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Oil Analysis

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About POLARISOil AnalysisWear Debris AnalysisData Interpretation/Alarm LimitsSampling Methods

Information Technology

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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-growingprivately-held companies inIndianapolis for past 3 years

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Industries Served

Power Generation

Transportation

Oil & Gas Industrial

POLARIS

Laboratoriessupports oil analysis

and reliabilitymaintenance

programming in awide variety of

industry applications.

Const/Mining

Marine

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Facility Locations

Houston

Salt Lake City Three locations 1database

Accessible within 48hours by ground

24-48 hour turnaround

Local technical salessupport

Indianapolis

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Fluids Tested

Oil Test for wear metals and contamination Monitor fluid properties and suitability for

useFuel Troubleshoot filter problems Determine compliance with supplier

specificationsCoolant

Detect corrosive chemicals Monitor silicate levels Determine compliance with OEM

antifreeze concentrationrecommendations

POLARIS specializes in testing oil,fuel, coolants and water-based fluids.

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ISO 17025 A2LA Accreditation

Takes quality standard ofISO 9000 to higher level

Ensures traceability back

to standard Determines uncertainties

and repeatability Is highest level of quality

attainable by a laboratorybacked by the moststringent accreditingbody in the industry ISO 9000

Guide 25

ISO 17025

ISO17025A2LA

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About POLARISOil AnalysisWear Debris AnalysisData Interpretation/Alarm LimitsSampling MethodsInformation Technology

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OIL IS THE LIFEBLOODOF 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

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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

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MAINTENANCE STRATEGIES

Unplanned Maintenance Run it to failure

Very high maintenance cost Short component life No historical data or root cause analysis

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Preventive Maintenance

Interval-based Maintenance Moderately high cost Short component life for unique equipment

No root cause analysis

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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

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TESTING LUBRICANT PROPERTIES

Viscosity Viscosity Index

TAN TBN Oxidation Nitration Demulsibility

Foaming Rust

Copper Corrosion RPVOT Pour Point Flash Point Aniline Point

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VISCOSITY

Shear force/shear rate Factors that affect viscosity Temperature/relationship by grade Pressure Measurement Comparative classifications Viscosity Index

Viscosity is a lubricants resistance to flow at agiven temperature.

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VISCOSITYThe force required to slide one object over anotherwhen the two surfaces are fully separated by a fluid isdependent on the fluids viscosity

Stationary Surface

Moving Surface

ShearedLiquid

Shear Force (per area)Viscosity =

Shear Rate (flow)

The higher a fluids

viscosity, the greaterthe force (energy)required to slide thesurfaces at a givenspeed and gap

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OPERATINGCONDITION

VISCOSITYNEEDED

HIGHER LOAD

HIGHERTEMPERATURE

INCREASEDSPEED

VISCOSITY SELECTION

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TOTAL ACID NUMBER

Measures amount of both organic andinorganic acid present

Indicates oxidation or contamination fromother 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

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TAN AND TBN BY TITRATION

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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

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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 toair-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

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FTIR - FUEL, SOOT,

OXIDATION, NITRATION

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REPORTING MEASUREMENTS

Fuel % Soot % Water % Vis @ 40 Vis @ 100 AN BN Oxi Nit

Per Cent By Volume

Viscosity InCentistokes cStat SpecifiedTemperature

NeutralizationNumber ExpressedIn Mg/KOH/g

FT-IR ResultsExpressed In Absorbance UnitsPer Centimeter

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CONTAMINANT LIMITSOil Silico

nSodium Potassiu

mFuel %

Soot%

Oxidation

Nitration

DieselEngine

20 70 20 2 2 20 20

160 250 250 6 6 30 30Transmission 20 50 20 N/A N/A 25 N/A

160 90 150 N/A N/A 40 N/A

Gear Box 20 75 80 N/A N/A 30 N/A

256 307 180 N/A N/A 50 N/AHydraulic 15 25 10 N/A N/A 20 N/A

65 114 78 N/A N/A 35 N/A

Natural GasEngine

20 50 20 N/A 0.5 20 20

160 175 165 N/A 1.1 25 25

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METALS BY ELEMENTAL ANALYSIS

Wear Metals ContaminantsLubricant Additives

Fe Cr Ni Al Cu Pb Sn Cd Ag Ti V Si Na K Mo Sb Mn Li B Mg Ca Ba P Zn13 0 0 1 2 0 0 0 0 0 0 3 3 0 0 0 0 0 5 0 2449 0 1260 1144

Reported in concentrations of parts per million - ppm

Refer to POLARIS Wear Metals Map

Multi - Source

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ICP SPECTROMETER

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FLAGGING POINTS & ALARMLIMITS

sample information YOU providethe lab

OEM/equipment specifications lubricant specifications laboratory database of samples

with same criteria statistical analysis of real life

laboratory data

Where do the numbers come from?

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SETTING ALARM LIMITS

Statistics used to establish alarm limits for wearmetal concentrations

Mean (average, indicated by x) and standarddeviation (the distance the spread of numbersare from the mean, indicated by ) aredetermined for each population of elementalconcentrations

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

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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

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Information PyramidTransmission 217

PPMIronFlaggingPoint

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Information PyramidTransmission

217


Automatic Transmission149

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Information Pyramid


Transmission217


Allison171

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Information Pyramid


Automatic Transmission 149

Transmission217

Allison 171

HT754CR 68

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Transmission217


Allison 171

HT754CR68

10mFltr 60

Information Pyramid

PPMIron

Flagging

Point

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WEAR METAL LIMITSOil Iron Chrome Nickel Aluminum Coppe

rLea

dTin

Gas Turbines 7 1 1 4 6 4 3

35 5 7 20 24 28 30

Rotary ScrewCompressors

62 1 2 5 15 5 7

217 7 6 32 120 40 56

InjectionMolding

19 1 1 1 42 6 1

95 5 4 8 88 54 10Roller Bearing 141 4 2 16 26 13 7

493 14 8 59 208 104 56

SleeveBearing

40 1 1 16 26 20 44

1379 6 4 47 208 160 352

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DIESEL ENGINE LIMITS BY MFRMFR Iron Chrome Nickel Aluminum Coppe

rLead Tin

Cummins 60 7 4 14 21 47 5

390 46 20 98 147 353 40

CAT 66 6 3 9 37 24 5

429 39 15 63 259 180 40

Navistar 77 7 3 6 17 20 5

501 46 15 42 119 150 40

Volvo 74 6 5 13 44 16 5

481 39 25 91 308 120 40

Mack 92 6 5 8 61 14 5

598 39 25 56 427 105 40

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DIESEL ENGINE LIMITS BY MODELCAT Iron Chrome Nickel Aluminum Coppe

rLead Tin

3406E 43 3 3 5 54 5 4

280 20 15 35 378 38 32

3304 49 6 3 9 38 7 5

319 39 15 63 266 53 40

3512B 19 3 3 6 43 7 3

124 20 15 42 301 53 24

3516 13 3 3 4 48 5 3

85 20 15 28 336 38 24

C15 57 4 3 6 100 7 6

371 26 15 42 700 53 54

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TREND ANALYSIS Oil Analysis works best when at least three samples

have been taken over a short period of time so thattrends can be identified

Result trends over a sufficient period of time are moreuseful than absolute numbers when trying to determinewhat is occurring in a sampled machine.

Trending and graphing offer an easy to readinstantaneous 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 ata Map

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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

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TREND ANALYSIS

Topping off will skew the trend andshould be noted when the sample issubmitted 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

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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 of100%, whichever is larger

Contaminant Metals an increase of 5 to 10 ppm or an increase of

100%, whichever is larger

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WHAT IS CONSIDERED

SIGNIFICANT CHANGE? Water an increase of 100%, or any increase that

approaches the advisory levels of that samplepoint

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

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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)

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HOW TO READ

OIL ANALYSIS REPORTS

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 toverify results

No Monitor unit vitals and sample at normal interval

1. Review highest severityreports first

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2. Review cautionary reports Pay particular attention to cautionary data as it becomes

more useful as more data is acquired trends willbecome easier to identify and appropriate actions to takewill appear clearer.

Sample results are borderline - some wear andcontamination results may be flagged but dont

necessarily indicate failure mode or results are notsignificant enough to warrant action.

HOW TO READ

OIL ANALYSIS REPORTS

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3. Review normal reports As time permits, review normal reports to learn whatnormal results are for each unit sampled. Trends are

then more easily recognized.

HOW TO READOIL ANALYSIS REPORTS

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SAMPLE INFORMATIONUnit Type and IDshould give as much detail aspossible. What kind of compressor, gearbox,engine, etc. influences flagging parameters anddepth of analysis. Differentapplications andmetallurgies require different lubrication and havegreat impact on how results are interpreted.

Manufacturer andModel can also

identify metallurgiesinvolved as well asthe OEMs standardmaintenanceguidelines andpossible wearpatterns to expect.

Lube Manufacturer, Type andGrade identifies a lubesproperties and its viscosity and iscritical in determining if the rightlube is being used.

Severity Status Levels:0Normal

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

ALab # is assigned to thesample upon entry forprocessing and serves as areference number whencommunicating questions orconcerns with the laboratory.

Filter Types and theirMicron Ratings areimportant in analyzingparticle countthehigher the micronrating, the higher theparticle count results.

Sump Capacityidentifies the totalvolume of oil (in gallons)in which wear metalsare suspended and iscritical to trending wearmetal concentrations.

Lube Time is how long theoil has been used. UnitTime is the age of theequipment andLubeAdded is how much oil hasbeen added since the lastsample was taken.

Make note of the differencebetween the Date Sampled andthe Date Received by the lab.Turnaround issues may point tostoring samples too long beforemailing or mail service problems.

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UNDERSTANDING RESULTS

ELEMENTAL ANALYSISCombinations of theseWear Metals canidentify components within the machine thatare wearing. Knowing what metals a unit ismade of can greatly influence an analystsrecommendations and determine the valueof elemental analysis.

Knowledge of the environmental conditions underwhich a unit operates can explain varying levels ofContaminant Metals . Excessive levels of dust anddirt can be abrasive and accelerate wear.

Additive and Multi-Source Metals may turn up in test results for a variety ofreasons. 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).

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TEST DATADepending on lube grade,

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

Too much disparity between oxidation and nitration

can indicate air to fuel ratio problems. AsOxidation/Nitration increases, TAN will alsoincrease and TBN will begin to decrease.

HighFuel Dilution decreases unit

load capacity. ExcessiveSoot is asign of reduced combustionefficiency.

Total Acid Numbers higher than that of new lubeindicate oxidation or some type of contamination.When TAN andTotal Base Number approach thesame number, the lube should be changed orsweetened, meaning more lube should be added.

The ISO Code is an index number that represents a range of particles within a specificmicron range, i.e. 4, 6, 14. Each class designates a range of measured particles perone 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.

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UNDERSTANDING RESULTS

FLAGGING AND COMMENTING

125^^^^^

Numbers withcarrotsprinted below them denotetest results the analyst hasflagged because theyexceed pre-set warningparameters and warrantcloser examination orrequire action.

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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

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About POLARISOil AnalysisWear Debris Analysis

Data Interpretation/Alarm LimitsSampling MethodsInformation Technology

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SAMPLING Objectives

Maximize data density Minimize data disturbance Determine proper frequency

Sampling Considerations Sampling location

Sampling hardware Sample bottle Sample procedure

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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 workingconditions and at normal operatingtemperature

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ACTIVE ZONE SAMPLING

Dont sample from dead pipe legs orhoses

Dont sample from laminar zones Dont sample after filters or from sumps Dont sample when machine is cold or

not operating

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ACTIVE ZONE SAMPLING

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SAMPLING PROCEDURES

Sampling Valve - Best

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

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SAMPLING DEVICES

Quick Draw Used on systems with 4-100

lbs. psi with a permanentlyinstalled valve and adisposable cap/needle/tubeassembly

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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 andthen dipstick or reservoir halfway pump activated until jar full

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BEST PRACTICES SUMMARY

Samples are taken at normal operating temperaturefrom an active zone upstream of filters anddownstream of machine components

Sampling valves and devices are flushed and cleansample 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

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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 laboratoryimmediately.

Turnaround issues can often be

attributed to the amount of time thatelapses from when the sample is takento the time it ships.

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Why was Aluminum Flagged?

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High ViscosityVALUES EXPRESSED IN PARTS PER MILLION (PPM) BY WEIGHT LUBE FLUID DATAWEAR METALS CONTAMINANT ADDITIVE METALS

LU

BE

IRON

CHROMIUM

MOLYBDENUM

ALUMINIUM

COPP

ER

LE

ADTIN

NICKEL

SILICON

SODIUM

POTASSIUM

BORON

MAGNESIUM

CALCIUM

PHOSPHORUS

ZINC

VIS @ 100C

TAN

12 1 0 3 3 1 1 0 0 2 7 9 0 141 774 221 13.9 0.86750

14 2 0 4 5 1 0 0 3 2 2 3 0 208 635 236 14.1 2.6790

15 2 0 3 6 2 2 0 5 2 3 3 0 208 635 236 16.2 2.6720

15 2 1 3 6 3 2 0 5 3 4 4 0 275 615 235 16.8 3.2750

CHG. I-R I-R I-R I-R I-RWATER HCARB OXID NITR GLYC

Y 1 771 18 20 0Y 1 722 22 21 0N 1 784 22 21 0Y 1 752 22 21 0

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VALUES EXPRESSED IN PARTS PER MILLION (PPM) BY WEIGHT LUBE FLUID DATAWEAR METALS CONTAMINANT ADDITIVE METALS

LUBE

IRON

CHROMIUM

MOLYBDENUM

ALUMINIUM

COPPER

LEAD

TIN

NICKEL

SILICON

SO

DIUM

POTAS

SIUM

BORON

MAGNESIUM

CALCIUM

PHOSPHORUS

ZINC

VIS @ 100C

TAN

12 1 0 3 3 1 1 0 0 2 7 9 0 141 774 221 13.9 0.86750

14 2 0 4 5 1 0 0 3 2 2 3 0 208 635 236 14.1 2.6790

15 2 0 3 6 2 2 0 5 2 3 3 0 208 635 236 14.2 2.6720

15 2 0 3 6 3 2 0 70 3 4 4 0 275 615 235 14.8 2.6750


Y 1 771 18 20 0Y 1 722 22 21 0N 1 784 22 21 0Y 1 752 22 21 0

High Silicon

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Iron Wear but why?

VALUES EXPRESSED IN PARTS PER MILLION (PPM) BY WEIGHTWEAR METALS CONTAMINANT ADDITIVE METALS

LUBE

IRON

CHROMIUM

MOLYBDENUM

ALUMINIUM

COPPER

LEAD

TIN

NICKEL

SILICON

SODIUM

POTASSIUM

BORON

MAGN

ESIUM

CA

LCIUM

PHOSPHORUS

15 1 0 3 3 1 1 0 10 2 7 2 0 141 774750

21 8 0 4 5 1 0 0 18 5 7 2 0 208 635790

97 21 0 3 6 2 2 0 35 6 7 4 0 208 635720

211 30 0 3 6 2 2 0 78 5 8 3 0 275 615750


Y 1 771 18 20 0Y 1 722 22 21 0N 1 784 22 23 0Y 1 752 22 22 0

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A n yQues t ions?

231500267-06-oil-analysis

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