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WorksheetsLubricant Sampling and Analysis Quiz
Total questions: 99
Worksheet time: 57mins
When storing lubricant drums outside, it is best to:
Store vertically (with the top surface flat) in the open sunlight
Store at an angle with the openings at the high and low positions
Store horizontally and covered
Cover them with a sheet of plywood
Store them upside down directly on the ground
Lubricant shelf life limits:
Are rigorously controlled by the manufacturer
Get longer over time
Are about 10 years
Vary according to the type of lube and type of storage condition
Can be stored indefinitely
Best practices for top-up oil containers could include:
Closeable galvanized containers
Dedicated and scalable containers, by oil type
Any available container will be satisfactory
Lubricants should be stored at the machinery location, regardless of the cleanliness
Use a funnel which contains a screen in the bottom to catch contaminants
Lubricant refilling best practices should include which of the following:
Use a filter cart to charge (fill) the system with oil, if possible
Refill the equipment while it is operating and hot
A funnel
A funnel if it has been capped (or scaled)
A sealed container with a tube for siphoning
A filter's differential pressure slowly increases over time. What's wrong?
The filter has burst
The filter bypass valve is open
ISO particle counts should be taken
Filter differential pressure does not increase
Nothing, it's removing dirt
The benefit that is achieved with the use of a hard-piped sampling valve (mini-mess) is:
Dead volume is minimized
Flushing is easy to do
Sampling is clean due to the threaded dust cap
There is low risk of leakage
All of the above
Which of the following contributes to poor quality and unreliable oil analysis data?
Sampling from drain ports
Sampling from cold systems
Sampling after an oil change
Sampling after a major top-up volume of oil has been added
All of the above
Sampling a wet sump gearbox with a small oil circulation system should be done where?
Downstream of the pump, upstream of the main pressure-line filter
Downstream of the sump, upstream of the pump (before the pump)
Downstream of the main pressure-line filter
From the sump
From the gearbox drain plug
Sampling for wear metals in a large multi-component circulating system with a reservoir should be done where?
Downstream of the pump, upstream of the main pressure-line filter
Downstream of the reservoir, upstream of the pump (before the pump)
Downstream of the main pressure-line filter
From the return line, downstream of the working parts
From the reservoir
Oil samples from an off-line (kidney-loop) filtration circuit should be taken:
Downstream of the pump, upstream of the filter
Downstream of the reservoir, upstream of the pump (before the pump)
Downstream of the filter
From the sump
From the drain plug
Sampling crankcase oil from an engine should be done:
Through the dipstick hole with a drop-tube
From a valve mounted after the pump and after the filter with the engine running
From a valve mounted after the pump, before the filter with the engine running
From a valve mounted after the pump, before the filter with the engine shut off
From the drain plug
The concentration of wear debris:
Always increases throughout the oil circulating system
Varies throughout the oil circulating system
Always decreases throughout the oil circulating system
Is constant throughout the oil system
Varies with the pressure in the oil system
Live-zone sampling a circulating oil system means:
Always use a live sample pump to take the sample
Take a sample from a static (non-flowing) straight piece of pipe in laminar flow
Take a representative sample from a flow line that contains flowing oil
Take a sample hot
Take a sample from a zone in the system that contains the most wear debris
Which hardware is the best for sampling pressurized lines above 500 psi?
A long dead-leg of piping with a plug at the end
A pressure-regulating valve or a helical coil connected to a mini-mess valve
A capped drain plug
A mini-mess valve located on an elbow
A mini-mess valve located on a straight length of pipe
Vacuum samplers are needed:
On low-pressure lines
From unpressurized sumps
From pressure lines
Answers a and b
All of the above
Sampling non-circulating, splash/bath machine sumps is best done by:
Drain Plug removal
Using a flexible, drop-tube, vacuum sample
Using a flexible, drop-tube, vacuum sample from the bottom of the sump
Obtaining a mid oil level sample from a fixed rigid tube within the sump
These systems should not be sampled
Drop-tube vacuum sampling of reservoirs and tanks is best done:
Off the bottom of the tank
Where the oil return line dumps back into the tank
Where the oil suction line pulls oil from the tank
From the top layer of the oil in the tank where water and dirt have settled out
From the middle of the tank
For a typical hydraulic fluid, how full should a sample bottle be filled with hydraulic fluid?
50%
75%
90%
100%
It doesn't matter
Oil sampling frequencies may be affected by:
Machinery age
Machine criticality
Fluid (oil) age
Operating conditions
All of the above
A common sampling frequency for an industrial oil would be:
Every two weeks
Monthly (500 to 1,000 hours)
Quarterly
Six months
Yearly
After some possible initial change, as oil ages, the acid number generally:
Trends down
Trends up
Stays very flat
Oscillates both up and down
None of the above
After some possible initial change, as oil ages, the base number of an oil generally:
Trends down
Trends up
Stays very flat
Oscillates both up as the oil ages and down as makeup oil is added
None of the above
After some possible initial change, as oil ages, the viscosity of an aging oil generally:
Trends down
Trends up
Stays very flat
Oscillates both up and down
None of the above
Upper and lower alarm limits are generally needed on which oil analysis test results:
Acid number
Base number
Viscosity
Fire point
RPVOT
Acid number and base number determinations:
Are reported in the same units, mg of KOH/gram of oil
Are reported in pH units
Are reported in ml of HCL per gram of oil
Are reported in Abs/cm
Are reported as the same number because they are both neutralization numbers
A downward base number trend indicates:
The type of base stock used in the finished oil
The build-up of alkalinity in the used oil
The neutralization of the acids in turbine oils
The depletion of the alkaline detergent additive in engine oils
The base oil density
FTIR can provide reliable information on:
Oxidation and soot
Wear metals
Viscosity and acid number
Particle counts
Oil density
In typical use, atomic emission spectroscopy (AES) (or elemental analysis) has which significant limitation?
It cannot detect the most important wear metals
It can only detect wear debris particles less than approximately 5 microns in size
It can only detect wear debris particles less than 12 microns in size
It can only detect additive elements
It can only detect large iron wear debris
Which is not correct related to oxidation?
Is the reaction of oxygen with water to form acids
Creates acids and sludges
Occurs at all oil temperatures bur becomes significant above 60 degrees C (150 degrees F)
Is the reaction of oil hydrocarbons with oxygen
Shortens oil life
Oxidation stability is not detectable and not monitored with:
Acid number
Karl Fischer
RPVOT
Infra-Red (FTIR) spectroscopy
Voltammetry
Thermal breakdown of lubricants typically:
Occurs at very high temperatures due to hear alone with an absence of oxygen
Is monitored with acid number
May result in thermal cracking of the base oil and a decrease in viscosity
All of the above
Answers a and c
Additive depletion can occur by which of the following mechanisms
Mass transfer and decomposition
Mass transfer (separation)
Hydrotrcating
Hydrolysis and coalescence
All of the above mechanisms
Additive depletion can be monitored with:
Acid number
Atomic emission spectroscopy (AES)
Voltammetry
FTIR
All of the above
Which test is not practical to run on-site as an oil analysis field test?
Viscosity
Particle count
Acid number
Wear metals by atomic emission spectroscopy
Glycol determination
Human sensory (no instrumentation) inspection of machinery can indicate:
Excessive water and foaming
Excessive heat
Highly oxidized, burnt oil
Neither a, b or c
Answers a, b and c
Inspection of used filter elements:
Is useless
Should only be done by highly trained lab technicians
Can provide useful information about wear debris
Costs too much money
Is difficult because it requires complex instruments
Magnetic plug inspections:
Crudely indicate presence of iron wear
Indicate water contamination
Indicate copper wear rates
Indicate oil circulation rates
Indicate corrosion is occurring
Visually checking the color of a used oil sample can indicates
Oxidation
Soot
Water contamination
A change in base number
Answers a, b and c
The smell of a used oil sample can indicate:
High-temperature thermal failure
Water contamination
High wear debris
A recent oil top-up
Air contamination
Which statement is incorrect regarding filter patch tests for solid contaminants?
Patch tests use very fine micron filters
The patch test is a form of automatic particle counting
Patch tests can be done in-house or in a lab
Patch discoloration can estimate overall particle concentration
The resulting patch can be viewed or weighed to assess the contaminant concentration
A crackle test can only detect water above:
The saturation point, which depends on oil type and temperature
100 ppm
1,000 ppm
10,000 ppm
1%
Water separation from oil (demulsibility):
Can be roughly determined with a kitchen blender
Cannot be determined in the field
Can be determined using a patch test
Is not important enough to worry about with a field test
Can be determined using a calcium hydride kit
Glycol antifreeze field test kits:
Determine glycol by density
Determine glycol by a chemical color change
Determine glycol by FTIR
Determine glycol by viscosity
Determine glycol by a change in smell
The blotter spot test is primarily used to detect:
Silicone sealant
Viscosity increase
Particles, soot and organic insoluble
Air entrainment
Spent additives
Which governing body is responsible for the designation of food-grade lubricants?
USDA
ISO
NSF
NLGI
ASTM
When should the reservoir be cleaned/flushed?
Every time the oil is changed
When the plant is in a shutdown
When the system fluid viscosity changes by 7% or more
When sludge and deposits are detected at the oil drain
When the breather is changed
Which of the following describes microscopic water droplets dispersed in stable suspension in oil?
Dissolved water
Evaporative solution
Emulsified water
Free water
None of the above
Oil Analysis is a key component, along with Ultrasonics, Vibration, and Thermography for which broader maintenance approach?
Reactive Maintenance
Condition-based Maintenance
Interval Based Maintenance
Just-in-time Just-In-Case
Which is typically the cleanest?
New oil from the drum
Oil filtered using 25-micron filters
Waste oil
Oil that just barely meets established cleanliness targets
Not typically considered a contaminant, but the presence of air in its various forms may have an impact on the ability of the lubricant to perform its desired function.
True
False
Reducing lubricant usage typically:
Reduces total lubricant costs, reduces labor for housekeeping, and reduces or eliminates some safety issues.
Reduces storage and handling costs, reduces waste oil generation and disposal costs
Reduces labor for housekeeping and minimizes some safety concerns
Both B&C
All of the above
Lube suppliers should supply you with a ________________ to that confirms the quality of the lubricant.
MSDS Sheet
Haz/Mat Code
Certificate of Analysis
Instructions
In the inspection of lubricant storage containers, a leak is found in a drum. What should be done with the drum and why?
Return to supplier - leaking containers are subject to contamination ingression
Fix the leak - put back in storage
Ignore it- someone else will get to it
Put into service immediately
What is the best test for water determination?
Flash point
Acid number
Crackle
Karl Fisher
What information should be placed on all lubricant containers received in the plant?
Which of the following would NOT be a procedure when receiving new oil?
Place new drums to the front so they may be used first.
Create a checklist to guard against contamination.
Sample and test all bulk deliveries.
Establish reasonable limits for new oil quality.
What happens to the viscosity of an oil as the oil oxidizes?
Which list below most closely represents Best Practices in a Lubrication Program?
Ensure all equipment complies with ISO 14-12 standards, continually adjust goals and targets based on results,
Consolidate lubricants without compromising performance, train all plant personnel as lube techs, and set a goal to increase reactive maintenance.
Consolidate lubricants without compromising performance, Set equipment cleanliness as goal to proactive maintenance, Establish an effective oil analysis program for proactive and predictive maintenance, Practice continuous improvement with lubrication program
Consolidate lubricants to match storage room capabilities, Utilize competent personnel for lubrication and provide adequate training, Establish replacement intervals according to outage, Establish procedures that will never have to be changed
Which of the following is not an advantage of manual lubrication?
Easy to apply
Inspection of equipment can be performed
Safety
Low upfront cost
What is trended with the use of a RULER system?
Change in viscosity
Rust & Oxidation additives
Flash point
Changes in anti-oxidant content
The purpose of oil analysis is to monitor?
Fluid properties
Machine condition
Both A&B
None of the above
What is the most difficult form of water to remove?
Emulsified
Free
Hot
Dissolved
What is the most common filter in a hydraulic system?
What is the most difficult form of water to remove?
Emulsified
Free
Hot
Dissolved
What is the most common filter in a hydraulic system?
Pressure line
Return line
Offline
Before pump
Which of the following fluids is the cleanest?
16/13/11
17/14/11
20/18/16
23/19/17
An unopened sealed lubricant drum stored outside will not contain any water?
True
False
In reservoir sampling, where should the sample be drawn?
Drain plug
Midpoint of reservoir, near return line
Side
Top
The dynamic clearance of rolling element bearings is higher than the dynamic clearance of journal bearings?
True
False
In regards to oil analysis, which answer is MOST TRUE of TAN?
Total Acid Number and is typically run on engine oils
Total Acid and Nitration and a higher number means the oil is oxidizing
Total Acid Number and decreasing TAN indicates oxidation
Total Acid Number and increasing TAN indicates oxidation
Manual lubrication will always guarantee the proper amount of lubrication is applied when needed?
True
False
Single point grease lubricators are a good alternative to manual lubrication when location of grease fitting is remote and safety is a concern?
True
False
Key objectives in an oil analysis program include all below answers except which one?
Improving asset reliability
Reducing unscheduled downtime
Obtaining maximum and most precise use of lubricants
Verifying the correct lubricant volume
For the ISO 4406-99 Solid contamination code a range number of 16 means there are between 320-640 particles per ml, how many particles per ml would there be for an ISO code of 18?
1300-2500
640-1300
160-320
80-160
The use of transfer containers that are open to the air are considered best practice?
True
False
The cost of excluding particle contamination is than the cost of removing it from the oil once it gets in?
Higher
Lower
Silt-size particles (5 microns and smaller) influence reliability by:
Causing erosion, valve sticking and abrasion
Causing surface softening
Silt is too small and does not affect machine reliability
Doesn't affect reliability because silt will always be removed by the filter system
Doesn't affect reliability because silt particles will settle out in the reservoir
The ISO solid contaminant code:
Is a means to characterize the chemical composition of debris found in the lubricant
is useful as a means to accurately state the concentration of dirt in a lubricant
Is useful as a means to characterize the concentration of solid particles in a lubricant
is the most useful condition-based measure to gauge oil life
Is a means of characterizing the type of solid contaminant
A typical ISO cleanliness code for new oil would be:
9/7/5
14/12/10
21/19/16
27/25/21
32/30/27
With regard to the ISO cleanliness code system:
The higher the value, the dirtier the oil
The higher the value, the cleaner the oil
The target value should be 200 - 400 ppm
The target value should be as high as possible
This is only useful to monitor new oil purchases
Which component generally requires the cleanest oil?
High-pressure hydraulics
Gears
Engines
Turbines
Journal bearings
The best location for a filter to achieve low-cost dirt removal is:
At the suction side of the pump
After the pump in the pressure line
In the return line
In an off-line (kidney-loop) system
No specific location has any advantage
The Beta ratio of a filter:
Is a measure of its dirt-holding capacity
Is a measure of its burst strength
Is a measure of its particle-removal efficiency
Relates only to the price of the filter
Is independent of the particle size
A Beta(3) = 200 filter:
Only removes 3-micron particles
Only removes particles less than 3 microns
Only removes particles greater than 3 microns
Removes some particles less than 3 microns
Removes particles between 3 and 200 microns
A Beta ratio of 200 means that the filter is how efficient?
200%
99.5%
98.7%
90%
50%
Of the following five filters, which is best at removing fine particles?
B(10) = 100
B(10) = 200
B(3) = 200
B(3) = 1,000
B(1000) = 3
It is a good idea to filter new oil before putting it into service when:
The container has been opened without protection by caps and breathers
A high degree of oil cleanliness is required for the machine
Product has been stored for a long time
All of the above
Answers a and b
Depth filters:
Involve a torturous path between fibers with high dir-holding capacity
Are made using square-weave wire cloth
Have pores of inconsistent sizes
Answers a and c
All of the above
Moisture exists in which of the following forms (related to oils):
Free, dissolved, detrained
Dissolved and micro-entrained
Demulsified
Entrained and floating
Dissolved, emulsified and free
What percentage of rolling bearing life can be lost before the oil develops a cloudy appearance due to water?
25%
50%
75%
90%
Cannot be determined without more information such as the lubricant type
Methods of removing water (moisture) from oil include:
Centrifuge, vacuum dehydration and gravity settling
Passing the oil through a screen
Electrostatic filtration
Using a 3-micron absolute micro-glass filter
Hydrolytic separation
Vacuum dehydration is a good option for drying oil because:
The method also vacuums up small particles
The method maintains a vacuum that prevents buildup of moisture in the future
The method boils the water off at high temperatures
The method removes all three forms of water
All of the above
The most damaging form of water is:
Dissolved
Emulsified
Demulsified
Free
Entrained
Foam and air entrainment:
Are generally not a lubrication problem
Can result in oil starvation and/or impair film strength
Can result in a change in air pressure in the reservoir
Can usually be eliminated by adding more antifoam additive
Are the same thing
When storing lubricant drums outside, it is best to:
Store vertically (with the top surface flat) in the open sunlight
Store at an angle with the openings at the high and low positions
Store horizontally and covered
Cover them with a sheet of plywood
Store them upside down directly on the ground
Lubricant shelf life limits:
Are rigorously controlled by the manufacturer
Get longer over time
Are about 10 years
Vary according to the type of lube and type of storage condition
Can be stored indefinitely
Best practices for top-up oil containers could include:
Closeable galvanized containers
Dedicated and scalable containers, by oil type
Any available container will be satisfactory
Lubricants should be stored at the machinery location, regardless of the cleanliness
Use a funnel which contains a screen in the bottom to catch contaminants
Lubricant refilling best practices should include which of the following:
Use a filter cart to charge (fill) the system with oil, if possible
Refill the equipment while it is operating and hot
A funnel
A funnel if it has been capped (or scaled)
A sealed container with a tube for siphoning
An oil sample shows high silicon and aluminum, with increasing ferrous wear metals. Likely root cause?
Oil oxidation
Abrasive dust ingestion
Internal corrosion
Additive dropout
