Executive Summary
When it comes to fluid cleanliness, the majority of TLT readers already have a fluid cleaning program implemented in their workplace, and they report cost-savings and increased equipment efficiency as a direct result. Filtration, condition monitoring programs and employee education are some of the most impactful ways that fluid cleanliness can be improved. Good housekeeping practices are essential to eliminating contamination and realizing the benefits of a fluid cleanliness program.
Q.1. How do you think you can improve the level of fluid cleanliness in your equipment looking toward the near future?

Proper filtration.

Improve filtration and skimming.

The quickest way to make progress on this subject for my site would be mass education of the operations and maintenance personnel on proper storage and handling practices. There has been some progress with individual sections of the plant, but many areas are still using outdated or plain incorrect (but convenient) practices.

Best maintenance storage practices should have the product stored in a cool, clean environment at 70% humidity. The product should be quarantined from use until it is filtered and then stored with a desiccant filter prior to use.

An offline (passive) filter cart with water filters and particulate filters (usually about 10 micron absolute).

Filtration.

Tighter filtration options 3-5 micron.

Filter on receipt. Use filter carts. Sample and test regularly. Ban open containers. Fit filter breathers to eliminate airborne solids and moisture significantly. Housekeeping is everything.

Filtration.

Better storage and handling, upgrade breathers and possibly pre-filter the oil for some applications.

Usually in the transmission or hydraulic system, they have the two or three stage filtration for the new oil adding, which can greatly improve the oil cleanliness. Also, in the gearbox or hydraulic oil tank, they have the magnetic plug for the wear debris collection.

By performing fluid condition monitoring frequently.

Better data collection techniques of the fluid status and the equipment operational parameters.

Through the use of hardware (filters, magnets) and improved design of components to eliminate pockets with limited or no oil flow.

Optimizing of types, materials and sets of filters.

Purchase filtered oil. Bulk tank oil filtration system. Filtration on metering guns. Training and education. Good housekeeping and dispensing practices.

As the fluid has different aspects of cleanliness: implement multi-stage filtration to target specific contaminants like metal fines (magnetic separators, cyclonic filters), tramp oil (separators, also baffling the sump) and bacteria (regularly inspect and add biocides).

By using high-efficiency offline filtration.

By training technicians to follow basic rules and guidelines.

Clean environment, better filtration and separation of water and contaminants. Oil analysis.

With proactive practices (avoiding contaminants ingression) and filtration.

By employing more restrictive filtration requirements.

Product handling, breather implementation, removing wear generated particles.

Filtering the air that enters the fluid tanks as liquids are dispensed from them is helpful in preventing containments from entering them. Filter and strainers, which are on equipment, being cleaned and changed at regular intervals is very important in keeping fluids clean.
 
Filtration.

Use higher performing products with top quality base stocks.

Filtration, closed system transfer containers, training.

Proper maintenance and care of the filters and filtration equipment.

With offline filtration.

Installing filtering system and having good maintenance practices.

Proper material handling and use of filters.

With better storage, handling and filtration practices.

Yes, we can. The key is the balance between cost and benefit.

Improved filtration and dedicated transfer containers and lines.

Maintenance tribology.

To install more bag filters in the plants if possible.

We are a lubricants producing company, but we see more filtration systems in use with our customers.

Using environment sustainability measures, such as fluids biodegradation.

Increased focus on the cleanliness of incoming lubricants. Filter all and store in clean containers. Use 4 micron filters on filter cart.

Using filters to remove contaminants. Using seals to prevent contaminants from getting in.

Filtration.

Do you have an adequate fluid cleaning program implemented in your plant?
Yes 67%
No 33%
Based on an informal poll sent to 15,000 TLT readers.

Have you perceived economic benefits from the implementation of these programs?
Yes 80%
No 20%
Based on an informal poll sent to 15,000 TLT readers.

Has the useful life of your equipment increased after the implementation of these programs?
Yes 85%
No 15%
Based on an informal poll sent to 15,000 TLT readers.

Better maintenance practices with low sludge/wear fluid in the system.

Using effective close loop transfer methods from new oil storage to dispensing. Also, outfitting this system with pre-filters.

In the near future, I plan to improve fluid cleanliness by implementing stricter filtration standards during both storage and handling stages, enhancing inspection protocols for contamination control and adopting proactive fluid analysis programs. Furthermore, I intend to train operators and maintenance staff to apply best practices for fluid handling to minimize ingress of contaminants throughout the equipment’s service life.

Purchase filtered oil, filter oil into the equipment. Filter breathers on the equipment.

Align all phases of oil handling to ensure oil cleanliness is at target levels. Focus on point of application filtration during oil dispensing into equipment.

Making sure that all equipment is operating in as clean an environment as possible and that all connections for machinery modifications are tight. Maintaining a good sampling schedule for all critical equipment and acting swiftly on any anomalies in the oil reports.

Regular analysis and a quick test to check performance to determine replacement versus replacing fluids at pre-defined intervals.

Promote better practices when conducting oil changeovers and incorporate better online oil filtration.

I think a major focus on education, especially the “basics,” for everyone involved with lubricants, coolants and fuels, as well as better monitoring and trend(s) analyses.

Q.2. How do you think improving good maintenance practices in order to prevent fluid contamination will impact the useful life of your equipment?

Absolutely, yes, it extends the life of the equipment. It extends life by alerting of needed repairs ahead of catastrophic failure.

Training is key; people first need to understand why it is important to ensure cleanliness. Trust is also key; in case of a human error, you need the person to tell you about this mistake, otherwise it can be long and painful to find the root cause by yourself.

Getting the site aligned with good lubricant storage and handling practices should show significant gains on my site, given the generally poor practices we have in action for most sections of the plant.

It would solve a lot of problems. A lot of the time fluid cleanliness levels are wrong just based on how samples are pulled and not necessarily the actual reservoir.

I believe that good maintenance practices dramatically increase the life of equipment. It is easier to maintain a well-run piece of equipment than try to draw additional life out of a machine that was not well maintained. However, this requires hard work and good leadership. Less than 20% of businesses are willing to do it.

It usually extends the life of the equipment, including bearings and valves and should extend the life of the fluid, since there would be less oxidative breakdown.

Contamination particulate causes machine wear, gear wear and hydraulic wear. Lifetimes of parts are decreased.

By reducing or removing clearance-sized particles, physical wear should be brought to a minimum.

It will keep your equipment for a longer life hence savings for the bottom line.

Greatly extend the life of the equipment as well as increasing the cost effectiveness of equipment maintenance.

This could have a considerable impact on component durability and service life.

The answer can be rather positive. However, this requires compliance with proper operating conditions and appropriate staff training.

Reduce corrosion, water contamination and particle induced wear.

Multiple times extension.

Operating a hydraulic test stand, fluid cleanliness prevents premature wear to the high-pressure pumps and motors that are used on it. It also reduces the impact to our client’s equipment that is connected to it for testing. Unfortunately, inadequate investment in continual filter and fluid changes, and no oil cooling (aside from radiant heat), needlessly oxidizes the oil, reducing its life.

Clean oils last long, perform better and the equipment lasts longer.

They are the best ways to increase equipment useful life.

Good maintenance practices are vital for preventing fluid contamination, hence increasing equipment life and performance.

What gets measured gets done. Design needs according to operating conditions and equipment within design operation, define all aspects of required maintenance and follow up on completion and effectiveness.

One of the main reasons for equipment failure is lubricant contamination. Any improvement in preventing containments from entering lubricants or fuel will be beneficial in equipment protection. The more filtration and water removal that can be done the better.

Proper maintenance and oil changes will greatly improve the life of equipment.

Avoids unexpected issues of filter equipment breaking or filters experiencing breakthrough.

Less interruption of the lubrication film through abrasive particles.

It will clearly extend the life of the equipment by avoiding wear problems due to contamination or degradation of the fluids.

Favorable.

Extend it by a minimum of two to three times.

Less wearing.

Based on past experience, improving cleanliness (i.e., eliminating contaminants) will dramatically increase equipment up time.

Taking and adopting total loss metalworking fluids and treating fluids pretreat measures.

Constant training and the provision of the correct tools and equipment. Quality filters, breathers and strict procedures for opening of plant items with regard to prevention of the ingress of contaminants.

Contaminants change fluid properties causing them to degrade faster.

Probably improved.

Abrasive wear has the maximum impact on life of the equipment. Preventing ingress of external contaminants by better maintenance practices facilitates that.

If this is done correctly and in a timely manner this can extend the life of equipment.

Improving maintenance practices aimed at preventing fluid contamination will significantly extend equipment life by reducing abrasive wear, corrosion and component fatigue. By maintaining optimal fluid conditions, equipment will operate within designed tolerances longer, leading to fewer failures, lower downtime and an overall increase in operational reliability and asset value.

Very significant in key equipment. In equipment with large clearances and tolerances, there’s not the same impact.

Cleaner oil increases mean time between repairs (MTBR).

Good maintenance practices contribute to fluid cleanliness by excluding contaminants from the start. If the contaminants are excluded, the reliability of the machinery increases exponentially because the contaminants may not be found until the next fluid sampling cycle.

Lower maintenance cost, reduced downtime, reduced wear and tear and overall improved productivity.

Conduct periodic oil analysis, raise awareness of good practices of oil handling.

In the case of lubrication, garbage in = garbage out. If you do not practice good maintenance techniques, and focus on keeping fluids clean, cool and dry, your equipment can suffer dramatically. Once you “allow” a small amount of fluid contamination, whether that is cross-contamination, particulate contamination, moisture contamination, etc., it can quickly cascade into a full-blown attack on your equipment and the effectiveness and reliability of that equipment. The utmost care must be given to protecting the lubricant, which in turn protects your equipment, to ensure your return on investment (ROI) is realized.

Editor’s Note: Sounding Board is based on an informal poll sent to 15,000 TLT readers. Views expressed are those of the respondents and do not reflect the opinions of the Society of Tribologists and Lubrication Engineers. STLE does not vouch for the technical accuracy of opinions expressed in Sounding Board, nor does inclusion of a comment represent an endorsement of the technology by STLE.