Contact E-mail : sales@particletest.com.au
Copyright 2007








Oil Cleanliness

At Particle Test we often get asked, “what is oil cleanliness and how should I measure oil cleanliness?” Oil cleanliness as the name suggests is how clean your oil is, but more to the point oil cleanliness is telling you how effectively your lubricant is working. Oil cleanliness is normal measured through the use of the ISO4406 or ISO code, NAS or the SAE 749D.

If the ISO4406, NAS or SAE 749D reports poor oil cleanliness this is telling the operator that the lubricating properties of your oil are not at an optimum state. As the oil gets contaminated with particles, these particles will start to abrade the surface of all moving parts in the compartment. This is due to the clearance between moving parts such as gears. The ISO code looks at 4mm, 6mm and 14mm as these are the size of importance when we start to look at the clearance of moving parts.

In the day of proactive maintenance we can no longer just rely on scheduled servicing to be sure that our equipment is working at optimum. Regularly monitoring our oil cleanliness is essential.  This can be done through a laboratory system however this can still mean a couple of days to find out if we have a problem, which now has no doubt got worse. The best solution where possible is online or onsite monitoring of your oil cleanliness.

Particle Test have a range of PAMAS laboratory, onsite and online oil cleanliness particle counters.

Portable Oil Contamination Monitoring

Affordable and portable oil contamination monitors are now available now at Particle Test. The PAMAS S50 is a small, portable workshop or field tool that can be used to measure the oil cleanliness or oil contamination and report the ISO code of the oil in your compartment. The PAMAS S50 can be connected directly to a high pressure port to measure your oil contamination; this avoids the operator having to take a bottle sample. If sample needs to run from a low pressure situation like a bottle, the PAMAS S50 is also capable of this.

The PAMAS S50’s is also a very useful tool of the measure of oil cleanliness during oil filtration. With the PAMAS S50 the operator now can check the oil cleanliness in real-time, and can filter the oil until the required ISO code is achieved. This avoids expensive machine time in filtering oil longer than need and at the same time gives the operator and customer confidence the oil cleanliness is met; very important in maintaining warranties!!

Another important feature of portable particle counters or oil contamination monitors is the ability to analysis high viscosities. The PAMAS S50 can measure viscosity up to a massive 1000 cSt! This is possible due to the PAMAS S50’s unique sensor design.

The PAMAS S50 is capable of measuring oil contamination in systems with pressures of 0 bar through to 400 bar.

Oil contamination is a fast growing area in the field of predictive maintenance. The ability to get on-site results will increase mechanical reliability.

Wear Metal Analysis in Used Oil

The Spectroil M/C-W is a compact, rugged, transportable and easy to use spectrometer designed specifically for the wear metal analysis of used oil samples. It measures trace quantities of elements dissolved or suspended as fine particles in natural or synthetic petroleum based products using the time-tested and reliable rotating disc electrode (RDE) technique.

The Spectroil M/C-W has the capability to analyze all the wear metals, contaminants and additives typically found in used oil samples. The Spectroil M/C-W was designed specifically for the wear metal analysis of used oil and is equally at home in the laboratory or on-site where immediate oil analysis results can be vital and sample turnaround time is crucial

The Spectroil M/C-W has become the standard instrument at most commercial used oil analysis laboratories and machine condition monitoring programs that require the rapid analysis of wear metals, contaminants and additives in lubricants. It fulfills the requirements of ASTM D6595 Standard Method for Determination of Wear Metals and Contaminants in Used Lubricating Oils or Hydraulic Fluids by Rotating Disc Electrode Atomic Emission Spectrometry.

The Spectroil M/C-W continues to be the ideal used oil analysis spectrometer for commercial applications because technology has made it smaller, faster, more stable, more accurate and easier to operate with new capabilities and enhanced performance.

Optional accessories include the D2R2 (Double Disc Rapid Robot) robotic system for automatic and unattended operation and the A-RFS (Rotrode Filter Spectroscopy) system for the analysis of large par­ticles. Additional capabilities to analyze engine coolants and sulfur in oil are also available as options. Other versions of the Spectroil include the Spectroil M/N-W for military used oil analysis and the Spectroil M/F-W for gas turbine and diesel engine fuel analysis.

Typical Applications include;

• Commercial Laboratories
• Oil Companies
• Railroads
• Airlines
• Public Transportation Companies
• Electric Power Generation Companies
• Mines
• Refineries
• Construction Equipment Dealers
• Chemical Processors
• Steel Mills
• Manufacturing Plants
• Marine Fleets
• Military
• Formula 1 Racing Teams

Surface Area and Porosity Analysis

The BELSORP-max is a high-end volumetric gas adsorption instrument. The BELSORP-max can measure up to 3 samples simultaneously offer high throughput at the same time as high-resolution analysis.

To obtain useful information about micropore, it is important to measure adsorption isotherm from low relative pressure with accuracy. The BELSORP-max is designed for wide range adsorption isotherm for surface area and pore size distribution analysis. It can measure adsorption isotherms from relative pressure as low as 1 x10^-8 (N2 at 77K, Ar at 87K), using a 13.3Pa pressure transducer.

Also AFSM, the new method for free space measurement, is applied and adsorption isotherm can be measured with high accuracy. Chemisorption option enables unattended chemisorption measurement from pretreatment with step programs.

Gas Adsorption Analyser

BEL offers a range of instruments to measure surface and pore size distribution by gas adsorption.

The BEL range of instruments offer the flexibility of a high-resolution research tool at the same time a system capable of high throughput.
The BEL range of surface area and pore size distribution instrumentation can measure surface areas as low as 0.01 m2 /g with N2 (and 0.0005 m2 /g with Kr).

This is possible through BEL’s patient method AFSM, which accuracy measures the free space in a sample tube without the need to keep the liquid N2 level at a constant level.
The BELsorp max is capable of using different adsorption gases to measure the surface area and pore size distribution including N2, Ar, Kr, CO2, CH4, CO, H2 and more.

Utilising a molecular drag pump the BELsorp max is capable of measuring pore size distributions from 0.35 nm.

The BELsorp max comes with a number of different dewer options so adsorptions cab be done from 77K to 673K. The standard liquid N2 dewer has a massive 60hrs capacity for those extended analysis times.

There is a BEL instrument to suit everyone’s surface area and pore size distribution needs. The BELsorp mini II for surface area and pore size distributions.

The BELsorp max for nano materials, micropore materials, surface area, pore size and chemisorption.

The BELcat for chemisorption analysis. BEL also offers instrumentation for fuel cell and catalyst research.

Viscosity of Lubricants

The Spectro-Visc is a bench-top semi-automatic kinematic temperature bath viscometer optimized for the viscosity analysis of used and new lubricants. It conforms to the requirements in ASTM D445, D446, D7279, IP 71 and ISO 3104. It is also the ideal system for used oil analysis laboratories that need to test the viscosity of a wide range of lubricants.

A significant reduction in viscosity of your lubricant can result in excessive wear, heat generation due to mechanical friction, increased sensitivity to particle contamination due to reduced oil film.

Also a significant increase in viscosity of your lubricant can cause excessive heat generation, lubrication starvation due to inadequate oil flow, excess energy consumption to overcome fluid friction, poor cold-start due to pumpability. With this in mind it is obvious the importance of continuously measuring the viscosity of lubricants to maintenance optimum machinery operation.

Through the use of proactive maintenance looking parameter like lubricant viscosity planned predictive maintenance will ensure the successful operation of your machinery.

Solution to Clean Injectables

An important factor in intravenous solutions is the correct dose, equally important is ensuring that the inject able solution contain no particles of a harmful size. Intravenous solutions with large particle contamination may result in problems as serious as a heart failure. The PAMAS SVSS is the means of testing the quality of inject able solutions. The SVSS will measure the particles in an inject able solution according to the USP, BP, JP and KP. The advanced SVSS USP software automatically performs sensor checks ensure quality analysis.

Surface Area of Dry Ingredients

The BELSORP mini II is a user friendly surface area analyzer with advance measurement principles.

This laboratory unit can measure 3 sample simultaneously and is capable of measuring sample with surface areas as low as 0.01m²/g. Equipped with the powerful and easy to use BEL master software makes the BELSORP mini II ideal for both research and QC applications.

Surface area is particularly important in industries using lactose, flour and starch just to name a few. If the surface of the dry ingredients is to low this will cause problems in the blending and result in problems with the final product. Ensuring the optimum surface area on dry ingredient is achieved will result in the utmost product quality. This is when a highly accuracy instrument like the BELSORP mini II will be a valuable measurement tool.

Proactive Maintenance

The Spectroil M/C-W Oil Analysis Spectrometer is a easy and fast way to perform analysis of wear metals, contaminants and additives in lubricants, hydraulic fluids and cololants.

The Spectroil M/C-W has the capability to analyse all the wear metals, contaminants and additives typically found in used oil samples. The Spectroil M/C-W was designed specifically for the analysis of used oil and is equally at home in the laboratory or on-site where immediate oil analysis results can be vital and sample turnaround time is crucial.

PAMAS S40 Water Glycol for Oil & Gas

The PAMAS S40 WG is designed for engineering work shop and laboratory use. It is small and portable and can be easily relocated to where it is needed. It is tried and tested with a reputation for dependability in the most demanding production environments.

Incorporating high resolution PAMAS laser light blockage technology trusted throughout industry for reliability and accuracy. Pressurised sensor reduces the need for degassing allowing the counter be plugged in and used on line up to 100 psi. pressure. No need to send samples to the laboratory, with a built in liquid pump the PAMAS S40 WG can draw its own samples from a bottle, producing results quickly where they are needed.

The PAMAS S40 WG is simple to operate via the touch screen user interface. A variety of  sampling profiles can be created offering choices of Standards such as NAS 1638 and AS 4059.

The number of channels requiring analysis, such as AS 4059 bands A to F ,6 channels or B-F, 5 channels can also be preconfigured. The sample size and the duration can also be varied and preconfigured. The operator simply selects the sampling profile from a drop down option list on the touch screen then proceeds by selecting start.

Rugged and tough portable workshop or laboratory particle counter; including a built in battery for mains free operation. The PAMAS S40 WG is a compact portable instrument for measuring hydraulic fluids used in the off shore oil industry.

The PAMAS S40 WG Laser particle counter is built for those hard working applications where flexibility in the work place is essential. The unit has built in protection from contamination including BACK FLUSH operation to remove over contamination from the system.

Specifically designed for the measurement of Water/Glycol hydraulic fluids and is compatible with subsea fluids such as Oceanic HW540, Oceanic 443, Castrol Trans aqua and Niche Pelagic 100.

Intelligent yet simple to operate the PAMAS S40 WG reports results to NAS1638 and AS SAE4059 and ISO cleanliness classes. AS 4059 special report function for class B to F only. Producing a result printout for these size bands where they are specified. Calibration according to ISO11171:1999, according to NAS1638 with NIST traceable standards.

Tried and trusted for flushing and qualification of Christmas trees, HPU’s, subsea umbilical’s, hydraulic accumulators, valves and control systems. With the online capability the PAMAS S40 WG is ideal for integration in to flushing rigs, offering real time results in NAS1638 and AS 4059.

Applications

• Water/Glycol Hydraulic fluid flushing
• Christmas trees
• HPU’s
• subsea umbilical’s
• hydraulic accumulators
• valves and control systems

Compatible with water/glycol hydraulic fluids including the following:

• MacDerimid -Oceanic HW 540, 443, 443r
• Castrol- Transaqua series
• Niche Products -Pelagic 100

FluidScan on-site Oil Condition Monitoring

The FluidScan is a handheld condition based maintenance system that protects machinery by determining when a lubricant needs to be changed due to excessive contamination or degradation. It detects lubricant contamination and degradation at the point of use by measuring key oil condition parameters in both synthetic and petroleum based lubricants and fluids.

The FluidScan analyzes lubricants and fluids using infrared spectroscopy, a technique that has found wide acceptance as a primary test for contamination and degradation. It performs the analyses with the same accuracy as laboratory instruments, but does so on-site in a handheld version. The FluidScan thus reports and stores information on lubricant condition at the point of use.

Application:
The FluidScan Lubricant Condition Monitor is applicable to any large mechanical system where unexpected down time is unacceptable. It enables operators of power generation equipment, marine vessels, trucks, wind turbines, mining and heavy construction equipment, or any large industrial system to establish predictive maintenance programs based on oil condition rather than in a preset schedule based on time or distance.

Benefit:
The FluidScan provides immediate on-site analysis of lubricant properties, accurately warning when it is time to change the lubricant due to contamination or degradation. The primary benefits of real-time, onsite analysis include:

• Extended oil change intervals
• No delay in waiting for laboratory analysis
• Reduced operational and maintenance costs
• Reduction of unscheduled maintenance outages
• Prevention of catastrophic failures
• Reduction of hazardous waste

Spectro Industrial Tribology Laboratory

The Spectro Industrial Tribology Laboratory (ITL) is a turnkey system providing condition monitoring for machines and engines by oil analysis. The measurements made using the Industrial Tribology Laboratory determine both lubricant and machine condition, the cornerstones of any effective predictive maintenance system.

A lubricant will not perform properly if it is out of specification, or if its additives have been depleted, or if it has become contaminated with dirt, water, or fuel. Likewise, when a machine or engine enters an abnormal wear mode, the lubricant carries with it fine wear particles generated by the abnormal wear. Spectro has put together an instrument package that makes the necessary measurements to effectively monitor all the oil lubricated equipment in your plant or fleet.

The instruments Spectro has chosen to accomplish this task are 1) a Spectro optical emission spectrometer for analysis of wear metals, additives and contaminants, 2) a Fourier Transform Infrared (FT-IR) spectrometer for analysis of organic components, 3) an automatic viscometer and 4) a computer (or network) for data storage, processing and retrieval. Optionally Spectro provides additional instruments to enhance the data generated by the basic instruments of the turnkey industrial tribology configuration. They include ferrography instruments, a particle shape classifier and counter, fuel dilution meter, and titrators for TAN, TBN or Karl Fisher water determinations. A local area network (LAN) version of the ITL system is also available for laboratories that process large numbers of oil samples.

The instruments of the ITL were chosen not only because they provide all the necessary data to effectively condition monitor your oil lubricated equipment, but because they are easy to operate, easy to maintain, require a minimum of special utilities to install, and have good sample throughput (most measurements take about 1 minute). The analytical instruments send results to the central computer (or a network) where they are stored in a database file for subsequent analysis.

Included in the ITL is a computerized expert equipment condition monitoring software program. It is a sophisticated, yet simple to use, LIMS software which administers the routine operations associated with a condition monitoring program based on oil analysis. The software implements the tasks of a full function oil analysis laboratory including sample logging, analysis, data storage and retrieval, automatic evaluation and reporting.

Particle Test Pty Ltd installs and provides training for all instruments as an integrated system. Since the Industrial Tribology Laboratory is a turnkey system, supplied and installed by one vendor, the worry and learning curve errors associated with new methods and equipment are minimized during the startup process. Condition monitoring of your equipment can begin immediately after the installation of your equipment and during the initial training of your personnel.

Wear  Metal Analyser

The MIDAS ferrous debris analyzer is rapid and simple to operator accompanied by supreme sensitivity. Cost effective operation enables routine on-site ferrous debris monitoring, and is also a valuable instrument for precision specialist condition monitoring laboratory work.

This MIDAS provides repeatable and accurate determination of ferromagnetic material concentration down to unprecedented levels. It provides a mass proportional output from any size of ferrous contaminant particles down to less than 1 micrometre diameter and reports the PPM of ferrous debris for your oil.

This Lightweight portable instrument is ideal for the onsite monitoring of equipment to prevent unexpected failures occurring. It is also ideal for applications such as monitoring break-in wear, evaluation filtration performance or quantity ferrous debris collected by filters.

The MIDAS ferrous metal Debris Monitor

Background

Condition Based Maintenance, as part of a modern predictive maintenance strategy is increasingly important in improving reliability of plant and machinery. A wide range of monitoring  techniques exists with the potential to dramatically reduce costs and increase profits. Of these techniques Lubricant Monitoring, or Oil Analysis offers a unique and direct means to assess machine or plant condition with a minimum of operator effort and experience. By taking regular oil or fluid samples, any wear present can be trended and any deviation from the normal pattern detected (and then corrected) at an early stage. Wear debris monitoring is of special value in detection of emerging problems in applications where vibration analysis, thermography or other indirect monitoring may lack sensitivity. Its value is compounded when used along with other approaches to gain a more complete insight into operating conditions.

Manor Technology has introduced The MIDAS free standing oil sample based ferromagnetic metal debris analyser, to facilitate ferrous debris analysis. The rapid and simple operation of MIDAS is accompanied by supreme sensitivity. MIDAS’ cost effective operation enables routine on-site ferrous debris monitoring, and is also a valuable instrument for precision specialist CM laboratory work.

How it works

Operation is based on a special inductive sensor and matching custom electronics with a unique, US & UK patented, combination of features. These guarantee uniquely stable and repeatable measurements, essential for meaningful wear data trending at a sufficiently early stage.

Key Features & applications

Ø      Avoid unpredicted failures; facilitate pla nned maintenance

Ø      Monitor system commissioning (‘break in’)

Ø      Assess filter performance and integrity

Ø      Supremely simple to use, small sample volume

Ø      Lightweight, robust and portable

Ø      Calibration independent of base fluid used

Ø      Data to Reliability Centred Maintena nce programmes

Ø      Throughput of 10 samples per minute achievable

Ø      Excellent price / performance

Operation

MIDAS provides repeatable and accurate determination of ferromagnetic material concentration down to unprecedented levels. It provides a mass proportional output from any size of ferrous contaminant particles down to less than 1 micrometre diameter. A lubricant sample is placed in a standard 2ml laboratory sample tube. A debris reading is taken by simply dropping the plastic sample tube into the sensor opening of the unit and reading the updated display.