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Why You Need to Double Check Your Oil Analysis

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Are you confident in your oil contamination results? The efficiency, safety, and reliability of your operations could depend on them. Don’t risk it—discover how using the OLYMPUS CIX100 cleanliness inspector to confirm results can help you identify dangers before they become a problem.

Conventional sensor-based oil analysis methods may not always precisely quantify particles, leaving you open to compliance issues and problems down the line. Filter particulate inspection with automated microscopes maximizes the precision of oil analyses, helping ensure safety and regulatory compliance, as well as helping to safeguard your machinery and extend its lifetime.

In this webinar, we explore the benefits of detailed, microscopy-based oil particulate inspection in the oil and gas, automotive, and aviation industries where safety, reliability, and conformance with industrial standards are vital.

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Why You Need to Double Check Your Oil Analysis

  1. 1. OLYMPUS CIX100 Cleanliness Inspector A New Era of Oil Contamination Inspection Audun Brekke, Europafilter Sugish Subramonia, Olympus Europa 19 February 2019
  2. 2. Agenda 2/19/2019 OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection2 1 Welcome and Introduction 2 Europafilter Norway: Who Are We? What Do We Do? 3 Oil Contamination: Why Are Oil Contaminants Dangerous? 4 Sample Preparation Techniques: Best Practices and Workflow 5 Microscope-Based Particle Inspections: Why Use a Microscope? 6 OLYMPUS CIX100: A User's Perspective 7 Customer Benefits and Values 8 Q&A
  3. 3. Agenda OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection3 1 Welcome and Introduction 2 Europafilter Norway: Who Are We? What Do We Do? 3 Oil Contamination: Why Are Oil Contaminants Dangerous? 4 Sample Preparation Techniques: Best Practices and Workflow 5 Microscope-Based Particle Inspections: Why Use a Microscope? 6 OLYMPUS CIX100: A User's Perspective 7 Customer Benefits and Values 8 Q&A 2/19/2019
  4. 4. Customers working offshore and in industry Makes special offline oil filters for fine filtration § Removes all types of contamination ‒ Soft and hard particles down to 0.1 μm ‒ Water (free and emulsified) ‒ Oxidation products (sludge and resin) § Intended to reduce or eliminate oil changes (change filters instead of oil) § Increase machine lifetime § Reduce operating and maintenance costs Oil analysis for customers § Investigate the status of a customer’s oil system § Validate the functionality of Europafilter implementation § Long-term oil status monitoring OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection4 Europafilter Norway Overview V2 2/19/2019
  5. 5. Agenda OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection5 1 Welcome and Introduction 2 Europafilter Norway: Who Are We? What Do We Do? 3 Oil Contamination: Why Are Oil Contaminants Dangerous? 4 Sample Preparation Techniques: Best Practices and Workflow 5 Microscope-Based Particle Inspections: Why Use a Microscope? 6 OLYMPUS CIX100: A User's Perspective 7 Customer Benefits and Values 8 Q&A 2/19/2019
  6. 6. Oil fulfills many roles in a system § Lubricating and separating parts § Transferring power § Cleaning § Picking up contaminants and transporting them to a filter § Heat transfer / cooling § Absorbing water and moisture § Preventing corrosion § Preventing oxidation § Preventing foaming OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection6 Oil Contamination: Why Are Oil Contaminants Dangerous? 2/19/2019
  7. 7. OIL CONTAMINANTS CAN LEAD TO Higher Operating Costs § Power § Heat § Noise § Higher Maintenance Costs § Wear of mechanical components § Maintenance downtime § Unplanned maintenance and downtime § Breakdowns § 85% of all problems with oil-lubricated machines are oil-related! OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection7 Oil Contamination: Why Are Oil Contaminants Dangerous? 2/19/2019
  8. 8. 0.19 0.24 0.31 0.41 0.57 0.76 1 1.33 1.81 2.48 3.52 4.76 6.19 8.57 19.05 0 2 4 6 8 10 12 14 16 18 20 24/21 23/20 22/19 21/18 20/17 19/16 18/15 17/14 16/13 15/12 14/11 13/10 12/9 11/8 10/7 OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection8 Oil Contamination: Why Are Oil Contaminants Dangerous? MACHINE SERVICE LIFETIME RELATIVE TO OIL CLEANLINESS Lifetime vs. ISO example calculated by hours LifetimeFactor Cleanliness level by ISO4406 Ave, ISO Code Ave, Hrs Between Breakdown Relative Life Factor 24 / 21 200 0.19 23 / 20 250 0.24 22 / 19 325 0.31 21 / 18 430 0.41 20 / 17 600 0.57 19 / 16 800 0.76 18 / 15 1050 1 17 / 14 1400 1.33 16 / 13 1900 1.81 15 / 12 2600 2.48 14 / 11 3800 3.62 13 / 10 5000 4.76 12 / 9 6500 6.19 11 / 8 9000 8.57 10 / 7 20,000 19.05 Source: BHRA (British Hydromechanics Research Association) Source: BHRA (British Hydromechanics Research Association) Relative life factor 2/19/2019
  9. 9. Agenda OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection9 1 Welcome and Introduction 2 Europafilter Norway: Who Are We? What Do We Do? 3 Oil Contamination: Why Are Oil Contaminants Dangerous? 4 Sample Preparation Techniques: Best Practices and Workflow 5 Microscope-Based Particle Inspections: Why Use a Microscope? 6 OLYMPUS CIX100: A User's Perspective 7 Customer Benefits and Values 8 Q&A 2/19/2019
  10. 10. § Cleanliness is important to prevent unwanted contamination in patch tests § Use a fume hood or safety cabinet when doing a patch test § Use heptane, for example, to clean the equipment and as a solvent ‒ Use a solvent tank with a filtered gun § Wear lint-free clothing during cleaning § Think “cleanliness!” § Always transport and store the patches in a petrislide after testing § It is also important to follow the correct procedure when extracting an oil sample from a system § There is a lot to think about when extracting an oil sample from a system: cleanliness, external contamination, sample point, machine state, etc. OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection10 Sample Preparation Techniques: Best Practices and Workflow 2/19/2019
  11. 11. Oil sampling procedures as described on www.oilsampling.com § Cleanliness is also important when preparing the oil sample § Use the described sampling procedure to help ensure that the oil sample is not contaminated by external contaminants § Use a vacuum to extract the oil; do not run it through pumps that might contaminate the oil § Extract oil from the middle of the tank; contamination might be concentrated in the bottom or corners of the tank OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection11 Sample Preparation 1 2 3 654 Image courtesy www.oilsampling.com 2/19/2019
  12. 12. § Wet the funnel with heptane and wipe with a lint-free cloth § Wet the mesh with heptane and wipe with a lint-free cloth OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection12 Patch Test Procedure 2/19/2019
  13. 13. § Put the funnel in place and wash the inside of the funnel and mesh § Now the equipment is clean and ready to use OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection13 Patch Test Procedure 2/19/2019
  14. 14. OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection14 Patch Test Procedure § Remove the funnel and place a patch filter disc on the screen; replace the funnel § Now the system is ready to do a patch test 2/19/2019
  15. 15. § Pour the oil sample into the funnel (the sample should be 100 mL) § Start drawing a vacuum inside the flask so the fluid is drawn through the filter OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection15 Patch Test Procedure 2/19/2019
  16. 16. OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection16 Patch Test Procedure § Fill the sample bottle up to one-third with solvent (heptane); shake the bottle and pour it into the funnel 2/19/2019
  17. 17. OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection17 Patch Test Procedure § When the sample level has dropped to the narrow end of the funnel, wash down the inner walls of the funnel § When the entire sample is drawn through the patch filter, wait a short while before removing the funnel § Remove the patch filter and dry it in a drying oven § Place the patch filter in a petrislide 2/19/2019
  18. 18. OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection18 Analysis with the OLYMPUS CIX100 Cleanliness Inspector § Consider placing the CIX100 system in a fume hood to prevent unwanted contamination of the patch and build-up of dust on the equipment § We placed the microscope inside a cleanroom and placed the workstation with the joystick outside the lab § Ensure consistent lighting 2/19/2019
  19. 19. Agenda OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection19 1 Welcome and Introduction 2 Europafilter Norway: Who Are We? What Do We Do? 3 Oil Contamination: Why Are Oil Contaminants Dangerous? 4 Sample Preparation Techniques: Best Practices and Workflow 5 Microscope-Based Particle Inspections: Why Use a Microscope? 6 OLYMPUS CIX100: A User's Perspective 7 Customer Benefits and Values 8 Q&A 2/19/2019
  20. 20. OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection20 Microscope-Based Particle Inspections WHY USE A MICROSCOPE? § “A picture says more than a thousand words!” § Text reports can often be hard to interpret and understand § Written reports may be easy to understand by people carrying out inspections, but others might benefit from image-based reporting § Technicians do understand, but people working in management, finance, or other decision makers might not 2/19/2019
  21. 21. OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection21 Benefits of Microscopic Analysis With microscopic analysis you can see the composition, shape, and color of every particle Fourier Transform Infrared Spectroscopy (FTIR) can tell you what the particles are made of, but this only works for very small particles Automated laser particle counters cannot provide the shape or composition of particles 2/19/2019
  22. 22. Mineral / salt (dirty) Particle identification examples Metal scuffing Gel varnish (dirty) Washing granule Mineral / salt Synthetic cloth fiber OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection22 Benefits of Microscopic Analysis Soot Polymer (dirty) Unknown Cotton fiber Gel varnish 2/19/2019
  23. 23. OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection23 Benefits of Microscopic Analysis Detection of fibers and polymers Other analysis systems can have difficulties detecting long fibers and polymers With microscopic analysis you might find out where the contaminants come from by looking at color and shape Cleaning cloth Filter debris Color / fabric (cotton, polyester, etc.) 2/19/2019
  24. 24. OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection24 Benefits of Microscopic Analysis § Exact particle counting ‒ Automated laser particle counters are prone to errors in counting. They might count air or gas bubbles as particles in, for example, compressor oil. If a sample is vacuumed through a particle counter, the vacuum may cause air bubbles to form in the oil. § With microscopy, the user can verify the result of the automated counting by looking at the pictures Particles Laser Flow Aperture Scattered Light Collection Box Photocell DetectorVolts Time Flow 2/19/2019
  25. 25. OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection25 Benefits of Microscopic Analysis Verifying results by eye NAS1638 / ISO4406 NAS 1 – ~ISO 9NAS 0 – ~ISO 8 NAS 2 – ~ISO 10 NAS 3 – ~ISO 11 NAS 4 – ~ISO 12 NAS 5 – ~ISO 13 NAS 7 – ~ISO 15 NAS 8 – ~ISO 17 NAS 9 – ~ISO 18 NAS 10 – ~ISO 19 NAS 11 – ~ISO 120 NAS12 – ~ISO20–21 NAS 6 – ~ISO 14 2/19/2019
  26. 26. OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection26 Benefits of Microscopic Analysis With microscopic analysis you can count particles, but you can also see levels of varnish and sludge No varnish or sludge. The patch background is clean and only the patch texture is visible. Light varnish or sludge shown as a gray background color on the patch. Light varnish that is starting to get burnt and darker. Clean oil with nearly no particles. The natural color of the oil can also affect its appearance. More varnish appears as a darker background on the patch. Lumps within the thicker layer of varnish become visible. Patch is highly contaminated with varnish. Lumps of varnish have become contaminated with small (dark colored) particles. Lumps of varnish have burnt and also appear dark colored. Patch is completely covered in a thick layer of sludge/varnish. Dark- colored varnish from particles and overheating. TO DETERMINE THE LEVEL OF VARNISH YOU CAN USE MPC VARNISH POTENTIAL TESTING INSTRUMENTS 2/19/2019
  27. 27. Agenda OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection27 1 Welcome and Introduction 2 Europafilter Norway: Who Are We? What Do We Do? 3 Oil Contamination: Why Are Oil Contaminants Dangerous? 4 Sample Preparation Techniques: Best Practices and Workflow 5 Microscope-Based Particle Inspections: Why Use a Microscope? 6 OLYMPUS CIX100: A User's Perspective 7 Customer Benefits and Values 8 Q&A 2/19/2019
  28. 28. 2/19/2019 OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection28 OLYMPUS CIX100 Cleanliness Inspector: A User's Perspective We chose the OLYMPUS CIX100 microscope after comparing competitor microscopes and other solutions § Olympus has a long track record in microscopy and lenses § The CIX100 is a new, updated solution § Support and updates § Intuitive user interface § Exact counting: no extrapolation required § Detailed particle pictures § Fast
  29. 29. § Better resolution ‒ ISO4407:2002 with sizes 4 μm / 6 μm / 14 μm ‒ Detailed picture of each particle § Counts whole patch without extrapolation ‒ Extrapolation can lead to bad particle counts § Sample database § Editable reports § Continuously updated 2/19/2019 OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection29 OLYMPUS CIX100 System Compared to Other Types of Microscopic Analysis
  30. 30. 2/19/2019 OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection30 OLYMPUS CIX100 Cleanliness Inspector § Detailed color picture of each particle § Easy to identify problems ‒ Fibers (e.g. from carpet) ‒ Polymers ‒ Dirt ‒ Varnish ‒ Sludge ‒ Minerals ‒ Scuffings ‒ Burnt particles and oil
  31. 31. § Some types of oil might make the patch bulky, making it difficult to produce a focused image § Dark and dirty oil can make the patch dark and make it hard to focus ‒ You can add an extra focal point ‒ You can manually focus on each focal point ‒ You can run the analysis with the focus on each frame ‒ You can manually adjust the exposure ‒ You can use the 5x lens instead 2/19/2019 OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection31 Patch Test Challenges
  32. 32. 2/19/2019 OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection32 Latest Version – CIX v. 1.4 Software § Real color mode § Extended focal image (EFI)
  33. 33. 2/19/2019 OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection33 CIX v. 1.4 Software Is the reflecting particle metallic? Pictures from sample inspection with polarized light Pictures after enhancement with EFI and real color mode
  34. 34. 2/19/2019 OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection34 CIX v. 1.4 Software § All particles appear blue when reflecting polarized light § With real color mode and EFI, we can see that only one of them is metallic
  35. 35. 2/19/2019 OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection35 CIX v. 1.4 Software § Better pictures of particles and a better understanding of what they are made of Pictures from sample inspection with polarized light Pictures after enhancement with EFI and real color mode
  36. 36. Agenda 2/19/2019 OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection36 1 Welcome and Introduction 2 Europafilter Norway: Who Are We? What Do We Do? 3 Oil Contamination: Why Are Oil Contaminants Dangerous? 4 Sample Preparation Techniques: Best Practices and Workflow 5 Microscope-Based Particle Inspections: Why Use a Microscope? 6 OLYMPUS CIX100: A User's Perspective 7 Customer Benefits and Values 8 Q&A
  37. 37. 2/19/2019 OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection37 Customer Benefits and Values § User-friendly software with an intuitive user interface LOW LABOR AND TRAINING COST
  38. 38. 2/19/2019 OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection38 Customer Benefits and Values § Multi-sample inspection with a unique polarization technique SAVE TIME FOR A FAST AND EFFICIENT INSPECTION
  39. 39. 2/19/2019 OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection39 Customer Benefits and Values § EFI acquisition on each individual particle avoids blurred areas NEVER MISS ANY PARTICLE DETAILS
  40. 40. 2/19/2019 OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection40 Customer Benefits and Values § See the particles in their real colors to find out if they are truly reflective SEE MORE WITH CLARITY Sample image Live observation Real color EFI EFI with real color
  41. 41. 2/19/2019 OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection41 Customer Benefits and Values § Intuitive reporting workflow and creation of smart reports in accordance with international standards EASY TO SHARE RESULTS
  42. 42. 2/19/2019 OLYMPUS CIX100 Cleanliness Inspector—A New Era of Oil Contamination Inspection42 Q&A
  43. 43. Thank you for your attention Olympus is a registered trademark of Olympus Corporation.

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