The Importance of Laboratory Analysis of Industrial Oils

Laboratory analysis of industrial oils is a crucial element for the maintenance and reliability of industrial machinery. Through these analyses, it is possible to monitor the condition of the oil, detect contamination, degradation, and signs of wear in mechanical components. However, like any technique, laboratory analysis has limitations that must be considered to optimize maintenance management.

Limitations of Laboratory Analysis

1. Time for Report:

One of the main disadvantages of laboratory analysis is the time required to obtain results. After the sample is taken, it must be sent to the laboratory, analyzed, and then a detailed report is prepared. This process can take several weeks, during which the machinery continues to operate potentially in suboptimal conditions.

2. Risk of Sampling Error:

Oil sampling is a critical phase that can affect the accuracy of the results. Incorrect sampling can lead to misleading results. Common errors include:

- Taking oil from non-representative points in the system.

- Contamination of the sample during collection.

-? Use of inappropriate or unclean containers.

-? Non-optimal sampling timing (e.g., not during normal operation of the machinery).?

3. Sampling Frequency:

Laboratory analyses are usually performed a few times a year, meaning the oil condition is not constantly monitored. This can lead to a lack of timely information on the operational conditions of the machinery, increasing the risk of sudden failures.

How to Perform Proper Sampling

To minimize errors and obtain representative data, it is essential to follow some guidelines during oil sampling:

1.?Preparation:

?Ensure you have all necessary tools: clean and sealable containers, sampling pumps, identification labels, and protective gloves.

2. Sampling Procedure:

- Take the sample during the normal operation of the machinery, preferably when the oil is warm and well mixed.

- Use a representative sampling point, such as a draw-off valve installed on the oil return circuit.

- Avoid taking samples from tanks or reservoirs where the oil can stagnate and may not be representative of the system in use.

3. Contamination:

- Use sterile techniques and equipment to avoid contamination.

- Immediately seal the sample in an appropriate container and label it with all necessary information (date, time, machinery, sampling point).

Real-Time Monitoring: The Use of In-Line Sensors

To overcome the limitations of laboratory analyses, the industry is increasingly adopting the use of in-line and real-time sensors. These devices offer numerous advantages:

1. Continuous Monitoring:

In-line sensors constantly monitor oil conditions, providing real-time data on the presence of contaminants, oxidation, viscosity, and other critical parameters.

2. Timely Intervention:

The availability of real-time data allows for immediate detection of any anomalies, enabling rapid corrective actions and preventing significant damage to the machinery.

3. Cumulative Information:

Sensors offer a cumulative view of operational conditions, making more effective predictive maintenance possible and reducing unplanned downtime.

4. Cost Reduction:

Although the initial installation of sensors may require a significant investment, the long-term benefits in terms of reduced failures, optimized maintenance, and increased machinery lifespan result in overall cost savings.

Conclusion

Laboratory analysis of industrial oils remains an essential component of predictive maintenance. However, its limitations can be effectively overcome through the integration of in-line and real-time sensors, which provide continuous and immediate data on oil conditions. This combination of techniques not only keeps machinery in optimal condition but also significantly reduces the risks and costs associated with sudden failures.