by Jeff Walkup, VP Sales & Marketing
As a maintenance and reliability professional focused on used oil analysis and complimentary technologies, one of the most overlooked methods of analysis is simply to observe, inspect and evaluate the material captured within the filter media and determine any abnormal and or advanced metallurgical wear that may be going on. From a forensics aspect, a considerable degree of both contamination and wear can be captured in filters or magnetic screens within a lubricated systems which might never be detected in an oil sample. Thus, it is important to increase the awareness of the extreme value in filter analysis. At first glance, it may not seem sophisticated, sexy, or leading edge, but it is a fundamental time-tested methodology, and quite effective, nonetheless.
Used Oil Filter Analysis
Used oil filter analysis in equipment reliability refers to the “process of analyzing and monitoring the condition of filters used in various industrial and mechanical systems, such as those in hydraulic systems, air filtration systems, and lubrication systems.” This analysis is an essential part of predictive maintenance and reliability engineering.
9 Advantages of Filter Analysis
The advantages of oil filter analysis in equipment reliability, diagnostics, and trouble shooting are certainly valuable. Here’s just a few points that come to mind.
- Early Detection of Contamination: Filters are designed to remove contaminants and particulate matter from fluids (such as oil, hydraulic fluid, or air) to protect critical components and maintain system efficiency. Filter analysis can detect the presence of contaminants before they cause significant damage to equipment, helping prevent costly breakdowns and downtime. Remember that filters are designed and manufactured to catch said anomalies and prevent that contamination from further doing damage within the closed system.
- Improved Equipment Lifespan: By identifying and addressing contamination issues early, filter analysis can extend the lifespan of equipment and components. Contaminants can accelerate wear and tear on critical parts, leading to premature failure. Proper maintenance based on filter analysis results can mitigate this risk.
- Cost Savings: Preventive maintenance and timely replacement of filters can be far more cost-effective than reactive maintenance and major repairs or equipment replacement. Filter analysis helps optimize filter change-out schedules and reduce overall maintenance costs and can assist in pinpointing the wear location and to what extent.
- Enhanced System Efficiency: Clean fluids and air are essential for maintaining the efficiency of mechanical systems. Clogged or dirty filters can lead to reduced system performance and increased energy consumption. Filter analysis ensures filters are changed at the right time, minimizing system downtime and energy waste. Filters that are plugged can and do lead to by-pass.
- Reduced Environmental Impact: Proper filter maintenance helps prevent leaks and spills of contaminated fluids, which can have adverse environmental effects. By ensuring filters are changed or cleaned when necessary, filter analysis contributes to environmentally responsible operations.
- Data-Driven Decision-Making: Filter analysis involves collecting data on filter performance over time. This data can be used to establish trends, identify patterns, and make informed decisions about maintenance schedules and equipment upgrades. You might even find it extremely useful when evaluating your current verses other vendor options at contract renewal or RFP time to compare the capabilities of your current vendor to other options.
- Increased Safety: In some industries, equipment reliability is critical for safety. For example, in aviation, hydraulic systems must operate flawlessly to ensure safe flight. Filter analysis helps maintain the reliability and safety of critical equipment.
- Regulatory Compliance: Many industries are subject to regulations that require regular maintenance and monitoring of equipment, including filtration systems. Filter analysis helps organizations demonstrate compliance with these regulations.
- Better Inventory Management: By analyzing filter performance and predicting replacement needs, organizations can manage filter inventories more efficiently, reducing excess inventory costs and ensuring filters are readily available when needed.
Summary
This short article is not intended to be all inclusive or a “Silver Bullet”; however, in my opinion and experience, used oil filter analysis is a proactive approach to equipment reliability that offers numerous advantages. In this day and age when companies are not looking to spend money, but to save money, a Maintenance Leader and skilled operator values structure and order rather than chaos and shooting from the hip with rash and hasty decisions. At Fluid Life, with our best-in-class sample turnaround times and customer experience, let us help you on implementing a routine filter analysis program. The “Road to Operational Excellence” need not be difficult when you partner with a friend not just a vendor, so let us schedule a time to discuss this and many other value driven solutions.