Make your Equipment last longer...
“UNDERSTANDING OIL SAMPLING”

Unplanned Maintenance
A decision to do nothing until failure

VERY HIGH MAINTENANCE COST `

• Overtime
• Lost production
• High inventory

SHORT COMPONENT LIFE &
REACTIVE MAINTENANCE

• No time for failure analysis
• Fix it when it breaks
• No data to learn from

MODERATELY HIGH MAINTENANCE COST

• Over and under-maintained equipment
• Time and money spent unwisely
• Production loss from unscheduled downtime

SHORT COMPONENT LIFE

• Repair start-up problems
• Exposure to external contaminants
• Unplanned maintenance
• No root cause analysis

Predictive Maintentance:
Condition-based maintenance considers the unique characteristics of each component.

REDUCED MAINTENANCE COST

• Less overtime
• Increased production
• Time spent more wisely
• Reduced repetitive repairs

INCREASED COMPONENT LIFE

• Minor problems corrected early
• Historical data encourages purchase of equipment
• Down time keep to a minimum

• Analyze and anticipate rather than react and repair
• Root cause analysis guides maintenance action
• Trending and developing unique component signatures
• Reliability through oil analysis / wear particle analysis
• Improved filtration reduces wear up to 80%
• Reduce the number of breakdown” catastrophic” failures.
• Reduce contamination of oil by improved filtration

• According to Caterpillar “dirt and contamination are by far the number one cause of hydraulic system failures” : the system must be keep clean in order to achieve the productivity they’re capable of. When fluid is fine filtered, hydraulic systems life can be extended by 50 times.

• A.C. Delco Division of General Motors also tested engines and found an eight-fold improvement in wear rates and engine life with lower contaminant levels. “Compared to a 40-micron filter, engine wear was reduced by 50% with a 30-micron filter. Likewise, wear was reduced by 75% with a 15-micron filter. The study also equates the resulting friction reduction with a 5% increase in fuel economy.

Spectro-Metals:

Glossary Description: Any of several techniques for detecting and quantifying trace metallic elements, in which the sample is energized to make the elements emit or absorb a quantifiable amount of light energy.

Reporting units: Parts-per-million(ppm) by weight. 1 ppm-0.0001%

Repeatability: (approx.): 1-20ppm (+/- 1ppm); 20-500 (+/- 5%); 500+(+/- 8-10%)

Technical overview: Spectro-metals is confined to the measurement of metallic particles <10 microns in size and is thus limited on detecting catastrophic failures. In some applications, it is a weaker alternative. There is insufficient energy available to enable ionization of particles well below 10 microns which must occur if spectral energy is to be developed.

Interpretation: Spectro-metals testing provides information on three distinct areas of interest: WEAR, CONTAMINATION, ADDITIVES.

Wear metals: Iron, Chrome, Aluminum, Molybdenum, Lead, Copper, Tin, Nickel, Silver, Antimony and Titanium

Contaminant metals: Silicon, Sodium, Potassium, Boron.

Additive metals: Magnesium, Calcium, Barium, Phosphorus, Zinc.

ALL TYPES OF SYSTEMS BENEFIT FROM THIS TESTING PROCEDURE. EQUIPMENT/COMPONENT HISTORY INFORMATION CAN BE OBTAINED FROM OIL ANALYSIS TO DETECT ANY PROBLEMS BEFORE THERE IS MAJOR DOWN TIME.

What causes viscosity to change?

Upward = above 16.5

• Lube oxidation
• Foaming/Pump Cavitation
• Emulsion with water
• Soot or solids contamination

Downward = below 10.0

• Fuel or solvent contamination
• Refrigerant
• Wrong fill or make up of lube

“Viscosity is recommended for any application”

Glossary description: Combustion solids from reciprocating engines, however, the primary application is diesel engines.

Cause-Operations:

Lube change intervals too long

• Over fueling or excessive idling
• Incorrect rack setting
• Restricted air intake(SILICON)
• Leaking down or worn injector

Where are you now?

If you already have a testing program or if you want to begin, we invite you to the LubeTrak platform, a web based system offered by Megatrol. For competitive prices, we can provide you with your test results, posted on a web page, dedicated to your company. Results will be posted to your page each day and will remain there for historical needs. Analysis of the results will appear as Normal , Abnormal or Critical. In the case of Abnormal or Critical you have the option for an expert analysis, ‘Analysis Pro’ which immediately notifies selected individuals by e-mail with recommendations to resolve the problem. Testing for all oil type systems is available. Contact either Jon Rose at jrose@megatrol.com or Dick Cisco at dcisco@megatrol.com .

What are your long term goals?

We encourage you to review your machine maintenance long term goals and suggest that regular and routine oil analysis be a part of these goals. The cost of a simple test through LubeTrak/Megatrol will pay large dividends should a problem start to develop that might mean a major overhaul of the equipment. Oil analysis can tell you what is going to happen long before it happens.

Do you have vendor support?

An oil analysis vendor is a good step in the right direction: Try the LubeTrak platform, offered by Megatrol to see how we compare! Should you have sufficient volume of tests we offer a superior on-site analysis machine to complete your testing in house while utilizing the advantage of the LubeTrak web based program. The notification of abnormal or critical results from tests you do in house would still be a part of the LubeTrak reporting package. In house testing can save you considerable money and still give you the control you want. Contact us at the above e-mail addresses and visit us on the web at: www.megatrol.com

THINK NEW SOLUTIONS - with Megatrol

• Fuel Handling Equipment
• Lubrication Fluid Handling Equipment
• Data/Asset Management Systems
• Safety Systems for Electronic Equipment
• Pro-Active Maintenance for Vehicles and Machinery

Come see us and our equipment at the Minexpo 2004 in Las Vegas , September 27-30, booth 5219