Assessing Methods to Analyze Particles: PQ vs FerroQ

What is Ferrous Debris?

The metallic fragments that linger onto lubrication oil are referred to as Ferrous Debris and have always posed an obstacle for condition monitoring laboratories or end-user facilities. Historically, there has always been challenges with spectroscopic methods not fully analyzing the ferrous debris load lower than about 10µm in diameter.

Credit to the Swansea Tribology Centre, the PQ has globally been an essential component of oil condition monitoring programs since 1985 to combat the full analyzation limitations. The PQ is a sensitive magnetometer that measures the influence on a magnetic field and provides a quantitative result of the ferrous wear in a sample. This result can be trended with acceptable linearity over a wide range of ferrous debris concentrations and particle sizes.

Limitations and Solutions of PQ

PQ comes with certain limitations that can disrupt the process of receiving accurate measurements for Ferrous Debris amounts. These limitations include bottle measurements only analyzing around the bottom centimeter or standards not being available from the manufacturer, thus not NIST traceable. Additionally, there is the issue that the result are unitless due to the PQ Index referring to a dimensionless number.

Fortunately, newer instruments such as Poseidon FerroQ was developed to meet these limitations which uniquely uses a set of coil windings; one for measurement and one for reference. When the sample is inserted, any ferrous material present in the oil/grease sample changes the inductance of the measurement coil relative to the reference coil. A sensitive signal conditioning circuit detects those minute changes in inductance of the measurement coil and the embedded processor interprets this signal to provide a mass/volume output based on calibration standards.

Single coil products such as PQ and certain PPM devices typically yield different results than set coil products such as FerroQ. This results in a device that is highly sensitive to particles at the bottom of a sample and insensitive to those at the top. FerroQ measurement coil surrounds the sample, providing uniform sensitivity, and superior repeatability.

How FerroQ is Measured?

The FerroQ reports results in mg/kg and utilizes standards that are NIST traceable back to a primary iron standard. This gives a result that is quantifiable and meets quality standards more fully.

To confirm the traceability and accuracy of the results from the FerroQ, 0.0151g of Iron Powder, <10 µm, ≥99.9% trace metal basis from Sigma Aldrich was prepared in 10.0007 g total of a UV reactive resin. The theoretical result was 1510 mg/kg.

Tube Replicate 1 Replicate 2
#1 1620 mg/kg 1630 mg/kg
#2 1610 mg/kg 1640 mg/kg
#3 1590 mg/kg 1590 mg/kg

There is a desire in some laboratories to switch from the venerable PQ to the FerroQ. To determine this, 1291 comparisons were made.

Using all data did show that above 1000 PQ™ Index the data did have a skew. This is likely the effect of PQ™ does nor analyze the whole sample.

Removing this data shows a definite correlation between the two methods:

In summary, the FerroQ technology shows that it will perform similarly to the PQ technology. This coupled with the FerroQ having NIST traceable standards, reporting in mg/kg, and analyzing the entire sample (as opposed to only the bottom) that it may be a superior method to the venerable PQ.

Proven Impact. Proven Uptime. Proven Savings.

Let us prove it to you.

Published March 21, 2024

 

Analysis Keeps Compressor Components in Top Shape

Seeing Proven Savings: One Report at a Time

Fluid analysis is a powerful tool in the preventive maintenance toolbox of many equipment and maintenance managers in industries ranging from construction to aggregates to mining to marine. Efficiently managed programs provide considerable benefits that translate directly into maintenance cost savings for industries who rely on the operation of their equipment.

When operating equipment, it’s inevitable to see some wear as the machine operates overtime. One of the most valuable advantages of fluid analysis is detecting early signs of wear within equipment by analyzing wear particles within the oil.

Saving $80,000 in Engine Replacement Cost

One of POLARIS Laboratories® customers in the Marine industry was able to save the entire replacement of an engine by performing recommended actions on a high severity lubricant analysis sample report. After collecting an oil sample during a break in the oil change schedule, the company’s sample report returned at a high severity. The recommended maintenance action based on the test results and interpretation was to borescope the cylinders, in which the team observed scoring on the cylinder liners.

Report showing high levels of iron with a recommendation to check cylinders

While continuing to investigate the concern, it was observed that the bottom of the engine piston crown showed signs of deterioration. After discovering this, a strategic maintenance decision was made to replace all six pistons, liners and connecting rods.

As the company shares this story with POLARIS Laboratories®, it was noted that there were no other condition monitoring indications or alarms that showed there was an engine issue – the concern was only identified based on the test results and recommendations on the lubricant analysis sample report. Without the sample report indicating abnormal wear and suggestion to evaluate the cylinders, the problem would not have been identified and would have led to a total engine loss and $80,000.

Avoiding Lost Production, Downtime and $260,000+ in Engine Loss

For a POLARIS Laboratories® customer in the Aggregates industry, equipment downtime can be detrimental to production, customer satisfaction, labor costs and operations. The company had coolant analysis report came back indicating a high freeze point which, if not addressed, would have caused the engine block to freeze resulting in a complete engine replacement of $135,000 (this does not include the downtime if the asset was out of production for repairs).

In another instance, the company was able to avoid a full axle rebuild that would have cost $50,000 by addressing a simple issue and replacing the oil after a lubricant analysis report came back with results indicating a leak in the axle which had resulted in dirt contamination causing wear.

Report showing high levels of sodium with a recommendation to check cooling system for leaks

A very recent equipment save through oil analysis for the company involved receiving a report back that indicated high levels of lead. The team was able to proactively replace the NRS coolers before the engine could experience failure – a failure that would have cost the company $75,000 to repair, plus the additional downtime loss.

Fluid analysis is a proactive, preventive, predictive and cost-effective condition monitoring tool proven to minimize unexpected and un-budgeted maintenance costs by detecting signs of early wear and contamination. Through interpreting test results and maintenance recommendations provided by the data analysts, maintenance and equipment managers can take action before failure even has a chance.

Proven Impact. Proven Uptime. Proven Savings.

Let us prove it to you.

Published November 14, 2023

Advancements in Detecting and Measuring Soluble Varnish

As part of our mission to improve the quality of our interpretation, POLARIS Laboratories® is constantly performing statistical analysis on our test results to evaluate typical parameters and establish thresholds for our tests. We are proud to announce improvements made to our new MPC method, which has the potential to measure soluble varnish in turbines, hydraulics and compressors using R&O formulations. This new method was introduced to our existing MPC method (ASTM D7843) as a tool for customers to more proactively identify and correct their oil’s potential to develop both soluble and insoluble varnish.

While our new method was introduced with the same severity range as ASTM D7843, we have now collected enough data to confidently establish new limits based on the same statistical methods used for other ASTM tests. Our findings show that the new method tends to produce higher values, and for this reason we will begin considering the results abnormal when they exceed a value of 25, whereas the threshold for the original method is 15.

Along with our new MPC method, we also began reporting L*a*b* values to quantify color value. Our findings show that the L value (black to white) has a strong correlation with our original MPC method, and will now be considered “low” when the value is below 75. Similarly, our findings show that the b* value (yellow) has a strong correlation with the new MPC method, so this value will now be considered “high” when it exceeds a value of 35.

As with any other test that has been introduced, we are working to make improvements and understand factors that will influence the results. The new MPC method has the potential to measure soluble varnish, however there are many other variables that can influence the results. We will now start listing these variables on the report if the new MPC method is high, and will not recommend that any action be taken unless results for the original method are high as well.

 

POLARIS Laboratories® strives to continually improve our methods and interpretation of the analysis conducted on fluid samples to assist our customers catch varnish contamination sooner, saving more equipment and improving reliability.

Proven Impact. Proven Uptime. Proven Savings.

Let us prove it to you.

Published July 28, 2023

Value of Oil Analysis: Lubricant Manufacturers, Marketers and Distributors

Delivering value through oil analysis separates you from the competition, validates your claims, builds credibility, can help extend oil drains and leads to increased customer satisfaction. If you’re a lubricant marketer or distributor, here are a few values that come along with oil analysis, both for you and your customer.

Talking Oil Analysis: Where to Start

1. An efficient, well-managed oil analysis program is a daily reminder of the service and can help safely extend your drains.

2. Independent laboratory oil analysis validates your claims and builds credibility for your lubricant.

3. New equipment? Oil analysis can find manufacturing defects and maintains warranties that ultimately increase the equipment’s lifecycle.

4. Extending oil drains is a good thing: if a customer wants to extend their oil drains, they’ll either do it with you or someone else.

5. Did you know 40-50% of preventable engine failures can be attributed to the cooling system? Cooling systems have changed dramatically in the last 30 years, and coolants have transformed with them. OAT, HOAT and NAPS formulas have joined conventional coolants, and mixing them together can make both coolants less effective.

6. Identify areas for improved maintenance: finding dirt and water contamination from maintenance problems or poor lubrication storage gives you even more opportunities to help your customers.

7. As an independent laboratory, POLARIS Laboratories® provides all the data analysis and reports, giving you the ability to use fact-based decisions with your customers.

8. Maintaining your profits and providing additional value is always more profitable than dropping prices and hoping to increase volume.

Proven Impact. Proven Uptime. Proven Savings.

Let us prove it to you.

Published July 26, 2023

Revolutionized Maintenance Training at INTEGRATE

Where can you find education and training designed to give you the tools you need to see success along your reliability journey?

The answer: at the 2023 Reliability Summit | INTEGRATE. 

We’ve revolutionized our annual maintenance training conference to provide all-encompassing training on every aspect of your fluid analysis program. From expanding your use of the HORIZON® platform, to understanding how to grow your program, learning how sampling can be made easier, to increasing understanding of result interpretation, to eliminating silos by integrating fluid analysis data into your maintenance management system, INTEGRATE is the one place you need to be.

View this year’s line up of speakers and learning sessions

In one trip to Indianapolis in October, you and your maintenance teams can gain new ideas, insights and knowledge to kick your maintenance into high gear and see your reliability program reap the benefits of effective, impactful fluid analysis.

Gain New Perspectives

Not only will you gain education, but you’ll also gain new perspectives. During this 2-day exclusive event, hosted by POLARIS Laboratories® at The Alexander in Indianapolis, you’ll have the chance to:

  • Meet one-on-one with your account representative
  • Ask subject matter experts your questions
  • Learn what others are doing to improve their reliability program
  • Network with fellow maintenance professionals to learn and grow from their experiences

See Operations in Action

When you attend INTEGRATE, you get more than education through learning sessions, you get a first-hand look at not one, but two facilities through exclusive tours – and a chance to see inside POLARIS Laboratories’ headquarters laboratory in Indianapolis.

Cummins Augmented & Virtual Environmental Lab

Experience a tour of Cummins technical center and environmental lab and see what Cummins engineers and scientists are creating, testing and evaluating to prepare for the future of manufacturing. See processes and devices, including 3D printers, tomography x-ray systems and Cummins’ use of virtual reality.

 

U.S. Aggregates Facility & Mine Tour 

Get a glimpse of U.S Aggregates’ 460-acre facility and see a glimpse into their mining operations. See how U.S. Aggregates mines and processes limestone, while getting a first-hand look and feel of a raw material reduction with the use of explosives.

 

POLARIS Laboratories® 

This tour gives you a first-hand look inside our state-of-the art laboratory and headquarters facility in Indianapolis. From the time your sample hits the facility doors, to laboratory testing, to data analysis and customer support, and everything in between, this tour gives you an exclusive look into our laboratory daily operations.

These tours have limited spots, first come first served – register early if you want a seat on the tour. See the available tours and information here.

Discover New Solutions

Our annual training conference would not be possible without our event sponsors. We’ve teamed up with several industry solutions providers (lube manufacturers, filter solutions, sampling supplies, data integration) to give you tools to advance your programs and expand your maintenance practices. Each sponsor will have an exhibitor booth at the conference as well. Please feel free to stop by their booths to see what they have to offer your program!

It’s All Here in Indianapolis

I’ll leave you with this question, where else can you find lube manufacturers, OEMs, testing experts, reliability professionals, integration solution providers and everyone in between? At INTEGRATE October 2-4 in Indianapolis.

From the Data Analyst: How Sample Information Affects Limits and Analysis

Two questions our Data Analysis team often receives from fluid analysis customers are “What information is necessary to analyze our samples?” and “Why is this information so important?”

Whether your sample is defined as a grease, diesel fuel, lubricant or coolant, there are complex interpretation factors accounted for each test result of the respective application. Aside from establishing the appropriate testing slate applied to a fluid, test limits may also vary and be comprised of SAE, ISO, POLARIS Laboratories®, OEM, industry charter and/or fluid manufacturer standards. Due to these reasons, it is imperative to supply as much relevant equipment and fluid information as accessible to your laboratory when submitting the sample for testing.

Here are a few scenarios… Without fluid information, a laboratory may not be able to see abnormal fluctuations for additive content or viscosity. The fluid’s basicity may become essentially depleted prior to detection, or the acidic levels may be too high for neutralization efforts. Without the specific equipment model, a laboratory may have to rely on generic data points to extrapolate typical wear accumulation. These limits may be too aggressive or not aggressive enough for the type of equipment tested. These are all exact scenarios we have previously experienced with customers.

For example, we may factor the following information when establishing statistical trends for wear metal content, lubricant properties and interpreted recommendations:

  • Equipment Type (e.g. engine)
  • Specific Application (e.g. diesel)
  • Equipment Manufacturer (e.g. Cummins)
  • Equipment Model (e.g. ISX)
  • Industry Type (e.g. logistics/transportation)
  • Lubricant Manufacturer (e.g. Chevron)
  • Lubricant Product (e.g. Delo 600 ADF)
  • Lubricant Viscosity (e.g. 15W40)
  • Filter Type (e.g. Full Flow)
  • Filter Micron Rating (e.g. 10 micron)
  • Sump Capacity (e.g. 14 gallon)
  • Time on Lubricant (e.g. 13,598 miles)
  • Time on Equipment (e.g. 124,600 miles)

While some equipment manufacturers have a ‘fixed’ wear limit table for operational guidelines, laboratories typically provide a more objective and literal statistical significance of normal wear accumulation. These statistics may reduce unnecessary calls for maintenance, which would otherwise lead to costly downtime or premature use of materials.

Read more in the Technical Bulletin

If you are unsure what information may be required to appropriately identify abnormal trends for your equipment samples, reach out to the laboratory for a list of the requisites and additional guidance. To receive an improved return on investment out of a lubricant, fuel, or coolant maintenance program, avoid delays or guesswork the laboratory may experience due to absent sample information.

Sampling Devices: Find the Right One for Your Program

Sampling devices are used to pull samples of lubricant, coolant or fuel out of system components. There is a range of sampling devices to fulfill specific needs, but they can be grouped into two basic categories – 1) vacuum pumps and 2) installed sampling devices.

Vacuum Pumps

vacuum pump

Vacuum pumps pull fluid from a component’s reservoir. Disposable tubing is fed through the pump and into a sample jar screwed onto the pump. The other end of the tubing is used to reach into the component’s reservoir. The vacuum from the pump pulls fluid out of the reservoir and into the sample jar without contacting the pump itself. Oil residue in the tubing would contaminate future samples, so it must be thrown away. The pump itself never touched the fluid and can be reused without cleaning.

Installed Sampling Devices

Commonly referred to as “valves,” small sampling devices are installed on components to create a permanent, easily accessible port for drawing samples. Using valves to pull fluid is typically faster than using vacuum pumps alone. The valves also minimize the chances of environmental contamination entering the sample or the fluid system. These permanent devices collect the most representative samples possible in the least amount of time. The two most common types differ based on if the system is pressurized or not.

Push Button (4-100 PSI) – Pushing a button on the device opens the port. The pressure from the system pushes fluid through the port and into an open sample jar held below the valve.

push button valve

Push Pin (4-1000 PSI) – Inserting a “pin” or “needle” into the device opens the port. System pressure or a vacuum pump moves fluid through tubing attached to the pin. A cap is screwed onto the sample jar to secure the other end of the tube when a vacuum pump isn’t used. The pin, tubing and cap cannot be easily cleaned and must be thrown away.

push pin valve

 

 

 

 

 

 

Installed Sampling Devices Save Time And Money

One vacuum pump can draw samples from multiple components, but it pulls samples slower than an installed sampling device. Generally, the reduced sampling time pays for the device and its installation after five samples.

So what are you waiting for? Order your sampling devices (i.e. Push Button or Push Pin) via the HORIZON Store, install them as soon as possible to start saving even more money with your fluid analysis program!

Maximize asset reliability and regain control of your production schedules with an effective fluid analysis program by POLARIS Laboratories® . . . it costs so little to protect so much.

Proven Impact. Proven Uptime. Proven Savings.

Let us prove it to you.

Published March 16, 2023

How to Ensure Optimum Performance of Wind Turbines

With the increase of greener energy production, wind turbines are playing an increasingly important role. It is vital that these energy producing turbines operate at optimum capacity for extended periods of time. To do this, a high level of equipment reliability is critical and, due to remote locations or access difficulties, all maintenance needs to be planned at optimum intervals to ensure maximum uptime and reductions in total cost of ownership (TCO).

The operating fluids inside a turbine, including lubricating oil in gearboxes and hydraulic systems, fluids used in cooling systems and greases all play a significant role in optimizing operation of the wind turbine. All of these operating fluids should be monitored closely to determine the condition of the fluid, identify contamination and measure the levels of wear metals generated within each system.

Monitoring conditions through routine fluid analysis allows you to avoid unplanned downtime and perform necessary maintenance based what is actually happening within the unit rather than on the hours in operation or calendar days. Planned, predictive maintenance will get you to optimum energy production.

See the recommended testing for power generation equipment here.

Proven Impact. Proven Uptime. Proven Savings.
Let us prove it to you.

Published January 5, 2023

Are You Certified in Oil Analysis?

Today’s oil analysis capabilities offer a great deal more than just monitoring component health. With today’s technology, along with performing the proper tests, we can:

  • Monitor the condition of the oil
  • See if it is suitable for continued use
  • Reduce the amount of used oil disposal
  • Adjust maintenance intervals
  • Adjust component replacement schedules
  • Improve forecasting and budgeting
  • Increase component life hours

With all of this in mind, it begs the question, are you able to maximize the return on investment from your oil analysis program? I believe the answer to this question would be for you to become certified as an Oil Monitoring Analyst (OMA I) via the Society of Tribologists and Lubrication Engineers (STLE).

What is an Oil Monitoring Analyst (OMA I)?

Predictive maintenance professionals who oversee the oil analysis program for a shop/plant would be suited for OMA I certification. At POLARIS we call this person a Program Champion. At POLARIS we believe the single most important ingredient in a successful oil analysis program is the Program Champion inside it. OMA I certification might also be beneficial for other members of a maintenance team to obtain as well (i.e. mechanics, operators, engineers, etc.). Anyone with the following core responsibilities would be a viable candidate for OMA 1 certification:

  • Responsible for oil sampling
  • Reviews oil analysis reports and performs the correct tests
  • Maintains overall care of equipment and maintenance actions

Becoming OMA I Certified

OMA I certification is obtained by scoring 70 percent or higher on the designated exam that standardizes the body of knowledge for an Oil Monitoring Analyst. Once obtained, the certification is valid for three(3) years, after which individuals are required to recertify to maintain their OMA I status.

OMA I Exam Topics

  • Sampling
  • Application/Test Methods
  • Data Interpretation
  • Troubleshooting
  • Lubrication Fundamentals

Requirements

  • 16 hours of training in oil analysis-related courses, which may include company training programs
  • One year of experience utilizing oil analysis in the field of lubrication

Society of Tribologists & Lubrication Engineers (STLE)

So what are you waiting for? Get your Oil Monitoring Analyst I (OMA I) certification today. Visit the STLE website for a list of recommended reading materials for certification.

Proven Impact. Proven Uptime. Proven Savings.
Let us prove it to you.

Published December 23, 2022