By Jeff Walkup, VP Sales & Marketing- Fluid Life
Balanced energy wins. The U.S. grid is being stretched by record demand, from heatwaves to the expansion of AI and data centers, while our energy mix continues to diversify. Gas remains the primary source, coal declines, nuclear stays stable, and renewables reach new highs. In 2024, gas supplied about 43% of U.S. electricity, coal around 15%, nuclear roughly 19%, and renewables about 21%, with renewables expected to continue rising into 2026. The message isn’t “either/or.” It’s about “and/and”, reliability and decarbonization, affordability, value and resiliency.
Condition Monitoring as the Common Denominator
In mining, construction, oil & gas, power generation, and data-center infrastructure, the key to success is a disciplined Condition Monitoring program, with used-oil analysis as its core. Early detection of wear, contamination, and chemistry changes allows you to plan rather than react.
What Good Looks Like
What’s a good strategy? We recommend combining:
- Used oil, fuel, and coolant analysis (Fluid Life provides quick turnaround, exception reporting, fleet summaries) with
- Vibration, infrared thermography, and ultrasound monitoring, as applicable.
These Non-Destructive Technologies (NDTs) provide meaningful signals, offering a risk-based machinery management (API 691 mindset) for critical assets. Actionable recommendations from lab findings and other data sources link to maintenance plans and warranty compliance.
Proof Points (Industry-Documented)
- Fleet/Mining (haul trucks & shovels): Predictive programs that include regular oil sampling detect developing faults and reduce unplanned maintenance costs, often by up to 30% compared to run-to-failure.
- Wind gearboxes: Oil and vibration-based condition monitoring minimizes downtime and improves reliability, crucial for high-torque gear stages and bearing lifespan.
- Power and process (critical rotating equipment): Risk-based machinery management (API 691) provides a structured framework to prioritize monitoring and prevent high-consequence failures.
- Bottom-line impact: Condition-based and reliability-centered maintenance programs typically save 5–20% on maintenance costs while increasing service reliability.
The Importance of this to us all
With U.S. power demand expected to hit new highs in 2025–26, significantly driven by data centers, every outage avoided and each additional percent of asset availability matters. An “all-sources” grid still depends on your assets starting, operating, and staying within specifications.
How Fluid Life Plugs In
- Mining & Construction: Monitoring engine and drive-train health on haul trucks, loaders, and dozers; maintaining hydraulic cleanliness across fleets; controlling contamination to extend component life and reduce warranty claims.
- Oil & Gas / Midstream: Tracking turbine, compressor, and gearbox performance according to API 691 risk categories; assessing varnish potential, particle counts, and MPC trend analysis to protect starts and prevent failures that cause trips.
- Power Generation & Wind: Combining oil analysis (PQ/TMI, elemental, FTIR, TAN/TBN, water) with vibration and grease practices for gearboxes and main bearings.
- Data Center & Industrial Facilities: Managing oil and coolant regimes for standby generators, chillers, pumps, and UPS cooling loops to maximize availability, with exception reports on dashboards for facilities teams.
If you’re developing a balanced energy strategy, pair it with a balanced CM program. Begin with oil analysis and progress to the right mix of NDT. That’s the foundation of reliable, affordable, lower-emissions operations.
Let’s have a conversation together. If you want a quick benchmark of your program, including turnaround times, sample plans, alarm limits, and what “good” looks like for your asset mix.
Sources & Case Study References
- U.S. generation mix & trends: EIA FAQs (2023 mix), Ember “US Electricity 2025 Special Report” (2024 mix), EIA STEO (2025–26 demand outlook).
- Mining predictive maintenance & haul trucks: IOSR Journal case insights; Pumps & Systems overview of predictive maintenance for mining vehicles.
- Wind gearbox CM: NREL gearbox CM round-robin; peer-reviewed reviews on intelligent CM and oil-analysis failure modes.
- API 691 risk-based machinery management: E^2G application notes; Emerson/API 691 white paper; industry training overview.
- RCM/CBM value: EPRI technical reference (5–20% maintenance cost savings with improved reliability).
Disclaimer: The information provided in this technical bulletin is intended for general guidance only. While Fluid Life strives to present accurate and up-to-date information, no warranty is given as to the completeness or accuracy of the content. Application of any recommendations or actions based on this bulletin is solely at the discretion and risk of the end-user. Fluid Life assumes no responsibility or liability for any loss or damage resulting from reliance on this document.