Fluid Testing Program

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Edgar Solberg
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1 Fluid Testing Program Overhaul of sample program Third party lab selected Extensive look at three labs Goal was independent testing Eliminate conflict of interest All Sullair fluids to one lab now Simplified

2 Fluid Testing Program Insight Services chosen All Sullair fluids Beta Testing New Data label developed Will be sent to distributors Sample kit updated

trending Data transferred Data available on the web

3 Fluid Testing Program Highlights of new program Complete test package Same day turnaround Prepaid postage Sample trending Data transferred Data available on the web Password protected Graphs of key test data Kit will be $45.00 List

4 Oil Analysis Tests Overview Matt McMahon CLS Senior Data Analyst Insight Services

5 Oil Analysis Lubricant Condition Contaminants Machine Wear Normal Report

6 Viscosity Measure of a lubricants resistance to flow at a specific temperature. Measured by Viscometer ASTM D-445 Reported as Kinematic Viscosity in Centistokes (cst) Industrial oils measured at 40 degrees C

7 Viscosity Limits Marginal Limits Viscosity should be within 10% (+ or -) of specified grade to be in spec Example: ISO VG 100 oil should be between 90 and degrees Critical Limits When the viscosity falls greater than 20% (+ or -) of the specified grade, action should be taken. Example ISO VG 100 oil less than 80 or higher than degrees Report with Viscosity Issue

8 Elemental Spectroscopy Measures the concentration of wear metals, contaminants and additives in a lubricant.

9 Elemental Spectroscopy 20 elements measured Wear metals Contaminants Additives Reported in parts per million (ppm) Measures metals in solution Solid debris below 7 microns in size Blind to larger particles

10 Wear Metal Sources Iron (Fe) Shafts, Gears, housings, Piston Rings, Cylinder Walls Copper (Cu) Brass/Bronze alloys, Bearings, Bushings, Thrust Washers Lead (Pb) Bearings, Anti-Wear Gear Additive (Rare) Tin (Sn) Bearing Alloys, Bearing Cages, Solder

11 Wear Metal Sources Aluminum (Al) Pumps, Thrust Washers, Pistons Chromium (Cr) Roller Bearings, Piston Rings, Cylinder Walls Nickel (Ni) Pumps, Gear Alloys, Valves Silver (Ag) Some Bearings

12 Wear Metal Limits Limits should be based on trends Sudden increases indicate problems Operational conditions can effect wear metal levels Oil changes, break-in periods, loading OEM Recommendations Report with Wear

13 Contaminants Silicon (Si) Airborne Dust & Dirt, Defoamant Additive Boron (B) Anti Corrosion in Coolants Potassium Coolant Additive Sodium Detergent Additive, Coolant Additive Report with Contaminants

14 Additives Magnesium (Mg) Detergent Additive Barium (Ba) Rust & Corrosion Inhibitor Calcium (Ca) Detergent/Dispersant Additive Zinc (Zn) Anti-wear Additive Phosphorus (P) Anti-Wear Additive, EP Gear Additive Molybdenum (Mo) Extreme Pressure Additive Report with Additive Issues

15 Karl Fischer Water Quantifies the amount of water in the lubricant. Karl Fischer Titrator ASTM D-6304C Reported in % or ppm Dissolved, emulsified or free water

16 Sources of Water Condensation External contamination Breathers Seals Reservoir covers Internal leaks Heat exchangers Water jackets Report with Water V40

17 FT-IR Spectroscopy Measures the chemical composition of a lubricant

18 FT-IR Spectroscopy Oil Degradation by chemical change Oxidation Nitration Additive levels (24KT) Contamination Soot Glycol Report with IR issue 24KT IR Report

19 Acid Number Measurement of acidic constituents in the oil Reported as AN ASTM D-974 Indicator of oil serviceability Oil oxidation & degradation produces acidic by-products

20 Acid Number AN is lowest when an oil is new*, and increases with use AN of a used oil is typically compared to the original AN Oils with higher levels of additives will generally have a higher AN Typical AN Values on new oils: o R&O Oil o AW Oil o EP Oil o Engine Oil Report with AN issues New Oil Example

21 ph Measurement Measurement of acidity of Sullube 32. New fluid approximately 8.5. Depending on time in use, different limits used to monitor acidity of the lubricant. Absolute limit of 4.5.

22 Particle Count Measures the size and quantity of particles in a lubricant Light Blockage Flow Decay

23 Flow Decay Method Also called pore blockage Passed through 5,10 or 15 micron screen filter Flow decay is recorded Particle counts are extrapolated No interference from water or entrained air Filter

24 Particle Count Particle Counts are broken down into 5 size ranges > 4 microns > 50 microns > 6 microns >100 microns > 14 microns Reported as particles per milliliter

25 ISO 4406 Cleanliness Code > >6 826 >14 88 >25 21 >50 2 >100 0 ISO 18/17/14

26 Sources of Contamination Built in contaminants Residual from construction or assembly New oil contamination External ingression Breathers, seals, hatches Internally generated Wear, oil degradation, filter deterioration Report with High PC

27 Questions?? Matt McMahon CLS Senior Data Analyst Insight Services

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