International Journal of Mechanical and Production Engineering Research and Development (IJMPERD) ISSN 2249-6890 Vol.

3, Issue 1 Mar 2013 1-8 TJPRC Pvt. Ltd.

CONDITION BASED MONITORING OF CH415W40 ENGINE OIL BY FTIR, AND ANALYTICAL FERROGRAPHY
R. K. UPADHYAY1 & L.A. KUMARASWAMIDHAS2
1 2

Indian School of Mines, Dhanbad , Jharkhand - 826004, India

Associate Professor, Department of Mechanical & Mining Machinery Engineering, Indian School of Mines, Dhanbad, Jharkhand-826004, India

ABSTRACT
Condition Monitoring is a technique used to monitor the equipments life and gives an advance alert. Oil condition monitoring technique is very useful for heavy-duty trucks; it gives the percentage of material present in the oil and life of lubricant. Infrared spectroscopy and Ferrography technique commonly used for health monitoring of oil. Infrared spectroscopy study provides the exact amount of particles in the form of wave number corresponding to the absorbance peak. Ferrography used for wear debris analysis i.e. contamination present in the solution, also provide the source of contaminant material where they come from. In this paper condition based monitoring of engine oil discussed with the help of FTIR and Ferrography at different operation hour. Chemical information about materials present in oil investigated by FTIR. Wear debris analysis performed by Ferrography. Particles generally form either by rubbing, sliding, cutting wear, or due to combined effect of rolling and sliding wear.

KEYWORDS: FTIR, Engine Oil, Ferrography, Wear Debris INTRODUCTION

Condition Monitoring is a technique used to monitor the equipments life and gives an advance alert in order to protect component from failure. Oil act as a lubricant barrier between two engines moving part and reduces friction and wear. It protects engine component from oxidation, contamination, heat and pressure [1]. In infrared spectroscopy, Infra read (IR) radiation passed through a sample, some of the infrared radiation absorbed by the sample and some of it transmitted. The resulting spectrum represents the molecular absorption and transmission creating a molecular fingerprint of the sample. Infrared spectroscopy useful for several types of analysis, like identification of unknown materials, quality of the sample and the amount of component in a mixture. This Technique is very fast and non destructive in nature. It requires only a small amount of material to test [2]. FTIR, combination with various multi-variety data analysis methods have allowed the rapid evaluation of a large volume of spectral data for quality control, quantification [3, 4] and pattern recognition [4-6]. Typically, this involves the profile of the entire spectrum or specific spectral regions containing relevant information [7]. Ferrography provides wear particle analysis of oil present in machine parts [9]. Particles present in oil carries important information about machine condition. This technique is useful to determine particles shape, size and characteristic. From the particle characteristic it is easy to determine the wear modes within the machine elements [9]. This study is an attempt to observe various changes taking place with the passage of time in CH415W40 engine oil circulating in heavy-duty trucks. FTIR done on fresh and degraded oil samples to draw a clear picture about chemical changes taken place in the oil. The degraded oil samples collected after 1000 mile, 2000 mile, and 3000 mile.

R. K. Upadhyay& L.A. Kumaraswamidhas

MATERIAL
CH415W40 high quality diesel engine oils designed for lubrication of units burning low sulphur distillate fuels and designed with the high detergent additive system. These oils have excellent Total Base Number (TBN) retention to ensure protection throughout the oil drain period. It has enhanced protection against corrosion and wear. CH415W40 Oils provide reliable all-year round performance in the application for which they intended [10]. Usually CH415W40 oils use in heavy long distance trucking and constant speed on road operations. The various properties of oil provided in Table 1. Table 1: Properties of Fresh Oil Properties Density, Kg/L 15.5 C Kinematic Viscosity @ 100C, cSt Viscosity Index Flash Point,COC Pour Point C TBN, mgKOH/gm Determined Values for Fresh Sample 0.870 14.0 -16.0 130 220 C -27 C 9.0

EXPERIMENTAL SETUP
Fourier Transform Infrared Spectroscopy (FTIR) The FTIR (Perkin Elmer Spectrum100 Series) schematic diagram shown in figure 1, it consists of light source, interferometer, sample container, detector, interferogram and computer. Infrared energy emitted from a glowing blackbody source [11] to the detector. The beam enters the interferometer where the spectral encoding takes place. Signal then exits the interferometer and enters the sample compartment where it transmitted through the surface of the sample, depending upon the type of analysis being accomplished. Here frequency of energy absorbed which depends on the characteristic of the sample. The beam finally passes into the detector for final measurements. The detectors are specially designed to measure the interferogram signal and further this signal sent to the computer where the Fourier transformation takes place in the form of spectral for interpretation and any further manipulation [11].

Figure 1: Schematic Diagram of FTIR

Condition Based Monitoring of CH415W40 Engine Oil by FTIR, and Analytical Ferrography

Analytical Ferrography

Figure 2: Schematic Diagram of Analytical Ferrograph Analytical Ferrography (made SPECTRO inc.) schematic diagram shown in figure 2. This technique is useful to analyze the wear particles present in the used oil. Large ferrous particles penetrate along the length of the ferrogram. This approach involves passing a volume of fluid over a chemically treated slid which supported over a magnetic field. Permanent magnets arranged to create varying field strength over the length of the substrate. This varying strength causes wear debris to precipitate distribution with respect to size over ferrogram. Debris deposited over slid serves as an excellent media for optical analysis of the composite wear particulates [9].

RESULTS AND DISCUSSIONS

Spectral Analysis FTIR of fresh oil and degraded oil carried out in absorbance basis to evaluate the constituents of the fresh oil sample and changes in the constituents after certain period of operation. Absorption spectroscopy refers to spectroscopic techniques that measure the absorption of radiation, as function of frequency/wave number, due to its interaction with a sample. The sample absorbs energy, i.e., photons, from the radiating field. The IR spectrum interpreted from an empirical comparison of spectra of studies of simpler molecules. Infrared absorption of organic molecules summarised in a chart of characteristic group absorbance in Table 2. FTIR, data result shown in Table 3. Many of the group absorbance varies over a wide range because the bands arise from complex interacting vibrations within the molecule. Absorption bands may represent predominantly a single vibrational mode. Certain absorbance bands those arising from the C-H, O-H, and C=O stretching modes, remain within narrow regions of the spectrum [12]. Table 2: Characteristics Group Absorption Characteristics Group Alkanes Alkenes Alkynes Mononuclear Aromatics Alcohols And Phenols Acetals Ethers Carbonyl Compound Absorption 2850-2960/1350-1470 3020-3080/675-1000 3300 1500/ 700 3350 1150 1180-970 3200-2500

R. K. Upadhyay& L.A. Kumaraswamidhas

Table 2: Characteristics Group Absorption Contd., Characteristics Group Acid Chlorides Anhydrides Amides Amines Nitriles Carbodiimides Nitro Compound Sulphur Compound Thiocarbonyl Group Halogen Compound Silicon Compound Phosphorus Compound Soot Water Oxidation (Carbon) Absorption 1790 1800 1640-1590 830-770/3180-2000 2300 1580-1370 1590-1570 2600 975 1380-1220/760-640 980-910 1100-900 2000 4000 1700

Table 3: Data Results Obtained by Fourier Transform infrared Spectroscopy Parameter of Interest and Spectral Location (cm-1) Distance (Miles) 0 Fresh oil A 1000 A 2000 A 3000 A Drained off A* Absorbance Soot (2000) Oxidation (1700) Nitration (1630) Sulphation (1150) Water (4000) Diesel Fuel (800) 0.075071 0.100338 0.102147 0.135808 Antiwear Additive (960) 0.087222 0.093901 0.116105 0.123779

0.068465 0.090061 0.100926 0.120379

0.079674 0.079665 0.103886 0.112228

0.070811 0.083713 0.115437 0.123912

0.098217 0.121547 0.144153 0.16646

0.094731 0.100711 0.118571 0.122345

Figure 3 shows the fresh engine oil characteristic, whereas, figure 4-6 shows degraded oil sample's characteristics at an interval of 1000 miles, 2000 miles, and 3000 hours. As the lubricant supply to the engine vibration response is negligible, but as the operating time increases lubricant oil gets contaminated and absorbance peak values continuous increases. At 1000 miles (figure 4) soot formation value increases from 0.068465 to 0.09006, very less change in oxidation number, nitration increases from 0.070811 to 0.083713, sulphides 0.098217 to 0.0121547, water 0.094731 to 0.0100711, diesel 0.075071 to 0.0100338, and antiwear additive increases from 0.087222 to 0.093901. These changes lead to an adverse effect on engine life and component. As the value of these particles increases, viscosity of oil also varies with time. After 2000 miles (figure 5) soot formation increases to 0.100926, oxidation 0.103886, nitration 0.115437, speeds 0.144153, water 0.118571, diesel 0.102147, and antiwear additive percentage increases to 0.116105. After 3000 miles of operation (figure 6) large change in oil properties, engine oil needs to changed at this stage because particle percentage is more, direct contact of engine moving parts (abrasion) that causes wear, which is an unfavourable condition for engine component and engine, may fail. As the rate of contact increases temperature also increases so as oil thinning occurs. Large changes occur in oil drained off from the engine due to its impurity conjugates present in the oil sample, at this stage in order to keep engine performance higher, degraded oil must remove by fresh oil as early as possible.

Condition Based Monitoring of CH415W40 Engine Oil by FTIR, and Analytical Ferrography

Figure 3: FTIR Result of Fresh Oil Sample

Figure 4: FTIR Result of Degraded Oil Sample after 1000 Miles

Figure 5: FTIR Result of Degraded Oil Sample after 2000 Miles

Figure 6: FTIR Result of Degraded Oil Sample after 3000 Miles

R. K. Upadhyay& L.A. Kumaraswamidhas

Ferrography Wear Debris Analysis

Fig. a

Fig. b

Fig. c Figure 7: Ferrography wear Debris Analysis after (a) 1000Miles, (b) 2000Miles, and (c) 3000Miles Wear rate defined as a most important parameter for engine component [13]. Particles Illustration present in oil schematically represented in Figure 7. In wear debris analysis lubricants monitored for particulate derived from engine components [14]. Offline method of wear debris analysis is useful tool to evaluate particle shape and size with the help of microscopic examination. It measures particle size up to 1-1000m. The size distribution shows severity of wear, and particle shape indicates the mechanisms involve in wear [14]. Figure 7 represents the type of material present in the oil; this can be found by wear particle atlas. Source of materials also designated with these illustrations like aluminium due to piston worn, chromium-piston rings, valve seats, copper-rolling element bearing, lead-plain bearing, nickel-valve seats, and silver due to fretting of joints, silver plated bearing surface. Wear of these particles occurs due to rubbing wear, cutting wear, rolling fatigue wear, combined rolling and sliding, and severe sliding wear [14]. From the figure it is clear that lubricant after 1000 miles of operation having less constituents than sample which collected after 2000 and 3000 miles. After this operation time lubricant needs to change.

CONCLUSIONS
Results obtained from the FTIR test and Ferrography has shown the degradation pattern of engine oil and changes in its physical properties. After the charging of fresh oil, engine oil suddenly gets contaminated in short period of time. Some contamination in the form of particles remains inside the reservoir. Whenever a recharge of fresh engine-oil is to made, the reservoir should cleaned [15]. It observed that degradation behaviour of engine-oil increases continuously with passage of time. Percentage absorbance recorded by FTIR and debris analysis by ferrogram. Spectrometer provides more accurate results indicating the state of oil at its operating condition. This gives the changes in engine-oils organic compound structure and its by-products relation with the wave number.

Condition Based Monitoring of CH415W40 Engine Oil by FTIR, and Analytical Ferrography

ACKNOWLEDGEMENTS
The authors wish to thank to members of Surface Engineering & Tribology Division, CMERI Durgapur, West Bengal-713209 for their support.

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10. Chakrol

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