Oil analysis (OA) is the laboratory analysis of a lubricant's properties, suspended contaminants, and wear debris. OA is performed during routine predictive maintenance to provide meaningful and accurate information on lubricant and machine condition. By tracking oil analysis sample results over the life of a particular machine, trends can be established which can help eliminate costly repairs. The study of wear in machinery is called tribology. Tribologists often perform or interpret oil analysis data.
OA can be divided into three categories:
Oil sampling is a procedure for collecting a volume of fluid from lubricated or hydraulic machinery for the purpose of oil analysis. Much like collecting forensic evidence at a crime scene, when collecting an oil sample, it is important to ensure that procedures are used to minimize disturbance of the sample during and after the sampling process. Oil samples are typically drawn into a small, clean bottle which is sealed and sent to a laboratory for analysis.
OA was first used after World War II by the US railroad industry to monitor the health of locomotives. In 1946 the Denver and Rio Grande Railroad's research laboratory successfully detected diesel engine problems through wear metal analysis of used oils. A key factor in their success was the development of the spectrograph, an instrument which replaced several wet chemical methods for detecting and measuring individual chemical element such as iron or copper. This practice was soon accepted and used extensively throughout the railroad industry.
By 1955 OA had matured to the point that the United States Bureau of Naval Weapons began a major research program to adopt wear metal analysis for use in aircraft component failure prediction. These studies formed the basis for a Joint Oil Analysis Program (JOAP) involving all branches of the U.S. Armed Forces. The JOAP results proved conclusively that increases in component wear could be confirmed by detecting corresponding increases in the wear metal content of the lubricating oil. In 1958 Pacific Intermountain Express (P.I.E.) was the first trucking company to set up an in-house used oil analysis laboratory to control vehicle maintenance costs which was managed by Bob Herguth. In 1960 the first independent commercial oil analysis laboratory was started by Edward Forgeron in Oakland, CA.
In addition to monitoring oil contamination and wear metals, modern usage of OA includes the analysis of the additives in oils to determine if an extended drain interval may be used. Maintenance costs can be reduced using OA to determine the remaining useful life of additives in the oil. By comparing the OA results of new and used oil, a tribologist can determine when an oil must be replaced. Careful analysis might even allow the oil to be "sweetened" to its original additive levels by either adding fresh oil or replenishing additives that were depleted.
Oil analysis professionals and analysts can get certified in compliance with ISO standards by passing exams administered by the International Council for Machinery Lubrication (ICML).
For purposes of Oil Analysis Program (OAP) trend analysis, replacement, replenishment or drain and flush of lubricating fluids in excess of half an engine’s oil capacity (2.5 gallons or more) will be considered an Oil Change and the engine will be placed in code Charlie (C) for three flights to establish a new working trend. Oil-Wetted Maintenance (OWM) is any replacement of engine components within an oil-lubricated system (bearings, gearbox, pumps, etc.). OWM actions shall be documented on DD Form 2026 and submitted to OAP lab for update of Oil Analysis database. (a) Special Samples can be requested by the laboratory whenever they feel its necessary. (b) Whenever directed by the unit maintenance activity to investigate suspected deficiencies.
The NDI/JOAP laboratory will set the standards and intervals of oil analysis.
A typical predictive maintenance technique is ferrography, which analyses iron in oil.
A lubricant is a substance that helps to reduce friction between surfaces in mutual contact, which ultimately reduces the heat generated when the surfaces move. It may also have the function of transmitting forces, transporting foreign particles, or heating or cooling the surfaces. The property of reducing friction is known as lubricity.
Fluid bearings are bearings in which the load is supported by a thin layer of rapidly moving pressurized liquid or gas between the bearing surfaces. Since there is no contact between the moving parts, there is no sliding friction, allowing fluid bearings to have lower friction, wear and vibration than many other types of bearings. Thus, it is possible for some fluid bearings to have near-zero wear if operated correctly.
Motor oil, engine oil, or engine lubricant is any one of various substances used for the lubrication of internal combustion engines. They typically consist of base oils enhanced with various additives, particularly antiwear additives, detergents, dispersants, and, for multi-grade oils, viscosity index improvers. The main function of motor oil is to reduce friction and wear on moving parts and to clean the engine from sludge and varnish (detergents). It also neutralizes acids that originate from fuel and from oxidation of the lubricant (detergents), improves the sealing of piston rings, and cools the engine by carrying heat away from moving parts.
A bearing is a machine element that constrains relative motion to only the desired motion and reduces friction between moving parts. The design of the bearing may, for example, provide for free linear movement of the moving part or for free rotation around a fixed axis; or, it may prevent a motion by controlling the vectors of normal forces that bear on the moving parts. Most bearings facilitate the desired motion by minimizing friction. Bearings are classified broadly according to the type of operation, the motions allowed, or the directions of the loads (forces) applied to the parts.
A hydraulic fluid or hydraulic liquid is the medium by which power is transferred in hydraulic machinery. Common hydraulic fluids are based on mineral oil or water. Examples of equipment that might use hydraulic fluids are excavators and backhoes, hydraulic brakes, power steering systems, automatic transmissions, garbage trucks, aircraft flight control systems, lifts, and industrial machinery.
Cutting fluid is a type of coolant and lubricant designed specifically for metalworking processes, such as machining and stamping. There are various kinds of cutting fluids, which include oils, oil-water emulsions, pastes, gels, aerosols (mists), and air or other gases. Cutting fluids are made from petroleum distillates, animal fats, plant oils, water and air, or other raw ingredients. Depending on context and on which type of cutting fluid is being considered, it may be referred to as cutting fluid, cutting oil, cutting compound, coolant, or lubricant.
Lubrication is the process or technique of using a lubricant to reduce friction and wear and tear in a contact between two surfaces. The study of lubrication is a discipline in the field of tribology.
Tribology is the science and engineering of understanding friction, lubrication and wear phenomena for interacting surfaces in relative motion. It is highly interdisciplinary, drawing on many academic fields, including physics, chemistry, materials science, mathematics, biology and engineering. The fundamental objects of study in tribology are tribosystems, which are physical systems of contacting surfaces. Subfields of tribology include biotribology, nanotribology and space tribology. It is also related to other areas such as the coupling of corrosion and tribology in tribocorrosion and the contact mechanics of how surfaces in contact deform. Approximately 20% of the total energy expenditure of the world is due to the impact of friction and wear in the transportation, manufacturing, power generation, and residential sectors.
Synthetic oil is a lubricant consisting of chemical compounds that are artificially modified or synthesised. Synthetic lubricants can be manufactured using chemically modified petroleum components rather than whole crude oil, but can also be synthesized from other raw materials. The base material, however, is still overwhelmingly crude oil that is distilled and then modified physically and chemically. The actual synthesis process and composition of additives is generally a commercial trade secret and will vary among producers.
Gear oil is a lubricant made specifically for transmissions, transfer cases, and differentials in automobiles, trucks, and other machinery. It has high viscosity and usually contains organosulfur compounds. Some modern automatic transaxles do not use a heavy oil at all but lubricate with the lower viscosity hydraulic fluid, which is available at pressure within the automatic transmission. Gear oils account for about 20% of the lubricant market.
Grease is a solid or semisolid lubricant formed as a dispersion of thickening agents in a liquid lubricant. Grease generally consists of a soap emulsified with mineral or vegetable oil.
Ferrography is a method of oil analysis used to inspect the severity and mechanisms of wear in machinery. This is achieved by separating ferrous debris from lubricating oil by use of a magnetic field with an instrument called a ferrograph, the result is then examined with microscopy. A trained analyst can then diagnose faults or predict failures.
Friction modifiers are added to lubricants in order to reduce friction and wear in machine components. They are particularly important in the boundary lubrication regime, where they can prevent solid surfaces from coming into direct contact, substantially reducing friction and wear.
Lubricity is the measure of the reduction in friction and/or wear by a lubricant. The study of lubrication and wear mechanisms is called tribology.
Oil additives are chemical compounds that improve the lubricant performance of base oil. The manufacturer of many different oils can utilize the same base stock for each formulation and can choose different additives for each specific application. Additives comprise up to 5% by weight of some oils.
Crankcase dilution is a phenomenon of internal combustion engines in which unburned diesel or gasoline accumulates in the crankcase. Excessively rich fuel mixture or incomplete combustion allows a certain amount of fuel to pass down between the pistons and cylinder walls and dilute the engine oil. It is more common in situations where fuel is injected at a very high pressure, such as in a direct-injected diesel engine.
Automotive oil recycling involves the recycling of used oils and the creation of new products from the recycled oils, and includes the recycling of motor oil and hydraulic oil. Oil recycling also benefits the environment: increased opportunities for consumers to recycle oil lessens the likelihood of used oil being dumped on lands and in waterways. For example, one gallon of motor oil dumped into waterways has the potential to pollute one million gallons of water.
Koehler Instrument, or Koehler, is a US based company that provides petroleum, petrochemical testing equipment, and technical support services to testing laboratories worldwide. The company’s corporate headquarters is in Holtsville, NY and manufacturing headquarters is located in Bohemia, NY.
Infineum International Limited is a joint venture between ExxonMobil and Shell plc through each companies' chemical divisions. Its headquarters are located in Abingdon, England and it has operating centers throughout the United Kingdom, United States, Germany, France, Italy, China, Singapore.
DN factor, also called DN Value, is a number that is used to determine the correct base oil viscosity for the lubrication of various types of bearings.