Oil and Grease analysis can help identify problems in the machinery such as abnormal wear, lube oil degradation, contamination of harmful agents, etc. all of which can lead to the potential failure of the machinery and its components.
Although oil and grease are used for the same reasons – to prevent metal-on-metal contact and protect equipment from wear and tear – they have different characteristics each providing different benefits.
Oil & Grease testing determines the amount of non-volatile hydrocarbons (i.e. petroleum derivatives), vegetable oils, animal fats, waxes, soaps, greases and related material in a sample.
A Case Study of the Importance of Oil and Grease Testing in Wastewater :
Industrial and food processing plants that have high levels of fats, oil and grease (FOG) in their effluent are faced with stricter wastewater regulations to avoid accumulations of FOG that cause sanitary sewer overflows (SSO). Oil and Grease Analysers provide accurate, easy on-site analysis to help both regulators and industry reduce excessive oil/grease discharges and comply with permit requirements. These analysers provide on-site results in 10-15 minutes, eliminating the wait for remote lab results which can take several days to a week. The extraction and measurement procedure is simple enough for an operator with minimal training to do the analysis.
By using hexane, pentane or Vertrel MCA for the extraction process. Measurement data will correlate to EPA Method 1664 as both procedures are based on evaporation techniques and measure the residual oil and grease. They are equipped with an exposed, easy to clean cubic zirconia horizontal attenuated total reflection (HATR) stainless-steel sample stage on which the extract is deposited for analysis.
The Oil and Grease Analysers are based on US EPA Methods 413.2 and 418.1 and ASTM D7066, which uses Freon 113, perchloroethylene, or S-316, as the extracting solvent. Since the oil concentration is measured directly in the solvent, light end volatile components are retained and measured. Oil and Grease Analysers have a minimum detectable limit of 2 ppm oil in water.
In addition to lower detection limits and a touch screen display, the Oil and Grease Analysers have added features which include multiple calibrations to cover a larger range of analyses, unlimited data storage that tags measurements with analyst, date and time, and security features with different user access levels.
There are three main types of lubricant testing:
- Lubricant Condition- This test checks the physical and chemical state of the lubricant to see how much life it has left before it needs to be replaced.
- Contamination Testing- This test looks for harmful pollutants in the lubricant and figures out where they might be coming from, either inside or outside the machine. It helps identify the cause of potential mechanical problems.
- Wear Debris Analysis- This test focuses on finding and identifying particles created by mechanical wear, rust, or damage to machine surfaces. The following are the types of wear:-
- Adhesive/Rubbing Wear – This happens when the lubricant doesn’t fully separate moving surfaces, causing them to rub together. This can lead to damage like scuffing or metal transfer if conditions like load or heat are extreme. Anti-wear additives in lubricants help reduce this type of wear.
- Abrasive Wear- Caused by hard particles, like dirt or contaminants, scraping against softer surfaces in the system, leading to damage.
- Fatigue Wear- Occurs due to repeated stress or load, leading to cracks or pits in surfaces. Common in bearings and gears where surfaces roll over each other.
- Corrosive (Chemical) Wear –This happens when chemical reactions cause rust or corrosion on parts, which then get dislodged due to movement or pressure.
- Cavitation Wear –Occurs when tiny air bubbles in a liquid collapse and hit part surfaces, removing small bits of metal.
Each type of wear can damage machinery, so regular maintenance and proper lubrication are key to prevention.
Types of Oil and Grease Testing Equipment
Oil and grease testing equipment comes in various forms, each designed to assess specific aspects of lubricant quality:
- Viscosity Testers: These measure the resistance of a lubricant to flow, which is an indicator of its ability to reduce friction and wear.
- Spectrometers: Used to analyze the chemical composition of lubricants, spectrometers detect the presence of metal wear particles, additives, and contaminants.
- Water Content Analyzers: These devices help measure the moisture content in lubricants, as excess water can significantly impact lubricant performance.
- Acid and Base Number Testers: These measure the acidity of the oil or grease, which can indicate oxidation or contamination.
- Particle Counters: These devices help detect particulate contamination in lubricants, providing early warnings of potential wear or failure.
Benefits of oil and grease testing equipment-
How does a blood test disclose the fitness level in your body similarly the oil and grease analysis uncovers the condition of the machine whether it is the engine, compressor, etc. From identifying fuel and coolant leaks to assessing additive levels, Continuous testing allows you to detect the faults and lead you toward the solution before any failure happens.
Ensures Reliability of equipment
In the current era of advancing machinery, where robotics is becoming increasingly common, their use has been normalized across various industries. Whether it’s guiding passengers at airports or serving customers in restaurants as a waiter. This is exactly why lubricant testing has become so essential, ensuring that modern systems meet their performance needs. Testing reveals how contaminants, such as microplastics, can significantly impact the efficiency and functionality of machines.
Detect harmful contaminants
Undetected contaminants are harmful to machinery and can lead to significant issues over time. Metals like aluminum or iron might cause damage to pistons or cylinders. Water or antifreeze leaks can create serious problems by thickening the oil, forcing the machinery to work harder to keep functioning. Additionally, water contamination may point to broken seals or suggest the equipment operates outside its optimal temperature range. Equipment will be protected if such issues are identified on time.
Extend machinery lifespan
Due to inflation and supply chain challenges testing regularly of oil and grease ensures that the lubricants used are of high quality. Good lubricants play a crucial role in extending the lifespan of equipment so that expensive machinery doesn’t wear out prematurely
extending the lifespan of equipment. Simply investing in costly machinery isn’t enough; maintaining it to ensure smooth, uninterrupted performance throughout its life is just as important.
Avoid unplanned downtime
Oil and grease testing in advance not only identifies problems before they occur but also helps save the industry from unplanned expenses. Breakdowns and repairs are expensive, especially when it comes to production downtime. Recent studies show that downtime can cost manufacturers an average of up to $5,000 per minute, whereas downtime costs vary depending on the industry and scale of operations. so testing is always a savior from early signs of lubricant degradation or contamination.
Efficiency with sustainable practice
To reduce the environmental impact of petroleum-based lubricants, many producers are now offering bio-based alternatives. These lubricants are made from renewable or biodegradable materials, with vegetable oils being a key ingredient. Such that Efficiency in 2024 is not just cost-cutting but also maintaining sustainability.
Enhances workplace safety and environment
Poor quality lubricants can create machinery malfunction, posing risk to employees and the work environment. Oil and grease testing equipment helps ensure that lubricants are free from harmful contaminants and are properly maintained, reducing the risk of leaks. Industries should put continuous effort into the proper disposal and recycling of used lubricants, this will benefit them to stay compliant with environmental laws. Recently AI has taken over analyzing and providing deeper insight into lubricant performance and improving workplace safety.
Promotes Seamless production
Quality control is an essential practice that needs to be carried out by industries keeping the law in mind. Industries must meet the standard set. Testing oil and grease maintains seamless production and product quality across the globe. Several new standards for lubrication were introduced recently, particularly in the automotive and aerospace industries. Investing with reliable oil and grease testing equipment suppliers ensures that industries stay compliant, avoid penalties, and maintain trust with their clients.
Investing in such equipment is more important than ever for industries aiming to thrive in today’s competitive, high-tech, and environmentally conscious landscape. Industries require specialized lubricants. For example, the renewable energy sector needs biodegradable greases for wind turbines, while pharmaceuticals demand non-toxic lubricants for sensitive machinery. However, teaming up with a reliable oil and grease testing equipment supplier offers customized equipment that helps to meet diverse needs
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