How to Read an
Oil Analysis Report
by
Jim Fitch
Odds of Catching a Problem...
Analysis of 100,000 Mobile Equipment Oil Samples
Problems Detected
Large Wear Particles
Abnormal Wear
(Ferrous Desity)
Degradation
Overheating
Combustion
(elemental)
Problem
Dilution
Coolant
Water
Leak
Fuie
Dirt
Oil
Which Machines Would
Diesel Engines You Sample?
23.3% of all samples 21% 9% 4% 3% 9% 3% 7% 43% _
showed problems
Drive Training
Gear Lubes 19% _ 4% _ _ 8% _ 22% 46%
20% of all samples
showed problems
Hydraulic Fluids
18.2% of all samples 22% _ 7% _ _ 4% _ 21% 45%
showed problems
© Copyright Noria Corporation 3808 Ref.: Wearcheck - S.A.
Oil Analysis Program Design (done in advance)
1. Develop the sampling scheme: where, how and how often
2. Select the laboratory
3. Design the test slate: routine, exception
© Copyright Noria Corporation 1192 REF: Noria
Oil Analysis Program Design (done in advance)
4. Set limits and alarms for all data parameters
2nd upper limit (critical)
1st upper limit (caution)
VISCOSITY
1st lower limit (caution)
2nd lower limit (critical)
TIME
© Copyright Noria Corporation 1887 REF: LubeWorks
Oil Analysis Program
Design (done in
advance)
5. Design the oil analysis data
presentation (report) for
quick viewing and effective
interpretation
• Visible alarms
• Well organized data
• Non-conforming data
highlighted
• Overall condition noted
• New oil reference shown
© Copyright Noria Corporation 4 REF: MecOil
Oil Analysis Program Design (done in advance)
6. Use software and digital technology to visibly present data and characteristic features
Particles Photos
Blotters/Patches Group Plots
4-28-11
© Copyright Noria Corporation 5 REF: Predict, ExxonMobil, Livingstone
Next… Learn the Meaning of Each Data Parameter and How it
Relates to Lubricant Health, Contamination, and Machine Health
1. Fluid Properties 2. Contamination 3. Wear Debris
• Physical and chemical • Fluid and machine • Presence and
properties of used oil destructive identification of
What is analyzed (aging process) contaminants wear particles
Possible Tests:
Particle counting
Moisture analysis
Viscosity analysis
Wear debris density
Analytical ferrography
AN/BN
FTIR
Patch test
Flash point
Elemental analysis
Proactive Proactive Predictive
Primary benefit Minor benefit No benefit
© Copyright Noria Corporation 84 REF: JCF
Learn What Can Cause Individual Data
Parameters to Change
Decreases Viscosity Increases Viscosity
• Oxidation
• Thermal cracking of oil
molecules • Polymerization
Changes to base oil
(molecular changes) • Shear thinning of VI improvers • Formation of carbon and oxide
insolubles
• Hydrolysis
• Evaporative losses
• Water emulsions
• Fuel
• Entrained air
Additions to base oil • Refrigerant
• Soot
(contamination) • Solvents
• Antifreeze (glycol)
• Wrong oil (low viscosity)
• Wrong oil (high viscosity)
Non-correctable change
Correctable by removal of the contaminant if feasible
© Copyright Noria Corporation 140 REF: JCF
Learn How Oil Analysis and
Machine Inspections Reveal Common Problems
CORROSION
CRANKSHAFT BEARING WEAR
Burst filter
Refrigerant leak
Wrong oil SEAL FAILURE
Oxidation
Microdieseling
© Copyright Noria Corporation 8 REF: JCF
Interpreting Results
Problem Revealed By
Overheating • Viscosity increase
• FTIR – oxidation
• Rising acid number
• Particle count increase
• Increased wear debris
• Varnish potential
© Copyright Noria Corporation 3483 REF:
Interpreting Results
Problem Revealed By
Additive • Falling Acid Number
Depletion • Spectrometric
analysis
• FTIR
• Wear metal increase
– abrasion, corrosion
• RULER (LSV)
© Copyright Noria Corporation 3484 REF:
Interpreting Results
Problem Revealed By
Glycol • Viscosity increase
Dilution • FTIR
• Spectrometric
analysis
• Wear metal increase
• Gas chromatography
• Schiff’s Reagent Test
© Copyright Noria Corporation 3485 REF:
Interpreting Results
Problem Revealed By
Failed • Particle count
Filter • Ferrous Density Analysis
• Spectrometric Analysis
• Patch Test
© Copyright Noria Corporation 3486 REF:
Interpreting Results
Problem Revealed By
Fuel • Oil thinning
Dilution • Flash point decrease
• FTIR
• Paper chromatography
• Increase wear debris
• Gas chromatography
© Copyright Noria Corporation 3488 REF:
Failed Filter – How It’s Revealed
© Copyright Noria Corporation 3495 REF: JCF
Monitoring Engine Oils By Particle
And Viscosity Trends
Oil Oxidation Filter Failure
(FTIR-Oxidation (Ferrous density
rises) remains
constant)
Fuel Dilution High Piston,
(Flash point Rings, and
lowers) Liner Wear
(Ferrous density
rises)
Glycol Corrosive Lube
Contamination Oil Conditions
(Sodium and (BN falls)
boron rises)
© Copyright Noria Corporation 828 REF: JCF
Define What’s Normal – Baseline New, Healthy Oil
Here it is
© Copyright Noria Corporation 1363 REF:
Data From Elemental Analysis
Dominate Most Oil Analysis Reports
PPM (parts per million)
Phosphorous
Sample Date
Molybdenum
Magnesium
Potassium
Chromium
Aluminum
Calcium
Number
Sodium
Sample
Barium
Copper
Silicon
Nickel
Boron
Lead
Zinc
Iron
Tin
New Oil: 7 1 2 1 1 0 0 2 2 1 2 1071 1343 1496 2 449 1
11/04 – 1001 10/10/31 5 12 2 6 1 0 4 2 2 1 5 1096 1371 1467 1 427 2
09/29 – 1001 10/09/25 3 0 1 13 1 0 2 0 2 1 2 986 1276 1237 1 0 1
08/25 – 1000 10/08/16 3 0 1 13 1 1 3 1 2 1 1 801 1173 1109 0 0 1
06/12 – 1031 10/06/02 3 0 1 8 0 0 1 0 2 1 1 853 1258 1565 2 0 1
05/06 – 1001 10/05/01 3 0 2 8 1 0 3 1 2 0 1 778 1290 1502 2 0 2
04/02 - 1001 10/03/29 2 0 2 5 1 0 2 1 2 1 1 1080 1318 1670 2 0 2
Contaminants Wear metals Additive Elements
Data trends upward Data trends downward
© Copyright Noria Corporation 1363.01 REF: Fluid Life
Typical Levels from Elemental Analysis
Diesel Engine Average of 209 Oil Samples
Wear Metals PPM
• Iron 98.46 – Cylinder, gears, crankshaft, valve train, wrist pins
• Chromium 4.13 – Rings, cylinders
• Aluminum 4.28 – Pistons, bearings, bushings
• Copper 17.01 – Wrist pin bushings, bearings, thrust washers
• Lead 9.38 – Bearings
Additives
• Magnesium 263.74
Detergents
• Calcium 2231.76
Alkalinity improvers
• Barium 9.44
Antioxidant & Antiwear additive
• Phosphorous 1118.29
• Zinc 1210.92
Contaminants
• Silicon 11.11 Foam inhibitor or dirt
• Sodium 66.55
• Potassium 10.50 Coolant contamination
• Boron 15.13
© Copyright Noria Corporation 3096.01 REF: Lubricon
Metallurgy Detroit Diesel Allison 3-53
Cylinder Liners Cam Follower Rollers
Pistons (Sn Plated Malleable Iron) (Fe, Si) (Fe, Cr)
Camshaft Bearings
Upper Connecting Rod (Cu, Pb, Sn, Zn)
Bearing (Cu, Pb, Sn)
Camshaft
(Fe)
Blower Rotors
(Al, Si)
Crankshaft (Fe)
Piston Rings Fire
and Compression
(Cr Plated)
Oil Control
(Fe)
Connecting Rod Bearings and
Main Bearings (Pb, Sn, Cu)
© Copyright Noria Corporation 346 REF: Noria
Lock-step Trends
After 3000 service hours silicon and aluminum
trend in “lock-step” indicating dirt entry.
HOURS
50
40 critical
30
SILICON
20 caution
10
0
0 2,000 3,000 4,000 5,000
20
critical
16
12
ALUMINUM
caution
8
4
0
0 2,000 3,000 4,000 5,000
HOURS
© Copyright Noria Corporation 705 REF: KOWA
Diesel Crankcase Elemental Families
When both Al and Si are detected, dust has contaminated the oil.
© Copyright Noria Corporation 711 REF: KOWA
Potential Sources of Metals in Oil
Calcium Silver Potassium Lead
Hard Water Bearing overlay Coolant inhibitor Babbit
Salt water Solder (oil coolers) Fly ash Journal bearing overlay
Engine oil additive Some needle bearings Paper mill dust Gasoline additive
Mining dust EMC wrist pin bushing Road dust Paint
Grease Granite Solder
Limestone Trace element in fuel Bronze alloy
Slag
Rubber Titanium
Fuller’s earth Zinc
Lignite
Gas turbine bearings
AW additive Sodium
Paint Coolant inhibitor
Cement dust Brass
Turbine blades Saltwater
Road dust Plating
Gypsum Galvanizing Some additives
Rust inhibitor Grease Grease
Detergent Base stocks (trace)
Dirt
Cadmium Phosphorous Road dust
Vanadium Journal bearings
AW/EP additive
Salt (road salt)
Turbine blades Plating Fly ash
Surface finish on
Valves Activated alumina
some gears
Found in some fuels Paper mill dust
Cleaning detergent
Boron Magnesium
Coolant inhibitor Hard water
EP addtive Engine additive
Oil drum cleaning Turbine metallurgy Barium
agent Seawater Engine oil additive
Boric acid (water Fuller’s earth Grease
treatment) Road dust Fuel additive
© Copyright Noria Corporation 3092 REF: Noria
Potential Sources of Metals in Oil
Iron Tin Silicon Aluminum
Wear debris Bearing cage (bronze) Road dust Road dust
Steel Solder Sealant Bearing metal
Cast iron Babbit Antifoam additive Paint
Rust Flashing on journal Steel alloy metal Abrasives
Mill scale bearing Synthetic lubricant Aluminum mill
Ore dust Wet clutch (alumina)
Fly ash Glass mfg Coal contaminant
Paint Coolant additive Fly ash
Paper mill dust Copper Foundry dust Foundry dust
Asbestos AW additive Filter fibers (glass) Activated alumina
Talc Bronze Fly ash Bauxite
Zeolite Brass Slag Granite
Cleaning detergent Bearing cage Mica Catalyst
Cooler cores Cement dust Wear debris
Copper mining Asbestos
Paint Granite
Nickel Limestone
Babbitt
Alloy of stainless steel
Slinger rings Talc
Plating
Bushings, washers
Stellite (cobalt-nickel)
Alloy of hard steels
Chromium Molybdenum
Ring plating EP additive
Chrome plating paint Alloying metal w/iron
Stainless steel Rings
© Copyright Noria Corporation 23 REF: Noria
How to Find Additive Depletion Data on an
Oil Analysis Report
Elemental Markers for Common Additives
Additives: Zinc Phosphorous Calcium Magnesium Barium Boron Sulfur Molybdenum Silicon Notes
Antioxidants:
ZDDP Emission Spectroscopy
Hindered Phenol Organic (Elemental Analysis)
Aromatic Amine Organic
Antiwear Agents: Care must be taken when
ZDDP using elemental analysis to
Tricresyl- determine additive
phosphate (TCP) depletion. Oftentimes,
EP’s depletion of additive
Sulfur molecules does not result
Phosphorus in any significant change in
MoS2 the atomic fingerprint since
Borate depletion by-products
Rust Inhibitors remain suspended or
Detergents dissolved in the oil.
Dispersants Organic
Foam Inhibitors Note: organic additives don’t
VI Improvers Organic have elemental markers
FTIR WITH ADDITIVE DEPLETION ANALYSIS (AD)
Infrared Spectroscopy (FTIR)
DATE 95-10-17 95-09-18 95-08-17 95-07-21 95-06-20 95-05-19 95-04-18 95-03-17 95-02-21 (nla)
FTIR can be used to monitor REFERENCES 8585 8585 8585 7695 9695 5177 5177 5177 5275
% CORREL 80 91 90 92 100 62 67 78 100
additive depletion. However, it is
SOOT 0.04 0.03 0.02 0.03 0.03 0.02 0.02 0.02 0.01
often a lagging parameter to other OXIDATION 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
indicators such as AN, RPVOT and SULFATE 0.00 0.00 0.00 0.00 0.00 0.06 0.06 0.10 0.00
PRODUCT 8 10 14 7 0 40 39 10 0
Additives
the RULERTM due to its imprecision
AW/EP 100 100 100 100 100 100 100 100 100
and sensitivity to new oil reference
ANTI-OXID 100 100 100 100 100 100 100 100 100
mismatches WATER POS NEG POS NEG NEG NEG NEG POS NEG
GLYCOL NEG NEG NEG NEG NEG NEG NEG NEG NEG
© Copyright Noria Corporation 24 REF: Insight Services
Influence of AN on Antiwear Additive Depletion
Additive Systems AW = Antiwear
High ZDDP (and higher overall antioxidant level R&O = Rust & Oxidation Inhibited
and oxidation stability)
Low ZDDP ZDDP, EP and Other AW
Large Volume
Acid Type Rust and
Turbine Oils
Depletion of Inhibited Oils R&O Oils
3 ZDDP
Depletion of Range of
phenolic New Range =
initial (new) 0.6 - 1.5 0 - 0.6
and aminic 0 – 0.1
antioxidants
oil AN
2
base oil Caution Inflection Initial AN Initial AN
AN
oxidation
limit point plus 0.2 plus 0.2 plus 0.03*
1
Critical Initial AN Initial AN Initial AN
limit plus 1.0 plus 1.0 plus 0.05*
0
0 200 400 600 800 1,000 1,200 1,400 1,600 1,800
TEST TIME (hours)
In new oils,
0.1 AN equates
ZDDP
to approximately
600 ppm ZDDP
AN
© Copyright Noria Corporation 189 REF: ECF, Lubrizol
Using BN to monitor Reserve Alkylinity
12
Makeup oil
10 Drain
BN measures detergent Loss of alkalinity
BN
6 from acid generation
alkalinity (reserve) Caution (50%
in crankcase of new oil BN) Change
oil here
4
Critical (BN of 3) Corrosion
2 is already
occurring
0
TIME
For diesel engine motor oils with BNs starting at 9-10, the BN will trend downward
to 5 to 5.5 before the AN starts to rise. By the time the BN falls to 3 to 3.5 the AN
will have risen by 1 to 1.5 (indicating increasing corrosion risk)
© Copyright Noria Corporation 137 REF: JCF
If You are Looking for Information on Particles,
Which of These Could Be Useful?
• Silicon, iron, copper
• ISO Code
• Particle Size Distribution
• Ferrous Density
• Patch Test
• Micro Patch Colorimetry
• Soot load by FTIR
• Blotter spot test
• Ferrography
• Particle Micro Patch Imaging
• Direct Image Particle Count (LNF)
© Copyright Noria Corporation 27 REF: Yellotec
Okay – Lets Look as Some
Actual Oil Analysis Reports
© Copyright Noria Corporation 28 REF:
Overview of Paper Report
Section #1
Sample / Customer Info
Recommendation / Lab Comments
Section #2
Physical
Properties
Section #3
Metals
Section #5 Histograms Analysis
Section #4
Particle Count
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