How to create a fluid analysis programme

Know which equipment to analyse

When beginning to implement an oil analysis programme, it is essential to identify which equipment and compartments should be analysed. 

There are methodologies such as the ABC curve, which help prioritise assets according to the available budget or the importance of the equipment in overall maintenance. 

Prioritisation can also be carried out by identifying critical points in the production process, considering failures that cause production losses, whether the asset is a backup, the cost and time required for repairs and replacements, maintenance history, among other criteria. Our specialised technicians can provide the most appropriate guidance for your case. 

Ensure Your Team Knows How to Sample 

Proper fluid sampling is crucial to ensure reliable and prompt results. It is imperative that the person responsible within your team is properly trained to take representative and consistent samples, as this is a key step in an efficient oil analysis programme. 

At ALS, we offer various tutorials and practical guidance on how to correctly collect and register samples to achieve accurate results. 

Choose the Right Company to Perform the Analysis 

An important aspect to consider is the type of maintenance plan implemented in your company and whether the chosen laboratory can meet the demands of that plan. 

It is also necessary to check whether the laboratory has experience in your sector, holds the appropriate quality certifications, and whether its infrastructure and track record qualify it as a reliable partner. 

Other relevant factors include access to technical support, availability of real-time and easily accessible data, the ability to integrate with your maintenance software, and the reliability of its services. 

Results 

The ALS Central Data Registry (CDR) receives the sample, validates the information, and immediately enters it into the laboratory analysis process, according to the previously defined scope. 

The laboratory performs the tests in accordance with ASTM standards, ensuring the reliability of the results. 

ALS’s interpretation process is geared towards predictive maintenance of equipment, using clear and objective language, covering all necessary inspection actions, thus reducing equipment downtime. 

Justifying the Programme 

A common way to justify an oil analysis programme is by documenting all oil changes carried out predictively, aligned with maintenance goals based on sample results. 

Another method is through a comparative “before and after” analysis, observing the benefits obtained over time from monitoring assets, such as reduced unexpected downtimes and lower costs from avoided corrective repairs. 

Types of Tests and Their Objectives 

Physicochemical Analysis: Evaluates the condition of the lubricant, either at a specific moment or periodically. 

Contamination Analysis: Identifies the presence of contaminants. Oil can become contaminated through equipment wear or chemical reactions of the lubricant itself. 

Spectrometry: Identifies chemical elements present in the lubricant. By breaking down the oil at the atomic level, it provides precise data on wear, contaminants, and additives. 

Ferrography: Analyses particles in the lubricant to determine the degree and cause of wear in machinery and equipment. 

ALS Package Types by Segment 

The main analyses by segment include: 

Insulating Fluids: Physicochemical analyses, chromatography, and PCB detection. 

Industrial Equipment: Packages for general industrial applications, thermal systems, industrial plus, greases, advanced industrial, combustion engines, and wind turbines. 

Fleets: Engine, hydraulic system, greases, diesel, transmission, gear system, and coolant. 

Now is the Time to Bring More Efficiency and Savings to Your Maintenance! 

Find out how we can help your company reduce costs and save time with ALS!