Resources | Technical Documents

WearCheck Knowledge & Expertise

WearCheck has the benefit of a global network of industry knowledge leaders. The following resources are drawn from hundreds of years of their experience in the oil analysis industry. We hope you find these resources helpful in your understanding of oil analysis and provide you with an oil analysis program of increased value.

Technical Documents
Maintenance Strategies

Diesel Emissions : A Breath of Fresh Air (Part 2)

We continue our discussion around reducing air pollution through stricter diesel engine emission standards and techniques. In this Technical Bulletin - the second of a two part series – we examine the intricacies of appropriate lubricant viscosity as well as the performance criteria of a range of additives and how they contribute to the war against harmful emissions, or not.

Maintenance Strategies

Diesel Emissions : A Breath of Fresh Air

As the world moves to adopt more planet-friendly strategies, air pollution is a key focus area for engine-manufacturers and operators. In this technical bulletin - the first of a two part series - global diesel engine emission standards are discussed, along with a range of techniques that reduce emissions, which ones are most effective, and why.

Maintenance Strategies

Navigating the Online Vibration Analysis Minefield

There is currently a notable spike in online installations in all industries, driven by Industry 4.0. This trend is also evident in the condit ion monitoring field. Installing online vibration transducers is a revolutionary step in the monitoring process but can be challenging without knowing what is available in the market and without a comprehensive understanding of the equipment capabilities and the relevant terminology. In this Technical Bulleting, we will guide you through the minefiled of available technology, discussing the different measuring capacities, installation levels and how these can be aligned with your requirements.

Maintenance Strategies

The Engine Killers

I have a colleague who believes that engines don’t just simply die, they are murdered. A rather dramatic sentiment, I know, but then we take the death of an engine quite seriously at WearCheck. Being an avid consumer of forensics crime drama television series like CSI (Crime Scene Investigation) I feel that I can confidently explain the procedure that takes place once a murder victim has come to the attention of the authorities.

Maintenance Strategies

Reliability, Procurement and Spares Management

Effective asset optimisation plays a key rôle in boosting reliability as well as the efficient management of maintenance costs in any given operation. This Technical Bulletin discusses various scenarios in which maintenance costs can be reduced through improved procurement systems and better management of spares.

Maintenance Strategies

Keep it Clean

In today’s highly competitive global economy, the concept of machine reliability has led many an organisation to make the paradigm shift to proactive maintenance practices that take a holistic approach to asset management and contamination control. This focus on asset management and contamination control has highlighted the important rôle lubricants play in achieving machine reliability. Lubricants are no longer seen as merely consumables, but rather an integral part of a mechanical system having just as much merit as the componentry they lubricate and protect.

Maintenance Strategies

Condition-Based Assessment of On-Load Tap Changers

On-load tap changers (OLTCs) are a crucial element of utility networks, as they must operate in a precise fashion in order to maintain a constant voltage output. This must be achieved regardless of variation on input or load. OLTCs have been a weak link in many networks, as they deteriorate over time due to mechanical problems or contact wear from repeated operation. Erosion of the contacts over time is expected due to the nature of their function. Coking of the contacts causes overheating, which can cause thermal runaway. Regular maintenance is necessary to ensure continued proper functioning.

Maintenance Strategies

Elimination of Poisonous PCB Contamination in Electrical Equipment

PCB (polychlorinated biphenyl) is a highly toxic combination of molecules, which first came into existence in the late 1800s. The prevalence of PCBs mushroomed in the late 1920s as the technical benefits of the chemical compound were recognised and developed. Present day scientists, governments and businesses are tasked with eliminating PCBs as much as possible, due to their harmful, carcinogenic properties.

Maintenance Strategies

CH4 can be Worth so much More (Part 1)

It is said that energy is the blood that runs through the veins of every economy. It is to the survival of an economy what water is to the survival of the human body. Without energy, the wheels of the economy literally do not turn. Energy is consequently a facilitator of economic development and stability. According to the South African department of energy (DoE), energy security within the South African context means ensuring that diverse energy resources, in sustainable quantities and at affordable prices, are available to the South African economy in support of economic development and poverty alleviation, taking into account environmental management requirements.

Maintenance Strategies

CH4 can be Worth so much More (Part 2)

In this final instalment, we will look at what oil analysis can measure in terms of the third function of oil analysis, which is to detect oil degradation. Oil is the lifeblood of any mechanical system and as such has many functions to perform. These functions can be categorised into four fundamental groups: reduction of wear, removal of contaminants, removal of heat and acting as a structural material. All these functions are negatively impacted if the oil physically or chemically degrades.

Maintenance Strategies

Using Oil Analysis to Monitor Your Lubrication Management Program

There is no question that an effective oil analysis program lowers maintenance costs on rotating equipment. The trick is knowing how to run an effective oil analysis program. Companies must be proactive, so that the solution to an oil-related problem is not always an oil change. The real benefit of oil analysis is using the data to steer you towards solutions to eliminate oil issues. Typical Internal Rates of Return (IRR) and Net Present Value over five years (NPV) for a lubrication management program in a medium sized plant are about 150% and $500,000. In this article, I will provide you with best practices for using oil analysis to monitor your lubrication management program.

Maintenance Strategies

World-Class Lubrication Management for Gearboxes

As the saying goes, "an ounce of prevention is worth a pound of cure." When it comes to maintenance of your plant's gearboxes, this is definitely true. By using an industry-leading Lubrigard gearbox adapter kit to perform regular maintenance, a company will save money and time, reduce operating costs and have longer-lasting, more reliable equipment. For an average $600 investment, a company can protect an $80,000 piece of equipment.

Maintenance Strategies

Oil - An Asset, Not a Consumable

The days of "oil is oil" have long gone. It is vitally important that in this day and age, oil needs to be considered as an asset rather than just a consumable, and as an asset, it needs to be managed. This brief paper will take a look at how oils are selected and then managed throughout the plant as a valuable asset like any other piece of industrial equipment.

Maintenance Strategies

The Low-down on Lower Emissions array(Part 1)

The automotive industry in South Africa is largely focused at the moment on lowering vehicle exhaust emissions. This follows a global movement towards more stringent air emission control laws in man’s attempt to slow down the destruction of our planet through global warming. So what is all the hype about? A basic understanding of the fundamentals of global warming in terms of the greenhouse effect is needed in order to understand the advances the automotive industry is implementing to combat dangerous exhaust emissions.

Maintenance Strategies

The Low-down on Lower Emissions array(Part 2)

It was seen in the last Technical Bulletin that, in order to reduce our effect on the environment due to harmful vehicular exhaust emissions, we need to ensure a reduction of the emissions. This is now reality due to the new laws being implemented around the world. So what is being done to ensure this happens and what part do we, as the consumer and concerned citizen, play in all this?

Maintenance Strategies

Clean Oil Saves Money

In our current economic age, companies are forced to pursue every avenue for cost saving to ensure that their chance of financial success is maximised. Lubricated mechanical equipment is a significant cost to many companies and, through careful management, significant savings can be achieved. This technical bulletin looks at particle counting, explains the jargon and technology, and shows you how by monitoring your oil’s cleanliness you can reduce repairs, maintenance costs and downtime and save on your bottom line.

Maintenance Strategies

How to calculate the effect Oil Analysis has on the Bottom Line

Over the last ten years there has been a paradigm shift that has seen maintenance become almost synonymous with achieving reliability. Let"s start by looking at a few definitions.

Maintenance Strategies

The humble sub-form is the linchpin of oil analysis array(Part 1)

In countless articles, seminars, training courses and technical bulletins it has been stressed that there are two main reasons for an oil analysis programme to fail. The first is that the oil sample is not representative of the oil in the system, in other words, the dreaded ‘bad sample’. The second involves information regarding the sample. This can either be wrong or, quite simply, missing. In the majority of cases it is the second reason that causes the most problems, not just in terms of the diagnosis but for data processing and the laboratory.

Maintenance Strategies

The humble sub-form is the linchpin of oil analysis array(Part 2)

This is the second part of the article on how to submit a submission form and what can go wrong if any information is missing or incorrect. This is vitally important considering that 20% of all samples are submitted to Wearcheck with incorrect or insufficient details, causing costly delays and hampering accurate diagnosis. An example of a submission form appears on page 3.

Maintenance Strategies

Keep your cool array(Managing Cooling Systems)

During operation, all internal combustion engines produce heat as a by-product of combustion. The temperature of burning fuel can reach 2000°C. However, only about 33% of this is transferred into power through the crankshaft. Approximately 30% is expelled through the exhaust whilst another 7% or so is lost through radiation. The remaining 30% must be dissipated through a cooling system. In addition to removing heat from burnt fuel, the cooling system also removes heat from other sources such as turbochargers, torque converters and hydraulic or transmission oil coolers.

Maintenance Strategies

The Perils, Pitfalls and Perks of extending oil drain periods

The extension of oil drain periods has long been an area of debate. There are many benefits to be obtained from extending oil drain periods and doing so is a legal requirement in certain countries around the world. These benefits are just as applicable to South Africa but it would be foolish to try to apply parameters recommended for European, Japanese or North American conditions (the source of most diesel engine technology) to this country.

Maintenance Strategies

Clean up your act

It is widely accepted that oil contamination is the one of the major causes of component failure. When practising proactive maintenance it therefore makes sense to give oil cleanliness a high priority. This technical bulletin will deal primarily with particulate contamination, the causes, and how to avoid it. By maintaining a high level of oil cleanliness, machinery failure, resultant downtime and expensive repair costs can be kept to a minimum.

Maintenance Strategies

Implementing Reliability-Centered Maintenance (RCM)

Using RCM to develop an initial maintenance program for new equipment as well as scheduled maintenance for existing plant, involves a structured decision-making process based on the consequences of functional failure of this equipment. RCM analysis produces a program which includes all scheduled tasks - and only those tasks - necessary to ensure safety and operating economy. The decision-making logic behind RCM analysis applies to any complex equipment which requires a maintenance support program aimed at maximizing operating reliability at the lowest cost.

Maintenance Strategies

Condition-Monitoring, Oil Analysis & More

In this day and age, predictive maintenance and condition monitoring are necessities for any company that has machinery which is critical in achieving production goals. Oil analysis is a condition monitoring technique that has been in use for more than 50 years and has proved to be a highly effective management tool for monitoring the health of lubricated machinery and the lubricants themselves. However, oil analysis is not the only condition monitoring technique available to today"s maintenance professional. Other techniques such as vibration monitoring, thermography and ultra-sonic analysis can also be used. This Technical Bulletin will look at the evolution of maintenance philosophies, the goals of a condition monitoring programme and how a combination of different analytical practices can be used to achieve these goals.

Maintenance Strategies

Reliability-Centered Maintenance

Maintenance philosophies and practices have been around for many years - the objective of these philosophies being the economic consideration of optimizing plant availability in industry. There has been a steady evolution from breakdown maintenance to predictive maintenance to proactive maintenance in the quest to keep industrial equipment operating economically, efficiently and safely.

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