1、Designation: D 7416 09Standard Practice forAnalysis of In-Service Lubricants Using a Particular Five-Part (Dielectric Permittivity, Time-Resolved DielectricPermittivity with Switching Magnetic Fields, Laser ParticleCounter, Microscopic Debris Analysis, and OrbitalViscometer) Integrated Tester1This s
2、tandard is issued under the fixed designation D 7416; the number immediately following the designation indicates the year oforiginal adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon () indicates an ed
3、itorial change since the last revision or reapproval.1. Scope1.1 This practice covers procedures for analysis of in-service lubricant samples using a particular five-part (dielectricpermittivity, time-resolved dielectric permittivity with switch-ing magnetic fields, laser particle counter, microscop
4、ic debrisanalysis, and orbital viscometer) integrated tester to assessmachine wear, lubrication system contamination, and lubricantdielectric permittivity and viscosity. Analyzed results triggerrecommended follow-on actions which might include conduct-ing more precise standard measurements at a labo
5、ratory. Wearstatus, contamination status, and lubricant dielectric permittiv-ity and viscosity status are derived quantitatively from multipleparameters measured.1.2 This practice is suitable for testing incoming and in-service lubricating oils in viscosity grades 32 mm2/s at 40C to680 mm2/s at 40C
6、having petroleum or synthetic base stock.This practice is intended to be used for testing in-servicelubricant samples collected from pumps, electric motors,compressors, turbines, engines, transmissions, gearboxes,crushers, pulverizers, presses, hydraulics and similar machin-ery applications. This pr
7、actice addresses operation and stan-dardization to ensure repeatable results.1.3 This practice is not intended for use with crude oils.1.4 The values stated in SI units are to be regarded asstandard. No other units of measurement are included in thisstandard.1.5 This standard does not purport to add
8、ress all of thesafety concerns, if any, associated with its use. It is theresponsibility of the user of this standard to establish appro-priate safety and health practices and determine the applica-bility of regulatory limitations prior to use.2. Referenced Documents2.1 ASTM Standards:2D 341 Test Me
9、thod for Viscosity-Temperature Charts forLiquid Petroleum ProductsD 445 Test Method for Kinematic Viscosity of Transparentand Opaque Liquids (and Calculation of Dynamic Viscos-ity)D 924 Test Method for Dissipation Factor (or Power Factor)and Relative Permittivity (Dielectric Constant) of Electri-cal
10、 Insulating LiquidsD 1298 Test Method for Density, Relative Density (SpecificGravity), or API Gravity of Crude Petroleum and LiquidPetroleum Products by Hydrometer MethodD 4057 Practice for Manual Sampling of Petroleum andPetroleum ProductsD 4177 Practice for Automatic Sampling of Petroleum andPetro
11、leum ProductsE 617 Specification for Laboratory Weights and PrecisionMass StandardsE 1951 Guide for Calibrating Reticles and Light Micro-scope MagnificationsD 6300 Practice for Determination of Precision and BiasData for Use in Test Methods for Petroleum Products andLubricants2.2 ISO Standards:3ISO
12、11171 Hydraulic fluid powerCalibration of automaticparticle counters for liquids3. Terminology3.1 Definitions:1This practice is under the jurisdiction of ASTM Committee D02 on PetroleumProducts and Lubricants and is the direct responsibility of Subcommittee D02.96 onIn-Service Lubricant Testing and
13、Condition Monitoring Services.Current edition approved July 1, 2009. Published August 2009. Originallyapproved in 2008. Last previous edition approved in 2008 as D 741608.2For referenced ASTM standards, visit the ASTM website, www.astm.org, orcontact ASTM Customer Service at serviceastm.org. For Ann
14、ual Book of ASTMStandards volume information, refer to the standards Document Summary page onthe ASTM website.3Available from International Organization for Standardization (ISO), 1, ch. dela Voie-Creuse, Case postale 56, CH-1211, Geneva 20, Switzerland, http:/www.iso.ch.1Copyright ASTM Internationa
15、l, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.3.1.1 integrated tester, nautomated, or semi-automatedstand alone instrument utilizing multiple technologies to pro-vide diagnostic recommendations (on-site or in-line) for con-dition monitoring of in-service lubr
16、icants.3.2 Definitions of Terms Specific to This Standard:3.2.1 chemistry index (Chem Index), nparameter com-puted from dielectric permittivity increase compared to newoil. The value is equal to dielectric difference multiplied by100.3.2.2 chemistry status (Chem Status), ndiagnostic sever-ity rankin
17、g having 0 to 100 score based on the highest alarmindication of dielectric permittivity and viscosity measure-ments.3.2.3 counts $ 4, nsensor 3 measured particle counts permL for particles $ 4 m.3.2.4 counts $ 6, nsensor 3 measured particle counts permL for particles $ 6 m.3.2.5 counts$10, nsensor 3
18、 measured particle counts permL for particles $ 10 m.3.2.6 counts $ 14, n sensor 3 measured particle countsper mL for particles $ 14 m.3.2.7 counts $ 18, n sensor 3 measured particle countsper mL for particles $ 18 m.3.2.8 counts $ 22 sensor 3 measured particle counts permL for particles $ 22 m.3.2.
19、9 counts $ 26sensor 3 measured particle counts permL for particles $ 26 m.3.2.10 counts$32 sensor 3 measured particle counts permL for particles $ 32 m.3.2.11 counts $ 38sensor 3 measured particle counts permL for particles $ 38 m.3.2.12 contaminant status (Cont Status), ndiagnostic se-verity rankin
20、g having 0 to 100 score based on the highest alarmindication of all contamination related parameters.3.2.13 dual-screen patch maker, napparatus with screensto support individual (most often) or stacked (occasionally forsize segregation) filter patches used to extract solid particlesfrom in-service l
21、ubricating fluid as the fluid is evacuated fromsensor 2 test chamber. This item is often referred to simply as“patch maker.”3.2.14 ferrous index (Fe Index), nferrous density typeparameter measuring relative concentration and size of mag-netically responsive iron particles $ 5 m collected on adielect
22、ric permittivity sensor.3.2.15 large contaminant droplet (LCont D), nindicationreporting sensor 2 detects presence of free-water drops in oil.3.2.16 large contaminant ferrous (LCont Fe), nindicationreporting sensor 2 detects presence of very large ferrous-metalparticles in oil, which are often the k
23、ind produced by abrasivewear mechanisms.3.2.17 large contaminant non-ferrous (LCont NF),nindication reporting sensor 2 detects presence of very largenon-ferrous-metal particles in oil, which are often the kindproduced by abrasive wear mechanisms.3.2.18 orbital viscometer, nfour-pole, magneticallydri
24、ven, orbital viscometer.3.2.19 new oil, nsample of as-purchased new oil assupplied by a manufacturer for use to measure baselinereference values for the following reference oil properties:dielectric permittivity, specific gravity (Test Method D 1298),kinematic viscosity at 40C (Test Method D 445), k
25、inematicviscosity at 100C (Test Method D 445), and sensor 2 waterfactor.3.2.20 particular five-part integrated tester, nintegratedtester including these five parts:4,5sensor 1 (dielectric permit-tivity sensor), sensor 2 (time-resolved dielectric permittivitysensor with switching magnetic fields),5,6
26、sensor 3 (laserparticle counter),5,7dual-screen patch maker (initial step inmicroscopic debris analysis),5,8and orbital viscometer.5,93.2.21 particle count ppm by volume10% are notacceptable. Avoid coincidence by performing second dilutionprior to sensor 3 testing. For example, if you dilute 4-to-1,
27、 thenyou can expect to detect less than 5 3 20 000 or 100 000particles per mL.7. Apparatus7.1 Bench Top SetupThe particular five-part integratedtester5,10with example arrangement shown in Fig. 1.7.2 Core AnalyzerThe core analyzer as shown on right inFig. 1 incorporates sensor 1 (dielectric permittiv
28、ity sensor),sensor 2 (time-resolved-dielectric-permittivity measurementwith switching electromagnet), sensor 3 (laser particle count-ing sensor), and a patch maker as outlined in the followingparagraphs. The core analyzer connects directly to the balance,orbital viscometer, and computer application.
29、 In addition, itcreates filter patches for wear debris analysis (WDA) classifi-cation and WDA severity determination.7.2.1 Sensor 1 includes a concentric-shell-type-capacitordielectric permittivity measurement sensor. Test fluid is in-jected into a port and pushed up around the annular spacebetween
30、a central metal electrode and the electrically groundedouter metal shell. By filling the cavity from the bottom, air isdisplaced as the fluid rises to fill the entire volume of thesensor. It takes approximately 8 mL of test fluid to completelyfill the tubing and sensor. Dielectric permittivity measu
31、rementis made by measuring capacitance of the calibrated sensor. Theconcentric-shell-type-capacitor dielectric permittivity is cali-brated to within 61 % of known values for standardizationfluids A, B, and C.7.2.2 Sensor 2 includes (1) a concentric-trace-type-capacitor dielectric permittivity measur
32、ement sensor mountedabove (2) a dual-coil electromagnet suitable for introducingswitching magnetic fields through the sensing surface.7.2.2.1 Sensor 2 performs a time-resolved-dielectric-permittivity measurement involving 360 separate measure-ments taken at 0.5-s intervals covering a total elapsed t
33、est timeof 3 min. During the first 2 min, the switching electromagnetproduces alternating axial-field and then radial-field patternswhich orient and re-orient ferrous particles on the sensorsurface at 0.5-s intervals, synchronous with the sequentialdielectric permittivity measurements. After 2 min,
34、the fieldpatterns are modified to draw ferrous debris entirely away fromthe concentric-trace-type capacitor sensor. The maximum fer-rous concentration on the sensor is detected at the end of 240measurements (2 min) and the maximum non-ferrous particleand water concentration is detected at the end of
35、 360 measure-ments (3 min). After the test sequence is completed, theelectromagnet coils are pulsed through a demagnetization ordegaussing sequence so that ferrous debris are easily flushedaway during cleaning.7.2.2.2 The concentric-trace-type-capacitor dielectric per-mittivity measuring sensor is c
36、onstructed using gold platedcopper traces on a ceramic-fiber reinforced PTFE (polytet-rafluoroethylene) substrate with a grounded metal backplane.The sensor is calibrated to within 62 % of standard values forstandardization fluids A, B, and C.7.2.2.3 The dual-coil electromagnet is used to collect an
37、dmanipulate ferrous debris on the sensor surface. The dual-coilelectromagnet produces -300 6 30 G field strength on thesensor surface above the center-post when both coils arepowered with fields adding, and it produces 70 6 2 G fieldstrength when the magnets when the polarity of the outer coilis rev
38、ersed so it effectively overpowers the inner coil. Theserelative field strengths allow the analyzer to gather ferrousdebris above the center-post, orient ferrous debris in axial andradial geometric pattern, and sweep ferrous debris off thesensor surface.7.2.3 Sensor 3 includes a laser particle count
39、ing sensormounted immediately below a Luer-tip injection port. Sampletest fluid is diluted, homogenized, drawn into 30 mL syringe,degassed, and then injected via the Luer-tip port through the10The sole source of supply of the apparatus known to the committee at this timeis A520010 Comprehensive Mini
40、lab, apparatus, and accessories, available fromMachinery Health Management, Emerson Process Management, 835 InnovationDrive, Knoxville, TN 37932.FIG. 1 Example of Layout for a Particular Five-Part IntegratedTesterD7416094laser window. Flow rate through the particle counter is main-tained at constant
41、 50 mL/min using a stepper-motor controlledsyringe pump. Sensor 3 is standardized using MTD standard-ization fluid in accordance with ISO 11171.7.3 Orbital ViscometerThe orbital viscometer measuresabsolute viscosity, also called dynamic viscosity, at a particulartemperature in units of centigrade (C
42、). A cross section of theorbital viscometer is shown in Fig. 2. The 12 mL sample testcup is filled with test fluid and contains a steel ball that orbitsaround the base of the test cup under the influence of foursequentially powered electromagnets. Under the circular pathof the ball are four ball-pos
43、ition sensors. Each time the ballpasses over one sensor, the next electromagnet is energized,thereby the orbital speed of the ball is a function of test fluidabsolute viscosity.Atemperature sensor in the center-bottom ofthe sample test cup measures temperature. A fan inside theorbital viscometer con
44、stantly pulls air around the electromag-net coils to keep the orbital viscometer from self heating. Thecomputer application software processes and controls theorbital viscometer, and uses the viscosity-temperature relation-ship as defined in Test Method D 341 to translate values fromroom temperature
45、 absolute viscosity (mPa 3 s) into 25Cabsolute viscosity (mPa 3 s) and into 40C kinematic viscosity(mm2/s). To do this, the application software uses laboratorymeasured values from its new oil database: specific gravity,kinematic viscosity at 40C, and kinematic viscosity at 100C.NOTE 1The viscosity
46、measurement is performed at room temperatureand converted to 40C using calculation based on user supplied new oilinformation.7.4 MicroscopeA microscope enables the operator toperform analytical wear debris analysis of 25-mm diameterfilter patches. As a minimum the microscope shall provideviewing sta
47、ge with top-lighting and magnification from 30 to2303. The microscope imaging system is standardized on thecomputer display (pixels per micron) using application soft-ware and a captured image from a NIST traceable lengthstandard (see 12.5).7.5 Computer Application SoftwareThe computer appli-cation
48、software provides the functionality for the particularfive-part integrated tester: an electronic user interface, hierar-chical equipment database to store and analyze and managedata, step-by-step testing guide, imbedded logic for datainterpretation, and automatic reporting tools.7.6 Solvent Filtrati
49、on DeviceThis device is used fordispensing the diluting and cleaning solvents. The device filterssolvents from the pressurized dispenser by passing the fluidthrough a 0.8-m (typical) filter patch.8. Reagents and Materials8.1 Disposable Luer-tip 10-mL SyringesSyringes shall besupplied individually wrapped to prevent contamination. Sy-ringes are all plastic with no rubber seals on plunger. Rubbermaterials may have material compatibility problems with somesolvents. Syringes are not reusable.8.2 Disposable Luer-tip 30-mL SyringesSyring
