PLANT MAINTENANCE

(ME-426)

Oil Analysis

` Assistant Professor
Adeel Ahmed Khan,
(MED)
Oil Analysis
 Rotating machinery needs correct lubrication but incorrect lubricant is used, or the
lubricant is contaminated this result is increased wear and equipment failure.
 There is also an economic issue - the lubricant is expensive, both to purchase and dispose
of.
 Machines that are usually the subject of oil analysis are gearboxes, high speed machines
with sleeve bearings, turbo-machinery, hydraulic systems etc.
 Too often perfectly good lubricant is changed out, at great expense. So testing is performed
on the oil and grease. The tests indicate:
i. Whether the lubricant is still able to perform its job (is the additive pack OK, etc.)
ii. whether there are any contaminants such as water or dirt
iii.whether there are any metals or other elements, which may give an early warning of wear

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Oil Analysis
Oil analysis tests and what they measure
 Samples should be taken from an active, low-pressure line, ahead of any filtration devices.
 For consistent results and accurate trending, samples should be taken from the same place
in the system each time (using a permanently installed sample valve is highly
recommended).
Various tests on the oil include:

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Oil Analysis
Additional tests that can be performed
 Visual analysis
 Vents/breathers: old or blowing vapor
 Sight glasses: check levels and color
 Leaks: oil or process fluid
 Moisture: water separation in oil samples
 Color: dark oil samples indicate oxidation
 Smell
 Acrid smell: oil may have been heated to a high temperature

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Wear Particle Analysis
 It provides an accurate insight into the condition of a machine's lubricated components by
examining particles suspended in the lubricant.
 By trending the size, concentration, shape, and composition of particles contained in
systematically collected oil samples, abnormal wear-related conditions can be identified at
an early stage.

Wear Particles are typically divided into six types

 Abrasive Wear is the result of hard particles coming in contact with internal components.
Such particles include dirt and a variety of wear metals.

 Adhesive Wear is generated when two metal surfaces come in contact allowing particles
to break away from the components. Insufficient lubrication or lubricant contamination
normally causes this.
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Wear Particle Analysis

 Corrosive Wear is caused by a chemical reaction that actually removes material from a
component surface.

 Cutting Wear can be caused when an abrasive particle has imbedded itself in a soft
surface.

 Fatigue Wear results when cracks develop in the component surface allowing the
generation and removal of particles.

 Sliding Wear is caused by equipment stress. Subjecting equipment to excessive speeds or

loads can result in sliding wear.

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