Our staff works with customers to create cost-effective test packages applicable to their particular equipment and mechanical designs. Testing of in-service lubricants will normally include checking for wear, contaminants, oil physical properties, and degradation. Typical testing programs for equipment reliability are comprised of standard routine tests that can meet most service requirements.
Diagnosing equipment condition and evaluating in-service lubricant test results includes looking at both the health of the equipment and the integrity of the oil. Trending of the test data over a period of time is a valuable tool to monitor ongoing equipment condition and predict corrective action before interruption to operations or increased maintenance costs occur. Effective trending analysis will minimize equipment downtime, permit more efficient maintenance scheduling, protect warranty claims, and increase equipment resale value.
Predictive maintenance is a key advantage of analyzing in-service lubricants. Scheduled maintenance alone, without using in-service lubricant testing, may occur too frequently or not allow enough coverage between services. Optimizing maintenance schedules leads to reduced costs and a greater return on investment. Companies that take in-service lubricant analysis to another level concentrate on root cause analysis. This allows monitoring contaminants, such as dirt or water, so that root causes are controlled and kept at a level at which resulting detrimental effects are minimized.
Evaluating a used lubricant sample is not always based on a single test parameter. Equipment or lubricant conditions may be flagged based on the range of acceptable limits for multiple parameters. In addition, it may not be necessary to wait for test parameters to reach a condemning or warning limit across the board, as changes in a combination of parameters may also lead to condemning the oil or flagging an equipment condition. Trained diagnosticians understand equipment application and design, oil formulation, and costs involved in draining and replacing in-service oil.
Good sampling procedures are also important in order to obtain reliable test data. Timely submission to the laboratory after taking a sample is imperative to receiving current equipment condition information. Complete and accurate information is important to proper sample processing and receiving the most value out of a testing program. In addition, we recommend documenting procedures to ensure that proper and timely sampling occurs, proper information is entered, and samples are shipped to the testing laboratory on time. Testing laboratories can provide a variety of sampling supplies, generally at an added cost. Good service providers are always willing to work with end users to develop sampling procedures and provide material applicable to an end user’s needs.
Analysis Reporting
Data reports can be delivered in several formats, but electronic, web-based reporting provides significant advantages for record keeping, data management, and maintenance integration. Companies with multiple sites, large equipment, or fleet inventories are able to manage information much more effectively using electronic reporting (as opposed to sorting through multitudes of paper reports). A web-based reporting service can effectively incorporate the use of in-service lubricant analysis with other maintenance processes.
Effective follow up by end users can maximize return on investment. Sometimes, information provided on a test report can be enhanced tenfold after a conversation with the testing laboratory. Abnormal test results require follow up on detrimental trends before they manifest into larger problems. A well-tuned analysis program is expected to complement other maintenance practices. It is a good practice to document and build on successes in order to realize improved maintenance, operating efficiency, and cost savings
Extensive Testing Capabilities
ALS Tribology laboratories offer an extensive variety of ISO, ASTM, and UOP test methods. All of our Tribology testing facilities provide consistent, industry recognized test methods globally. Specialized testing and technical services are available to address specific needs. Examples include:
- Wear particle analysis and analytical Ferrography
- Varnish potential
- Lubricant compatibility
- Rotating pressure vessel oxidation test (RPVOT)
- Over 100 ASTM test methods
General Sampling Guidelines:
ALS Tribology offers a variety of sampling supplies. Following are general sampling guidelines:
- Use safe sample extraction methods
- Use consistent practices
- Use optimal sampling points and choose a representative location
- Minimize sources of garbage data
- Never sample directly from a filter
- Take samples before the oil is changed and before adding make-up oil
- Have the oil warmed up and thoroughly mixed before sampling
- Do not overfill sample bottles, but ensure there is enough sample to perform all tests
- Allow samples to cool before sealing container lids
- Use in-line sample ports for circulating systems for best results
- Sample in areas of turbulence, such as bends, and avoid straight sections of pipe
- Always use clean sample containers and equipment
- Use well-sealed containers so they don’t leak after replacing the container cap
- Provide required sample information
- Keep sample bottles sealed and clean for sending to the lab
- Keep paperwork clean
- Establish procedures for forwarding samples to the laboratory
- Send samples immediately to the testing lab to ensure applicable test results