We at Techenomics really value our customers and are constantly striving to provide the best service and solution to any problem.

It is with this in mind that five years ago we decided to purchase a service vehicle, a five tonne 4WD Mitsubishi tray truck that we could equip to provide lubricating services on site in the Hunter Valley region including at Mount Arthur Coal and Glennies Creek mine. We call this truck an OnSpec Services truck and we believe it could be used in many other areas of the mining industry.

Our OnSpec Services truck pumps its range of ONSPEC lubricants 24/7 and also delivers directly onto equipment in the pits. The truck is flexible and has the capacity to access most areas on mine sites on a daily basis, during both normal and extreme weather conditions. It can quickly and accurately dispense lubricants and avoid the contamination issues normally faced.

To modify the truck to ensure it operated perfectly, engineers modified the tray to fit two 700kg product storage tanks with air driven pumps powered by the vehicle. Filtration units from the company were installed to carry and dispense lubricants from fluid bags, drums or intermediate bulk containers.

Our OnSpec Services truck has been a successful tool for many clients in the Hunter Valley region, being used at brambles for bulk filling of grease tanks at Glennies Creek mine and at Mount Arthur Coal, and will continue to provide lubricating services for many years to come.

Darrin Garland, OIC, Techenomics based at the Mt. Arthur site.

We are the experts, so please contact Darrin Garland to solve all your lubricant pumping issues:

E-mail: d.garland@techenomics.com

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For further information please contact Darrin Garland, email: d.garland@techenomics.com

or visit www.techenomics.net

For media enquiries please contact Brooke Tolar, DragonFly Public Relations on T: 0411 553 246 or e-mail: brooke@dragonflypr.com.au

Routine Oil Analysis carried out on equipment can provide maintenance personnel with the ability to improve availability rates on equipment, lower downtime and most importantly save companies extraordinary amounts of money that could be used on other maintenance requirements.

Background

In today’s manufacturing design process, enormous efforts are placed on producing cleaner emissions by having tighter, more precise engine tolerances, this creates extra horsepower and extended mileage on fuel and oil. These stringent guidelines and standards were introduced by governments and associated companies to ensure air pollution, fuel and oil usage would be reduced over time.

The necessity on such tolerances have placed enormous pressure on producing cleaner fuels and oils throughout the globe. Oil Manufacturers now have to ensure their products reach and meet a cleanliness standard, this can only be done by using Oil Analysis.

Equipment Manufacturers establish base line limits for each piece of equipment that are released for production. This is done by having scheduled samples taken on numerous equipment around the world and having the data sent back to the Equipment Manufacturers for analysis trending. After enough data sets have been achieved and a mathematical trend can be established, this information is then released as the OEM Limits for that equipment. Data sets that contain water, abnormal silicon results, fuel contamination and a few other sequences are discarded from the analysis trend to ensure a more accurate and repeatable result can be obtained.

Large companies that employ maintenance engineers to provide proactive and preventative maintenance strategies, trend and graph availability rates and produce downtime reports to senior management, these maintenance engineers have already done the hard yards and analytical background work to measure the cost effectiveness of an Oil Analysis program.

How money is saved

An example of costs savings on a single engine is as follows; say you spent $80,000 on parts or an engine replacement, an average oil sample cost you about $30 per sample, equipment usually gets sampled once a month, so you could sample that engine just over 222 times (18½ years) to equal that amount of money spent on the parts or engine replacement that may be needed. Based on this you can safely say, that Oil Analysis could have prevented or reduced the cost of the part or replacement within the 18½ years.

For example, Techenomics Australia sees anywhere from 3000 to 5000 samples per month that are indicating potential catastrophic failure and call for the piece of equipment to be withdrawn from operations and repaired immediately. A catastrophic failure will result in lost productivity, major inconvenience and unplanned costs of a failure as opposed to a planned service event to repair a failing component.

Across the range if only 10% of these potential failures are “saves” then that could amount to about a saving of $30 million. The cost of the analysis is about 0.1 cent per dollar of saving.

Conclusion

One thing is certain, Oil Analysis will find faults within the oil, whether it be wear, contamination, additive breakdown, acid or carbon build-up, viscosity or TBN loss. These are fundamental elements that need to be monitored constantly, they will need to be addressed whenever a change indicates a potential breakdown or failure of the lubricant or an internal component.

A well-established proactive and preventative maintenance program can save companies thousands on the bottom line. By being proactive and ensuring that lubricants and fuels are clean and fall within the standards, equipment components will last longer, reduce fuel and lubricant consumption, and overall, live a longer healthier life.

Oil Analysis can also provide insight information into the lubricants breakdown, possibly even identify other key indicators of the failure that if sampled and picked up earlier, may have prevented this failure from occurring.

Techenomics International is a lubrication and condition monitoring specialist, with over twenty years of experience, offering preventative maintenance tools, including Oil Analysis, to the mining industry and helping companies save millions.

Techenomics operates throughout Australia, Asia, Mongolia and Madagascar. Condition monitoring services include oil analysis, magnetic plug inspections, lubrication and filtration solutions for fixed and mobile plant, all of which will significantly extend the life of equipment, lower unscheduled downtime and most importantly decrease operating costs.

For further information and all enquiries please contact Sam, Email: sreejith.b@techenomics.com

For those in Indonesia and SE Asia contact Freddy, Email:  freddy@techenomics.com

For those in Northern Asia, Mongolia and Russia contact Sugraa, Email: sugraa@techenomics.com

For those in Turkey, the Middle East and Northern Africa contact Yasemin, Email: yasemin.fadil@techenomics.com

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For media enquiries please contact Brooke Tolar, DragonFly Public Relations on T: 0411 553 246 or

E-mail: brooke@dragonflypr.com.au

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For further information please contact Freddy Tamara, email: freddy@techenomics.com or visit www.techenomics.net

For media enquiries please contact Brooke Tolar, DragonFly Public Relations on T: 0411 553 246 or e-mail: brooke@dragonflypr.com.au

A new page was created on the website, http://www.techenomics.net/buy-oil-analysis-sample-kits-online.html making it easy for customers to purchase kits via a secure paypal / credit card payment option.

“Previously customers could only purchase oil analysis kits via a purchase order or by paying cash at the laboratory in Newcastle and with the demand for these kits so high, we wanted to make the purchasing of them easier, so came up with the idea to create a secure online ordering page”. Said Chris Adsett,Executive Director of Techenomics.

Customers are able to purchase Oil Sample Analysis Kits, Dielectric Analysis Kits, Aluminium Oil Sample Extraction Pump and a Brass Oil Sample Extraction Pump.

The online ordering is only for Australian customers with allshipping or postage costs free to anywhere within Australia. For customers outside Australia who wish to purchase the oil analysis kits, they can contact Siti at siti@techenomics.com.

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For further information please contact Sam, email: sreejith.b@techenomics.com

or visit www.techenomics.net

For media enquiries please contact Brooke Tolar, DragonFly Public Relations on T: 0411 553 246 or e-mail: brooke@dragonflypr.com.au

“We have for a long time now established ourselves in the rail sector. We deliver Condition Monitoring services for 200 locomotives particularly Engine, Compressors and Traction Motors.” Explains Chris Adsett, Executive Director of Techenomics.

Techenomics also have conducted research over the past 10 years to establish trends based on the collection of data, to correlate various analysis results.

“We have done ample research into Viscosity vs Fuel Dilution, so we can correctly identify when a locomotive is in critical condition, we have also developed a ferrography technique which identify’s contamination and wear debris.” Says Mr Adsett.

The Viscosity vs. Fuel Dilution research was conducted to establish an effective trend for oil analysis data against OEM guidelines. The purpose of the research was to identify how oil viscosity drops on each fuel dilution percentage for virgin and used oil samples, so as to develop a trending graph.

The below graph demonstrates how Viscosity vs. Fuel Dilution generates a platform for identifying Locos in critical condition.

To identify abnormal levels of contamination and wear debris so that corrective actions can be scheduled accordingly, Techenomics is also using the research to successfully introduce Ferrography, a condition monitoring technique, in Locomotives. Aligned in-relation to spectrometric results and PQ value to better interpret the source of wear generation, the test is a microscopic analysis of oil samples to identify the wear modes and sizes.

“We are always looking at ways that we can provide a better service for our clients and being able to use Ferrography in Locomotives, in conjunction with routine Oil Analysis, will provide a better insight into wear generation in return to oil analysis dollars.

Ferrography also provides microscopic examination and analysis of wear particles for all types of lubricant fluids and greases regardless of its size, whereas spectrometers, which we currently use, do have a limitation of identifying wear particle < 8 microns.” Explains Mr Adsett.

The diagrams below illustrate how Ferrography provides Early Warning for Main Bearing Failure in Diesel Engine of Locomotive

For further information please contact Sam, email: sreejith.b@techenomics.com
or visit www.techenomics.net
For media enquiries please contact Brooke Tolar, DragonFly Public Relations on T: 0411 553 246 or e-mail: brooke@dragonflypr.com.au

Transformer oil analysis, which Techenomics believes is an essential part of maintenance services, is offered by the company alongside oil analysis, magnetic plug inspections, and lubrication and filtration solutions to fixed and mobile plants. These maintenance services offered can significantly extend the life of equipment, lower unscheduled downtime and most importantly decrease costs.

Image 1 – Dielectric tester                                   Image 2 – Lab technician testing transformer oil

“Techenomics is always striving to offer our customers the best possible maintenance services to help them save money and Transformer Oil Analysis is part of this service.” Explains Chris Adsett, Executive Director of Techenomics.
“This testing is applicable to all industries where the use of transformers exists, including the Mining Industries, Power Plants, Sub stations and Waste treatment Plants.” Adds Mr. Adsett.

The dielectric strength of transformer oil is defined as the maximum voltage that can be applied across the fluid without electrical breakdown. Because transformer oils are designed to provide electrical insulation under high electrical fields, any significant reduction in the dielectric strength may indicate that the oil is no longer capable of performing this vital function.

Factors that can result in a reduction in dielectric strength include polar contaminants, such as water, oil degradation by-products and cellulose paper breakdown.

Continuous monitoring of Transformer Oil Analysis has numerous benefits for companies as it enables them to identify the point at which oil drops its dielectric strength thereby taking immediate action on that particular piece of equipment. If unnoticed it may result in the transformer heating up, short circuiting and finally exploding costing companies hundreds of thousands of dollars.

Other benefits is that the analysis of insulating oils not only provides information about the oil, but also enables the detection of other possible problems, including contact arcing, aging insulating paper and other latent faults and is an indispensable part of a cost-efficient electrical maintenance program.

Dielectric Constant is an indicator of oil quality. Changes in the dielectric constant of used oil from the new oil are an indication of the presence of contaminants, such as water or particles, additive depletion or oxidation.

Techenomics offer the standard test package which tests for Dielectric strength via the IEC 156 method, total acid number via the ASTM D 974 method, Water content via the ASTM D 6304 and Flash point via the ASTM D 93 method.
Techenomics has performed Transformer Oil analysis for a major client in NSW, for the past few years.

Highlighted below is a report for this client highlighting the benefits of Transformer Oil Analysis.

As is indicated in the report, the continuous monitoring of the transformer oil enabled Techenomics to identify the point at which the oil dropped its dielectric strength. When the client was made aware of this, they then took immediate action to rectify the problem for that piece of equipment. If the drop in the oils dielectric strength went unnoticed it may have resulted in the heating up of the transformer, as the oil has lost its insulating property, and ended up in a short circuit. The transformer would have then exploded costing the company hundreds of thousands of dollars.

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For further information please contact Sam, email: sreejith.b@techenomics.com or visit www.techenomics.net

For media enquiries please contact Brooke Tolar on T: 0411 553 246 or e-mail: brooke@dragonflypr.com.au

The laboratory is now capable of testing, lubricants, greases, transformer oils, coolant and fuel. By the recent addition of an Atomic Emission Spectrometer we are now able to process up to 5000 samples per month operating to ISO 17025 standards.

I look forward to showing you around our laboratory and answering your queries with respect to our capabilities and discussing your condition monitoring requirements”

Sugarkhorloo E. Marketing Manager, Mongolia.

In a presentation focused on the sophisticated Oil Analysis services offered by Techenomics Mongolia to the burgeoning mining sector, Mr Adsett outlined some important factors -

•  extended machinery life,
• lower downtime, and
• reduced failure rates of machinery,

when Techenomics Oil Analysis and condition monitoring is performed on a regular basis.

Mr Adsett also emphasised that oil cleanliness and/or contamination control is a major contributor to prolonging component life and hence cost reduction and increased equipment availability.
Monitoring the cleanliness of virgin lubricants is a vital aspect of any condition monitoring and oil analysis programme.
The life of hydraulic systems can be extended 3 or 4 times through careful management of oil cleanliness.

Techenomics  can advise on both a contamination control programme and manage a programme to assist with keeping the oils clean.

Click on the image below to see the presentation.

Foam is a collection of small bubbles of air that accumulate on or near the surface of the fluid. Foam is an efficient thermal insulator, so the temperature of the oil can become difficult to control. The presence of air bubbles in the fluid can lead to excessive oxidation, cavitation, and the reduction of lubricating properties of the oil and hydraulics system failure.

The causes of foaming are many, but the most common include water contamination, solids contamination, mechanical issues (causing excessive aeration of the fluid), cross contamination of the fluid with the wrong lubricant, contamination of the fluid with grease and too much antifoam additive, either by incorrect formulation or by incorrect reconstruction of the additive package.

Many companies have a problem with foaming in Hydraulic Oil and consequently regularly filter their hydraulic oil to extend lubricant life.

After discovering a lot of their clients were doing just this, Techenomics Indonesia decided to carry out testing to show how to control foaming and to see if aggressive filtration affects foaming tendencies.

Six clients took part in the testing including Hexindo, Pama, Thiess, SIS, Madhani and Liebher.

The following graphs show the impact of topping up with extra oil when the oil is out of spec.

Results show that a 20% top up can reduce the foaming tendency to 87.5% (normal limit).

Future results of this study and subsequent research will be grouped according to:

1. Unit
2. Oil type
3. Oil hours
4. Normal operation condition

This grouping is done to classify the top up and so far the results vary, most likely  caused by:

1. Different units of large capacity and small capacity, which affects the load.
2. Type of oil, the additive composition of the various brands is very influential on the oil resistance.
3. Oil hours, use of long-term and short term will have a different impact on the performance of existing  additive in oil.
4. Abnormal operation conditions, over-heating, over-load, seal leaks and other.

Overall, testing shows that levels of foaming in lubricants can be controlled by regular top up. This minimises the volume of oil consumption as complete oil changes can be reduced and ultimately reduces the cost of operations as equipment availability is also improved.

The work showed that even with aggressive filtration top ups can balance the foaming tendencies. Due to the wide variance of results it is recommended that testing for foaming tendency, especially if secondary filtration is being used, should be carried out routinely.

These results will provide information for customers to understand the importance of testing foaming tendencies so as to provide good information for a quality maintenance programme and reduce the risks associated with excessive foaming in hydraulic systems and gearboxes.

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For further information please contact Eka Kamila on e-mail: eka@techenomics.com or visit www.techenomics.net

For media enquiries please contact Brooke Tolar, DragonFly Public Relations on T: 0411 553 246 or e-mail: brooke@dragonflypr.com.au

Techenomics PNG has acquired new business, recently winning the contract to provide a full condition monitoring service to the Simberi gold mine in PNG owned by St. Barbara.

“We have been working with a number of organisations in PNG for some time and this new opportunity fits perfectly with our longer term aim to expand our global reach for our oil analysis services.

We are looking forward to working with the St. Barbara team assisting them in developing a maintenance management structure that will minimise their costs and maximise their equipment and over time we will expand the available services to include specialty lubricants and field services” explains Chris Adsett, Executive Director of Techenomics.

The contract includes used oil sample analysis, fresh oil sample analysis, grease analysis, coolant analysis, fuel analysis, supplying of sample kits (warehouse stock item), oil test results trending online (via Blue Ocean software program), equipment life hours trending online (via Blue Ocean software program), oil test history online (via Blue Ocean software program), on line reporting (via Blue Ocean software program) and nominated CM personnel will be given access to Techenomics Blue Ocean software program via their webpage.

2012 saw Techenomics open their first laboratory in Mongolia and in 2013 they can now offer the widest range of condition monitoring testing available in Mongolia from any other service provider.

A superior local and worldwide technical support team led by Francisco Bernabe, Andaru Gusnawan and Anuu Mandul has also been put together and the laboratory is now well poised to provide a very complete, broad and extensive condition monitoring service to all industrial segments in Mongolia, especially the mining industry.

“I’m proud of the progress that has been made in Mongolia and the strong relationship that we have established with virtually all of the substantial miners. As of this week we can now do about 5000 oil analysis samples per month, coolant analysis, grease analysis, fuel analysis and transformer oil analysis, which is a major achievement for the company” says Mr Adsett.

Further expanding their horizons, Techenomics showed their versatility by completing their first coal seam gas project in Tanzania, East Africa and although no gas was discovered the project for NuEnergy was considered a huge success as explained by NuEnergy Chairman Dave Mason.

“NuEnergy didn’t achieve the results we were looking for, however the field program went smoothly and the AAA and IEC personnel involved were able to learn something about the gas collection and testing procedures.”

Going forward Techenomics are looking to add gas testing to their Indonesian operations and to monitor closely the opportunities in East Africa.

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For further information please contact Chris Adsett, Executive Director, email: c.adsett@techenomics.com or visit www.techenomics.net

For media enquiries please contact Brooke Tolar, DragonFly Public Relations on T: 0411 553 246 or e-mail: brooke@dragonflypr.com.au