Wear

Industrial
Oil
Analysis

Clean,
Tribology
Dry

Story Book
& Fit for
Use

Contamination Chemistry
 Industrial Oil Analysis Requirements
M.I.T. Study Wear Debris Analysis, Ferrous Index (> 5 microns)
Spectrometric (Fe, Cu, Pb, Sn, Cr, Al, Ni, Ag) (< 5 microns)

Equipment Fails
because...
Wear Stop
Obsolete Surfaces Degrade Accident Conventional Oil Analysis False
15% 70% 15% Sense of
Security
Corrosion Wear
20% 50%

Industrial Oil Analysis

Caused by
water-in-oil, degraded oil,
process contamination,
coolant, condensation...
abrasive particles between
Abrasive Wear
Damage resulting from
two moving surfaces.
Adhesive Wear
Damage resulting from
metal surfaces dragging
over each other.
Fatigue Wear
Damage resulting from
micro-cracks caused
by cyclic loading.
Contamination Chemistry

ASLE Bearing Workshop Caused by Caused by Caused by Particle Counting with Size Viscosity at 40C and 100C,
Rabinowicz, 1981
abrasive particles-in-oil inadequate lubrication misalignment, imbalance, Distribution (> 5 microns), Viscosity Index, Dielectric,
dirt, secondary wear, low visc, no oil, high temp, improper fit/assembly, Contaminant Index Chemical Index, Water,
process contamination... excess load, slow speed... secondary damage... Spectrometric (Zn, Mg, Ca,
Spectrometric (Si, B, Ni) P, K, Ba, Li, Mn), TAN, TBN,
(< 5 microns), Water FTIR

Typically > 5:1 ROI

OilView® Laboratory
5200
Information Management Trivector
Extend Overhauls
System (LIMS) Software Analyzer
(Contamination Control)
Clean, Dry and Fit for Use Industrial
Minilab

Less Reactive
(Early Detection and
CSI
Confirmation of Problem) Industrial
Essential to reap the
Oil
benefit of your Oil Analysis Analysis
program. Laboratory
 The Hidden Cost of “Free Oil Analysis”
Laser Turntable operating a Laser Turntable samples were collected and sent off to two different
labs who provide “Free Oil Analysis.” The labs reported:-
Robotic Welder
“Analysis indicates component &
“No corrective action required.” lubricant conditions are acceptable.”

5100 Analyzer Minilab Results on the same sample

Moral of the Story

Ensure proper Industrial Oil
Analysis by either using the
On-Site 5100/5200 Industrial
Minilab or a Lab that performs
Industrial Oil Analysis (Particle
Counting and Wear Debris
Analysis) such as CSI’s
Industrial Oil Analysis Lab.
Trivector indicates Spikes on 5100 The Shop Microscope
Extreme Wear condition Analyzer plot indicate Showed
and Alarming numerous Large Iron Spheres in Laser
Contamination condition! Ferrous Particles Turntable Oil Reservoir Based on a case study by Frank D’Arcio and Ed
Bohn at the GM Linden Truck and Bus Assembly
Plant
 Maximizing Bearing Life
Bearing Life Timeline
New Proactive Stage (Damage Free) 1 2 3 4 Failed

Proactive Stage Initial Damage Stage Second Stage Third Stage Final Stage
Vibration Analysis

Find and Correct Root Causes
Before Damage.
Check for Misalignment,
Imbalance, Structural
Resonance, Rub, Looseness
and Correct Assembly to keep
equipment in good working order.
PeakVue® will detect and
identify bearing component
damage.
Demodulation generally will
not detect.
Normal Vibration generally
will not detect.
PeakVue will detect and
identify bearing component
including severity.
Demodulation can detect,
but no trending and no
indication of severity.
Normal Vibration may
detect.
PeakVue shows fault
frequencies and trending
shows severity.
Demodulation can detect,
but no trending and no
indication of severity.
Normal Vibration shows
bearing defect frequencies.
PeakVue shows an increase in
harmonic (spectral) activity and
a rapid increase of peak values
(g’s) of impacting events (time
waveform).
Demodulation can detect, but
no trending and no indication of
severity.
Normal Vibration shows
increasing amplitude, broad band
and looseness.

Find and Correct Root Causes
Before Damage.
Measure Dust and other hard
Oil Analysis
Initial Onset of Wear. Early Detection of Bearing Excellent Detection of Severe Damage
Damage. Severity. Indications.
Early detection of small wear
debris (>5 micron) at the Particles from rollers, races, Dramatic increase in wear Increasing friction from

particles leading to abrasion.
Measure Water and other fluids
leading to corrosion.
Check Viscosity to ensure correct
lubrication.
Extend Bearing Life by keeping
oil Clean, Dry and Fit for Use.
onset of abrasion, fatigue, and retainers are counted,
and adhesion. sized, and examined.
Quantity and size of wear
debris increasing (> 15
micron). Identify root cause
using wear debris analysis.
particle counts and particle
sizes as defects grow. More
large fatigue chunks and
platelets in the oil (> 30
microns). Evidence of
secondary damage as hard
particles promote abrasion.
damaged bearing
components rapidly
generates wear particles.
Extreme concentrations of
wear debris and secondary
contamination found in the
oil. Very high concentrations
of very large wear particles
(>50 microns).

“The effective integration of oil analysis with Normal Vibration and PeakVue® for
machine health monitoring provides much more than the sum of the parts. For example,
PeakVue analysis will detect corrosion after damage is present but oil analysis will detect the
presence of contaminants which will lead to corrosion damage if left unchecked. Normal vibration,
PeakVue and Oil analysis will be very supportive of each other in severe damage situations allowing
confidence in severity assessment and accompanying action items to reduce chances of catastrophic
failure.”
Dr. Jim Robinson
Jim Robinson is a recognized innovator in signal processing technology and has participated in the development of
patented techniques such as PeakVue®, SST and others.
“Oil analysis effectively detects certain problems within
rotating machines before they are evident with vibration
analysis - particularly on multi-stage gearboxes, plain bearings,
rotary screw air compressors, roots blowers and certain rolling
elements bearings which might be located at a distance from an
accelerometer mounting location.”
James E Berry
From the article “Good Vibes About Oil Analysis” in Practicing Oil
Analysis by James E. Berry who is a recognized expert in vibration
analysis.
 Monitoring Grease using Ultrasonics
Difficulties Monitoring Greased Bearings SonicScan 7100 Methodology
• Maintenance professionals often report that the biggest problem with their • Sensor specifically designed to
Tribology program is anti-friction bearing lubrication – specifically grease. measure lubrication regime by
• Greasing problems include when to grease, methods to grease, how much to monitoring stress waves at 30kHz
grease, using the wrong grease, no grease at all. using tuned resonant wave guide.
• Over greasing results in bearing damage and premature grease breakdown as a • Also detects mechanical faults,
results of shield and seal damage and increased bearing temperature. Under using a tuned 4 kHz resonant wave
greasing causes inadequate lube delivery and possible contamination entry guide, and able to distinguish them
resulting in premature bearing failure. from the 30kHz lubrication faults.
• Improper lubrication generates increased mechanical energy (high frequency
• Monitoring performed without
stress waves) and thermal energy (increased temperature).
intrusion while machine is
operating.

Three Distinct Frequencies • Indicates when to grease and

Compressor when to stop greasing.
SonicScan 7100 Most Bearing Bearing Lube, Valves
Impacts Small Bearing Steam Traps • Condition-based rather than
Analyzer Gear Defects Impacts Internal leaks schedule-based greasing.
• Grease sampling not required.

Lubrication Regimes

1
0.1

Friction
0.01
0.001
D B M E H
0.0001
0.001
none0.01 0.1 1 10 100 1000
Specific Film Thickness
Checking bearing for correct
grease lubrication

4 kHz 30 kHz 40 kHz Tuned Resonant Wave Guides

 Clean Up Your Plant Oil Storage
Before Solution
Unmarked and poorly Unmarked and Poor labeling and Fingerprint your
marked oil storage inappropriate oil transfer disorganized storage Oils using Dielectric
containers... containers... lead to many problems... and Viscosity to
ensure correct
Labeling
Oil Type
Labels
Clean Up, Label
Pocket
Containers and
Linden Oil Codes Linden Oil Codes
Texaco
Rando Lube
Rando HD 68 Lube Con 663

Reference
68 Con 663

MEROPA Texaco Rando Texaco

Equipment,
150 Meropa 150 32 Rando HD 32

Meropa Texaco Meropa Texaco

Guide
320 Meropa 320 220 Meropa 220

Texaco Tribol 290 High

Vanguard 680 Tribol
Vanguard Heat Oil
680 290

Accurately
Tribol Tribol Chain Oil
Silogram 85 Silogram 22 22
85/140 SAP

Ucon Vacuum
Way 100 Texaco Way Ucon 300 Oil
100 Oil LB-300-XY26

Label Sample
OMALA
100
Shell Omala 100 ATF-210 Mobil Type “F”
Transmission Fluid

Bottles

After
Well-Organized, Oil Labels on Plant Well Labeled Containers Accurately Labeled
Well-Marked Oil Equipment for New Oils Oil Sample Bottles
Storage

Ensure that good practices are being followed by implementing a sampling and analysis program.
 5200 Trivector Analyzer Industrial Minilab
Ferrous Particles Water
3 - Laser Particle Counter
Measures the number and size
distribution of particles in the oil
sample.
The results are reported as
particle size distribution and ISO
codes and are compared to a
target cleanliness level assigned to
the piece of equipment.
2 - Ferrous and Water The 52DV digital
viscometer uses a
rotating ball to
Measures the change in time measure the
resolved dielectric. An oscillating viscosity of the oil
sample
magnet is used to detect ferrous
material.
1 - Oil Chemistry (Dielectric +
The results are reported as
Viscosity)
contamination and ferrous indices
as well as estimated water Measures the dielectric of the undiluted oil
content. and compares it to the reference oil
dielectric to calculate the chemical index.
The Chemical Index gives an indication of
Scale used to the deterioration of the oil due to oxidation,
Measure nitration, contamination, etc. It also gives a
Oil/Solvent
Dilution clear indication of wrong oil.
Ratio
Viscosity is used to find wrong oil, mixed oil,
check incoming oil, oil storage points, used
oil.

Particle Size Distribution

4 - Wear Debris Analysis

The Patch Maker creates filter patches for viewing under
A Fatigue Wear Particle as
a microscope. The images can be captured using a video seen by an optical
camera attached to the microscope. microscope.

The type of Wear Debris particle identifies the wear

mechanism such as adhesive wear, abrasive wear, Industrial Oil Analysis
fatigue wear, etc. Results
 CSI’s Industrial Oil Analysis Laboratory
Particle Counting
Particle Size Distribution
CSI’s Oil Lab performs particle
counting using a laser particle
counter to obtain an accurate size
distribution on most industrial oil
samples, irrespective of viscosity.
Furthermore, it uses a patented
water masking solution to
eliminate water droplets from
NAS Plot
the counts.
Particle counting is used to
monitor the cleanliness level of the
machinery. The cleaner the system
the longer the equipment lasts.
FTIR Fourier Transform Viscosity
Infrared Absorption
spectroscopy is used to
measure the extent to
which a lubricant has
been oxidized, its
nitration levels, sulfate
levels, water content,
soot content and any fuel
dilution.
Neutralization Numbers
Total Acid Number (TAN) measures
the extent to which a lubricant has been
oxidized by monitoring the acid content.
Total Base Number (TBN) measures
the amount of neutralizing agents still
available to counteract the acid build-up.
Wear Debris Analysis
No industrial oil analysis is complete without a comprehensive
wear debris analysis. CSI’s Oil Laboratory performs detailed wear
debris analysis on industrial samples to identify root cause of abnormal
conditions. This analysis of large particles provides the essential difference
between conventional oil analysis and industrial oil analysis.
CSI’s Scanning Electron
Microscope is ideal for
examining individual particles with
magnification up to 400,000. It
can also give a detailed elemental
analysis of individual particles
using an energy dispersive
technique. These detailed studies
are essential for root cause
A Fatigue Wear Particle as Cutting Wear Ribbon. X-Ray analysis.
seen by an optical spectrum shows the ribbon is almost
microscope. pure Iron.
Viscosity is one of the most Spectrometric Metals
important properties of an
oil. Without the correct Spectrometric analysis is used to
viscosity a machine will not measure wear metals (particle size
have the correct typically less than 5 microns),
lubrication, resulting in contaminants such as silica (dust),
severe damage. Viscosity is and additive levels (adding wrong
measured at 40°C and lubricant, additive depletion).
100°C.
Water Reporting
The presence of water Reports and/or
is detected using a data are
simple crackle test. automatically
The quantity of water emailed to
is then measured customers using
using the Karl Fisher the Oilview LIMS.
method.
 OilView® Laboratory Information Management System
Sample Login 52DV 51FW CSI or
Start Start
Other Lab
51PC
5100 5200 WDA
Email
Run Minilab Tests
Data
List of Samples in
Batch for
Sample Tree convenient Testing,
by Year,
Month, Day Diagnosing and
and Batch #
Automatic
Reporting.
Wear, Contamination
and Chemistry Data is automatically
Severity of each Reviewed, Print, Test Complete
imported into Sample
Sample in Batch Exported and Flags
Batches for easy Viewing
Diagnosed Flags and Reporting.
RBMware
Customers Spectrometer RS232 Viscometer
Link
FTIR TAN
Other
Data is automatically
imported into Sample Diagnosis
Batches for easy Automatic Report Statistically
set Alarm
Viewing and Reporting.
and Data Limits

Distribution

Observations
Print Reports and Actions

Contact Contact List.

Address Reports can be
Details sent to Multiple Each Parameter is allocated to
including Contacts Diagnostic
Email Address either Wear, Contamination or
Message
OilView PDF Chemistry. The Trivector Plot
Reports to be Check boxes to indicate
Reports generated for whether report is to be
shows the maximum Severity
Contact printed, emailed and/or faxed for each of these categories.
 Tribology Solutions
OilView Minilab Options CSI Industrial Oil Analysis Laboratory
Emerson Financial Services low-interest leasing Lab options available as Kits and Single Samples.
is available.
Customized Sample testing on request.
Comprehensive 5200 Minilab
• 5200 Trivector Analyzer
• 52DV Digital Viscometer
Clean Industrial Oil Analysis
• 52ZM Stereoscopic Zoom Microscope • 40 C and 100 C Viscosity
• Wear Debris Image Capture System • Emission Spectroscopy
• OilView Minilab Module
• OilView WDA Module
• Particle Counting
• OilView LIMS Module • Water Determination (Karl Fisher Water when appropriate)
• 4-Day On-Site Startup Service • FTIR
• TAN or TBN
Basic 5200 Minilab • Wear Debris Analysis where appropriate
• 5200 Trivector Analyzer
• 52DV Digital Viscometer
• OilView Minilab Module Advanced Industrial Oil Analysis
• 3-Day On-Site Startup Service • Clean Industrial Oil Analysis
• Rotrode Filter Spectroscopy (Larger Particles)
Basic 5100 Minilab
• Scanning Electron Microscopy when appropriate
• Single Channel 5100 OilView Analyzer
• Wear Debris Patch Maker
• Shop Microscope
• OilView Minilab Module
• Training Certificate OilView Software

SonicScan Fault OilView Software Modules

Isolation System • OilView Minilab Module
• OilView WDA Module
• SonicScan 7100 Fault
Isolation Kit • OilView LIMS Module
• SonicRoute Data Collector • Link to non-CSI
• RBMware Sonic View
Instruments
 Asset Reliability-Based Maintenance
A Business Initiative for Businesses with Initiative
At the core of any successful plant is asset reliability. It is
a fundamental business aspect that your entire company
must be committed to. Reliability-based Maintenance®,
RBMTM, is a comprehensive long-term strategy that
increases your asset reliability, reduces maintenance costs,
and ensures that maintenance resources are focused on
the areas that drive overall plant business and operational
objectives. Examples of significant, measurable results
with RBM include:
• Increased productivity: 4 - 40%
• Reduced maintenance expense: 7 - 60%
• Reduced rework and scrap rates: 5 - 90%
• Extended equipment life: 10 - 1000%
• Reduced spares inventory: 10 - 60%
• Increased inventory turns: up to 70%
• Reduced energy consumption: 5 - 15%
• Increase safety and environmental protection
CSI pioneered RBM to improve industrial productivity by
systematically identifying and prioritizing critical
equipment assets and applying an integrated set of
condition monitoring and diagnostic technologies to
increase availability and reduce failure. RBM balances
preventive, predictive, and proactive maintenance
strategies.
Dan Stedham
Director Product & Services Marketing
Tribology as an Integral Part of Reliability-Based
Maintenance
A machine’s operating life is most often determined by the
oil that lubricates its load-bearing surfaces. Good
lubrication normally provides long life, even under harsh
operating conditions. On the other hand, poor lubrication
results in short life, even under mild operating conditions.
Industrial machines are generally supposed to have
40,000 hour (about 5 years) mean time between failures
(MTBF). This only happens if you have “good
lubrication.” If you have “poor lubrication” or “no
lubrication” you get far shorter operating life.
How do you know when the lubrication is good or poor?
There are four parts to this answer.
• Keep the oil clean
• Keep the oil dry
• Keep the oil fit for use
• Monitor the contamination and wear debris in the oil
Please take a moment and browse through this very
informative brochure and see how we can help you
improve your machinery health and thereby increase your
asset reliability.
Ray Garvey
Tribology Solutions Product Manager
For more information contact:

Your Local Sales Representative

or

Customer Sales Support

Phone: 1 800 675 8033

or

Tribology Solutions Product Manager

Ray Garvey
Phone: (865) 675 2400 x 3435
Email: Ray.Garvey@EmersonProcess.com
Other Contacts: CSI World Headquarters

Engineering R&D
835 Innovation Drive
Dr. Tony Hayzen Knoxville, TN 37932
Phone: (865) 675 2400 x 2186
Email: Tony.Hayzen@EmersonProcess.com Phone: (865) 675 2110
CSI Industrial Oil Analysis Laboratory Fax: (865) 218 1401
John Mountain
Phone: (865) 675 2400 x 2456
Email: John.Mountain@EmersonProcess.com

Training World Wide Web Site

Doug Belew
Phone: (865) 650 2400 x 2610
Email: Doug.Belew@EmersonProcess.com
http://www.CSImeansReliability.com

Compiled and edited by Dr. Tony Hayzen