Oil Monitoring

What is Oil Monitoring?

Oil Monitoring, also known as used oil analysis, is an advanced diagnostic technique that involves regularly taking oil samples from working machines and devices and subjecting them to detailed laboratory tests. It is a key element of predictive maintenance (PdM) strategy, allowing the assessment of the condition of both the lubricant itself and the lubricated components.

Definition of Oil Monitoring

Oil monitoring is the process of systematically tracking changes in the physicochemical properties of oil, as well as the level of contaminants and wear products during its usage. It operates on the principle of “blood testing” for machines – just like a blood test provides information about a person’s health, oil analysis reveals much about the machine’s condition and the oil itself.

Goals and Benefits of Regular Oil Analysis

Regular oil analysis offers numerous benefits, especially in industrial environments and vehicle fleets:

• Early problem detection: It enables the identification of potential failures (e.g., excessive bearing wear, coolant leaks, filtration problems) before they lead to serious damages and unplanned downtimes.
• Optimizing oil change intervals: Instead of changing the oil according to a strict schedule (e.g., after a certain number of operational hours), it can be done based on its actual condition. This allows for safe extension of change intervals (if the oil is in good condition) or shortening them (if the oil has prematurely degraded), translating into savings.
• Preventing costly failures: Early intervention based on analysis results can prevent severe damages, the repair of which would be much more expensive.
• Assessing machine condition: Wear element analysis (e.g., iron, copper, chromium) helps identify which machine components are wearing out faster.
• Reducing operating costs: Fewer breakdowns, optimized oil changes, and extended machine lifespans lead to lower total cost of ownership (TCO).
• Increasing machine reliability and availability.
• Improving work safety.
• Environmental protection: Optimizing oil usage and reducing waste.

What Oil Parameters Are Tested?

The scope of tests depends on the type of oil, the machine, and the monitoring goals. Typical parameters tested include:

• Kinematic viscosity: A key parameter determining the oil’s ability to form a lubricating film. Changes in viscosity may indicate oxidation, contamination with fuel, or other oil.
• Acid Number (TAN) / Base Number (TBN): TAN indicates the level of oil oxidation and acidic product presence. TBN determines the oil’s (mainly engine oil) ability to neutralize acidic combustion products.
• Water content: Water in oil is very harmful – it causes corrosion, accelerates oil oxidation, and impairs lubricating properties.
• Solid contaminants (Oil cleanliness class): Determines the amount and size of solid particles (e.g., dust, sand, wear products).
• Elemental analysis (spectrometry):
  • Wear elements: E.g., iron (Fe), copper (Cu), chromium (Cr), aluminum (Al), lead (Pb) – indicate wear of specific machine parts.
  • Additive elements: E.g., zinc (Zn), phosphorus (P), calcium (Ca), magnesium (Mg) – their levels may indicate degradation of the additive package or mixing with another oil.
  • Contaminant elements: E.g., silicon (Si – dust, sand), sodium (Na – coolant), potassium (K – coolant).
• Fuel presence (in engine oils): Dilution of oil with fuel lowers its viscosity and lubricating properties.
• Soot presence (in Diesel engine oils): Excessive soot can lead to oil thickening and increased wear.
• Specialist tests: E.g., foaming, air release, oxidation resistance (RPVOT), ferrographic analysis.

Oil Analysis Procedure

1. Sample collection: A crucial step. The sample must be representative of the oil operating in the system. It should be taken from the same location, under the same machine operating conditions, using clean tools and containers.
2. Sending the sample to a laboratory: The sample, along with a detailed description (machine, type of oil, operating time of oil and machine, any observations) is sent to a specialized laboratory.
3. Laboratory analysis: Conducting ordered tests.
4. Interpretation of results and recommendations: Results are compared with threshold values (for the specific type of oil and machine) and previous analysis results (trend analysis). Based on this, conclusions and recommendations are formulated (e.g., continue operation, change oil, check a specific machine part).

When and How Often to Conduct Oil Analysis?

The frequency of sampling depends on:

• The machine’s criticality to the production process.
• Operating conditions (load, temperature, dustiness).
• The type of oil and its volume in the system.
• The history of breakdowns of the given machine.
• The manufacturer’s recommendations for the machine or oil supplier.

For key machines, samples can be taken monthly or even more frequently. For less critical ones – quarterly, semi-annually, or once a year.

Oil Monitoring with Mobipol

Mobipol, as an authorized distributor of ExxonMobil lubricants, offers professional oil monitoring services such as Mobil Serv2 Lubricant Analysis. Thanks to advanced analyses and expert interpretation of results, we help our clients optimize lubrication management, increase machine reliability, and reduce maintenance costs. Contact us to learn more.