SECTOR FOCUS: TESTING
Condition monitoring and analysis
Peter Hardy, Business Manager, Lubricant and Fluid Condition Testing, Infrastructure & Energy Services, SOCOTEC
Lubricants, engineering fluids and coolants are an essential component to any moving part and therefore the analysis of oils and greases – for engines, gearboxes and hydraulics – is vital to ensure that machinery and manufacturing processes are appropriately and effectively lubricated for safe, cost-effective performance.
As oil and grease play such an important part in the correct functioning of manufacturing processes, chemical and physical analysis is fundamental to ensure the oil is fit for purpose and that the asset is fit for operation. Condition monitoring and analysis of lubricants can support a number of sectors in their asset management; transport, manufacturing and energy generation are but a few examples of industry that require frequent oil testing and analysis to guarantee longevity and high performance of equipment.
Poor or infrequent monitoring can lead to lubricant deterioration, such as metal or water contamination, therefore weakening the effectiveness of the lubricant or coolant. In some cases, machinery failure can be catastrophic and, in the automotive and rail sectors, engine wear or lubricant quality degradation can be high risk to peoples’ safety. The Rail industry has been conducting chemical and physical analysis for over 40 years and this approach has been key to extending the asset life cycle and ensuring assets fit for use on today’s modern rail infrastructure.
Depending on the type of oil or grease, a full test suite will look at both the lubricating physical properties of the oil and then any subsequent wear or contamination within the asset. Typically, ICP full spectrographic, viscosity, water and acidity are some of the key tests to determine the quality of the oil and the condition of the asset. Levels of silicon, iron, copper and zinc can indicate that there is wear on the bearing or gears, while viscosity, oxidation and acid levels suggests the
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oil is aged. Dirt ingress (grit or brake dust, for example) is also an indication of wear of the asset as it can no longer prevent dirt entering into the system, which only causes further deterioration.
e dust for example)
The analysis can detect the ‘unseen’ issues in advance to prevent mechanical failure and equipment damage, reducing costly repairs and production downtime. By determining the quality of oil and lubricants on a regular basis – often through the use of sample collection kits – trends and patterns can be identified at an early stage to allow for informed maintenance decisions via online asset management software. Predicting and preparing for maintenance errors can prevent untimely failures and support a cost-effective performance.
With a dedicated UKAS accredited lubricant and fluid analysis laboratory based in Hexthorpe, South Yorkshire, SOCOTEC’s highly experienced specialists provide full analysis for mechanical and electrical oils as well as fuels and greases.
As part of SOCOTEC’s complete condition monitoring offering, services include: chemical, physical and microbiological analysis of lubricant and fuel and for electrical transformer oils, water content, electric strength, contaminants and acidity. To ensure a full asset management solution, provision of bespoke sample collection kits, analysis of lubricants for wear, additive and contaminant elements within engine, gearbox and hydraulic oil as well as expert interpretation and trend analysis of results are also included in the service package.
For more information about SOCOTEC’s services or advice on condition monitoring and analysis, please visit the SOCOTEC website or call 0845 603 2112.
LINK:
www.socotec.co.uk
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