231500267-06-Oil-Analysis

Oil Analysis

 About POLARIS Oil Analysis Wear Debris Analysis Data Interpretation/Alarm Limits Sampling Methods Information Technology

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Significant Accomplishments Since start-up in 1999: • Established customers in all 50 states and over 15 countries • Total customer base of over 40,000 • Reports available in 3 languages • 300% growth rate over past 2 years •  Among top 25 fastest-growing privately-held companies in Indianapolis for past 3 years 3

Industries Served Transportation

Power Generation

Oil & Gas

POLARIS Laboratories supports oil analysis and reliability maintenance programming in a wide variety of industry applications.

Const/Mining

Industrial Marine 4

Facility Locations Indianapolis

Salt Lake City •Three locations – 1 database •Accessible within 48 hours by ground •24-48 hour turnaround Houston

•Local technical sales support 5

One Lab Three Locations BIG Advantages •

Ship your sample to the closest lab reducing transit time and cost

•

One phone number to call for entire program

•

Centralized Customer Service ensures a thorough knowledge of your program

•

Centralized Data Analysis ensures consistent commenting and recommendations on all data from each of our laboratories

•

One database secures data history even when samples are sent to a different lab

•

Redundancy for disaster recovery 6

Fluids Tested POLARIS specializes in testing oil, fuel, coolants and water-based fluids. Oil • Test for wear metals and contamination • Monitor fluid properties and suitability for use Fuel • Troubleshoot filter problems • Determine compliance with supplier s upplier specifications Coolant • Detect corrosive chemicals • Monitor silicate levels • Determine compliance with OEM antifreeze concentration recommendations 7

ISO 17025  A2LA Accreditation •

Takes quality standard of ISO 9000 to higher level

•

Ensures traceability back to standard

•

Determines uncertainties and repeatability

•

Is highest level of quality attainable by a laboratory backed by the most stringent accrediting body in the industry

ISO 17025

Guide 25

ISO 9000

8

 About POLARIS Oil Analysis Wear Debris Analysis Data Interpretation/Alarm Limits Sampling Methods Information Technology

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OIL IS THE LIFEBLOOD OF MANY SYSTEMS • Oil analysis is like a blood test  –  A sample is taken  – Sample is documented  – Sample is delivered to a lab  – Tests are performed  – Results are interpreted  – Diagnostic report is issued

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Oil Analysis Basics

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WHY DO OIL ANALYSIS? • To monitor changes in lubricant properties • To identify contamination and its affect on a lubricant properties • To determine type and severity of wear occurring

12

WHAT DOES OIL ANALYSIS TELL US? • Determine condition of the oil − Monitoring changes in the lubricant to determine if the oil is suitable for continued use

• Determine condition of the unit  –  Analysis provides clues that can identify problems so they can be corrected before permanent damage occurs  – Evaluates wear data

• Determine effectiveness of maintenance strategy  – Run to failure  – Preventive  – Predictive 13

MAINTENANCE STRATEGIES

Unplanned Maintenance • Run it to failure  – Very high maintenance cost  – Short component life  – No historical data or root cause analysis

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MAINTENANCE STRATEGIES Preventive Maintenance • Interval-based Maintenance  – Moderately high cost  – Short component life for unique equipment  – No root cause analysis

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MAINTENANCE STRATEGIES Predictive Maintenance • Condition-based and Planned  – Lowest overall cost  – Considers unique component characteristics  – Provides trending that can predict problems and failures  – Increases component life  – Maintenance guided by root cause analysis 16

TESTING LUBRICANT PROPERTIES • Viscosity

• Foaming

• Viscosity Index

• Rust

• TAN

• Copper Corrosion

• TBN

• RPVOT

• Oxidation

• Pour Point

• Nitration

• Flash Point

• Demulsibility

•  Aniline Point

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VISCOSITY Viscosity is a lubricant’s resistance to flow at a given temperature. • • • • • • •

Shear force/shear rate Factors that affect viscosity viscosity Temperature/relationship Temperature/relationship by grade Pressure Measurement Comparative classifications Viscosity Index

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VISCOSITY The force required to slide one object over another when the two surfaces are fully separated by a fluid is dependent on the fluid’s viscosity Moving Surface

Sheared Liquid

Stationary Surface

Viscosity =

The higher a fluid’s viscosity, the greater the force (energy) required to slide the surfaces at a given speed and gap Shear Force (per area) Shear Rate (flow) 19

OPERATING CONDITION

VISCOSITY NEEDED

HIGHER LOAD HIGHER TEMPERATURE INCREASED SPEED 20

TOTAL ACID NUMBER • Measures amount of both organic and inorganic acid present • Indicates oxidation or contamination from other corrosives •  ASTM D-664M reported as mg/KOH per/g of sample  – Caution level >2X starting point of new oil  – Severe level >4X starting point of new oil

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TAN AND TBN BY TITRATION

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OXIDATION • Breakdown of a lubricant due to age and operating conditions • Prevents additives from performing properly • Causes the formation of acids and increases viscosity • Testing done by Infrared Analysis (FTIR) • Report Reported ed as as au’s au’s/cm /cm (absor (absorpti ption on uni units ts per per cent centime imeter ter))  – 25 condemnation level by CAT & Waukesha  – >30 is severe and will lead to corrosive wear

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NITRATION • Indi Indica cate tes s exce excess ssiv ive e “b “blow low-by” from cylinder walls and/or compression rings • Indicates presence of nitric acid, which speeds up oxidation • Too much disparity between oxidation and nitration points to air-to-fuel ratio problems does TAN and viscosity, •  As oxidation/nitration increases, so does while total base number will decrease • Testing done by Infrared Analysis (FTIR) • Report Reported ed as au’s/cm au’s/cm (Absor (Absorpti ption on units units per centim centimete eter) r)  – 25 condemnation level by CAT & Waukesha  – >30 is severe and will lead to corrosive wear 24

FTIR - FUEL, SOOT, OXIDATION, NITRATION

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REPORTING MEASUREMENTS Neutralization Number Expressed In Mg/KOH/g

Per Cent By  Volume

 Viscosity In Centistokes –  cSt  cSt at Specified Temperature

Fue Fuel % Soot Soot % Water % Vis Vis @ 40 Vis Vis @ 100 AN

FT-IR Results Expressed In  Absorbance Units Per Centimeter

BN Oxi Nit Nit

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CONTAMINANT LIMITS Oil

Silico n

Sodium

Potassiu m

Fue l%

Soot %

Diesel Engine

20

70

20

2

2

20

20

160

250

250

6

6

30

30

20

50

20

N/A

N/A

25

N/A

160

90

150

N/A

N/A

40

N/A

20

75

80

N/A

N/A

30

N/A

256

307

180

N/A

N/A

50

N/A

15

25

10

N/A

N/A

20

N/A

65

114

78

N/A

N/A

35

N/A

20

50

20

N/A

0.5

20

20

160

175

165

N/A

1.1

25

27 25

Transmission

Gear Box

Hydraulic

Natural Gas Engine

Oxidatio Nitration n

METALS BY ELEMENTAL ANALYSIS Wear Metals

Fe

Cr

Ni

Al

13

0

0

1

Contaminants

Cu Pb Sn Cd Ag 2

0

0

0

0

Ti

V

Si

0

0

3

Lubricant  Additives

Multi - Source

Na

K

Mo

3

0

0

Sb Mn 0

0

Li

B

0

5

Mg Ca 0

2449

Ba 0

P

Zn

1260

1144

Reported in concentrations of parts per million - ppm

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ICP SPECTROMETER

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FLAGGING POINTS & ALARM LIMITS Where do the numbers come from?

• • • • •

sample information YOU provide the lab OEM/equipment specifications lubricant specifications laboratory database of samples with same criteria statistical an analys lysis of of “re “rea al lilife” laboratory data 30

SETTING ALARM LIMITS • Statistics used to establish alarm limits for wear metal concentrations • Mean (average, indicated by x) and standard deviation (the distance the spread of numbers are from the mean, indicated by σ ) are determined for each population of elemental concentrations • How many standard deviations from the mean (3 to +3) alarm limits will be set is based on frequency distribution 31

 ALARM LIMIT LIMIT SPECIFICS SPECIFICS • Base alarm limits on specific information  – Unit Type • Diesel Engine • Turbine • Compressor  – Reciprocating, Rotary Screw, Centrifugal

• Gear System  – Helical, Double Helical, Hypoid, Worm

• Hydraulic System • Bearing  – Babbitt, Roller, Spherical Roller, Needle

• Pump  – Piston, Gear, Vane

 – Unit Manufacturer  – Unit Model Number 32

Information Pyramid Transmission

217

PPM Iron Flagging Point

33

Information Pyramid Transmission

 Automatic Transmission Transmission

217

149

PPM Iron Flagging Point

34

Information Pyramid Transmission

217

 Automatic Transmission Transmission 149

 Allison

171

PPM Iron Flagging Point

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Information Pyramid Transmission 217

 Automatic Transmission Transmission

 Allison

HT754CR

171

68

149

PPM Iron Flagging Point

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Information Pyramid Transmission

217

 Automatic Transmission Transmission

149 PPM

 Allison

171

Iron Flagging

HT754CR

68

Point

10µm Fltr

60

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Information Pyramid 217 Lack of information allows 165 ppm where failure may occur!!!

Iron PPM Flagging Point

10µm Fltr

52

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WEAR METAL LIMITS Chrome Nickel  Aluminum Coppe r

Oil

Iron

Gas Turbines

7

1

1

4

35

5

7

62

1

217

Injection Molding Roller Bearing

Rotary Screw Compressors

Sleeve Bearing

Lea d

Tin

6

4

3

20

24

28

30

2

5

15

5

7

7

6

32

120

40

56

19

1

1

1

42

6

1

95

5

4

8

88

54

10

141

4

2

16

26

13

7

493

14

8

59

208

104

56

40

1

1

16

26

20

44

1379

6

4

47

208

160

39 352

DIESEL ENGINE LIMITS BY MFR Chrome Nickel  Aluminum Coppe Lead r

MFR

Iron

Cummins

60

7

4

14

21

47

5

390

46

20

98

147

353

40

66

6

3

9

37

24

5

429

39

15

63

259

180

40

77

7

3

6

17

20

5

501

46

15

42

119

150

40

74

6

5

13

44

16

5

481

39

25

91

308

120

40

92

6

5

8

61

14

5

598

39

25

56

427

105

4040

CAT

Navistar

Volvo

Mack

Tin

DIESEL ENGINE LIMITS BY MODEL Chrome Nickel  Aluminum Coppe Lead r

CAT CAT

Iron

3406E

43

3

3

5

54

5

4

280

20

15

35

378

38

32

49

6

3

9

38

7

5

319

39

15

63

266

53

40

19

3

3

6

43

7

3

124

20

15

42

301

53

24

13

3

3

4

48

5

3

85

20

15

28

336

38

24

57

4

3

6

100

7

6

371

26

15

42

700

53

5441

3304

3512B

3516

C15

Tin

TREND ANALYSIS • Oil Analysis works best when at least three samples have been taken over a short period of time so that trends can be identified • Result trends over a sufficient period of time are more useful than absolute numbers when trying to determine what is occurring in a sampled machine. • Trending and graphing offer an easy to read instantaneous analysis of the condition of the equipment, condition of the lubricant, and level of contamination. • Never base a decision to tear down a machine on the results of only one (1) oil analysis report 42

TREND ANALYSIS • Physical property trends help determine if the best lubricant is being used • Trend analysis helps in scheduling regular maintenance such as oil and/or filter changes • Tren Trend d anal analys ysis is hel helps ps est estab ablilish sh “be “best st practices” maintenance procedures

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TREND ANALYSIS • “Top “Toppi ping ng off off”” will will ske skew w the the tren trend d and and should be noted when the sample is submitted to the laboratory for processing • Note sump or reservoir capacity • Note if multiple components are lubricated from same sump, i.e. motor or turbine, gearbox, compressor

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WHAT IS CONSIDERED SIGNIFICANT CHANGE? • Wear Metals  – an increase of 5 to 20 ppm - depending on the metal and the unit type - or an increase of 100%, whichever is larger

• Contaminant Metals  – an increase of 5 to 10 ppm or an increase of 100%, whichever is larger

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WHAT IS CONSIDERED SIGNIFICANT CHANGE? • Water  – an increase of 100%, or any increase that approaches the advisory levels of that sample point

• Total Acid Number  – an increase of 0.1 for R&O oils  – an increase of 0.2 for AW oils  – an increase of 0.3 for EP oils 46

WHAT IS CONSIDERED SIGNIFICANT CHANGE?

• Viscosity

 – an increase or decrease of 5% • increases usually indicate lubricant degradation • decreases indicate product contamination

• Direct Read Ferrography  – a 50% increase of either DRS or DRL

• ISO Particle Count  – an increase of 2 classes in any of the reporting ranges (2/5/15 or 4/6/14) 47

HOW TO READ OIL ANALYSIS REPORTS 1. Review highest severity reports first •

Does the report suggest maintenance action?  –  Yes • Consider all other available diagnostic information (vibration, thermography, in-line sensors) recommendation or order order more testing. •  Act on the recommendation • If lube change recommendation is due to contamination,  ACT ON RECOMMENDATION to RECOMMENDATION  to ensure fluid integrity

 – No • Is re-sampling recommended?  –  Yes » Send second second sample sample immedi immediately ately or at half half normal normal sample sample interval interval to verify results  – No » Monitor Monitor unit unit vitals vitals and sample sample at normal normal interval interval

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HOW TO READ OIL ANALYSIS ANALYSIS REPORTS 2. Review cautionary reports • Pay particular attention to cautionary data as it becomes more useful as more data is acquired – acquired – trends  trends will become easier to identify and appropriate actions to take will appear clearer. • Samp Sample le res resul ults ts are are “bor “borde derl rlin ine” e” - some wear and contamination contamination results may be flagged but don’t necessarily indicate failure mode or results are not significant significant enough to warrant action.

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HOW TO READ OIL ANALYSIS ANALYSIS REPORTS 3. Review normal reports •  As time permits, permits, review normal normal reports to learn what what “normal” results are for each unit sampled. Trends are then more easily recognized.

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SAMPLE INFORMATION

Severity Status Levels: 0—Normal 1—Some items have violated initial flagging points yet are still considered minor. 2— A trend is developing. 3—Simple maintenance and/or diagnostics are recommended. 4—Failure is eminent if maintenance not performed.

Unit Type and ID should give as much detail as possible. What kind of compressor, gearbox, engine, etc. influences flagging parameters and depth of analysis. Different applications and applications and metallurgies require different lubrication and have great impact on how results are interpreted.

Manufacturer and Model can Model can also identify metallurgies involved as well as the OEM’s standard maintenance guidelines and possible wear patterns to expect.

Lube Manufacturer, Type and Grade identifies a lube’s properties and its viscosity and is critical in determining if the right lube is being used.

Make note of the difference between the Date Sampled and the Date Received by Received by the lab. Turnaround issues may point to storing samples too long before mailing or mail service problems.

Filter Types and their Micron Ratings are important in analyzing particle count— count—the higher the micron rating, the higher the particle count results.

Sump Capacity identifies the total volume of oil (in gallons) in which wear metals are suspended and is critical to trending wear metal concentrations.

Lube Time is how long the oil has been used. Unit Time is the age of the equipment and Lube Added is how much oil has been added since the last sample was taken.

 A Lab # is assigned to the sample upon entry for processing and serves as a reference number when communicating questions or concerns with the laboratory.

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UNDERSTANDING RESULTS ELEMENTAL ANALYSIS Combinations of these Wear Metals can identify components within the machine that are wearing. Knowing what metals a unit is made of can greatly influence an analyst’s recommendations and determine the value of elemental analysis.

Knowledge of the environmental conditions under which a unit operates can explain varying levels of Contaminant Metals. Metals. Excessive levels of dust and dirt can be abrasive and accelerate wear.

Additive and Additive and Multi-Source Metals may Metals may turn up in test results for a variety of reasons. Molybdenum, antimony and boron are additives in some oils. Magnesium, calcium and barium are often used in detergent/dispersant additives. Phosphorous is used as an extreme pressure additive in gear oils. Phosphorous, along with zinc, are used in anti-wear additives (ZDP).

52

TEST DATA High Fuel Dilution decreases Dilution decreases unit load capacity. Excessive Soot Soot is  is a sign of reduced combustion efficiency.

Depending on lube grade, Viscosity is Viscosity is tested at 40° and/or 100° C and reported in centiStokes.

Total Acid Numbers higher than that of new lube indicate oxidation or some type of contamination. When TAN and Total Base Number approach the same number, the lube should be changed or “sweetened,” meaning more lube should be added.

Too much disparity between oxidation and nitration can indicate air to fuel ratio problems. As Oxidation/Nitration increases, Oxidation/Nitration increases, TAN TAN will also increase and TBN will TBN will begin to decrease.

The ISO Code is an index number that represents a range of particles within a specific micron range, i.e. 4, 6, 14. Each class designates a range of measured particles per one ml of sample. The particle count is a cumulative range between 4 and 6 microns. This test is valuable in determining large particle wear in filtered systems.

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UNDERSTANDING RESULTS FLAGGING AND COMMENTING

125 ^^^^^ Numbers with “carrots” printed below them denote test results the analyst has flagged because flagged because they exceed pre-set warning parameters and warrant closer examination or require action.

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Test Reports •

Report 24 metals (wear, contaminant, multi-source & additive

•

10 graphs on every report

•

5 severity status levels

•

Flags clearly identifiable on all reports

•

New lube reference availability

•

Reports accessible by internet, fax and paper

•

Report Particle Sizes and ISO Code 55

 About POLARIS Oil Analysis Wear Debris Analysis Data Interpretation/Alarm Limits Sampling Methods Information Technology

56

SAMPLING • Objectives  – Maximize data density  – Minimize data disturbance  – Determine proper frequency

• Sampling Considerations  – Sampling location  – Sampling hardware  – Sample bottle  – Sample procedure 57

 ACTIVE ZONE SAMPLING SAMPLING • Sample from live fluid zones • Sample from turbulent zones such as elbows • Sample downstream of bearings, gears, pumps, cylinders and actuators • Sample machine during typical working conditions and at normal operating temperature 58

 ACTIVE ZONE ZONE SAMPLING SAMPLING • Don’ Don’tt samp sample le from from dead dead pip pipe e leg legs s or hoses • Don’ Don’tt sam sampl ple e from from lami lamina narr zon zones es • Don’t Don’t sample sample after after filte filters rs or or from from sumps sumps • Don’ Don’tt samp sample le when when mac machi hine ne is is cold cold or or not operating

59

 ACTIVE ZONE ZONE SAMPLING SAMPLING

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SAMPLING PROCEDURES • Sampling Valve - Best • Suction Pump - Second Best • Drain Plug - Least Best • Dip Method - Not Recommended

61

SAMPLING DEVICES Quick Draw • Used on systems with 4-100 lbs. psi with a permanently installed valve and a disposable cap/needle/tube assembly

62

SAMPLING DEVICES Push Button Valve • Used on systems with 4-100 lbs. psi and does not require tubing

Vacuum Pump • Used on non-pressurized systems – systems – pump is attached to sample jar, tubing is inserted into pump and then dipstick or reservoir halfway – halfway – pump activated until jar ¾ full 63

BEST PRACTICES SUMMARY • Samples are taken at normal operating temperature from an active zone upstream of filters and downstream of machine components • Sampling valves and devices are flushed and clean sample bottles are used at each sampling interval • Samples are taken at the proper frequency • Lube type, equipment ID and hours on the oil and the machine are accurately recorded • Samples are forwarded immediately to the laboratory via a trackable shipping service 64

THE IMPORTANCE OF TIME • Trend analysis is most effective when sampling intervals are consistent. • Samples should be taken according to schedule and shipped to the laboratory immediately. • Turnaround issues can often be attributed to the amount of time that elapses from when the sample is taken to the time it ships. 65

Why was Aluminum Flagged?

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High Viscosity V ALUES EXPRESSED IN PA RTS PER MILLION (PPM) B Y W EIGHT W EAR ME TA LS M O A C L L Y H U R B C M N O D O IC I E M P L L N I R N P U E K I I T U U O U B E A E IN M M M N E R D L

LUBE FLUID DATA CONTAMINA NT

ADDITIVE METALS P H M O A S G C P N A H E L O C S R IU IU U M M S

P O S O

IU

T

S

A

IL

S

B M N

O

R IU

M N

O S

D IC

O

V IS @ 1 Z IN C

0 0 C

T A N

12

1

0

3

3

1

1

0

0

2

7

9

0

141

774

221

13. 9

0. 0. 86

14

2

0

4

5

1

0

0

3

2

2

3

0

208

635

236

14. 1

2.6

15

2

0

3

6

2

2

0

5

2

3

3

0

208

635

236

16. 2

2.6

15

2

1

3

6

3

2

0

5

3

4

4

0

275

615

235

16. 8

3.2

I -R NITR NITR 20 21 21 21

I -R GLY GLYC 0 0 0 0

750 790 720 750 CHG. Y Y N Y

I-R I -R I-R WATE WATER HCAR HCARB B OXID 1 771 18 1 722 22 1 784 22 1 752 22

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High Silicon VALUES EXPRESSED IN P ARTS PER MILLION (PPM) BY W EIGHT W EAR METALS M O A C L L H Y U R B C M N O D O IC I E M P L L N I R N U P E K I I T U U O U B E A E IN M M N M E R D L

LUBE FLUID DATA CONTA MINANT

ADDITIVE ME TA LS P H M O A S G C P N A H E L O C S R IU IU U M M S

P O

S S O

IU

T A

IL

S

B M N

O

R IU

M N

O S

D IC

O

V IS @ 1 Z IN C

0 0 C

T A N

12

1

0

3

3

1

1

0

0

2

7

9

0

141

774

221

13. 9

0. 0.86

14

2

0

4

5

1

0

0

3

2

2

3

0

208

635

236

14. 1

2.6

15

2

0

3

6

2

2

0

5

2

3

3

0

208

635

236

14. 2

2.6

15

2

0

3

6

3

2

0

70

3

4

4

0

275

615

235

14. 8

2.6

I -R NITR NITR 20 21 21 21

I-R GLY GLYC 0 0 0 0

750 790 720 750 CHG. Y Y N Y

I -R I-R I-R WATE WATER HCAR HCARB B OXID 1 771 18 1 722 22 1 784 22 1 752 22

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Iron Wear but why? VALUES EXPRESSED IN PARTS PER MILLION (PPM) BY WEIGHT W EA R METALS M O A C L L H Y U R B C M O D O I E M P L L N IR N U P E IU UI O U B E A M M M N R E D

CONTAMINANT

S

E

O

IU

IN

A

IL IC N L

S

C

M N

H

E R

IU M

S

P A L

O S

D

C

S

G N B

O

O

A

T

N K T

O

O R IU

IU O

P H

M P

S IC

ADDITIVE METALS

U M

M

S

15

1

0

3

3

1

1

0

10

2

7

2

0

141

774

21

8

0

4

5

1

0

0

18

5

7

2

0

208

635

97

21

0

3

6

2

2

0

35

6

7

4

0

208

635

211

30

0

3

6

2

2

0

78

5

8

3

0

275

615

I-R W ATER 1 1 1 1

I-R HC HCARB 771 722 784 752

I -R OXID 18 22 22 22

I-R NITR 20 21 23 22

I-R GLYC 0 0 0 0

750 790 720 750 CHG. Y Y N Y

69

Any Questions?

70