5.0 Wear Elements & Contaminants

Oil Analysis Training
5.0 Wear Elements &

Contaminants
1
For ExxonMobil use only
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Oil Analysis
1.0 Why Oil Analysis
What oil analysis is

Goals of an analysis program
Reasons for doing oil analysis
The value of analysis to customers
2.0 Taking the Sample
Safety First
Taking a Representative Sample
Sampling Techniques
Visual Inspection
3.0 Sample Frequency

Considerations
Suggested Frequencies
4.0 Oil Testing & Analysis
Viscosity & Soot

Water
Oxidation
Nitration
Particle Count
5.0 Wear Elements & Contaminants
Wear Elements
Trend Analysis
Contaminants
PQ Index
Additives
6.0 Final Exam Instructions

Final Exam Instructions
Oil Analysis Final Exam
Section Objectives
At the completion of this section, you will be able to:
1. Describe how the presence of various metals in the lubricating
oil indicates the point of wear in the equipment.
2. List at least four common wear metals with at least two usual
origins for each.
3. List and describe common introduced or ingressed
contaminants.
4. List some common system-generated contaminants, e.g.,
coolant and additives.
Wear Elements & Contaminants

Wear Elements
Trend Analysis
Contaminants
PQ Index
Additives
Submenu
Wear Elements Types of Wear

Whatever the type of wear, the end result is that traces
of metallic elements end up in the lubricating oil.
Adhesive
Abrasive
Erosive
Fatigue
Four Factors Affecting Wear

Analyzing the lubricating oil tells what wear elements are present.
The next step is to consider possible source(s) of each element within the equipment.
Unusually high or changing amounts of any element may provide an early indication of a part or system that needs preventive care.
Four Factors Affecting Wear
ICP Metals/Elements Test

The Inductively Coupled Plasma (ICP) test is the most common method
for identifying traces of wear elements in the lubricating oil.
Diluted portions of the sample are burned in a plasma flame.
Elements in the oil give off different wavelengths of light that can be
detected and measured for quantitative analysis.
All elements are measured at once.
Particles greater than 5-8 microns in size are not burned and are not
detected.
X-Ray & Atomic Absorption Spectrophotography are other
comparable methods, though ICP is most common.
Wear Elements - Iron

Now lets look at some individual elements and their
characteristics.
Iron
With Silicon = dirt ingression
Evaluate with Chromium
Evaluate with Aluminum
Evaluate Component Composition

Drain Plug Magnet
Wear Elements - Copper

Copper
Look at Hydraulic System Components
With Sodium & Potassium = cooler (engine)
Cooler Core Leaching?
Brass Alloy?
Additive (linked to zinc?)
Never-Seez (anti-seize compound)?
10
Wear Elements Copper & Iron

Copper & Iron
30,000 engine oil samples1
95% of iron below 136 ppm
97% of copper below 167 ppm
1. Source: Noria Corporation
11
Wear Metals Aluminum, Chromium

Aluminum
Dirt or component
Chromium
Evaluate with iron trend dirt ingression
Rings on engine the killer. Look at dirt ingestion
Hydraulic rod cylinders
Rolling element bearings
12
Wear Metals Tin, Lead

Tin
Lead
Determine the composition of bearings

when doing wear metal analysis.
How are they layered?
13
Wear Metal Origins

Engine
Transmission
Differential
Hydraulic
Torque
Converter
Iron (Fe)
Copper
(Cu)
Aluminum
(Al)
Chromium
(Cr)
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Tin (Sn)
Lead (Pb)
Silicon
(Si)
Sodium
(Na)
14
Wear Metal Origins

Engine
Iron (Fe)
Copper
(Cu)
Aluminum
(Al)
Cylinders
Block
Gears
Crankshaft
Wrist Pins
Rings (Cast)
Camshaft
Valve Train
Oil Pump
Liners
Transmission
Gears
Discs
Housing
Bearings
Brake Bands
Shift Spools
Pumps
PTO
Differential
Gears
PTO
Shafts
Bearings
Housings
Hydraulic
Pump/Motor
Vanes
Gears
Pistons
Cylinder Bores
& Rods
Bearings
Valves
Pump Housing
Torque
Converter
Housings Bearings
Shafts
Chromium
(Cr)
Tin (Sn)
Lead (Pb)
Silicon
(Si)
Sodium
(Na)
15
Wear Metal Origins

Engine
Transmission
Differential
Hydraulic
Torque
Converter
Iron (Fe)
Copper
(Cu)
Aluminum
(Al)
Chromium
(Cr)
Wrist PinBushings
Bearings
(Near Failure)
Cam Bushings
Oil Cooler
Valve TrainBushings
Thrust Washers
Governor
Oil Pump
Clutches
Steering Discs
Bushing
Thrust Washers
Oil Cooler
Bushings
Thrust Washers
Oil Pumps
(where used)
Pump Thrust
Plate
Pump Piston
Cylinder GlandsGuides
Bushings
Oil Coolers
Bushings
Thrust Washers
(where used)
Tin (Sn)
Lead (Pb)
Silicon
(Si)
Sodium
(Na)
16
Wear Metal Origins

Engine
Transmission
Differential
Hydraulic
Torque
Converter
Iron (Fe)
Copper
(Cu)
Aluminum
(Al)
Chromium
(Cr)
Tin (Sn)
Pistons
Bearings
(near failure)
Bushings (some)
Blocks (some)
Housing
Oil Pump Bushing
Blowers
Thrust Bearing
Pumps
Clutches (some)
Thrust Washers
Bushings
Thrust Washers
Pump Bushings
(some)
Pump/Motor
Housing
Cylinder Gland
(some)
Impeller Turbine
Pump (some)
Lead (Pb)
Silicon
(Si)
Sodium
(Na)
17
Wear Metal Origins

Engine
Transmission
Differential
Hydraulic
Roller/Taper Bearings
Water Treatment
(oil cooler)
(some)
Rods
Spools
Roller/Taper
Bearings (some)
Torque
Converter
Iron (Fe)
Copper
(Cu)
Aluminum
(Al)
Chromium
(Cr)
Tin (Sn)
Rings
(some)
Liners
Exhaust Valves
Water Treatment
Roller/Taper
Bearings (some)
Lead (Pb)
Silicon
(Si)
Sodium
(Na)
18
Wear Metal Origins

Engine
Transmission
Differential
Hydraulic
Torque
Converter
Iron (Fe)
Copper
(Cu)
Aluminum
(Al)
Chromium
(Cr)
Tin (Sn)
Pistons (overlay)
Bearings (overlay)
Bushings
Lead (Pb)
Silicon
(Si)
Sodium
(Na)
19
Wear Metal Origins

Engine
Transmission
Differential
Hydraulic
Torque
Converter
Iron (Fe)
Copper
(Cu)
Aluminum
(Al)
Chromium
(Cr)
Tin (Sn)
Lead (Pb)
Bearings
Gasoline Octane
Improver
Oil Additives (some)
Oil Additives
(some)
Silicon
(Si)
Sodium
(Na)
20
Wear Metal Origins

Engine
Transmission
Differential
Hydraulic
Torque
Converter
Iron (Fe)
Copper
(Cu)
Aluminum
(Al)
Chromium
(Cr)
Tin (Sn)
Lead (Pb)
Silicon
(Si)
Anti-Foam
Ingested Dirt
Disc Lining
Ingested Dirt
Ingested Dirt
Ingested Dirt
Sodium
(Na)
21
Wear Metal Origins

Engine
Transmission
Differential
Hydraulic
Torque
Converter
Iron (Fe)
Copper
(Cu)
Aluminum
(Al)
Chromium
(Cr)
Tin (Sn)
Lead (Pb)
Silicon
(Si)
Sodium
(Na)

Anti-freeze
Road Salt
Ingested Dirt
Oil Additives
Ingested Dirt
Road Salt
Anti-freeze
Ingested Dirt
Ingested Dirt
Oil Additives
Ingested Dirt
22
Q15
Question
What wear element might have its source in
roller/taper bearings?
a. Iron
b. Chromium
c. Aluminum
d. Tin
23
Q15
wrong
Question
Wear
WearMetal
MetalOrigins
Origins
Iron (Fe)
Iron (Fe)
Copper
Copper
(Cu)
(Cu)
Aluminum
Aluminum
(Al)
(Al)
Chromium
Chromium
(Cr)
(Cr)
Tin (Sn)
Tin (Sn)
Lead (Pb)
Lead (Pb)
Silicon
Silicon
(Si)
(Si)
Sodium
Sodium
(Na)
(Na)
Engine
Engine
Torque
Torque
Transmission Differential Hydraulic Converter
Transmission Differential Hydraulic Converter
Use
this
to
origins
Use
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for
Use
grid
discover
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to
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for
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equipment.
elements
within
equipment.
elements within
equipment.
within
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Click
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each
element.
your mouse
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element.
Click
Click
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element.
That is not correct.

Review the Wear Metal Origins
slide, then return to the question.
13
13
24
Q15
correct
Question
What wear element might have its source in
roller/taper bearings?
a. Iron
b. Chromium
c. Aluminum
d. Tin
That is correct.
Proceed to the next slide.
25

Wear Elements
Trend Analysis
Contaminants
PQ Index
Additives
Submenu
26
Trend Analysis - Viscosity & Soot

How would you rate these trends?
Cr
Si
Mo
Fe
Pb
Cu
Sn
Na
Al
Jan
100
12
Feb
100
15
Mar
100
16
Ox
Vis
1.30
15.0
1.44
15.1
1.39
15.0
Low
X
Moderate
Normal
X
High
X
Viscosity
Wear Metals
Soot
Soot
Choose a box and see correct

answers next slide.
27

Cr
Si
Mo
Fe
Pb
Cu
Sn
Na
Al
Jan
100
12
Feb
100
15
Mar
100
16
Soot
Ox
Vis
1.30
15.0
1.44
15.1
1.39
15.0
Moderate soot with normal viscosity and normal wear metals.
Soot
Low
X
Moderate
Normal
High
X
Viscosity
Wear Metals
28

Cr
Si
Mo
Fe
Pb
Cu
Sn
Na
Al
Jan
100
12
Feb
100
15
Mar
100
16
Soot
Ox
Vis
1.30
15.0
1.44
15.1
1.39
15.0
These trends are probably OK. They are fairly tight.
Soot
Low
X
Moderate
Normal
High
X
Viscosity
Wear Metals
29

Cr
Si
Mo
Fe
Pb
Cu
Sn
Na
Al
Jan
100
12
Feb
100
15
Mar
100
16
Soot
Ox
Vis
1.30
15.0
1.44
15.1
1.39
15.0
Now how would you rate these trends?

Cr
Si
Mo
Fe
Pb
Cu
Sn
Na
Al
Soot
Ox
Vis
Jan
100
54
1.30
130
17.1
Feb
100
57
1.44
144
17.8
Mar
100
70
1.39
139
19.2
Low
Wear Metals X
Normal
X
High
X
Choose a box and see correct

answers next slide.
Low Moderate High

X
X
Soot X
Viscosity
30
Cr
Si
Mo
Fe
Pb
Cu
Sn
Na
Al
Soot
Ox
Vis
Jan
100
54
1.30
130
17.1
Feb
100
57
1.44
144
17.8
Mar
100
70
1.39
139
19.2
Low
Wear Metals X
Normal
X
High
Low Moderate High

X
Soot X
Viscosity
31
The chromium and

iron are trending
slowly up.
Viscosity is high.
It should be in the
14-16 range.
Cr
Si
Mo
Fe
Pb
Cu
Sn
Na
Al
Soot
Ox
Vis
Jan
100
54
1.30
130
17.1
Feb
100
57
1.44
144
17.8
Mar
100
70
1.39
139
19.2
There could be a
problem with use of
the wrong oil.
32
Trend Analysis - Viscosity & FDIL or Shear
Low Viscosity with Fuel Dilution or Shear:

Cr
Si
Mo
Fe
Pb
Cu
Sn
Na
Al
Jan
100
12
Feb
100
15
Mar
100
69
Soot Loading
Soot
Ox
Vis
0.65
15.0
0.60
15.1
0.99
12.5
Permanent Shear
Fuel Dilution
33
Trend Analysis - Viscosity & FDIL or Shear

This could indicate
ring wear.
Maybe a fuel
problem.
Cr
Si
Mo
Fe
Pb
Cu
Sn
Na
Al
Soot
Ox
Vis
Jan
100
12
0.65
15.0
Feb
100
15
0.60
15.1
Mar
100
69
0.99
12.5
Soot Loading
Permanent Shear
Fuel Dilution
34

Wear Elements
Trend Analysis
Contaminants
PQ Index
Additives
Submenu
35
Contaminants
Lubricant
Lubricant Condition
Condition
Equipment
Equipment Condition
Condition
Operating
Operating Conditions
Conditions
Contaminants
Contaminants
Next we will discuss one of the chief causes of failure we identified
in the previous section: contaminants.
There are two main sources for contaminants:
Introduced or Ingressed
System Generated
36
Sources of Ingressed Contaminants
Pump
Pump~~Tote
Tote
Pump
not
seated
Pump not seated
Dirty
DirtyEnvironment
Environment
Huffy
HuffyBucket
Bucket==Dirt
DirtMagnet
Magnet
Oil
OilRite
RiteJug
Jug==covered
covered
37
Lube Truck Ideal
In an ideal world, there would be few opportunities

for contaminants to be ingressed or introduced.
38
Lube Truck Reality, too often
Lube Truck
But most of us live and work Cat
in something
less than an ideal world.
39
Contaminant Elements
Here are some common contaminant elements and
their sources. Many of these are system generated.
Silicon
Dirt
Unrepresentative/poorly taken sample
Recent mechanical work
Antifoam additive normal (5-20 ppm)
Gasket sealants
Antifreeze (coolant inhibitor)
Calcium
Additive from an admixed oil, can be contaminant

In circulating systems, look at H2O trend
Sodium & Potassium

Coolant inhibitors
Road salt
Seawater
40
Contaminant Elements
Coolant
Sodium, Potassium - - detect here first by
ICP in lab
Boron
Coolant inhibitor, dispersant additive in
some oils
Vanadium
Present in heavy fuel oil
41

Wear Elements
Trend Analysis
Contaminants
PQ Index
Additives
Submenu
42
PQ Analysis
In PQ analysis, a sensitive magnetometer measures the mass of
ferrous debris in a sample and displays this as a PQ index.
Sample Bottle
Upper
Balance Coils
Excitation Coil
Lower
A ferrite rod passes
through the center of
the coil assembly.
Ferrite Core
Adjustment Screw
43
PQ Index
The PQ index is a quantitative unitless number that can be

trended with accepted linearity over a wide range of ferrous
debris content and particle size.
Since ICP/DCP is measuring Iron, you would expect a strong
correlation between PQ and Iron.
But because the ICP/DCP measures only small particles (<5
Microns) the correlation is low. See the following slide.
The PQ tells us if we have large particles or lots of small
particles.
Most engines do not have large particles.
44
PQ Index
Low PQ
High Iron
PQ-60 Iron-286
Iron
PQ
High/ PQ
Low Iron
PQ-67 Iron-15
Low PQ
Low Iron
PQ-66 Iron-64
Since ICP/DCP is measuring Iron, you would expect a strong correlation between
PQ and Iron. But because the ICP/DCP measures only small particles (<5
Microns) the correlation is low.
PQ-154 Iron-407
PQ-105 Iron-52
PQ-52 Iron-56
45

Wear Elements
Trend Analysis
Contaminants
PQ Index
Additives
Submenu
46
Additives
Lubricant oil additives can become contaminants as well.
What They Do:
Barium - Detergent, Dispersant, or Rust Inhibitor
Calcium - Detergent
Magnesium - Detergent (engines)
Phosphorus - EP
Zinc - AW and antioxidant ***Keep this out of Turbine Oil***
Evaluate For:
Oil Performance
Correct Product in Service
47
Congratulations!
You have completed the objectives
for Section 5.0 Wear Elements &
Contaminants.
Press ESC to return to main menu
and continue with
Section 6.0 Final Exam Instructions.
48

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Oil Analysis Training

5.0 Wear Elements &

What oil analysis is

2.0 Taking the Sample

3.0 Sample Frequency

4.0 Oil Testing & Analysis

Viscosity & Soot