Oil analysis on your machinery gives vital information about the operating levels of your equipment and the lubricant that runs through them. You're leaving the efficiency of your equipment to chance if you don't do appropriate and regular analysis.
Because lubrication is so important in keeping your plant operating smoothly, properly maintaining your lube system implies properly maintaining your whole facility's operations.
According to studies, poor lubrication causes:
Mechanical failures account for 43% of all failures.
Bearing problems account for 54% of all bearing failures.
Damage to roller bearings accounts for 50% of all damage.
70% of equipment failures are caused by human error.
Approaches in Acquiring Oil Analysis Reports
Personnel participating in oil analysis and interpretation of testing findings must have extensive knowledge and expertise. When components fail, the people who did the analysis should be a part of the inquiry. What tools and/or resources your company should employ for oil analysis will be determined by your familiarity with the demands of your industry and equipment specifications.
The following are some examples of resources that may be used in an oil analysis program, along with their benefits and drawbacks:
Commercial Testing Lab
Pros: Commercial oil laboratories employ specialists with advanced degrees. Instrumentation that is both efficient and precise
Cons: Poor control of sampling methodology
In-House Testing Lab
Pros: Analysts and maintenance crews are all housed together. Less sample handling equals better sample integrity management.
Cons: Additional in-house operational costs. Budget constraints may prevent the acquisition of the most efficient and precise testing equipment. Report interpretation may pose a challenge.
Mobile Oil Lab
Pros: Mobile oil lab allows for on-site testing, reduced sample handling, and elimination of capital investment requirements.
Continuous or Online Monitoring Technology
Pros: Availability of data across the whole operating cycle. Real-time monitoring and decision-making are possible thanks to certain very advanced sensors.
Cons: Large quantities of data require more infrastructure. Additional maintenance is required to keep track of the technology.
Portable Analysis Tools
Pros: Onsite test kits are easy to use, budget-friendly, and time-saver. When you get faster results, you get faster reaction times when you need them.
Cons: The capacity of the user to comprehend new technology and the results may not be laboratory-grade.
Establishing a regular oil analysis program is critical for avoiding component failures and maintaining the best possible condition of the equipment. Consistent oil analysis can diagnose a range of concerns, from detecting fuel and coolant leaks to assessing additive levels, and can help you avoid breakdowns and failures. One of the most significant advantages of oil analysis is that the information you obtain leads you to remedies that remove lubrication problems. Here are five more advantages of having your equipment's oil analyzed on a regular basis
A Comprehensive Analysis of Lubricant Performance
The functioning of your lubrication system is broken down in detail after a thorough examination of the oil in your equipment. This review can identify regions with issues and the possible issues that may develop.
In addition, when pollutants are not identified early enough, they might create serious issues. Certain metals, such as aluminum and iron, might signal damage to the piston or cylinder. Leaks of water or antifreeze could pose severe problems as it puts pressure on the entire system as it attempts to force the thicker oil through. Water detection might also mean that seals are damaged or that the equipment isn't functioning at the right temperature.
Finding issues before they become a problem
Knowing ahead of time that your equipment may have a problem will save you time and money. Oil analysis gives you a detailed look at the lubricant in your gear. Small faults may be recognized and addressed before they become major issues with regular oil testing.
Oil analysis can detect particular forms of wear in specific sections of the equipment. Filtration system problems, such as combustion soot pollution, can also be detected. Filtration difficulties may create a slew of problems for your devices, resulting in lengthy - and costly - repairs. When you can pinpoint prospective issue areas and halt them in their tracks, you may save time and money.
Longer Uptime and Less Down Time
The majority of major machinery issues begin modestly and then worsen over time. Larger issues may necessitate substantial repairs and result in significant downtime of your equipment and organization. When your factory isn't operating at full capacity, your company isn't making as much as it could be.
High amounts of wear metal that signify internal parts breaking down can be identified early by frequent oil tests. External or cross-contamination is indicated by increasing trends in particle counts, moisture, elements, and even viscosity. In-depth testing reveals important information about your equipment's health. You'll detect difficulties early and be able to remedy problems quickly and effectively if you analyze the lubricants in your equipment on a regular basis, rather than waiting for expensive repairs and unforeseen downtime.
Equipment that lasts longer
Regular inspections and maintenance extend the life of your equipment and boost productivity across your whole plant's activities. Early identification through oil analysis can help you avoid huge maintenance expenditures and lost output by improving the overall operating state of your equipment and extending the life of your machinery.
Equipment that runs better and lasts longer requires less maintenance during its lifetime. It also implies better efficiency and fewer component part replacements in your machine. These advantages help you save money and keep your company going forward.
Oil analysis can aid in the smooth operation of your machinery and the long-term viability of your company. According to Machinery Lubrication, medium-sized facilities with successful oil analysis programs have internal rates of return of around 150 percent, with a net present value of $500,000 over five years.