Ensuring Safety and Efficiency in the Railway Industry: The Critical Role of Used Oil Analysis

Why Oil Analysis is Vital for Safety

The primary reason for conducting oil analysis in railways is safety. Train axle gearboxes, for instance, rely on oil to reduce friction and wear on gears and bearings. By analysing the oil for wear elements such as copper and iron, potential gear and bearing issues can be identified early. If these components fail, the consequences can be dire, including train derailments that may result in loss of life, serious injuries, and substantial financial and operational repercussions.

Enhancing Maintenance with Predictive Monitoring

Predictive maintenance is essential for keeping railway operations smooth and cost-effective. Oil condition monitoring forms the backbone of this approach by providing continuous data on the health of various components. By tracking changes in the composition of oil over time, sudden increases in elements such as iron, copper and also ferrous particles can be detected, signalling potential issues.

For example, a spike in iron or copper particles might indicate accelerated wear in gears or bearings, prompting immediate investigation and intervention. This proactive maintenance strategy helps avoid unexpected breakdowns, ensuring that the railway network remains operational and minimizing costly service disruptions.

Contamination Detection and Impact

Oil analysis is not just about identifying wear particles; it also involves detecting various types of contamination. For example, silicon contamination, common in the railway environment due to silica-rich ballast and dirt, can indicate the presence of abrasive materials that increase wear. Other sources of silicon include degradation of silicon seals, O-rings, gaskets, and hoses. This contamination can lead to accelerated wear and tear, particularly in gearboxes, hydraulic and engine components.

Monitoring oil viscosity and additive levels helps ensure that the correct oil is being used and that it hasn’t been contaminated. For engines, a decrease in viscosity could indicate fuel contamination, which requires prompt attention to prevent damage.

Optimising Maintenance and Reducing Costs

Used oil analysis also helps in determining the optimal timing for oil changes, extending the life of the oil and reducing unnecessary maintenance costs. Regular monitoring can reveal when oil is sufficiently degraded or contaminated to warrant a change, thereby avoiding premature changes, and saving on the cost of new oil, labour, and downtime.

For example, if oil analysis shows that the oil is still in good condition, maintenance teams can defer oil changes, thereby saving on materials and labour costs. Conversely, if contaminants are detected at critical levels, an oil change can be scheduled before any damage occurs.

Component-Specific Tests

Certain tests are tailored to specific components. For example, the Total Acid Number (TAN) and Total Base Number (TBN) are critical for engines. TAN measures the acidity of the oil, which increases as the oil degrades, while TBN measures the oil's capacity to neutralize acidic by-products from combustion. Maintaining the right balance between TAN and TBN is essential to ensure the oil continues to protect the engine effectively.

These tests provide detailed insights into the condition of the oil and the components it lubricates, allowing for more precise maintenance decisions and extending the lifespan of critical equipment.

Fuel and Coolant Testing

Fuel testing can reveal the presence of particles, water contamination, and microbial growth, all of which can lead to fuel system blockages and engine performance issues. Coolant testing assesses the strength and contamination levels, helping prevent corrosion and ensuring the cooling system operates efficiently.

For example, if fuel testing reveals high levels of particulate contamination, it may indicate that fuel filters need to be replaced or that the fuel supply is compromised. Similarly, coolant testing can identify issues with coolant strength or contamination, which might necessitate system flushing or the replacement of cooling fluids.

How can we help?

Our team ensures railway safety and operational efficiency through comprehensive used oil analysis. By testing oils from key components like axle gearboxes, engines, and hydraulics, we detect wear and contaminants early, preventing serious issues like derailments and breakdowns. Our expertise in interpreting oil trends enables proactive maintenance, minimising disruptions and reducing costs.

We also analyse fuels and coolants to detect impurities that could impair performance. Our services help railway operators maintain smooth operations, extend the lifespan of their equipment, and avoid costly repairs and operational halts, all while ensuring the highest safety standards.