Oil Condition Monitoring (OCM) is essential for keeping machinery running smoothly and preventing unexpected breakdowns. Maintenance teams can spot early signs of wear and tear by regularly checking the condition of the oil in engines, gear systems, and hydraulic machines. This proactive approach allows them to address issues before they lead to costly repairs or downtime.
Over the years, OCM has evolved into a sophisticated process that involves analyzing oil samples to understand the health of the machinery. Some companies perform these tests in-house, while others rely on specialized third-party services. Each option has its pros and cons. Third-party services offer expert analysis and advanced equipment but can be expensive and slow. On the other hand, in-house monitoring is faster and gives companies more control, but it requires investment in equipment and training.
Case Study: OCM in Practice
A comprehensive study was conducted on 67 oil samples from an Austrian steel producer to better understand the effectiveness of different oil monitoring methods. These samples included fresh industrial lubricants, artificially aged oils, and oils that had been in service for some time.
The study aimed to compare various techniques used in oil condition monitoring. The oils tested ranged from engine oils to hydraulic and gear oils, covering both traditional mineral-oil-based lubricants and modern synthetic alternatives.
The Sample Matrix
- Fresh Oils: 9 different fresh lubricants were chosen as the starting point.
- Artificially Aged Oils: These fresh oils were aged under controlled conditions to simulate long-term use, resulting in 3 to 4 aged samples per fresh oil type.
- In-Service Oils: Samples of oils already used in machinery were also collected.
Sixty-seven samples were analyzed, allowing for a thorough comparison of how different oils perform over time and under various conditions.
Key Findings from the Case Study
- Viscosity Matters: One of the most important tests in OCM is measuring the oil's viscosity or thickness. This study used a new method called the "differential pressure capillary method" to measure viscosity. This method proved highly accurate and provided detailed insights into how the oil's viscosity changes with use and aging.
- Elemental Surprises: The study also looked at the presence of specific elements, such as metals, which can indicate wear or contamination. While most elements were measured accurately, calcium presented a challenge. The traditional method underestimated the amount of calcium in some samples, leading researchers to investigate further. They discovered that calcium particles in certain oils were not fully detected due to how they interact with other chemicals in the oil.
- Infrared Insights: Infrared spectroscopy was used to detect chemical changes in the oil, such as oxidation or contamination. This method was beneficial for comparing fresh oils with aged and in-service samples.
Despite some differences in the results from various devices, the study confirmed that infrared spectroscopy is a reliable tool for monitoring oil health.
Simplifying the Process
In simpler terms, consider oil condition monitoring a regular health check-up for your machinery. Just as doctors use different tests to check your health, maintenance teams use various methods to check the oil's health. This ensures that the machinery continues to run efficiently and avoids potential issues that could lead to expensive repairs or downtime.
This case study highlights the importance of choosing the right monitoring methods and shows how advanced techniques can provide deeper insights into oil and machinery health. By understanding these findings, companies can make more informed decisions about maintaining their equipment and ultimately save time and money.
About the Author
Thomas Feischl, based in Graz, Styria, AT, is currently a Director of Business Development at eralytics GmbH, bringing experience from previous roles at Nynas AB, Anton Paar GmbH and Fugro Austr...
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