Lubricant life cycle
Executive Summary
According to TLT readers, issues related to extending a lubricant’s life fall into two distinct categories. The first involves the strategy and logistics of implementing a sound lubrication program, including understanding the machine’s operating conditions and environment, correctly taking an oil sample, factoring in unpredictable variables and generating an accurate and timely report. But the larger issue relates to getting buy-in on the program from both senior managers and hands-on people. Without it a lubricant program is destined to fail, as schedules aren’t followed and procedures are ignored. Asked which item they would most want in inline and online sensors, readers cited accurate particle counting, hand-held functionality and the ability to work in harsh environments.
Determining how the lubricant will be used.
Securing buy-in from all staff and ensuring that the teams are trained and fully understand the whole process, including the importance of accurately completing data before submitting samples.
The time it takes to implement a plan.
Leadership, communication, training.
Educating management on the benefits of lubrication.
Implementation assistance from vendor.
Understanding the operating conditions of the system and the main reasons for lubricant life to be limited (which are normally various with a variety of probabilities), and then making sure these are measured and monitored suitably.
(1.) Lubricant suppliers insist on changing oil based on some parameters they measure themselves without proving the lubricant is not fit for further service. Independent laboratories rarely provide needed measurements. (2.) It is unclear which criteria is most important for lubricant performance. Oxidized oil quite frequently still performs very well.
Reliability of data. Maintaining continuous data gathering.
(1.) Even with a baseline fluid for reference, there can never be 100% certainty of a fluid’s many constituent additives being effective any longer or knowing which one is depleted. (2.) If one of a fluid’s additives becomes depleted, there is little chance of knowing (or obtaining) a compatible (or the exact) additive to replenish the depleted one. This will then require the fluid to be replaced—just for one additive’s depletion.
Initial cost, system maintenance, developing trust among operators.
Difficulty controlling environmental variables.
Competent sample takers. Proper lube in the compartment. Oil cleanliness.
(1.) Getting buy-in from the customer. (2.) Sticking to the plan (PMs, downtime, etc.) (3.) Pulling samples regularly and reliably.
(1.) Properly taking the samples. (2.) Not contaminating samples before review. (3.) Understanding the variables at each location that might be causing variations in the oil.
Compliance, FIFO.
Buy-in from upper management as well as the hands-on maintenance people.
Testing costs.
Proper training, following procedures, management oversight.
Storage, filtering, costs, data mining.
Resolving objections on cost and time of program.
Consistent sampling regiment. Accounting for add oil.
Keeping the lubricants clean and dry.
Consistent sampling. Timely reactions to identified problems.
End-of-life prediction on recycled fluid.
Consistency of processes and accurate application of results.
Lack of flexible maintenance scheduling. Resources and differing priorities.
(1.) Filter flogging with wear debris. (2.) Water contamination.
Date for all equipment initial lubricant fill and operation. Equipment operating hours. Life span projections.
Making sure used-oil samples are taken properly and on a set schedule, that the results are interpreted correctly, and corrective action is taken to prevent a shutdown.
How to know what the change interval should be. How to account for lubricant losses, if any. How much lube degradation is acceptable, and what are those parameters?
Balancing risk and opportunity. Sometimes oil does not need to be changed, but there is too long of an interval before the next opportunity arises to risk postponement.
Monitoring oil degradation. Monitoring additive depletion. Monitoring thermal stability.
Proper maintenance of the system.
Will emerging technologies such as the Internet of Things and Cyber Physical systems be incorporated into inline or online oil-monitoring sensors?
Yes, I’ve seen big changes
28%
Yes, sort of
58%
Not really
14%
Definitely not
0%
Based on responses sent to 15,000 TLT readers.
© Can Stock Photo / cookelma
Q.2. Please describe the top item on your wish list for inline or online monitoring sensors.
Accurate particle counting.
Cleanliness, acidity, key additive level. Wish list? For some oils that would be air release, demulsibility.
Ability to measure basic oil characteristics, the presence of foreign inclusions and wear parts, repeatability of measurements, the ability to code signals.
Hand-held functionality.
FTIR or such to monitor changes in chemistry over time or identify contaminants.
(1.) Base number (alkalinity). (2.) Iron contents. (3.) Particle size distribution.
The ability to work in harsh environments.
(1.) Accurate sensing of various particulate shapes to the new ISO 11171:2016 standard in a way cost effective for non-laboratory environments. (2.) Detection of oil varnishing. (3.) Water content in fluids, from emulsified to free. (4.) Entrained air content in fluids.
Viscosity, AN, particulate contaminants.
Predictive maintenance.
Low cost and accuracy.
An inline particle counter that is actually accurate.
Temperature, volume, density.
Elemental analysis.
Online ISO 4406 sampling inline water detection sensors in gear oils.
A way to convert viscosity index and temperature to a recognized viscosity unit, cSt or cP.
Accurate collection sites and apparatus that gives ability to accurately measure contamination levels.
Customer connection.
Viscosity oxidation PC.
Discriminate ferrous/non-ferrous. Full flow count and size in real time.
Timely reactions to identified problems.
Flow, concentration.
Tech training and application for online oil monitoring. Continuing education is needed most. Systems and tools will always be available and improved upon and the training must stay relevant to current technology.
Network connectivity. Ability to tie in to other applications. Accuracy.
Online contamination sensor.
Quick and accurate results.
Acid level, contamination level, temperature, opacity.
An engine oil sensor that truly measures and indicates the level of contamination in the oil. I think this could really help drive the average consumer’s understanding of why oil needs to be changed.
Real-time response.
To what extent do you foresee condition-based oil change being widely adopted?
More
84%
Less
16%
Same
0%
Based on responses sent to 15,000 TLT readers.