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PREDICT offers used oil services to PdM users requiring lubricant monitoring. The used oil test programs may be included in conjunction with our ferrography program or used as a stand alone tool. Various tests are offered to determine viscosity properties, additive package quality, and identification and severity of contamination. We offer customized programs that will cover any and all of your wear particle/used oil analysis needs.

Identification	Test Description	Purpose of Test
Machine Specific Analysis	Results from the following tests are reviewed by your Machine Condition Analyst and recommendations for your equipment is given with supporting data on each report.	Both Lubricant Condition & Equipment Condition are analyzed based on specific characteristics of your equipment, previous component performance, and test data.
Elemental Analysis	Elemental analysis is performed in accordance with atomic emission spectroscopy (AES). A specific volume of lubricant is energized using an electrical arc. The light frequencies and intensities are measured and reported in parts per million of various elements.	Elemental analysis is useful for identifying contamination, confirming additive content, and indicating system wear. The following elements are analyzed: Fe, Cr, Al, Pb, Sn, Cu, Ag, Ni, Na, V, Cd, Ti, Mo, Ca, Ba, P, Zn, B, K, Mg, and Si.
Water by Karl Fischer (ASTM D-4928)	Results from the following tests are reviewed by your Machine Condition Analyst and recommendations for your equipment is given with supporting data on each report.	Quantification of water contamination - water in a lubricant not only promotes corrosion and oxidation, but also may form an emulsion having the appearance of a soft sludge.
Total Acid Number (ASTM D664)	TAN is determined by titration of a known substance, such as KOH in order to determine an unknown quantity. Weighed samples are titrated using an automatic titration system	TAN of a used lubricant is one measure of its degree of degradation by oxidation.
Total Base Number (ASTM D4739)	TBN is determined by titration of a known substance, such as HCl, in order to determine an unknown quantity. Weighed samples are titrated using an automatic titration system.	TBN of a used lubricant is a measurement of its ability to neutralize the acid using basic buffers.
Infrared Analysis FT-IR	The infrared absorption spectrum of a lubricant furnishes a means of fingerprinting organic compounds and functional groups. Test results are trended and quantitative and qualitative determinations can be made.	Infrared analysis is often used for identifying additives and their concentrations, reaction products, and contamination by organic materials in used lubricants. Oxidation (carboxylic acids and esters), nitrate esters, water, soot, and glycol can be quantified.
Crackle	Eye Dropper test of lubricant on a hot plate heated to 100� C to determine presence of water. Detection can be made of water concentration > 800 ppm	This screening test is used by the analysts to check for water contamination and determination of whether more sensitive testing is required to determine more exact concentration.
Viscosity (Kinematic/Oil Bath ASTM D445/446)	ASTM test uses a constant temperature bath. The efflux time is measured between two points. The viscosity is computed by using a calibration constant and the efflux time. Viscosity is reported in centiStokes (cSt) at 40�C or 100�C.	Viscosity is the single most important property of a lubricant. A reduction usually indicates that the system has been contaminated with a solvent or refrigerant fluid. A significant increase normally is traced to mixture with a high viscosity product, contamination, or oil oxidation. Normal measurement range for 40�C is +30% and -20% and for 100�C is +20% and -10%.
Fuel Dilution of Diesel Lubricants (ASTM D3524-90) Gas Chromatograph	The sample is mixed with a specific amount of an internal standard. One microliter of the mixture is injected into a 10 meter HP-1 WCOT capillary column, heated at a specified rate, detected via a Flame Ionizing Detector, and the results (in percentages/peak area) are displayed in a report generated from the computer software	Some fuel dilution of the engine oil may take place during normal operation. However, excessive fuel dilution (> 5%) is of concern in terms of possible performance problems. Immediate effects of high fuel dilution are decreased lubricant viscosity resulting in increased wear.
Flash Point (ASTM D92)	The lubricant sample temperature is raised at a constant rate as the flash point is approached. At specified intervals, a small test flame is passed across the cup containing the sample. The lowest temperature at which application of the test flame causes the vapors above the surface of the liquid to ignite is taken as the flash point.	Flash Point indicates the presence of highly volatile and flammable materials in a relatively nonvolatile or nonflammable material. Example: an abnormally low flash point on a test specimen of engine oil can indicate fuel contamination.
Rotating Bomb Oxidation Test (ASTM D2272)	The test lubricant, water, and a copper catalyst coil contained in a covered glass container, are placed in a bomb equipped with a pressure gage. The bomb is charged with oxygen to a pressure of 620 kPa, placed in a constant-temperature oil bath set at 150�C, and rotated axially at 100 rpm at an angle of 30� from the horizontal. The number of minutes required to reach a specific drop in gage pressure is the oxidation stability of the test sample.	Test is used to assess the remaining oxidation test life of in-service lubricants.
Demulsibility (ASTM D1401-96)	40 ml of sample and 40 ml of distilled water are stirred for 5 min. at 54�C in a graduated cylinder. The time required for the separation of the emulsion thus formed is recorded or volumes of water, oil, and emulsion remaining after 30 minutes.	Test provides a guide for determining the water separation characteristics of oils subject to water contamination and turbulence.
Pour Point (ASTM D97)	After preliminary heating, the petroleum sample is cooled at a specified rate and examined at intervals of 3�C for flow characteristics. The lowest temperature at which movement of the specimen is observed is recorded as the pour point.	Determination of the lowest temperature at which a petroleum product may be used if fluidity is necessary to the application.
%Sulfur (ASTM D4294-90)	A petroleum sample is placed in the beam emitted from an X-ray source. The resultant excited characteristic X radiation is measured, and the accumulated count is compared with counts from previously prepared calibration samples to obtain the sulfur concentration in mass %.	The degree of sulfur concentrations in a petroleum product may be used to qualify the product's processing characteristics or compliance with environmental regulations.
Particle Count (ASTM D4406)	As particles in the lube flow pass a laser, the laser light is blocked allowing individual particles to be counted and sized. The resulting data is a distribution of the concentration of particles in various size ranges.	Since all contaminants in the oil are counted as particles, the particle count includes wear particles, soot, dirt, and other contaminates. This test provides information on lubricant cleanliness.
Foam Test (ASTM D892-95) Sequence I, II, III	A defined volume of air is forced through a set volume of sample lubricant at a specified temperature. The resulting volume of foam is measured	Determination of the foaming characteristics of lubricating oils at specified temperatures. Means of empirically rating the foam tendency and the stability of the foam.
Cone Penetration of Lubricating Grease (ASTM D 217)	A measured amount of grease sample is placed under a cone apparatus. The cone is attached to a gauge that measures from 85-475. The cone is dropped into the grease sample from a specified height and time. The measured amount that the cone penetrates into the grease is dropping point.	This test measures the consistency of grease. Harder grease will have a low NLGI rating number such as 00 or 1. Most industrial greases penetrate in the 265-295 ranges and have a NLGI rating of 2.
Dropping Point of Lubricating Greases (ASTM D566)	A grease sample is heated in the dropping point apparatus. The point where the grease starts separating and the oil drops out of the apparatus is the dropping point. The temperature is measured in degrees Celsius.	This test is a determination of the maximum operating temperature of grease.
% Sediment in Lubricating Oils	An oil sample is well shaken and dissolved in a solvent at a 1:1 ratio. The solvent: oil mixture is well shaken and 100 mls of sample is poured into two centrifuge tubes. The tubes are placed in the centrifuge at opposite ends and spun for 30 minutes. The sediment collected on the bottom is calculated and multiplied by two to give the total percentage of sediment in the oil.	This test is an excellent determination of sediments suspended in lubricating oil. Excessive amounts of sediments can impede oil capability

FERROGRAPHY & OIL ANALYSIS

Ferrographic wear particle analysis is a machine condition analysis technology that is applied to lubricated equipment. It provides an accurate insight into the condition of a machine's lubricated components by examining particles suspended in the lubricant.

By trending the size, concentration, shape, and composition of particles contained in systematically collected lubricant samples, abnormal wear-related conditions can be identified at an early stage.

Wear particle analysis complements vibration analysis by providing, in many cases, much earlier fault detection and is less susceptible to the limitationsimposed by slowly rotating
or reciprocating equipment. PREDICT acquired ferrographic wear particle analysis technologies in the early 1980's and has been the primary developer of this condition monitoring tool. Currently, we operate the world's largest commercial ferrography laboratory. Our systems and procedures have evolved over time, not merely keeping pace with technology, but driving it.

What you can't see can hurt your machinery. Large wear particles (of 10 microns or larger) abraded or broken from critical wear components, cannot be detected by standard, spectrographic used oil analysis. Used oil analysis gives you vitally important information about the condition of the lubricant within your equipment, but tells you nothing about the particles that are indicative ofimminent component failure. During the past 20 years, PREDICT professional analysts have analyzed abnormal wear particles in more than 22,000 individual machine components. We have correlated particle size, concentration, shape, and material composition to machinery wear related problems. This depth of knowledge in the science of ferrography provides your condition monitoring team the expertise to ensure your condition monitoring success.

Case Study:

On February 13, 1997, PREDICT received a sample from The Aristech Chemical Corporation in Haverhill, Ohio. This was taken from the Inboard Bearing on a Air Compressor Motor. The Direct Reading levels increased significantly, from 117 to 1,132. Ferrographic Analysis revealed very large white nonferrous metal wear particles. These particles measured up to 180 microns in size, and after heat treatment of the slide, it was determined that they were composed of a lead/tin babbitt. Water was also detected in the oil and excessive quantities of contaminants were present. The equipment was rated CRITICAL and this information was immediately conveyed to the General Foreman at the plant. Shortly afterwards an inspection was performed on the motor and it was discovered that the sleeve bearing was badly worn. The analysis provided to this customer resulted in a total cost savings of $11,800.