Behind The Scene

of Why Oil Analysis

PT. Tiara Vibrasindo Pratama

A-1

Why Oil Analysis.???

Equipment Fails
because...

Obsolete
15%

Surfaces Degrade
70%

Corrosion
20%

Accident
15%
Wear
50%

Caused by

Abrasive Wear

Adhesive Wear

Fatigue Wear

water-in-oil, degraded oil,

process contamination,
coolant, condensation...

Damage resulting from

abrasive particles between
two moving surfaces.

Damage resulting from

metal surfaces dragging
over each other.

Damage resulting from

micro-cracks caused
by cyclic loading.

Caused by

Caused by

Caused by

abrasive particles-in-oil
dirt, secondary wear,
process contamination...

inadequate lubrication
low visc, no oil, high temp,
excess load, slow speed...

misalignment, imbalance,
improper fit/assembly,
secondary damage...

ASLE Bearing Workshop

Rabinowicz, 1981

Six to seven percent of the Gross National Product ($612 billion) is

required just to repair the damage caused by mechanical wears.
(Professor Ernest. Rabinowicz, MIT)

A-2

Case of Cooling Towers

Motor Failures
Gearbox Failures
Aero dynamic loading
Gear teeth misalignment
Environmental factor

Vibration monitoring
Oil monitoring

A-3

Case of Cooling Towers

Vibration monitoring

A-4

Case of Cooling Towers

W EA R - Sev ere W e ar Exa mple

P5 - Sa mp le f ro m dra in a t O /C
Sa mple Da t e: 22/MA R /8 8

Ex t reme
B ad
W e ar
Marg in al
Fa ir

W e ar - Ex t reme
C on t amin at ion - G o od
C he mis try - G ood
Th is is a d oz er cran kc ase o il. N ot ice
t he larg e w e ar part icles .

G oo d
C he ck - B re at h er, Sh op Mic , Mech an ic al
A ct ion - N o t if y mec ha nic
Es t ima t ed t ot a l wa t er con t en t 0 .00 00 %
In Solut ion 0% +Emu ls if ied 0%
+F ree 0% = 10 0%

C on t amin at ion

C he mis try

H2O - Water Contamination

P9 - Sump for ster ntube oil.
Sample Date: 25/MAY/92

Extreme
Bad
Marginal

Wear - Good
Contamination- Extreme
Chem istry - Extreme

Fair

Oil contaminated with 16.0% water .

Good

Check - Ref. file, Viscosity, Contamination

Action - Rem ove Contaminants (water?)
Estim atedtotal water content 12.6700%
InSolution 77% +Em ulsified 23%
+Fr ee 0% = 100%

Wear

CELL 2 - C OOLIN G TOW ER CELL #92

OIL - GEARBO X OIL - 5100
Sample Date: 24/FEB/99

Extreme
Bad
Marginal

W ear - Good
Cont aminat ion - Good
Chemistry - Good

Fair

mont hly pm test

Good

Check - None
A ction - None
Estimat ed tot al w at er content 0.0000%
In Solution 0% +Emulsif ied 0%
+Free 0% = 100%

W ear

Cont aminat ion

Chemistry

Contamination

Chem istry

Oil condition
monitoring
A-5

Why Oil Analysis (cont..)

A-6

P-F Curve
Method, Tools & Technology
conditional

incipient
impending
precipitous

catastrophic
Time

PDM
A-7

TAHAPAN KEGAGALAN
Conditional

Incipient
Impending
Precipitous
Catastrophic
End of Life

kondisi yang bisa mendorong terjadinya

kerusakan misalnya pelumas
tercemar air, konduktifitas air tinggi
mulai terbentuk kerusakan misalnya
akibat pelumas kehilangan fungsinya,
terjadi gesekan metal-to-metal

Kegagalan yang bisa

dikelola (manageable
failures)

muncul gejala dengan analisis vibrasi

diketahui adanya frekuensi kegagalan
bearing/bearing failure frequency
telah terjadi kerusakan tidak fatal, bisa
diperbaiki
kerusakan fatal terjadi bearing rusak,
shaft macet, unit tidak berproduksi

Kegagalan yang
tidak bisa dikelola
(unmanageable
failures)

A-8

Equipment Maintenance
Strategies

A-9

Technology Owners
PdM

To Control
Room

Vibration

Pressure

Motor
Current

Lube Oil

GateCycle
Thermography

Performance
Monitoring

A-10

Tribology
Definisi: the study of surfaces in relative motion
Menyangkut:
Friksi, Lubrikasi, dan Keausan

Terdapat pada hampir semua sistem mekanikal

Salah satu faktor terpenting dalam industri

(Major cost impacts)
A-11

Tribology
Keausan mesin berarti:
Perawatan,

Penggantian, &
Terganggunya proses produksi.

A-12

Apa tujuan kita?

Hindari breakdown,
Ketahui kondisi mesin,
Integrasi dengan berbagai teknologi
perawatan
Vibrasi, Thermografi, Ultrasonic, etc.

Value based application,

Integrasi dengan sistem perawatan secara
umum,
A-13

Apa tujuan kita (contd)?

Pemilihan pelumas yang optimal,
Contamination control,

Perpanjangan umur mesin dan pelumas,

Root cause analysis, dan
Quality assurance dari pelumas, filter,
breather, etc.

A-14

Oil analysis - what?

Sampel Pelumas yang sedang dipakai
Lubricant Oil

Sampel Hydraulic fluid

Sampel Transformer oil

A-15

Oil analysis mengapa?

Mengungkap penurunan kualitas dan
rusaknya pelumas
Mengetahui kontaminasi air atau
partikel padatan lainnya, dan
Memonitor keausan mesin

A-16

Oil analysis di mana?

On-site,
Oleh tim Reliability/PDM, atau
Oleh staf lab metalurgy atau chemistry.
ATAU

Off-site
Oleh pihak ketiga
fluid analysis laboratory.

A-17

Oil analysis nilai?

Tindakan yang terorganisir dan teratur

Database
"Oil routes"

Laporan dalam bentuk elektronik

(digital)
A-18

Best tribology programs address

Pemilihan jenis pelumas,

pembelian,
penyimpanan,
Handling,
Monitoring,
Recycling, dan
pembuangan
A-19

Best tribology programs

Memulai perawatan "on condition"
dukungan pihak management,

bersifat proaktif,
Melibatkan root cause
failure analysis dan
contamination control.
A-20

Best tribology programs

Menggunakan aplikasi profile untuk
inspeksi, sampling, dan analisa

Menganalisa berdasarkan load,

kecepatan, umur mesin
dan mekanisme kerusakan

A-21

Procurement Practices
Menjamin kualitas lubricants, Filters,
dan Breathers
Menjalin kerjasama dengan
penyalur pelumas dan filter

A-22

Tiga Katagori Utama Analisa Oli

A-23

Trivektor
Wear

Contamination
- Particle Counting
- Water

- WDA (Wear Debris Analysis)

- Spectroscopy
- Ferrous Density
- Analytical Ferrography

Chemistry
- Oksidasi (AN/BN)
- Viscositas
- FTIR (aditif)
A-24

Trivector example
ABRAS W E AR - Ab rasive W ear Exampl e
P3 - Mo bil DT E hydrauli c f lui d
Samp le Date: 21-FE B- 93

Extreme
Bad
M arg inal
Fair

W ear

W ear - Bad
Co nt aminatio n - E xtreme
Ch emistry - G oo d
Bad seal leaking co ol an t in to hydraul ics
Saw ab rasive w ear particles on g rid 100x

G oo d
Ch eck - Vi sco sit y, Breath er, Co nt aminatio n, Sh op M ic, Mech an ical
Actio n - Remove Con tamin ant s ( w ater? )
Estimat ed tot al w ater co ntent 2.5089%
In So lu tio n 1% + Emul sifi ed 72%
+ F ree 27% = 100%

Co nt aminatio n

Ch emistry

A-25

On-site atau Off-site

Mana yang harus dipilih?
Kemampuan apa yang dibutuhkan?

A-26

On-site

Ownership and control,

Immediate results,
Immediate retest when needed,
Analysis is done by the people who know the
most about these machines (> 10 years
experience typical),
Electronic data with no transfer,
Test more points more often,
Test incoming lubricants, and
Find, fix, and verify problems are fixed all in
same day.
A-27

Langkah Pertama

Lihat,
Cium,
Sentuh, dan
Pikirkan

A-28

Lihat, Cium, Sentuh, & Pikirkan

Degradasi pelumas umumnya membuat
pelumas berubah warna
Rusaknya zat aditif seperti EP dan anti-wear
dapat menimbulkan bau tidak sedap.
Seringkali Geram hasil keausan cukup besar
untuk dirasakan dan dilihat. Umumnya pada
Filter Patch atau bagian dalam tutup botol
sampel
Dengan memakai magnet dan pemanas, kita
dapat membedakan antara partikel besi dan
air.
A-29

Lihat!

Tanpa alat pengukur, bandingkan kondisi

oli/pelumas
A-30

Secara prinsip, ada perbedaan

antara pengujian pelumas
konvensional dan analisis
pelumas yang terprogram

A-31

1. Ambil sampel dari mesin

4. Laporan hanya difile, tidak dipakai

Pengujian konvensional

2. Kirim sampel ke Laboratorium

3. Terima hasil setelah 3 minggu, sedikit pemahaman

A-32

Pengujian Konvensional
Isu :
Tidak ada perencanaan tentang:
Alarm level
Tindak lanjut

Menunggu hasil
Data pasif.

A-33

1. Ambil sampel dari mesin

7. Laporan detil dan

langkah tindak lanjut

2. Sortir data dengan peralatan sendiri

Oil Analysis
Program

6. Data dibandingkan
dengan teknologi PdM
yg lain

C
4. Penyimpanan dan Analisis data
dengan komputer
3. Kirim sampel bermasalah
ke Laboratorium
5. Teknisi terlatih mengerti data
A-34
dan batas alarm

Mesin Sehat = Sedikit Abrasi

Abrasion depends on
three key factors:
1. Threshold particle size
2. Threshold hardness
3. Concentration
R. Bayer, Wear for Engineers HNB Publishing.

Roots Blower
Parameter
ISO 4
ISO 6

Nominal
K/p Wear Factors
Value
K = Wear Coefficient
22
p = Penetration Hardness
22

ISO 14

121
0.1
22,052
0.01
Count > 6
20,628
0.001
Count > 14
13,631
0.0001
0.00001
Count > 22
7,250
Count > 4

Count > 40

449

Count > 54

14.5

PPM by Vol

116.2

1st Peak

24

2nd Peak

40

New
sand
paper

Used
sand
paper
Dry

Fine
abrasive
particles

Silico
n
Large
Ferrous
Particle
s

Course
abrasive
particles

100-micron = 0.004 inch

50-micron = 0.003 inch

Journal
Bearing
Sliding
on
Oil Film

50-micron = 0.002 inch

25-micron = 0.001 inch

Lubricated

Roller Bearing

A-35

Mesin Sehat = Sedikit Adesi

Aus karena adesi

disebabkan oleh buruknya
pelumasan
Tidak ada pelumas atau
level pelumas rendah
Viskositas rendah

Salah pelumas
Temperatur tinggi
dilusi
Gross water
Kontaminasi air

Beban tinggi
Statik
Dinamik

Sliding, metal-to-metal
contact
Gesekan yang hebat
menyebabkan
temperatur tinggi
seperti terlihat pada
partikel aus.

Melted
Smeared
Black oxides
Tempered

Slow speed
A-36

Mesin Sehat = Sedikit Fatik

Fatigue Life (%)

Design
Life 100%

75%
50%
25%
0%
100%
Design
Load

200%

300%

400%

500%

Load Increase (%)

R. Bayer, Wear for Engineers HNB Publishing, pg. 8.

A-37

Mesin Sehat = Sedikit Korosi

Korosi pada umumnya

disebabkan oleh air atau
fluida yang
Kontaminasi yang bersifat
korosif mungkin berasal dari
pembersihan, kondensasi,
hujan, proses, dan mungkin
juga dari pelumas yang
kualitasnya menurun.
Korosi mempercepat
mekanisme aus yang lain
Disebut juga
Chemical Wear.

Based on 100% Bearing Life

at 0.01% Water
250%

Bearing Life

200%
150%
100%
50%
0%
0.0%

0.1%

0.2%

0.3%

0.4%

0.5%

Percent Water-in-Oil

A-38

Elemen Program Pelumasan

Pelumas
Seleksi dan
spesifikasi
Pembelian dan
penerimaan
Storage and
handling
Level-check and
top-off
Flushing, cleaning
and disposal

Greasing
Contamination Control
Training
Oil Analysis

A-39

Seleksi dan Spesifikasi

Original equipment
manufacturers
(OEMs)
Supplier Pelumas
Konsultan pihak
ketiga
Konsolidasi
berbagai merk
pelumas

Case History: Steel Mill

Year 0: 1400 lubricants

Year 2: 400 lubricants

Year 4: 100 lubricants

> $1 Million savings

A-40

Pembelian dan Penerimaan

Spesifikasi
Functional specification
Military specification
Automotive SAE
specification
Supplier brand specification

Incoming inspection

SAE
Starburst

Dielectric
Viscosity
ISO code (optional)
Moisture (optional)

A-41

Flushing, cleaning and disposal

Filtration is often better
than disposal
Non-intrusive
If not broken, dont fix it!

Flush all the low places

Water, dust, & wear

Solvents destroy
viscosity
Burn or dispose
properly

A-42

Filter the oil, dont change it...

Calendar based oil change
Either too soon or too late...

<< Too soon if

life remaining,
Too late if >>
contaminated.
A-43

Cradle to Grave Process Control

A-44

Lubricant Management

A-45

Lubrication Management

A-46

Lubrication System

A-47

Storage and handling

Gudang yang bersih
dan kering
Menyimpan drum
secara horizontal
Pemberian tanda
yang jelas

A-48

Level-check and top-off

Easy-to-view sight
glasses
Transfer dengan
memakai tanda
yang jelas dan
kontainer yang
bersih
Final filtration

Linden Oil Codes

Rando
68
MEROPA
150
Meropa
320

Vanguard
680

Silogram 85

Way 100

OMALA
100

Texaco
Rando HD 68
Texaco
Meropa 150
Texaco
Meropa 320
Texaco
Vanguard 680

Pocket
Reference Guide
Template

< Front Side

Shell Omala 100

Lube
Con 663

Lube Con 663

Rando
32

Texaco
Rando HD 32

Meropa
220

Tribol

290

Tribol
22

Silogram
85/140 SAP
Texaco Way
100 Oil

Linden Oil Codes

Back Side >

Ucon 300

ATF-210

Texaco
Meropa 220

Tribol 290 High

Heat Oil
Tribol Chain Oil
22
Ucon Vacuum
Oil
LB-300-XY26
Mobil Type F
Transmission Fluid

A-49

Clean Up Your Plant Oil Storage

A-50

Pencegah masuknya debu

kedalam sistem pelumasan
Air cleaner filter
Breather
Seals

A-51

Contoh Air Cleaner filter

The close tolerances in an

engine make it susceptible to
even the smallest dust particle.

A-52

Contoh Seal & Breather

Front crankshaft oil

seal

Engine breather of
turbocharged engine
A-53

Jadi.
Melakukan Kontrol untuk kontaminasi
air dan partikel padatan,
Terbukti dapat memperpanjang umur
mesin.

A-54

Analisis Pelumas
Analisis pelumas dengan tujuan
perawatan dapat dibandingkan dengan
analisa darah untuk tujuan medis.

A-55

Pertanyaan???
Metoda pengujian apa yang perlu dilakukan
untuk jenis mesin tertentu?
Instrumen apa yang dipakai?
Apa tujuannya?

A-56

Apa tujuannya?
Mengetahui kondisi pelumas
Mengetahui Tingkat Kebersihan (tingkat
kontaminasi) pada sistem pelumasan
tersebut
Mengetahui kesehatan dari Mesin yang
dilumasi.

A-57

Oil Analysis...Mencari tanda-tanda (clues)

Engine

Hydraulic

Transformer

Gear and
Roller
Bearing
Journal

Wear
Fe, Pb, Sn, Cu wear is mostly oxide
and mostly <5 micron size.
Concentration in direct proportion to
soot and oxidation and inversely
proportional to TBN. Steady
increase in wear concentration
between oil changes.
Any wear is an abnormal condition.
Abrasive wear results from dust and
corrosive wear from moisture. Seal
wear from contamination or fit.
Wear due to arcing generates
dissolved gases in oil.

Contamination
Soot, dust, and
coolant
contamination.

Chemistry
Combustion gases
consume TBN,
contaminants
consume detergent
additives, hot surfaces
oxidize oil.

Dust, water, and

air
contamination.

High temperatures
oxidize oil and
produce acidity.

Water
contamination.

Abrasion, fatigue, and adhesion

generate ferrous wear debris 10 to
100 micron. Size increases with
severity.
Negligible wear except from rub
which generates 0 to 50 micron Pb,
Sn, Sb, Cu, and Fe. Abrasion
generates Fe due to dust imbedding
into soft journal.

Dust, water, and

wear debris.

Prolonged arcing,
moisture, and heat
may oxidize oil.
Moisture, heat, and air
entrainment may
oxidize oil.

Dust, water, and

process
contamination.

Moisture and heat

may oxidize oil.

A-58

UNSUR

KEMUNGKINAN SUMBER

Aluminum(Al)

Bearings, bushing, block, piston, blower,pumps, clutch, washer

Barium (Ba)

Detergen/Aditif dispersan

Boron (B)

Coolant additive, EP Additive

Cadmium (Cd)

Coating on metal

Chromium (Cr)

Bearings, rings, rollers, liner, exhaust valves, seals, shafts, coolant treatment

Copper (Cu)

Bearing, bushing, washer, pumps, gears, Antiwear additive

Iron (Fe)

Blocks, bearing, pumps, liner, gears, piston, rings, discs, shaft, valve, screws

Lead (Pb)

Bearing, additive

Magnesium (Mg)

Detergen/Aditif dispersan

Molybdenum(Mo)

Rings, friction modifier, antiwear additive

Nickel (Ni)

Bearing, valve, shaft

Phosphor (P)

Antiwear additive

Silicon (Si)

Seal, gasket, debu pasir, coolant additive, antifoaming additive

Silver (Ag)

Bearing, bushing, solder

Sodium (Na)

Coolant additive, debu garam, detergent additive

Tin (Sn)

Bearing, bushing, piston

Titanium (Ti)

Turbine blade, coating

Vanadium (V)

Valve, coating

Zinc (Zn)

Antiwear/Inhibitor additive

A-59

Apa Metoda Pengujian dan

Instrumen yang dipakai?
Harus diketahui aplikasi dari sistem mesin yang
dilumasi.
Hidrolik
Gearbox
Engine dsb

Masing-masing aplikasi mempunyai

karakteristik yang berbeda,
membutuhkan pengujian yang berbeda pula

A-60

Profile -- hydraulic system:

Kontaminasi padatan, dari segi jumlah
maupun distribusi ukurannya
Kontaminasi air,
Pengumpalan Anti-wear additive,
Oil oxidation, dan
pengasaman.

A-61

Aplikasi -- gearbox:
Mechanical wear, dimana partikel
geram hasil keausan bisa berukuran
10 100 mikron
Penggumpalan zat aditif: Anti-wear,
anti-oxidant, dan anti-scuff additive,
Oil oxidation,
Naiknya tingkat keasaman,
Air dan kontaminan lainnya.
A-62

Contamination Of Oils
Particle count
Particle size
distribution
ppm < 6 micron
ppm 6 to 14 micron
ppm >14 micron

Water-in-oil

Glycol (engine)
Soot (diesel engine)
Spectrometals
Sodium (Na)
Boron (B)
Silicon (Si) < 5
micron

Abrasion and Corrosion

are two of the most serious reliability
problems for industry today.
A-63

Physical/Chemical Tests

Viscosity
Viscosity Index
Specific Gravity
Flash Point
Pour Point
Dielectric

OR
OR

Okay

Spectrometric
TAN
For Additives
TBN
Zn, P, Ca, Mg
Oxidation
Color

Physical/chemical tests
measure oil chemistry, not
contamination or wear
A-64

Minilab Analysis Parameters

Parameters
Ferrous Index
Large Ferrous Indication
Large Non-Ferrous Indication
Analytical Wear Debris
Analysis
Particle Count
Contaminant Index
Water Contamination
Free Water Droplet indication
Chemical Index
Dielectric Permitivity
Viscosity

What is measured?
Wear Parameters
Iron particles > 5 microns
Iron particles >> 60 microns
Other metals >> 60 microns
Microscopic particle
examination
Contamination Parameters
ISO counts at 8 different sizes
Non-ferrous contaminants
Water or other corrosive fluid
Imiscible fluid droplets in oil
Chemistry Parameters
Deteriorated lubricant
Physical property of lubricant
ISO viscosity grade

Significance
Recent abnormal wear
Abrasive wear indication
Abrasive wear indication
Wear severity and root cause

Dust, wear, & process

particles
Corrosive fluid contamination
Corrosive fluid contamination
Corrosion and poor lubrication
Lubricant no longer fit for use
Wrong oil or degraded oil
Wrong oil or dilution with fuel

A-65

Tiga hal penyebab kegagalan program

Training yang tidak
memadai
Pemahaman yang
terbatas

Pengujian yang
dilakukan salah
Partikel yang lebih besar
tidak terihat

Pengambilan sample
salah

What can
I see?

Training

Wear

Sampling
Contamination Chemistry

Testing

Harus di zona aktif

A-66

Accurately Labeled Oil Sample Bottles

A-67

Oil Sampling
Sample yang baik
Desintas data maksimal
Data disturbance minimal
Frekuensi yang sesuai
Pertimbangan saat mengambil sampel oli
Lokasi sampel
Alat yang digunakan untuk mengambil sample
Botol tempat sampel
Prosedur pengambilan sampel
A-68

Oil Sampling
Sampling di zona aktif

Agitated - mixed
Flowing
Hot
After machinery
Before filter
Before dilution
Away from walls
Before settling
Clean procedures

Machine

Ideal Place
to Sample

Oil Supply

A-69

Contoh lokasi sampel

A-70

Contoh lokasi sampel .

A-71

Metode Sampling
Sampling Port

- High Pressure Hose

- Minimess Port

Sampling Probe
- Low Pressure Hose

- Vacuum Pump

- Pitot Tube

A-72

Oil Sampling Procedure Best Practice

A-73

Faktor yang mempengaruhi frekuensi

pengambilan oil sampling

A-74

Benefit dari Analisa Oil

A-75