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Revolutionizing oil analysis: Traditional vs Cutting edge technology

By Sanya Mathura (Strategic Reliability Solutions Ltd) & Neil Conway (Spectrolytic)

In our last article we focused on the question of whether oil analysis was still relevant today? While this is an age-old process, the benefits of oil analysis still continue to live on today although the methods involved have significantly evolved since its inception. In this article, we will do a deeper dive into the traditional methods of oil analysis versus some of the new cutting-edge technologies which exist today and whether we may see a replacement of one method over the other or a union moving forward.

If you’ve ever performed an oil analysis you know that this process follows certain standards which are listed in the report.  These standards govern the world of oil analysis and form the basis of how these tests are executed. There are committees dedicated to revising these standards to ensure that they are still relevant to the applications of today, one such committee falls under the ASTM body (American Society for testing and Materials).

Equipment has changed over time where oil sumps have become smaller but now produce more power. Oils are under more stress as they are expected to perform at higher temperatures under elevated environmental conditions and still protect the equipment. Global oil manufacturers work together with OEMs (Original Equipment Manufacturers) to ensure that the oils developed can work with their components in these increasingly harsher conditions. But what constitutes an oil “working properly”?

This is where oil analysis / sample testing plays a crucial role. Oil analysis tests have been standardized through authorized committees to ensure that the same test can be performed in different parts of the globe using the same procedures. This ensures that there can be a fair comparison of the results of these tests across the globe. These tests should also be repeatable (or get the same results every time they are performed). 

Typically, these tests are usually carried out in a laboratory environment, using state of the art equipment to achieve / maintain the required standards. However, sample taking, sample shipping and other human factors often result in misleading and / or extremely delayed reporting of the results. This is where emergent technology can alleviate some of these challenges.

Emerging technology – FluidInspectIR®

Spectrolytic’s FluidInspectIR-Inline is a comprehensive fluid monitoring system that uses an array of sensors (MIR, OPC, wear, viscometer, conductivity) to provide real time data on oil and fluid degradation parameters. At the heart of the system is a novel mid-infrared (MIR) sensor that measures the chemical composition of the fluid with parameters such as; TAN, TBN, ipH, oxidation, sulphation, nitration, water, glycol, soot, fuel dilution and additives. These can be measured, as a first in the field, with the same accuracy and in the same units as conventional labs.

There are a couple of areas where the FluidInspectIR can offer advantages as compared to traditional oil analysis. Here are a few of them:

Real Time Monitoring and Faster Results – with these online monitoring devices, users can readily get data throughout the day without waiting for the sample to be taken, shipped to a laboratory and then tested there. This significantly reduces the time between making decisions which could negatively impact the equipment’s performance. Within our industry, this time is absolutely critical as the cost of unplanned downtime for the affected assets can be millions of dollars.

Cost-Effectiveness – every time a sample is taken, there is a cost involved. The sample taking process is usually quite lengthy as often permissions have to be obtained since more organisations are trying to reduce potential health & safety risks by minimizing human-machine interactions.
Once a sample has been obtained it needs to be shipped to a laboratory. This not only has costs attached to it, but many couriers are now making it very difficult to ship oil samples. In addition, each shipment of a sample carries also an implied CO2 footprint.

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Figure 1: Comparison of different routes of oil sampling

As shown in figure 1 the resulting cost savings from utilizing real time inline sensors compared to other methods can be summarized as follows:

  • Human assets can be utilized more effectively without allocating time for them to take oil samples
  • Trend analysis based on real time; laboratory equivalent data allows the end customer to move from a time-based maintenance process to a data driven maintenance process
  • Early failures can be spotted very easily and unplanned down time, the nightmare of every asset manager, can be minimized
  • Oil drain intervals can be extended in a safe and controlled manner which can result in significant operational efficiency gains and reduced CO2 footprint

Accuracy and Reliability – getting an accurate representative sample using conventional oil sampling methods can be challenging at times. If the sample is taken at the wrong point (right after the filter or at a dead leg), it might not be representative of what is happening on the inside of the equipment. As such, it can completely derail the trend being established for that component and allow the users to believe that something is terribly wrong with that component.

With the FluidinspectIR online monitoring system, the sample delivery to the sensor is automated and standardized ensuring that the sample is delivered to the sensor in the correct way every time. Therefore, the users can rest assured of getting the sample taken at the right location (ensuring a proper representation of the system), at the same location (ensuring an accurate trend of the data) and with the same technique (which completely avoids any variation from human operators).

 As the FluidInspectIR uses mid-infrared spectroscopy which is identical to the technique used by laboratories (FTIR), the data provided by the FluidInspectIR system has, at least, the same accuracy as those produced by a laboratory as shown in figure 2 below.

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Figure 2: Comparison of the FluidInspectIR technology to periodic oil checks using a laboratory (red circles)

Actionable data and improved maintenance – with real time data, failures can be prevented and major unplanned downtime eliminated. With the online monitoring system, it is easier to trend an increase in wear metals, change in viscosity, water ingress or any other parameter changes which would warrant some form of maintenance intervention. This provides users with the information they need at the right time without any further delays due to shipping of samples or an inaccurate sample being sent off as shown in the case study in figure 3 where a diesel engine on a dredging vessel saw spiked concentrations of water that coincided with the vessel being moored in harbour. With the quick action of the inline sensors, they were able to save £115k over 9 months.

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Figure 3: Case Study for Diesel engine customer  

Data Integration and Remote Monitoring – traditionally, oil analysis results lived in databases which could be accessed electronically, or they were emailed and stored in a filing system. But these results are only available after a sample has been taken and sent off to the lab. This is how FluidInspectIR takes it a step further where assets can also be monitored remotely, in real time.

Imagine being able to monitor the conditions of a particular component while being offsite or multiple components for various sites. This can be particularly useful when trying to troubleshoot an issue related to a system process, especially across sites. This is one area that traditional oil analysis would not be able to mimic as the sample may not be taken at the exact same time as the ongoing system process therefore not allowing a correlation. 

Of particular importance is the ability to trend data across multiple assets. This can be critical if there is a significant environmental factor influencing the condition of the oil which may affect many of the components in the fleet. Being able to easily and quickly detect this can be the difference between a productive day and one that has gone into unplanned downtime.

The above offers some advantages of using these inline sensors but what really sets the FluidInspectIR apart?

Historical inline sensors have employed dielectric or impedance-based sensing. Impedance based sensing is slightly more advanced than dielectric sensing but still only measures a few electrical parameters such as oil resistance, capacitance and inductance which assist in detecting the polar molecules in the oil.

However, complex algorithms are usually used to convert the electrical data into a meaningful value such as TBN or develop a trend based on a dimensionless value. Laboratories use MIR Spectroscopy which is the same technology utilized by FluidInspectIR. As such, the data / results are given in the same units and accuracy as labs.  

The FluidInspectIR technology analyses the spectra in the wavelength ranges which have a chemical meaning for the application in which the sensor is being used, such as turbine oils, EALs, gear oils, engine oils etc. This specificity in the MIR spectrum, coupled with several mechanical and electrical design features allow lab accuracy in the field.

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Figure 4: Market validation and asset examples

The Hybrid approach

While the FluidInspectIR Inline sensors can provide actionable data required for preventive maintenance strategies, there are some parameters where a lab analysis would certainly be advisable. These are more specialized tests such as Air separation / Demulsibility or FZG loading tests which require some fairly complexed processes in which the oil has to stand for some time during the procedure or different loads have to be added until a particular characteristic is met.

With that being said, inline OCM technology has made significant advancements and the FluidInspectIR is currently considered state of the art providing lab equivalent data in real time. In addition, it is also capable of measuring nonstandard properties, such as oxidation by-products which can relate to varnish by-products or the potential to form varnish as well as monitor the quantity of antioxidants. The monitoring of these parameters could not have been done a decade ago as the technology simply wasn’t available.

The future of oil analysis will certainly be a hybrid approach where inline sensors continuously monitor the fundamental parameters and when limits are reached (either below or above), or the trending analysis shows a peculiar behavior, then specialized additional testing can be pursued using the lab infrastructure and expertise.

In this way, resources are conserved when the oil appears to be within its limits and functioning as it should. However, when these limits are reached and the component could be in danger, specialized resources will be deployed to ensure that the component does not suffer a fatality. The way forward for oil analysis is definitely a hybrid approach mixing the traditional with some of the cutting-edge technologies.

Bio:

Neil Conway – Applications Manager, Spectrolytic

Neil is the Applications manager for Spectrolytic where he develops and manages new and current measurement applications for all the product lines. Neil is also extensively involved in sensor characterisation, product development, customer training, and technical marketing.

Previously Neil has held Process Engineering positions in semiconductors with Motorola and Atmel and operated as Wafer Fabrication Manager with IR Sensor company Pyreos where he developed and commercialised the first thin film PZT IR sensor manufacturing line. 

Neil is a chartered Engineer (CEng) and Scientist (CSci) and corporate member of the Institution of Chemical Engineers (MIChemE) and holds a BEng (Hons) in Chemical & Process Engineering from Strathclyde University.

Bio:

Sanya Mathura, REng, MLE

Founder, Strategic Reliability Solutions Ltd

Sanya Mathura is a highly accomplished professional in the field of engineering and reliability, with a proven track record of success in providing solutions to complex problems in various industries. She is currently the Managing Director of Strategic Reliability Solutions Ltd, a leading consulting firm that specializes in helping clients improve their asset reliability and maintenance practices.

Sanya holds a Bachelor's degree in Electrical & Computer Engineering as well as a Masters in Engineering Asset Management from The University of the West Indies and has over 15 years of experience in the industry. She has worked with several well-known companies and has been recognized for her exceptional work in the field of reliability and lubrication engineering. Her expertise in developing and implementing asset management strategies, risk assessments, and root cause analysis has earned her a reputation as a subject matter expert.

As the head of Strategic Reliability Solutions Ltd, Sanya leads a team of highly skilled professionals who provide a wide range of services to clients across various industries, including oil and gas, manufacturing, and transportation. Under her leadership, the company has expanded its services and is now recognized as a leading provider of reliability engineering services in the industry across the globe.

In addition to her work at Strategic Reliability Solutions Ltd, Sanya is an active member of several professional organizations, including the International Council for Machinery Lubrication and writes technical papers for several organizations. She is also a sought-after speaker and has presented at various conferences and seminars on the topics of reliability engineering and lubrication. She is also an avid advocate for women in STEM.

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