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About POLARIS
Oil Analysis
Wear Debris Analysis
Data Interpretation/Alarm Limits
Sampling Methods
Information Technology
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-growing
privately-held companies in
Indianapolis for past 3 years
3
Industries Served
Transportation
Power Generation
POLARIS
Laboratories
supports oil analysis
and reliability
maintenance
programming in a
wide variety of
industry applications.
Marine
Const/Mining
Industrial
4
Facility Locations
Indianapolis
Fluids Tested
Oil
Test for wear metals and contamination
Monitor fluid properties and suitability for
use
Fuel
Troubleshoot filter problems
Determine compliance with supplier
specifications
Coolant
Detect corrosive chemicals
Monitor silicate levels
Determine compliance with OEM
antifreeze concentration
recommendations
7
ISO 17025
A2LA Accreditation
Takes quality standard of
ISO 9000 to higher level
Ensures traceability back
to standard
Determines uncertainties
and repeatability
Is highest level of quality
attainable by a laboratory
backed by the most
stringent accrediting
body in the industry
ISO
17025
A2LA
ISO 17025
Guide 25
ISO 9000
8
About POLARIS
Oil Analysis
Wear Debris Analysis
Data Interpretation/Alarm Limits
Sampling Methods
Information Technology
A sample is taken
Sample is documented
Sample is delivered to a lab
Tests are performed
Results are interpreted
Diagnostic report is issued
10
11
12
MAINTENANCE STRATEGIES
Unplanned Maintenance
Run it to failure
Very high maintenance cost
Short component life
No historical data or root cause analysis
14
MAINTENANCE STRATEGIES
Preventive Maintenance
Interval-based Maintenance
Moderately high cost
Short component life for unique equipment
No root cause analysis
15
MAINTENANCE STRATEGIES
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
16
Viscosity
Viscosity Index
TAN
TBN
Oxidation
Nitration
Demulsibility
Foaming
Rust
Copper Corrosion
RPVOT
Pour Point
Flash Point
Aniline Point
17
VISCOSITY
Viscosity is a lubricants resistance to flow at a
given temperature.
18
VISCOSITY
The force required to slide one object over another
when the two surfaces are fully separated by a fluid is
dependent on the fluids viscosity
Moving Surface
Sheared
Liquid
Stationary Surface
Viscosity =
VISCOSITY SELECTION
OPERATING
CONDITION
VISCOSITY
NEEDED
HIGHER LOAD
HIGHER
TEMPERATURE
INCREASED
SPEED
20
21
22
OXIDATION
Breakdown of a lubricant due to age and operating
conditions
Prevents additives from performing properly
Causes the formation of acids and increases viscosity
23
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 to
air-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)
25
REPORTING MEASUREMENTS
Neutralization
Number Expressed
In Mg/KOH/g
Per Cent By
Volume
Viscosity In
Centistokes cSt
at Specified
Temperature
FT-IR Results
Expressed In
Absorbance Units
Per Centimeter
BN Oxi Nit
26
CONTAMINANT LIMITS
Oil
Silico
n
Sodium
Potassiu
m
Fue
l%
Soot
%
Diesel
Engine
20
70
20
20
20
160
250
250
30
30
20
50
20
N/A
N/A
25
N/A
160
90
150
N/A
N/A
40
N/A
20
75
80
N/A
N/A
30
N/A
256
307
180
N/A
N/A
50
N/A
15
25
10
N/A
N/A
20
N/A
65
114
78
N/A
N/A
35
N/A
20
50
20
N/A
0.5
20
20
160
175
165
N/A
1.1
25
27
25
Transmission
Gear Box
Hydraulic
Natural Gas
Engine
Oxidatio Nitration
n
Fe
13
Cr Ni
0
Al
1
Contaminants
Cu Pb Sn Cd Ag
2
Ti
Si
Na
Lubricant
Additives
Multi - Source
K Mo Sb Mn
Li
Mg Ca Ba
0
2449
Zn
1260
1144
ICP SPECTROMETER
29
30
How many standard deviations from the mean (3 to +3) alarm limits will be set is based on
frequency distribution
31
Gear System
Helical, Double Helical, Hypoid, Worm
Hydraulic System
Bearing
Babbitt, Roller, Spherical Roller, Needle
Pump
Piston, Gear, Vane
Unit Manufacturer
Unit Model Number
32
Information Pyramid
Transmission
217
PPM
Iron
Flagging
Point
33
Information Pyramid
Transmission
Automatic Transmission
217
149
PPM
Iron
Flagging
Point
34
Information Pyramid
Transmission
217
Automatic Transmission
149
Allison
171
PPM
Iron
Flagging
Point
35
Information Pyramid
Transmission
217
Automatic Transmission
Allison
HT754CR
171
68
149
PPM
Iron
Flagging
Point
36
Information Pyramid
Transmission
217
Automatic Transmission
149
PPM
Allison
171
Iron
Flagging
HT754CR
68
Point
10m
Fltr
60
37
Information Pyramid
217
Lack of
information
allows 165
ppm where
failure may
occur!!!
Iron
PPM
Flagging
Point
10m
Fltr
52
38
Oil
Iron
Gas Turbines
35
62
217
Injection
Molding
Roller Bearing
Rotary Screw
Compressors
Sleeve
Bearing
Lea
d
Tin
20
24
28
30
15
32
120
40
56
19
42
95
88
54
10
141
16
26
13
493
14
59
208
104
56
40
16
26
20
44
1379
47
208
160
39
352
MFR
Iron
Cummins
60
14
21
47
390
46
20
98
147
353
40
66
37
24
429
39
15
63
259
180
40
77
17
20
501
46
15
42
119
150
40
74
13
44
16
481
39
25
91
308
120
40
92
61
14
598
39
25
56
427
105
4040
CAT
Navistar
Volvo
Mack
Tin
CAT
Iron
3406E
43
54
280
20
15
35
378
38
32
49
38
319
39
15
63
266
53
40
19
43
124
20
15
42
301
53
24
13
48
85
20
15
28
336
38
24
57
100
371
26
15
42
700
53
5441
3304
3512B
3516
C15
Tin
TREND ANALYSIS
Oil Analysis works best when at least three samples
have been taken over a short period of time so that
trends can be identified
Result trends over a sufficient period of time are more
useful than absolute numbers when trying to determine
what is occurring in a sampled machine.
Trending and graphing offer an easy to read
instantaneous 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 Data Map
42
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
43
TREND ANALYSIS
Topping off will skew the trend and
should be noted when the sample is
submitted 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
44
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 of
100%, whichever is larger
Contaminant Metals
an increase of 5 to 10 ppm or an increase of
100%, whichever is larger
45
WHAT IS CONSIDERED
SIGNIFICANT CHANGE?
Water
an increase of 100%, or any increase that
approaches the advisory levels of that sample
point
WHAT IS CONSIDERED
SIGNIFICANT CHANGE?
Viscosity
an increase or decrease of 5%
increases usually indicate lubricant degradation
decreases indicate product contamination
HOW TO READ
OIL ANALYSIS REPORTS
1. Review highest severity
reports first
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 to
verify results
No
Monitor unit vitals and sample at normal interval
48
HOW TO READ
OIL ANALYSIS REPORTS
2. Review cautionary reports
Pay particular attention to cautionary data as it becomes
more useful as more data is acquired trends will
become easier to identify and appropriate actions to take
will appear clearer.
Sample results are borderline - some wear and
contamination results may be flagged but dont
necessarily indicate failure mode or results are not
significant enough to warrant action.
49
HOW TO READ
OIL ANALYSIS REPORTS
3. Review normal reports
As time permits, review normal reports to learn what
normal results are for each unit sampled. Trends are
then more easily recognized.
50
SAMPLE INFORMATION
Manufacturer and
Model can also
identify metallurgies
involved as well as
the OEMs standard
maintenance
guidelines and
possible wear
patterns to expect.
Sump Capacity
identifies the total
volume of oil (in gallons)
in which wear metals
are suspended and is
critical to trending wear
metal concentrations.
51
UNDERSTANDING RESULTS
ELEMENTAL ANALYSIS
Combinations of these Wear Metals can
identify components within the machine that
are wearing. Knowing what metals a unit is
made of can greatly influence an analysts
recommendations and determine the value
of elemental analysis.
Additive and Multi-Source Metals may turn up in test results for a variety of
reasons. 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).
52
TEST DATA
High Fuel Dilution decreases unit
load capacity. Excessive Soot is a
sign of reduced combustion
efficiency.
The ISO Code is an index number that represents a range of particles within a specific
micron range, i.e. 4, 6, 14. Each class designates a range of measured particles per
one 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.
53
UNDERSTANDING RESULTS
FLAGGING AND COMMENTING
125
^^^^^
Numbers with carrots
printed below them denote
test results the analyst has
flagged because they
exceed pre-set warning
parameters and warrant
closer examination or
require action.
54
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
55
About POLARIS
Oil Analysis
Wear Debris Analysis
Data Interpretation/Alarm Limits
Sampling Methods
Information Technology
56
SAMPLING
Objectives
Maximize data density
Minimize data disturbance
Determine proper frequency
Sampling Considerations
Sampling location
Sampling hardware
Sample bottle
Sample procedure
57
59
60
SAMPLING PROCEDURES
61
SAMPLING DEVICES
Quick Draw
Used on systems with 4-100
lbs. psi with a permanently
installed valve and a
disposable cap/needle/tube
assembly
62
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 and
then dipstick or reservoir halfway
pump activated until jar full
63
66
High Viscosity
VALUES EXPRESSED IN PARTS PER MILLION (PPM) BY WEIGHT
WEAR METALS
ADDITIVE METALS
IRON
CHROMIUM
MOLYBDENUM
ALUMINIUM
COPPER
LEAD
TIN
NICKEL
SILICON
SODIUM
POTASSIUM
BORON
MAGNESIUM
CALCIUM
PHOSPHORUS
ZINC
VIS @ 100 C
TAN
LUBE
12
141
774
221
13.9
0.86
14
208
635
236
14.1
2.6
15
208
635
236
16.2
2.6
15
275
615
235
16.8
3.2
I-R
NITR
20
21
21
21
I-R
GLYC
0
0
0
0
750
790
720
750
CHG.
Y
Y
N
Y
I-R
I-R
I-R
WATER HCARB OXID
1
771
18
1
722
22
1
784
22
1
752
22
67
High Silicon
VALUES EXPRESSED IN PARTS PER MILLION (PPM) BY WEIGHT
WEAR METALS
ADDITIVE METALS
IRON
CHROMIUM
MOLYBDENUM
ALUMINIUM
COPPER
LEAD
TIN
NICKEL
SILICON
SODIUM
POTASSIUM
BORON
MAGNESIUM
CALCIUM
PHOSPHORUS
ZINC
VIS @ 100 C
TAN
LUBE
12
141
774
221
13.9
0.86
14
208
635
236
14.1
2.6
15
208
635
236
14.2
2.6
15
70
275
615
235
14.8
2.6
I-R
NITR
20
21
21
21
I-R
GLYC
0
0
0
0
750
790
720
750
CHG.
Y
Y
N
Y
I-R
I-R
I-R
WATER HCARB OXID
1
771
18
1
722
22
1
784
22
1
752
22
68
CONTAMINANT
ADDITIVE METALS
IRON
CHROMIUM
MOLYBDENUM
ALUMINIUM
COPPER
LEAD
TIN
NICKEL
SILICON
SODIUM
POTASSIUM
BORON
MAGNESIUM
CALCIUM
PHOSPHORUS
LUBE
15
10
141
774
21
18
208
635
97
21
35
208
635
211
30
78
275
615
I-R
WATER
1
1
1
1
I-R
HCARB
771
722
784
752
I-R
OXID
18
22
22
22
I-R
NITR
20
21
23
22
I-R
GLYC
0
0
0
0
750
790
720
750
CHG.
Y
Y
N
Y
69
Any
Questions?
70