All About Fluid Analysis in One Place
A comprehensive guide from ALS to support your predictive maintenance learning journey.
What is Oil and Lubricant Analysis?
Fluid analysis is a predictive maintenance tool that assesses the quality of oils and lubricants used in machinery and equipment, identifying early signs of wear and contamination before they cause serious failures and disrupt operations.
Think of fluid analysis as an ally in your maintenance and asset management:
Fewer headaches and problems
If prevention is better than cure, fluid analysis is like a blood test indicating the best treatment.
Optimising component lifespan
Reducing the need for corrective maintenance on parts.
Savings through corrective maintenance
You will avoid unnecessary oil changes and extend the life of your components.
60% to 70%
of industrial facilities
Consider oil analysis an important part of their reliability programmes.
If machinery and equipment are part of your daily operations, this fluid analysis guide is for you!
Oil and lubricant analysis (ALS) is part of the daily routine for maintenance managers and teams. Here, we share our expertise on oil and lubricant analysis.
If you are looking for greater operational control, reliability, and cost reduction, this guide is here to support your decisions.
- Industries
- Fleets
- Mining
- Agribusiness
- Geochemistry
Do you work with any of these machines?
Find out why you should adopt oil and lubricant analysis in these cases:
The industrial and manufacturing sector accounts for around 60% of global adoption of oil analysis for predictive maintenance, followed by the energy and utilities sector (25%).
Source: Market Report Analytics
Industry is essential for a country’s development. Given current challenges, it is crucial to promote cost-reduction initiatives. Predictive maintenance is an ally in this process. Discover how it can help you in this eBook!
Complete and Free eBook on Predictive Maintenance
Oil and Lubricant Analysis
Physical Chemistry
Evaluating basic properties
Contamination
Detecting contaminant particles
Ferrograhy
Identifying wear
Spectrometry
Quantifying metals
Gas Chromatography
Fuel dilution in oil
Types of Oil Analysis
Physical-Chemical Analysis =
Contamination Analysis
Detects water, fuel, dust, solid particles, and other contaminants that compromise system integrity.
Ferrograhy
Identifies the type, origin, and severity of wear through morphological analysis of metal particles present in the oil.
Spectrometry (ICP and Plasma)
Measures chemical elements in the oil with high precision, useful for identifying wear metals, additives, and contaminants.
Gas Chromatography
Used to measure fuel dilution in oil, according to standards such as ASTM D7593. Ideal for engines suspected of diesel contamination.
For more information on ferrograhy and spectrophotometry, read our article explaining how to detect contaminants in industrial equipment and components.
What Issues Can Oil and Lubricant Analysis Detect?
- Contamination by water, fuel, dust, and metals
- Oil foaming
- Oxidation, thermal degradation, loss of viscosity
- Improper fluid mixing
- Premature component wear
ALS dashboards are customised for specific equipment, such as:
Hydraulic systems, transmissions, engines, gearboxes, diesel systems, and cooling systems. For more information, explore our fluid analysis testing services.
Cause and Effect Table: From Identified Problem to Potential Impact and Recommended Action
| Equipment | Abnormality found | Potential problem | Maintenance practice |
|---|---|---|---|
| Engine | Presence of iron, chromium, aluminum, and silicon | Failure of the moving assembly and loss of performance | Inspect the air intake system and oil filter |
| Hydraulic system | High particle contamination | Reduced component lifespan | Perform lubricant dialysis |
| Radiator | High coolant conductivity | Engine with poor grounding | Inspect the grounding connection and condition. |
For more combinations of classic wear elements, access the full comparison.
Essential Fluids for Analysis
Fluid analysis can mainly be performed on:
- Diesel: Contamination affects equipment productivity and leads to premature failure of pumps and injector nozzles.
- Hydraulic: Contaminated systems can experience pump and valve failures, internal leaks reducing efficiency, premature wear, and excessive oil changes.
- Lubricant: Contaminated lubricants compromise efficiency and can cause serious machinery issues, requiring frequent maintenance and part replacement, significantly affecting productivity. This is achieved by preventing lubricant escape through gaps and contaminant ingress, such as the film blocking combustion gases.
- Radiator/Cooling: Tests monitor coolant condition, ensuring proper system performance. Early detection of potential problems helps determine the precise timing for anti-corrosion additive application.
Learn more about fluid analysis in our full post.
How the Fluid Analysis Process Works at ALS
Before receiving the report that provides cost savings and data intelligence, samples follow this path from the field to the laboratory:
01
Sampling and pre-registration
02
Submission to the ALS laboratory
03
Technical testing using certified equipment
04
Report generation, interpretation, and recommendations
05
Report availability in S360
S360 is an exclusive ALS client platform for asset management.
Direct Benefits of Oil and Lubricant Analysis
Fluid analysis is key to increasing efficiency, reliability, and sustainability in your operation. By integrating it into maintenance planning, you gain short-, medium-, and long-term benefits:
Cost reduction through corrective maintenance:
Early identification of faults reduces emergency interventions and replacement of damaged components.
Extended equipment lifespan:
Monitoring lubricant condition helps preserve systems and prolong operational cycles.
Prevention of catastrophic failures:
Planned downtime avoids unexpected interruptions without high costs.
Prevention of catastrophic failures:
ALS laboratory reports provide objective data and customer success team recommendations to prioritise actions and justify investments.
Maintenance strategies differ; some work better depending on the equipment and objectives.
Maintenance Strategies to Learn and Apply
When and How Often Should I Analyse Oils and Lubricants?
Frequency depends on factors such as:
Operating hours
Continuous runtime
Type of equipment
Specific events
(e.g., injector nozzle replacement)
It is common to be unsure which equipment to analyse. We provide a complete guide on creating a fluid analysis programme to assist you.
Recommendation Table by Segment
Ever wondered what the ideal collection interval is for your operation? Here are some recommendations to help plan your predictive maintenance.
| Equipment | Anomaly found | Potential problem |
|---|---|---|
| Agribusiness | Every 250 hours | Increase frequency during harvest and peak operating periods |
| Mining | Every 100 to 200 hours | Heavy equipment requires continuous monitoring |
| Logistics | Every 10,000 km | Include analysis after critical events such as overheating |
| Industry | Monthly or bimonthly | Variable depending on asset type and workload |
| Civil construction | Every 150 to 300 hours | Strengthen collection in environments with high dust levels |
ALS fluid analysis delivers greater cost savings and reliability for operations across the country. Get inspired by our practical case studies!
Fluid analysis is key to increasing the efficiency, reliability, and sustainability of your operation. By integrating this care into maintenance planning, benefits can be achieved in the short, medium, and long term:
Trends and Innovations in Fluid Analysis
The oil and lubricant analysis sector is increasingly evolving thanks to data-driven technologies and solutions. Current trends focus on a more integrated, automated, and sustainable approach:
Integration with AI and Real-Time Sensors
Continuous monitoring of oil and equipment condition allows immediate data-driven actions.
Smart Dashboards
S360 is a digital platform that centralises analysis results and historical data intuitively for maintenance and asset management teams.
Predictive and Prescriptive Maintenance
Beyond predicting failures, AI algorithms are beginning to recommend specific actions based on asset behaviour and historical laboratory data.
Sustainability and Circularity
Fluid analysis supports the ESG agenda by promoting responsible lubricant use, reducing premature disposal, and optimising reuse cycles.
Effective maintenance should be data-driven, never guesswork.
ALS is a pioneer in fluid analysis and continuously evolves to provide innovation and data intelligence to its clients. With S360, you have reports, history, and diagnostics all in one place!
How to Procure ALS Oil and Lubricant Analysis Services
In case you are not yet familiar with us and our services, ALS is a global leader in testing, inspection, certification, and verification services.
We operate dedicated laboratories in Brazil, following rigorous quality processes to meet your demands with maximum efficiency and safety!
