Five Best Practice steps in Oil Analysis

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Five Best Practice steps in Oil Analysis
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Step 1 - Setting Goals

• Quantify opportunity based on estimates
• Examine resources available to commit to the
  program.
• There are usually 3 types of goals for oil
  analysis
• Oil Analysis for PM purposes
• Oil Analysis for PdM purposes
• Oil Analysis to support the goal of Potential
  Reliability
• Make them practical
• Communicate them throughout the organisation

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Oil Analysis for PM Purposes

• Store history for the equipment
• Identify problems that are likely to occur
  between maintenance intervals
• eg glycol or dirt contamination
• Warranty requirements

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Oil Analysis for PdM Purposes

• Anticipating or predicting the performance of
  individual components in each machine
• Deeper analysis of history used to set limits
• Scope of fluid testing is expanded

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Oil Analysis aimed at Potential Reliability

• To get the maximum service life from every
  component
• Oil analysis is used to identify all the factors
  in an operation that could diminish the potential
  service life of a component.
• Decision to correct problems.

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Step 2 - Lab Selection

• What certification/standards the laboratory
  operates under.
• What analysis the laboratory can do and compare
  that to what you require based on the goals set
  in Step 1.
• Strengths and limitations of lab analysis
  -lubricant technical specs.
• Good communication between lab and site

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Step 3 - Taking the Samples

• Set up standard operating procedures describing
  where on the machine the sample point is.
• Physically mark sample points to ensure
  visibility and reduce error
• Maintain education and feedback to those taking
  samples

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Operating Procedures - Standards of Sampling

• For the Sample point
• Ensure the samples are representative of the
  fluid circulating in the system
• dont draw fluid from the bottom of a reservoir
• dont take fluids when the component is cold
• Consult with the lab/OEM about the best method
  for drawing samples
• Ensure the sample point area is clean to prevent
  contamination falling into the reservoir or the
  sample container

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Standards of Sampling (Cont)

• For the Oil Sample Labels
• fill out all the necessary details to ensure
  correct analysis when results are returned from
  the lab.
• use pre-printed labels where possible
• use ink instead of pencil to ensure the contents
  of the label remains legible
• record information such as make and model of
  engine
• record brand, type and weight of oil used in the
  component
• record top up oil

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Standards of Sampling Cont..

• For the Sampling Interval
• Determine what is sampled (oil, hydraulics,
  coolant)
• Understand how frequency is determined
• Ensure you sample at regular intervals to gain
  maximum potential output value of oil analysis,
  ie showing what changes over time
• OEM requirements
• Checks and flags for interval
• Review process for sample interval
• Vary sample interval based on need

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Step 4 - Analysing the resultsSix Key
Requirements

• Knowledge of Equipment to be monitored
• Metallurgy of components
• Awareness of likely contaminants
• Understanding of Lubricants in Use
• Monitoring of Trends
• Establishing relevant alarm levels

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Analysing the results (cont...)

• View your current results compare them to your
  history
• View calculated wear rates compare them to your
  history
• Set standards of action
• eg what is a severe problem, a potential problem
  and a good result
• eg if the results show a severe problem can you
  force the machine out of service

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Analysing the results (cont...)

• Compare oil sample results against vibration
  data, infrared scanning, ultrasonic etc to get a
  better picture of the component
• Downtime analysis to determine the effectiveness
  of PM and PdM programmes
• Emergency (breakdown) rate analysis to determine
  the condition of equipment.
• Keep case notes accessible to retain and share
  the knowledge

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Step 5 - Taking Action

• Usually the weak link in the cycle
• Knowing what to do requires training, research
  and monitoring
• Some trial and error required
• Used before failure, not after
• Must be regular
• Document in software

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Taking Action (cont...)

• Decide on predictive proactive courses of
  action eg extend oil drains, increase time
  between overhauls
• Do extensive studies or pilot programs before
  making global changes

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Benefits

• Optimum Equipment Life
• Asset utilization maximized
• Simplified oil data management
• Timely, graphical analysis
• Early detection of problems
• Expensive failures avoided
• Costly overhauls reduced
• Extended oil change intervals
• Reduce paperwork and administration

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