Miles Lubricants Contamination and Oil Analysis Miles Lubricants LLC 66 Marine St. Farmingdale, NY 11735
Phone: 877-683-8086 Fax: 631-229-8000 Email: support@mileslubricants.com
Topics •
Contamination • • •
•
Particles – Testing and Filtration Water Prevention
Oil Analysis • • •
Sampling Reading Report Other Tests
Preventative Maintenance Program
Categories of Lubricant Degradation •
Contamination • •
•
Particulates (Dirt, Fibers, Metal, etc.) Water
Oxidation / Thermal Breakdown • •
Over Extended Change Interval Heat • • • •
•
Increases in acidity and viscosity •
•
Over/Under Lubrication Debris Incorrect Lubricant Mechanical Sludge and Varnish
Additive Depletion
Roller Bearing Film Thickness Separation of the two surfaces is a function of LOAD, SPEED, TEMPERATURE, and VISCOSITY
www.moynulislam.com
Particle Size Comparison • Grain of table salt • 100 microns
• Human hair (Limit of Sight)
1 micron
• 40 microns
Human Hair
• Milled flour • 25 microns
• Red blood cells • 8 microns
Salt Flour
Most damaging particles are below 10 microns.
Blood
Particle Counting Particles are counted and sized based on the number and length of time the laser is interrupted
ISO Cleanliness Code
• Expressed as: x/x/x • Example: 16/14/11 − 22 ---> 4 µm − 21 ---> 6 µm − 18 ---> 14 µm • Previous system was 2µm, 5µm, 15µm • Oldest system was 5µm, 15µm
ISO 4406 Range Number
Greater Than
Less Than
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
80,000 40,000 20,000 10,000 5,000 2,500 1,300 640 320 160 80 40 20 10 5 2.5 1.3 0.64 0.32 0.16 0.08 0.04 0.02 0.01
160,000 80,000 40,000 20,000 10,000 5,000 2,500 1,300 640 320 160 80 40 20 10 5 2.5 1.3 0.64 0.32 0.16 0.08 0.04 0.02
Machinery Target Levels Amount of dirt per 100 gallons
Roller Bearing Cleanliness Target
12/10/7 26/24/21
14/12/9
16/14/11
18/16/13
20/18/15
22/20/17
24/22/19
Oil Pump or Dirt Pump?
Filter (A)
ISO Code Dirt (lbs.) (B) (C)
50 lb Bags
Relative Pump life
25 micron 21/18/13 nominal
6789
136
1
10 micron 19/16/13 nominal
1809
36
1.9
10 micron 16/13/11 absolute
211
4.2
4.4
6 micron absolute
14/11/9
53
1
8.8
3 micron absolute
12/9/7
14
0.28
15
All figures are approximations.
At ISO 14/11/9, (128 x cleaner) only one 50-lb. bag of dirt passes through. 167.03
Ref: JCF, BHRA
At ISO 21/18/13, this system passes 136 50-lb. bags of dirt through in one year
Roller Bearing Life Extension Table
Caffrey, Caren. LET. Digital image. N.p., 2013.
Summary
Partial New Drum 18/16/13
After Filter 21/19/15
12/10/7 26/24/21
14/12/9
16/14/11
Fuller’s Earth 24/23/19
18/16/13
20/18/15
Cold Separator 25/24/21
22/20/17
24/22/19
Beta (b) Ratio _Number of particles upstream > x μm_ Filtration ratio Bx = Number of particles downstream > x μm
Beta Ratio vs. Efficiency
Water in Oil Analysis
Prevention Desiccant breather prevents moisture accumulation
Prevention
• Funnels should NEVER BE USED for new lubricants. • If you currently have to use a funnel you don’t have the right tools. • Funnels can be a leading cause of contamination. When not being used they attract dirt and debris.
Oil Safe
Oil Analysis Program Miles Lubricants provides an oil analysis program that is free of charge when testing Miles Lubricants Products. The program provides basic level testing which is performed by POLARIS Laboratories. •
Viscosity @ 40°C
•
Total Acid Number
•
Water Content
•
Spectrographic (Elemental) Analysis
◦ Wear Metals ◦ Additives ◦ Contaminants
Why Use Oil Analysis?
•
To Monitor changes in lubricant properties
•
To identify contamination and its affect on lubricant properties
•
To determine type and severity of wear occurring
Oil Analysis – Bathtub Curve •
Infant mortality
•
Contamination
•
Incorrect Lubricant
•
Insufficient Lubricant
•
Must sample regularly to build and identify trends
Oil Analysis Flow Sample Taken and Shipped Fedex/UPS received faster than USPS
(Collection Hold)
Sample Processing Unboxed and Grouped in Trays
Lab station runs testing Data electronically imported to LIMS
Data Analyst review Data is reviewed and comments are made. Some are computer generated.
Data and Comments Generate Horizon Report. Miles Lubricants reviews before sending to customer.
A Look Inside The Lab
Best Sampling Practices •
Machine at operating temperature and running if possible
•
Keep sample bottles clean and lid closed
•
Flush sampling valves and sampling devices
•
Draw sample from active zone
•
Draw sample upstream of filters and downstream of machine components
•
Sample at proper frequency
•
Record the operating hours that the oil has been in use
•
Send samples to the laboratory immediately
Advanced Sample Techniques
Old Form
New Form
New Packaging
VISCOSITY– Fluid’s Resistance to Flow
VISCOSITY– Fluid’s Resistance to Flow
Total Acid Number (TAN) Measures the total concentration of strong and •
weak acids
◦
Byproduct of lubricant degradation
•
Titrated with Potassium Hydroxide
•
The results are expressed as milligrams of KOH required per gram of oil (mgKOH/g)
•
All oils have an initial TAN value
•
Since oxidation produces weak acids, a increased TAN can be an indicator of oil oxidation.
(KOH),
a base.
Water – Hotplate / Karl • Screened by Hotplate Method Fischer •
Positive water is confirmed by Karl Fischer
Elemental Analysis • Inductively Coupled Plasma (ICP)
− A diluted oil sample is pulverized by inert gas (argon) to form a mist, then introduced to a flame (plasma @ 9000oC/12000oF) and vaporized − Light emitted by vaporized sample is separated into frequencies (color) − Each color represents an element (i.e. iron, nickel, copper, etc.) − Light concentrations are then converted to parts per million (ppm) of 24 elements present in the sample
− LIMIT 8-10 Microns
Sources of Metals
Rule of Thumb– Flag Limits
Advanced Testing •
Particle Count
•
Karl Fischer Water
•
Micropatch / Ferrography
•
Filter Debris Analysis
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Questions?