Destiny International

Case Study - Oil Analysis, A Powerful Tool For Maintenance

Oil analysis is the process of analyzing a sample of lubricating oil from a machine or engine to determine its condition and to predict potential problems. The analysis typically includes tests for wear metals, contaminants, and the presence of fuel or coolant. It can also include measurements of the oil’s viscosity and acidity. By regularly analyzing oil samples, maintenance personnel can detect problems early and take appropriate action to prevent costly equipment failures. This can include scheduling maintenance, replacing filters, or adding additives to the oil. Additionally, the oil analysis can help to optimize the oil drain intervals and reduce the overall cost of lubrication.

A good doctor prescribes only after proper diagnosis likewise a maintenance person monitors all the vitals of his machine. Plant-wide reliability is achieved by proactively monitoring various indicators of oil.

By analyzing oil-following are accomplished:-

When your machines are going to fail?

Early detection of incipient machine failures?

When an oil change is required?

A better understanding of contamination levels?

Optimizing machine reliability at the lowest possible cost?

WHAT IS ANALYSED

FLUID PROPERTIES

CONTAMINATION

WEAR DEBRIS

Physical and chemical properties of used oil

Fluid and machine destructive elements

Presence and identification of wear particles

 

Particle counting

No benefit

Primary benefit

Minor benefit

Moisture analysis

No benefit

Primary benefit

No benefit

Viscosity analysis

Primary benefit

Minor benefit

No benefit

Patch test

No benefit

Primary benefit

Minor benefit

 

Proactive

Proactive

Predictive

 

New/ In Service

In Service

After Failure

 

 

What oil analysis is telling

Root cause detection

Incipient (Early) Fault detection

Problem diagnosis

Failure Prognosis

Post mortem

Maintenance Mode

Proactive

Predictive

Predictive

Predictive

Autopsy-learning from failure

Relative savings

10

6

3

2

1

Oil Analysis

Cutting wear on a ferrogram

Adhesive wear particles

Adhesive wear particles

Babbitt Particle (After Heat Treatment)

Babbitt Particle (After Heat Treatment)

Copper from ring gear on a worm drive

Copper from ring gear on a worm drive

Surface fatigue Particle

Surface fatigue Particle

Corrosive Wear Particles

Corrosive Wear Particles

Red Iron Rust

Red Iron Rust

Dark Metallo- Oxide

Dark Metallo- Oxide

VISCOSITY-REFERENCE LIMITS

How to set viscosity Limits

Viscosity
  • *Twice this amount for oils with VI improvers 
  • **Crankcase  of limits  based on cSt @100*c  ; industrial oil based on cSt @ 40*c
  • Note : Severe  Environment oils are at high risk for  thermal and oxidative degradation . 
Industrial Oil

Control Contamination Oil Dehydration and Filtration System

Contamination : Damaged Caused

ferrocare collector

Data Speaks For Itself :

Data From Elemental Analysis Dominate Most Oil Analysis Reports

ferrocare collector

Summary

  • Know which questions you are trying to answer
  • Know what the tests can tell you and how they can answer your questions
  • Don’t neglect the other oil analysis checklist items.
  • Always ensure all the machine and lubricant data is on the report
  • Always ensure relevant historical data is reported, such as top- ups or failures.
  • Always keep a new oil baseline for references
  • Sample routinely and optimize the frequency
  • Know the three categories of oil analysis, how they influence each other and their significance

Costs And Benefits – Critical Machine of an Oil Analysis Program

The approximate annual cost if a well-implemented Oil ANALYSIS PROGRAM –

0.2 To 2% of equipment value

Approximate annual benefits :

5-20% of equipment value

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