SGS is one of the world’s leading inspection, verification, testing and certification companies. With its more than 90,000 employees within a network of more than 2,000 offices and laboratories around the world, SGS told us how they make the oil analyses, the importance of tests, the meaning of reports and the techniques they use. We made a highly informative and comprehensive interview with Belkız Engin, SGS Turkey Oil, Gas and Chemicals Laboratory Manager.
Mrs. Engin, please briefly introduce us the Used Oil Analysis Laboratory of SGS. Which services do you provide at your laboratory?
As SGS Vernolab Turkey, we offer solutions to our customers in Turkey and abroad in terms of used oil sample analysis within the scope of predictive maintenance services since 2010. Since our establishment, the sample tracking software that we use, the devices and methods to make quick analyses with samples in little quantities, and our competent chemist analyst staff enable us to provide services with optimum liabilities. Result assessment services that we offer with the lubricant analysis services, regardless of the type, brand/model of the lubricant, are provided by a staff of specialist engineers at the France unit which have more than 43 years of experience.
What is predictive maintenance?
Predictive maintenance is a type of maintenance that detects the malfunctions in machine parts via various methods such as vibration analysis, used oil analysis and heat analysis, and prevents any breakdown before they occur.
What is the purpose of used oil sample analyses within the scope of predictive maintenance?
Although not sufficiently known and regarded in the country, used oil analyses are a type of service which is considered as an additional cost at first or believed to be carried out only to check the status of the lubricant being used. However, such analyses are carried out to review the current status and health of the entire system in which the lubricant is used and to prevent any unexpected and potential costs. The persons and businesses which are aware of this fact liken the used oil analyses to “blood tests”; which is the most straight-forward, short and explanatory description of these tests.
What are the advantages of predictive maintenance for companies?
Predictive maintenance either minimizes or fully eliminates down time, extends the service life, and decreases maintenance costs. It helps lower the electricity consumption as inefficient machines consume more electricity. It ensures consistency in product quality, and more importantly, reduces the unnecessary labor and material expenditures by guiding reparation and maintenance works. It plays a key role in mainstreaming total productive maintenance in all operations.
How do you take and send the samples? What are the key sampling considerations to be able to achieve the most accurate result?
Accuracy of the analyses and quality of the assessment depend on the representability of the sample taken. In this regard, the points that must be considered on sampling are as follows:
Sampling from vehicles
- Oil sampling should be carried out from a warm engine.
- In order to get accurate results, the oil should have been used in the engine for a sufficient period (2500 km or 50 hours).
- Do not take samples from the filter.
- When the oil is changed, through the sump drain plug, after having left 1 or 2 liters flow.
- Sampling can be made with a syringe or a pump and a plastic tube through the dipstick. In the latter case, the tube should be replaced for each new sample.
Sampling from industrial machines
- Oil sampling should be carried out on a system or requirement in operation.
- In order to get accurate results, the oil should have been used in the machine for a sufficient period (minimum 250 hours).
- In any case, it is very important that each sample from a machine is taken under similar conditions (temperature, sampling point).
- Do not take samples from the filter or from the bottom of the tank.
- Sampling can be made through special sampling plugs.
- Sampling can be made with a syringe or a pump and a plastic tube. In the latter case, the tube should be replaced for each new sample.
As SGS Vernolab Turkey, we not only provide support services for sampling with our professional staff but also organize seminar programs for the personnel of our customers. We provide all necessary equipment and supportive materials for sampling from the initial phase of taking samples to the process of delivering them under favorable conditions.
What is the purpose of used oil analyses?
Used oil analyses are designed to detect the changes in the concentration of metals accumulated in lubricants and other deposits, and to provide early warning about potential problems in your machines. Analysis of used lubricants, greases and hydraulic liquids is a great source of fast and accurate information about the status of your electricity generator, gear cases, compressors, hydraulic systems and other critical machines, and also reveals significant details about the status of the lubricant. Effective control of the lubricant enables you to make prior effective planning for maintenance of expensive equipment so as to prevent breakdown risks and unexpected problems. SGS Dilovası Vernolab Laboratories bring together the high technology for the analysis of lubricants, greases and hydraulic liquids with its expert chemists who conduct the analyses, and the engineers who provide assessment services. Physical and chemical properties of the product are examined, and detailed information is collected about the status of the equipment and the oil. Assessment of analysis results is important for obtaining the necessary data to see if your machines are efficiently working and if there is a need for corrective measures to prevent significant problems before they occur.
Mainly our tests for analyzing used lubricants are: Viscosity, ICP – Element analysis, Water Amount, Color Determination, Density Determination, Freezing Point, Pour Point, Flash Point (for diesel engine oils), Total Acid and Base Number, Particle Number, FTIR (Fourier Transform Infrared Spectroscopy) Test, Air Release, MPC (Varnish Potential), Ruler (Remaining Useful Life of Oil), Anti-Rusting, pH and i-pH, insoluble in n-Pentan and n-Heptan, Conductivity (Cutting Oils), Concentration (Cutting Oils), Bacteria Test (Cutting Oils), Rust and Corrosion Test (Cutting Oils).
Moreover, we can offer solutions to our customers for the product and test types that are needed here but not included in the portfolio provided by Vernolab Turkey by getting support from other Vernolab Laboratories abroad.
How do you prepare the analysis reports? How should we read these reports?
As SGS; we deliver the analysis reports within 5 working days at the latest following the completion of the required procedures and tests for the lubricant samples that arrive at our laboratory. Depending on the structure of some tests, the delivery time may get a little longer. When the analyses are completed, reports that show the analysis results in numbers and graphs, and reports that show the interpretation of the assessment with traffic light images are prepared. Meaning of traffic light images are:
- Green – everything is okay.
- Yellow – there may be a problem that requires a certain action.
- Red – the equipment needs immediate action for maintenance.
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What are the benefits of all these analyses for the companies?
SGS is aware of the fact that data quality, efficiency and saving is highly important for laboratory management and operation. Vernolab Used Oil Analysis Laboratory provides your maintenance department with precious information collected from the analyses. We know how important regular tests are and how they can maximize the useful life of your lubricant and machines. Analysis results give raw data about the status of your lubricant. To be able to make a correct diagnosis for the status of the machine, the results must be interpreted by taking into consideration the type of the machine, operating conditions and environment. Our experts have the capacity to detect the source of wearing parts and deposits by reading the results, and to determine the potential impacts of these on your equipment. They give you care and maintenance recommendations on the basis of this data.
