In previous articles, I have frequently emphasized that proactive approaches are fundamental to creating a successful maintenance strategy. Today, we will explore this concept through Arrhenius Law, formulated by Swedish chemist Svante Arrhenius in the 19th century.
The Arrhenius Law explains how the rate of a chemical reaction varies with temperature, predicting that the reaction rate increases exponentially as the temperature rises.
Arrhenius equation is as follows:
k = A · e^(-Ea/RT)
– k: Reaction rate constant
– A: Pre-exponential factor (a constant that affects the reaction rate)
– Ea: Activation energy (minimum energy required for a chemical reaction)
– R: Universal gas constant
– T: Absolute temperature (Kelvin)
This equation demonstrates how the rate of chemical reactions increases significantly with rising temperature. Specifically, for every 10°C increase, the rate of oil oxidation doubles, effectively halving its lifespan. Oils used in industrial machinery are also subject to oxidation over time and with temperature changes, running temperature checks and conducting regular oil analyses are essential.
As the equipment operates, high temperatures accelerate the deterioration of the oil. This deterioration occurs through a chemical reaction known as oxidation. Oxidation alters the chemical structure of the additives and base oil, causing the oil to lose its protective and lubricating properties.
In this process:
- Carboxylic acids and sediment form,
- Filters become clogged, and oil fluidity deteriorates,
- Excessive wear and even failure of equipment parts occur.
Oil analysis examines the chemical structure and performance of oil to detect issues such as oxidation, metal corrosion, and contamination. These analyses enable proactive measures to maintain equipment health. Understanding the rate at which oil deteriorates due to temperature is directly related to the Arrhenius Law. Data collected through oil analysis includes:
- Oxidation levels: The increase in oxidation products in the oil indicates how temperature affects the oil.
- Viscosity changes: Viscosity can increase or decrease due to oxidation and contamination. According to the Arrhenius Law, rising temperatures accelerate these changes.
- Metal wear: Higher temperatures increase oxidation, which in turn accelerates the wear of metal surfaces. Wear particles found in oil analysis indicate the extent of wear on internal parts.
Proactive maintenance involves predicting failures and optimizing maintenance processes based on data collected during equipment operation. The Arrhenius Law helps predict the rate of oil degradation with temperature, enabling better adjustment of maintenance schedules. As oil temperature rises, maintenance intervals can be shortened to prevent major failures caused by oil degradation.
According to an IBM study, accurate temperature control and fluid analysis can help businesses save up to 20% on annual maintenance costs.* This not only reduces interruptions in the production process but also extends the lifespan of equipment.
The Arrhenius Law helps us understand how temperature affects the rate of oil oxidation, enabling a more informed and proactive approach to equipment maintenance. Oil analysis allows for the early detection of oxidation and wear by monitoring these processes. Consequently, science and data-based approaches enhance business efficiency by extending the lifespan of industrial equipment and reducing maintenance costs. I believe we can achieve failure-free production through the application of scientific principles.
* https://www.ibm.com/topics/predictive-maintenance, https://www.ibm.com/think/topics/generative-ai-for-asset-management
