fluids. DISADVANTAGES No

52 Quick analysis by handheld IR analyzer Q 1100 Handheld Infrared Oil Analyzer that helps confirm that new oil is of the proper type and free of water, and verifies that in-service oil is fit for use, by measuring the degradation of the oil chemistry, and contamination by other liquids such as water. Its Ideal for Machinery Condition Monitoring of in-service machinery oil and extending oil change intervals for engines/back-up generators.

53 Application Mineral oils Synthetic oils Hydraulics

54 Benefits One drop of oil to test One minute for results Wipe clean w/o solvents Immediate & actionable information

55 Addressing the challenges of on-site oil analysis Built in lubricant reference library w/ preset, adjustable Alarm Limit set Fine-tuned algorithms by oil type correlates to lab FT/IR and Water/TAN/TBN titration Simple to use, its all on the DVD! Diffraction grating Detector Cramber IR radiation source

56 High correlation to Lab measurements

57 Elemental analysis ANALYTICAL TESTS Concentration of metals, silicium, phosphorus or sulfur. Detection limits depend on the used method and device design. DISANVANTAGES Complexity in use Can be used only in laboratory Usually very huge equipment

58 Elemental spectrometer Spectroil Q100 Its a modern spectrometer without moving parts in design. It has the most up-to-date solid-state electronics and optical systems. Spectroil Q100 fulfills the requirements of ASTM D6595 Standard Method for Determination of Wear Metals and Contaminants in Used Lubricating Oils or Hydraulic Fluids by Rotating Disc Electrode Atomic Emission Spectrometry.

59 Standard Elements and Ranges

60 Features No sample preparation tests per hour. Bench-top and transportable Requires no special utilities or gases, only AC power. Standard and readily available consumables. Simple to operate without special training or background. Graphite Rod and Disc Electrodes Grating Oil Sample & Holder Fiber Optic Cable Entrance Slit Readout & Control A/D Converter CCDCCD Exit Slits Excitation Source

61 Ferrography - is a technique for analysing the particles present in fluids that indicate mechanical wear. It uses microscopic examination. Minilab-5300 – laboratory for oil analysis with capability WDA tests Minilab-5300 Detects lubricant related problems and enables on-site analysis of machinery oils and lubricants. Provides clear indications of metals wear, lubricant chemistry and contamination.

62 Particle Counter LNF series Q200 It is a bench-top analytical tool that combines the oil analysis techniques of particle shape classification and particle counting in one instrument. LaserNet Fines Direct Particle Recognition is used in Particle Counter Q200. Its the only technology coupling similar CCD-based image capture found in digital cameras with pattern recognition software to automatically classify particles in lubricating fluids. Can handle particle concentrations over 5,000,000 particles/ml.

63 Features Algorithms perform shape analysis and wear particle identification Measures particles from 4 μm to greater than 100 μm Classifies particles greater than 20 μm in size Categorizes sample per cleanliness ratings ISO 4406, NAS 1638 and NAVAIR 01-1A-17 Detects air bubbles greater than 20 μm and excludes them from particle counts Automatically compensates for fluid darkness and soot levels Requires no calibration, sizing set by known linear dimensions in flow cell Compatible with synthetic oils, mineral-based lubricants and hydraulic fluids Can handle fluid viscosities up to 320 ISO grade without dilution

64 Expeditionary Fluid Analysis System Q5800 DISADVANTAGES Very expensive Compact and portable. Operates on battery power. Gas- and solvent-free. Combines particle counting, filtration and an elemental spectrometer with an infrared spectrometer and a viscometer. You can test for machine condition (wear), contamination detection, and lubricant condition by using only a small amount of oil. Battery runtime >4 hours Full oil analysis minutes

65 Expeditionary Fluid Analysis System Q5800 Application Oil condition monitoring by the following parameters Viscosity TAN, TBN, Oxidation, Nitration, Sulfation, Water content, soot, glycol and incorrect fluid, Antioxidant and Antiwear Depletion. Particle Count >4 micron Detection 13 elements by XRF technology

66 Features It gives you ALL of the information you need for faster, more informed decision-making Need only 15 ml oil for the test Rapidly results No external PC No solvents or chemists

67 BALTECH GmbH Kronsforder Allee 45, Lübeck Germany Tel: +49 (0)