Introducing Lubripedia: The Definitive Illustrated Encyclopedia of Industrial Lubrication

Lubripedia is a full-color, 918-page encyclopedic reference featuring 1,001 carefully curated lubrication terms. Designed as the most comprehensive single-source guide to industrial lubrication ever published, the book bridges technical precision with accessible understanding in a discipline where accuracy matters.

Built for engineers, tribologists, maintenance professionals, lubrication practitioners, technicians, researchers, students, and decision-makers, Lubripedia works as both a quick-reference tool and a deeper learning resource. It covers foundational concepts alongside emerging terminology driven by synthetic materials, nanotechnology, sustainability, and digital condition monitoring.

Each entry delivers a concise definition supported by full-color illustrations, photographs, contextual explanations, and cross-references. Where relevant, entries include historical background and modern applications—connecting individual terms to the broader world of lubrication science and practice.

Why It Matters

Lubrication is fundamental to engineering, manufacturing, and everyday life—yet often invisible until failure occurs. From aerospace bearings to industrial gear systems to medical devices, effective lubrication directly impacts asset reliability, performance, and service life. Despite that, lubrication terminology remains dense and fragmented, creating barriers to communication, training, and operational excellence.

Lubripedia establishes a common, precise language that strengthens knowledge transfer, improves decision-making, and elevates professional practice across the lubrication and reliability community.

About the Author

Ken Bannister is an internationally recognized authority in machinery lubrication, reliability engineering, and asset management. He has authored more than 500 books, articles, and white papers in the field. Recent titles from River Publishers include Practical Lubrication for Industrial Facilities (Fourth Edition), Lubrication Strategies and Tips: How to Kick Start Your Lubrication Program, and The Maintenance Partnership Relationship.

Book Details

• Title: Lubripedia: A 1001 Concise Illustrated Encyclopedia Reference of All Things Lubrication
• Publisher: River Publishers
• Format: Full-color, 918 pages
• Scope: 1,001 lubrication terms with illustrations, photos, and cross-references
• ISBN (Hardback): 978-87-7004-140-9
• ISBN (Paperback): 978-87-802-2
• ISBN (Online): 978-87-4380-661-5

Oil analysis is widely recognized as one of the most potent tools in precision lubrication and reliability engineering. Yet, despite decades of industry experience, many organizations unknowingly undermine their effectiveness before the first sample is even taken.

A Real-World Example of a Hidden Oil Analysis Failure

Recently, we received an enquiry for an oil analysis call-off contract from a major industrial organization for their critical rotating machinery. The scope initially appeared comprehensive – until we examined the details. A closer review of the Scope of Work revealed a fundamental issue that, unfortunately, is becoming increasingly common across several industrial facilities.

The client attached the lubricant specification sheet, extracted directly from the OEM manual, assuming these parameters specified the tests to be performed on used oil samples during routine condition monitoring. When questioned regarding the selected oil analysis test package, the client reiterated that the OEM required the lubricant to meet the specifications stated in the Operation and Maintenance manual and therefore assumed that all such tests must be applied to used oil samples.

Where Oil Analysis Programs Go Off Track

This increasingly common assumption, observed in several recent cases, exposes a deeper industry-wide problem: a lack of understanding of what used oil analysis is intended to achieve.

New oil specifications and used oil analysis serve entirely different purposes.

OEM lubricant specification sheets are designed for one primary objective: To define the quality and performance requirements of fresh oil at the time of purchase and commissioning.

These specifications typically include properties such as:

• Viscosity grade limits
• Viscosity Index
• Flash point
• Pour point
• Density
• Rust-preventing characteristics
• Foaming characteristics
• Demulsibility
• Oxidation and ageing tests
• FZG or load-carrying capacity

All of these tests are essential – but only for qualifying new oil before it enters the system.

Once the oil is in service, the objective changes completely.

Used oil analysis is not about confirming what the oil was when it was new. It concerns understanding what is happening inside the machine at present.

Used Oil Analysis Is a Condition Monitoring Tool, Not a Compliance Checklist

In operating equipment – especially gas turbines, steam turbines, compressors, and hydraulic control systems – used oil analysis must answer particular reliability questions:

• Is the oil in healthy condition or degrading faster than expected?
• Is contamination entering the lubrication system?
• Are wear mechanisms developing inside bearings or gears?
• Is varnish or insoluble material forming?
• Are control valves, journals, or servo systems at risk?

Tests such as Pour point, Rust Prevention, Viscosity Index, or FZG ratings provide little to no actionable insight once the oil is in service. Meanwhile, critical failure mechanisms often go undetected when the wrong test slate is applied.

This is how organizations end up with beautiful laboratory reports but poor machine reliability.

What Goes Wrong When Spec Sheets Drive Your Oil Analysis Program

When OEM new-oil specifications are incorrectly used as an in-service oil analysis program, several things happen:

1. Early failure indicators are missed
   Parameters that actually trend degradation—such as varnish potential, water contamination, Particle cleanliness, and additive depletion—are either overlooked or underemphasized.
2. Oil analysis becomes reactive instead of predictive and proactive
   Issues are detected only after alarms, trips, or component damage occur.
3. Lubrication decisions lose credibility
   Maintenance teams receive reports that do not translate into clear actions, leading to distrust in oil analysis as a reliability tool.
4. Critical machinery reliability is compromised
   Bearings, journals, and hydraulic components fail prematurely – not solely due to oil quality, but also due to poor visibility into oil condition.

The True Purpose of Oil Analysis

To simultaneously assess three conditions:

1. Oil condition – how well the lubricant is holding up in service
2. Contamination condition – what unwanted materials are entering the system
3. Machine condition – what the oil is revealing about internal wear and distress of the machine.

When properly designed, an oil analysis program serves as an early-warning system, detecting degradation and failure mechanisms well before alarms, trips, or component damage occur.

However, this only works if the right tests are selected for the right purpose.

Before You Design an Oil Analysis Program, Audit Your Lubrication Practices

A robust oil analysis program should never be built by copying tables from OEM manuals.

Global best practice dictates that a Lubricant Benchmarking and Assessment Audit must precede the design of any oil analysis program.

A structured lubrication audit enables organizations to systematically identify gaps across all critical elements of machinery lubrication management.

• Lubricant Selection and Purchase
• Assess staff competency, training needs, and lubrication awareness
• Evaluate contamination control practices, including ingress prevention and filtration
• Review lubricant storage, handling, and dispensing methods
• Examine oil sampling practices and the condition monitoring program
• Verify machine-specific lubrication requirements and target cleanliness levels

Addressing these areas holistically ensures that oil analysis objectives are properly aligned with overall reliability and asset performance goals.

Oil Analysis Is Not a Lab Activity – It Is a Reliability Discipline

Oil analysis does not fail because laboratories lack capability. It fails because programs are often designed without a clear understanding of what needs to be detected, why it matters, and when it must be detected early.

The difference between oil analysis that merely reports numbers and oil analysis that prevents failures lies in program design, not testing volume.

More data doesn’t mean better reliability. Better questions do.

Oil analysis is one of the most powerful reliability tools available – when applied correctly. However, when new oil specifications are mistaken for used-oil condition monitoring, the entire purpose is undermined.

The industry does not suffer from a lack of data. It suffers from misaligned data.

Understanding the distinction between oil quality and oil condition is not a laboratory issue – it is a responsibility of reliability leadership.

Until that distinction is clearly understood, companies will continue to spend on oil analysis while still incurring unplanned downtime costs.

The reliability and availability of industrial assets are critical factors for the competitiveness of modern organizations. In this context, maintenance has evolved from a predominantly corrective model to preventive, predictive, and more recently, proactive approaches. Oil analysis stands out as one of the most effective tools for early failure detection, contamination control, and assessment of equipment operating conditions.

This article aims to discuss in depth the role of oil analysis as a strategic instrument in industrial asset management, grounding its application in the principles established by ISO 55001 and ICML 55.1. It is demonstrated that integrating oil analysis into a structured lubrication and asset management program contributes significantly to risk reduction, extending equipment service life, optimizing maintenance costs, and strengthening operational reliability.

Transforming Data into Reliability: Oil Analysis in Advanced Industrial Asset Management

The increasing complexity of industrial systems, combined with the demand for greater availability, safety, and operational efficiency, has driven the adoption of advanced maintenance and physical asset management practices. Failures in critical equipment result not only in production losses but also in significant impacts on personnel safety, the environment, and the corporate image of organizations.

Breakdowns are events; degradation is a process.

Although many failures are perceived as unexpected events, several studies indicate that most failure modes present detectable early warning signs over time (Mobley, 2002; Bloch & Geitner, 2019). In this scenario, condition monitoring techniques play a fundamental role in the early identification of progressive degradation processes.

Oil analysis, traditionally associated with evaluating lubricant condition, has evolved into a diagnostic tool capable of providing detailed information on the condition of internal equipment components, operating conditions, and the maintenance practices adopted. When properly applied, it becomes a central element of proactive maintenance.

The ISO 55001 standard, which addresses asset management, emphasizes the need for decision-making based on reliable data and aligned with organizational objectives. Complementarily, the ICML 55.1 standard establishes guidelines for developing robust lubrication programs, recognizing oil analysis as one of its essential technical pillars.

Asset Management and Maintenance: A Standards-Based Approach

ISO 55001 Principles Applied to Maintenance

ISO 55001 defines asset management as the coordinated activity of an organization to realize value from its assets throughout their entire life cycle. Among its fundamental principles are:

• Risk-based approach, considering failure probability and consequences;
• Evidence-based decision-making supported by reliable data;
• Strategic alignment integrating maintenance, operations, and organizational objectives;
• Continuous improvement through performance monitoring and organizational learning.

Within this context, maintenance shifts from a reactive function to a strategic role, using analytical tools to anticipate failures and mitigate risks. Oil analysis directly supports these principles by providing objective data on the actual condition of assets.

The Role of Lubrication According to ICML 55.1

The ICML 55.1 standard establishes the requirements for the development of world-class lubrication programs, structured around several pillars, including:

• Proper lubricant selection;
• Appropriate storage, handling, and application methods;
• Rigorous contamination control;
• Monitoring of lubricant and equipment condition;
• Technical training and competency development of teams.

Oil analysis is presented as an essential tool for validating the effectiveness of these pillars, providing objective indicators of the lubricated system’s health and enabling continuous adjustments to the lubrication program.

Technical Fundamentals of Oil Analysis

Oil analysis involves applying laboratory and interpretive techniques to evaluate the physicochemical properties of lubricants and detect contaminants and wear particles. Its value lies in the ability to correlate this information with the degradation mechanisms of internal equipment components.

Wear Metal Analysis

The identification and quantification of metals present in the oil allow inference of which components are undergoing wear and to what extent. Techniques such as optical emission spectrometry and ICP (Inductively Coupled Plasma) enable the detection of elements such as iron, copper, aluminum, chromium, and tin, each associated with specific components. The temporal evolution of these concentrations is essential to differentiate normal operating conditions from abnormal wear processes.

Analytical Ferrography

Analytical ferrography enables evaluation of wear-particle morphology, providing qualitative information on active wear mechanisms, such as abrasive, adhesive, fatigue, or corrosive wear. This technique is particularly relevant in failure investigations and root cause analysis.

Evaluation of Lubricant Properties

The analysis of the lubricant’s physicochemical properties—such as viscosity, total acid number (TAN), total base number (TBN), oxidation, and additive condition—allows assessment of whether the lubricant maintains its ability to form an adequate lubricating film under operating conditions. Degradation of these properties directly compromises component protection and accelerates wear mechanisms.

Oil Analysis in Failure Cause Identification

Identification of Affected Components

The correlation between detected metals, their morphology, and their rate of evolution enables identification of affected components and the severity of damage. This approach significantly reduces the time and uncertainty associated with failure investigations.

Evaluation of Lubricant Suitability

The use of an unsuitable lubricant, in terms of viscosity, additive package, or material compatibility, can result in premature failure. Oil analysis enables verification that lubricant properties align with equipment specifications and actual operating conditions.

Oil Analysis in Failure Cause Identification

Identification of Affected Components

The correlation between detected metals, their morphology, and their rate of evolution enables identification of affected components and the severity of damage. This approach significantly reduces the time and uncertainty associated with failure investigations.

Evaluation of Lubricant Suitability

The use of an unsuitable lubricant, in terms of viscosity, additive package, or material compatibility, can result in premature failure. Oil analysis enables verification that lubricant properties align with equipment specifications and actual operating conditions.

Diagnosis of Installation and Assembly Failures

Particles characteristic of fatigue or localized wear may indicate misalignment, imbalance, or improper installation of bearings, gears, and other critical components. These deviations, often undetectable through visual inspections, can be identified early through oil analysis.

Evaluation of Operating Conditions

The presence of large metallic particles or high particle concentrations may indicate overload, excessive speeds, or operation outside design limits. In this way, oil analysis serves as an indirect indicator of the actual operating conditions of the equipment.

Contamination Control

Contamination by water, solid particles, and foreign fluids is recognized as a primary cause of lubricant degradation and premature failure. Oil analysis enables identification of both the presence and the source of contamination, allowing corrective actions aligned with ICML 55.1 best practices.

Oil Analysis as a Pillar of Proactive Maintenance

Proactive maintenance seeks to eliminate the root causes of failures before they manifest in functional failures. In this context, oil analysis plays a central role by providing reliable data for:

• Failure anticipation;
• Condition-based intervention planning;
• Optimization of maintenance intervals;
• Reduction of unplanned downtime;
• Increased asset reliability and service life.

When integrated into an asset management system compliant with ISO 55001, oil analysis ceases to be an isolated activity and becomes part of a structured decision-making process aligned with organizational strategy.

The adoption of oil analysis as a strategic tool requires more than laboratory testing alone. Proper sample collection, qualified technical interpretation, trend history management, and well-defined corrective actions are essential. Organizations that treat oil analysis merely as a reactive practice fail to capture its full potential.

Conversely, when embedded in a structured lubrication program aligned with ISO 55001 and ICML 55.1 standards, oil analysis becomes a competitive advantage, enabling safer and more sustainable decision-making.

Oil analysis is an indispensable tool for modern maintenance and industrial asset management. Its structured application enables early failure detection, effective contamination control, and continuous improvement of operational reliability. Aligned with the principles of ISO 55001 and the practices recommended by ICML 55.1, oil analysis evolves from a monitoring technique into a strategic instrument for maximizing asset value throughout its life cycle.

References

• ISO 55001:2014 – Asset Management — Management Systems Requirements.
• ICML 55.1 – Lubrication Program Development Standard.
• MOBLEY, R. K. An Introduction to Predictive Maintenance. Elsevier, 2002.
• BLOCH, H. P.; GEITNER, F. K. Machinery Failure Analysis and Troubleshooting. Gulf Publishing, 2019.

In industrial and manufacturing facilities, lubrication and condition-monitoring programs focus on equipment that runs every day, such as compressors, gearboxes, pumps, turbines, and hydraulic systems that keep production moving. These critical assets are often routinely sampled, trended, and reviewed because their failure has an immediate and visible impact on operations.

But there is another side to operations that often receives less attention until it’s urgently needed in emergencies: backup power generators.

When backup power fails, the consequences aren’t minor – they’re catastrophic. You can’t troubleshoot an oil problem during a grid failure.

Backup generators are expected to perform flawlessly under the worst possible conditions, during storms, grid failures, or emergency shutdowns. Yet many facilities treat them as “standby” assets rather than mission-critical ones. The reality is simple: when backup power fails, the consequences can be severe, resulting in lost production, safety risks, equipment damage, and costly downtime.

Fluid analysis plays a critical role in ensuring backup generators are ready on a moment’s notice in the event they’re needed to maintain uninterrupted operations.

Standby Equipment, High Consequences

Unlike continuously operating industrial equipment, backup generators may run infrequently or under variable conditions. Long idle periods, short test runs, and sudden load demands introduce unique risks that traditional time-based maintenance alone cannot fully address.

Oil degradation, fuel contamination, and coolant issues often develop quietly while generators sit idle. Without routine fluid analysis, these problems remain hidden until startup, and when it’s far too late to correct them.

The worst time to discover a fluid problem is the moment you need your generator to perform.

Treating backup generators with the same condition-based mindset applied to primary assets is essential for reliability.

Oil Analysis: More Than Just Hours on the Meter

Oil analysis is often associated with runtime hours, but for backup generators, time and environment can be just as damaging as operation.

Routine oil testing helps identify:

• Oxidation and oil degradation during extended idle periods through Viscosity, Oxidation, and Base Number (BN) testing
• Contamination from dirt, moisture, or coolant leaks using Elemental Analysis by ICP and Water Content
• Abnormal wear metals indicating internal component issues through Elemental Analysis by ICP and Ferrous Debris Monitoring testing
• Improper viscosity or additive depletion that can reduce engine protection and lead to accelerated wear

Trending oil results over time allows maintenance teams to distinguish between normal aging and developing mechanical problems. This is especially important for generators that may appear “healthy” based on limited run hours but are slowly deteriorating internally.

The Most Overlooked Risk: Diesel Fuel

Fuel quality is a leading cause of backup generator failure. Diesel fuel can degrade significantly during storage, especially when exposed to moisture, temperature fluctuations, or poor housekeeping practices.

Routine diesel fuel testing helps monitor:

• Water contamination and condensation through Karl Fischer testing
• Microbial growth that leads to sludge and filter plugging through Microbial and Adenosine Triphosphate (ATP) testing
• Fuel stability through Thermal Stability and fuel acidity through Copper Corrosion testing
• Contamination through Viscosity and Flashpoint testing
• Identify fuel type and detect the presence of petroleum-based contaminants using Distillation, API Gravity, and Cetane Number testing
• Particulate contamination that can damage injectors using Particle Count testing and Elemental Analysis by ICP testing to detect signs of dirt and tank corrosion

Fuel-related issues often surface only during startup or load testing: exactly when reliability matters most. A proactive diesel fuel testing program enables corrective actions, such as fuel polishing, tank cleaning, or additive treatment, before an emergency occurs.

Coolant Analysis: Protecting the Engine You Can’t Afford to Lose

Coolant condition is critical to engine health, yet it is frequently under-tested in backup power systems. Depleted inhibitors, improper chemistry, or contamination can lead to corrosion, liner pitting, overheating, and premature engine failure.

Coolant analysis provides insight into:

• Freeze point and boil protection through Glycol Concentration and Freeze/Boil point testing
• Signs of glycol breakdown and degradation through Ion Chromatography
• Additive depletion and corrosion inhibitor health using pH, Reserve Alkalinity, Nitrite/Molybdate testing, and Organic Acid Monitoring through High Performance Liquid Chromatography (HPLC) testing
• Contamination from oil, diesel fuel, or external sources through Visual Analysis and Elemental Analysis by ICP
• Scale-forming minerals, improper coolant mixtures, and water quality indicators through Hardness, Chlorides, Sulfates, and Conductivity testing

Regular coolant testing ensures the cooling system can handle sudden load demands and temperature spikes when generators are required to run continuously.

Turning Fluid Data into Reliability

The value of fluid analysis lies not just in testing, but in using results to make smarter maintenance decisions. Trending oil, fuel, and coolant data together provides a comprehensive view of generator health and allows teams to prioritize actions based on condition rather than assumptions.

If you’re already trending fluid data on your primary assets, there’s no reason your backup generators should be flying blind.

For industrial facilities that already have strong lubrication programs in place, extending fluid analysis to backup generators is a natural and necessary step in maintenance planning.

Reliability Isn’t Optional

Backup generators may not run every day, but when they do, failure is not an option. Fluid analysis provides the earliest warning of developing issues and ensures these critical assets are ready when the unexpected occurs.

If your lubrication program protects the equipment that drives production, it should also protect the equipment that keeps everything running when production and safety are on the line.

Sometimes we can spend hours poring over technical data sheets, comparing oil performances, and finally selecting the “right” oil which aligns with the needs of our equipment. Then, within 2 months, the oil degrades, our machines shut down, and we have a bunch of maintenance repairs lined up. What went wrong? We clearly had the “right” oil in the equipment; everything should have worked beautifully. This is where the awareness of lubrication and its practices becomes critical.

Having the correct oil is only one part of the puzzle. Being able to deliver that oil in its purest, cleanest form to the machine is often one of the other pieces that go missing. Another piece is selecting the right oil, not just based on the sales guy’s advice, but on the actual operating conditions of your machine. In this article, we dive a bit deeper into ways you can align the right oil with the proper practices, or avoid the wrong ones, to help extend the life of your asset.

Spec Sheet vs Strategy

For this example, we will consider a turbine oil selection. If a customer wants to change the oil in their turbine, then they may consider the following:

• What are the OEM specifications that need to be met?
• Is this oil available from the local supplier?
• How does it compare to other oils on the market?
• Does the cost justify the value? (or will the purchasing department want something cheaper?

For most of these questions, engineers or the person tasked with selecting the oil can readily find the answers in the oil’s technical data sheet and by talking to their sales representative. But if we dive a bit deeper, are we selecting the right oil for the operating and environmental conditions? Let’s examine the selection of a turbine oil for the Siemens SGT 200 Gas turbine that meets the Siemens TLV 9013 04 specification.

As seen in this document from Shell Lubricants, a few of their products meet that specification, namely Shell Turbo T, Turbo S2GX, Turbo S4X & Turbo S4GX.

On the other hand, Mobil provides some solutions as well, namely, Mobil DTE 732, 746, or DTE 832, 846

Chevron also provides an option of Chevron GST as follows:

With so many options, how can one choose the “right” oil? They all meet the required Siemens specification, TLV 9013 04. This is where the data sheets, OEM manual, and knowledge of the equipment’s operating conditions play a crucial role.

As per the manual, there are preset conditions for temperatures and pressures, but if your actual system runs hotter (or production is being pushed a bit more), it is functioning outside the operating envelope.

The spec sheet tells you what the oil can do. Your operating conditions tell you what it must do.

Additionally, if your surroundings are harsh (close to the sea or in a corrosive environment, or in a non-ventilated area where heat can build up), these can place additional stress on the equipment. For these harsher conditions, a synthetic oil might be more appropriate than a mineral oil, albeit more expensive in terms of the initial investment.

The manual also specifies which tests/characteristics should be used to monitor the condition of the oil, namely: viscosity, particle count, water content, demulsibility, air release, foaming characteristics, RULER®, and MPC. Based on the performance of your current oil in the system, you can determine whether these values fluctuate toward the higher warning zones. This can also influence your decision about which oil to choose.

It’s not just about the right oil or one that aligns with OEM requirements. The selection should also be based on the environmental conditions of the oil and the equipment, and on whether the oil is suited to perform in these conditions. A mineral oil will not withstand the temperatures that a synthetic oil can for extended periods without degrading. Similarly, given the “right” conditions, synthetic oils can also degrade. By cross-examining your spec sheet, OEM manual, and actual conditions, you can determine the best-suited oil for your operations.

Common Modes of Failure

Regardless of the oil selected, common modes of failure can occur with every lubricant. These include: contamination, improper storage and handling practices, and environmental factors, as shown in Figure 4.

Contamination can be defined as any foreign particle entering the system. This includes any gases, liquids, or solids. Especially when the lubricant system runs alongside the process side, process gases and liquids can leak into the oil. These contaminants can influence the oil’s degradation, leading to deposits or chemical reactions that break it down. Common process contaminants include ammonia or treated water.

 The biggest threat to the right oil is often what gets added to it – whether it’s process contamination or the wrong oil during a top-up.

Another liquid that can contaminate oil is another oil. During top-ups, operators can add the wrong oil to the system, causing contamination and, depending on the oil, a possible shutdown. Adding motor oil to hydraulic oil can be catastrophic, as the additive packages work differently and the motor oil additives may counteract the hydraulic additives, removing them from the oil, leaving the asset open to wear and failure. Despite selecting the correct lubricant for your system, adding the wrong oil (mistakenly) will shorten its lifecycle and cause the asset to fail. 

Bad storage and handling practices can also erode your oil, regardless of the oil you choose. Turbine and hydraulic oils are used in precise equipment. As such, they need to be clean and free of dirt or other contaminants. However, if oils are not stored correctly, contaminants can enter and contaminate the oil.

Simple techniques, such as transferring oil from larger storage containers (pails, drums, or totes) into smaller, more manageable containers (2-3 liters or less), can introduce contaminants into the oil if not done correctly. If oils are to be transferred to another storage container, the storage container must be clean. The transfer process should use clean hoses (not previously used for another lubricant) and be completed in a dust-free environment.

If you wouldn’t use a dirty needle for a blood transfusion, why would you use a dirty hose for an oil transfer?

The transfer of oils from one container to the next can be thought of as a blood transfusion. Would you use dirty needles or vials to transport the blood to be placed into another human? Similarly, oil can be likened to the equipment’s lifeblood and should be treated accordingly. Just as we observe sterile practices for blood transfusions, we should also observe similar types of practices for oil transfers.

Environmental and operational factors can also influence lubricant degradation. As stated earlier, all lubricants can degrade over time under harsh conditions. The lubricant formulation largely influences this, as does whether it was blended to withstand those conditions.

Oxidation can easily occur when temperatures increase, free radicals are present, or when wear metals are present. Thermal degradation occurs when the temperatures exceed 200°C. On the other hand, microdieseling occurs in the presence of entrained air, despite the lubricant used in the system, as shown in Figure 5.

Any of these degradation mechanisms can occur regardless of the type of oil chosen. Hence, it is essential to remember that operational conditions and environmental factors can heavily influence oil degradation, even when the oil is appropriate for the system.

Role of Condition Monitoring

As mentioned earlier, choosing the right oil for the system is just one part of the puzzle. How do we know the oil is performing when it’s in the system? This is where condition monitoring can work hand in hand to help ensure that the oil does not fail the asset.

If a proper oil analysis program does not exist, operators will not know whether the oil is properly lubricating the asset. They will also not be aware of whether the oil is breaking down too quickly and failing to protect the asset. Oil analysis can also alert operators to signs of wear in the asset, so they can fix them before they turn into functional failures.

An oil analysis program that lives in a drawer protects assets about as well as no program at all.

There is also the possibility that an oil analysis program exists but is not top of mind, or that its results are put in a drawer. This can also cause the asset to fail even though the correct oil is being used. Apart from the aforementioned factors, if operators are not warned of the impending failure of the oil, this can result in production losses, increased downtime, and, in some extreme cases, the complete loss of the asset if it has failed beyond repair. 

Incorrect sampling is another area in which the actual condition of the asset is not reported. Even with the correct oil used, if a sample is collected from a dead leg or an area that is not truly representative of the conditions inside the component, its actual condition will not be known. With incorrect data about the component, the asset can be misdiagnosed or treated for symptoms that do not exist, which can lead to its detriment.

Human and Organizational Factors

Not all failures occur at the equipment level; human and organizational factors can also cause the asset to fail even when the correct oil is used. If humans aren’t properly trained in oil sampling techniques or storage and handling practices, these can affect the asset’s functionality. We often forget that, at the heart of it all, lies the human factor, which is partially governed by the organization’s systems.

Training needs are an organizational factor that is often overlooked when considering how an asset can fail. However, if operators have not been trained in condition monitoring techniques, they will not be able to read oil analysis reports or take appropriate actions to protect the asset. Training can help bridge some competency gaps that directly impact asset performance.

It doesn’t matter what oil is in the system if no one is trained to monitor it – or motivated to care.

Culture is another factor swept under the rug. If the culture doesn’t exist to look after the assets, it doesn’t matter what type of oil is placed in the system; the asset will fail eventually. The performance of the asset does not only rely on using the correct oil. By implementing a culture of Asset ownership, where operators look after the asset and are accountable for its performance, assets are optimized to provide the functionality they should. This is one way to ensure the right oil is used to enable the assets’ performance.

Another area of concern is the documentation of maintenance procedures. If maintenance procedures are not adequately documented, someone new to the operation may not be aware of the correct practice. This, coupled with a lack of training, can spell disaster for the equipment. In these cases, even though the right oil was selected, the wrong practice or lack thereof can fail the asset.

Turning the “Right oil” into the “Right Outcome.”

As explained in this article, improper practices can jeopardize the asset’s health, even when the right oil is used. However, if all the right things align, we can have an asset that lasts for its expected lifetime or beyond.

This starts with selecting the right oil based on the application, environmental conditions, and OEM recommendations. If we follow this up with good storage and handling practices, proper condition-monitoring programs, documentation, and training, we can look toward a longer-lasting asset. The right oil enables reliability – but only disciplined practices deliver it.

What’s the Right Number of Lubricants for Your Plant?

Over the years, I have been to sites with either too many or too few lubricant types.

Both scenarios are potentially costly.

On the one hand, too many types of lubricant are costly in terms of purchase price and ultimately risk downtime due to the wrong lubricant being used.

On the other hand, too few lubricant types are costing the company due to overzealous consolidation, leading to a possible substandard lubricant specification in use.

Why Do Lubricant Inventories Get Out of Hand?

Generally, I find that where too many lubricant types exist, usually differing brands, is the result of procurement blindly following the Original Equipment Manufacturer (OEM) insistence on a brand for “Warranty reasons”.  Legally, the OEM should provide a recommended lubricant specification and include a list of brands.  However, if a non-recommended brand can be shown to meet or exceed the required specification, the warranty issue is no longer a concern, especially if the OEM is contacted and obtains written approval. 

I have been through this process on several occasions, especially on new builds, where various electric motor and pump suppliers will try to enforce a particular brand, sometimes for commercial rather than technical reasons.

Where too many lubricant types exist, usually differing brands, is the result of procurement blindly following the OEM insistence on a brand for warranty reasons.

Another possibility is that the procurement team is shopping around for the best pricing, resulting in numerous brands in the storeroom.  This has happened in both small, family-run businesses and in larger operations where a procurement contractor is responsible and is shopping for the best deal. 

What Makes Lubricant Consolidation Worth the Effort?

Primarily, the main reason is cost-benefit.

Purchasing fewer lubricant types means each remaining type in use is purchased in greater volumes, thereby realizing potential cost savings through negotiated discounts for higher volumes. 

This goes further: particularly with oils, these can be bought in larger container sizes, further reducing the purchase price, as typically the larger the container, the cheaper the unit cost.  However, while handling small pails is cheap, handling drums is more complex. Still, with the installation of a “best practice” bulk storage system, the oil can be purchased in drums but handled and transferred via smaller, more easily managed, sealable, and refillable containers that also meet “best practice” guidelines.

A secondary cost reason is the reduced risk of using the wrong lubricant and the resulting damage from cross-contamination.

This latter issue, however, is also the result of a lack of “best practice” with no tagging of the machines and no internal company policy of colour-coding the lubricants, either, allied to poorly written work orders that lack detail.

Is There a Business Case for Consolidation?

Yes…and no.

Be careful of being penny-wise and pound-foolish, as we say in the UK, or should that be cents-wise and dollars-foolish?

Let’s clarify.  In the late 1990s, working with BP, they stated that the average customer will spend less than 1% of their annual maintenance budget buying lubricants, but will spend more than 40% of it dealing with the outcomes of poor lubrication practices on site.

To put that into context, with a $10 million annual maintenance budget, less than $100,000 is spent on lubricants, while $4 million is spent on repairs, rebuilds, and other downtime costs associated with poor lubrication management.

So, would you rather chase a $20,000 savings or deal with an internal issue costing $4 million and recover at least $1 million of that?

The average customer will spend less than 1% of their annual maintenance budget buying lubricants, but will spend more than 40% of it dealing with the outcomes of poor lubrication practices.

In my opinion, the cost-benefit of a lubricant consolidation exercise will also depend on the industry type.  In some instances, certain industries, such as Food & Beverage and Pharma, have limited lubricant ranges, with consolidation already underway, particularly for NSF-approved Food-Grade lubricants, and limited asset types. 

On the other hand, Oil & Gas, mining, Pulp & Paper, for example, not only have a larger range of lubricants to suit a wide variety of asset types, but these industries will also utilise greater quantities, especially in fluid power systems, engines, transmissions, and turbine trains for compressors or power generation.

The Right Way to Consolidate Your Lubricant Program

Lubricant consolidation, in my opinion, is again an essential first step in implementing a world-class lubrication management programme.  Apart from getting a handle on all the lubricants on site, it will help identify obsolete stock, address issues arising from product name changes, and create a plan for the discontinued and hard-to-obtain products still on the list.

Ideally, using internal or sub-contracted, independent expertise, a list of the lubricants in use should be compiled at the beginning.  This is a useful exercise, as I often find multiple duplicates in Enterprise Resource Planning systems (SAP, Maximo, etc.) for lubricant accounting codes.  While each container size of a lubricant type should have its own accounting code, there are often instances where procurement has inadvertently added another, but under a slightly different term, for example, as 15-40 instead of the original 15W-40.

Once the duplicates have been removed, the list should be tabulated in a spreadsheet with columns denoting the brand, product, and then further itemized by column headings not only for the base oil type, thickener type, and intended application, but also relevant to the lubricant type, showing the physical, chemical, and performance properties.

 I would then prioritise the lubricants, with the highest priority given to those used in critical assets or specialised equipment that must remain, and the lowest to those in general applications and low-criticality assets.

However, be aware that, for greases. At the same time, it is tempting to use a multi-purpose grease for the motors; the base oil’s viscosity may be too high compared to a specialist electric motor bearing grease, which can increase power consumption.

In addition, gearboxes and transmissions need investigation, as Sulphur-Phosphorus-based Extreme Pressure oils may not suit all designs. In fact, apart from the chemical issue with the S_P EP oils, which require a solid-suspension type physical EP oil, some gears may only need an Anti-Wear oil.

Rather than dumbing down to the cheapest level, take the opportunity to raise the bar to the highest level.

A final comment here is that rather than dumbing down to the cheapest level, take the opportunity to raise the bar to the highest level.  For example, switching from mineral to synthetic base oils may seem counterintuitive in terms of cost; however, there are several benefits.  The higher VI of the synthetic base oils may help consolidate into different Viscosity Grade oils, while potential cost benefits include longer oil change intervals and reduced energy consumption.

What Comes After Consolidation?

While the consolidation may be your only objective, the cost-benefit of such a process will be limited and, in fact, incur additional costs due to downtime resulting from uncertainty about the new lubricant range and cross-contamination. 

In addition, it is simply not possible to start topping up with a revised oil grade, such as an ISO VG 22 synthetic oil, on a gearbox currently using an ISO VG 320 mineral oil. Hence, the likelihood is that the consolidation won’t happen.

Further, even if consolidation reduces the number of lubricant types in use, it may still result in a variety of container sizes or require purchasing smaller containers at a higher unit cost unless steps are taken to address processing with larger containers in the lubricant store.

Simply put, the real benefit comes from a structured process of improvement across the whole lubrication management strategy.

Should You Let Your Supplier Run the Consolidation?

It is, of course, possible, and increasingly, lubricant vendors are going down this road with their clients.  A strong supplier with your best interests as the end user at heart is the ideal approach.  Unfortunately, I have seen too many instances of a cursory review of the lubricants resulting in over-consolidation to the detriment of the machinery.

One outcome of creating a spreadsheet, as mentioned earlier, is the generation of an internal lubricant specification document.  With actual product names removed, the folder of specifications for each lubricant can be shared with all suppliers as part of a single-source procurement process.  This means that, without the current product name, the lubricant supplier must review the specification document in detail, note its properties and performance criteria, and recommend a suitable lubricant.

What Are the Benefits of a Single Lubricant Supplier?

Just as there is a cost-benefit to lubricant consolidation, rationalising the supplier base can also realise cost savings.  Buying all the lubricants from one source will also help push for discounts beloved of bulk purchasing.

There are other benefits to single sourcing, too.  When evaluating responses to the tendering process, a single-source supplier is more likely to support the process once in place.  Naturally, this depends on the volume of business, but a single-source supplier is more likely to commit to your process of improving the lubrication management strategy.

With actual product names removed, the folder of specifications for each lubricant can be shared with all suppliers as part of a single-source procurement process.

Of course, a single-source supplier may not be able to cover all lubricants, so some allowance will need to be made for specialist lubricants.

What’s the Big Picture Here?

While a cost-benefit, the desire for lubricant consolidation should not be driven by procurement looking to maximise short-term savings, especially by avoiding the temptation to err on the side of cheaper, lower-performing products. 

Lubricant consolidation should be driven by reliability professionals looking to improve the overall lubrication strategy, in which knowledge of future improvements in storage and handling will enable more effective consolidation decisions, maximising the cost-benefit.

It is very likely that you have encountered the RPVOT (Rotating Pressure Vessel Oxidation Test), a laboratory test developed in the 1960s and later standardized by ASTM D2272. It measures the antioxidant stability of lubricating oils by accelerating oxidation in a rotary pressure vessel.

The most common result is an integer expressed in minutes that measures the time until the pressure drops by 25 psi from the initial maximum (T0 to T1) under conditions of 150°C, oxygen at ~90 psi, and a copper catalyst. Some labs include the graphic that most closely resembles one of the most famous drawings in Antoine de Saint-Exupéry’s book, An Elephant Inside a Boa Constrictor.

Although this laboratory test has a lot to say about the state and condition of the oil, it has been assumed that the result depends only on the numerical value, being that it is much more than a simple number, and knowing this test in slightly more detail can be very useful when planning the lubricant. In this article, we will analyze the oil’s behavior during this test from an energy perspective. We will examine the relationship with other laboratory tests and, finally, the application of new methodologies to assess the test’s performance.

Let’s look at three samples of the same type of oil, a zinc-free mineral oil designed for gas and steam turbines with antioxidant additives, rust and corrosion inhibitors, and anti-foaming agents. According to the technical sheet, the RPVOT test of the new oil reports 1000 minutes.

Remember that the objective of the test is to force the oxidation of the oil.

RPVOT Regions

PART 1: Graph Analysis

Oxidation Induction Region, Gas Heating and Expansion

An initial period where antioxidants (phenolics, amines, phosphorus) neutralize free radicals (ROO-, O2-) formed by temperature (150°C) and Cu, H2O, and O2 catalysts. In this phase, the gas’s thermal expansion predominates, water evaporates, but oxidation is still low.

• Graphically: Low slope (<0.05 psi/min), stable pressure ~192 psi.​
• Entropy: minimum ΔS (+10-19 J/mol· K); under molecular disorder.
• Gases: Very few volatiles (residual H2O).
• Duration: ~35-100 min; longer in sample 2 (additives in good condition).

Region of Propagation of Quasi-Stationary Oxidation

The primary antioxidants are exhausted; the oxidative chain begins when free radicals attack the hydrocarbons of the base oil, initiating a sequence of peroxide formation, aldehyde formation, and acid formation, leading to varnish (degradation byproducts). In this phase, O2 is rapidly consumed.

• Graphically: Tipping point, average slope (-0.05 to -0.2 psi/min), drop ~192→175 psi.
• Entropy: High ΔS (+25-32 J/mol· K); Disorder increases due to the increase in molecular fragments of the hydrocarbon chain.
• Gases: CO, CO2, volatile hydrocarbons cause ~10-20 psi drop.​
• Sample 3 has a steeper curve due to the consumption or condition of additives.

 Region of Termination or Pressure Drop

The secondary inhibitors present in this oil, such as phosphates, recombine the remaining radicals, and in this phase, the oxidation slows, but the presence of residues is evident, which can increase viscosity and AN.

• Graphically: Low slope (<-0.2 psi/min), stabilization ~170 psi.
• Entropy: moderate ΔS (+16-22 J/mol· K); residual disorder.
• Gases: Minimal, but there is evidence of varnish or accumulated sediment.
• Sample 2 is more stable; this is evidenced by a flat curve.

Analysis by Sample

Sample 2 (more stable, total ΔP ~22 psi in ~300 min): Low degradation, additives are efficient and limit clutter.​

• Induction Region (t≈48-100 min, 192.1→190.5 psi): ΔS = +10.2 J/mol· K and phenolic antioxidants intact.
• Propagation Region (100-220 min, 190.5→182 psi): ΔS = +24.8 J/mol·K. With a moderate concentration of peroxide.
• Termination Region (>220 min, 182→170 psi): ΔS = +16.5 J/mol·K. Total: +51.5 J/mol·K.

Sample 1 (mean degradation, ΔP ~23 psi): a higher initial additive consumption.​

• Induction Region (46-90 min, 192→183 psi): ΔS = +14.7 J/mol·K.
• Propagation Region (90-230 min, 183→173 psi): ΔS = +27.1 J/mol·K.
• Termination Region (>230 min, 173→169 psi): ΔS = +19.2 J/mol·K. Total: +61.0 J/mol·K.

Sample 3 (the most degraded, ΔP ~25 psi): High early oxidation.​

• Induction Region (35-80 min, 192→167 psi): ΔS = +18.9 J/mol·K. The exhausted phosphate additive is exhausted.
• Propagation Region (80-260 min, 167→160 psi): ΔS = +32.4 J/mol·K. Increase in volatile compounds and acid production.
• Termination Region (>260 min, 160→155 psi): ΔS = +22.1 J/mol·K. Total: +73.4 J/mol·K.

PART 2: Relationship with Other Laboratory Tests

The relationship between RPVOT and other laboratory tests is very weak and unreliable, and it is unlikely to predict a low RPVOT result.

Following our case study, we have:

On the other hand, the repeatability and reproducibility of the RPVOT is low and this greatly reduces its reliability when making a decision in case of results that do not meet the expectations of the end user.

So, what laboratory analysis can be a good ally when performing the RPVOT? As Table 2 shows, traditional tests do not correlate with RPVOT results. However, there are two analyses that do show potential problems and can be used to work in conjunction with this test; Differential pulse voltammetry (DPV) is a powerful electroanalytical technique designed to measure the concentration of redox-active species with high sensitivity and resolution, often allowing the detection of analytes at concentrations as low as 10^-8 to 10^-9 molar. The next is FTIR, which allows identifying compounds in the fluid.

PART 3: Price Matters and Goes Hand In Hand with Innovation

Depending on the country and laboratory, the cost of an RPVOT analysis is usually between 150 and 650 $US, with an estimated turnaround time for results easily exceeding 10 days, not only because of the time it takes to test but also because samples may be on hold. If it is simply to comply with the oil manufacturer’s recommendations or the turbine OEM’s warranty, the end user will pay little attention to the result or the graph in the report.

The analytical tools available to us today have facilitated many aspects of our lives, including data analysis and the detection of patterns that help us identify future behaviors. Within the scope of RPVOT, in mid-2024, I was fortunate to develop an analytical tool that I called RPVOT_[SYN]. Its function basically aims to minimize two key aspects of this laboratory test: time and cost.

Thus, by applying a Bayesian analysis, it is possible to determine with a degree of confidence greater than 75% what the expected result of the RPVOT of a turbine oil will be. For a fraction of the cost of the laboratory test and in less than 6 hours, you get a result very similar to this:

RPVOT_[SYN] : 180 – 200

Some Recommendations: What Is Important When Receiving the RPVOT Results?

We said before that the numerical result matters, but it is not the only thing that should matter in this test. If you work with a respectable laboratory with sufficient technical knowledge, they will be able to report the graph (even in csv format) in such a way that it can be analyzed from the point of view of their regions.

Remember, the regions say much more than the simple numerical result. Cross-referencing this information with FTIR and DPV can yield much more insight into the condition of the lubricant. And it can help plan, in conjunction with other tests, a possible intervention on the lubricant, whether it’s a partial or complete change, or finding a solution due to problems related to the lubricant’s chemistry.

Don’t miss the opportunity to get the most out of an analysis of this caliber; it can tell you a lot about the condition of your lubricant.

The International Council for Machinery Lubrication (ICML) today announced the election of three new members to its Board of Directors: Kelley Evans, Matthew G. Collins, and Mike Ramsey. Their appointments became effective January 23, 2026.

The election of Evans, Collins, and Ramsey brings a diverse range of leadership experience spanning organizational development, engineering, asset integrity, industry publishing, and professional education. Their combined backgrounds will support ICML’s continued growth and global impact in advancing lubrication and oil analysis standards.

“ICML is pleased to add these leaders who are highly motivated to shape our next stage of growth,” said Bryan Coggins, ICML’s Chief Executive Officer. “We look forward to leveraging their experience and passion for service to further elevate ICML’s support of the current, as well as next, generation of maintenance and reliability professionals.”

Paul Dufresne, Board Chairman and Chief Reliability Officer at Reliability Playbook, said, “The addition of our newest board members marks an exciting chapter for ICML. With their insight and stewardship, we will continue to advance our global standards, certification programs, and industry partnerships with added strength.”

Kelley Evans

Kelley Evans brings more than 20 years of executive and operational leadership experience across organizational development, human resources, and manufacturing operations. Most recently, she served in several executive roles at Industrial Oils Unlimited (IOU) / Adjuvants Unlimited, including five years as co-chief operating officer, overseeing company-wide operations across human resources, finance, information technology, customer care, quality, manufacturing, and sales.

In these roles, Evans witnessed firsthand the positive career impact of ICML certifications on lubrication professionals, motivating her to contribute her experience in strategy, governance, and organizational development to the ICML board.

“People are the most important asset any organization can have,” said Evans. “Serving on ICML’s board gives me an opportunity to make a positive impact in an industry that has supported and shaped my career the past 15 years.”

Prior to IOU, Evans held HR leadership roles with Deloitte and Convergys, where she developed professional growth initiatives and led regional employee relations strategies across multiple business units and states.

Matthew G. Collins

Matthew G. Collins is a professional mechanical engineer and professional welding engineer with more than 34 years of technical and managerial experience. His background includes 22 years as a welding and mechanical engineering subject matter expert within the oil and gas industry and at Los Alamos National Laboratories, as well as six years in senior asset integrity, maintenance, and reliability leadership roles.

Collins spent much of his career with ConocoPhillips and ARCO Alaska, supporting complex onshore and offshore facilities worldwide, with deep involvement in corrosion control, inspection programs, welding technology, and international codes and standards.

“I have passion for the multiple industries supported by the ICML and have worked the entirety of my career in an industry (Energy/Oil & Gas) that is highly dependent on multiple lubrication products and personnel,” said Collins. “I am intrigued by the prospect of being part of ICML’s multi-discipline team from varied industries, coming together to provide consistent guidance while also providing a view of the future state of the industry.”

Collins currently serves on the ASME B31.3 Process Piping Code Committee and the Edison Welding Institute Industry Advisory Board. He consults through WeldMech LLC and also owns GJW Farm LLC, a 580-acre family-operated farm in Missouri.

Mike Ramsey

Mike Ramsey is a long-time industry leader in lubrication education, publishing, marketing, and professional development. He previously served on ICML’s inaugural Board of Directors and now returns with decades of experience helping organizations expand training, publishing, and certification-aligned programs worldwide.

“I was fortunate to be part of ICML’s formation 25 years ago, and from the beginning, I believed strongly that our industry needed a professional body to set global standards and provide certifications that give credibility to the work of lubrication and oil analysis practitioners. That belief hasn’t changed,” said Ramsey. “What motivates me now is the opportunity to give back to this organization that shaped both my career and the careers of so many others, and to help ICML continue evolving.”

Ramsey is the co-founder and former president of Noria Corporation, where he led the growth of publishing, training, consulting, events, software, and industrial products aligned with ICML’s vendor-neutral certifications. He currently publishes Precision Lubrication Magazine and Reliable.

Learn more about the International Council for Machinery Lubrication. 

Maintenance teams are entering a new era, one where data-driven insights enable automation and transform how equipment health is monitored and maintained. For years, the industry has been moving from preventive maintenance to predictive maintenance, but what’s next? It’s predictive reliability.

For lubrication and condition monitoring programs, this means harnessing connected data and smarter systems to make faster, more accurate decisions that predict problems before they impact uptime.

Setting the Foundation

To move toward actually predicting maintenance, the foundation and the data must be strong.

Condition monitoring relies on continuous streams of information from oil analysis, vibration sensors, thermography, and telematics. However, these data sets are often siloed, inconsistent, or manually reported, which significantly limits their usefulness. Data standardization is key. Standardized data formats, consistent naming conventions, and unified reporting structures enable automated systems and machine learning models to analyze, interpret, compare, and act on information.

Without reliable data, even the most advanced AI platform can’t identify meaningful trends or correlations. Prioritizing standardized data processes ensures that every data point can be confidently integrated into reliability systems.

For POLARIS Laboratories®, data standardization comes into play with customers’ database of equipment, OEM, components, assets, lubricant manufacturers, and those of the like. It’s imperative that this data be kept accurate, up to date, and as complete as possible.

Cloud-Based Reliability Systems

Cloud technology has accelerated this transformation by centralizing condition monitoring data. Through cloud-based platforms powered by API connections, maintenance and reliability managers can securely access results, trends, and recommendations in real time – from anywhere in the world.

For example, POLARIS Laboratories’ API integration, HORIZON® Connect, automatically feeds oil analysis results into a customer’s Computerized Maintenance Management System (CMMS) or Enterprise Resource Planning (ERP) system. This eliminates the need for manual data entry, reduces delays, and creates a single source of truth for decision-making. Cloud systems also support continuous learning; as more data is analyzed, AI-powered models can refine predictions and improve reliability.

AI and Condition Monitoring

Integrating artificial intelligence into condition monitoring practices can enhance what traditional analysis can achieve. Instead of reviewing static data points, AI algorithms evaluate trends over time and across equipment fleets, identifying subtle anomalies that might signal early signs of wear or contamination.

For example, AI can detect minor deviations in lubricant properties, such as gradual increases in oxidation or shifts in base number, that precede measurable wear. When integrated with other data streams, such as vibration and load, these patterns can pinpoint root causes of failure before they escalate. Rather than waiting for sensor alarms, maintenance teams can receive predictive insights that guide them to act sooner.

This is especially valuable in lubrication analysis, where AI models can compare millions of test results across different equipment types, environments, applications, and formulations. The result is a system that continuously learns and improves its ability to predict issues and recommend maintenance actions.

Feedback Loops and Continuous Improvement

AI and Machine Learning technologies thrive on feedback loops. In a condition monitoring program, every maintenance action (such as replacing a bearing or adjusting oil-drain intervals) generates data that feeds back into the condition monitoring system.

With an established API connection between oil analysis and maintenance systems, this also provides feedback to the laboratory, which can, in turn, improve analysis of future samples.

Setting up this feedback loop can help assess the effectiveness of those actions and adjust future predictions accordingly. Over time, the system becomes increasingly accurate and capable of recommending optimal interventions with minimal human oversight.

For lubrication management, this feedback cycle ensures that maintenance strategies evolve in sync with real-world equipment performance. The result is a more adaptive, efficient maintenance process that maximizes asset health and minimizes waste.

Clearing the Path Forward

As reliability teams prepare for the next generation of condition monitoring, the integration of AI, cloud-based platforms, and strict data standardization will define the leaders in uptime, safety, and operational efficiency. The future of reliability is intelligent, connected, and powered by data.

The EGR (Exhaust Gas Recirculation) system recirculates a fraction of the exhaust gases into the intake manifold to lower combustion temperature, reduce NOx emissions, and, in some cases, improve fuel consumption in both diesel and gasoline engines. This recirculation of hot gases introduces more soot, acids, and contaminants into the lubricant, accelerating its degradation and reducing engine life if not controlled with proper design, oil, and maintenance.

In diesel engines, the EGR valve diverts a portion of the exhaust gases before or after the turbocharger. It reintroduces them, often after cooling in an exchanger, into the intake to reduce effective oxygen and flame temperatures, thereby decreasing NOx formation.

The valve is governed by the ECU (Engine Control Unit) based on load, temperature, and rpm, opening primarily at partial loads and closing at cold idle or full load.

In gasoline, EGR can be hot or cooled. It is used to reduce part-load pumping losses and to lower NOx emissions. By recirculating inert gas, the valve can be opened wider at the same torque, reducing intake vacuum and improving efficiency. In GDI (Gasoline Direct Injection) and turbo engines, external or internal EGR (through valve overlap) is adopted to control combustion temperature and mitigate knock.

The latter refers to reducing the mixture’s tendency to detonate spontaneously before or just after the spark, a common problem in high-compression gasoline engines. Recirculating inert gases lowers the combustion temperature and slows the reaction rate, reducing the likelihood of knocking and allowing greater advance or load without damaging the engine.

Typical EGR Failure Modes

No precise statistics indicate exact percentages of EGR valve failure modes. However, there are two failure modes that, depending on the engine type (diesel or gasoline) and the OEM, account for a high percentage of total failures. (1)

Open seized EGR valve ~ 65%

Excess recirculated gases, loss of power, smoke, possible increase of soot in the manifold and in the combustion chambers of the engine cylinders.

When the EGR valve is seized open, it recirculates excess exhaust gases (with soot and contaminants) into these chambers, diluting the fresh mixture too much, reducing power, and causing incomplete combustion that generates more soot accumulated on the walls of the chambers, pistons, valves, and intake manifold.

Excess soot in combustion chambers tends to raise temperatures, increase wear, and complicate gas flow in subsequent cycles, aggravating failures such as compression loss or excessive emissions.

In open-valve failure, the vicious cycle of soot obstructing the intake reduces airflow, forcing more fuel to compensate, increasing consumption and emissions. In contrast, NOx is reduced by excessive dilution. In diesel engines, it triggers frequent DPF regeneration due to low soot levels.

DPF regeneration is the automatic or manual cleaning process of the Diesel Particle Filter, which burns the soot accumulated in its ceramic channels to prevent clogging and keep emissions low, converting carbon particles into CO₂ and ash at temperatures of 500-600°C.

Closed seized EGR valve ~ 15%

High NOx, possible detonation, higher temperatures, and risk of thermal damage to metal components.

In a closed-valve failure, the ECU detects high NOx and enters safety mode (reduces power, limits rpm), accelerates piston thermal wear, and saturates the DPF due to insufficient dilution. In this failure mode, lubricating life degrades dramatically, reducing TBN at an accelerated rate.

In some post-2021 diesel engines, or Boxer-type engines with high-pressure EGR, a mixture of soot and light-fraction oil vapors from the combustion chamber forms dense sludge in the manifold, valve, and cooler, thereby aggravating EGR-system failures.

EGR failure identification opened by oil analysis

The failure mode of EGR valve seized open, excess recirculation introduces high volume of soot (carbon particles) and acidic contaminants (SOx, NOx dissolved) to the crankcase via blow-by, drastically raising the soot content (>2-5% wt), increasing viscosity and TAN (total acid number), and lowering TBN (total basic number) in an accelerated manner. This indicates incomplete combustion and dirt in intake – combustion chambers; oil detergents-dispersants become saturated, forming sludge and accelerating abrasive wear (Fe, Al, Pb high in iron, aluminum).

Closed EGR failure identification by oil analysis

In the closed-seized EGR valve failure mode, combustion is hotter. It generates greater oxidation/nitration of the oil, reflected in a high oxidation index (IR spectrum >30 Abs/cm), an increase in viscosity is evidenced by polymerization, and TBN is depleted by neutralization of the excessive load of NOx acids.

On the other hand, rising temperatures cause thermal wear due to thermal expansion. Increasing wear is measured by metal loss (chromium and iron from bearings/pistons). A low soot concentration (<2%) may be observed, possibly due to ECU injection adjustments that increase fuel dilution. In some cases, this dilution can cause the absence of soot despite high temperatures.

Global market for the sale of used and new cars

There is no accurate global data for annual sales of new and used cars worldwide. On the other hand, used markets vary significantly by region and country, and there is no unified source like OICA for used. But the data shows a worldwide trend where the sales of used cars exceed new cars by at least 3:1, according to the estimated data:

According to the data, it is very likely that, at some point, you will have to buy a used car; specifically, there is an 80% chance (equivalent probability) that you will do so.

At the same time, you’ve likely never done an oil analysis on your car. But if you’ve paid some attention to this article, chances are you’ve understood the value of a simple oil analysis—an analysis with a cost of nearly $30.

Over the years, I have helped several friends choose a second-hand car. Where the exterior can be very presentable, clean and very well maintained; But inside, where many times not even today’s computers can identify the problem unless it is very advanced states, a simple analysis of the oil in service can be the difference between buying a problem or making sure that the car’s engine – the heart of the machine – is working properly.