With the capacity issues facing the railway at the moment, it is vastly important that every available unit is in full working order and ready to be used at any given time. With the pressures facing rail operators, in terms of smooth operation and minimal downtime, the cost of oil condition monitoring provides extensive benefits, including cost savings that go beyond the initial spend. Downtime of any assets could have massive ramifications; not only in financial aspects such as expensive repair costs and the fines and penalties for train delays and blocked rail lines, but the reputational damage with the public that may occur as a result of asset failure. Train delay penalties and the expense of equipment repairs can be avoided with predictive maintenance, in addition to the reputational benefits when the railway operates as it should.


By analysing processes and the asset environment to identify potential and future problems, greater cost savings can be made. Identifying a root cause or condition that can lead to failure will allow the preventative maintenance to take place on the rolling stock. Not only will that reduce downtime dramatically when the failure eventually occurs, it will ensure longevity of the train itself by protecting the integrity of the engine and rail machinery.


Analysis methodology For root cause detection, screening tests can assess the status of the oil by monitoring particle size, additive content, oil viscosity, total acid number (TAN), total base number (TBN) and total insoluble matter (TIM).


Similar properties are monitored for early fault detection too. In conducting oil condition monitoring at regular intervals, rail operators can be made aware of any recognisable faults that would otherwise go undetected until the asset had failed.


ICP spectroscopy provides a full elemental scan to determine the wear, oil additive and external contaminants.


Levels of iron, copper and zinc within the engine oil, transmission or hydraulic system can indicate the bearing or gears are wearing or degrading. Likewise, ageing oil can be detected through the levels of viscosity, oxidation and acid present. In doing so, it indicates that the oil (and asset) will not be performing at maximum efficiency. The results of


such can allow train operators to make an informed decision to change the oil, and avoid a systematic fail further down the line.


Silicon and sodium indicates ingress of dust / dirt into the asset highlighting it can no longer prevent dirt entering into the system, which only causes further deterioration.


For engines on rolling stock, there are a number of analysis types that can provide crucial indication of the integrity of the component. Fuel dilution will lower the viscosity of the oil; a basic comparison between new and used oil will determine this. Low viscosity can lead to contact and friction between the surfaces of the asset, causing deterioration.


When things go wrong


Rail maintenance managers and engineers should seek guidance from specialists for thorough investigative fault diagnosis.


While preventative and predictive maintenance offers the most benefits to support continuous and smooth- running rail operations, that is not to say that oil analysis does not provide information at other stages of the maintenance programme.


Reactive analysis – otherwise known as post-mortem analysis – can look at the condition of the oil and lubricant following failure. Once at this stage of asset failure, however, the rail operator will already be suffering the consequences of having rolling stock or rail equipment out of action through potentially costly repairs and compensation in delays.


Screening tests can assess the status of the asset for contamination, wear damage, acidity, thickness of oil, age of oil and particle size. These indicators will provide the right information to determine where the fault began, and if that fault could have been avoided.


Frequency of monitoring


Oil condition monitoring can identify a root cause or condition that can lead to failure; identify an early stage fault that might otherwise go undetected; identify the location and cause of failure; determine severity of the condition and potential correction actions needed; and identify the cause of machine failure after the event.


Continued on page 16 LUBE MAGAZINE NO.150 APRIL 2019 15


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