www.kittiwake.com

sales@kittiwake.com

How to manage an

Onsite Oil Analysis Programme Zainudin Yahya

Managing Director

CbM Solutions Sdn. Bhd.

August 2013

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

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

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.

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.

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

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.

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

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

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

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)

Application Specific Condition Monitoring

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

Kittiwake’s Global Presence

The Kittiwake group of companies

Kittiwake - Serving your needs on a global basis.

Shell Co-brand

Shell Analex Alert

Ferrous Debris Monitor

For marine market

Wartsila Co-brand

Wartsila Power Plant Test

Cabinet

Fuels & Lubricant test kits

For power plant market

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 University Varnishing in Turbine Bearing

Wear Debris Analysis

Vibration Analysis

Why Oil Analysis?

Contamination

Oil Condition

Machine condition

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

What does it takes?

NOTE

1. People

2. Time

3. Equipments

4. Money

5. Know – how

6. Long Term Commitments

7. Continuity

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!!!

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

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

Clean Oil Particle Test

Visual indication of cleanliness

Easy reference chart given

Easy to use

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

We

ar

Pa

rtic

le C

on

ce

ntr

ati

on

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

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

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

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?

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?

NOTE

1. Representative sample

2. Return line

3. Dipstick tube

4. Oil sump

5. Drum / supplier’s packaging

Where to take sample?

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?

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

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.

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

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

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

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

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.

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

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

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

Salamat Po

•Any Questions?

•www.kittiwake.com

•zainudin@cbmsolutions.com.my

www.kittiwake.com

sales@kittiwake.com

World Class Asset Protection