The term oil condition monitoring refers to the practice of regular oil analysis to collect valuable data on both lubricant products and the machines they maintain.
In system reliability and proactive maintenance programmes, monitoring the condition of oil in active service is a vital tool to manage uptime of critical assets onsite.
In-depth laboratory analysis assesses a range of parameters like a fluid’s viscosity, chemistry and contamination levels, but also looks for signs of mechanical wear that indicate a potential failure.
The main benefit of monitoring oil condition is that problems can be predicted and therefore avoided before a critical malfunction occurs. However, it offers other advantages that help operators improve their bottom line. As a result, whether you’re using food safe oils from Fuchs for manufacturing, or metalworking lubricants from Mobil like cutting fluid, periodic oil condition monitoring is strongly advised.
Here, we take a detailed look at the process including what is monitored, the main benefits and how monitoring works.
What does oil condition monitoring assess?
Oil conditioning monitoring can detect metal particles suspended in lubricants like copper and iron. Such matter is an indication that machine components are becoming worn unnecessarily due to incorrect or insufficient lubrication.
Levels of contamination are also monitored. Oils are checked for traces of foreign fluids like fuel, coolant and water that may impact the effectiveness of lubricants by diluting or negating their desired properties. Solid matter like soot and dust is also assessed.
Finally, the overall health of the lubricant is looked at. Oxidation levels and moisture content are measured and any changes to viscosity are noted. Over time, a lubricant’s additives can deplete, and monitoring can also evaluate if they are still present in appropriate amounts.
What are the key benefits of oil condition monitoring?
The main gain from regular oil condition monitoring is preventative maintenance. Monitoring provides an early warning system that there are issues, allowing machine operators to adjust their lubrication processes to head off serious breakdowns.
There are financial benefits to monitoring too. It can reduce running costs considerably as it can ensure the right amount of lubricant is used. Analysis ensures lubricant that is still fit for service is not discarded, avoiding wastage costs, but also informs when it is no longer usable, avoiding the expense of repairs and mechanical downtime when machines are not lubricated correctly.
Monitoring can also optimise maintenance processes. Instead of using a time basis, detailed analysis promotes condition-based maintenance. As such, it can effectively extend both the lifespan of machinery and the lubricant serving it. This reduces expenditure and protects investment in expensive machinery.
How does oil condition monitoring work?
Monitoring starts with sampling. Technicians take periodic lubricant samples from key mechanical systems like hydraulics, engines and gearboxes. Samples are sent to labs for expert analysis, employing techniques like particle counting and spectroscopy. Key indicators looked for include wear debris, water content viscosity, additive levels and elemental composition. Specialists interpret indicators to help diagnose issues – for instance, an increase in iron particles can point to premature gear wear. Actions are recommended to counter issues, which may involve an oil changeover, a new filter or repair work.
Are you looking for an oil condition monitoring service?
At Oil Store, we work with an independent laboratory to help our customers routinely condition monitor oil samples with analysis to prevent maintenance problems. Through our service, lubricant users select the type of analysis they need and order a kit. This pack contains a sample bottle, sample info ticket, sample label, tubing and a leak-proof bag, along with a pre-paid return envelope.
All results can be interpreted by expert lab technicians to provide users with a full understanding of the professional analysis. Recommended actions to remediate issues will also be provided, and results are supplied via an online portal, which is accessible around the clock.
We work closely with British Engineering Services Asset Reliability to supply DIN, ISO and ASTM accredited analysis that covers chemical makeup, wear metals and contamination levels for a wide range of lubricants.
To access a streamlined oil condition monitoring sample analysis or find out more about our easy-to-use service, get in touch with a member of our team at Oil Store today.
