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QUALITY CONTROL SIGNIFICANCE OF TESTS

QUALITY CONTROL SIGNIFICANCE OF TESTS. AWARENESS ABOUT HANDLING OF PETROLEUM PRODUCTS. AT A GLANCE. Introduction. PETROLEUM PRODUCTS FUEL OILS LUBRICATING OILS LUBRICATING GREASES. PETROLEUM PRODUCTS TESTS AND SIGNIFICANCE

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QUALITY CONTROL SIGNIFICANCE OF TESTS

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  1. QUALITY CONTROL SIGNIFICANCE OF TESTS

  2. AWARENESS ABOUT HANDLING OF PETROLEUM PRODUCTS. AT A GLANCE

  3. Introduction • PETROLEUM PRODUCTS • FUEL OILS • LUBRICATING OILS • LUBRICATING GREASES

  4. PETROLEUM PRODUCTS TESTS AND SIGNIFICANCE THE MAJOR FUNCTION OF LUBRICATING OIL IS REDUCTION OF FRICTION & WEAR BY SEPARATION OF SURFACES LUBRICATING OILS ALSO ACT AS A CARRIER FOR ADDITIVES ADVANCEMENT IN LUBRICATION TECHNOLOGY GOOD QUALITY OF BASE OILS HAVE MORE RESPONSE TO ADDITIVES PROPERLY FORMULATED LUBRICATNS LAST LONGER AND GENERATE LESS WASTE SYSTEMATIC MANAGEMENT & TRANSFER OF KNOWLEDGE IS KEY TO SUCCESS

  5. PETROLEUM PRODUCTS TESTS AND SIGNIFICANCEcontd. IT IS POSSIBLE TO MAKE LUBRICANTS SAFE FOR PEOPLE & ENVIRONMENT CLOSE RELATIONSHIP WITH OEM’S OEM’S ARE BECOMING INCREASINGLY RECEPTIVE BECAUSE IT IS THEIR OBJECTIVE OF GIVING BETTER PERFORMANCE TO GENERATE QUALITY AWARENESS IN THE USER COMMUNITY THROUGH PROPER CUSTOMER EDUCATION CHALLENGE -TO CONVINCE THE PUBLIC TO PAY MORE FOR QUALITY PRODUCTS

  6. ASSESSMENT OF QUALITY vADOPTION OF NEW FORMULATION TECHNOLOGY v CONSTANT REVIEW OF TEST METHODS v INSTRUMENTAL TECHNIQUES v PRODUCT QUALITY TAILOR MADE FOR CUSTOMERS v TRADITIONAL TEST METHODS ARE SUPPLIMENTED BY MODERN INSTRUMENTAL TECHNIQUES v TEST MODULES FOR PERFORMANCE TESTS AND BENCH TESTS v TEST RIGS AND ENGINE TESTING TO SATISFY CUSTOMERS FOR ENERGY SAVING, POWER REDUCTION, TO REDUCE MACHINERY DOWN TIME, SAFETY AND HEALTH ASPECTS ARE ALSO BEING CONSIDERED WHILE ASSESSING THE QUALITY OF PRODUCTS.

  7. PETROLEUM PRODUCTS TESTS & SIGNIFICANCE

  8. TESTS ON PETROLEUM PRODUCTS CAN BE BROADLY CLASSIFIED AS : • PHYSICAL TESTS • CHEMICAL TESTS • PERFORMANCE - BASED TESTS

  9. A. PHYSICAL TESTS • APPEARANCE • ANILINE POINT • ASH CONTENT • COLOUR • COPPER STRIP CORROSION • DENSITY • DISTILLATION • FLASH POINT • INSOLUBLES • POUR POINT • RESIDUE ON EVAPORATION • VISCOSITY • VISCOSITY INDEX • WATER CONTENT

  10. B. CHEMICALS TESTS NEUTRALIZATION NO : TOTAL ACID NUMBER STRONG ACID NUMBER TOTAL BASE NO. STRONG BASE NO. LEAD,SULPHUR,BENZENE CONTENT METAL CONTENT : Ca, Ba, Zn etc

  11. C. PERFORMANCE BASED TESTS • OXIDATION STABILITY • EXTREME PRESSURE CHARACTERISTICS • LEAKAGE TENDENCY • WATER WASHOUT PROPERTIES • RUST PROTECTION • FOAMING CHARACTERISTICS • AIR RELEASE PROPERTY • KNOCK RATING

  12. PHYSICAL TESTSAPPEARANCE APPEARANCE : VISUAL OBSERVATION BRIGHT & CLEAR : GOOD PRODUCT, FREE FROM CONTAMINATION HAZY/CLOUDY : PRESENCE OF SEDIMENT, WATER AND/OR WAX

  13. ANILINE POINT MINIMUM TEMPERATURE AT WHICH ANILINE AND OIL IN EQUAL QUANTITY ARE MISCIBLE. IT IS USEFUL IN THE CHARACTERISATION OF PETROLEUM PRODUCTS. IT INCREASES WITH INCREASE IN PARAFFIN CONTENT IT GIVES THE IDEA OF COMPOSITION OF PETROLEUM CARBON RESIDUE.

  14. ASH CONTENT METALLIC DEPOSITS FORMED IN THE COMBUSTION CHAMBER & OTHER ENGINE PARTS DURING THE HIGH TEMPERATURE OPERATION.

  15. PHYSICAL TESTSASH CONTENT ASH CONTENT : ASTM D 482/874,IP 4/163,IS 1448 P:4 EQUIPMENT : CRUCIBLE ANALYTICAL BALANCE MUFFLE FURNACE BURNER ASH IS NON COMBUSTIBLE MATERIAL IN PETROLEUM PRODUCT CONTRIBUTED BY 1) SOLID PARTICLES 2) OIL OR WATER SOLUBLE METALLIC COMPOUNDS …….CONTD

  16. PHYSICAL TESTSASH CONTENT ASH FROM FUELS : AFFECTS FUEL INJECTION SYSTEMS, INDUCES BOILER CORROSION, ATTACKS REFRACTORY LINING OILS : INDICATES PRESENCE OF OIL SOLUBLE METALLIC COMPOUNDS. SULPHATED ASH : BASIC TOOL FOR MFG. QUALITY CONTROL …….CONTD

  17. PHYSICAL TESTSASH CONTENT LOWER : LESSER ADDITION OF ADDITIVES, ADMIXTURE OF BASE OIL. HIGHER : INCREASED ADDITIVE DOSAGE, ADMIXTURE WITH OILS OF HIGHER ADDITIVE CONCENTRATION.

  18. COLOUR TEST IS USED FOR MANUFACTURING CONTROL PURPOSES. IT IS IMPORTANT SINCE COLOUR IS READILY OBSERVED BY CUSTOMER.

  19. PROPERTIES OF FUELS AND LUBRICANTS • COLOUR • USED FOR MANUFACTURING CONTROL PURPOSE. • READILY OBSERVED BY THE CUSTOMER. • A VARIATION OUTSIDE THE ESTABLISHED RANGE INDICATES CONTAMINATION/ADULTERATION.

  20. PHYSICAL TESTSCOLOUR COLOUR : 1. SAYBOLT : ASTM D 156 / IS 1448 P :14 2. ASTM : ASTM D1500 / IP 196 / IS 1448 P :12 EQUIPMENT : SAYBOLT CHROMOMETER ,ASTM COLORIMETER NO DIRECT SIGNIFICANCE IN QUALITY : ENSURES PRODUCT UNIFORMITY APPRECIABLE CHANGE FROM NORMAL INDICATES CONTAMINATION PETROL COLOUR INDICATIVE OF PRODUCT IDENTIFICATION.

  21. COPPER STRIP CORROSION A QUALITATIVE MEASURE OF THE TENDENCY OF A PETROLEUM PRODUCT TO CORRODE PURE COPPER.

  22. PHYSICAL TESTSCORROSION COPPER STRIP COROSSION : ASTM D 130 / IP 156 / IS 1448 P:15 EQUIPMENT : WATER BATH - THERMOSTATICALLY CONTROLLED. STD. COPPER STRIP,TEST TUBES, POLISHING MATERIAL,ASTM STANDARD TEST INDICATES PRESENCE OF CORROSIVE SULPHUR IN PETROLEUM PRODUCTS CAUSES : IMPROPER REFINING IMPROPER STORAGE CONDITIONS WATER BOTTOMS & PRESENCE OF SULPHIDES INDUCE CORROSION. …..CONTD.

  23. PHYSICAL TESTSCORROSION ATTACKS FUEL SYSTEM & ALL COPPER/COPPER BEARING COMPONENTS “POSITIVE” TEST INDICATES PROBABLE ADMIXTURE OF ACTIVE SULPHUR BASED CUTTING OIL.

  24. DENSITY MASS/VOLUME DENSITY PROVIDES CHECK ON UNIFORMITY OF SHIPMENT.

  25. PHYSICAL TESTSDENSITY DENSITY : ASTM D 1298 / IP-160 / IS 1448 P:32 EQUIPMENT : HYDROMETER, GLASS JAR, THERMOMETER, IP-64C/ASTM 12C HELPS TO COMPUTE WEIGHT - VOLUME RELATIONSHIP ASSISTS IN DETECTING CONTAMINATION IN COMPARISON TO PARENT FIGURE IN FUELS. SERVES AS BASIC GUIDE FOR PRODUCT MOVEMENT. ….CONTD.

  26. PHYSICAL TESTSDENSITY FOR OILS : LOWER VALUE : FUEL OIL DILUTION, ADMIXTURE OF LOW DENSITY PRODUCT. HIGHER VALUE :OXIDATION, INSOLUBLES, WATER, MIXTURES OF HIGH DENSITY PRODUCT. PRECAUTIONS : 1.HYDROMETER CALIBRATION MUST BE AT 15°C 2. SHIFTING OF GRADUATED SCALE 3. BREAK IN THERMOMETER THREAD

  27. SPECIFIC GRAVITY • RATIO OF A WEIGHT OF A GIVEN VOLUME OF MATERIAL TO THE WEIGHT OF THE SAME VOLUME OF WATER.

  28. API GRAVITY API GRAVITY, DEGREE = 141.5 131.5 SP.GR. @15.5/15.5OC CO-EFFICIENT OF THERMAL EXPANSION INDICATES CHANGE OF DENSITY WITH TEMPERATURE.

  29. DISTILLATION THE SIGNIFICANCE OF DISTILLATION RESULTS IS BASED ON CLOSE RELATIONSHIP TO VOLATILITY

  30. VOLATILITY • THE TENDENCY OF A LIQUID OR LIQUIFIED GAS TO VAPOURISE IS CALLED IT’S VOLATILITY. • IT HAS IMPORTANCE DURING COMBUSTION. • IT KEEPS THE LIQUID IN GASEOUS STATE. • FOR VAPOURIZATION FLASH POINT, FIRE POINT, VAPOUR PRESSURE & EVAPORATION ARE ESSENTIAL.

  31. DISTILLATION TEMPERATURES INITIAL BOILING POINT (IBP) THE TEMPERATURE AT WHICH THE FIRST DROP OF DISTILLATE IS COLLECTED IN THE MEASURING CYLINDER. END POINT OR FINAL BOILING POINT (FBP) THE HIGHEST TEMPERATURE RECORDED DURING THE DISTILLATION PROCESS. DRY POINT THE TEMPERATURE AT WHICH THE LAST DROP EVAPOURATES AND THE DISTILLATION FLASK BECOMES DRY DURING THE DISTILLATION PROCESS.

  32. DISTILLATION TEMPERATURE (continued) RECOVERY THE TOTAL VOLUME OF DISTILLATE RECOVERED IN THE CYLINDER. RESIDUE MATERIAL REMAINED IN THE FLASK AFTER DISTILLATION. IF RESIDUE IS HIGH IT GIVES THE INDICATION OF IMPURITY.

  33. PHYSICAL TESTSDISTILLATION DISTILLATION : ASTM D 86/IP-123 / IS 1448 : P18 EQUIPMENT : FRONT VIEW DISTILLATION APPARATUS, STD. THERMOMETER , DISTILLATION FLASK,MEASURING CYLINDER (100 ML) CONTROLS VOLATILITY CHARACTERISTICS OF FUELS. CONTRIBUTES TO : EASE OF STARTING WARM UP AND UNIFORM DISTRIBUTION OF FUEL. …..CONTD.

  34. PHYSICAL TESTSDISTILLATION LIMITS : UNWARRANTED HEAVY ENDS ARRESTS : EXHAUST SMOKING - ENGINE DEPOSITS FUEL DILUTION - IMPROPER MIXTURE DISTRIBUTION TO CYLINDER. DISTILLATION TEST HELPS DETECTION OF PETROL ADULTERATION WITH SKO

  35. FLASH POINT IMPORTANT INDICATION OF FIRE AND EXPLOSION HAZARD

  36. PHYSICAL TESTSFLASH POINT FLASH POINT : 1. ABEL, CLOSED CUP :IP 170 / IS 1448 P:32 2. PENSKY MARTEN’S : ASTM D 93/IP 34/IS1448 CLOSED CUP P :21 3.CLEVELAND OPEN : ASTM D 92/ IP 36 / CUP IS-1448 P 69 EQUIPMENT : ABEL FLASH TESTER - FUELS UPTO 70°C PM FLASH TESTER - FUELS & OILS COC FLASH TESTER - OILS ……CONTD.

  37. PHYSICAL TESTSFLASH POINT FLASH POINT CONTROLS FLAMMABILITY PROPERTY OF PETROLEUM PRODUCTS INDICATES DEGREE OF SAFETY IN STORAGE, TRANSPORTATION AND USE. IN USED CRANKCASE OILS, LOWER FLASH INDICATES FUEL DILUTION. BASIC CRITICAL TEST FOR FUEL DELIVERIES.

  38. FLASH & FIRE POINT • IT IS THE TEMPERATURE TO WHICH THE OIL MUST BE HEATED UNDER SPECIFIED TEST CONDITIONS TO GIVE OFF SUFFICIENT VAPOURS TO FORM A MIXTURE WHICH WILL IGNITE IN THE PRESENCE OF A SOURCE OF IGNITION • FLASH POINT TEST GIVES AN INDICATION OF PRESENCE OF VOLATILE COMPONENTS IN AN OIL. • FIRE POINT IS THE TEMPERATURE AT WHICH THE PRODUCT STARTS BURNING CONTINUOUSLY • IT GIVES AN INDICATION OF FIRE HAZARD. FOR FUELS,THE DIFFERENCE IS VERY SMALL

  39. INSOLUBLES CONTAMINANTS FOUND IN USED OILS DUE TO DUST, WEAR PARTICLES AND OXIDATION PRODUCTS

  40. PHYSICAL TESTSINSOLUBLES INSOLUBES - ASTM D 893 EQUIPMENT : OIL CENTRIFUGE - CONE SHAPED 100 ML TUBES ANALYTICAL BALANCE , AIR OVEN THIS TEST IS BASICALLY FOR USED LUBRICATING OILS HEXANE INSOLUBLE = CARBON + OXIDISED OIL + RESINS + SEDIMENTS BENZENE INSOLUBES = CARBON + SEDIMENTS ASH ON BENZENE INSOLUBES; SEDIMENTS, SILICA,WEAR METAL PARTICLES. ESSENTIAL TOOL FOR JUDGING USED OIL QUALITY.

  41. POUR POINT AN INDICATOR OF THE ABILITY OF OIL TO FLOW UNDER COLD OPERATING CONDITIONS

  42. CLOUD & POUR POINT • CLOUD POINT. • TEMPERATURE AT WHICH THE OIL BECOMES HAZY WHEN COOLED IN A SPECIFIED CONDITION. • IT HAS IMPORTANCE WHEN NARROW CLEARANCE MIGHT BE RESTRICTED BY ACCUMULATION OF SOLID MATERIAL EX-SUCTION LINE STRAINERS, SMALL SIZE OIL-FEED LINES OR FILTERS.

  43. CLOUD & POUR POINT • POUR POINT IS THE LOWEST TEMPERATURE AT WHICH THE OIL WILL JUST FLOW UNDER SPECIFIC TEST CONDITIONS. • IT'S USE IS FOR LOW TEMPERATURE APPLICATION. • POUR POINT OF WAXY OILS CAN BE REDUCED BY POUR POINT DEPRESSANTS (PPD) • SIGNIFICANCE IN REFRIGERATION COMPRESSOR LUBRICANTS & AUTOMOTIVE ENGINE OILS.

  44. PHYSICAL TESTSPOUR POINT POUR POINT : ASTM D 97/ IP 15 /IS 1448 P :10 EQUIPMENT : CLOUD & POUR TEST CABINET , STD. THERMOMETER , POUR POINT JARS PETROLEUM PRODUCTS ON COOLING SEPARATE WAX CRYSTALS. FIRST APPEARANCE OF WAX IS CLOUD POINT. CONTINUED CHILLING INCREASES WAX PRECIPITATION AND ENDS IN MATRIX FORMATION. THIS MATRIX OF WAX STRUCTURE ARRESTS OIL FLOW. ……CONTD.

  45. PHYSICAL TESTSPOUR POINT POUR POINT CONTROLS FLOW CHARACTERISTICS AND PUMPABILITY PROPERTY. POUR DEPRESSANTS RETARD MATRIX FORMATION AND CONTRIBUTE TO LOWERING OF POUR POINT AND IMPROVEMENT IN FLOW PROPERTIES.

  46. PHYSICAL TESTSRESIDUE ON EVAPORATION RESIDUE ON EVAPORATION : ASTM D 381 / IP 131 / IS 1448 P:29 EQUIPMENT : EXISTENT GUM BATH WITH PRESSURE GAUGE & THERMOMETER , STD.GUM BEAKER, ANALYTICAL BALANCE,AIR OVEN. TEST IS APPLICABLE TO FUELS & SOLVENTS. ALL FUELS CONTAIN CERTAIN UNSATURATED HYDROCARBONS. …..CONTD.

  47. PHYSICAL TESTSRESIDUE ON EVAPORATION THESE COMBINE WITH THEMSELVES AND WITH OXYGEN TO FORM NON-VOLATIE STICKY SUBSTANCE CALLED GUM WHICH GETS DEPOSITED ON ENGINE PARTS: - CARBURETTER & INTAKE SYSTEM (INTAKE MANIFOLD,VALVE STEMS, VALVE SEATS ETC) - RESTRICTS FLOW THROUGH CARBURETTER JETS, FLOAT STICKING AND IN EXTREME CASES VALVE STICKING.

  48. VISCOSITY VISCOSITY OF A FLUID IS A MEASURE OF ITS RESISTANCE TO FLOW. VISCOSITY AND VISCOSITY VARIATION WITH TEMPERATURE ARE IMPORTANT FACTORS FOR ESTABLISHING PERFORMANCE STANDARD OF LUBE OILS

  49. VISCOSITY • MEASURE OF FLOW CHARACTERISTICS. • VISCOSITY CHANGES WITH TEMPERATURE. • IT FORMS BY THE COHESION OF FORCE OF MOLECULES. • AS THE PRESSURE INCREASES VISCOSITY INCREASES. • VISCOSITY INCREASE IN USED OIL INDICATES THE OIL HAS OXIDISED. • VISCOSITY DECREASE USUALLY INDICATES FUEL DILUTION .

  50. PHYSICAL TESTSVISCOSITY VISCOSITY = ASTM D 445 / IP 71 / IS 1448,P:25 MEASUREMENT OF RESISTANCE TO FLOW. EQUIPMENT : CONSTANT TEMPERATURE VISCOSITY BATH ,CALIBRATED CAPILLARY GLASS VISCOMETERS, STOP WATCH. UNITS OF VISCOSITY : ABSOLUTE, CENTI-POISE, KINEMATIC,CENTI-STOKES RELATIONSHIP : CENTI-POISE=CENTI-STOKESXDENSITY @ TEMPERATURE LUBE OILS ARE CONTOLLED AT 40°C AS PER ISO VISCOSITY SYSTEM. * VISCOSITY FORMS BASIS FOR SELECTION OF LUBRICANTS. *VISCOSITY CHANGES REFLECT USED OIL CONDITION.

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