How to manage an onsite oil analysis programme

1. www.kittiwake.com
sales@kittiwake.com
How to manage an
Onsite Oil Analysis Programme
Zainudin Yahya
Managing Director
CbM Solutions Sdn. Bhd.
August 2013

2. Who are Parker Kittiwake?
Parker Kittiwake are one of the
world’s leading asset protection
experts
We manufacture products that allow
our customers to monitor and manage
the following:
Lubrication
Fuel
Gas
Machinery
Marine Water
Our key customers are leaders in the following application spaces:
Marine, Industrial, Renewable Energy, Offshore, Power, Food Manufacturing
Kittiwake are trusted and used by the majority of the major
companies in our key application areas to provide products to
monitor and manage their assets

3. Kittiwake’s Credentials
1992 to 2012 - 20 years of successful industry experience.
Strong financial growth over this period. ~ $20m Turnover for 2011.
> 500 product lines
> 1,000 global customers
~ 90 staff. Offices in UK, USA,
Germany, India and Malaysia.
Quality Assurance: ISO 9001:2008
Strong, continued, organic growth over the past 20 years,
enhanced by acquisitions, offering added value for our
customers
Acoustic Emissions Gas Fuel & Lube

4. Certified solutions to give representative samples for analysis
Oil Sampling
Simple to use
No operator/sample contact
Major UOA programme logistics
Fuel Sampling
In-line, continuous sampling
LR Type approved
IMO MARPOL Annex VI compliant
Oil and Fuel Sampling
Obtaining a representative sample is one of the most
important aspects of any scheduled oil analysis programme.

5. Lube Test Kits
On-Site condition based monitoring - high specification & exact results.
DIGI Kits (6 Parameters)
Simple to use
Economical
Rugged
EasySHIP – non hazardous option
Analysis Laboratories (8 Parameters)
High specification
Laboratory accuracy levels
Tested for harsh environments
In use globally with oil companies, engine OEMs,
international navies, shipping companies, offshore
contractors, power generators, etc.

6. Marine Water Test Kits
Helping customers to comply with current and forthcoming
legislation requirements
Marine hygiene & potable water test kits
Full Compliance with ILO 178 (1996) & ILO MLC (2006)
Sewage effluent test kits
Full Compliance with MARPOL Annex IV, V, 26
Cooling & boiler water test kits
Offer real time analysis
User friendly with full instructions provided
Avoids costly laboratory analysis
Training available for fleet purchases

7. Laboratory/Field based equipment for ultimate accuracy and repeatability
pqL
Total ferrous (ANALEX fdMPlus)
Ferrography
Oil test centre
FTIR
Density meter
Heated viscometer
Compatibility tester
Flashpoint tester
Cloud point tester
Particle counter (Through Parker)
Laboratory/Field Test Equipment
Trusted by Oil Testing Laboratories Worldwide
Including Caterpillar, ExxonMobil, BP, Shell, Castrol,
ITS Caleb Brett, Wearcheck, etc.

8. Real-time Machinery Condition
Monitoring
There is an increasing desire to move from on-site to on-line analysis
Kittiwakes offerings remove the “man” between machine and ultimate reliability
On-line Sensors
Total ferrous debris
Metallic Wear Debris
Oil condition
Moisture
Total water / insolubles
Exhaust Emissions (Kittiwake Procal)
Acoustic Emissions (Kittiwake Holroyd)
Under Development
Online Viscosity sensor
•Real-time measurements
From multiple locations
Flexible In/Output options

9. Kittiwakes Online Sensors
Effective trending relies upon the provision of regular and accurate information
Real time monitoring provides:
Ultimate reliability
Removes sampling errors
Web Visibility
Empowers fast and informed decisions
Kittiwakes sensor range
Total Ferrous
Metallic Wear Debris
Oil Condition
Moisture
Online Viscosity (under development)
Sensor suite – containing combinations of the above sensors
Kittiwakes MWDS is the most sensitive Metallic Wear Debris
Sensor available in the market today

10. Holroyd - Acoustic Emissions (AE)
AE monitoring provides:
Early indication of machine degradation
Monitors:
Fast and Slow speed (>0.25 rpm)
Bearings, motors, pumps, gearboxes
Complementary to oil analysis to provide an overall
condition monitoring solution
Holroyd sensor range:
MHC – Machinery Health Check
Online modules
SetPoint
SloPoint
Smart Sensors
DM1/SM1
Sigma
Wireless
Ultraspan
Specialists in acoustic emissions sensors and systems

11. 25 years in the emissions industry, over 2800 installed
analysers in 41 countries, > 120 million device hours.
Continuous Emissions Monitoring
In-situ IR and UV exhaust gas monitoring
Multiple gases analysed within a single unit
(up to 6 of: SOx, NOx, N2O, CO, CO2, NH4,
C2H6, C2H4, HCl, HF, CH4, C3H8, H2O).
Global Approvals:
ATEX/IEC (Hazardous areas)
MCERTS (Europe)
US EPA 40 CFR Part 60 and 75 (US)
MED 2008/67/EC (Marine)

12. Application Specific Condition Monitoring

13. World Class R & D
Highly qualified R&D team (13 BEng/BSc, 4 MEng,
5 PhD’s) covering:
Electronics
Mechanical Design
Software
Chemistry
Physics
Research and utilise novel technologies
Develop and improve existing products
Extended product life cycles
Joint customer partnerships
>10% of turnover invested back into R&D

14. Kittiwake’s Global Presence

15. The Kittiwake group of companies
Kittiwake - Serving your needs on a global basis.

16. Shell Co-brand
Shell Analex Alert
Ferrous Debris Monitor
For marine market

17. Wartsila Co-brand
Wartsila Power Plant Test
Cabinet
Fuels & Lubricant test kits
For power plant market

18. Why condition monitoring is
important?
Detection
Range
= 15X
Time
Detection Range
= X
Time
Ref.: B.T. Kuhnell, Director of The Center For Machine Condition Monitoring,
Monash UniversityVarnishing in Turbine Bearing
Wear Debris Analysis
Vibration Analysis

19. Why Oil Analysis?
Contamination
Oil Condition
Machine condition

20. Why do we do it?
NOTE
1. QA/QC
2. Troubleshoot problems
3. Identify potential failure
4. Extend oil service life
5. Proof of performance
6. Monitor equipments wear and tear
7. Preventive maintenance
8. Save money

21. What does it takes?
NOTE
1. People
2. Time
3. Equipments
4. Money
5. Know – how
6. Long Term Commitments
7. Continuity

22. Why onsite?
•Viscosity, Water, TBN, Insolubles, TAN,
Particles, Metal Analysis, Additive content,
RPVOT etc.
•Take time, 48hrs – 1 month
•> 3 manhour, >USD10 of manpower cost/test
• >USD50/test, or included in lubricant cost
•80% of sample are OK
•Spoon feed information
Viscosity, Water, TBN, Insolubles, TAN, Particles,
Ferrous Wear Debris
Fast less than 30 mins
0.5 manhour
Low cost per test
Easy to re-confirm alarming sample
80% saving on lab oil analysis
Ownership of the data
Easy to start!!!

23. Onsite Oil Test Matrix
Test Engine Oil Industrial Remarks
Viscosity @ 100 oC @ 40 oC
Water in Oil R R Typically below 2000ppm.
Acid / Base Number BN AN
Insolubles / Soot Soot Insolubles
Particle counts R Especially clean oils
Oxidation O R Especially long-life lubricants
Antioxidant depletion O R Especially long-life lubricants
Sulphation O O When exposed to Sulphur
Nitration O O When exposed to Nitrogen
Phosphate Anti-wear depletion O O Especially AW type oil
Ferrous Concentration R R Especially gear oil
Flash Point O O Once viscosity dropped significantly.
Glycol/Diesel O O Especially when suspected

24. Oil Test Centre
Viscosity @ 40oC
– 15 – 500cSt within +/- 2cSt
– compute @ 100oC given density & VI
Water in Oil (WIO)
– 0 – 2.5% or 0 – 6000ppm or 0 –
3000ppm
– +/- 0.1 or 100ppm
– EasySHIP version
Total Base Number (TBN)
– 0 – 50 TBN within +/-10% of fresh TBN
Total Acid Number (TAN)
– 0 – 6 mgKOH within +/-0.2mgKOH
Insolubles
– 0 – 3.5% w/w within +/-0.1% w/w

25. Clean Oil Particle Test
Visual indication of cleanliness
Easy reference chart given
Easy to use

26. Analex Alert Ferrous Debris Monitor+
Ferrous Mass in Oil / Grease / Scrapedown
Ferrous as leading indicator of wear
Range 0- 2000ppm
All range of particle size incl. > 5 microns
Wear Particle Size Being Generated
.1 1 10 100 1,000 Microns
Catastrophic
Failure
Advanced Failure
Mode
Onset of Severe Wear
Mode
Slow Wear
WearParticleConcentration

27. Flash Point Test
• Indication of the level of
flammability of the sample in the
presence of:-
– Oxygen
– Source of Ignition
(Fire/Spark)
• Typical condemning limit for
lubricant is <180degC

28. The Kittiwake FTIR 3 Oil Analyser
ASTM Compliant and field deployable, all in a small, portable instrument
Measures:
Sulphation – TO ASTM D7415-09
Oxidation – To ASTM D7414-09
Nitration – To ASTM D7624-10
Phosphate Antiwear – To ASTM D7412-09
Soot – To ASTM E2412-10
Water – To ASTM E2412-10
Ethyl Glycol Coolant – To ASTM E2412-10
Antioxidant depletion – To ASTM E2412-10
Diesel
Fuel Contamination
As new ASTM methods become adopted, these can be added to the instrument.

29. 29
iCount BS+
8 channels of particle sizes
User selectable standard (ISO 1999,
NAS, AS4059, ISO11171,DEF91-91,
GOST, NAVAIR)
User programmable flush volume
User programmable test cycle

30. Onsite Oil Analysis Master Plan
Identify Equipment
With Alarming
Result/Trend
Verify Result
Resampling?
Retesting?
Take action Compile result
REVIEW OK?
Equipments
List to Monitor
High Impact
High Probability
Set Frequency
& Parameter
Of Testing
Evaluate
Implementation
Cost & Benefits
ROI OK?
APPROVAL?
Identify Sampling
Points & Methods
Identify
Personnel
Set Training
Program
Deploy
Monitoring
Equipments
PREPARED?
Brief on
Objectives
& Plan of Onsite
Oil Analysis
Train on
Sampling
&
Onsite Testing
Train on
Result
&
Interpretation
Discuss
on
Possible
Responses
TRAINED?
Take sample Onsite Testing Get Result
Trend &
Compare with
Baseline
Inteprete
IMPLEMENTED?

31. Equipment Typical Service Life Recommended Sampling
& Intervals
Remarks
Compressor 2,000 running hours Fresh, 0 hrs and every 500
running hours
Gas Turbine 3 – 10 years
depending on
severity
From drums, from storage
tanks, 0 hrs, 24 hrs
and every 500 hrs
1. Follow recommended
flushing procedures prior to
installing a new oil charge
2. Increased frequency for
severe turbine or oil
approaching the end of
their service life
Steam Turbine 5 – 20 years
depending on
severity
From drums, from storage
tanks, 0 hrs, 24 hrs
and every 3 months
Hydraulic System 2,000 running hours Fresh, 0 hrs and every 500
running hours
Industrial Gear 2,000 running hours Fresh, 0 hrs and every 500
running hours
Or 300 hours for high speed
and 1,000 low speed.
Frequency of Sampling – less frequent or more?

32. NOTE
1. Representative sample
2. Return line
3. Dipstick tube
4. Oil sump
5. Drum / supplier’s packaging
Where to take sample?

33. NOTE
1. Locate the sampling point.
2. Prepare the sampling gun and bottles.
3. Make sure the hose reach the mid-point.
4. Make sure it is safe to take oil sample.
5. Take sample as soon as possible.
6. Ensure the sampling gun is upright.
7. Pump the first charge to flush the hose.
8. Replace the sampling bottle with the fresh one.
9. Then start pumping until the bottle is ¾ full.
10. Unscrew the bottle from the sampling gun.
11. Close the bottle properly ensuring the inner cap seal is
intact.
12. Fill up the details required on the sample tag ID.
How to take sample?

34. Good Practices
Do’s
1. Separate pump for coolant and oil
2. Flushed sampling valves, sampling
devices and use clean bottles
3. Running Hours / Mileage recorded
4. Samples forwarded immediately to lab
5. Dedicated personnel

35. Diesel Engine Oil Analysis
Type Fuel Viscosity Insolubles TBN Water Flash Point
Change Maximum Change/Min Maximum Minimum
Automotive Distillate + / - 25% 2% -60% / 1 0.5% 180°
High Speed Distillate + / - 20% 2% -50% / 2 0.3% 180°
Medium Speed Distillate +20% -10% 2.5% -50% / 5 0.2% 180°
Medium Speed Residual +20% -10% 2.5% -50% / 10 0.2% 180°
Fuel Dilution has reduced oil
thickness resulting in wear
of the bearing and journal.

36. Hydraulic Oil Analysis
Viscosity
(cSt at 40°C)
Exceeds limit < +/- 10%
Viscosity increase is more common than decrease. It should be
noted and checked at more frequent intervals. Check that the
correct grade of oil is used for top-up.
Water (%) Satisfactory
0.05% -
0.15%
Upper limit should be checked against manufacturers’ data.
Some oils cannot tolerate water - BEWARE. Data not applicable
to water or phosphate ester-based hydraulic fluids.
Borderline 0.15% - 0.2%
Exceeds limit > 0.20%
TAN Exceeds limit + 0.6 of fresh
TAN should always be monitored by trend as the TAN of some
oils can fall from new then rise again as the oil ages.
Particulates
Refer to
manufacturer
s data
Hydraulic systems can be extremely sensitive to wear from
particulate contamination and great care should be taken to
ensure all filters are in good condition and no dirt enters via top-
up oil or tank vents.
Failure due to acidic-erosion

37. Natural Gas Engine Oil Analysis
Engine Type Viscosity Insolubles TBN TAN Water Flash Point
Natural Gas 100° +25% 1.0% 2 2.5 0.3% 180°
Lean Burn 40° +50%
Rise from
New
Failure due to water
contamination

38. Turbine Oil Analysis
Viscosity
(cSt at
40°C)
Exceeds
limit
< +/- 10%
nom
Viscosity increase is more common than decrease. It should
be noted and checked at more frequent intervals. Check that
the correct grade of oil is used for top-up.
Water (%)
Satisfactor
y
0.05% -
0.15%
Upper limit should be checked against manufacturers’ data.
Some oils, especially synthetic oils, cannot tolerate water -
BEWARE. Water contamination may lead to hydrolysis of
synthetic oils and rapid TAN increase.
Exceed 0.20%
TAN Exceed
Change +/-
0.4 from
nominal
TAN should always be monitored by trend as the TAN of some
oils can fall from new then rise again as the oil ages.
Lubricant varnishing

39. Compressor Oil Analysis
Viscosity
(cSt at
40°C)
Satisfactory < +/- 15%
A viscosity increase is more common than decrease. It should
be noted and checked at more frequent intervals. Check that the
correct grade of oil is used for top-up.
Borderline
nom >15-
20%
Water (%) Satisfactory
0.05% -
0.10%
Water can enter the oil via the compressor cylinders; always
check that inter-cooler drains are operated effectively.
Refrigeration oils cannot tolerate water at all.
Exceeds limit > 0.10%
Insolubles
(%)
Exceeds limit > 0.10%
Formed by carbon from oxidised oil, high insolubles will rapidly
foul air delivery valves and particles contaminants & wear
metals.
TAN
(mg.KOH)
Exceeds limit +/- 1.0
TAN should always be monitored by trend as the TAN of some
oils can fall from new then rise again as the oil ages.
Abrasive wear due to
insolubles

40. Gear Oil Analysis
Viscosity
(cSt at
40°C)
OK < +/- 15%
Viscosity increase is more common
than decrease. It should be noted and
checked at more frequent intervals.
Check that the correct grade of oil is
used for top-up.
Exceed >+/-20%
Water (%) OK
0.05% -
0.15%
Upper limit should be checked against
manufacturers’ data. Some oils
cannot tolerate water - BEWARE.
Steam turbine gearbox oils are often
more tolerant of water than most.
Synthetic oils can be less tolerant
than most.
Exceed > 0.20%
TAN OK
Refer to
manufactu
rers limits.
TAN should always be monitored by
trend as the TAN of some oils can fall
from new then rise again as the oil
ages.
Ferrous OK
Refer to
manufactu
rers limits.
Iron (ppm) should always be
monitored by trend as compared to
normal, as wearing rate is dependent
on operational conditions.

41. Trending, Cross-referencing & Alarms
Allow to extrapolate internal trend
Allow to forecast internal trend
X-Refering to other parameters to
confirm hyphothesis
X-Refering to other equipment data to
identify normal level
Simplify localise decision making
Traffic Light Green = OK &
Continue
Amber = Retest
& Report
Red = Change Oil /
Further Inspection

42. Further Analysis
Laboratory Wear Metal Analysis through XRF / AAS /
ICP
Identify other wear metals other than Ferrous
Identifying which components is wearing
Not able to detect metal of > 5 microns
Ferrography
Identify shape & sizes of wearing component
Identify the cause of wear
Confirming the stage of wear

43. Summary
• Oil Analysis provide earlier detection
of failure as compared to vibration
analysis
• Oil analysis provide 70% of
mechanical failure detection
• Early detection of contamination will
reduce failure rate
• Early detection of failure will reduce
cost of rectifications

44. Salamat Po
•Any Questions?
•www.kittiwake.com
•zainudin@cbmsolutions.com.my

45. www.kittiwake.com
sales@kittiwake.com
World Class Asset Protection