Avoid unplanned outages and costly downtime

You have a continuous process and if any key piece of equipment goes down, your production may be significantly interrupted. When unplanned outages occur, it may be days or weeks to obtain and install spare parts. Routine fluid analysis gives you a window inside your equipment to identify and resolve problems at a very early stage, which puts you back in full control of your production schedules.

OIL TEST PACKAGES

Oil analysis is a proven technique for monitoring and maintaining critical plant assets such as hydraulics, gearboxes, compressors, turbines, pumps, etc.. In order to maximize the benefits of oil analysis, it is important to select a test package that gives you the information and quality you’re looking for while staying within your budget.

Fluid Life offers a series of five standard test packages, along with a myriad of individual test options.

WE CAN HELP YOU:

  • Detect failures at an early stage
  • Mitigate equipment safety concerns
  • Manage your contamination control efforts
  • Confirm oil selection and condition
  • Plan and schedule upcoming mechanical repairs
  • Identify necessary shutdown work
  • Prolong the useful life of your components
  • Optimize your oil drain intervals
  • Better manage spare parts inventory
  • Integrate with other condition-monitoring techniques

The PLANT 1 package satisfies the basic requirements for monitoring fixed-plant equipment. This package identifies any abnormal component wear, indicating the presence of potential failures in-progress. It also allows you to ensure the proper lubricant is being used by determining if the viscosity is within the appropriate range, whether the oil is a mineral or synthetic (or a mix) and if the additive package is correct. Lastly it is used to confirm that your lubricant is not overheating or being exposed to moisture (cool and dry).

PLANT 1 TESTS:

  • Spectrometry (23 Elements)
  • Viscosity 40C/100C
  • Viscosity Index
  • Water by Crackle
  • % Soot by FTIR (Diesel Engines)
  • % Glycol, Triggered GC (Engines)
  • % Fuel, Triggered GC (Engines)
  • Acid Number By FTIR

Lubricant contamination is typically the #1 failure mode of lubricated components, and may be responsible for 70 – 85% of all lubricant related failures. For this reason The PLANT 2 package is the most commonly used test slate for fixed-plant equipment. In addition to the PLANT 1 tests listed above, this package also measures total system contamination using ISO particle counts. Fluid Life performs the best type of particle count for each component ensuring the most accurate results and usable information.

PLANT 2 TESTS:

  • Spectrometry (23 Elements)
  • Viscosity 40C/100C
  • Viscosity Index
  • % Water by Karl Fisher (PR Crackle Trigger)
  • % Soot by FTIR (Diesel Engines)
  • % Glycol, Triggered GC (Engines)
  • % Fuel, Triggered GC (Engines)
  • Acid Number By FTIR
  • ISO Particle Count (Non Gears)
  • OPC ISO Particle Count (Gears)

While the PLANT 2 package is sufficient for most fixed-plant applications, the PLANT 3 package is for customers with large critical assets who cannot afford to have unplanned downtime.  Fluid Life`s PLANT 3 package provides a more advanced assessment of oil degradation, contamination and wear. Typical applications are power generation and turbo-machinery such as pipeline or refinery equipment.

PLANT 3 TESTS:

  • Spectrometry (23 Elements)
  • Viscosity 40C/100C
  • Viscosity Index
  • % Water by Karl Fisher
  • % Soot by FTIR (Diesel Engines)
  • % Glycol, Triggered GC (Engines)
  • % Fuel, Triggered GC (Engines)
  • Total Acid Number
  • ISO Particle Count (Non Gears)
  • OPC ISO Particle Count (Gears)

Varnish issues have become more common in recent years due to higher operating temperatures and machine load factors.  PLANT4 is the suggested test package for assets that are prone to varnish-related issues or failures.  Typical applications are turbines, large hydraulics & hydraulic injection molding machines and large circulating lube oil systems.

PLANT 4 TESTS:

  • Spectrometry (23 Elements)
  • Viscosity 40C/100C
  • Viscosity Index
  • % Water by Karl Fisher
  • % Soot by FTIR (Diesel Engines)
  • % Glycol, Triggered GC (Engines)
  • % Fuel, Triggered GC (Engines)
  • Total Acid Number
  • ISO Particle Count (Non Gears)
  • OPC ISO Particle Count (Gears)
  • Varnish Potential

PLANT 5 is the recommended test package for validating turbine oils during delivery and commissioning activities.  It is also used as an annual validation of the oil condition to determine whether or not it needs to be changed.  Turbine downtime and oil changes are expensive; ensure you are not performing maintenance unnecessarily.

PLANT 5 TESTS:

  • Spectrometry (23 Elements)
  • Viscosity 40C/100C
  • Viscosity Index
  • % Water by Karl Fisher
  • Total Acid Number
  • ISO Particle Count
  • Varnish Potential (MPC)
  • RPVOT Oxidation Stability
  • RULER
  • Rust Test
  • Demulsibility
  • Foam Test (Sequence 1)
  • Air Release (Outsourced)

ADDITIONAL TESTS AND PACKAGES

TEST PACKAGES

Basic Grease Package:

  • Penetration Test 1/4 cup Unworked
  • Dropping Point
  • Color
  • Total Magnetic Iron

Advanced Grease Package:

  • Penetration Test 1/4 cup Unworked
  • Dropping Point
  • Color
  • Total Magnetic Iron
  • Analytical Ferrography

AVAILABLE INDIVIDUAL TESTS

  • Penetration Test (unworked)
  • Penetration Test (worked)
  • Penetration Test 1/4 cup (unworked)
  • Penetration Test 1/4 cup (worked)
  • Dropping Point
  • Color
  • Base Oil Viscosity
  • Total Magnetic Iron Equivalent to PQ Index
  • Analytical Ferrography
  • X-Ray Flourescence Grease Analysis

Oil analysis alone is not enough to predict impending machinery failures. The only way to capture larger particles is to extract them from the filter since it is a ‘chronological data bank ‘ for machinery components. The filter traps the larger wear metals and contaminants (metallic and non-metallic) over a period of time, thereby retaining both present and past failure mode indicators.

AVAILABLE INDIVIDUAL TESTS:

  • Filter Debris Analysis
  • X-Ray Flourescence (XRF) Filter Analysis (Industrial / Spin-on)
  • X-Ray Flourescence (XRF) Filter Analysis (Spinner)

Heat Transfer Fluid (HTF) Test Package:

  • Spectrometry (23 Elements)
  • Viscosity 40C/100C
  • Viscosity Index
  • Flash Point (Open Cup)
  • Flash Point (Cleveland Closed Cup)
  • Pentane Insolubles (Outsourced)
  • Total Acid Number (ASTM D664)

WATER SOLUBLE TEST PACKAGES

Basic:

  • Viscosity 40C
  • ISO Particle Count
  • % Water (Refractive Index)
  • pH

Advanced:

  • Viscosity 40C
  • ISO Particle Count
  • % Water (Refractive Index)
  • pH
  • Reserve Alkalinity
  • ICP Spectrometry (Outsourced)

Fluid Life takes a consultative approach to help you define and document the scope of your fluid analysis program.

Talk to a Fluid Life representative today to get the answers you’re looking for.