Analysis of hydraulic fluids, if done properly, can suggest maintenance procedures to improve hydraulic equipment reliability and extend system life. Significant cost savings can result. Where to take a sample There are two types of fluid sampling: static and dynamic. Static sampling involves extracting a fluid sample from a reservoir or a dead zone, where there is slight fluid movement. Little useful information is gained from static sampling because: • contaminant concentration gradients exist within static fluids. Water and particles tend to segregate and settle due to gravity. Therefore, samples taken from different sections within the static container yield completely different results, and • particles from reservoirs may describe system histories, but provide little information on what is happening now. Large reservoir volumes dampen out dynamic changes and conditions within the system.

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Optical particle counters (OPC’s) have a long history of use in industrial hydraulic applications. Traditionally, their success has been limited to scientific laboratories and other highly controlled environments. However, in recent years, attempts have been made to apply the use of OPC’s to the particle counting of used hydraulic fluids and industrial lubricants. As a result, serious concerns have been raised regarding the accuracy and reliability of OPC’s in such applications. The objective of this bulletin is to present important facts from reliable and documented sources for the general benefit of existing or prospective users of OPC’s. As particle counting moves into the mainstream of machine condition monitoring, users must have reliable information to identify and select appropriate technologies.

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The term “oil analysis” has been used with respect to lubrication and machine reliability since the 19th century. Yet, over the years I have seen only a few attempts to assign a specific definition to the activity despite its widespread application in industry. Most of these definitions are too narrow or fail to include important integral activities such as machine wear monitoring and fault detection.

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The field of maintenance technology is going through a revolution of change. Gone are the days when a machine had a predictable service life, after which it was replaced, continuing the cycle. Today, machinery and equipment can be maintained to achieve useful operating lives many times that attainable just a few years ago.

Historically we’ve relied on the popular practice of predictive maintenance and condition monitoring to combat rising maintenance costs. Today we implement predictive maintenance with greater confidence and precision. These early warnings have proven effective at reducing the magnitude of failure and amount of unscheduled downtime; however, no real progress has been made in reducing frequency. Any maintenance strategy targeting the reduction of failure frequency must address lhe fundamental causes of failure. Such a strategy of eliminating causes would be “proactive” to failure, not “reactive” to failure.

This approach, known as proactive maintenance, is the latest and most promising wave of new maintenance technology. Its fundamental and logical approach seems likely to gamer deeply entrenched inroads into the cost-driven maintenance industry this decade. Case studies documenting cost reductions exceeding 90% have provided a solid lead for others to follow seeking similar savings.

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This was one of those defining moments. It was some surprising insight on where maintenance and reliability professionals are in the journey to lubrication excellence.

I received a phone call from a stranger who introduced himself as a maintenance manager of a large steel mill. He told me he was preparing to teach a group of lube techs about how and when to perform an oil change on mill machinery. However, he first wanted my advice.

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