Engines

Engine oil testing is a key component of a Predictive Maintenance Program (PMP) for heavy Mining equipment owners. Engine oil testing can be scheduled based on test data trends of the equipment. Depending on the test data it is possible to extend the time between engine oil changes which can help to save money and schedule equipment utilization.

A vital test for mining equipment is the Total Base Number or TBN that measures acidity or acid build up in the engine oil. When crankcase oils are exposed to acidic compounds, it is key to monitor TBN to ensure the oil has sufficient alkaline properties thereby reducing the corrosive effects of acidity in the oil. The TBN is tested in accordance with ASTM D2896 or IP400.

Other important tests to consider for engine oil testing includes contaminants such as dust, glycol or antifreeze in the engine block. The introduction of these impurities into the engine crankcase will cause corrosion, clogging and accelerated wear of the engine. Clark Lab’s Engine Test Package (ETP) will analyze the health of the engine oil and help identify typical contaminants of impediments to the reliability of the engine.

Recommended Test Package Includes:

• ASTM D445 - Viscosity
• ASTM D93 - Flash Point
• ASTM D2709 - Water & Sediment
• ADTM D5453, D2622, D129 - Sulfur
• ASTM D613 - Cetane Number
• ASTM D4052 - Density
• Bio2

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• ASTM D976 - Aromatic A
• ASTM D1319 Aromatic B
• ASTM D130 - Copper Strip
• ASTM D86 - Distillation A
• ASTM D1160 - Distillation B
• ASTM D482 - Ash Content
• Cloud Point

Hydraulic Fluid

Particulate contamination is the leading cause of hydraulic equipment failure.  Uncontaminated hydraulic fluid will ensure continuous operation and help to avoid schedule interruptions. Hydraulic system failure will often require the temporary removal of equipment from the farm causing unscheduled downtime.

The cleanliness level of hydraulic fluids is determined by particle count. The particle count test measures solid particle contaminants in the fluid sample. Particle counts can be measured in accordance with various industry standards.

There are two rating systems that define fluid cleanliness: National Aerospace Standard (NAS 1638) and International Standards Organization (ISO 4406).

The NAS 1638 standard classifies the particle size into five distinct groups that include:

•  5 to 15 microns
• 15 to 25 microns
• 25 to 50 microns
• 50 to 100 microns
• >100 microns

NAS 1638 categorizes contamination levels ranging on a scale from 0 to 12 (dirtiest) based on the number of particles per 100mL of fluid for each of the categories above.

ISO 4406, rates particles in three size classes instead of size ranges:

•  >4 microns
• >6 microns
• >14 microns

 

The ISO code classifies contamination levels using three numbers, each of which represents a contaminant level based on the number of particles per 1mL of fluid for the corresponding size class (respectively larger than 4 microns, larger than 6 microns and larger than 14 microns).

Clark provides particle size testing in accordance with ASTM D6595. Particle count analysis includes the following test package. In addition to particle count, other typical test packages for hydraulic fluid include physical properties, wear properties oxidation/corrosion and moisture. The minimal cost of hydraulic fluid testing compared to the expense of equipment failure is a simple business case.

Recommended Test Package Includes:

• ASTM D445 - Viscosity
• ASTM D974, D664 - Acid Number
• ASTM D4377 - Karl Fischer
• ISO 4406 - Particle Count
• ASTM  E2412 - FTIR
• Wear Elements & Containments (Spec, XRF, ICP)

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Fuel Analysis

Diesel fuel testing is critical for ensuring quality control, specification validation and regulatory compliance. Diesel fuel or distillate oil testing can provide analysis of fuel quality by monitoring sulfur, trace metals, and biodiesel blends. Bulk storage of diesel fuel can sometimes compromise the integrity of fuel, Clark provides fuel sampling consultation and recommendations to ensure homogeneity and quality of the test sample.

Clark provides diesel fuel testing package in accordance with ASTM D975. In addition to analyzing fuel quality, Clark’s diesel fuel test package provides analysis of cold weather conditions, containments and emission compliance. Our laboratory can also provide analysis of ultra-low sulfur diesel, fuel additives and biodiesel testing ASTM D6751.

Standard Test Packages Includes:

• ASTM D5185 - ICP Spectroscopy
• ASTM D4377 - Karl Fischer
• ASTM D445 - Viscosity
• ASTM  E2412 - FTIR
• ASTM D664- Base Number

Coolant Analysis

The condition of an engine is largely determined by the cleanliness of the engine oil in the crankcase, however another critical characteristic for engine operation is associated with the engine coolant. A significant number of equipment failures are attributed to coolant system failures. The continuous development heavy-duty diesel engines with high efficiency, high temperature and variable material cooling properties creates challenges for engine cooling systems.

Testing coolants is an essential predictive maintenance program that works in tandem with condition monitoring programs to optimize reliability, reduce unscheduled downtime and avoid engine failure. Regularly analyzing glycol will confirm potential need to replenish or replace coolant, determine if any contaminants have been introduced and assess the coolant protection for engine integrity.

Clark’s coolant testing package includes several ASTM test methods for alkalinity, freeze point, and pH level. We are typically test particle count to determine if there is any debris in the cooling system

Standard Test Packages Includes:

• ASTM D5185 - ICP Spectroscopy
• ASTM D4377 - Karl Fischer
• ASTM D445 - Viscosity
• ASTM  E2412 - FTIR
• ASTM D664- Base Number

Transmission Fluid

Manual and automatic transmission fluids are affected by thermal conditions, gear loads and traffic variables. Harsh operating conditions of mining sites can create significant challenges for transmission and gearbox fluids.  Regular analysis of transmission fluids will determine wear debris, contaminants and moisture. Heavy loads and high stress on mining equipment will have an effect on the transmission fluid thereby causing a thermal breakdown.

Under high load conditions, the breakdown or failure of transmission fluid will cause oxidation that produces a sludge or varnish in the gearbox. Left unchecked, these conditions will ultimately have an effect on the mechanical systems affecting performance and eventually cause gear failure.

Clark Labs has specialty gearbox testing services to measure gear wear performance, friction, oxidation and wear resistance. Our FZG Gear Lubricant Test evaluates anti-wear characteristics and load carrying capacities of lubricants. The FZG gear test rig simulates a misaligned gear set operating in a bath of lubricant subjected to 12 increasing torque load stages. Tooth-wear is examined between stages for scuffing or scoring to assess the fluids performance.

Standard Test Packages Includes:

• ASTM D445 - Viscosity
• ASTM D974, D664 - Acid Number
• ASTM D4377 - Karl Fischer
• ISO 4406 - Particle Count
• PQ 90 - Wear Index
• Wear Elements & Containments (Spec, XRF, ICP)

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Brake Fluid Analysis

Moisture, corrosion and oxidation are common contaminants that will affect the functionality of brake fluid and braking systems. Introduction of moisture or water into brake fluid can cause an adverse operating condition by increasing the functioning temperature of the fluid. Brake fluid is designed to operate at high temperatures due to heat generated during the braking process. Water contamination will reduce the lower the boiling point of brake fluid therefore causing less effectiveness of the fluid and the potential for brake failure. Along with moisture, we also test oil contamination and glycol content.

Standard Test Packages Includes:

• ASTM D5185 - ICP Spectroscopy
• ASTM D4377 - Karl Fischer
• ASTM D445 - Viscosity
• ASTM  E2412 - FTIR
• ASTM D664- Base Number