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Oil Analysis
1.0 Why Oil Analysis
Safety First
Taking a Representative Sample
Sampling Techniques
Visual Inspection
Wear Elements
Trend Analysis
Contaminants
PQ Index
Additives
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.
Submenu
Adhesive
Abrasive
Erosive
Fatigue
Iron
Brass Alloy?
10
11
Dirt or component
Chromium
12
13
Transmission
Differential
Hydraulic
Torque
Converter
Iron (Fe)
Copper
(Cu)
Aluminum
(Al)
Chromium
(Cr)
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element.
Tin (Sn)
Lead (Pb)
Silicon
(Si)
Sodium
(Na)
14
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
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
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
Transmission
Differential
Hydraulic
Roller/Taper Bearings
Water Treatment
(oil cooler)
Roller/Taper Bearings
(some)
Rods
Spools
Roller/Taper
Bearings (some)
Torque
Converter
Iron (Fe)
Copper
(Cu)
Aluminum
(Al)
Chromium
(Cr)
Tin (Sn)
Rings
Roller/Taper Bearings
(some)
Liners
Exhaust Valves
Water Treatment
Roller/Taper
Bearings (some)
Lead (Pb)
Silicon
(Si)
Sodium
(Na)
18
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
Transmission
Differential
Hydraulic
Torque
Converter
Iron (Fe)
Copper
(Cu)
Aluminum
(Al)
Chromium
(Cr)
Tin (Sn)
Lead (Pb)
Bearings
Gasoline Octane
Improver
Oil Additives
(some)
Silicon
(Si)
Sodium
(Na)
20
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
Transmission
Differential
Hydraulic
Torque
Converter
Iron (Fe)
Copper
(Cu)
Aluminum
(Al)
Chromium
(Cr)
Tin (Sn)
Lead (Pb)
Silicon
(Si)
Sodium
(Na)
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
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your mouse
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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
Submenu
26
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
27
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
Soot
Low
X
Moderate
Normal
High
X
Viscosity
Wear Metals
28
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
Soot
Low
X
Moderate
Normal
High
X
Viscosity
Wear Metals
29
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
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
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
Viscosity
31
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
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
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
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
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
38
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
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
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
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
Submenu
46
Additives
Lubricant oil additives can become contaminants as well.
Calcium - Detergent
Phosphorus - EP
Evaluate For:
Oil Performance
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