Condition monitoring is a natural partner to good lubricating practices and if we deem ourselves to be efficient and effective at one then it follows that we should be proficient at the other. Indeed, results obtained from the analysis of specific condition monitoring techniques can directly affect the type of lubricant, the frequency of application, the quantity utilised, as well as the frequency of lubricant change which is, of course, based on it’s condition. 

By providing manufacturing industry with the correctly applied condition monitoring techniques we have the ability to increase plant efficiency and, more importantly, to increase plant profitability. There is, of course, the added bonus of potentially improving a particular plant’s Health and Safety standing and related credibility. 

Lubricant Analysis 

Taking a sample of the lubricant and having it analysed is an excellent condition monitoring technique to be able to ascertain either the condition of the lubricant or the condition of the system within which it is functioning, or indeed both, and is usually only applicable to Newtonian fluids, which does not include greases. It is logical that it is only possible to monitor the condition of the system if the lubricant is allowed to flow freely around it, but there are limitations as to the size of particles that traditional lubricant analysis can detect, so to be able to detect larger wear particles then it is necessary to employ Analytical Ferrography.

Lubrisolve Engineering Solutions Ltd. can provide a complete lubricant sampling and analysis service, which can include graphical trending of lubricant properties and/or wear metals.

Analytical Ferrography 

Ferrography is predominantly concerned with the condition of the system within which the lubricant is functioning rather than the condition of the lubricant itself.

It can be used either as an addition to traditional lubricant analysis or as a separate condition monitoring technique in itself, particularly where knowledge of the condition of the system is considered far more important than any information which could be gained from analysing the condition of the lubricant. Its major advantages over traditional lubricant analysis are that firstly it can identify wear particles of a much larger size, and over a broader range, and at an increased quality.

Analytical Ferrography has the ability to pinpoint almost exactly which components of a system are wearing and to what degree by virtue of the fact that the debris detected, within a sample, can be viewed by an electron microscope at incredible magnification. Individual particle size, shape, colour, and morphology can be determined, as well as quantity which, in turn, leads to the identification of the likely component, or components, from whence they were derived. The results derived from analytical ferrography can include pictures, very similar to photographs, of the debris detected.

Acoustic emissions 

This is a very simple condition monitoring technique that produces remarkable results. Ultrasonics, when used to detect faults within mechanical components, is often able to detect potential problems before other condition monitoring techniques, such as vibration analysis. Lubrisolve Engineering Solutions Ltd. uses and recommends Holroyd acoustic emission equipment.

This is particularly relevant in respect of slower rotating bearings and minute surface imperfections. Ultrasonics has the ability to actually detect the sudden burst of activity associated with mechanical damage, at an earlier stage, perhaps, than vibration analysis which may otherwise overlook the potential problem, as the sound waves generated are still in the ultrasonic range.

Vibration Analysis 

All rotating plant has, what is commonly termed, a vibration signature. That is to say that all of the constituent elements combine to provide a vibration signal with a particular amplitude and frequency. Any defects, or problems encountered, during rotational movement can naturally affect that vibration signal, normally permanently, and it is the sole task of vibration analysis to be able to detect these changes and provide an indication as to the probable fault.

Thermography 

Thermography, or thermal imaging, is definitely one of the simplest condition monitoring techniques to employ and is totally non-contact and non-intrusive thereby enhancing the Health and Safety aspect of utilising this method, although certain precautions have to be taken when undertaking analysis of electrical equipment. The ease with which readings can be taken and the results analysed does not deter from the fact that this technique can provide valuable information from a multitude of circumstances within any typical manufacturing plant. 

All rotating mechanical and electrical plant can be viewed using a thermal imaging camera to detect any potential problems and, interestingly, there are many instances where problems in rotating plant can be detected at an earlier stage using a thermal imaging camera, than with vibration analysis, due to the fact that thermography has the ability to detect extremely small differences in temperature that may not have manifested themselves as detectable changes in vibrations.