D02.96.07 - Integrated Testers, Instrumentation Techniques for In-Service Lubricants

SIGNIFICANCE AND USE
5.1 Trending the wear, contamination, consistency, and oxidative properties of a lubricating grease is a crucial part of condition-monitoring programs. Changes in these properties or deviations from the new grease can be indicative of problems within the lubricated component, such as the mixing of incompatible thickener types, excessive wear or contaminant levels, or significant depletion of antioxidant levels. These test methods also makes it possible to develop trends that can be used to predict failures before they occur and allow for corrective action to be taken.
SCOPE
1.1 This test method covers the determination and evaluation of flow properties, wear levels, contaminants, and oxidative condition of new and in-service lubricating grease.  
1.2 This test method provides guidance on evaluating in-service grease samples, NLGI grades 00 to 3, for wear, consistency, contamination, and oxidation.  
1.3 The values stated in SI units are to be regarded as the standard. The values given in parentheses are for information only.  
1.3.1 Exception—The exception to this will be where units of references were developed by the developers of the test equipment and necessary to report the results of the test.  
1.4 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.  
1.5 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

SIGNIFICANCE AND USE
5.1 This test method is intended for use in analytical laboratories including on-site in-service oil analysis laboratories. Periodic sampling and analysis of lubricants have long been used as a means to determine overall machinery health. Atomic emission spectroscopy (AES) is often employed for wear metal analysis (Test Methods D5185 and D6595). A number of physical property tests complement wear metal analysis and are used to provide information on lubricant condition (Test Methods D445, D2896, D6304, and D7279). Molecular spectroscopy (Practice E2412) provides direct information on molecular species of interest including additives, lubricant degradation products and contaminating fluids such as water, fuel and glycol. Direct imaging integrated testers provide complementary information on particle count, particle size, particle type, and soot content.  
5.2 Particles in lubricating and hydraulic oils are detrimental because they increase wear, clog filters and accelerate oil degradation.  
5.3 Particle count may aid in assessing the capability of a filtration system to clean the fluid, determine if off-line recirculating filtration is needed to clean the fluid, or aid in the decision whether or not to change the fluid.  
5.4 An increase in the concentration and size of wear particles is indicative of incipient failure or component change out. Predictive maintenance by oil analysis monitors the concentration and size of wear particles on a periodic basis to predict failure.  
5.5 High soot levels in diesel engine lubricating oil may indicate abnormal engine operation.
SCOPE
1.1 This test method covers the determination of particle concentration, particle size distribution, particle shape, and soot content for new and in-service oils used for lubrication and hydraulic systems by a direct imaging integrated tester.  
1.1.1 The test method is applicable to petroleum and synthetic based fluids. Samples from 2 mm2/s to 150 mm2/s at 40 °C may be processed directly. Samples of greater viscosity may be processed after solvent dilution.  
1.1.2 Particles measured are in the range from 4 μm to ≥ 70 μm with the upper limit dependent upon passing through a 100 μm mesh inlet screen.  
1.1.3 Particle concentration measured may be as high as 5 000 000 particles per mL without significant coincidence error.  
1.1.4 Particle shape is determined for particles greater than approximately 20 µm in length. Particles are categorized into the following categories: sliding, cutting, fatigue, nonmetallic, fibers, water droplets, and air bubbles.  
1.1.5 Soot is determined up to approximately 1.5 % by weight.  
1.1.6 This test method uses objects of known linear dimension for calibration.  
1.2 The values stated in SI units are to be regarded as standard. No other units of measurement are included in this standard.  
1.3 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.  
1.4 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

SIGNIFICANCE AND USE
4.1 This practice is intended for the application of in-line, full-flow inductive wear debris sensors. According to (1), passing the entire lubrication oil flow for aircraft and aero-derivative gas turbines through a debris-monitoring device is a preferred approach to ensure sufficient detection efficiency.  
4.2 Periodic sampling and analysis of lubricants have long been used as a means to determine overall machinery health (2). The implementation of smaller oil filter pore sizes for machinery operating at higher rotational speeds and energies has reduced the effectiveness of sampled oil analysis for determining abnormal wear prior to severe damage. In addition, sampled oil analysis for equipment that is remote or otherwise difficult to monitor or access is not practical. For these machinery systems, in-line wear debris sensors can be very useful to provide real-time and near-real-time condition monitoring data.  
4.3 In-line full-flow inductive debris sensors have demonstrated the capability to detect and quantify both ferromagnetic and non-ferromagnetic metallic wear debris. These sensors record metallic wear debris according to size, count, and type (ferromagnetic or non-ferromagnetic). Sensors are available for a variety of oil pipe sizes. The sensors are designed specifically for the protection of rolling element bearings and gears in critical machine applications. Bearings are key elements in machines since their failure often leads to significant secondary damage that can adversely affect safety, operational availability, or operational/maintenance costs, or a combination thereof.  
4.4 The main advantage of the sensor is the ability to detect early bearing damage and to quantify the severity of damage and rate of progression of failure towards some predefined bearing surface fatigue damage limiting wear scar. Sensor capabilities are summarized as follows:  
4.4.1 In-line full flow non-intrusive inductive metal detector with no moving parts.  
4.4.2 Det...
SCOPE
1.1 This practice covers the minimum requirements for an in-line, non-intrusive, through-flow oil debris monitoring system that monitors ferromagnetic and non-ferromagnetic metallic wear debris from both industrial aero-derivative and aircraft gas turbine engine bearings. Gas turbine engines are rotating machines fitted with high-speed ball and roller bearings that can be the cause of failure modes with high secondary damage potential.  (1)2  
1.2 Metallic wear debris considered in this practice range in size from 120 μm (micron) and greater. Metallic wear debris over 1000 μm are sized as over 1000 μm.  
1.3 This practice is suitable for use with the following lubricants: polyol esters, phosphate esters, petroleum industrial gear oils and petroleum crankcase oils.  
1.4 This practice is for metallic wear debris detection, not cleanliness.  
1.5 The values stated in SI units are to be regarded as standard. The values given in parentheses are provided for information only.  
1.6 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.  
1.7 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

SIGNIFICANCE AND USE
5.1 In-plant Oil Analysis—The particular five-part integrated tester practice is primarily used by plant maintenance personnel desiring to perform on-site analysis of as-received and in-service lubricating oils.  
5.2 Detect Common Lubrication Problems—The software application interprets data from integration of multiple sensing technologies to detect common lubrication problems from inadvertent mixing of dissimilar lubricant viscosity grades and from particulate or moisture contamination. The redundant views of ferrous particulates (sensor 2), all particulates larger than 4 μm (sensor 3), and all solid particulates larger than filter patch pore size (patch maker) provides screening for oil wetted mechanical system failure mechanisms from incipient to catastrophic stages.  
5.3 Supported by Off-Site Lab Analysis—The particular five-part integrated tester is normally used in conjunction with an off-site laboratory when exploring the particular nature of an alarming oil sample. An off-site laboratory should be consulted for appropriate additional tests.
SCOPE
1.1 This practice covers procedures for analysis of in-service lubricant samples using a particular five-part (dielectric permittivity, time-resolved dielectric permittivity with switching magnetic fields, laser particle counter, microscopic debris analysis, and orbital viscometer) integrated tester to assess machine wear, lubrication system contamination, and lubricant dielectric permittivity and viscosity. Analyzed results trigger recommended follow-on actions which might include conducting more precise standard measurements at a laboratory. Wear status, contamination status, and lubricant dielectric permittivity and viscosity status are derived quantitatively from multiple parameters measured.  
1.2 This practice is suitable for testing incoming and in-service lubricating oils in viscosity grades 32 mm2/s at 40 °C to 680 mm2/s at 40 °C having petroleum or synthetic base stock. This practice is intended to be used for testing in-service lubricant samples collected from pumps, electric motors, compressors, turbines, engines, transmissions, gearboxes, crushers, pulverizers, presses, hydraulics and similar machinery applications. This practice addresses operation and standardization 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 as standard. No other units of measurement are included in this standard.  
1.5 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.  
1.6 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

SIGNIFICANCE AND USE
5.1 This practice is intended for the application of online, full-flow, or slip-stream sampling of wear debris via inductive sensors for gearbox and drivetrain applications.  
5.2 Periodic sampling and analysis of lubricants have long been used as a means to determine overall machinery health. The implementation of smaller oil filter pore sizes for machinery has reduced the effectiveness of sampled oil analysis for determining abnormal wear prior to severe damage. In addition, sampled oil analysis for equipment that is remote or otherwise difficult to monitor or access is not always sufficient or practical. For these machinery systems, in-line wear debris sensors can be very useful to provide real-time and near-real-time condition monitoring data.  
5.3 Online inductive debris sensors have demonstrated the capability to detect and quantify both ferromagnetic and non-ferromagnetic metallic wear debris (1, 2). These sensors record metallic wear debris according to size, count, and type (ferromagnetic or non-ferromagnetic). Sensors can be fitted to virtually any lubricating system. The sensors are particularly effective for the protection of rolling element bearings and gears in critical machine applications. Bearings are key elements in machines since their failure often leads to significant secondary damage that can adversely affect safety, operational availability, operational/maintenance costs, or combinations thereof.  
5.4 The key advantage of online metallic debris sensors is the ability to detect early bearing and gear damage and to quantify the severity of damage and rate of progression toward failure. Sensor capabilities are summarized as follows:  
5.4.1 Can detect both ferromagnetic and non-ferromagnetic metallic wear debris.  
5.4.2 Can detect 95 % or more of metallic wear debris above some minimum particle size threshold.  
5.4.3 Can count and size wear debris detected.  
5.4.4 Can provide total mass loss.
Note 1: Mass is an inferred value which ...
SCOPE
1.1 This practice covers the minimum requirements for an online inductive sensor system to monitor ferromagnetic and non-ferromagnetic metallic wear debris present in in-service lubricating fluids residing in gearboxes and drivetrains.  
1.2 Metallic wear debris considered in this practice can range in size from 40 μm to greater than 1000 μm of equivalent spherical diameter (ESD).  
1.3 This practice is suitable for use with the following lubricants: industrial gear oils, petroleum crankcase oils, polyalkylene glycol, polyol esters, and phosphate esters.  
1.4 This practice is for metallic wear debris detection, not oil cleanliness.  
1.5 The values stated in SI units are to be regarded as standard. No other units of measurement are included in this standard.  
1.5.1 Exception—Subsection 7.7 uses “G’s”.  
1.6 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.  
1.7 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

SIGNIFICANCE AND USE
5.1 The integrated tester is primarily used to perform on-site analysis of in-service lubricants used in the automotive, highway trucking, mining, construction, off-road “mining,” marine, industrial, power generation, agriculture, and manufacturing industries.  
5.2 The immediate results of analysis of in-service lubricants are critical when performing proactive and preventative maintenance. On-site oil analysis, when used in conjunction with these programs, allows continuous system monitoring and contamination control potentially improving equipment “up-time” and equipment life.
SCOPE
1.1 This test method covers the quantitative analysis of in-service lubricants using an automatic testing device that integrates these varied technologies: atomic emission spectroscopy, infrared spectroscopy, viscosity, and particle counting.  
1.2 This is suited for in-service lubricating oils having viscosities in the range between ISO 10 and ISO 320 and properties in the ranges given in Tables 1 and 2.
TABLE 1 Element Test Parameters Measured, Calculated, and Reported    
Element  
Low Range, mg/kg  
High Range, mg/kg  
Element  
Low Range, mg/kg  
High Range, mg/kg  
Aluminum  
5 to 100  
NA  
Molybdenum  
10 to 1000  
NA  
Barium  
25 to 150  
150 to 2000  
Nickel  
5 to 100  
NA  
Boron  
5 to 100  
100 to 1000  
Phosphorous  
100 to 600  
600 to 4000  
Calcium  
25 to 500  
500 to 9000  
Potassium  
10 to 1000  
1000 to 4000  
Chromium  
8 to 100  
NA  
Silicon  
5 to 150  
150 to 3000  
Copper  
5 to 500  
500 to 1000  
Sodium  
10 to 1000  
NA  
Iron  
6 to 1000  
1000 to 3000  
Tin  
6 to 100  
NA  
Lead  
6 to 150  
NA  
Titanium  
8 to 100  
NA  
Magnesium  
5 to 100  
100 to 3000  
Vanadium  
7 to 100  
NA  
Manganese  
5 to 100  
NA  
Zinc  
8 to 100  
100 to 4000  
TABLE 2 Physical Properties Parameters Measured, Calculated, and Reported
Note 1: Review Test Method D4739 and D2896 for particular lubricating oil applications.    
Physical Property  
Range  
Water, % by mass  
0.1 to 3  
Glycol, % by mass  
0.1 to 2  
Soot, % by mass  
0.1 to 4  
Fuel Dilution, % by mass  
0.1 to 15  
Oxidation, abs.  
0.1 to 50  
Nitration, abs.  
0.1 to 35  
Calculated Viscosity - IR  
4 to 35 (100° cSt)  
Viscosity 40 °C, cSt (optional)  
30 to 320  
Viscosity 100 °C, cSt (optional)  
5 to 25    
Viscosity Index  
5 to 150  
Base Number, mg/g KOH  
1.0 to 17  
1.3 This test method may be used to establish trends in wear and contamination of in-service lubricants and may not give equivalent numerical results to current ASTM test methods.  
1.4 This test method is not intended for use with crude oil.  
1.5 The values stated in SI units are to be regarded as standard. No other units of measurement are included in this standard.  
1.6 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use. (Specific hazard statements are given in Section 9 and 11.3.)  
1.7 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

SIGNIFICANCE AND USE
5.1 Trending the wear, contamination, consistency, and oxidative properties of a lubricating grease is a crucial part of condition-monitoring programs. Changes in these properties or deviations from the new grease can be indicative of problems within the lubricated component, such as the mixing of incompatible thickener types, excessive wear or contaminant levels, or significant depletion of antioxidant levels. These test methods also makes it possible to develop trends that can be used to predict failures before they occur and allow for corrective action to be taken.
SCOPE
1.1 This test method covers the determination and evaluation of flow properties, wear levels, contaminants, and oxidative condition of new and in-service lubricating grease.  
1.2 This test method provides guidance on evaluating in-service grease samples, NLGI grades 00 to 3, for wear, consistency, contamination, and oxidation.  
1.3 The values stated in SI units are to be regarded as the standard. The values given in parentheses are for information only.  
1.3.1 Exception—The exception to this will be where units of references were developed by the developers of the test equipment and necessary to report the results of the test.  
1.4 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.  
1.5 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

SIGNIFICANCE AND USE
5.1 Trending the wear, contamination, consistency, and oxidative properties of a lubricating grease is a crucial part of condition-monitoring programs. Changes in these properties or deviations from the new grease can be indicative of problems within the lubricated component, such as the mixing of incompatible thickener types, excessive wear or contaminant levels, or significant depletion of antioxidant levels. These test methods also makes it possible to develop trends that can be used to predict failures before they occur and allow for corrective action to be taken.
SCOPE
1.1 This test method covers the determination and evaluation of flow properties, wear levels, contaminants, and oxidative condition of new and in-service lubricating grease.  
1.2 This test method provides guidance on evaluating in-service grease samples, NLGI grades 00 to 3, for wear, consistency, contamination, and oxidation.  
1.3 The values stated in SI units are to be regarded as the standard. The values given in parentheses are for information only.  
1.3.1 Exception—The exception to this will be where units of references were developed by the developers of the test equipment and necessary to report the results of the test.  
1.4 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.  
1.5 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

SIGNIFICANCE AND USE
4.1 This practice is intended for the application of in-line, full-flow inductive wear debris sensors. According to (1), passing the entire lubrication oil flow for aircraft and aero-derivative gas turbines through a debris-monitoring device is a preferred approach to ensure sufficient detection efficiency.  
4.2 Periodic sampling and analysis of lubricants have long been used as a means to determine overall machinery health (2). The implementation of smaller oil filter pore sizes for machinery operating at higher rotational speeds and energies has reduced the effectiveness of sampled oil analysis for determining abnormal wear prior to severe damage. In addition, sampled oil analysis for equipment that is remote or otherwise difficult to monitor or access is not practical. For these machinery systems, in-line wear debris sensors can be very useful to provide real-time and near-real-time condition monitoring data.  
4.3 In-line full-flow inductive debris sensors have demonstrated the capability to detect and quantify both ferromagnetic and non-ferromagnetic metallic wear debris. These sensors record metallic wear debris according to size, count, and type (ferromagnetic or non-ferromagnetic). Sensors are available for a variety of oil pipe sizes. The sensors are designed specifically for the protection of rolling element bearings and gears in critical machine applications. Bearings are key elements in machines since their failure often leads to significant secondary damage that can adversely affect safety, operational availability, or operational/maintenance costs, or a combination thereof.  
4.4 The main advantage of the sensor is the ability to detect early bearing damage and to quantify the severity of damage and rate of progression of failure towards some predefined bearing surface fatigue damage limiting wear scar. Sensor capabilities are summarized as follows:  
4.4.1 In-line full flow non-intrusive inductive metal detector with no moving parts.  
4.4.2 Det...
SCOPE
1.1 This practice covers the minimum requirements for an in-line, non-intrusive, through-flow oil debris monitoring system that monitors ferromagnetic and non-ferromagnetic metallic wear debris from both industrial aero-derivative and aircraft gas turbine engine bearings. Gas turbine engines are rotating machines fitted with high-speed ball and roller bearings that can be the cause of failure modes with high secondary damage potential.  (1)2  
1.2 Metallic wear debris considered in this practice range in size from 120 μm (micron) and greater. Metallic wear debris over 1000 μm are sized as over 1000 μm.  
1.3 This practice is suitable for use with the following lubricants: polyol esters, phosphate esters, petroleum industrial gear oils and petroleum crankcase oils.  
1.4 This practice is for metallic wear debris detection, not cleanliness.  
1.5 The values stated in SI units are to be regarded as standard. The values given in parentheses are provided for information only.  
1.6 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.

SIGNIFICANCE AND USE
5.1 In-plant Oil Analysis—The particular five-part integrated tester practice is primarily used by plant maintenance personnel desiring to perform on-site analysis of as-received and in-service lubricating oils.  
5.2 Detect Common Lubrication Problems—The software application interprets data from integration of multiple sensing technologies to detect common lubrication problems from inadvertent mixing of dissimilar lubricant viscosity grades and from particulate or moisture contamination. The redundant views of ferrous particulates (sensor 2), all particulates larger than 4 μm (sensor 3), and all solid particulates larger than filter patch pore size (patch maker) provides screening for oil wetted mechanical system failure mechanisms from incipient to catastrophic stages.  
5.3 Supported by Off-Site Lab Analysis—The particular five-part integrated tester is normally used in conjunction with an off-site laboratory when exploring the particular nature of an alarming oil sample. An off-site laboratory should be consulted for appropriate additional tests.
SCOPE
1.1 This practice covers procedures for analysis of in-service lubricant samples using a particular five-part (dielectric permittivity, time-resolved dielectric permittivity with switching magnetic fields, laser particle counter, microscopic debris analysis, and orbital viscometer) integrated tester to assess machine wear, lubrication system contamination, and lubricant dielectric permittivity and viscosity. Analyzed results trigger recommended follow-on actions which might include conducting more precise standard measurements at a laboratory. Wear status, contamination status, and lubricant dielectric permittivity and viscosity status are derived quantitatively from multiple parameters measured.  
1.2 This practice is suitable for testing incoming and in-service lubricating oils in viscosity grades 32 mm2/s at 40 °C to 680 mm2/s at 40 °C having petroleum or synthetic base stock. This practice is intended to be used for testing in-service lubricant samples collected from pumps, electric motors, compressors, turbines, engines, transmissions, gearboxes, crushers, pulverizers, presses, hydraulics and similar machinery applications. This practice addresses operation and standardization 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 as standard. No other units of measurement are included in this standard.  
1.5 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.

SIGNIFICANCE AND USE
5.1 Trending the wear, contamination, consistency, and oxidative properties of a lubricating grease are a crucial part of condition monitoring programs. Changes in these properties or deviations from the new grease can be indicative of problems within the lubricated component, such as the mixing of incompatible thickener types, excessive wear or contaminant levels, or significant depletion of antioxidant levels. These test methods also makes it possible to develop trends that can be used to predict failures before they occur and allow for corrective action to be taken.
SCOPE
1.1 This test method covers the determination and evaluation of flow properties, wear levels, contaminants, and oxidative condition of new and in-service lubricating grease.  
1.2 This test method provides guidance on evaluating in-service grease samples, NLGI grades 00 to 3, for wear, consistency, contamination, and oxidation.  
1.3 The values stated in SI units are to be regarded as the standard. The values given in parentheses are for information only.  
1.3.1 Exception—The exception to this will be where units of references were developed by the developers of the test equipment and necessary to report the results of the test.  
1.4 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.

SIGNIFICANCE AND USE
5.1 This practice is intended for the application of online, full-flow, or slip-stream sampling of wear debris via inductive sensors for gearbox and drivetrain applications.  
5.2 Periodic sampling and analysis of lubricants have long been used as a means to determine overall machinery health. The implementation of smaller oil filter pore sizes for machinery has reduced the effectiveness of sampled oil analysis for determining abnormal wear prior to severe damage. In addition, sampled oil analysis for equipment that is remote or otherwise difficult to monitor or access is not always sufficient or practical. For these machinery systems, in-line wear debris sensors can be very useful to provide real-time and near-real-time condition monitoring data.  
5.3 Online inductive debris sensors have demonstrated the capability to detect and quantify both ferromagnetic and non-ferromagnetic metallic wear debris (1, 2). These sensors record metallic wear debris according to size, count, and type (ferromagnetic or non-ferromagnetic). Sensors can be fitted to virtually any lubricating system. The sensors are particularly effective for the protection of rolling element bearings and gears in critical machine applications. Bearings are key elements in machines since their failure often leads to significant secondary damage that can adversely affect safety, operational availability, operational/maintenance costs, or combinations thereof.  
5.4 The key advantage of online metallic debris sensors is the ability to detect early bearing and gear damage and to quantify the severity of damage and rate of progression toward failure. Sensor capabilities are summarized as follows:  
5.4.1 Can detect both ferromagnetic and non-ferromagnetic metallic wear debris.  
5.4.2 Can detect 95 % or more of metallic wear debris above some minimum particle size threshold.  
5.4.3 Can count and size wear debris detected.  
5.4.4 Can provide total mass loss.
Note 1: Mass is an inferred value which ...
SCOPE
1.1 This practice covers the minimum requirements for an online inductive sensor system to monitor ferromagnetic and non-ferromagnetic metallic wear debris present in in-service lubricating fluids residing in gearboxes and drivetrains.  
1.2 Metallic wear debris considered in this practice can range in size from 40 μm to greater than 1000 μm of equivalent spherical diameter (ESD).  
1.3 This practice is suitable for use with the following lubricants: industrial gear oils, petroleum crankcase oils, polyalkylene glycol, polyol esters, and phosphate esters.  
1.4 This practice is for metallic wear debris detection, not oil cleanliness.  
1.5 The values stated in SI units are to be regarded as standard. No other units of measurement are included in this standard.  
1.5.1 Exception—Subsection 7.7 uses “G’s”.  
1.6 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.

SIGNIFICANCE AND USE
5.1 This test method is intended for use in analytical laboratories including on-site in-service oil analysis laboratories. Periodic sampling and analysis of lubricants have long been used as a means to determine overall machinery health. Atomic emission spectroscopy (AES) is often employed for wear metal analysis (Test Methods D5185 and D6595). A number of physical property tests complement wear metal analysis and are used to provide information on lubricant condition (Test Methods D445, D2896, D6304, and D7279). Molecular spectroscopy (Practice E2412) provides direct information on molecular species of interest including additives, lubricant degradation products and contaminating fluids such as water, fuel and glycol. Direct imaging integrated testers provide complementary information on particle count, particle size, particle type, and soot content.  
5.2 Particles in lubricating and hydraulic oils are detrimental because they increase wear, clog filters and accelerate oil degradation.  
5.3 Particle count may aid in assessing the capability of a filtration system to clean the fluid, determine if off-line recirculating filtration is needed to clean the fluid, or aid in the decision whether or not to change the fluid.  
5.4 An increase in the concentration and size of wear particles is indicative of incipient failure or component change out. Predictive maintenance by oil analysis monitors the concentration and size of wear particles on a periodic basis to predict failure.  
5.5 High soot levels in diesel engine lubricating oil may indicate abnormal engine operation.
SCOPE
1.1 This test method covers the determination of particle concentration, particle size distribution, particle shape, and soot content for new and in-service oils used for lubrication and hydraulic systems by a direct imaging integrated tester.  
1.1.1 The test method is applicable to petroleum and synthetic based fluids. Samples from 2 to 150 mm2/s at 40°C may be processed directly. Samples of greater viscosity may be processed after solvent dilution.  
1.1.2 Particles measured are in the range from 4 μm to ≥ 70 μm with the upper limit dependent upon passing through a 100 μm mesh inlet screen.  
1.1.3 Particle concentration measured may be as high as 5 000 000 particles per mL without significant coincidence error.  
1.1.4 Particle shape is determined for particles greater than approximately 20 µm in length. Particles are categorized into the following categories: sliding, cutting, fatigue, nonmetallic, fibers, water droplets, and air bubbles.  
1.1.5 Soot is determined up to approximately 1.5 % by weight.  
1.1.6 This test method uses objects of known linear dimension for calibration.  
1.2 The values stated in SI units are to be regarded as standard. No other units of measurement are included in this standard.  
1.3 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.

SIGNIFICANCE AND USE
This practice is intended for the application of in-line, full-flow inductive wear debris sensors. According to (1), passing the entire lubrication oil flow for aircraft and aero-derivative gas turbines through a debris-monitoring device is a preferred approach to ensure sufficient detection efficiency.
Periodic sampling and analysis of lubricants have long been used as a means to determine overall machinery health (2). The implementation of smaller oil filter pore sizes for machinery operating at higher rotational speeds and energies has reduced the effectiveness of sampled oil analysis for determining abnormal wear prior to severe damage. In addition, sampled oil analysis for equipment that is remote or otherwise difficult to monitor or access is not practical. For these machinery systems, in-line wear debris sensors can be very useful to provide real-time and near-real-time condition monitoring data.
In-line full-flow inductive debris sensors have demonstrated the capability to detect and quantify both ferromagnetic and non-ferromagnetic metallic wear debris. These sensors record metallic wear debris according to size, count, and type (ferromagnetic or non-ferromagnetic). Sensors are available for a variety of oil pipe sizes. The sensors are designed specifically for the protection of rolling element bearings and gears in critical machine applications. Bearings are key elements in machines since their failure often leads to significant secondary damage that can adversely affect safety, operational availability, or operational/maintenance costs, or a combination thereof.
The main advantage of the sensor is the ability to detect early bearing damage and to quantify the severity of damage and rate of progression of failure towards some predefined bearing surface fatigue damage limiting wear scar. Sensor capabilities are summarized as follows:
In-line full flow non-intrusive inductive metal detector with no moving parts.
Detects both ferromagnetic and non-f...
SCOPE
1.1 This practice covers the minimum requirements for an in-line, non-intrusive, through-flow oil debris monitoring system that monitors ferromagnetic and non-ferromagnetic metallic wear debris from both industrial aero-derivative and aircraft gas turbine engine bearings. Gas turbine engines are rotating machines fitted with high-speed ball and roller bearings that can be the cause of failure modes with high secondary damage potential. (1)  
1.2 Metallic wear debris considered in this practice range in size from 120 μm (micron) and greater. Metallic wear debris over 1000 μm are sized as over 1000 μm.
1.3 This practice is suitable for use with the following lubricants: polyol esters, phosphate esters, petroleum industrial gear oils and petroleum crankcase oils.
1.4 This practice is for metallic wear debris detection, not cleanliness.
1.5 The values stated in SI units are to be regarded as standard. The values given in parentheses are provided for information only.
1.6 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.

SIGNIFICANCE AND USE
The integrated tester is primarily used to perform on-site analysis of in-service lubricants used in the automotive, highway trucking, mining, construction, off-road “mining,” marine, industrial, power generation, agriculture, and manufacturing industries.
The immediate results of analysis of in-service lubricants are critical when performing proactive and preventative maintenance. On-site oil analysis, when used in conjunction with these programs, allows continuous system monitoring and contamination control potentially improving equipment “up-time” and equipment life.
SCOPE
1.1 This test method covers the quantitative analysis of in-service lubricants using an automatic testing device that integrates these varied technologies: atomic emission spectroscopy, infrared spectroscopy, viscosity, and particle counting.
1.2 This is suited for in-service lubricating oils having viscosities in the range between ISO 10 and ISO 320 and properties in the ranges given in Tables 1 and 2.
1.3 This test method may be used to establish trends in wear and contamination of in-service lubricants and may not give equivalent numerical results to current ASTM test methods.
1.4 This test method is not intended for use with crude oil.
1.5 The values stated in SI units are to be regarded as standard. No other units of measurement are included in this standard.
1.6 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use. (Specific hazard statements are given in Section 9 and 11.3.)