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An Explanation of the Coolant Analysis Components
Aug 10, 2022 · Knowledge
Article Number
000011836
Title
An Explanation of the Coolant Analysis Components
Article Type
Tech Note
Question
Answer
Fluid Condition
Viscosity (Visc 40o C)
Measure of the internal friction or resistance to flow of the fluid
One of the most important physical properties
A lubricant must have a suitable viscosity to ensure that an adequate supply reaches parts
needing lubrication
If Viscosity is too high – at lower temperatures the fluid will be too thick and
unable to pump to all needed parts
If Viscosity is too low – at higher temperatures the fluid can shear and loose film
strength
If Viscosity is Abnormal (Caution)
Verify that the correct fluid was specified (different fluids have different viscosities)
Verify that correct fluid was used for top offs
Verify number of hours on fluid (fluid properties change as the fluid reaches the end of it's expected life)
Resample after 500 hours or 1 month (unless you changed the coolant)
If Viscosity is Critical (Serious)
Verify that the correct fluid was specified (different fluids have different viscosities)
Change Coolant
If coolant is not near the 'Normal' change out period – change fluid and do the following
Consider flushing system
Check for source of contamination
Verify that correct fluid was used for top offs
Total Acid Number (TAN)
Indicates the remaining useful life of the fluid
Measure of the acidity of a fluid due to the effects of oxidation on the fluid
Abrupt changes in TAN may indicate abnormal operating conditions
High Temperatures
Lubricant Starvation
Incorrect Lubricant
Excessive Water
Wear Debris
Ineffective Filtration
Coolant over 8000 hrs old
Other environmental conditions
Contaminated Intake Air with Acidic Gases (Ammonia, Chlorine, Hydrochloric Acid, Sulphur Dioxide, metal cleaning solvents, welding fumes, boiler or vehicle exhaust
fumes, etc.)
If TAN is Abnormal (Caution)
Check for cause of contamination – see above list for possible causes
Improve Operating Conditions if needed
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Resample after 500 hours or 1 month
If TAN is Critical (Serious)
Change Coolant (consider flushing system)
Check for cause of contamination – see above list for possible causes
Check inlet condition
Use Air Analysis Coupon Test – CCN 68144765
Improve Operating Conditions if needed
Water (H2O)
Water can damage the metal surfaces that the lubricant is designed to protect
Excessive water or moisture reduces the lubricant's ability to separate moving parts, which results in higher friction, which results in wear and higher temperatures that further
break down the lubricant
Friction etc. can cause temperatures in excess of water's boiling point. The boiling off of water can result in places where the lubricant is forced out of the space between parts
allowing moving surfaces to contact and cause wear.
Water promotes oxidation in lubricant, corrosion on surfaces, and excessive wear
Possible Causes of High Water Content
minimum pressure valve not working
inadequate weatherproofing
heat exchanger leak (water cooled units)
compressor running too cool
new lubricant not being properly stored
no load for long periods
light load after extended downtime
high humidity
ambient air conditions
If Water level is Abnormal (Caution)
Check for cause of contamination – see above list for possible causes
Improve Operating Conditions if needed
If possible, run machine unloaded to burn off condensate
Resample after 500 hours or 1 month
If Water level is Critical (Serious)
Change Coolant
Check for cause of contamination – see above list for possible causes
Improve Operating Conditions if needed
Oxidation
Oxidation occurs when a fluid is exposed to air
It is a measure of how the fluid is standing up to the environment in which it is operating
A high Oxidation level usually indicates a thickening (rise in viscosity) and eventual failure of the lubricated component due to lack of effective lubrication
Oxidation Inhibitors (Oxidation preventing additives) are utilized to counteract the effect of Oxygen and Heat (ie: Barium)
Synthetic fluids have a high oxidation level due to their chemical structure
A sudden rise in Oxidation may indicate abnormal operating conditions
High Temperatures (#1 Cause)
Lubricant Starvation
Incorrect Lubricant
Excessive Water
Wear Debris
Ineffective Filtration
Coolant over 8000 hrs old
Other environmental conditions
Contaminated Intake Air with Acidic Gases (Ammonia, Chlorine, Hydrochloric Acid, Sulphur Dioxide, metal cleaning solvents, welding fumes, boiler or vehicle
exhaust fumes, etc.)
If Oxidation level is Abnormal (Caution)
Check for cause of contamination – see above list for possible causes
Check inlet condition
Improve Operating Conditions if needed
If Oxidation level is Critical (Serious)
Change Coolant
Check for cause of contamination – see above list for possible causes
Check inlet condition
Use Air Analysis Coupon Test – CCN 68144765
Improve Operating Conditions if needed
pH
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The pH indicates if a fluid is a base or an acid (7 is neutral, Less that 7 is an acid, Greater than 7 is a base)
The lower the pH, the more acidic the fluid
A low pH can indicate corrosive wear of the bearings
If pH is Critical (Serious), the fluid is no longer able to protect against corrosion, this will shorten the life of the airend. Change Fluid.
If pH is Abnormal (Caution)
Check inlet condition
Resample after 500 hours or 1 month
If all other indicators are normal, it may indicate the intake air is contaminated with acidic gases (Ammonia, Chlorine, Hydrochloric Acid, Sulphur Dioxide, metal cleaning
solvents, welding fumes, boiler or vehicle exhaust fumes, etc.)
If pH is Critical (Serious)
Change Coolant
Check for cause of contamination
Use Air Analysis Coupon Test – CCN 68144765
Check inlet condition
Elemental Analysis – Additives (ppm)
Additives are used in the lubricant to help protect the fluid and machine from degradation. A reduction is the amount of the additive in not desirable.
Additives in lubricants include the following:
Barium (Ba)
Corrosion Inhibitor
It is normal for Barium to deteriorate as fluid ages. If you are near the end of the specified life for the coolant, lower Barium levels will be normal.
If Barium level is Abnormal (Caution)
If no other issues, simply monitor the machine
If there are other Abnormal (Caution) items, follow direction for those items
If Barium level is Critical (Serious)
Change Coolant
Phosphorus (P)
An additive in some lubricants
If you have levels of Phosphorus in Ultra Coolant, it is a contaminate – it's not used in Ultra Coolant
If Phosphorus level is Abnormal (Caution)
Check for cause of contamination
If Phosphorus level is Critical (Serious)
Check for cause of contamination
Zinc (Zn)
Corrosion of the galvanized parts of the air/oil separator in a rotary compressor will result in elevated levels of Zinc
If Zn is elevated and TAN is over 1.0, acid could be removing Zn from the compressor system (Brass components)
Elevated levels of Zinc and Copper, indicate particles from Brass / Brass Plated components
If Zinc level is Abnormal (Caution)
Check for signs of contamination, corrosion or wear and correct as necessary
If Zinc level is Critical (Serious)
Check for signs of contamination, corrosion or wear and correct as necessary
Magnesium (Mg)
An additive in some lubricants
Not used in Ultra Coolant
If Magnesium level is Abnormal (Caution)
Check for signs of contamination, corrosion or wear and correct as necessary
If Magnesium level is Critical (Serious)
Check for signs of contamination, corrosion or wear and correct as necessary
Elemental Analysis – Contamination and Wear Particles (ppm)
Wear Particles
It is normal for contact between two moving surfaces to result in a gradual wearing of the surfaces. This gradual wearing rubs off small metal particles from the surfaces, which
remain in the lubricant. Since a particle is made up of the material from which it originated, the relative amount of each metal present in the lubricant indicates the wear condition of
the machine components. Coolant filters are used to remove these particles from the system.
Contaminant Particles
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Contaminant Particles are materials that have been ingested into the system. Contaminates can enter the system through many avenues.
Intake Air (gases, salt air, small particles like dust, etc.)
Adding Oil (different oil, contaminated oil, etc.)
Environment
Other methods
Iron (Fe) - Ferrous
Wear Metal
Possible sources of excessive Iron:
Wear or corrosion of castings, bearings, rotors, etc.
Corrosion from water in the system – check water levels
Corrosion due to high TAN / low pH
Contamination - environmental
If Iron level is Abnormal (Caution)
Carry out BOTH Vibration & SPM tests
Check for possible corrosion – see list above
Resample after 500 hours or 1 month (or as soon as practically possible)
If Iron level is Critical (Serious)
Carry out BOTH Vibration & SPM tests
Check for possible corrosion – see list above
Resample after 250 hours or 2 weeks (or as soon as possible)
Consider stopping machine until cause is identified
Chromium (Cr) and Molybdenum (Mo)
Chromium is a Wear Metal. Molybdenum is a Wear Metal and possible Contaminate.
These are alloy metals for the steel used in bearings
If large amounts of these elements are present, check for bearing wear
If Chromium or Molybdenum levels are Abnormal (Caution)
Check for possible wear or corrosion
Check for signs of Iron (Ferrous)
If Chromium or Molybdenum levels are Critical (Serious)
Carry out BOTH Vibration & SPM tests
Check for possible wear or corrosion
Check for signs of Iron (Ferrous)
Resample after 250 hours or 2 weeks (or as soon as practically possible)
Silicon (Si)
Contaminate
High levels indicate contaminates have been ingested into the machine, most likely past the Air Filters
Contaminates may include: dirt, sand, etc.
If Silicon level is Abnormal (Caution)
Check for source of contamination
Inspect and change Inlet Filters if needed
If ISO level is also high, consider changing coolant and oil filter
If Silicon level is Critical (Serious)
Check for source of contamination
Inspect and change Inlet Filters
If ISO level is also high, consider changing coolant and oil filter
Sodium (Na)
Contaminate
Check for contaminated intake air (Ocean Air, Salt Flats, etc.)
Sodium (Na) and Calcium (Ca) together may indicate a water leak across a cooling water heat exchanger
If Sodium level is Abnormal (Caution)
Check for source of contamination
Inspect and change Inlet Filters if needed
Check Barium level
If Sodium level is Critical (Serious)
Check for source of contamination
Inspect and change Inlet Filters
Check Barium level
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Calcium (Ca)
Additive - Corrosion Inhibitor in some lubricants
If used some Calcium present is desirable
Contaminate
In combination with elevated levels of Sodium - indicates possible leak across a cooling water heat exchanger
If Calcium level is Abnormal (Caution)
Check for source of contamination
If Calcium level is Critical (Serious)
Check for source of contamination
Copper (Cu)
Wear Metal
Check Coolers (extreme caution if it is a water-cooled machine)
Elevated levels of Zinc and Copper, indicate particles from Brass / Brass Plated components
If Copper level is Abnormal (Caution)
Check for source of wear
If Copper level is Critical (Serious)
Check for source of wear
Consider pressure testing water cooled coolers
Aluminum (Al)
Wear Metal
If Aluminum level is Abnormal (Caution)
Check for source of contamination or wear
Inspect and change Inlet Filters if needed
Check TAN
If Aluminum level is Critical (Serious)
Check for source of contamination or wear
Inspect and change Inlet Filters if needed
Check TAN
Boron (B), Potassium (K), Lead (Pb), Silver (Ag), Vanadium (V)
Contaminate
Lead can indicate possible breakdown of solder
If Boron, Potassium, Lead, Silver, or Vanadium levels are Abnormal (Caution)
Check for source of possible contamination
If Boron, Potassium, Lead, Silver, or Vanadium levels are Critical (Serious)
Check for source of possible contamination
Tin (Sn), Nickel (Ni), Titanium (Ti)
Wear Metals
If Tin, Nickel or Titanium levels are Abnormal (Caution)
Check for source of possible wear
If Tin, Nickel or Titanium levels are Critical (Serious)
Check for source of possible wear
ISO Cleanliness (Particle Count)
ISO Cleanliness monitors how much debris, metallic and non-metallic, is in a fluid. This method measures the number of particles per million. With the 3 number ISO value, the
first number measures the number of particles greater than 4 microns, the second number is the number of particles greater than 6 microns, and the third is greater than 14 microns.
A high particle count signifies that there is a lot of solid debris in the fluid, such as wear particles, sand, dirt, organic material, etc. Since most Ingersoll Rand coolant filters screen
out 5 microns or greater, it is the second and third number that indicates how well the coolant filtering system is working.
Causes of high particle counts include, but are not limited to:
clogged lubricant filter
bypassing lubricant filter
clogged intake air filter
bypassing air intake filter
excessive wear debris generation
fluid Oxidation
heat exchanger leak (water cooled units)
degraded/corroded seals and gaskets
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excessive idling
light load after extended downtime
incorrect sampling procedure
other causes
Number of Particles per Million Greater Than: Number of Particles per Million Less Than ISO Range Number
80,000 160,000 24
40,000 80,000 23
20,000 40,000 22
10,000 20,000 21
5,000 10,000 20
2,500 5,000 19
1,300 2,500 18
640 1,300 17
320 640 16
160 320 15
80 160 14
40 80 13
20 40 12
10 20 11
5 10 10
If ISO Particle Count levels are Abnormal (Caution)
Inspect / Change (if needed) Inlet Filters
Inspect / Change (if needed) Oil Filters
Check for source of contamination – see list above
If ISO Particle Count levels are Critical (Serious)
Change Inlet Filters
Change Oil Filters
Check for source of contamination – see list above
Created Date
Last Published Date
Aug 10, 2022
URL Name
ID-5291
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