Revolutionising Industrial Sustainability
In the recent landscape of infrastructure development and industrialisation there has an increase in mechanised operations of both construction and mining industry. Rapid mechanisation has led to huge carbon emissions which is of concern the people living on the planet.
Being competitive and sustainable has become need of the day, leading machine manufacturers to develop equipments that would be more efficient, reliable, emitting less carbon. This has led to research and development in the industry of construction and mining equipment. Focus being on fuels that leave a smaller carbon foot print. Simultaneously lubricants manufacturers have also been relentlessly working to develop more efficient lubricants that can minimise the drag forces and be energy efficient.
CO2 emission is only one part of the problem, reliability of these machines is also of paramount importance that impacts the operational cost of these machines.
Oil in the machine is like blood in the human body, just like the blood being indicator of human health, oil analysis can prove a lot of useful information about the machines condition and its reliability. Apart from this, oil analysis also provides a wide spectrum of data that can be used to predict when the asset will fail and seize to operate.
Traditional approach of changing lubricating oil based on fixed schedules is undergoing a paradigm as the focus shifts towards sustainability. The adoption of periodic oil analysis and condition-based oil changes not only extends the life of valuable lubricants but also acts as a proactive shield against equipment failures. This write-up explores the significance of oil analysis in the industrial realm, emphasising its transformative impact on sustainability, proactive maintenance, and operational efficiency.
Oil analysis programme
At the core of this transformative approach lies the oil analysis programme, a dynamic tool that monitors both the condition of the oil and the health of the machinery. With approximately half of equipment damage attributed to oil-related issues, and around 80 per cent of equipment defects detectable through lubrication oil analysis, the significance of this practice becomes evident. The oil analysis programme addresses challenges posed by oil contamination and degradation in industrial lubrication and further highlights emerging trend, such as oil regeneration programs, that breathe new life into oils, aligning with sustainability goals.
Proactive maintenance
Modern industries are integrating the practice of drawing periodic oil samples to meticulously track the condition of lubricants and machine health. This proactive approach serves as an early warning shield against catastrophic equipment failures, ensuring operational continuity and offering substantial financial savings.
Proactive maintenance stands in stark contrast to the traditional reactive maintenance approach, where equipment is serviced or repaired only after a breakdown occurs. In the realm of industrial machinery, particularly those reliant on lubricating oils along with other condition monitoring aids, a proactive maintenance strategy is gaining prominence. This involves actively monitoring the condition of machinery and its lubricants to identify potential issues before they escalate into costly and disruptive failures.
The proactive maintenance approach leverages oil analysis as a powerful tool to gain insights into the health of both the lubricating oil and the machinery it serves. Rather than adhering to rigid schedules for oil changes, industries are adopting a more dynamic strategy based on the true condition of the lubricant. Periodic oil sampling, when coupled with comprehensive testing, allows for the early detection of issues such as contamination, wear, and degradation, providing a preemptive advantage in maintenance planning.
Operational continuity is a critical goal for any industrial facility. Downtime due to unexpected equipment failures can have severe consequences, including production delays, financial losses, and a negative impact on overall efficiency. The integration of proactive maintenance, facilitated by the meticulous tracking of lubricant condition through oil analysis, serves as a robust mechanism to ensure operational continuity.
One of the most compelling aspects of proactive maintenance, enabled by oil analysis, is the substantial financial savings it offers. Traditional maintenance practices often lead to unnecessary oil changes based on fixed schedules, resulting in the disposal of lubricants that may still have valuable operational life. Moreover, unexpected equipment failures can incur exorbitant costs related to repairs, replacements, and lost production.
On-premise oil testing laboratories
Recognising that the time frame of analysis report is critical for maintenance, there is a growing need for near-site oil test laboratories. Traditionally, oil testing laboratories have been situated far from industrial plants, providing test reports after 10 to 15 days. This results in analysis delays, increasing the carbon footprint associated with transporting samples to distant laboratories.
One of the primary advantages of on-site oil testing laboratories is their proximity to the industrial plant. The traditional model of sending oil samples to distant laboratories inherently involves transportation time, which can be a critical factor in the context of maintenance. Recognising that mechanical damage can start setting in within 48 hours, the need for rapid and timely analysis becomes apparent. On-site laboratories address this need by providing real-time or near-real-time results, allowing for swift decision-making and prompt implementation of maintenance measures.
Establishing on-site oil testing facilities offers a practical solution to the challenges associated with transporting oil samples over long distances. The traditional model involves packaging and shipping samples to external laboratories, incurring costs not only in terms of shipping fees but also in the resources required for secure packaging. By conducting testing on-site, these transportation costs are significantly reduced or eliminated, contributing to overall cost savings for the industrial facility.
The sustainability aspect of on-site oil testing laboratories is particularly noteworthy. The transportation of oil samples over long distances contributes to the carbon footprint associated with industrial operations. This includes the emissions from vehicles used for transportation, as well as the energy consumed in packaging and logistics processes. By minimising the need for transportation through on-site testing, industries can significantly reduce their environmental impact, aligning with broader sustainability goals.
Having an on-site oil testing laboratory provides industrial facilities with enhanced control over the entire testing process. From sample collection to analysis and reporting, the facility can maintain confidentiality and control over sensitive data. This is particularly important in industries where proprietary formulations or processes are involved. On-site facilities offer a secure environment for handling and analysing samples, reducing the risks associated with external laboratories.
On-site oil testing laboratories seamlessly integrate with the broader proactive maintenance strategy adopted by modern industries. The immediate availability of test results allows maintenance teams to make informed decisions promptly, minimising downtime and preventing potential equipment failures. This integration contributes to the overall efficiency and effectiveness of the maintenance practices within the industrial facility.
Quality of Testing Laboratories
The reliability and utility of oil analysis hinges on the caliber of the testing laboratory conducting the assessments. Several pivotal factors collectively contribute to the overall quality of a testing facility, influencing the accuracy and significance of the results obtained.
Accreditation from esteemed organisations such as NABL (National Accreditation Board for Testing and Calibration Laboratories) or adherence to ISO/IEC 17025 standards signifies that the laboratory maintains a high level of competence and impartiality, following internationally recognised protocols in its operations.
The adoption of cutting-edge testing methods and state-of-the-art equipment is essential for a reputable laboratory. Technological advancements in oil analysis allow for more nuanced measurements and a deeper understanding of the composition of the oil. Utilising advanced testing methods ensures that the laboratory can detect subtle variations in the oil, providing comprehensive insights into its condition.
Third-party laboratories often are in business of selling reports and not offer holistic technical solution, what is needed by the industry is a prognostic approach, a prescription of equipment health is what is needed by the maintenance team with clear recommendations on the action to be provided. This is needs in depth understanding of lubrication, tribology and machine. This has led major OEMs such as Komatsu to establish oil analysis laboratories called KOWA Centre, this trend has also been adapted by mining companies who value machine availability and reliability such as Vedantas Hindustan Zinc, to name few.
Conclusion
By embracing oil analysis and condition monitoring on site, industries contribute not only to environmental sustainability through extended oil life but also experience cost savings, proactive maintenance, and optimised equipment performance. This transformative approach ensures that machinery keeps running smoothly, aligning with the broader goal of sustainable industrial practices. The write-up concludes by summarising the key points and highlighting the long-term benefits of integrating oil analysis into industrial maintenance strategies.
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