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Oil analysis services are a relatively inexpensive and simple way to help monitor the condition of the oil & the equipment used within a system. \u00a0One of the largest advantages of sampling & analyzing oil is the early detection of system issues – potentially preventing larger problems in the future. \u00a0Our state of the art testing laboratory is equipped with automated processes, instruments, and advanced technologies that enable us to deliver consistent and accurate test results. We apply our technical expertise to an extensive range of analytical, physical, and mechanical testing capabilities, demonstrating our commitment to keeping your valuable equipment running efficiently.<\/p>\n
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Routine analysis of oil samples properly taken from your compressor(s) can offer many benefits. \u00a0Some of these include:<\/p>\n
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[\/et_pb_image][et_pb_toggle title=”Oil Analysis FAQs” _builder_version=”3.22.7″]<\/p>\n
Oil analysis is a relatively inexpensive and simple way to help monitor oil condition and equipment condition while possibly preventing big problems from showing up down the road.<\/p>\n
During an oil analysis, a small amount of oil is analyzed for additive elements and contaminant and wear metals. The oil is also tested for its physical characteristics, such as viscosity, and for chemical properties, such as TAN. The results of these tests can give the user an indication of the condition of both the oil and the equipment. The main purpose of oil analysis is to generate information about the condition of the lubricant and the equipment. This information can be used to:<\/p>\n
Trend Analysis is based on current and past sample results where changes in the tested result can indicate the development of problems that can affect the lubricant and compressor performance. The result may be within the products specifications. Trend Analysis plays an important role in determining proper drain intervals as well as in predicting equipment failure.<\/p>\n
Marginal means that the results are still within specifications but are close to the condemning limits.<\/p>\n
Four ounces is need for routine oil analysis.<\/p>\n
Although the original equipment manufacturer’s (OEM) recommendations provide a good starting point for developing preventative maintenance practices, sampling intervals can easily vary. Extreme conditions and applications can affect the sampling interval. The completed oil analysis report can provide guidance on when a new sample should be taken.<\/p>\n
All customer, distributor, lubricant, and equipment information needs to be entered onto the sample label in order to process the sample. Include on the sample label if there was a lubricant or filter change during sampling. It is imperative that the sample label be applied directly to the plastic sample bottle, not the cardboard canister. The mailing label can be applied to the cardboard mailing canister or if using a box to send in more than one sample, it can be attached to the outside of the box and therefore, does not need to be applied to the canister. Missing information from the sample label can result in a longer turn around time as the laboratory will need to request the information before the sample can be processed.<\/p>\n
The laboratory processes most routine samples within 2-3 business days. An Oil Analysis Report will be emailed to the customer contacts with recommendations or customers and distributors can access their reports through the website. The website will show if the sample is completed or in process. If you do not receive your report within the 2-3 business days and the tracking number shows we received the sample, please call 1-800-637-8628 to inquire about the delay.<\/p>\n
A compressor cleaner is used to remove varnish, dirt, and oxidized fluid from a compressor. They are also used to flush a system when converting to a different lubricant to prevent contamination between the two different fluids. A compressor cleaner has a short life, <500, hours so additional fills of compressor cleaner could be needed depending on the cleanliness of the system. More varnished systems will require multiple fills of compressor cleaner.<\/p>\n
The maximum life of a compressor cleaner is 500 hours. It is recommended to test the compressor cleaner every 200 hours to monitor the condition of the compressor cleaner.<\/p>\n
Viscosity is a measure of a fluid\u2019s resistance to flow. It is one of the most important physical properties of a lubricant. If a lubricant does not have the proper viscosity, it may not flow to the equipment parts that need protection, or have sufficient film thickness to provide adequate lubrication. Kinematic viscosity is the measure of a fluid\u2019s resistance to flow under gravity at a specific temperature.<\/p>\n
The main cause for a fluid\u2019s viscosity to increase is due to oxidation. Contamination and evaporation can also cause the viscosity to increase. If the viscosity is too high it can result in:<\/p>\n
Decreased viscosity can be caused by chemical ingestion, solvent contamination, or different fluid contamination. If the viscosity is too low it can result in:<\/p>\n
The main cause for a fluid\u2019s TAN to increase is oxidation. Lubricant hydrolysis and contamination can also cause the TAN to increase.<\/p>\n
Oxidation is a process that occurs when a lubricant is exposed to oxygen. The negative effects of oxidation on an oil product include acid formation, sludge and varnish formation, increased viscosity, and lubricant decomposition. Since the major component of a lubricant, and base oil, is also the component that is most susceptible to oxidation, controlling this process is particularly important. A number of factors can accelerate the oxidation process, including increased temperatures and the presence in the lubricant of acids and metallic catalysts. Two of the most common causes of accelerated lubricant oxidation are high operating temperatures and over-extension of the drain interval. Oxidation stability is the ability to resist the oxidation process. Oil with good oxidation stability will typically have a longer working life than an oil with poor stability, and may hold up better under extended drain operation conditions.<\/p>\n
The by-products of oxidation can lead to the formation of a varnish contamination. The varnish is what causes the smell of crayons. There are many problems associated with fluid that has varnished but one of the main problems is increased component wear due to varnish attracting dirt and contaminant particles. There will also be increased maintenance costs due to cleanup and disposal of oil.<\/p>\n
Antioxidants are one of the primary additives used in lubricant formulations. The main function of the antioxidant is to prevent the lubricant from breaking down. When a lubricant breaks down, it will typically result in polymerization or volatilization of the oil. The antioxidant prevents this by reacting with the breakdown product of the lubricant to prevent further decomposition. For this reason, the antioxidant level in a lubricant will drop with time or is considered sacrificial. An increase in Total Acid Number is a direct correlation to the depletion of antioxidants.<\/p>\n
Moisture content of a lubricant is important as the presence of water, even at low levels, can:<\/p>\n
The results formulate the ISO (International Standards Organization) code fraction. The ISO code (i.e. 3\/2\/1) represents the ratio between particles present at levels greater than 4 micron (the denominator(1)) versus the particles present at levels greater than 6 micron (the middle number (2)) versus the particles present at levels greater than 14 micron (the numerator (3)).<\/p>\n
The particle count test is counting metal particles and non-metallic particles. Non-metallic particles could consist of water, dirt, or any solid material. The particle count test can not distinguish from metallic and non-metallic particles.<\/p>\n
Wear metals are minute particles of metal formed from the erosion between moving parts, abrasion, or corrosion. Wear metals are related to surface interactions and more specifically the removal of material from a surface as a result of mechanical action.<\/p>\n
Contaminant metals cause the fluid to be impure. These impurities can come from ground water, coolant, or another fluid type. \u00a0Additive metals are any material added to a base stock which enhances the existing properties of the base oil and\/or imparts new performance properties. Additives are used as anti-wear agents, detergents, pour point depressants, rust and corrosion inhibitors, foam inhibitors, etc. \u00a0Particles include metallic and non-metallic, fibers, dirt, water, bacteria and any other kind of debris.<\/p>\n
Common Sources of metals:<\/p>\n
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Karl Fischer Operations<\/strong><\/p>\n The Karl Fischer method is used for many substances as a reference method. It is a chemical analysis procedure which is based on the oxidation of sulfur dioxide by iodine in a methanolic hydroxide solution. In principle, the following chemical reaction takes place:<\/p>\n H2O + I2 + SO2 + CH3OH + 3RN -> [RNH] SO4CH3 + 2[RNH] I<\/p>\n The titration can be performed volumetrically or coulometrically. In the volumetric<\/i> method a Karl Fischer solution containing iodine is added until the first trace of excess iodine is present. The amount of iodine converted is determined from the burette volume of the iodine-containing Karl Fischer solution.<\/p>\n In the coulometric<\/i> procedure, the iodine participating in the reaction is generated directly in the titration cell by electrochemical oxidation of iodide until again a trace of unreacted iodine is detected. Faraday’s law can be used to calculate the amount of iodine generated from the quantity of electricity required.<\/p>\n Importance of the Karl Fischer Test<\/strong><\/p>\n The Karl Fischer test is important because it informs the user how much dissolved water is in their system. High water can cause coalescing filter and bearing damage\/failure. It also causes corrosion in the compressor.<\/p>\n <\/p>\n Total Acid Number (TAN) Operations<\/strong><\/p>\n The total acid number (TAN) is the number expressed in milligrams (mg) of potassium hydroxide needed to neutralize the acid in one gram of oil. The test is used to indicate the amount of oxidation that the fluid has undergone. The acid number increases as the fluid begins to oxidize.<\/p>\n Importance of the TAN Test<\/strong><\/p>\n The TAN test is used to condemn nearly all fluid types, thus a precise and accurate analysis is crucial. The TAN signifies the basic condition of the fluid by giving a value that signifies the amount of oxidation that the fluid has undergone. The TAN can also indicate if a compressor is running too hot, or if the compressor is ingesting a foreign chemical that is harmful to the lubricant and\/or the compressor.<\/p>\n <\/p>\n Particle Count Operations<\/strong><\/p>\n The particle count uses a laser diode as the illumination source and a photodiode as the detector. The particles pass through a sensor. When particles are present within the sensor\u2019s micro cell, the particles block the laser beam from the photodiode detector. The loss of laser light generates an electronic pulse for each particle. These pulses are proportional in amplitude to the light intensity or light extinction, which is a measure of the particle size. The particle counter identifies the quantity and the height of the pulses by sorting the pulses into bins with predefined pulse amplitude ranges. The data is transferred to digital numbers and printed. The test breaks the size ranges down from 4-70 microns. The results formulate the ISO (International Standards Organization) code fraction. The ISO code (i.e. 3\/2\/1) represents the ratio between particles present at levels greater than 4 micron (the denominator(1)) versus the particles present at levels greater than 6 micron (the middle number (2)) versus the particles present at levels greater than 14 micron (the numerator (3)).<\/p>\n Importance of the Particle Count Test<\/strong><\/p>\n The importance of particle count analysis includes: identification of solid material, identifying abnormal wear conditions, monitoring the effects of filtration, and measuring overall system cleanliness.<\/p>\n Particle Count Values<\/strong><\/p>\n The rule for all fluids that are completed is based on the ISO Code. If the third number is greater than 19 we will ask for a filter change or a fluid change depending on fluid type. (>XX\/XX\/19).<\/p>\n <\/p>\n Kinematic Viscometer Operations @ 40\u00baC<\/p>\n The term viscosity is defined as the internal resistance of a liquid to flow over a certain amount of time with larger numbers relating to thicker fluids. Kinematic viscosity is the measure of a fluid\u2019s resistance to flow under gravity at a specific temperature. The S.I. unit for the measurement of viscosity is the centistoke (cSt). A fixed volume of liquid flows under gravity through a calibrated viscometer capillary, under a reproducible driving head and at a closely controlled and known temperature, 40\u00baC. If the oil increases in viscosity, it means that the oil is becoming thicker. The most common cause of increased viscosity is oxidation. Oxidation is a normal process of a lubricant and is the reason for most oil changes.<\/p>\n Importance of the Viscosity Test<\/strong><\/p>\n The viscosity test is considered the most imperative property of lubricating oils, and an active indicator of the oils\u2019 functionality. The viscosity can be used to indicate high operating temperatures, contamination of another fluid, overloading, and water\/coolant contamination conditions. An increase or decrease in viscosity can lead to overheating, increased friction, and ultimately catastrophic failure.<\/p>\n <\/p>\n With ICP emission, elemental concentrations are determined by measuring light intensities at discrete wavelengths. Because the ICP is a very high temperature source, it emits many thousands of wavelengths – a “complex spectrum”. The job of the spectrometer’s optics is to make sense of this information and the best way to do this is to use an Echelle optical system with a large output format.<\/p>\n The ICP’s Echelle optics disperse the spectrum, widely separating the wavelengths thereby minimizing interferences and the need for inter-element corrections. The design also improves resolution – the ability of a spectrometer to distinguish between two closely spaced wavelengths – without reducing the amount of light that gets to the detector.<\/p>\n Metals analysis determines what wear and contaminant metals are present. The particles are <5 microns when in solution. The detection limit is 1 ppm. Al, Ag, Ba, Ca, Cr, Cu, Fe, Mg, Mo, NA, Ni, P, Pi, Si, Tn, V, and Zn are the significant metals being analyzed.<\/p>\n The importance of ICP Analysis is to monitor lubricant additive levels, identify abnormal wear conditions, and determine if contamination is present in the lubricant.<\/p>\n <\/p>\n [\/et_pb_toggle][et_pb_toggle title=”Sample Collection Guidelines” _builder_version=”3.0.105″]<\/p>\n <\/p>\n Consistently following proper sample-taking guidelines is vital to ensuring that the analysis data you receive is the best representation of the lubricant within your system. Utilizing proper sampling techniques will allow for better data consistency &\u00a0accuracy when determining the condition of your lubricant. Inconsistent sampling will cause the trend analysis, which is used to determine the condition of the fluid, to be inaccurate. \u00a0This could compromise early detection of potential issues in compressor systems often identified with an accurate trend analysis.<\/p>\n There are several tools that can be utilized to help ensure the sample taking process is consistent over time. While specific tools will not be mentioned,\u00a0the guidelines below focus on the appropriate locations &\u00a0timing of collecting the\u00a0lubricant sample.<\/p>\n [\/et_pb_toggle][et_pb_toggle title=”Flushing Procedures” _builder_version=”3.0.105″]<\/p>\n <\/p>\n <\/p>\n <\/p>\n <\/p>\n <\/p>\n <\/p>\n [\/et_pb_toggle][\/et_pb_column][\/et_pb_row][\/et_pb_section][et_pb_section fb_built=”1″ _builder_version=”3.23.3″ background_color=”#0c71c3″ inner_width_tablet=”50px” inner_max_width_tablet=”50px” custom_margin=”-2px|||||” custom_padding=”0px|0px|0px|0px|false|false” top_divider_style=”ramp” top_divider_color=”#ffffff” top_divider_height=”56px” top_divider_flip=”vertical” z_index_tablet=”500″ box_shadow_horizontal_tablet=”0px” box_shadow_vertical_tablet=”0px” box_shadow_blur_tablet=”40px” box_shadow_spread_tablet=”0px”][et_pb_row _builder_version=”3.25″ custom_padding=”0px|0px|65px|0px|false|false”][et_pb_column type=”4_4″ _builder_version=”3.0.47″ custom_padding=”|||” custom_padding__hover=”|||”][\/et_pb_column][\/et_pb_row][\/et_pb_section][et_pb_section fb_built=”1″ _builder_version=”3.24″ background_image=”https:\/\/cpifluideng.com\/wp-content\/uploads\/2019\/04\/AdobeStock_188987457-copy.jpg” custom_padding=”60px|0px|54px|0px” top_divider_style=”ramp” top_divider_color=”#0c71c3″ top_divider_height=”56px” top_divider_flip=”horizontal|vertical” z_index_tablet=”500″ box_shadow_horizontal_tablet=”0px” box_shadow_vertical_tablet=”0px” box_shadow_blur_tablet=”40px” box_shadow_spread_tablet=”0px” saved_tabs=”all”][et_pb_row column_structure=”1_5,3_5,1_5″ _builder_version=”3.25″ background_size=”initial” background_position=”top_left” background_repeat=”repeat”][et_pb_column type=”1_5″ _builder_version=”3.25″ custom_padding=”|||” custom_padding__hover=”|||”][\/et_pb_column][et_pb_column type=”3_5″ _builder_version=”3.25″ custom_padding=”|||” custom_padding__hover=”|||”][et_pb_code _builder_version=”4.9.7″ _module_preset=”default” hover_enabled=”0″ sticky_enabled=”0″]Total Acid Number<\/strong><\/h4>\n
Particle Count<\/strong><\/h4>\n
Kinematic Viscosity<\/strong><\/h4>\n
Spectrochemical Analysis by Inductively Coupled Plasma (ICP)<\/strong><\/h4>\n
Guidelines for Successful Sample Collection<\/strong><\/h2>\n
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Recommended Flushing Procedures<\/strong><\/h2>\n
Flushing Non-Varnished or Non Oxidized Units<\/strong><\/h4>\n
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Flushing Slightly High Total Acid Number Machines (TAN 1.5-5.0)<\/strong><\/h4>\n
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Flushing Medium to Heavy Varnished Machines (TAN >5.0-10.0)<\/strong><\/h4>\n
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Extremely Varnished Machines (TAN >10.0)<\/strong><\/h4>\n
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Flushing Varnished Vacuum Pumps or Vane Air Compressors<\/strong><\/h4>\n
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Flushing Food Grade Application Machines<\/strong><\/h4>\n
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