ISO 14830-1:2019
(Main)Condition monitoring and diagnostics of machine systems — Tribology-based monitoring and diagnostics — Part 1: General requirements and guidelines
Condition monitoring and diagnostics of machine systems — Tribology-based monitoring and diagnostics — Part 1: General requirements and guidelines
This document specifies requirements and guidelines for the analysis of lubricating oils, hydraulic fluids, synthetic fluids and greases. Tests for electrical insulating oils and heat transfer oil are outside the scope of this document.
Surveillance et diagnostic de l'état des systèmes de machines — Surveillance et diagnostic basés sur la tribologie — Partie 1: Exigences et lignes directrices générales
General Information
Standards Content (Sample)
INTERNATIONAL ISO
STANDARD 14830-1
First edition
2019-12
Condition monitoring and diagnostics
of machine systems — Tribology-
based monitoring and diagnostics —
Part 1:
General requirements and guidelines
Surveillance et diagnostic de l'état des systèmes de machines —
Surveillance et diagnostic basés sur la tribologie —
Partie 1: Exigences et lignes directrices générales
Reference number
ISO 14830-1:2019(E)
©
ISO 2019
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ISO 14830-1:2019(E)
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ISO 14830-1:2019(E)
Contents Page
Foreword .v
Introduction .vi
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 1
4 Symbols (and abbreviated terms) . 2
5 Lubricant and wear particle analysis . 2
5.1 Asset management . 2
5.2 Strategies. 2
5.2.1 Before failure onset (as a proactive strategy tool) . . 2
5.2.2 During failure development (as a predictive strategy tool) . 2
5.2.3 Following machine failure (as a reactive strategy tool) . 2
5.2.4 Other benefits . 2
5.3 Information to be gained through lubricant and wear debris . 3
5.3.1 Lubricant properties . 3
5.3.2 Lubricant contamination . 3
5.3.3 Machine wear . 3
6 Measurement parameters . 3
6.1 Lubricant and wear debris parameters . 3
6.2 Lubricant test suites . 3
6.3 Sampling frequency . 4
7 Sampling . 4
7.1 Objectives. 4
7.2 Pressurized sample points . 5
7.3 Static sample points . 6
7.4 On-line and in-line sampling . 7
7.5 Magnetic plug sampling . 7
7.6 Grease sampling . 8
8 Fluid sampling equipment . 8
8.1 General . 8
8.2 Sample containers . 8
8.3 Sample tubing . 8
8.4 Manually operated hand held sample pumps . 8
8.5 Other equipment . 9
8.6 Sample transport . 9
9 Sample analysis . 9
9.1 General . 9
9.2 On-site analysis . 9
9.3 Off-site analysis .10
9.4 Sample documentation .10
10 Alarm criteria .10
11 Diagnosis and prognosis .11
12 Results reporting .12
13 Personnel qualifications.12
13.1 Field analysts .12
13.2 Laboratory analysts .12
Annex A (informative) Common lubricant and wear debris parameters .13
Annex B (informative) Typical lubricant test suites and frequencies .22
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ISO 14830-1:2019(E)
Annex C (informative) Sampling procedure examples .25
Annex D (informative) Commercial laboratory selection guidelines .29
Annex E (informative) Sample documentation requirements .31
Annex F (informative) Alarm criteria guidelines .33
Annex G (informative) Diagnosis and prognosis guidelines .38
Bibliography .48
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ISO 14830-1:2019(E)
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
through ISO technical committees. Each member body interested in a subject for which a technical
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular, the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2 (see www .iso .org/ directives).
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of
any patent rights identified during the development of the document will be in the Introduction and/or
on the ISO list of patent declarations received (see www .iso .org/ patents).
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation of the voluntary nature of standards, the meaning of ISO specific terms and
expressions related to conformity assessment, as well as information about ISO's adherence to the
World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT) see www .iso .org/
iso/ foreword .html.
This document was prepared by Technical Committee ISO/TC 108, Mechanical vibration, shock and
condition monitoring, Subcommittee SC 5, Condition monitoring and diagnostics of machine systems.
A list of all parts in the ISO 14830 series can be found on the ISO website.
Any feedback or questions on this document should be directed to the user’s national standards body. A
complete listing of these bodies can be found at www .iso .org/ members .html.
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ISO 14830-1:2019(E)
Introduction
Tribology and lubricant-based monitoring is a broad field comprising the activities of monitoring,
reporting and responding to information obtained from the analysis of lubricating oils, hydraulic fluids
and greases. Common terms used to describe this practice are "oil analysis", "lubricant" and "wear
debris". Because it also encompasses the analysis of used hydraulic fluids and greases, this document
generically refers to the entire practice as "lubricant analysis".
Lubricants are used in a wide range of machine types, including stationary industrial equipment
and mobile equipment used in transportation, construction and mining. Examples of machine types
include gearboxes, pumps, hydraulic systems, turbines, compressors, engines and transmissions. Many
different condition types can be analysed and reported in the practice of lubricant and wear debris,
including:
a) quality and condition of new oil deliveries;
b) state of lubricants during storage and dispensing;
c) distressed, degraded or non-compliant in-service lubricant properties;
d) lubricant contamination;
e) wear particle composition and physical characteristics;
f) abnormal failure root causes or stressing conditions.
The methods of gathering and analysing fluid properties and conditions vary widely and evolve directly
from which conditions listed above will be reported. Often instruments and procedures are employed
in a laboratory to analyse lubricant samples. Similar instruments can be used remotely in the field
or plant. In certain cases, instruments or sensors can be used in real time, including on-line particle
analysis, dedicated to a specific machine and fluid.
This document for lubricant condition monitoring, also known as tribodiagnostics, forms a vital
component of asset management and as such will form one of the platform condition monitoring
knowledge base documents required for the application of ISO 55000, ISO 55001 and ISO 55002
(asset management International Standards) to machines which establishes the management system
requirements for performance monitoring.
Using lubricant and wear debris to monitor condition and diagnose faults in machinery is a key activity
in predictive maintenance programmes for most industries. In certain cases, instruments or sensors can
be used in real time, including on-line debris analysis, dedicated to a specific machine and fluid types.
Other non-intrusive technologies including thermography, vibration analysis, acoustic emission and
motor current analysis are used as complementary condition analysis tools. Those in the manufacturing
industry who have diligently and consistently applied these techniques have experienced a return on
investment far exceeding their expectations. However, the effectiveness of these programmes depends
on the capabilities of individuals who perform the measurements and analyse the data.
This document contains general requirements and guidelines for activities relating to monitoring of
physical and chemical properties of lubricants, lubricant contamination and wear particle suspended
in lubricants. The monitoring objective is to assess tribological health and condition of machine system
surfaces, as well as condition of the lubricant itself, to provide information on the operating condition of
the machine for protection and predictive maintenance.
The accuracy and repeatability of lubricant analysis results are dependent upon both sample
acquisition techniques and analyst’s competence. The competence requirements for both are detailed
in ISO 18436-4 and ISO 18436-5.
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INTERNATIONAL STANDARD ISO 14830-1:2019(E)
Condition monitoring and diagnostics of machine
systems — Tribology-based monitoring and diagnostics —
Part 1:
General requirements and guidelines
1 Scope
This document specifies requirements and guidelines for the analysis of lubricating oils, hydraulic
fluids, synthetic fluids and greases.
Tests for electrical insulating oils and heat transfer oil are outside the scope of this document.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any amendments) applies.
ISO 13372, Condition monitoring and diagnostics of machines — Vocabulary
ISO 13379 (all parts), Condition monitoring and diagnostics of machines — Data interpretation and
diagnostics techniques
ISO 13381-1, Condition monitoring and diagnostics of machines — Prognostics — Part 1: General
guidelines
ISO 17359, Condition monitoring and diagnostics of machines — General guidelines
3 Terms and definitions
For the purposes of this document, the terms and definitions given ISO 13372 and the following apply:
ISO and IEC maintain terminological databases for use in standardisation at the following addresses:
— ISO Online browsing platform: available at https:// www .iso .org/ obp
— IEC Electropedia: available at http:// www .electropedia .org/
3.1
analytical ferrography
magnetic precipitation and subsequent analysis of wear particles from a fluid sample
3.2
contamination control
set of planning, organizing, managing and implementing activities for the purpose of achieving and
maintaining a specific contamination level
3.4
tribology
science and technology of interacting surfaces in relative motion, and of related subjects and practices
including lubrication, friction and wear
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ISO 14830-1:2019(E)
4 Symbols (and abbreviated terms)
2
cSt centistoke (1 cSt = 1 mm /s)
L litre
µm micron, micrometre
-6
ppm parts per million, generally by weight (1 ppm = 10 , 10 000 ppm = 1 %)
5 Lubricant and wear particle analysis
5.1 Asset management
Lubricant and wear debris analysis is one of the key methodologies required for the monitoring of
machinery asset performance and condition. The overarching management system for condition
monitoring should be in accordance with ISO 55001, which establishes the management system
requirements for performance monitoring and enables the achievement of the asset management
principles contained in ISO 55000.
5.2 Strategies
5.2.1 Before failure onset (as a proactive strategy tool)
Before the lubricant is used and prior to the onset of failure, lubricant, contamination and wear debris
analysis can confirm that the lubricant is physically and chemically fit for service and compatible prior
to use and that the machine contains the correct lubricant. It also confirms that contamination levels
are within acceptable limits. Lubricant and wear debris can be an important tool in efforts to assure
quality of new lubricant deliveries and fitness for service, storage and dispensing effectiveness, and
reclamation activities. These are proactive applications of the practice that have the potential to extend
machinery life.
5.2.2 During failure development (as a predictive strategy tool)
When a machine fails, wear particles, contaminants and lubricant property changes are often produced
prior to any observable operational deterioration. Lubricant, contamination and wear particle analysis
provides early detection and diagnosis of problems. Failure prognostics, the process of estimating
residual machine or lubricant life, can also be performed. Prognostic forecasts are improved when
multiple data parameters are measured and defined. This process can include comparison with
benchmarking and manufacturer’s data.
5.2.3 Following machine failure (as a reactive strategy tool)
Users can analyse lubricant properties, wear particles and contaminants from a failed machine to
diagnose problems and design solutions to prevent recurrence.
5.2.4 Other benefits
Lubricant and wear debris can be used to avoid unnecessary oil changes or extend drain intervals,
resulting in reduced lubricant consumption and associated costs. In certain hazardous applications, it
can help ensure safety of machinery. Lubricant and wear debris can also be used to optimize lubricant
selection, potentially resulting in reduced energy consumption.
Machine criticality, probability of failure and operating environment (temperature, contamination, etc.)
are other factors that influence the selection of lubricant and wear debris type and sampling frequency.
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ISO 14830-1:2019(E)
5.3 Information to be gained through lubricant and wear debris
5.3.1 Lubricant properties
This category of analysis deals with the assessment of chemical, physical and additive properties of a
lubricant, to confirm its identity and that it complies with specified requirements.
5.3.2 Lubricant contamination
External contaminants of various types can be either externally ingested or internally generated. They
can enter systems and lubricants during manufacture or servicing, or from the environment or internal
generation. It can also include microbiological inclusive of bacteria, fungus and yeast organisms
requiring specialised testing.
Contamination compromises machine reliability and promotes lubricant failure. Lubricant analysis
targeting contamination can help ensure goal-driven targets for contamination control are maintained.
5.3.3 Machine wear
When friction surfaces wear, they generate wear particles that enter the lubricant. Monitoring and
analysis of internally generated wear particles enable the detection and evaluation of abnormal
conditions, which assists in directing necessary remedial actions.
6 Measurement parameters
6.1 Lubricant and wear debris parameters
Commonly measured used lubricant and wear debris parameters are summarised in Annex A.
Many parameters have multiple test methodologies or instruments, each with specific limitations of
detection, accuracy, repeatability and reproducibility. The lubricant and wear debris program strategies
and objectives determine the most appropriate test method(s) to employ.
Test method modifications can vary between laboratories, resulting in differences in results.
Sometimes, results cannot be comparable between instruments due to variances in test method and
instrumentation. Tests are also susceptible to human and method error.
The valve arrangement for sampling can also give a great variation in results, due to the narrow
passages of the valve, which has an increasing influence as system pressure increases.
Many commonly used ISO, ASTM and equivalent test methods are designed for testing new lubricants.
The properties of used lubricants can cause variation of test results.
6.2 Lubricant test suites
Single lubricant tests cannot usually satisfy all analysis objectives, particularly for routine condition
monitoring. For this reason, a suite of tests is normally performed to measure all parameters of
interest. Test selection criteria include machine and lubricant type, likely failure modes and symptoms,
and technique sensitivity, accuracy and feasibility.
Typical test suites for common lubricant types and applications are shown in the tables of Annex B. Also
shown are exception tests that may be applied when investigating particular problems.
The same suite of tests should generally be used for each lubricant type and application. Variables that
typically change are frequency of testing and parameter alarm levels.
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ISO 14830-1:2019(E)
6.3 Sampling frequency
FMSA analysis, which shall be carried out in accordance with ISO 13379-1, is recommended to determine
initial sampling and inspection periods. These should be short to allow creation of a baseline for each
machine. The tables in Annex B also show typical frequencies for common tests and lubricant types.
Similar practices can be employed to determine magnetic particle detector inspection periods.
Sampling and inspection intervals can be optimised by taking into account the following machine and
application-specific conditions:
a) Criticality: safety, environmental, downtime, repair and business interruption failure consequences.
b) Operational and fluid environment conditions: these influence frequency and rate of machine and
lubricant failure. They include pressure, load, temperature, speed, contaminant ingression rate,
wear rate and duty cycle severity.
c) Lubricant age: problems often occur immediately after lubricants are serviced (drains, refills and
top-ups) due to contamination by incorrect and/or incompatible lubricants. Lubricants approaching
the end of their useful life are also at high risk due to depleted additives, incipient oxidation and
high levels of various contaminants.
d) Machine age and maintenance factors: the chances of failure for most machines are greater during
break-in and after major repairs, rebuilds or extended downtime; or machine modifications. Risks
can also increase as a machine approaches the end of its expected life.
e) Failure behaviour: known and expected failure modes, including historical P-F intervals (as defined
in IEC 60300-3-11) for failure mode and measurement technique combinations.
f) Machine condition: whenever abnormal condition reports are received, sampling frequency should
be increased to improve diagnosis and prognosis confidence.
Computer based software is available to manage lubricant and wear particle sampling intervals, based
on condition analysis results obtained. This makes use of cumulative distribution and probability
density functions, suitably adjusted for time intervals, condition status and cost/risk potential. As
a further step, when combined with costs of inspection and failure, the software can determine the
economically optimum point to undertake inspection.
7 Sampling
7.1 Objectives
Analysis results interpretation is only valid if samples are representative of the lubricant under
operating conditions. Errors in obtaining samples impair all further analytical efforts. Example
procedures are given in Annex C.
The primary goals of sampling are:
a) Maximizing data density: information contained per sample unit volume.
b) Minimizing data disturbance: information is uniform, consistent and unaltered by the process.
Ensure samples are not contaminated; this can distort the data, making it difficult to distinguish
between contaminants and what was originally in the lubricant.
When selecting and locating sample points, inclusive of wear particle and contamination detectors, the
following applies:
i) Sampling points shall provide safe acquisition of the sample during dynamic operating conditions if
required.
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ISO 14830-1:2019(E)
ii) Points should provide representative and repeatable samples, be easy to use, minimize leaks or
spills and be self-sealing if appropriate. They should be located in areas with minimal contamination
that are easily and safely accessible during normal machine operation.
iii) Sample points shall be compatible with the fluid, operating pressure, external environment,
sampling procedure and analysis type used.
iv) Point design should minimize areas where contaminants can settle out when not in use, minimize
generation of internal contaminants and permit self-flushing. They should be easily cleanable
externally and
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