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GREASES HYDRAULICS INDUSTRIAL LUBRICANTS SYNTHETICS FILTRATION STORAGE/HANDLING OIL ANALYSIS

Selecting the Right Oil Analysis Lab

Bennett Fitch, Noria Corporation
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Tags: oil analysis

When you go in for a blood test, do you want

to be told what your red and white blood
counts are, what your platelet or hemoglobin
levels are, or what the mean corpuscular
volume is? Unless you’re a medical doctor,
probably not. You rely on a reputable doctor
to analyze the blood count report and tell you
if you’re healthy. If he spots concerns, does
he say, “You’re unhealthy,” and that’s it? No.
You expect him to act with urgency to figure
out why you’re not healthy and what can be
done to make you better. You expect him to
ask a battery of questions to help pinpoint
the root causes and explain the problem at
hand. That’s why we have doctors and not just blood counts or healthy/unhealthy alarm
limits. We need a true diagnostic methodology to help us stay healthy.

Just like blood analysis, oil analysis is undoubtedly complicated. First, someone is tasked
with ensuring samples are collected in just the right way to minimize human interference in
the results. This requires training. Then, laboratory technicians are rushed to process the
sample through a gambit of instruments. They must use precise and consistent methods to
avoid the potential interference from such things as previously run samples or variations in
sample agitation technique. This calls for a lot of training.

Once the lab tests are completed, the job isn’t finished. You should expect a skilled
diagnostician (just like a doctor) to analyze the results, uncover the clues behind the raw
data and produce clear recommendations to address any concerns. This last step is probably
the most important reason why oil analysis is performed. It also is arguably the most difficult
and often the most overlooked part of it all. This article will offer selection principles
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cost.

While the actual responses varied, a unified answer to the question can be surmised. That is,
the end goal of oil analysis is to aid in the optimization of plant-wide reliability by
proactively monitoring various indicators within the oil of individual machines. This should
be what motivates each plant to design its oil analysis program effectively. This same
motivation will also be the deciding factor when evaluating each aspect in selecting and
working with a laboratory.

Selection Principles
A laboratory likely will not excel in every aspect of oil analysis as you might hope. In order
for it to be competitive, the lab may concentrate its efforts on those areas most valued in
the market. The problem is many people are often too focused on price and may
unknowingly fall short of their end goal by overlooking some of the most important oil
analysis principles.
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To capture the scope for evaluating an oil analysis laboratory, selection principles can be
Desiccant Breathers: A Front Line Defense In
grouped into five categories: preparation, regulation, interpretation, communication and The War On Contamination
evaluation.
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1. Preparation The Benefits of Combining Ultrasound &

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Sample shipping time/distance to the laboratory Vibration for Condition Monitoring

Provide certified-clean bottles and labels
Support with sampling methods
Test slate availability and selection assistance
Buyers Guide
Oil Analysis Laboratories
Preparation includes all things leading up to the laboratory obtaining the oil sample.
Choosing a lab that is located close enough to where samples can be delivered within 24 Oil Analysis Instruments
hours or as soon as possible from when the sample was drawn is a must.
Oil Sampling Hardware
The laboratory should supply certified-clean bottles that are selected based on cleanliness
targets and the type of oil to be collected. Lab personnel should be knowledgeable about
bottle types and when it is appropriate to select one over another.
Poll
Along with the bottles, sample labels should be provided requiring the collection of relevant
data for the machine, lubricant, environment and maintenance practices. Without this Have you seen the effects of
information, the laboratory will not be able to fully interpret the results. The lab may also lubricant starvation in any of
furnish special packaging materials to facilitate safe and effective shipping of the oil.
the machines at your plant?
If you are new to oil sampling, your laboratory should offer support on the best practices.
This will include how often to sample, where to draw a sample and what type of extraction Yes
tools should be utilized.
No
One of the first steps in developing an oil analysis program is understanding which tests
should be performed for each equipment class based on the criticality of each machine. This
will involve routine testing (potentially performed in-house) and exception testing (for when
results come back questionable or abnormal). Your lab should be able to provide the
required tests and assistance for optimizing test slates. The more you measure, the more
you can analyze and the more potential opportunities ultimately arise.

2. Regulation
Instrument testing standards validation
Operating technician certification
Sample handling process (e.g., agitation)

Most oil analysis test methods are not

straightforward but will necessitate having
regulations to carefully follow. The
regulations may come from standards
provided by ASTM, ISO or other comparable
standardization organizations. These test
standards define the generally accepted
procedure, the proper application of the test,
the method’s repeatability or reproducibility,
calibration requirements and other pertinent
data. The laboratory may even choose to follow a modified version of a test standard based
on the lab’s preferences. It is critical to understand which standard the lab will use for the
required tests as well as the measures taken to ensure the operating technicians are
conforming to those standards. There should also be minimum requirements regarding the
operating technician’s certifications to perform all necessary tasks within the lab (though
outside of the actual test standards).

The lab’s sample handling processes before and even after the tests are performed will be
crucial. Find out how quickly samples are processed for analysis, the sequence of tests and
how the remaining sample is stored for potential exception testing. At times, laboratories
must take additional steps outside the scope of the testing standards to improve the
accuracy of the results, such as the method to effectively agitate the sample prior to analysis
or a quick physical inspection of the oil as the initial indicator of a potential concern.

Additionally, each laboratory may decide (and is expected) to go through an extensive

self-assessment based on generally accepted standards for maintaining and managing a
lubricant testing laboratory. In recent years, ASTM D7776-12 (Self-Assessment of Quality
System Practices in Petroleum Products and Lubricant Testing Laboratories) has been
developed to better outline the specific criteria that should be reviewed. If possible, end
users should request any documents that can provide the results of laboratory
self-assessments and the methodology and criteria that were employed.

3. Interpretation
Three categories of oil analysis
Statistical trends and calculations
Multiple data point correlations
Maintenance history considerations

If only raw data from the oil analysis tests is presented in the final report, it can be quite
confusing and overwhelming for end users who have little to no interpretation experience.
To achieve the end goal of oil analysis, there must be a comprehensive interpretation of the
data. The interpretation stage can be challenging to summarize, as each oil analysis test
provides different forms of data. Nevertheless, some general guidelines should be followed
during the interpretation of routine oil analysis.

First, the overall results should focus on verifying or identifying the three oil analysis
categories: fluid properties, contamination and wear debris. Second, tests performed on a
single sample will not be sufficient to obtain quality results. Developing statistical trends of
specific data points and calculations across multiple data points will likely be required to
determine if there are any concerns. Perhaps the most important comparison will be against

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the baseline sample results (new oil test results from the same batch of the used oil result).

The various trends developed for each sample point along with the collected maintenance
history and understanding of the machine’s criticality will allow cautionary and critical alarm
limits to be set. The lab should offer assistance in establishing these limits, but they must be
in agreement with the plant’s overall reliability objectives.

Another thing you must consider is whether your laboratory’s interpreters are familiar with
the types of machines from which the oil samples were obtained. If they are not, make sure
a specialist is involved to give you the diagnostic skills your machines require. Remember,
providing oil analysis data and providing a good explanation of the data are two different
things.

of lubrication professionals are not

32% confident in the validity of their oil analysis

data, according to a recent poll at
MachineryLubrication.com

4. Communication
Quality, user-friendly report presentation
Software integration
Urgent notification of critical results

After the interpretation has been performed, you should expect your lab to effectively and
quickly communicate the results in a quality, user-friendly report. You should see supporting
graphs, highlighted concerns, pictures and written interpretations in addition to the complete
raw data. In recent years, it’s common for all reports to be routed through a cloud-based
software to allow you to easily scan multiple reports and modify charts and trend graphs to
suit your needs. The last thing you want is the important details to get lost in the jumble of
data or to spend too much time trying to make complex interpretations yourself. While it’s
always wise to make your own interpretations (since you are most familiar with your
machinery’s history), you don’t want to have to spend an unreasonable amount of time
doing so.

Every minute matters when your machines are in distress. Your laboratory should be
prepared to immediately contact you if there are any critical concerns. This may be via call,
text, email or whatever method works best for you. When it comes to these critical
notifications, do not rely on the standard delivery methods for your oil analysis results, as
you may overlook their urgency. For example, if you normally receive all oil analysis results
by email, you may not perceive the urgency of an email about a critical concern because it
might be seen as a typical report in your inbox, likely delaying its review.

5. Evaluation
Exception test recommendations
Root cause investigation
Assess other condition monitoring results
Customer-focused support

After critical alarms are triggered and urgent notifications are sent, subsequent
communication from the lab should help you evaluate the problem at hand and make quick
decisions. The laboratory should assist you in determining exception tests that could provide
more information about any concern identified by a routine test. This further analysis should
include techniques like microscopic analysis, which can be obtained from any remaining oil
from the original sample. More oil may also need to be drawn from the machine. These
exception tests are intended to confirm, deny or provide more details in order to find the
root cause of the issue. With this data and more in-depth examination into the recent events
of the machine’s operating conditions, investigation reports and other condition monitoring
technologies, remediation recommendations can be formulated.

In many cases, the laboratory may be able to provide the investigative assistance you need
to get to the root cause of a potential failure. Know your lab’s full capabilities and set your
expectations accordingly. The laboratory should be passionate about detecting and solving
problems, and share your end goal of aiding in the optimization of plant-wide reliability by

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proactively monitoring various indicators within the oil of individual machines.

At What Cost?
Each of these oil analysis selection principles can be refined by considering the optimum
reference state (ORS) of each machine or, more importantly, your plant’s overall reliability
objectives. If price was not a concern, you would simply choose a lab that could deliver on all
of these principles. Unfortunately, price eventually must be a concern.

So when does the price of oil analysis outweigh its returns? First, you must consider the
impact of a potential failure for any of your machines, including the resulting cost of parts,
labor and lost revenue from a production interruption. Then, depending on the magnitude of
this impact, you must decide how much you would be willing to spend to avoid the average
incident, regardless of whether there is a history of failure. In almost every circumstance, a
single catch that avoids the average failure would more than justify the typical cost of an oil
analysis program for an entire plant.

Oil analysis services are generally competitively priced in the market. Nevertheless, beware
of the potential shortcomings of very low-cost or even free oil analysis programs, such as
those provided by a lube supplier. Even if the oil analysis is free, it still costs you time and
money to collect samples and manage results. If the oil analysis program isn’t created with
your end goal as the focus, you may not be giving yourself any sort of advantage. You may
be better off spending a few extra dollars to guarantee you get the value you’re trying to
achieve. Asking the questions specified by the selection principles will help ensure this. As
the optimum reference state suggests, there is an optimum effectiveness zone that is a
balance between the cost of an investment (like oil analysis) and the cost of unreliable
operation. The total cost of reliability will be the lowest at this optimum effectiveness zone.

So while price must be taken into consideration, it should not be your top priority. Consider
price only after you can verify your satisfaction with the level of service and quality the lab
offers in each of the selection principles as it relates to your end goal. Like most things, it is
often a tradeoff between price, service and quality, where two of the three are achievable at
a desired level. Do not sacrifice the necessary levels of service and quality for price. The
attainment of your end goal is depending on it.

Machinery Lubrication (6/2016)

About the Author

Bennett Fitch
Bennett Fitch is a technical consultant with Noria Corporation. He is a mechanical
engineer who holds a Machine Lubricant Analyst (MLA) Level III certification and a
Machine Lubrication ... Read More

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