WEBINAR

LUBRICANT CONTAMINATION
CONTROL
11 Februari 2021
Maintenance Strategies
Run to Failure
• Use and change with the new one when it is fail to function

Preventive Maintenance (PM)

• Change its part periodically, to prevent the system to un-function

Predictive Maintenance (PdM)

• Scheduling test / check for the system part

Proactive Maintenance (PAM)

• Inspect, Test and Analyze to find the root cause to prevent to system from un-function
2
Why Perform Oil Analysis?
to understand the condition of the oil and to unveil
the condition of the machine.

Oil analysis categories: Viscosity?

TAN/TBN?
A. fluid properties Oxidation?
B. contamination Water content?
Oil Cleanliness?
C. wear debris Wear metal?
PQ index?

Oil Analysis Basics - Jim Fitch & Drew Troyer

A. Fluid Properties
Focus on oil’s current physical and chemical properties as well
as on defining remaining oil life (RUL). It answers questions
such as:

Does the sample match the specified oil

identification?
Is it the correct oil to use?
Are the right additives active?

Have additives depleted?

Has the viscosity shifted from the expected
viscosity? If so, why?
What is the oil’s RUL?
Oil Analysis Basics - Jim Fitch & Drew Troyer
B. Contamination
Detecting destructive contaminants and narrowing down their
both internal or external probable sources, and can help answer
questions such as:

Is the oil clean?

What types of contaminants are in
the oil?
Where are contaminants
originating?
Are there signs of other types of
lubricants?
Is there any sign of internal
leakage?

Oil Analysis Basics - Jim Fitch & Drew Troyer

 C. Wear Debris
Determining the presence and identification of particles produced
as a machine surface degradation. It answers questions relating to
wear, including:

Is the
machine
degrading
abnormally?

From which
internal
Is wear
component
debris
is the wear
produced?
likely
originating?

What is
the wear How severe is
the wear maintenance.org
mode and
cause? condition?

atten2.com

Oil Analysis Basics - Jim Fitch & Drew Troyer

 Benefit of Oil Analysis
• Reduce unnecessary work orders. Perform maintenance on-
condition.
• Troubleshoot problems with more precision and less
guesswork.
• Early detection of fault and failure avoid large repairs and
collateral damage.
• Reduce component replacement costs by extending machine
life using the proactive maintenance strategy.
• Optimize lubricant life and perform condition-based oil
changes to cut lubricant consumption costs.
• Avoid production losses and unnecessary downtime

https://www.machinerylubrication.com/
LUBRICANT CONTAMINATION
 Contaminants

Kontaminasi merupakan salah satu penyebab utama terjadinya

kerusakan pelumas dan keausan mesin

Pengendalian Kontaminasi sangat penting & strategis untuk

‘Proactive Maintenance Program’
 Outline Presentation
1. Water Contamination
2. Particle Contamination
3. Filtration and Filter Rating
4. Soot Contamination
5. Fuel Contamination (Fuel Dilution in Oil)
WATER CONTAMINATION
 Kontaminasi Air (1)
Sumber Penyebab
• Lingkungan : Air dapat juga berasal dari
Air berasal dari lingkungan sekitar kondensasi pada ceiling & dinding
operasi. Hujan, bocornya saluran headspace tangki atau reservoir.
pendingin, wash-down sprays
merupakan sumber potensi Dan bisa juga karena kebocoran
masuknya air melalui seal, vent, seal.
reservoir, pelumas baru.
• Kebocoran saluran pendingin :
• Kondensasi :
Saluran pendingin dpt pecah karena
Operasi mesin yang terlalu sering bahan kimia pendinginnya atau
start & stop akan meningkatkan pipanya mengalami erosive wear,
proses kondensasi. sehingga air pendingin masuk ke
dalam sistem pelumasan.
 Kontaminasi Air (2)
Pengaruh pada Pelumas Pengaruh pada Mesin

• Air akan bereaksi dengan aditif • Free & emulsified water

membentuk endapan dan dapat menurunkan kekuatan
senyawaan yang berbahaya lapisan pelumas sehingga
• Air dapat bertindak sebagai berpotensi terjadi
katalis yang mempercepat peningkatan keausan
oksidasi terutama bila ada (abrasive, adhesive, fatique
wear metal seperti Cu, Fe, Pb wear)
• Air merupakan media • Air menyebabkan korosi
pertumbuhan mikroba, dapat pada permukaan besi dan
menyebabkan dekomposisi baja
menghasilkan senyawaan
asam yang mempercepat
oksidasi dan penyumbatan
filter (plugging)
 States of Coexistence
1. Dissolved water, is characterized by
individual water molecules dispersed
throughout the oil. Most industrial oils can
hold 0.02 to 0.06 % water in the dissolved
state depending temperature and age of the
oil
2. Emulsified water in oil, after water
exceeded maximum level of dissolved water
in oil, it will suspended in the oil in
microscopic droplets known as emulsion.
Reffered as hazy or cloudy
3. Addition more water to an emulsified
oil/water mixture will lead separation the
two phases producing a layer of free water
Oil Analysis Basics - Jim Fitch & Drew Troyer
as well as free and/or emulsified oil.
 Karl Fischer, Distillation and FTIR

Karl Fischer ASTM D 6304 Distillation ASTM D 95 FTIR ASTM E 2412

Chemical Reaction Boiling Point Characteristic Molecule Vibration

Can detect water until 10 Minimum detection 500 Only detect in the unit of
ppm ppm Absorbance
(0.05%vol)
Weak to be used for - -
Engine Oil, and Gear Oil

Chapter
15
08 -
 Detecting water by field test
Visual Check
Clear Hazy Opaque
< 100 ppm 350 – 500 ppm > 1000 ppm

Crackle Test Amount of water,

Appearance of oil
ppm  Crackle Test done with
0 Bright and clear burnings oil in the
100
Trace of translucent plate
haze
 Oil with water content
200 Slight translucent haze > 500 ppm will make
250 Translucent haze “crackle” sound
500 Opaque haze  More hard and
1000
Opaque haze with slight frequent the crackle
water drop out and the bubbles, more
high the water content
 General Condemning Limit for Water Content
in Lubricating Oil

Water Content Max

Equipment Method Unit
Attention Critical

Karl Fischer
Compressor ppm 350 500
(ASTM D 1744)
Karl Fischer
Turbine ppm 350 500
(ASTM D 1744) Reference:
ASTM D 6224
Gearbox “In-Service Monitoring of Lubricating
ASTM D 95 %vol 0.1 0.2
System Oil for Auxiliary Power Plant
Equipment”
Karl Fischer
Pump ppm 350 500
(ASTM D 1744) ASTM D 4378
“Standard Practice for In-Service
ASTM D 95 or Monitoring of Mineral Turbine Oils
Hydraulic Karl Fischer %vol 0.05 0.1 for Steam and Gas Turbines”
(ASTM D 1744)
Engine ASTM D 95 %vol 0.05 0.1
 Infrared Analysis
 Often used for Lubricant Finger
Print Test
 Very effective to decide whether
the oil is original or fake by
comparing the graphical finger
print

Frequent used for Oil Analysis for:

- Water detection
- Fuel Dilution Detection
- Soot Detection
- Glycol detection
- Oxidation
- Nitration
- Sulphating

Unit = Absorbance
How Fourier Transform Infrared (FTIR) Works
Example of FTIR overlay graph
Certain
molecule will
vibrate

IR Radiation
Sample
Oli
Detector

IR radiation is passed through a sample. Some of

the infrared radiation is absorbed by the sample
and some of it is passed through (transmitted).
The resulting spectrum represents the molecular
absorption and transmission, creating a molecular
fingerprint of the sample
Reference: Thermo Nicolet
http://mmrc.caltech.edu/FTIR/FTIRintro.pdf
Simple Guidance to Analyze FTIR Wave Number
Wave Number
Suspected Source
(cm-1)
Mineral Oil – 1750
Oxidation Oraganic Ester – 3450
Phosphat Ester - 815
Suphation 1150

Nitration 1630

Soot 2000

Mineral Oil – 3400

Water
Organic Ester - 3625

Glycol 880, 3400, 1040 and 1080

Diesel – 800
Fuel Gasoline – 750
Jet Fuel: 795-815

Phenol Inhibitors 3650

ZDDP Anti-Wear / Anti Oxidant 980

Source: NORIA
PARTICLE CONTAMINATION
 Particle Contamination (1)
• Partikel abrasif akan meningkatkan
pembentukan wear yang dapat
mengakibatkan terjadinya kerusakan
mekanikal.
• Besarnya kerusakan yang ditimbulkan
tergantung pada ukuran (size), bentuk
(shape), kekerasan (hardness) dan
susunan kimia.

Sumber Kontaminan
• Kontaminasi saat top up Pelumas :
Penggunaan wadah, selang, corong yang kurang bersih saat top up
pelumas
• Filtrasi:
- Filter udara/oli yang sudah penuh kotoran / rusak dapat melepaskan
kembali partikel kotorannya (desorption).
- Tutup filter udara tidak rapat dan bocornya selang-selang sistem filter
udara merupakan celah masuknya debu ke dalam sistem pembakaran
 Particle Contamination (2)
Pengaruh pada Pelumas Pengaruh pada Mesin
• Partikel debu (Silika) • Partikel abrasif akan meningkatkan
meningkatkan proses abrasi pada pembentukan wear yg
komponen mesin sehingga mengakibatkan komponen
meningkatkan keausan mesin mekanikal cepat rusak.
• Partikel khususnya partikel logam • Pada kondisi sliding, partikel yang
spt tembaga (Cu), besi (Fe) dan berukuran lebih kecil dari tebal
timbal (Pb) merupakan katalis lapisan pelumas akan menggores
yang dapat mempercepat proses komponen metal (cutting wear).
oksidasi pelumas. • Pada kondisi rolling contact,
• Partikel-partikel akan menurunkan dimana partikel berada di antara
polaritas aditif (antiwear, extreme dua komponen yg bergerak dapat
pressure, rust inhibitor, menyebabkan surface fatique,
dispersant) & membentuk suspensi pitting & spalling.
yg stabil dgn partikel shg
menurunkan kemampuan aditif
dan meningkatkan viskositas.
Particle Size Distribution
Tujuan : mengetahui tingkat kebersihan dari
suatu pelumas/bahan bakar

Kondisi pelumas/bahan bakar yang kotor

akan menyebabkan:
 Blocking pada filter sehingga
menurunkan lifetime dari filter
 Wear and debris dapat menjadi pemicu
wear lebih lanjut karena akan bertindak
sebagai material abrasif
 Beberapa kontaminan menjadi katalis
untuk reaksi kimia lebih lanjut yang
membahayakan fuel system maupun
lube system

Reference: NORIA Alat Uji: Particle Counter

Reference: Polaris Lab
http://www.polarislabs1.com/test-explanations/particle-count.htm
Method and Unit to Detect Particle Contamination

Optical - Automatic Particle Counter (APC)

Source: www.machinerylubrication.com
 Number of Particle per mL
Up to and
More Than Number (R)
including

ISO 4406 80.000

40.000
160.000
80.000
24
23
20.000 40.000 22
10.000 20.000 21
5.000 10.000 20
ISO 4406 Code:
2.500 5.000 19
Method 1987 : ISO R2/R5/R15
Shortening : ISO R5/R15 1.300 2.500 18
640 1.300 17
Method 1999 : ISO R4/R6/R14
Shortening : ISO */R6/R14 320 640 16
160 320 15
80 160 14
Example: 40 80 13
Laboratory send a report of particle counter
20 40 12
Particle > 4 micron = 15.000 particle / mL 10 20 11
Particle > 6 micron = 9.000 particle / mL 5 10 10
Particle >14 micron = 1.100 particle / mL
2,5 5 9
1,3 2,5 8
0,64 1,3 7
ISO Clean Lines Code = ISO 21/20/17
0,32 0,64 6
Shortening = ISO 20/17
0,16 0,32 5
0,08 0,16 4
 NAS 1638 Class
CLASS
Particle Size 00 0 1 2 3 4 5 6 7 8 9 10 11 12
Range
5-15 microns 125 250 500 100 200 400 800 1600 32000 64000 12800 25600 51200 102400
0 0 0 0 0 0 0 0 0

15-25 microns 22 44 89 178 356 712 142 2850 5700 11400 22800 45600 91200 182400
5

25-50 microns 4 8 16 32 63 126 253 506 1012 2025 4050 8100 16200 32400

50-100 microns 1 2 3 6 11 22 45 90 180 360 720 1440 2880 5760

> 100 microns 0 0 1 1 2 4 8 16 32 64 128 256 512 1024

Sample A Sample B
Example: Particle Size No. of Class No. of Class
Range Particle Particle
5-15 microns 50100 8 122100 9

15-25 microns 4500 7 11100 8

25-50 microns 1300 8 3200 9

50-100 100 7 300 8

microns
> 100 microns 20 7 110 9

NAS = 8 NAS = 9
 Conversion Table

Condemning Limit ISO ISO Code NAS Class

Cleanliness 23/21/18 12
22/20/18 --
22/20/17 11

EQUIPMENT Clean Dirty 22/20/16 --

21/19/16 10
Piston (Reciprocating) Compressor 17/14 20/17
20/18/15 9
Screw Compressor 16/13 18/15
19/17/14 8
Turbo Compressor 15/12 17/14 18/16/13 7
Turbine 15/12 17/14 17/15/12 6
16/14/12 --
Gearbox System 18/15 22/18
16/14/11 5
Bearing System 15/12 17/14
15/13/10 4

Reference:
14/12/9 3
ASTM D 6224 13/11/8 2
“In-Service Monitoring of Lubricating Oil for Auxiliary Power Plant Equipment”
12/10/8 --
ASTM D 4378
“Standard Practice for In-Service Monitoring of Mineral Turbine Oils for Steam and 12/10/7 1
Gas Turbines”
12/10/6 --
http://www.contractorsunlimited.co.uk/toolbox/hy
drauliccomparison.shtml
 Techniques for Controlling / Prevent Particle
Contamination
Monitor Your Transmitter (DCS)
• Perform offline filtration
• Perform any top-up using filter cart

• Oil pump discharge pressure

• Oil filter delta pressure

Use desicant breather

Filter Rating
The efficiency of the filter can be calculated
directly from the beta ratio because the
percent capture efficiency is ((beta-1)/beta)
x 100.

A filter with a beta of 10 at five microns is

thus said to be 90 percent efficient at
removing particles five microns and larger.

Source: www.machinerylubrication.com

Chapter
31
06 -
 Source of Contamination and Preventive actions

 New Oil, remember new oil is not always clean oil.

“Always filter new oil before top up to machine”
 Built-in machine, during assembly on manufacture particle
were generated.
“Flushing new machine before running well”
 Ingressed / external contamination during operation.
“Always check seal, breather caps”
 Maintenance procedure.
“Keep your system closed as much as posible during
maintenance”
FUEL CONTAMINATION
Kontaminasi Fuel/BBM
Sumber Penyebab
• Tidak sempurnanya sistem
pembakaran karena :
 idling yang berlebihan
 rusaknya/tersumbatnya
injektor BBM
 fuel/air ratio tidak
sempurna

• Fuel masuk melalui blowby

bersama-sama dengan gas-gas
hasil pembakaran maupun
karena kebocoran ring piston.
 Kontaminasi Fuel/BBM (2)
Pengaruh pada Pelumas Pengaruh pada Mesin

• Premature Oxidation • Peningkatan wear karena

Molekul fuel mudah teroksidasi viskositas encer & menurunnya
menghasilkan senyawaan anti-wear additive (karena
reaktif yang mempercepat terencerkan).
proses degradasi pelumas.
• Peningkatan korosi pada
• Viskositas menjadi encer yang permukaan logam karena
menyebabkan penipisan adanya peningkatan asam sulfur
lapisan pelumas. dan asam-asam organik.

• Pengenceran aditif yang • Adanya kandungan fuel yang

menurunkan kemampuan aditif sangat tinggi berpotensi
menyebabkan resiko ledakan.
Existing Approaches to Detecting Fuel Dilution

ASTM D3524
ASTM D3525
DIN 51380

ASTM D92
ASTM D93
ASTM D56
ASTM D3828

ASTM E2412

Source: www.machinerylubrication.com
 Controlling Fuel Dilution
Any things that possibly cause fuel dilution should
be controlled:

• Leaking injectors
• Excesseive idle time
• Incomplete combustion
• Restricted air filter/bad air to fuel ration
• Fuel pump / over fueling
• Seals and gaskets
• Improper injector timing
SOOT CONTAMINATION
Kontaminasi Soot/Jelaga

Deskripsi
Soot merupakan produk hasil
pembakaran & tidak terkait
dengan kualitas pelumas.
Pemakaian pelumas yang terlalu
lama atau tidak sempurnanya proses
pembakaran menyebabkan akumulasi
soot yang abnormal yang
membahayakan kondisi pelumas dan
mesin.
Kontaminasi Soot/Jelaga
Soot mencemari pelumas melalui blowby bersama-sama
dengan gas-gas hasil pembakaran dan disebabkan oleh :
– Kompresi mesin terlalu rendah (sehingga
pembakaran tidak sempurna menyebabkan
peningkatan pembentukan soot)
– Rasio Fuel/Udara terlalu tinggi (karena
tersumbatnya filter udara atau setting campuran
yang tidak benar)
– Temperatur udara terlalu rendah (operasi pada
kondisi suhu dingin)
– Lugging (kelebihan beban atau penggunaan gigi
terlalu tinggi)
– Idle yang berlebihan (berhenti terlalu lama atau
kecepatan/speed operasi terlalu rendah)
 Kontaminasi Soot/Jelaga (2)
Pengaruh pada Pelumas Pengaruh pada Mesin
• Dispersancy loss : • Penyumbatan filter
Soot akan mengadsorpsi molekul • Peningkatan abrasive wear
aditif dispersant shg menurunkan
kemampuan mendispersikan • Pembentukan deposit, sludge
partikel insoluble. yang berpotensi penyumbatan
aliran pelumas.
• Antiwear performance loss :
Oil soluble tail
Molekul aditif antiwear akan (oleophilic)
diserap (adsorp) oleh permukaan Polar
soot shg tidak dapat mencegah Head

terjadinya gesekan pada komponen

mesin.
• Peningkatan viskositas : Dispersant
Mesin menjadi cepat panas dan forms micelle
by enveloping
aliran pelumas ke bagian mesin particle
menjadi lambat.
 Measuring soot contamination
ASTM E2412, FTIR is a method to check soot
contamination in oil. Can be checked at 2000 cm-1
Infra red region.
“Simply compare used oil absorbance to it’s new oil”
 Controlling Soot
 Fuel and air injection ratio is working well
 Avoid air filter clogged
 Use lube with high dispersant additives will maintain
soot aglomerate and attach to machine
 Follow oil analysis schedule or Change oil regularly
TERIMA KASIH