Transmissions are very complex systems for converting and directing power from an engine to a drive train or other end use. Transmissions are typically found on mobile equipment and consist not only of gear sets, but also brake and clutch sets, torque converters and valves. Mobile transmissions are typically broken down into two categories - highway and off highway. Off highway consists of mining equipment, heavy-duty construction equipment, agricultural equipment and other mobile equipment typically used somewhere other than on a paved road.
Getting started with an on-site oil analysis program for Fleets
We have worked with many fleets to bring oil analysis capability on site with the MicroLab® analyzer. The programs can be very successful in helping fleets save money by extending oil drain intervals and by identifying mechanical issues before they result in catastrophic failures.
Provides comprehensive data and maintenance actions
The MicroLab® produces a comprehensive oil analysis report in less than 15 minutes to provide a complete picture of oil and machine condition, which allows a technician to make real-time maintenance decisions while the equipment is still in the garage.
Pumps are used in industrial and fleet applications to move liquids and gases. Most pumps used in industrial applications are either positive displacement or centrifugal. In both cases bearings are the component that must be lubricated and monitored. Rotary positive displacement pumps have gears, screws, lobes or vanes which are also lubricated, usually by the fluid they are pumping, whether it is a lubricant or an oil /air mix.
When companies are considering adding on-site oil analysis capability to their maintenance program with the MicroLab analyzer they typically want to know how quickly the investment will pay off for them. To help fleets evaluate the potential savings that on-site oil analysis can bring to them we developed a savings calculator that allows you to input specific information about your fleet to determine the estimated annual savings you may achieve.
The calculator considers three areas of savings potential.
Hydraulic systems are used in industrial, mobile and aviation applications to transmit power to operate equipment. They are incredibly efficient, compact, and lightweight relative to a mechanical equivalent. Hydraulic fluids transmit force in the system, and as such are carefully chosen by the system maker. Chemical stability, high flash and fire points, viscosity, and oxidation resistance are all valued, and as a result mineral and synthetic hydrocarbon fluids are selected for mobile and industrial systems, whereas functional chemicals such as phosphate esters are chosen for aviation and specialized industrial applications.
Oil analysis was first employed on engines as a predictive maintenance tool, and it remains a predominant technique for insuring the reliability of engine systems. Reciprocating internal combustion engines power most of the world's mobile equipment, such as cars, trucks, buses, locomotives, mining equipment, agricultural equipment and are also common in stationary backup power generators, oil and gas exploration rigs, and pipeline compression stations.
There are 5 common tests for glycol in engine oil. These include:
- IR Spectroscopy
- Atomic Emission Spectroscopy
- Blotter Test
- Schiffer's Reagent Method
- Gas Chromatography
Liquid cooled engines and rotating equipment use glycol based coolants because of their excellent heat transfer abilities. However, glycol based coolants are not desirable at all in lubrication oil itself – Coolant ingression to the lubricant is a particularly nasty contaminant for the variety of damage it can cause. Glycol coolants break down in the high temperature engine environment, leading to formation of glycolic acids. These acids attack nonferrous bearing surfaces and form metal salts. The acids also react with the oil anti wear and anti oxidant additives and, along with water, create sludges that plug filters and cause the oil to lose its lubricity properties, thus increasing abrasive wear. Glycol contamination in engines and transmissions is considered to be a more severe contaminant than water alone (up to 10 times more damaging). Depending on the oil temperature, the glycol coolant may break down rapidly, or over time. This instability is a major challenge for determining the true glycol content in the oil at a given time, and is the major reason why field and lab tests often do not agree with each other.
Learn how a gold mine saved more than $1 million in repair costs and lost operating time using an on-site Industrial Tribology Lab (ITL) for predictive maintenance.