Application Guide for Lubricant and Transformer Oil

Oil Analysis

Ref:OilTest_AG_E

TESTING PROCEDURES

Oil analysis is the evaluation of the oil itself and any contamination that is present. The information derived from the following tests looks for different types of wear and contamination. Each test looks at a different aspect of the oil. This is the reason for the different tests. The tests are as follows:

PHYSICAL TESTING

VISCOSITY

The viscosity test measures the thickness of the oil. The oil is heated and run through the viscosity bath. The results are then compared to the new oil specification. This test is valuable in determining the condition of the oil and an indicator of water contamination and oxidation.

Field SmartTest: H-VS1742 Viscometer

Online Mornitoring:TBD5xMD-VS1742

WATER CONTENT (GREATER THAN 1%)
The mechanical switches in circuit breakers and transformers must be insulated with transformer oil or SF 6 (sulfur hexafluoride) gas to protect the electrical current routing through them from arcing or "flash over." The higher insulating value of SF6 permits circuit designers to position switches closer to the walls of the enclosure and other components, resulting in smaller, lighter, and less costly switches. But if moisture migrates inside the enclosure, it contaminates the SF6, creating decomposition and toxic effects.

The oil used as insulation in power transformers is also adversely affected by moisture. In order to cushion the effects of the oil's expansion and contraction with temperature, a nitrogen blanket covers the oil. If moisture from the environment or from the oil itself enters the blanket, it can oxidize the switches and reduce efficiency.

Field SmartTest: H-BD5MS1204N10 Moisture Teller

Online Mornitoring:TBD5xMD-MS1204 Moisture Transducer

PARTICLE ANALYSIS

The particle count is the single most important part of the report to measure the efficiency of the system filtration. The particle count measures all particulate in the oil larger than 5 microns.

Particulate include: dirt, carbon, metals, fiber, bug parts, etc.

The particle count can be done using either laser or optical methods. The laser method reports the quantity, size and distribution of particulate, but not what they are. The optical method gives a quantity, size, distribution and identification.

A combination of these two methods are used in BDTI's PARTICLE ANALYSIS. Through the use of the two methods, we can provide the most representative analysis available.

Field SmartTest: P-BD5 PC4000 Particle Counter

Online Mornitoring:

1) TBD5xMD- PC1739 SPM Transducer Transducer (recommended)

2) CLA-PC4000 Particle Counter Transducer (more standard)

ELEMENTS ANALYSIS

SPECTROANALYSIS

Spectroanalysis is the analysis of the metal content and additive package. This test checks 19 elements and reports them in parts per million. These numbers represent the elements less than 5 microns in size. The spectrometers design limits its detection level to 5 microns and below. To evaluate the particulate larger than 5 microns, other test methods must be implemented.

The spectroanalysis is used to look for bearing or bushing wear in the form of copper, lead, or tin. The spectroanalysis also looks at dirt levels in the form of silicon. Wear in pumps, housings, and other points of contact can be evaluated using this information. It is important to remember that these are small particulate. If there are large particles of metals in the oil, larger than 5 microns, the spectroanalysis will not detect them. The larger particulate will be detected in the particle count and or the filter analysis, if the particulate are large enough.

The additive package of the oil can be identified and evaluated using the spectroanalysis.

X-Ray Analysis

Systems available to measure sulfur and lead, vanadium, nickel, iron... in diesel, gasoline, reformulated gasoline, kerosine, jet fuel, naphtha, residual oil, crude oil, heating oils, coker feed...

Field SmartTest: p-6640-300T Lab and in-situ X-ray Fluorescence Analyzer

Online Mornitoring: online 6640 XRFp X-ray Fluorescence Analyzer

OTHER TESTS

Other tests are needed in some situations. For example, some systems have a low tolerance to water content or acidity levels. Additional testing is required in these situations. The following is a brief description of additional tests and the information they provide:

Low WATER
BY KARL FISHER - ASTM D-1744. This test measures water content down to 50 parts per million, which is .005%. It is used in turbine system analysis, servo systems and any other system that has low tolerance.

Field SmartTest:

H-MS2100N Water Activity/Moisture Teller (0.01-1.0 a_w)

H-MS1204 Moisture Teller (100ppm-100%)

Online Mornitoring:

T-BD5xMD+lMS2100N Water Activity/Moisture STIM (0.01-1.0 a_w)；

T-BD5CMD+MS1204N Moisture Transducer (100ppm-100%)

CLA MS4120NIR Moisture Analyzer; (10ppm to13.5g/L)

TOTAL ACID NUMBER - ASTM D-664
This test measures the acidity level of a system. Over time the acidity level of the system increases. This can be detected with this test. In addition, some forms of contamination can also increase the acidity levels.

Field SmartTest: HBD5EC3226pH pH Analyzer

Online Mornitoring: T-BD5-EC3226pH pH Analyzer

FOAM TEST - ASTM D-892
In some systems high amounts of carbonization of oil occurs and pump cavitation is a problem. In these cases the oil could be foaming and causing these charastics. This test measures the ability of the oil to resist foaming when air is injected into the oil in a controlled environment. In many instances the problem, once identified, can be corrected by changing to a different type of oil.

FLASH POINT - ASTM D-3828
Each oil has a known flash point when it is porduced at the refinery. In some situations, contamination such as solvent, fuels, or other flammable substances are present in the system. This test is an indicator of this type of contamination. The procedure uses the new oil flash point as a base line, for example 525 degrees F. If the sample in question has a flash point of 250 degrees, then the oil could be contaminated with a flammable substance.

INFARED ANALYSIS
In many situations the customer is looking for the source of external contamination. This is initially discovered by a high particle count or short filter life. In some cases the contamination is due to a cross contamination of fluids. In this case we can run a foot print of the oil in question to determine if there is cross contamination.

In addition to cross contaminatoin situations, this test can also give information on oxidation, nitration, water content, and sulfur levels.

Desolved GASES ANALYSIS

Field SmartTest: Portable Chromatography.

Online Monitoring: online Chromatography

HEADSPACE GASES ANALYSIS

Field SmartTest:

pGas 2000TFODGA-Oil Fault Gas Analyzer

pGas 4630TFODGA-Oil Fault Gas Analyzer

Online Mornitoring:

PGA 2000TFODGA-Oil Fault Gas Analyzer

PGA 4630TFODGA-Oil Fault Gas Analyzer

* The headspace gas analysis is to evaluate the dissolved gases.