Gear box oil Analysis and oil testing importance

            Oil analysis is not just about telling us when oil has bad condition and also tells us as proactive measures to monitoring antioxidant additive concentrations should generate activities.

Despite being designed to be highly reliable, they bring about disruption and incurred costs when they wear or break due to contamination or poor operation. Oil analysis helps in detecting the developing failure conditions, and fundamentally, a majority of the gear manufacturers recommend condition monitoring, including oil analysis.

Coming to oil analysis we have to consider below mentioned points.                                          

1.     Viscosity: -

Viscosity is the resistance of a fluid to flow and is the most significant lubricant physical property for gear drives. It is necessary for lubricants to have appropriate flow properties to ensure that a sufficient supply of oil reaches lubricated parts at different operating temperatures.

2.     Ferrous Density: -

Ferrous density is a measure of the total amount of ferrous magnetic debris that exists in PPM and is measured using a magnetometer. Ferrous debris that ranges in size from sub-micron to visible will initiate a change in the electrical current proportional to the amount of metal that exists.

PPM means parts per million. 

3.     Water: -

The presence of water in oil is generally undesirable and can be visually detected in the presence of gross contamination (giving a cloudy appearance). Excessive water in a system destroys the potential of a lubricant to separate opposing moving parts, enabling severe wear to occur with ensuing high frictional heat.

Water measuring test: Karl Fischer test is used for finding water content in oil.


1.     TAN Value

Total acid number (TAN) is a titration technique developed to detect the relative acidity in a lubricant. It is used as a guide to follow the oxidative degeneration of oil in use. Oil changes are usually indicated when the TAN value attains a preset level for a given lubricant and application. A sudden drop in TAN would be suggestive of abnormal operating conditions of a system.

2.     Particle count

Particle count is a technique used for counting and categorizing particulate in a fluid according to accepted size ranges, often based on ISO standards. This test is very useful for improving the reliability as the reduction in particulates in the oil will increase the service life of the gearbox.

Monitoring the 4, 6, 12, 14, 20-, 25-, 75- & 100-microns particles.

What to Look for When Reviewing an Oil Analysis Report

1.     Read and check the data on the oil type and machine type for accuracy.

2.     Verify that reference data is shown for new oil conditions and that trend data is at an understood frequency (preferably consistent).

3.     Check the measured viscosity.

4.     Verify elemental wear data and compare to reference and trended data. Use a wear debris atlas to match elements to their possible source.

5.     Check the elemental additive data and compare to reference and trended data. Use a wear debris atlas to match elements to their possible source.

6.     Verify elemental contamination data along with particle counts and compare with reference and trended data. Use a wear debris atlas to match elements to their possible source.

7.     Check moisture/water levels and compare to reference and trended data.

8.     Verify the acid number and base number and compare to reference and trended data.

9.     Check other analyzed data such as FTIR oxidation levels, flash point, demulsibility, analytical ferrography, etc.

10. Compare any groups of data that are trending toward unacceptable levels and make justifications based on these trends.

11. Compare written results and recommendations with known information on the oil and machine, such as recent changes in environmental or operational conditions or recent oil changes/filtration.

12. Review alarm limits and make adjustments based on the new information.


Oil testing importance



1.     Maximizes equipment performance Oil testing helps to ensure that the oil used in equipment is performing at optimal levels.

2.     Reduces maintenance costs Regular oil testing can help to reduce maintenance costs by identifying problems before they escalate.

3.     Increases safety Oil testing helps to ensure that equipment is operating safely.

4.     Enhances oil quality.

5.     Planning oil replacement activity depends on oil analysis report due to this cost will reduce and more profitability.

6. Lower maintenance costs

7.     Improved reliability

8. Detection of increases levels of contamination before it can lead the problems.


 

 

 



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