What’s Lurking in Your Oil Filter and How we Test for it

What’s Lurking in Your Oil Filter and How we Test for it

by | Feb 25, 2025 | General

What’s Lurking in Your Oil Filter and How we Test for it

Why Filter Analysis Tells the Full Story

When it comes to keeping your machinery running smoothly, oil analysis is the go-to move. It gives you a quick health check on your lubricant, machine, and contamination levels—all from one tiny sample. But here’s the thing: it’s just a snapshot. Like a single frame from a movie, it only shows what was happening the moment that oil was pulled. Sometimes, you need the full story.

Enter filter analysis
Think of your oil filter as your machine’s diary. It quietly collects bits and pieces of the machine’s life—wear debris, contaminants, and particles that are too big to float around in the oil. While traditional oil analysis might miss these larger particles (especially in systems with huge sump volumes where debris gets super diluted), the filter holds onto them, waiting to spill its secrets.

Piece of aluminium from a sudden death of an engine that had recently been overhauled. Note that the hone marks are still visible on the piece of debris. Analysis also revealed a high level of coarse dirt which may have been the cause of failure.

So, how do we crack it open?
We take a small piece of the filter and give it a good shake with special solvents to loosen up all the trapped debris. That mix gets filtered through a fine membrane, and then the fun starts. Under the microscope, we get to play detective—spotting and identifying metals like iron, copper, aluminium, and white metal. But it’s not just about metals. We also catch dirt, rust, carbon grit, and even sticky oil residues.

Then, we measure the mass of all that debris and its PQI (Particle Quantifier Index) to understand how much wear is really happening. If something unusual pops up, we snap a pic, jot down what we see, and—here’s the kicker—we suggest what might be causing the issue and how to fix it.

The result? A detailed report (print or digital) that gives you a deeper look into your machinery’s health. So next time you’re wondering what’s really going on inside your machine, remember—it’s not just in the oil. The filter’s got stories to tell.

For more information on filter analysis service, contact Chris Hattingh – chrish@lubrigard.co.za.

Unlocking Lubricant Longevity with RPVOT Testing

Unlocking Lubricant Longevity with RPVOT Testing

by | Feb 25, 2025 | General

Unlocking Lubricant Longevity with RPVOT Testing

Degradation Pathways

There are multiple degradation pathways that turbine oil faces under operational stress, but the dominant failure mode in an operating system is oxidation, one of the primary causes of lubricant degradation.

Simply put, oxidation occurs when oxygen reacts with the hydrocarbon molecules in the base oil of a lubricant. The oxidation process is significantly accelerated by heat, with a 10°C increase in oil temperature effectively doubling the oxidation rate. Contaminants such as water, and metallic wear particles containing copper or iron, act as catalysts, further speeding up oxidation.

As oil oxidises, it forms acids and insoluble oxidation products, which can lead to formation of sludge or varnish. These degradation products can coat bearing and oil-cooler surfaces, preventing adequate cooling of the bearings. Areas with tight tolerances such as hydraulic control valves can also become coated, causing operational issues. What’s more, as the oil oxidises, its foam control, demulsibility and air-release characteristics will likely deteriorate.

In a nutshell, poor oxidation resistance shortens the oil’s service life.

All turbine oils contain antioxidants, which serve as the base oil’s first line of defence against oxidation. However, like all additives, antioxidants are sacrificial in nature and must be monitored through advanced oil analysis to determine the oil’s remaining life. This allows for proactive planning of oil replenishment and maintenance activities.

One such advanced oil analysis technique is the Rotating Pressure Vessel Oxidation Test (RPVOT).

RPVOT

The RPVOT is an essential tool in the lubricant industry for evaluating a lubricant’s oxidation resistance, particularly for turbine oils, hydraulic fluids, and other industrial lubricants. This test is crucial for ensuring that lubricants can withstand the oxidative stress encountered during operation, thereby extending their service life and protecting machinery from premature wear.

Let’s take a closer look at how WearCheck performs RPVOT analysis using ASTM D2272 – Method B.

The test begins by placing a predetermined amount of the lubricant sample, along with distilled water and a copper catalyst coil, into a glass container. This container is then sealed and placed inside a rotating pressure vessel, which is filled with oxygen to a specified pressure and heated to a standardised temperature (typically around 150°C).

Initially, the antioxidant additives in the oil resist oxidation. However, once these additives are depleted, the oil starts to oxidise, leading to a pressure drop within the vessel. The test continues until the pressure drops by a predetermined amount, with the time taken for this drop indicating the oxidation stability of the sample.

Depending on the condition of the sample, the test duration can range from 200 minutes to over 3,000 minutes. The result is reported as the time, in minutes, required for the pressure drop to occur. A longer RPVOT time suggests better oxidation stability, indicating that the lubricant is more robust and capable of performing well under oxidative stress.

For industries where equipment reliability is paramount, performing regular RPVOT analysis is invaluable, as it provides an early warning of potential lubricant degradation issues that can escalate to unplanned downtime. The cost of changing the oil in an industrial turbine is substantial, so maximising lubricant life is key. However, the greatest financial benefit of advanced oil analysis techniques like RPVOT is improved machine reliability and overall operational integrity.

For more information on filter analysis service, contact Chris Hattingh – chrish@lubrigard.co.za.

The Importance of a Well-Organised Lube Store

The Importance of a Well-Organised Lube Store

by | Feb 21, 2025 | General

The Importance of a Well-Organised Lube Store

Key Benefits of a Well-Managed Lubricant Store Minimising Contamination Risks

Lubricants are highly susceptible to contamination from dust, moisture, and other environmental factors. A properly maintained store with sealed containers, adequate ventilation, and effective filtration systems prevents contaminants from degrading lubricant quality. The use of high-quality breathers and climate-controlled storage further enhances cleanliness and longevity.

Extended Lubricant Shelf Life

Exposure to sunlight, fluctuating temperatures, and humidity can lead to oxidation, additive breakdown, and water ingress, ultimately shortening a lubricant’s lifespan. By implementing stock rotation and adhering to manufacturer-specified shelf lives, a well-managed store ensures that only fresh, effective lubricants are used.

Improving Equipment Reliability

A well-organised lubricant store eliminates delays caused by misplaced or hard-to-find products. Clear labelling, designated storage zones for different lubricant types, and an up-to-date inventory system streamline access to the correct products, reducing downtime and improving productivity.

Enhanced Operational Efficiency

An organised lube store reduces delays caused by searching for the right product. Clear labelling, designated storage zones for different lubricant types, and an up-to-date inventory system make it easier to locate and apply the correct product promptly, minimising downtime.

Ensuring Regulatory Compliance and Safety

Proper storage minimises the risk of spills, leaks, and accidents, ensuring compliance with environmental and workplace safety regulations. A well-maintained store also promotes a culture of responsibility and professionalism among personnel.

Best Practices for Lube Store Management Design and Organisation

• Use a climate-controlled, well-lit area with clearly defined zones for different lubricant types.
• Store drums and containers on racks to prevent direct contact with the floor and protect against water ingress.

Inventory Control

• Implement a robust inventory management system to track stock levels and ensure timely reordering.
• Follow a first-in, first-out (FIFO) rotation system to prevent the use of expired lubricants.

Handling and Dispensing

• Pre-filter lubricants before storage to remove contaminants. (click here for more – link to brochure)
• Use sealable and cleanable containers for transferring lubricants to machines.
• Establish protocols for cleaning dispensing equipment to prevent cross-contamination.

Quality Assurance

• Test lubricants upon receipt to verify compliance with specifications.
• Regularly inspect stored products for signs of contamination or degradation.

Staff Training

• Train personnel on proper storage, handling, and dispensing practices.
• Emphasise the importance of cleanliness and correct procedures in maintaining lubricant quality.

Conclusion

A well-maintained lubricant store is more than just a storage solution—it is a cornerstone of effective asset optimisation. By reducing contamination risks, ensuring product quality, and streamlining operations, an organised lube store plays a pivotal role in enhancing equipment reliability and operational efficiency. Investing in proper storage and handling practices is a cost-effective strategy that yields long-term benefits, contributing to a robust and sustainable asset optimisation plan.

For more information on filter analysis service, contact Chris Hattingh – chrish@lubrigard.co.za.

Elevate Your Fleet Lubrication Program with ISO 55000 Principles

Elevate Your Fleet Lubrication Program with ISO 55000 Principles

by | Jan 25, 2025 | General

Elevate Your Fleet Lubrication Program with ISO 55000 Principles

Unlocking the Power of ISO 55000 in Fleet Lubrication

In today’s fast-paced and competitive environment, fleet reliability and reduced downtime are more critical than ever. For maintenance professionals aiming to enhance their Fleet Lubrication and Condition (FLAC) programs, integrating ISO 55000 asset management principles can be a game-changer. But how do you get started? Let’s break it down into practical, actionable steps.

Why ISO 55000?

ISO 55000 is the global standard for asset management, designed to maximise value over the lifecycle of your assets. When applied to lubrication, it ensures that every drop of oil and every grease application aligns with your organisation’s broader goals—minimising costs, boosting performance, and preventing equipment failures.

Laying the Groundwork

1. Understand the Big Picture

ISO 55000 isn’t just about processes—it’s about delivering value. Define how your lubrication practices contribute to fleet performance and align with your company’s objectives, such as reducing downtime and operating costs.

2. Assess Your Current Program

Start with a gap analysis. Review your lubrication schedules, oil analysis practices, and asset criticality rankings to identify areas for improvement. This step helps pinpoint inefficiencies and ensures that every maintenance decision is data-driven.

3. Set Clear Goals

Establish measurable objectives, such as:
• Extending oil drain intervals
• Reducing lubricant waste
• Achieving specific performance KPIs
Clear goals provide direction and help measure success over time.

Building a Strong Foundation

1. Develop a Lubrication Policy

A well-defined lubrication policy outlines roles, responsibilities, and standards. When everyone—from technicians to supervisors—understands their role, consistency and excellence in lubrication management become achievable.

2. Integrate Advanced Technology

Leverage tools like:
• Oil analysis: Provides insights into lubricant condition and contamination levels
• IoT sensors: Enable real-time monitoring of lubrication performance
• Predictive maintenance software: Helps prevent costly failures before they occur
These technologies improve decision-making and optimise lubrication effectiveness.

3. Standardise Lubrication Processes

Implement consistent procedures for lubricant selection, application, storage, and monitoring. Standardisation enhances efficiency and reduces errors, ensuring optimal fleet performance.

Continuous Improvement: The ISO 55000 Mindset

ISO 55000 emphasises continuous improvement. Regularly monitor key performance indicators such as lubricant contamination levels, fleet downtime, and maintenance costs. Use this data to refine your processes and achieve long-term operational success.

Why It Matters

Integrating ISO 55000 into your FLAC program does more than improve lubrication—it transforms it into a strategic advantage. By focusing on lifecycle value and aligning with your organisation’s goals, lubrication shifts from a routine maintenance task to a driver of fleet reliability and profitability.

Take Action Today

Ready to elevate your lubrication program? Start by aligning with ISO 55000 principles and unlock the potential of world-class asset management for your fleet. The future of lubrication excellence is within your reach—seize it now!

For more information on filter analysis service, contact Chris Hattingh – chrish@lubrigard.co.za.