Lubricant Analysis and Condition Monitoring

Cover
Half Title
Title Page
Copyright Page
Dedication
Table of Contents
Preface
Author
Chapter 1 Introduction
	1.1 Purpose
	1.2 Approach
Chapter 2 Reasons for Analysing Lubricants and Monitoring Their Condition
	2.1 Introduction
	2.2 Methods to Define Lubricant Service Life
	2.3 Chemical Causes of Lubricant Deterioration
	2.4 Physical Causes of Lubricant Deterioration
	2.5 Deterioration of Machines and Equipment
	2.6 Relationships between Lubricant and Machine Deterioration
	2.7 Root Cause Analysis of Problems or Failures
	2.8 Failure Mode and Effect Analysis
	2.9 Summary
Chapter 3 Sampling Lubricants
	3.1 Introduction
	3.2 Sample Bottles
	3.3 Methods for Taking Lubricant Samples
		3.3.1 Oil Samples
			3.3.1.1 Drop Tube Sampling
			3.3.1.2 Drain Port Sampling
			3.3.1.3 Valve Sampling
			3.3.1.4 Safety Factors
		3.3.2 Grease Samples
	3.4 Sampling Locations
		3.4.1 Sampling Dry-Sump Circulating Systems
		3.4.2 Sampling Wet-Sump Circulating Systems
		3.4.3 Sampling Non-circulating Systems
		3.4.4 Multiple Sampling Points
	3.5 Sampling Frequency
	3.6 Summary
Chapter 4 Testing New Lubricants
	4.1 Introduction
	4.2 Organisations that Develop and Specify Tests for Lubricants
		4.2.1 American Society for Testing and Materials
		4.2.2 Coordinating European Council
		4.2.3 Institute of Petroleum (The Energy Institute)
		4.2.4 International Standards Organization
		4.2.5 Society of Automotive Engineers
		4.2.6 Comité Européen de Normalisation
		4.2.7 Deutsches Institut für Normung
		4.2.8 American National Standards Institute
		4.2.9 Association Français de Normalisation
		4.2.10 Japanese Automobile Standards Organization
	4.3 Sources of Defects with New Lubricants
	4.4 Particulate Contaminants
	4.5 Moisture Contamination
	4.6 Establishing a Baseline for Subsequent Testing and Monitoring
	4.7 Lubricant Storage
		4.7.1 Storage Vessels and Containers
			4.7.1.1 Bulk Storage in Tanks
			4.7.1.2 Drum Storage
			4.7.1.3 Plastic Bottles and Tin-Plate Cans
		4.7.2 Siting the Lubricants Store
			4.7.2.1 Indoor Storage
			4.7.2.2 Outdoor Storage
			4.7.2.3 Storage of Special Types of Lubricant
	4.8 Dispensing Lubricants
	4.9 Summary
Chapter 5 Testing Lubricants in Use
	5.1 Introduction
	5.2 Procedures for In-Service Testing of Lubricants
		5.2.1 Field Test Kits
		5.2.2 In-House Laboratories
		5.2.3 Independent Laboratories
	5.3 Sample Transportation
	5.4 Lubricant Analysis Flagging Limits
	5.5 Trend Analysis
	5.6 Lubrication and Lubricant Problems and Their Resolution
	5.7 Summary
Chapter 6 Chemical Tests for Lubricants
	6.1 Introduction
	6.2 Chemical Tests for Oils
		6.2.1 Acid Number
		6.2.2 Base Number
		6.2.3 Oxidation Resistance
		6.2.4 Anti-Oxidant Content
		6.2.5 Varnish Formation Potential
		6.2.6 Corrosion Resistance
		6.2.7 Copper Corrosion
		6.2.8 Emulsion Characteristics
		6.2.9 Demulsibility
		6.2.10 Hydrolytic Stability
		6.2.11 Foaming Properties
		6.2.12 Carbon Residue
		6.2.13 Ash and Sulphated Ash
		6.2.14 Insolubles Contents
		6.2.15 Dissolved Gas Analysis
		6.2.16 Water Content
		6.2.17 Sulphur, Nitrogen and Phosphorous Contents
		6.2.18 Metals Contents
		6.2.19 Fourier Transform Infrared Spectroscopy ( FTIR)
	6.3 Chemical Tests for Greases
		6.3.1 Corrosion Resistance
		6.3.2 Copper Corrosion
		6.3.3 Oxidation Resistance
		6.3.4 Metals Contents
	6.4 Future Chemical Tests for Oils and Greases
	6.5 Summary
Chapter 7 Physical Tests for Lubricants
	7.1 Introduction
	7.2 Physical Tests for Oils
		7.2.1 Colour
		7.2.2 Density
		7.2.3 Kinematic and Dynamic Viscosity
		7.2.4 Apparent Viscosity
		7.2.5 Low-Temperature Viscosity
		7.2.6 Viscosity Index
		7.2.7 Pour Point
		7.2.8 Flash Point
		7.2.9 Volatility
		7.2.10 Air Release
		7.2.11 Electrical Properties
		7.2.12 Ultrasound
		7.2.13 Particle Counts
		7.2.14 Ferrography
	7.3 Physical Tests for Greases
		7.3.1 Penetration
		7.3.2 Apparent Viscosity
		7.3.3 Pumpability and Flow Properties
		7.3.4 Dropping Point
		7.3.5 Oil Separation
		7.3.6 Tackiness
	7.4 Future Physical Tests for Oils and Greases
	7.5 Summary
Chapter 8 Mechanical Rig Tests for Lubricants
	8.1 Introduction
	8.2 Requirements for Mechanical Rig Tests for Lubricants
	8.3 Mechanical Rig Tests for Oils and Greases
		8.3.1 Four-Ball Wear and Weld Load Tests
		8.3.2 Falex Pin and Vee Tests
		8.3.3 Timken Machine Test
		8.3.4 SRV Tests
		8.3.5 Pin-on-Disk Tests
		8.3.6 FE-8 Bearing Rig Test
		8.3.7 FZG Test
		8.3.8 Filterability Tests
		8.3.9 Shear Stability Tests
	8.4 Future Mechanical Rig Tests for Oils and Greases
	8.5 Summary
Chapter 9 Engine Tests for Lubricants
	9.1 Introduction
	9.2 Engine Tests
	9.3 Field Tests
	9.4 Summary
Chapter 10 Condition Monitoring of Engines
	10.1 Introduction
	10.2 Gasoline and Light-Duty Diesel Engine Oils Used in Cars, Vans and Taxis
	10.3 Heavy-Duty Diesel Engine Oils Used in Trucks and Buses
		10.3.1 Oil Drain Intervals
		10.3.2 Wear Metals
		10.3.3 Fuel Contamination
		10.3.4 Coolant Contamination
		10.3.5 Other Contaminants and Products of Degradation
		10.3.6 Lubricant Formulations and Additives
		10.3.7 Alarm Limits for Heavy-Duty Diesel Engine Oils
	10.4 Oils Used in Hybrid and Electric Vehicles
	10.5 Two-Stroke and Four-Stroke Oils Used in Motorcycle Engines
	10.6 Oils Used in Marine Engines
		10.6.1 Two-Stroke and Four Stroke Diesel Engine Oils
		10.6.2 Liquefied Natural Gas Engine Oils
	10.7 Natural Gas and Biogas Engine Oils
	10.8 Industrial and Off-Highway Engine Oils
	10.9 Railroad Engine Oils
	10.10 Summary
Chapter 11 Condition Monitoring of Gears and Transmissions
	11.1 Introduction
	11.2 Types of Gears and Their Lubrication
	11.3 Monitoring of Automotive Gears
	11.4 Automatic Transmissions
	11.5 Monitoring Industrial Gears
	11.6 Bearings
	11.7 Wind Turbines
	11.8 Chains
	11.9 Couplings
	11.10 Summary
Chapter 12 Condition Monitoring of Hydraulic Systems
	12.1 Introduction
	12.2 Hydraulic Oil and Hydraulic System Issues
	12.3 Hydraulic Oil Performance
	12.4 Monitoring Hydraulic Oils and Systems
	12.5 Hydraulic Fluid Filtration and Contamination Control
	12.6 Monitoring Fire-Resistant Hydraulic Fluids
		12.6.1 High Water-Based Hydraulic Fluids
		12.6.2 Water Glycol Hydraulic Fluids
		12.6.3 Phosphate Ester Hydraulic Fluids
	12.7 Summary
Chapter 13 Condition Monitoring of Compressors and Turbines
	13.1 Introduction
	13.2 Air Compressors
	13.3 Gas Compressors
	13.4 Refrigeration and Air Conditioning Compressors
	13.5 Steam and Gas Turbines for Electricity Generation
	13.6 Aviation Gas Turbines
	13.7 Water (Hydroelectric) Turbines
	13.8 Summary
Chapter 14 Condition Monitoring of Metalworking and Production Engineering Fluids and Pastes
	14.1 Introduction
	14.2 Production Engineering Processes
		14.2.1 Metalworking and Metal Forming
		14.2.2 Heat Treatment ( Quenching)
		14.2.3 Temporary Corrosion Protection
	14.3 Types of Metalworking Fluids
	14.4 Types of Metal Forming Fluids and Pastes
	14.5 Types of Heat Treatment Fluids
		14.5.1 Quenching Oils
		14.5.2 Polymer Quenchants
		14.5.3 Water and Salt Solution Quenchants
	14.6 Types of Temporary Corrosion Protectives
	14.7 Testing Methods for Production Engineering Fluids and Pastes
	14.8 Monitoring and Control Methods
		14.8.1 Metalworking Fluids
		14.8.2 Metal Forming Fluids and Pastes
		14.8.3 Heat Treatment Fluids
		14.8.4 Temporary Corrosion Preventatives
	14.9 Presentation of Results
	14.10 Summary
Chapter 15 Condition Monitoring of Automotive and Industrial Greases
	15.1 Introduction
	15.2 Types of Greases and Solid Lubricants
	15.3 General Condition Monitoring for Greases
	15.4 Grease Lubrication for Bearings
	15.5 Monitoring Automotive Greases
	15.6 Monitoring Industrial Greases
	15.7 Summary
Chapter 16 Lubricant Condition Monitoring Programmes, Their Implementation, Benefits and How to Avoid Problems
	16.1 Introduction
	16.2 Developing a Condition Monitoring Programme
	16.3 Predictive Maintenance of Machines, Equipment and Systems
	16.4 Lubricant Sampling Issues
	16.5 Contamination Control
	16.6 Assessing Analytical Results and Trend Analysis
	16.7 Solving and Correcting Problems
	16.8 Summary
Glossary
Index