Program Enrichment Review: It’s Not Just Data, It’s What You Do With It

Today’s fluid analysis capabilities offer a great deal more than just monitoring component health. With today’s technology, along with performing the proper tests, we can:

  • Monitor the condition of the oil
  • See if it is suitable for continued use
  • Reduce the amount of used oil disposal
  • Adjust maintenance intervals and strategies
  • Adjust component replacement schedules
  • Improve forecasting and budgeting
  • Increase component life hours

With all of this in mind, it begs the question, how can we be sure to maximize the return on investment from fluid analysis?  I believe the answer to this question is a Program Enrichment Review. Let’s take a look at some of the features/benefits of a Program Enrichment Review and what it can do with your data:

Pareto Principle

A “Pareto Principle” approach identifies the components that are contributing to the majority of high severity reports and helps identify corrective actions for your maintenance team. Let me share with you how POLARIS Laboratories® was able to use this principle to help a coal mining customer (see figure 1 below).  Using Pareto Charts, POLARIS Laboratories® was able to determine that out of the 87 component types on file, only 11 component types were accounting for 80% of the high severity (3’s & 4’s) reports. By using additional Pareto Charts (not shown), POLARIS Laboratories® was able to identify the coal mine’s biggest problem was abrasive contaminants (ie. coal dust, dirt, etc.). By focusing the maintenance team’s efforts on these 11 component types, and using filter carts, kidney loop filtering, seal replacement, etc., the coal mine was able to address the abrasive contaminants issue and thereby realize a 6% reduction high severity reports over a 6 month period.  The head of the maintenance team made the following statement about their fluid analysis program: “Guys, where can we spend a dollar today and get this kind of return on investment when it comes to protecting our equipment and extending its life cycle?”

Figure 1

Typical Data Shared in a Program Enrichment Review

  • Sample volume (i.e. total number of samples submitted per quarter)
  • High severity reports (severity 3’s & 4’s / scale of 0-4) by region, location, asset, etc.
  • Identify issues via Pareto charts (i.e. 80% of the effects come from 20% of the causes)
  • Scatter plots – help determine optimum drain intervals via key performance indicators (e.g. viscosity, acid number, base number, oxidation, fuel dilution, soot loading, etc.)
  • HORIZON® web-based management reports (e.g. Problem Summary Report, Severity Summary Report, Data Analysis Report, Action Taken Summary Report – ROI, etc.)
  • Scorecards (i.e. Component Compliance, Sampling Frequency Compliance, High Severity %, Shipping Time, etc.)
  • Technical Business Consultant’s subject matter expertise (i.e. observations & recommendations)

Quarterly Program Enrichment Reviews

Delivering the Program Enrichment Review via a quarterly virtual meeting with the customer’s “Program Champion” and maintenance team will serve as a venue to share both challenges and best practices associated with their fluid analysis program and maintenance “best practices”.

It’s Not Just Data, It’s What You Do With It!

Maximize asset reliability and regain control of your production schedules with an effective fluid analysis program by POLARIS Laboratories® . . . it costs so little to protect so much.

Proven Impact. Proven Uptime. Proven Savings.
Let us prove it to you.

Published September 22, 2020

How to Stay Afloat: Tips to Increase the Value of Your Fluid Analysis Program

A properly executed oil analysis program delivers operational cost savings while increasing component life and reducing time between scheduled and unscheduled equipment overhauls. An oil analysis program can also address safety concerns and minimize risk to personnel and assets.

The goal of an oil analysis program is to become more proactive, less reactionary and to conduct maintenance and repairs at a lower level of intervention. Such practices can reduce labor costs, spare parts and oil consumption. In turn, this decreases urgent demands on the supply chain to replenish lubricating oil or spare parts.

Oil Analysis + Planned Maintenance

Linking the right oil analysis program with the right planned maintenance program will allow you to generate better work orders based on precise oil analysis conditions and laboratory recommendations. This will lead to improved maintenance actions and more accuracy in spare parts purchase orders and lubrication inventory.

Moving to a steady state where planned maintenance is associated with an oil analysis program across multiple ships reduces the pressure and stress on engineering staff. Data collection across multiple vessels and across like-for-like equipment creates a view of what’s happening now and what happened in the past. This insight especially the past conditions, is useful in forming a plan to reduce or even eliminate certain recurring oil conditions.

It Starts with Ownership

A successful oil analysis program begins with everyone involved in the program taking ownership. From the engineer taking samples, to other engineering team members carrying out appropriate, timely maintenance actions. Knowing where in the system to sample, and sampling consistently each time from the designated sample point under the same operating conditions, is crucial to program success.

Create a Feedback Loop

Maintaining a constant, positive approach to your oil analysis program will reward you with a measurable return on your oil analysis program investment. In time, this will serve as a feedback loop for program self-improvement and increased equipment reliability.

Proven Impact. Proven Uptime. Proven Savings.
Let us prove it to you.

Published September 10, 2020

Do You Have the Right Coolant Testing?

Providing a Greater Understanding

Do you have an extended life coolant? Did you know that mechanical and/or contamination can occur causing the extended life coolant properties to decrease and reduce the life of the fluid? Have you ever had an unknown coolant formulation in the cooling system and a coolant top off was needed? Including High Pressure Liquid Chromatography (HPLC) testing to your program will provide the additional information to assist with providing a greater understanding of your fluid properties. When HPLC testing is included in your coolant test package, additional coolant inhibitors that may be in the coolant formulation will be monitored. Results for the inhibitors will be reported in parts per million.

What is High Pressure Liquid Chromatography (HPLC) Testing?

HPLC testing will report two different inhibitor types:

  1. Carboxylic organic acids
    • These acids will be utilized in extended life coolant formulations and hybrid formulations. The inhibitors will provide corrosion protection of the metals in the cooling system. The corrosion protection inhibitors needed for your application and formulation must be maintained and adequate to protect your cooling system.
    • There are a lot of different organic acids that may be used in the coolant formulation. Understanding the coolant formulation is a key factor in maintaining the coolant appropriately.
    • Carboxylic organic acids our method reports:
      • Benzoic Acid
      • Sebacic Acid
      • 2-Ethylhexanoic Acid
      • Octanoic Acid
      • P-Toluic Acid
      • Adipic Acid
      • 4-Tert-Butylbenzoic Acid
  2. Azoles
    • Azoles may be utilized in any coolant formulation on the market. Azole inhibitors are for copper and brass protection in the coolant formulation.
    • Azoles our method reports:
      • Benzotriazole (BZT)
      • Tolytriazole (TTZ)
      • Mercaptobenzothiazole (MBT)

HPLC Compared To Test Strip

HPLC testing will provide more insight of the type of inhibitors in the coolant formulation compared to a pass/fail carboxylic acid test strip. Test strips are subjective as a color determination is usually the indicator for the result. Test strips will only work for certain coolant formulations determined by what the test strip is looking for. Whereas HPLC testing can be performed on any coolant formulation and report each of the organic acids and azoles the method is able to report in ppm. The HPLC testing will indicate concerns of mixing coolant formulations when compared to a baseline. HPLC testing will also help determine if carboxylic organic acids and azoles are utilized in the coolant formulation or not. A test strip will not be able to provide this information and may or may not be applicable for the coolant formulation providing an inaccurate result making more difficult to maintain your fluid appropriately.

Reach out today! Add High Pressure Liquid Chromatography testing to your program.

Including HPLC testing to your program will provide testing to determine if organic acids and azole inhibitors, utilized in some coolant formulations, are being maintained for proper protection.
HPLC testing will provide more insight on how to maintain the coolant formulation and will determine if concerns are present impacting your corrosion protection inhibitors. Catching concerns early and making corrections will lower corrosion concerns and even possible cooling system issues that could have led to engine problems.

Check out our Technical Bulletin to find out more information on how High Pressure Liquid Chromatography (HPLC) Testing works:

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Proven Impact. Proven Uptime. Proven Savings.
Let us prove it to you.

Published September 8, 2020