[‫]دليل العمليات الكيميائيه – لجنة الزيوت‬ ‫الشركه السودانيه للتوليد الحراري‬

LUBE OIL ANALYSIS

Oil analysis is the most widely accepted and implemented form of proactive
maintenance technology. It is an integral part of the maintenance plan for power
plants, manufacturing plants, trucking companies, construction equipment, aircraft,
refrigeration systems, processing and chemical plants, etc. Any piece of equipment
that has a lubricating system is an excellent candidate for oil analysis. A successful oil
analysis program requires an organized and sustained effort. Both the user and the
laboratory must work closely together to achieve the desired results.

Oil analysis objectives

Oil analysis can be applied to equipment utilization, maintenance and management:
1. Utilization
Increase margins of operational safety
Increase availability by decreasing downtime
Increase overall component lifespan
Control standby equipment and replacement part requirements
Decrease fuel and oil consumption
2. Maintenance
Identify and measure lube contamination and component wear
Eliminate unnecessary overhauls or inspections
Reduce in‐service failures and field repairs
Establish proper lubricant service intervals
3. Management
Improve cost assessment and control for equipment, labor and materials
Improve equipment record‐keeping procedures
Evaluate equipment designs / applications
Reveal faulty operator practices

Lube oil analysis program

The lube oil analysis program can tell us

 The condition of the oil lubricated wear components of your equipment.

 The condition of your lubricant and whether it is suitable for continued use or
should be changed.
 The contamination level in your lubricant and what the contamination is.

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Lube oil analysis – Important Tests

1. Viscosity/Viscosity Index

Viscosity is defined as a measurement of resistance to flow and is a KEY physical

property of lubricants. Industrial lubricating oils are generally measured at 40° C and
results are reported as centistokes (cSt). Engine Oils are most often measured at 100°
C. Most industrial lubricating oils are classified by their viscosity. For example, an
ISO Viscosity Grade 32 (ISO VG) will have a viscosity of 32 cSt @ 40° C, ± 10%.
Engine oils are classified by their Society of Automotive Engineers (SAE) grade.
SAE 20 or SAE 30 for example. Engine oils often have additives that give them
multi-grade characteristics, such as SAE 10W40. This refers to the oil that has the
viscosity characteristics of SAE 10 oil when it is cold, and the viscosity characteristics
of SAE 40 weight oil in normal temperatures. Viscosity of oils is inversely
proportional to temperature.

Viscosity is determined by measuring the time it takes for a liquid to flow between
two sensors on a glass tube immersed in a constant temperature bath.

Viscosity Index is a calculated number that indicates the rate of viscosity change
as the lubricant is heated. The lubricant's viscosity is determined at two different
temperatures, usually 40° C and 100° C, and using an ASTM formula, the
Viscosity Index is calculated.

2. Spectroscopy

Spectrographic metals analysis is usually the 'heart' of most oil analysis programs.
Using either a Rotrode Emission Spectrometer or an Inductively Coupled Plasma
Spectrometer (ICP), 20 or more metals can be simultaneously determined. The metals
analyzed for include wear, additive, and contaminant metals and are reported in parts
per million (ppm).

Wear Additive Contaminant

Iron Silicon Silicon
Lead Boron Boron
Copper Copper Sodium
Tin Sodium Phosphorus
Aluminum Phosphorus Potassium
Chromium Zinc Calcium
Nickel Calcium Magnesium
Silver Magnesium Vanadium
Titanium Molybdenum
Antimony Antimony

Zinc Potassium

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3. Neutralization Number

As lubricants degrade from oxidation they form a number of acids. These acids are
corrosive to Babbitt, yellow metals, carbon steel, cast iron, and if left uncorrected for
a period of time will begin a corrosion process and possibly eventual bearing failure.
While small increases in the Total Acid Number (TAN) usually indicate oxidation and
lubricant degradation, contaminants with acidic constituents can also be a factor.
Monitoring the oil's Total Acid Number should be an important part of your lubricant
maintenance program. Generally when a lubricant's acid number reaches a
condemning limit, replacement or sweetening is your best option.

Total Acid Number (TAN) is the standard neutralization number test for industrial
lubricating oils. It is performed by titrating a solution of oil and diluent with an
alcohol/potassium hydroxide (KOH) solution, a base, until all the acids present are
neutralized. The results are reported as milligrams of potassium-hydroxide per gram
of sample, or mg/Gm

Strong Acid Number (SAN) is similar to TAN, except the 'strong' acids are first
extracted from the lubricant. That extract is then titrated with KOH and the SAN
reported as mg/gm.

Total Base Number (TBN) is a standard test for engine lubricants. It is a measurement
of the amount of protection in the lubricant remaining to neutralize acids formed as a
result of combustion. A solution of oil and diluents is titrated with an
alcohol/Hydrochloric Acid (HCl) solution until all the alkaline or base constituents in
the oil are neutralized. Results are reported as milligrams of HCl per gram of sample,
or mg/gm.

4. Karl Fischer Water Titration

Water is the most common contaminant found in lubricating oils. It is also one of the
most damaging to bearings and other lubricated components. It causes corrosion to
metal surfaces, lubricant degradation, and poor lubrication. Water can be present in
three forms in lubricating oils:

Dissolved: There is a limited amount of solubility of water in oil which is very

temperature dependant. At 120° F, about 100 ppm of water can be dissolved in oil.
Dissolved water is not harmful nor does it affect the appearance or performance of the
lubricant.

Emulsified: Water and oil can form tight bonds that are difficult to break. This form
of water in oil is what causes oil to become milky and is the most harmful. Oil will
begin to become 'milky' at about 150 - 300 ppm, depending on the base stock and
additive in the lubricant.

Free Water: These are free water droplets, often suspended in the lubricant due to
surface tension. This form of water in oil is also very harmful to lubricated parts, but
is also the easiest to separate. Often free water is routinely drained from sumps and
reservoirs. The ability of the oil to separate from the water is an important

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characteristic of the lubricant in many applications, such as steam turbines and

centrifugal compressors.

The Karl Fischer Water Titration is the only suitable test for determining how much
moisture is present in a lubricant at levels less than 500 parts per million (0.05%).
Depending on the procedure used, accurate results can be obtained down to the 4 or 5
parts per million (ppm) levels. Karl Fischer Water Titrations will determine the total
amount of water present, regardless of the form it is in.

5. Flash Point

The Flash Point of an industrial lubricant is an important test to determine if light-end

hydrocarbons are getting into the oil through seal leaks or other means. It is an
effective way to monitor seal performance in light end hydro-carbon compressors.
Low Flash Points pose a safety hazard in the event of component failure than can
generate heat above the flash point of the oil, such as bearing failure. The Flash Point
of most ISO VG 32 R&O mineral oils are in the 370 - 390° F range. Generally, the
more viscous and the more additives in the oil, is the higher the Flash Point. Typical
automotive or diesel engine oil will have a Flash Point in the 425 to 460° F range.

The test is conducted by slowly heating a sample of lubricant. Directly above the
sample container is an ignition source, either an open flame or spark source. As the
sample heats, the light-ends boil off and form flammable gasses. When there is
enough gas built-up to be ignited by the ignition source, the gases will flash. The
temperature at which the oil was heated to when this occurs is called the Flash Point.
It is reported in degrees F or degrees C.

6. Sulfur Analysis

Sulfur in the form of Hydrogen-Sulfide (H2S) or other sulfur compounds are usually
corrosive to most metals found in your equipment. If moisture is also present, strong
Hydro-Sulfuric acid can form, and corrosion occurs. Sulfur ingression, in whatever
form, is usually a result of seal leakage in applications such as sour gas compression.
Some lubricants contain sulfonated additives such as phosphorus-sulfur compounds
use in some EP additives. These additives can be corrosive, especially to yellow
metals.

Unless the application involves sour gas or another source of sulfur, Sulfur Analysis
should not be a part of your routine oil analysis program. In cases of wet-gas
compression where monitoring seal performance is importance; routine sulfur
analysis should be added to the test list.

Sulfur Analysis is performed by X-Ray Fluorescence and reported as percent.

Detection limits are in the .01 % range.

7. Fuel Dilution %

Fuel Dilution % is the amount of raw, unburned fuel that ends up in the crankcase. It
lowers oil's viscosity and flash point - creating friction-related wear almost

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immediately by reducing film strength. Gas Chromatography is a method for

separating the components of a mixture and measuring the amounts of each.
Components are separated from one another by vaporizing the sample into a carrier
gas stream that is passed through a column containing a substance that selectively
adsorbs then releases the components to be measured.

8. Cloud and Pour Point

As oil cools to temperatures in the 40's and below, waxes in the oil will crystallize. As
the oil where cooled further to freezing or below, moisture in the oil will form ice.
The temperature at which these crystals form and are visible is called the Cloud Point.
The greater the quantity of wax present, the higher the cloud point. Wax crystals have
a different appearance than ice crystals and will form above 32° F.

If you continue to chill the oil, eventually the oil will not flow out of the test tube
when turned upside down. Remember, viscosity of oil is inversely proportional to
temperature. The temperature at which this occurs is call the Pour Point. The tests are
conducted by simply chilling the oil and observing at what temperature these events
occur.

The Cloud and Pour Point characteristics of oil are important factors when selecting a
lubricant for chiller applications, oil mist applications, and in Northern regions where
temperatures routinely reach 0° F in the winter time.

The Cloud Point and Pour Point tests should not be a part of your routine analysis
program. It is a quality check of the lubricant and should be performed for evaluation
of new oils or when a wax problem is apparent or suspected in the system.

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Lube Oil Test Lists

Standard Test Method Units of

Name of Test
Used Measure

Viscosity @ 40° or 100° C centistokes

Viscosity Index (includes Vis @ 40° &

no units
100°C)

Elemental Metals Analysis ppm

Acid Number mg KOH/g

Base Number mg KOH/g

Water by Karl Fischer ppm

Flash point ̊C

Sulfur Analysis % by Volume

Fuel Dilution % % by Volume

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