Oil monitoring is a great proactive practice that should be incorporated into any maintenance routine. It enables Operations Managers to have a better understanding of what’s happening under their watch. Oil analysis allows things like hydraulic system wear or contamination to be caught and stopped long before serious damage occurs.

For critical pieces of equipment, the attractive return on investment makes oil analysis completely worthwhile. An initial investment for a full program’s test kits and quarterly monitoring can easily translate into significant equipment downtime savings. However, not every piece of equipment necessarily needs to be monitored. Operations Managers need to take inventory and determine which equipment is the most critical for monitoring.

For example, Operation Managers need to think about the consequences of that piece of machinery going down and whether it would shut down the mine. If the sampling process is more expensive than potential damage or shorter drain intervals, it will not be worth it.

Used oil analysis can also provide the opportunity to safely optimize drain intervals. Regular oil analysis and trend monitoring may prove that change-outs can be extended because the oil quality has not yet been compromised. For large systems, extending drain intervals can be a huge opportunity for savings.

Managers can also use oil monitoring to check the right lubricant is being used as any changes in additive and wear metal levels can be that guide that something is wrong and should be looked at.

The first step in setting up an oil monitoring program is ensuring there is an experienced, dedicated member of the team who will take on the responsibility of organizing the sampling process and reviewing the results. Often operators send oil samples to the lab but neglect to follow up on the results of the testing.

The next step is identifying critical equipment that needs to be monitored, and creating a list of priorities so that important pieces don’t get left out.

Taking an oil sample every 3 months is always recommended as sampling every 6-12 months may allow for too much degradation to take place, defeating the very purpose of the monitoring analysis. At Petro-Canada Lubricants, our Technical Sales Advisors are always available if you need help getting an oil monitoring program established.

In many cases, the results of oil analysis aren’t thoroughly understood, leading to oil being changed routinely at certain intervals. By doing so, opportunities to extend drain intervals are missed, which can be costly in terms of time and money.

Oil analysis reports can provide lots of valuable information and need to be comprehensively understood. Choosing an efficient lab to conduct such analyses can be of great help as they will flag any problems that come through in the results of the test.

The most important indicator to watch out for is viscosity as it will indicate whether the right oil is being used for the right equipment.

For example, when using HYDREX AW 46, the viscosity should be within an allowable range of 46 – typically within 10% of the original manufacturer's viscosity. If the results show a significant difference, there could be an issue.

Taking a close look at the worn metals or conducting an elemental analysis is important as it can indicate component wear.

For example, excess iron in a gearbox is indicative of an issue and excess copper in hydraulic fluid is indicative of component wear.

For hydraulic oils, the Acid Number (AN) is an important factor.

The AN gives you an indication of whether the oxidation is increasing. Industry practice sets a condemning limit as the acid number rises to 1.5 – 2.0 (ASTM D943).

Depending on your industry, you may focus on certain aspects of the analysis.

In mining, for example, you may be looking closely at silicon levels, as an indication of dirt getting into the system. When uncertain, Petro-Canada Lubricants’ expert team can help translate or explain results for better monitoring processes.

When contamination occurs within equipment systems, many Operations Managers quickly assume that their lubricant is at fault. However, it is often external factors causing the problem. Anything found in lubricants, apart from its ingredients, are contaminators. This includes dirt, loose particles, air and water. In many cases, contamination results from improper storage and handling techniques.

Cross-contamination is another risk stemming from using the wrong product for your equipment. This can happen if someone is either unaware of the suitability of each product, or simply uses the wrong product out of convenience. Operation managers should never assume "an oil is an oil” as each product has a specific use and shouldn’t be mixed with another one.

Contamination within your system can be avoided through:

• Proper lubricant handling and storage.

• Ensuring the right product goes in the right place for maximum performance and cost efficiency.

It’s critical to always treat lubricants with care. These proper storage and handling practices make good economic and safety sense:

• All lubricants need to be kept cool, clean and dry.

• When handling, use the proper care to preserve the integrity of the fluid while shifting it from storage to usage. This will help to eliminate leakage or spills from damaged or improperly closed containers.

• All oil dispensing containers should be kept clean and dry – in storage and equipment. Misuse and/or improper storage of oil transfer equipment is the primary cause of oil contamination during application. These contaminants can easily cause wear of critical parts and increase the oxidation of the oils, reducing their lifespan.

• All grease and oil drums, kegs and tanks should be properly identified with the product name. This will help to eliminate the possibility of mixing different brands or types of lubricants that are incompatible.

• Proper ‘oil-house’ rotation of lubricants is essential to make sure that the oil that is ‘first in’ from the supplier is always ‘first out’ into equipment. Employ the FIFO (first in, first out) method of stock rotation and avoid oil deterioration due to prolonged storage.