The document summarizes a seminar presentation on machine condition monitoring through oil analysis. It discusses various techniques for analyzing lubrication oil samples such as FTIR spectroscopy, ferrography, particle counting, and online debris monitoring. These analysis methods examine properties of the oil like viscosity and acidity, as well as contamination levels and concentrations of wear metals. The results can provide insights into equipment health and identify failure risks to enable preventative maintenance.

1. DEPARTMENT OF MECHANICAL ENGINEERING
A Seminar on
DETERMINATION OF MACHINE CONDITION BY
OILANALYSIS
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Guided by,
Mr Hareesh NV
Asst Professor
Dept. of Mechanical Engineering
JECC
Presented by,
Mr Raymon Charly
JYAOEME096, S8 ME:B
Dept. of Mechanical Engineering
JECC

2. OUTLINE OF PRESENTATION
 Introduction
 Steps in Lubrication oil sampling
 Condition indicators
 Working of FTIR
 Ferrographic Oil Analysis
 Pore Blockage Particle Counter
 Online oil debris monitoring
 Working of AES
 Conclusion
 Reference
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3. INTRODUCTION
• All machines gradually wear out. In the course of normal
operation, microscopic particles will be generated from
bearings, gears, liners and rings etc. and will be carried away
by the oil that lubricates these parts.
• How long the machine lasts depends largely upon the
maintenance scheme employed and condition based
maintenance is one strategy which is being used by more and
more machinery operators.
• Oil is the lifeblood of a machine - it circulates around the
moving components lubricating, cooling and removing dirt
and debris.
• Having taken the sample, what tests do you perform on the oil,
and how do you interpret the results?
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4. HOW LUBRICATING OILS ARE MADE
• Mineral oils are refined from naturally occurring petroleum, or
crude oil.
• Typically lubricants contain 90% base oil (most often
petroleum fractions, called mineral oils) and less than 10%
additives.
• Vegetable oils or synthetic liquids such as hydrogenated
polyolefin and many others are sometimes used as base oils.
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5. FUNCTIONS OF LUBRICANTS
• Reduce friction
• Protect against wear
• Transfer heat
• Carry away contaminants and debris
• Prevent corrosion
• Seal for gases
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6. PURPOSE OF LUBRICANT MONITORING
• Lubricants monitoring is an important method on proactive
maintenance achievement.
• It is a tool which can be used not only to guarantee the
lubricant condition to fulfil its function but to accompany the
equipment state evolution as well and identify failure risks,
allowing an anticipation, in order to avoid expensive
consequences and prolong the equipment life time.
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7. STEPS IN LUBRICATION OIL SAMPLING
• Handling and Storage –
When we are monitoring a lubricant, we need the information
to be precise and representative of the oil and equipment functioning
conditions.
• Frequency –
Some machines are highly critical and must be inspected daily
or in every shift, while some others should be weekly or monthly.
• Parameters to observe –
1. Sight glass foaming Varnished sight glass
2. Darkened oil
3. Water emulsion appearance
4. Information gathering and managing
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8. CONDITION INDICATORS
• The condition indicators obtained from observed SOAP data
reveal that there are 28 indicators, which can be classified into
three categories:
• lubricant conditions, contaminants and metal concentrations.
• Checking the lubricant conditions is to assess whether the oil
itself is fit for further service or is ready for a change.
• Assessment of contaminants measures the dirt, water, etc.,
which could degrade the oil.
• Metal concentrations measure several wear particles that
become entrained in the oil due to component wear.
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9. LUBRICANT CONDITION MONITORING
• Viscosity. Viscosity is a measures of the flow ability of an oil
under a particular temperature and pressure.
• Flash Point or Fire Point. The lowest temperatures at which
the oil flashes and fires, known as flash and fire points.
• Pour Point. The lowest temperature at which the oil pours is
called its pour point.
• Emulsification. A lubricant when mixed with water tends to
separate. The emulsification number is an index of the
tendency of any oil to emulsify with water.
• Alkalinity. The lube oil alkalinity plays an important part in
engines. When fuel burns, the fumes carry sulphuric acid
which can cause acidic corrosion.
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10. • TAN - is the total acid number and indicates the oil acidity
level. TAN determination method, is based on measuring the
amount of alkaline reagent, necessary to neutralize the acid
content.
• Oxidation - indicates the oil degradation, usually caused by
the oil exposure to very high temperature in the presence of
oxygen, or an inevitable depletion of anti-oxidation additives
due to an over extended oil drain period.
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11. • In its present form, elemental analysis is used to determine the
concentrations of 15 to 25 different elements ranging from
wear metals and contaminants to oil additives.
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12. LUBRICANT CONTAMINANT
MONITORING
• Water is one of the most widespread and destructive
contaminant in lubricants, which promotes oil degradation and
is detrimental for the equipment's.
• Due to the strong effect of the water on the lubricants, it is
necessary to test, quantify and take appropriate steps for
removing in order to prolong the service lifetime of lubricants.
• IR spectroscopy is being used extensively for rapid and routine
screening of used lubricants for remaining additives, oxidative
degradation of base oils and oil contaminants.
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13. FTIR WORKING
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Moisture measurements in lubricating oils by
FTIR spectroscopy

15. Wear Analysis
• Additive content, wear metals and the presence of
contaminants, can be measured by the following methods.
1. Emission spectroscopy
2. Analytical ferrography
3. Automatic Particle Counting
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16. WORKING OF AES
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17. CASE STUDY
• Wear elemental spectrometric quantitative analysis of used
perodua automatic transmission fluid-3 series (atf-3)
Spectrometer - SPECTROIL Q100
Developed Temperature - 5000°C to 6000°C
Disc rotation speed - 3000rpm
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18. VIRGIN ATF-3 (VO) WEAR ELEMENTAL
CONCENTRATION (PPM) RESULT
• wear elemental concentration for the unused (virgin) ATF-3
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20. RESULT ANALYSIS
• In the viewpoint of A1-B3 sampling category wear elements
result; it was found that the elements of Fe, Cu and Al were the
most significant wear elements occurred during the actual
operating condition basis.
• The average wear concentration (ppm) value obtained for each
element was
• Fe - 22.161 ppm,
• Cu - 16.048 ppm
• Al - 11.577 ppm
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21. • It has been affirmed that the typical value of concentration of
Fe for the engine oil studied were between 40-200 ppm.
• It can therefore be noticed that the overall Fe average
concentration was lower than 100 ppm. Despite the element of
Fe was the highest concentration compared to Cu and Al, the
overall concentration values were within the acceptable wear
concentration range and the occurrence of Fe wear element
was insignificant.
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22. • The element of Cu meanwhile was higher than 20 which
exceeded 41.45% than the alarm level. It was asserted that the
alarm level of Cu is set at 20 ppm.. Due to the high value of
Cu wear concentration, it is crucial and important for the tested
samples to be analysed in terms of its oxidation level, since the
high Cu concentration resulted towards high oxidation level
and eventually increases the rate of oxidative degradation of
the lubricant.
• As such, the oxidation level for the ATF on both mission
profiles are required to be analysed in order to predict the
capability of the ATF to be extendedly used than the
recommended period at accepted level of wear occurrence.
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23. FERROGRAPHIC OILANALYSIS
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24. PORE BLOCKAGE PARTICLE COUNTER
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25. ONLINE OIL DEBRIS MONITORING
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• The device detects the passage of metallic debris by
monitoring the inductance change of a two-layer
planar coil with a meso-scale fluidic pipe crossing its
centre.

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Measured relative inductance change caused by
(a)75–105 mm iron particles,
(b)50–75 mm iron particles and
(c)105–150 mm copper particles.

27. CONCLUSION
• Lubrication monitoring is to be used as a tool for proactive
maintenance implementation, and not to be seen as a method
to determine lubricant’s end time. The aim is to achieve the
equipment health, where the information delivered by
lubricant monitoring in articulation with other useful tools, can
be used as a base for more significant actions involving
changes in the maintenance program and in the equipment
itself.
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28. REFERENCE
[1] Syazuan Abdul Latipa, Salmiah Kasolanga, Siti Khadijah, Syarifah Yunus, Abdul Hakim
Abdullah, Norhisyam Jenal “Wear Elemental Spectrometric Quantitative Analysis of Used
Perodua Automatic Transmission Fluid-3 Series (ATF-3)”, The Malaysian International Tribology
Conference 2013, MITC2013
[2] Li Du, JiangZhe “A high throughput inductive pulse sensor for online oil debris monitoring ”
Tribology International 44 (2011) 175–179
[3] Eng-Poh Ng , Svetlana Mintova , “Quantitative moisture measurements in lubricating oils by
FTIR spectroscopy combined with solvent extraction approach” Microchemical Journal 98 (2011)
177–185
[4] Morten Henneberg, RenéL.Eriksen, JensFich “Modelling and measurement of wear particle
flow in a dual oil filter system for condition monitoring” Wear362-363(2016),153–160.
[5] T.H. Loutas, D.Roulias, E.Pauly, V.Kostopoulos “The combined use of vibration, acoustic
emission and oil debris on-line monitoring towards a more effective condition monitoring of
rotating machinery” Mechanical Systems and Signal Processing 25 (2011) 1339–1352
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29. THANK YOU
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