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The Hybrid approach – Sensors & Labs

By Sanya Mathura (Strategic Reliability Solutions Ltd) & Neil Conway (Spectrolytic)

The above offers some advantages of using these inline sensors but what really sets the FluidInspectIR apart?

Historical inline sensors have employed dielectric or impedance-based sensing. Impedance based sensing is slightly more advanced than dielectric sensing but still only measures a few electrical parameters such as oil resistance, capacitance and inductance which assist in detecting the polar molecules in the oil.

However, complex algorithms are usually used to convert the electrical data into a meaningful value such as TBN or develop a trend based on a dimensionless value. Laboratories use MIR Spectroscopy which is the same technology utilized by FluidInspectIR. As such, the data / results are given in the same units and accuracy as labs.

The FluidInspectIR technology analyses the spectra in the wavelength ranges which have a chemical meaning for the application in which the sensor is being used, such as turbine oils, EALs, gear oils, engine oils etc. This specificity in the MIR spectrum, coupled with several mechanical and electrical design features allow lab accuracy in the field.

Figure 4: Market validation and asset examples

The Hybrid approach

While the FluidInspectIR Inline sensors can provide actionable data required for preventive maintenance strategies, there are some parameters where a lab analysis would certainly be advisable. These are more specialized tests such as Air separation / Demulsibility or FZG loading tests which require some fairly complexed processes in which the oil has to stand for some time during the procedure or different loads have to be added until a particular characteristic is met.

With that being said, inline OCM technology has made significant advancements and the FluidInspectIR is currently considered state of the art providing lab equivalent data in real time. In addition, it is also capable of measuring nonstandard properties, such as oxidation by-products which can relate to varnish by-products or the potential to form varnish as well as monitor the quantity of antioxidants. The monitoring of these parameters could not have been done a decade ago as the technology simply wasn’t available.

The future of oil analysis will certainly be a hybrid approach where inline sensors continuously monitor the fundamental parameters and when limits are reached (either below or above), or the trending analysis shows a peculiar behavior, then specialized additional testing can be pursued using the lab infrastructure and expertise.

In this way, resources are conserved when the oil appears to be within its limits and functioning as it should. However, when these limits are reached and the component could be in danger, specialized resources will be deployed to ensure that the component does not suffer a fatality. The way forward for oil analysis is definitely a hybrid approach mixing the traditional with some of the cutting-edge technologies.

Bio:

Neil Conway – Applications Manager, Spectrolytic

Neil is the Applications manager for Spectrolytic where he develops and manages new and current measurement applications for all the product lines. Neil is also extensively involved in sensor characterisation, product development, customer training, and technical marketing.

Previously Neil has held Process Engineering positions in semiconductors with Motorola and Atmel and operated as Wafer Fabrication Manager with IR Sensor company Pyreos where he developed and commercialised the first thin film PZT IR sensor manufacturing line.

Neil is a chartered Engineer (CEng) and Scientist (CSci) and corporate member of the Institution of Chemical Engineers (MIChemE) and holds a BEng (Hons) in Chemical & Process Engineering from Strathclyde University.

Bio:

Sanya Mathura, REng, MLE

Founder, Strategic Reliability Solutions Ltd

Sanya Mathura is a highly accomplished professional in the field of engineering and reliability, with a proven track record of success in providing solutions to complex problems in various industries. She is currently the Managing Director of Strategic Reliability Solutions Ltd, a leading consulting firm that specializes in helping clients improve their asset reliability and maintenance practices.

Sanya holds a Bachelor's degree in Electrical & Computer Engineering as well as a Masters in Engineering Asset Management from The University of the West Indies and has over 15 years of experience in the industry. She has worked with several well-known companies and has been recognized for her exceptional work in the field of reliability and lubrication engineering. Her expertise in developing and implementing asset management strategies, risk assessments, and root cause analysis has earned her a reputation as a subject matter expert.

As the head of Strategic Reliability Solutions Ltd, Sanya leads a team of highly skilled professionals who provide a wide range of services to clients across various industries, including oil and gas, manufacturing, and transportation. Under her leadership, the company has expanded its services and is now recognized as a leading provider of reliability engineering services in the industry across the globe.

In addition to her work at Strategic Reliability Solutions Ltd, Sanya is an active member of several professional organizations, including the International Council for Machinery Lubrication and writes technical papers for several organizations. She is also a sought-after speaker and has presented at various conferences and seminars on the topics of reliability engineering and lubrication. She is also an avid advocate for women in STEM.

Find out more in the full article, "Revolutionizing oil analysis: Traditional vs Cutting edge Technology" featured in Engineering Maintenance Solutions Magazine by Sanya Mathura, CEO & Founder of Strategic Reliability Solutions Ltd & Neil Conway (Spectrolytic).

Used Oil Analysis

Emerging technology – FluidInspectIR®

By Sanya Mathura (Strategic Reliability Solutions Ltd) & Neil Conway (Spectrolytic)

Spectrolytic’s FluidInspectIR-Inline is a comprehensive fluid monitoring system that uses an array of sensors (MIR, OPC, wear, viscometer, conductivity) to provide real time data on oil and fluid degradation parameters. At the heart of the system is a novel mid-infrared (MIR) sensor that measures the chemical composition of the fluid with parameters such as; TAN, TBN, ipH, oxidation, sulphation, nitration, water, glycol, soot, fuel dilution and additives. These can be measured, as a first in the field, with the same accuracy and in the same units as conventional labs.

There are a couple of areas where the FluidInspectIR can offer advantages as compared to traditional oil analysis. Here are a few of them:

Real Time Monitoring and Faster Results – with these online monitoring devices, users can readily get data throughout the day without waiting for the sample to be taken, shipped to a laboratory and then tested there. This significantly reduces the time between making decisions which could negatively impact the equipment’s performance. Within our industry, this time is absolutely critical as the cost of unplanned downtime for the affected assets can be millions of dollars.

Cost-Effectiveness – every time a sample is taken, there is a cost involved. The sample taking process is usually quite lengthy as often permissions have to be obtained since more organisations are trying to reduce potential health & safety risks by minimizing human-machine interactions.
Once a sample has been obtained it needs to be shipped to a laboratory. This not only has costs attached to it, but many couriers are now making it very difficult to ship oil samples. In addition, each shipment of a sample carries also an implied CO₂ footprint.

Figure 1: Comparison of different routes of oil sampling

As shown in figure 1 the resulting cost savings from utilizing real time inline sensors compared to other methods can be summarized as follows:

Human assets can be utilized more effectively without allocating time for them to take oil samples
Trend analysis based on real time; laboratory equivalent data allows the end customer to move from a time-based maintenance process to a data driven maintenance process
Early failures can be spotted very easily and unplanned down time, the nightmare of every asset manager, can be minimized
Oil drain intervals can be extended in a safe and controlled manner which can result in significant operational efficiency gains and reduced CO₂ footprint

Accuracy and Reliability – getting an accurate representative sample using conventional oil sampling methods can be challenging at times. If the sample is taken at the wrong point (right after the filter or at a dead leg), it might not be representative of what is happening on the inside of the equipment. As such, it can completely derail the trend being established for that component and allow the users to believe that something is terribly wrong with that component.

With the FluidinspectIR online monitoring system, the sample delivery to the sensor is automated and standardized ensuring that the sample is delivered to the sensor in the correct way every time. Therefore, the users can rest assured of getting the sample taken at the right location (ensuring a proper representation of the system), at the same location (ensuring an accurate trend of the data) and with the same technique (which completely avoids any variation from human operators).

As the FluidInspectIR uses mid-infrared spectroscopy which is identical to the technique used by laboratories (FTIR), the data provided by the FluidInspectIR system has, at least, the same accuracy as those produced by a laboratory as shown in figure 2 below.

Figure 2: Comparison of the FluidInspectIR technology to periodic oil checks using a laboratory (red circles)

Actionable data and improved maintenance – with real time data, failures can be prevented and major unplanned downtime eliminated. With the online monitoring system, it is easier to trend an increase in wear metals, change in viscosity, water ingress or any other parameter changes which would warrant some form of maintenance intervention. This provides users with the information they need at the right time without any further delays due to shipping of samples or an inaccurate sample being sent off as shown in the case study in figure 3 where a diesel engine on a dredging vessel saw spiked concentrations of water that coincided with the vessel being moored in harbour. With the quick action of the inline sensors, they were able to save £115k over 9 months.

Figure 3: Case Study for Diesel engine customer

Data Integration and Remote Monitoring – traditionally, oil analysis results lived in databases which could be accessed electronically, or they were emailed and stored in a filing system. But these results are only available after a sample has been taken and sent off to the lab. This is how FluidInspectIR takes it a step further where assets can also be monitored remotely, in real time.

Imagine being able to monitor the conditions of a particular component while being offsite or multiple components for various sites. This can be particularly useful when trying to troubleshoot an issue related to a system process, especially across sites. This is one area that traditional oil analysis would not be able to mimic as the sample may not be taken at the exact same time as the ongoing system process therefore not allowing a correlation.

Of particular importance is the ability to trend data across multiple assets. This can be critical if there is a significant environmental factor influencing the condition of the oil which may affect many of the components in the fleet. Being able to easily and quickly detect this can be the difference between a productive day and one that has gone into unplanned downtime.

Find out more in the full article, "Revolutionizing oil analysis: Traditional vs Cutting edge Technology" featured in Engineering Maintenance Solutions Magazine by Sanya Mathura, CEO & Founder of Strategic Reliability Solutions Ltd & Neil Conway (Spectrolytic).

Used Oil Analysis

Revolutionizing oil analysis: Traditional vs Cutting edge technology

By Sanya Mathura (Strategic Reliability Solutions Ltd) & Neil Conway (Spectrolytic)

In our last article we focused on the question of whether oil analysis was still relevant today? While this is an age-old process, the benefits of oil analysis still continue to live on today although the methods involved have significantly evolved since its inception. In this article, we will do a deeper dive into the traditional methods of oil analysis versus some of the new cutting-edge technologies which exist today and whether we may see a replacement of one method over the other or a union moving forward.

If you’ve ever performed an oil analysis you know that this process follows certain standards which are listed in the report. These standards govern the world of oil analysis and form the basis of how these tests are executed. There are committees dedicated to revising these standards to ensure that they are still relevant to the applications of today, one such committee falls under the ASTM body (American Society for testing and Materials).

Revolutionizing oil analysis Traditional vs Cutting edge technology

Equipment has changed over time where oil sumps have become smaller but now produce more power. Oils are under more stress as they are expected to perform at higher temperatures under elevated environmental conditions and still protect the equipment. Global oil manufacturers work together with OEMs (Original Equipment Manufacturers) to ensure that the oils developed can work with their components in these increasingly harsher conditions. But what constitutes an oil “working properly”?

This is where oil analysis / sample testing plays a crucial role. Oil analysis tests have been standardized through authorized committees to ensure that the same test can be performed in different parts of the globe using the same procedures. This ensures that there can be a fair comparison of the results of these tests across the globe. These tests should also be repeatable (or get the same results every time they are performed).

Typically, these tests are usually carried out in a laboratory environment, using state of the art equipment to achieve / maintain the required standards. However, sample taking, sample shipping and other human factors often result in misleading and / or extremely delayed reporting of the results. This is where emergent technology can alleviate some of these challenges.

Find out more in the full article, "Revolutionizing oil analysis: Traditional vs Cutting edge Technology" featured in Engineering Maintenance Solutions Magazine by Sanya Mathura, CEO & Founder of Strategic Reliability Solutions Ltd & Neil Conway (Spectrolytic)

Oil Properties

The Future of Gear Oils

According to (Industry ARC (Analytics. Research. Consulting), 2024), the global industrial gear oil market size is forecasted to reach USD 5.2 B by 2027. While the Asia-Pacific market holds a significant market share for industrial gear oils in 2021 at around 56.2%, it is interesting that its nearest rival is Europe, at 17.7% or less than ⅓ of its size.

The rise in the Asia Pacific market can be accounted for due to the increase in the rising population and, by extension, the needs of that population and the service sectors they support, including the energy, oil & gas, construction, and steel industries. The figure below depicts the global industrial gear oil market revenue share by Geography for 2021.

Figure 6: Industrial Gear Oils (Mineral & Synthetic) Market Revenue Share by Geography 2021 adapted from (Industry ARC (Analytics. Research. Consulting), 2024)

From the research conducted by (Industry ARC (Analytics. Research. Consulting), 2024), helical gears appear to be the most popular choice for industrial gears. Interestingly enough, synthetic gear oil held the largest market share and is forecasted to grow by a CAGR of 5.6% for the forecasted period of 2022-2027.

Smaller gearboxes are being manufactured, tasked with outperforming their previous counterparts and producing more torque in a smaller space. With the advent of better, more precise machining tools for gears, there is an increase in the amount of pressure these gears now must handle in smaller spaces.

As such, we will continue to see the rise in the use of synthetic gear lubricants formulated to handle these extreme conditions, as well as more advanced additive packages that can help minimize foaming, reduce oxidation, and aid in the demulsibility of these oils.

References

Industry ARC (Analytics. Research. Consulting). (2024, September 04). Industrial Gear Oils (Mineral & Synthetic) Market - Forecast(2024 - 2030). Retrieved from Industry ARC: https://www.industryarc.com/Report/20008/industrial-gear-oils-mineral-and-synthetic-market.html

Mang, T., & Dresel, W. (2007). Lubricants and Lubrication - Second Edition. Weinheim: WILEY-VCH GmbH & Co. KGaA.

Mang, T., Bobzin, K., & Bartels, T. (2011). Industrial Tribology - Tribosystems, Friction, Wear and Surface Engineering, Lubrication. Weinheim: WILEY-VCH Verlag GmbH & Co. KGaA.

Pirro, D. M., Webster, M., & Daschner, E. (2016). Lubrication Fundamentals - Third Edition, Revised and Expanded. Boca Raton: CRC Press, Taylor & Francis Group.

Rensselar, J. v. (February 2013). Gear oils. Tribology and Lubrication Technology - STLE, 33.

Sander, J. (2020). Putting the simple back into viscosity. Retrieved from Lubrication Engineers: https://lelubricants.com/wp-content/uploads/pdf/news/White%20Papers/simple_viscosity.pdf

Santora, M. (2018, March 20). Tips on properly specifying gear oil. Retrieved from Design World: https://www.designworldonline.com/tips-on-properly-specifying-gear-oil/#:~:text=CLP%20Gear%20Oils&text=Often%2C%20a%20gear%20manufacturer%20will,a%20CLP%20polyglycol%20PAG%20oil

Find out more in the full article, "Gear Oil: Types, Applications, and Benefits" featured in Precision Lubrication Magazine by Sanya Mathura, CEO & Founder of Strategic Reliability Solutions Ltd.

Oil Properties

Gear Oil Storage and Handling

Similar to most oils, gear oils should be stored in a clean and dry space. Often (especially in the past), these gear oils see a settling of the additives to the bottom of the container, indicating a slightly shorter oil life span than other lubricants. However, this is no longer a highly occurring incident with the advancements in additive technology and improved blending practices.

As usual, it is always best to adhere to the OEM’s expiry dates for these products, as different OEMs recommend varying storage times for their products. Generally, synthetic lubricants have an estimated shelf life of 5-10 years, while mineral oils usually last for around 2-3 years, but this is heavily dependent on the OEM and storage conditions.

In some cases, customers tend to store these drums outside in the elements as it makes it easier for them to be readily accessible for decanting into the equipment. However, in these environments, the drums can collect water, which will enter the oil and then, by extension, enter the gearbox. This can cause issues for the equipment and lead to accelerated oil degradation.

Ideally, these oils should be stored in a cool, dry place with ready access to decanting equipment where the decanted oil will not be easily contaminated. Many industrial gearboxes typically require larger quantities of oil, and decanting can take place directly from the drum into the equipment or via a pump.

In these cases, the level of contamination must be minimized by ensuring that the fittings, hoses, etc., are clean and have not been used to decant other types of oils.

Find out more in the full article, "Gear Oil: Types, Applications, and Benefits" featured in Precision Lubrication Magazine by Sanya Mathura, CEO & Founder of Strategic Reliability Solutions Ltd.

Oil Properties

How do Gear Oils Degrade?

The first set of additives to decrease in gear oils is often the antiwear or extreme pressure additives. This is no surprise, as these oils are subjected to high levels of wear and must withstand extreme pressures. One can also notice a decline in the rust and oxidation additives or even a change in the air release values.

All these properties significantly impact how a gear oil functions. As such, they should be monitored when establishing the health of the oil.

When monitoring the health of these lubricants, some guidelines can be utilized. If there is a change in viscosity of either ±10%, one should look for any other correlating changes.

Typically, if the viscosity increases by 10%, we’re looking at increases in wear metals or the risk of oxidation and development of some deposits in the oil or even contamination of the oil with some water. However, for a decline of 10%, one can expect some form of contamination, typically fuel or another substance which will thin out the lubricant.

The lubricant’s warning levels for wear metals will vary depending on the manufacturer/OEM. However, any consistent rise in wear metals indicates that some component on the inside of the equipment is slowly wearing away.

Find out more in the full article, "Gear Oil: Types, Applications, and Benefits" featured in Precision Lubrication Magazine by Sanya Mathura, CEO & Founder of Strategic Reliability Solutions Ltd.

Oil Properties / Used Oil Analysis

Is Oil analysis still relevant today?

With the many advancements in Artificial Intelligence, Machine Learning and the advent of countless different sensors on the market, the question arises, “Is Oil Analysis still relevant today?”. Granted that these advancements have significantly transformed the industry, we need to recognize that they are here to help evolve what we already do and not necessary replace it.

These advancements build upon the foundations of the techniques of oil analysis. With artificial intelligence and machine learning, we can train models to interpret oil analysis data and trigger alerts accordingly but there should always be a human present to overview these. In the real world, not every situation has occurred or been recorded yet hence the models do not have that particular data to learn from nor can they make decisions about it since it simply doesn’t exist in their “brain”.

Humans can “think outside the box” and formulate patterns or trends which may not be triggered by the models simply because these models have not been taught these patterns. Hence it is important to always have a human in the loop and not rely solely on these models especially when million-dollar decisions can be negatively initiated with the wrong interpretations.

Lately, sensors have gained more traction and a wider adoption as they can be integrated into warning systems to alert users to potential deviation from known characteristics of the oil. However, as noted above, sensors rely on data sets to compare the information and on some form of capacitance which must be converted into a signal before it can be interpreted.

With lab equipment performing the actual tests, there is a higher rate of accuracy plus the added advantage of having humans review the results for discrepancies before sending off the report. While sensors can be the first warning system for some users, lab equipment should be utilized for those more precise tests which require a higher level of accuracy.

In essence, oil analysis remains very relevant today. However, it has significantly evolved over the last few decades. Today, oil analysis can achieve a higher efficiency level with the integration of the advancements in technology (AI, machine learning and sensors) and other available monitoring technologies. Together, these should all be used to create a greater impact on improving the reliability of the machines.

Find out more in the full article, "Is oil analysis necessary with so many other technologies available?" featured in Engineering Maintenance Solutions Magazine by Sanya Mathura, CEO & Founder of Strategic Reliability Solutions Ltd.

Oil Properties / Used Oil Analysis

Oil analysis vs Other technologies

Just as oil analysis is similar to blood testing, we can think of our bodies as a critical machine with various components which need to be monitored. If we get a fractured bone, a blood test will not help us to assess if the bone is broken or can be repaired. In this case, we may need an x-ray. Similarly, with machines, there are various types of tests to determine different aspects to be monitored.

Typically, oil analysis can provide the operator with insight into whether there has been any internal damage to the equipment in the form of wear particles which can be quantified. As with most condition monitoring methods, being able to trend the patterns over time helps the operators to identify if wear is occurring at an increased rate or whether the oil is degrading.

On the other hand, other technologies such as vibration analysis or ultrasound analysis or even thermography are not able to detect the presence of molecules. These other types of analyses focus on alignment, or other mechanical issues as they occur and can trend them over time. However, oil analysis can accurately detect the presence or absence of contaminants or additive packages which could affect the health of the oil and by extension that of the machine.

Oil analysis should not be used as the only technology in your condition monitoring artillery. Other technologies can be used alongside oil analysis to provide the user with a more comprehensive overview of the health of the asset. For instance, if the oil analysis discovered high wear, the next step would be to identify where the wear was coming from. Perhaps in this case, one of the other technologies could identify a misalignment or other mechanical issue which could be the source of this wear. Thus, these technologies should be used to work together to achieve better reliability for their asset owners.

Find out more in the full article, "Is oil analysis necessary with so many other technologies available?" featured in Engineering Maintenance Solutions Magazine by Sanya Mathura, CEO & Founder of Strategic Reliability Solutions Ltd.

Oil Properties / Used Oil Analysis

Why oil analysis?

The P-F curve is one that is used throughout reliability to demonstrate the point at which a component is expected to have a functional failure. There are many variations of the PF curve, and different monitoring technologies can be placed in specific orders accordingly. However, it remains dominant that oil analysis is among the top three techniques used for early detection of failure.

Oil analysis can be used to detect the presence of contaminants, metals and other molecules at a microscopic level and quantify these appropriately. Most OEMs (Original Equipment Manufacturers) publish their acceptable standards for various tests (usually standardized tests by some accredited body such as ASTM) and have these available to laboratories around the world. When an oil analysis test is performed (as per the stipulated standards), the lab will compare the actual values to the expected values (from the OEM) and then provide some guidance to the user on possible steps forward.

Every lab will have a specific format for reporting the results of your oil analysis (similar to the labs for reporting on blood samples). Typically, the actual value is shown and then there may be an expected range for the various characteristics or just an indication of whether the actual value falls outside of the range (on the higher or lower end of the scale).

Bureau Veritas, 2017, gives an example of a report and all of the variables involved here:

BV_Understanding-An-Oil-Analysis-Report_FINAL_11_8_2017

While this is their reporting standard, other labs will have a different format, but the tests will all conform to the same internationally recognized standard. As such, if oil is tested in the United States (as per a particular standard) and then tested in Italy (as per the same standard) then there can be some comparisons of these results. However, one must also be aware of the types of instruments being used and their calibration as this can account for slight differences in test results. As such, oil analysis provides a global standard for which equipment performance can be compared across regions.

Find out more in the full article, "Is oil analysis necessary with so many other technologies available?" featured in Engineering Maintenance Solutions Magazine by Sanya Mathura, CEO & Founder of Strategic Reliability Solutions Ltd.

Oil Properties / Used Oil Analysis

What is oil analysis?

For those not familiar with oil analysis, it can be likened to performing blood tests for the human body. Oil in our machines is often compared to the blood in our bodies. Blood circulates throughout the body taking important blood cells with food and oxygen in it to the various organs, similarly oils follow this behaviour. However, oils transport additives which provide varying functions including reducing wear or friction or even preventing corrosion or oxidation to name a few.

When performing a blood test, we can test for a few things; the overall condition of the organs or we can test for specific things such as the presence of bad cholesterol. With oils, we do a very similar practice where we can test for the overall health of the machine or pinpoint exact components and look for distinct changes which are reflected in the characteristics of the oil.

Basically, oil analysis can help you to determine the condition of your oil (if it is degrading or if the additives have depleted such that it no longer protects the equipment) and the health of your asset as the oil can reflect if there is wear occurring in the components. As such, it can provide very useful information to help operators and maintenance personnel to plan effectively for any type of maintenance to be done on the components.

Find out more in the full article, "Is oil analysis necessary with so many other technologies available?" featured in Engineering Maintenance Solutions Magazine by Sanya Mathura, CEO & Founder of Strategic Reliability Solutions Ltd.

Tagged: used oil analysis

The Hybrid approach

References