PRACTICAL USED LUB.
OIL TESTS AND THEIR SIGNIFICANCE
1. APPEARANCE
In this procedure the oil sample is placed in narrow glass container
and is visually examined for colour.The results are reported as clear,
hazy, cloudy, milky or opaque.
SIGNIFICANCE:
The appearance of oil can provide a number of distinctive clues about
oil condition and contamination, while a gradual darkening occurs as
the oil is oxidized. Particles as small as 40 microns can be detected
by the unaided eye, providing an indication, of gross particulate
contamination. This test is limited by the subjective nature of the
observer and it cannot be used for the oils are dark to begin with.
2. KINEMATIC VISCOSITY
Time taken for a given volume of oil to pass through a specific size
orifice at a given temperature is measured and is converted into
Kinematics Viscosity in Centistokes.
SIGNIFICANCE:
This is the most important property. Used oil viscosity may increase
due to oxidation, ingress of insoluble products or contamination with
higher viscosity products. Viscosity reduces due to fuel dilution,
ingress of low viscosity products e.g.refrigerants.Oils incorporating
polymeric compounds as viscosity index improvers may have
viscosity loss due to permanent shear of VI improvers.
3. VISCOSITY INDEX
This is calculated or reads from viscosity of oil at 40 degree C and
100 degree C and is reported in whole number.
SIGNIFICANCE:
Generally Viscosity index of used oils does not change from original
value. Higher or Lower Value indicates contamination. Used engine
oil may show higher VI due to fuel dilution.
4. FLASH POINT
Flash point of lubricating oil is measured by ASTM D 92 procedure in
an open cup. For used engine oils, flash point is measured as per
ASTM D 93(PMCC) procedure as they may contain lighter fractions.
The test oil is heated in the prescribed apparatus and the oil
temperature at which vapour flashes in the presence of pilot flame is
noted. Values are expressed in degree C.
SIGNIFICANCE:
A reduced flash point value indicates presence of volatile products
like solvents or fuel. Cracking of oil also reduces flash point. Higher
flash point indicates admixture with wrong grade of oil
5. TOTAL BASE NUMBER
ASTM D 2896 procedure determines the level of alkalinity in the oil
samples by measuring the change in electrical conductivity during
titration with Perchioric Acids. The Results are expressed as
mg.KOH/g
SIGNIFICANCE:
Most motor oil are formulated with variety of additives that enhances
lubricity, retard oxidation, improve viscosity characteristics and pour
point and reduce the tendency for sludge and deposit formation. The
level of additives is determined by measuring the TBN.With use TBN
value decreases from new oil value. When it reaches critical limit oil
require change.
6. TOTAL ACID NUMBER
ASTM D 974 procedure determines the level of acidity by mixing in
an indicator solution and then adding potassium hydroxide (KOH)
until solution changes colour.Some samples may be too dark to use a
color in indicator and for such cases ASTM D 664 procedure
measure the change in electrical conductivity as the KOH is added.
The acidity is expressed as MG.KOH/g.
SIGNIFICANCE:
As oils oxidize they form acidic by products which can be corrosive to
metal components. The greater the oil degradation, higher would be
the level of corrosive acids and greater the danger of components
failure. Some oils, like hydraulic fluids, have additives which are
themselves acidic. For such cases, the most meaningful measure is
the change in acidity from new oil values. TAN should not be used as
the sole criterion for oil deterioration due to oxidation and other
properties such as viscosity, insolubles and sludge contents must
also be considered.
7. WATER
ASTM d 95 procedure determines water content by distillation and
expresses the results in volume percent(Vol % ).Water contents can
also be determined as per ASTM D 1744by reacting the oil sample
with Karl Fisher reagents. This method is particularly accurate for
small quantities of water and results are expressed in PPM.
SIGNIFICANCE:
Water reduces the lubricity of the oil and leads to corrosion of metal
parts. Higher levels of water may emulsify the oil. In steam turbine
water can also enter from steam condensation. In automotive oil
water can enter due to condensation of blow- by.
8. SEDIMENTS
In this test the oil sample is kept in a tumbler and is washed with a
solvent in the specified apparatus. The sediments so collected are
weighed and results are reported as percent mass.
SIGNIFICANCE:
A). Less than 0.05 % by volume of sediments is reported as trace.
B) No more than a trace of sediments indicates:
a) Relatively little or no oxidation or no contamination and the product
being in satisfactory condition.
b) The purification system is functioning properly.
C) More than a trace (0.05 %) of sediments indicates:
a) Oxidation, accompanied by increased neutralization number and
viscosity.
b).The presence of inorganic impurities (e.g. metal particles, dust, dirt
etc.)When accompanied by a high ash value.
c).The purification system is not functioning properly.
The nature of sediments is determined by their solubility in the
chloroform. If the sediments are soluble in chloroform the presence of
oxidized oil and /or metallic soaps is indicated. If the sediments are
completely or partially insoluble in the chloroform, further analytical
work is required to determine the exact nature. Where more than a
trace of sediment is reported, efforts should be made to correct the
condition.
9. HEXANE AND TOLUENE INSOLUBLES
ASTM D 893 procedures measure quantum of insolubles remaining
un dissolved in Hexane solvent after centrifuging. Insoluble Matter is
further dissolved in Toluene solvent and centrifuged and insoluble
matters is weighed. In soluble are reported as percent mass.
SIGNIFICANCE:
Hexane insoluble products, consist of oxidation resins plus
extraneous matters like Carbon, soot, wear particles, dirt and dust,
etc.Toluene dissolves the oil oxidation products and therefore
Toluene in soluble consists of only extraneous matters. Difference
between Hexane Insoluble and Toluene insoluble indicates amount of
oil oxidation products. Low Hexane insoluble that the oil is in good
condition. If Hexane insolubles are high, the subsequent Toluene
insoluble indicates whether contamination is due to oil oxidation or
extraneous matters or both.
10. DEMULSIBILITY
40 ml sample of oil and 40 ml 0f distilled water are mixed in a 100 ml
cylinder and kept at 54 degree C.The time taken for emulsion to
reduce to 3 ml or less is recorded in steps, of 5 minutes.
If the emulsion is more than 3 ml. After one hour, the test is
discontinued and the remaining amount 1(in ml) of oil, water and
emulsion are recorded.
SIGNIFICANCE:
Water promotes rusting of ferrous parts and accelerates oxidation of
the oil. For effective removal of water, the oil must have good
demulsibility characteristic.
11. FOAMING
The test oil is kept at 23.9 degree C temperature and air is passed
through the oil sample for 5 minutes. The amount of foam generated
and the time taken by the foam to collapse is noted. A fresh sample
of oil is tested at 93.3 degree C.In the third stage, after carrying out
the test is repeated at 23.9 degree C.The results are reported as
volume of foam in ml, at the end of blowing period and at the end of
settling period for three different test temperatures. The foam volume
at the end of blowing period is termed as the foaming tendency of the
oil, while the foam volumes at the end of the setting period is termed
as the stability of foam
SIGNIFICANCE:
Foaming in a circulating oil system is a serious service condition that
may interface with the satisfactory system performance and even
lead to mechanical damages. Foaming consists of bubbles that rise
quickly to the surface of the oil and it should be distinguished from the
air entrainments which consists of slow rising bubbles dispersed
throughout the oil. Foaming can be both system oriented and oil
related. Excessive turbulence of the oil or air leakage in the oil flow
may lead to foaming. Trace contamination of lubricant by surface
active material such as rust preventive oil and detergents can also
cause foaming. Foaming in industrial oil is undesirable because the
foam may over flow the reservoir and create a nuisance.
12.TRACE METAL ANALYSIS
Emission spectroscopy and atomic absorption are two common
methods for determining trace metal in new oil or used oils. Both
these technique require small quantity of oil sample. Results are
reported in parts per million for concentration of inorganic metals in
the oil sample.
SIGNIFIANCE:
New oils contains metallic additives and the quantum of these
additives can be determined by concentration of trace metals like zinc
, calcium , phosphorus, etc.Trace metal analysis in used oil indicates
depletion of additives and wear particles concentration. The analysis
of wear metal particles can be used for monitoring condition condition
of the equipment. The list of elements generally found in used
industrial and engine oil and their sources is given below.
ELEMENTS TYPICAL SOURCE
Aluminum(Al) Dirt, Pistons.
Antimony(Sb) Greases, Bearings
Barium(Ba) Additives,Water,Greases
Boron(B) Sea Water, Additives, Coolants.
Cadmium(Sd) Bearings,Platings
Calcium(Ca) Additives,Water,Grease,Dirt
Chromium(Cr) Bearing ,Turbine Components
Cobalt(Co) Bearings,Bushings,Bronze
Copper(Cu) Cylinders,Rust,Crank
Shafts,Water,etc
Iron(Fe) Bearings ,Greases,Paints,Gasoli
ne
Lead(Pb) Sea
water,Bearings,Additives,Dirt
Magnesium(Mg) Shafts, Valves
Manganese(Mn) Additives, Rings
Nickel(Ni) Shafts,Gears,Rings,Turbine
components
Phosphorus(P) Additives,Coolants,Gears
Potassium(K) Coolants,Additives,Dirt
Silicon(Si) Defoaments,Dirts
Sodium(Na) Coolant, sea Water,Additive,Dirt
Tin(Sn) Bearings,Solder,Cooler
Titanium(Ti) Turbine
Components,Springs,Paints
Vanadium(V) Catalysts, Turbine
Blade,Valves,Fuel Oil
Zinc(Zn) Additives,Bearings,Plating
INTERPRETTING TEST RESULTS
Most machines are highly complex, consisting of exotic metallurgy
and intricate mechanism. The numerous frictional and sealing
surfaces usually employ varying contact dynamics and loads, all
sharing a common lubricant. A failure to gain knowledge about these
many internal machine details as a reference base for use in
interpreting oil analysis data may lead to confusion and indecision in
response to oil analysis results. A good approach is to build a three –
ring binder with index tabs for each machine types. Include in this
binder photocopied pages from the service and operation manuals
plus accumulated information. The following are example of data and
information to include:
1. Identify types of bearings in use and their metallurgy.
2. Identify inputs and out put shaft speeds / torque.
3. Identify type of gears in use, speed, and loads. Determine gear
metal hardness, surface treatments, alloying metals.
4. Locate and identify all other frictional surfaces, such as cams,
pistons, bushings, swash plates etc.Determine metallurgy of surface
treatments.
5. Locate and identify coolers and heat exchangers and type of fluid
used.
6. Obtain fluid flow circuit diagram/schematics.
7. Locate and determine type of seals in use, both external and
internal.
8. Identify possible contacts with process chemicals and types.
9. Record lubricant flow rates, lubricant bulk oil temperature, bearing
drain and inlet temperature, and oil pressure.
10. Record detailed lubricant specification and compartment capacity.
11. Record filter performance specification and location.
In many cases oil analysis data can be inconclusive when used
alone. When combined with sensory inspection information, however,
a reliable, more certain, determination can be made.Likewise, the
application of companion maintenance technologies (like vibration
and thermography) can help support a conclusion prior to expensive
machine tear down or repair. Table gives example for combining
analytical data with sensory and inspection data in defining operating
problem. The analytical data are primarily generated from on-site or
laboratory oil analysis tests.
