Executive Summary
Online or inline systems for condition monitoring and oil analysis are becoming increasingly commonplace. The benefits over offline systems include real-time monitoring, quick detection of conditions that could lead to a failure and ease of use in applications that are difficult to access. There are some challenges, most notably the costs to implement one of these systems and train personnel on their use. While most readers agree that online/inline condition monitoring systems will continue to become more commonplace, opinions are mixed on how quickly that will happen.

Q.1 What are some of the benefits of online/inline systems over offline systems for condition monitoring using oil analysis?

I don’t think you should limit the idea of online monitoring to oil analysis because there are many additional tools that can be intelligently used to better understand machinery condition. Having said that, I believe the online monitoring does not yet give as accurate or thorough results as the laboratory analyses.

Quicker response for better prevention of catastrophic failure.

Immediate response whenever something changes.

Constant access to vital information versus a once-a-month snapshot of conditions.

A better chance of catching or predicting a failure before it does catastrophic or costly damage. Trend data can be more easily captured.

It provides information on the system performance rather than a delayed response. This provides an opportunity for a quick corrective action. There may be other issues regarding sample collection, preparation, shipping, etc., and a possibility of contamination.

Real-time and continuous monitoring—especially useful in difficult access applications.

Determining when an upset event occurred can be narrowed down to the exact time with real-time monitoring allowing for better root cause analysis. Corrective actions can be taken sooner as well.

The immediacy of information allows you to make better decisions.

When they work, these systems should provide ease of application and service by saving time and providing a higher degree of accuracy.

Quicker results, which would help to address issues with equipment or the lubricant in a timely manner.

One intent is to capture the variability associated with operation. Another intent is to reduce the impact of oil sampling errors.

The online/inline systems capture up to the minute data. They can predict upcoming events and prevent equipment/machinery from going down due to failure. The analysis acts as an early warning system that maintenance needs to take place, hopefully avoiding catastrophic failure or unplanned downtime.

Rapid response.

Real-time monitoring, proactive approach.

Instant monitoring of abnormal conditions versus days or weeks after the fact.

1.) Safety measures. 2.) System maintenance. 3.) Easy and cost effective.

They can be a good solution for applications that involve access difficulties, e.g., wind turbines.

Online/inline condition monitoring on a critical asset gives the earliest possible warning of a failure.

1.) The results will be on-the-spot analysis, so we can immediately identify any issues on the spot and rectify them. 2.) Also, transport and delays in testing are eliminated. 3.) Maintenance staff immediately understand the condition of the oil and machinery so they can take proactive, preventive measures immediately after testing. 4.) Test cost is less as compared to offline checking in the lab.

Using online/inline monitoring systems allows a quicker response to issues that occur, meaning you take equipment offline prior to damaging it.

The timing of the information from the sensors to decision makers/operators. Online/inline data is during operation, and the offline takes time to be analyzed.

For online/inline systems, the benefit is the ability to monitor or be alerted in real time virtually anywhere on how the system is operating. Offline system requires relying on an expert to analyze the solution but can identify other problems not seen by online systems.

Having the ability to tie them into your phone to alert you. 

The online systems provide real-time and dynamic traceable data, avoiding oil sampling and possible secondary contamination. In addition to data on contamination, moisture, oil viscosity, pressure, flow, temperature, liquid level and other operational indicators can be simultaneously tracked, enabling a comprehensive response to lubrication conditions. Numerous device status data can be collected, saving labor costs. Offline systems facilitate tests of many parameters and their greater stability.

Real-time results.

With staff shortages, this gives the user a better on-time way for condition monitoring. I still believe that you also should cross check when given time with a good lab.

Online or inline systems can enable an immediate feedback loop and potential for meaningful corrective action implementation and failure mitigation. With offline or offsite used oil analysis (UOA), there will always be time lag such that corrective action may not be implemented in a timely fashion to prevent downtime, failure, continued conditions worsening, etc. It also may mean that when a corrective action is finally put in place, it is no longer addressing the root cause but the root cause at the time point the UOA sample was taken.

Why are real-time condition monitoring systems using oil analysis not commonplace despite their advantages?
High capital cost 33%
Poor accuracy 8%
Technology still not proven 5%
Some key parameters not measurable 16%
All of the above 38%
Based on an informal poll sent to 15,000 TLT readers.

It is happening in real time as it is. It is there to view anytime as and when you need it. There will be better planning to execute the job if there is an issue detected in the samples. There would be repeatability in the analysis if an issue is detected in the analysis.

Mainly checking for the big hitters—cleanliness and water.

They provide immediate feedback and alerts when a failure starts to occur. Also some of these condition monitoring systems are able to detect larger particles in the system that may not always be present and may not be detected using offline systems.

Knowing the condition of oil at any time.

Real-time and timely data, real-time insights and proactiveness.

Real-time live data streaming.

Quick and accurate diagnosis and problem resolution.

More data available improving the statistical value.

Less time consuming, easy to operate, any time monitoring, etc.

Online oil monitoring systems for oil quality are only valuable in systems that are extremely critical or have a high risk of contamination or failure caused by specific quality faults such as water or incorrect lubrication. Continuous monitoring of other related oil issues such as temperature, level or pressure are far more common.

You can get live data and more representative data.

Samples tested in real time are typically more predictive than a sample collected and sent to a laboratory. A major problem can be reacted to immediately.

They may be more accurate.

Continuous live data.

The oil is analyzed almost in working condition (temperature, humidity).

Give a rapid indication for recommending a fast action before getting a full lube oil test report from the laboratory.

Real-time analysis, which will minimize the time lag for corrective measures/actions.

Online/inline systems provide real-time monitoring of oil condition, which allows for early detection of abnormalities and the ability to take corrective action before equipment damage occurs. It also provides more accurate data than periodic offline sampling. With online/inline systems, maintenance can be scheduled based on actual equipment condition, rather than on a predetermined schedule. This can help reduce maintenance costs by minimizing unnecessary maintenance activities. These systems can provide data on equipment performance, which can be used to optimize equipment operation and reduce downtime, thus increasing system efficiency.

1.) Cost saving—cost related to the oil sampling, logistics and lab analysis is saved. 2.) Real-time monitoring of the oil can help in predicting the failure event accurately and efficiently.

Saves time and effort. Saves manpower. Safer. Reliable due to automation.

Q.2 In your opinion, what would you do to make the online/inline condition monitoring systems using oil analysis more effective for promoting wider implementation?

Develop algorithms to spot trends and not rely on thresholds/limits; the latter requires empirical data with few variables, but reality has countless variables.

Buy a car with an inline system. I’d like to believe it would become more commonplace in consumer automobiles. It is an added cost and might not appeal to ignorant consumers. Show them they can continue to use their oil without harm (lowering the cost per change), and it might become appealing.

Make them more reliable and durable. Also introduce a dashboard where you can select the information that you specifically need to cut down on unnecessary data.

Make it a mandatory part of a warranty extension on a piece of equipment.

I am not directly involved with online condition monitoring, and it is hard for me to provide an insight. Online oil condition monitoring is currently used in some newer vehicles to monitor engine oil performance.

Lowering prices and convincing companies that condition monitoring is an investment, not an expense.

Combining multiple measurements into one unit and reducing the cost.

A wide implementation is born from the need, and this from the knowledge of the benefits.

Develop monitoring systems with better accuracy and lower price points.

Management likes cost savings, data collection cost savings being the more valuable.

Capture testimonials from actual customers currently using monitoring systems; share time/cost savings so others understand the ROI. Actual online/inline condition monitoring systems can control one or several key parameters (not too much) while with offline monitoring, you can get a very complete picture of your system condition, including lubricant degradation, potential contamination and wear. Attending that, with an inline system you get a partial view of the problem—that can be enough for detecting or anticipating some potential failures but not enough to have a complete panorama.

Could real-time condition monitoring systems using oil analysis replace offline systems in the next decade?
Yes 54%
No 46%
Based on an informal poll sent to 15,000 TLT readers.

Training/awareness of existing online/inline tools for condition monitoring.

The industry needs to develop sensors that can measure changes in physical/chemicals of fluid properties at more sensitive levels, then creating the algorithms that can translate those changes in actionable messages through the machine’s controllers and telematics.

Make the data live stream, with appropriate limits and action plans, such that it would be available for anyone involved in the process to see. That way folks can react appropriately without having to contact three or four different folks.

Provide continuous customer support and online training.

Engagement of multi-level inline filtration and sight glass installation. Constant attention on pressure valves and gauges to check oil levels.

There is need to have more different kinds of sensors that are accurate enough.

The reduction in cost would facilitate wider adoption.

Linking them with ultrasound control of devices or thermogravimetric cameras.

Meaningful results. Percent saturation is not easy to equate when you are used to seeing ppm.

Training and certification for staff to know what they are looking at.

I would give it a try on a machine that is a bad actor in the plant, and if the results turn out it works well, as in the analysis is the same as what we are getting in our scheduled oil sampling analysis, then I would promote to have this online system installed on more machinery.

Have OEMs add sensor ports to their equipment.

The factors below are all significant barriers to entry, and while technical solutions exist, they are not frequently cost effective for many non-critical applications. Having access to reliable and reasonably accurate online condition monitoring solutions at a much lower price point would be a key to wider implementation.

Centralized database.

Demonstrate how rapidly oil condition changes without effective and robust predictive maintenance inspections. Show variation in results due to techniques and locations.

Measurement of a wider range of properties. Nowadays that is often so limited, so that still the offline analysis is necessary as well, limiting the possible variable cost benefit of online/inline analysis. Lower use of chemicals.

Least cost possible.

Providing support for installation and transparent communication with customers.

It would be economical.

Proof that the technology would have prevented a failure that offline monitoring, regardless of frequency, would have missed. One other argument might be the lack of expertise or access to equipment. Continuous monitoring of vibration is more common.

I believe sensors technology is one thing but their calibration and maintenance need to be very clear for data verification.

Do you think real-time condition monitoring would become so commonplace, such as being installed in the dashboard console of your car to monitor your engine oil?
Yes 67%
No 33%
Based on an informal poll sent to 15,000 TLT readers.

Cost effectiveness, increased capability. More support for interpretation.

Ease and friendliness of use.

Presenting case studies proving the benefits.

Training staff and making them understand the importance of online condition monitoring.

Yes, my opinion is that it’s very useful for conducting oil analysis through in/online systems at wide ranges very efficiently and effectively.

I believe online condition monitoring is an indicator, but oil analysis tests in the lab can give a real situation and point to the real problem.

By focusing on the advantage of online/inline and offline condition monitoring over offline systems for condition monitoring.

For wider implementation, several strategies could be considered. 1.) Educating industry professionals about the benefits of online/inline oil analysis systems. Offering training programs to operators and technicians on how to use and maintain the online/inline monitoring systems. 2.) Enhancing the accuracy of the systems, reducing false alarms and minimizing downtime could help increase reliability and promote wider implementation. 3.) Online/inline monitoring systems generate a large amount of data, and providing easy-to-use data analysis tools could help operators and technicians quickly identify potential issues and take corrective action.
1.) Initial capital cost of the inline condition monitoring is high, so taking steps to reduce its cost is essential for promoting wider implementation. 2.) Sensitizing the customers about the benefits of the online condition monitoring systems.

Implement such systems in laboratories and test facilities at my workplace.

Editor’s Note: Sounding Board is based on an informal poll sent to 15,000 TLT readers. Views expressed are those of the respondents and do not reflect the opinions of the Society of Tribologists and Lubrication Engineers. STLE does not vouch for the technical accuracy of opinions expressed in Sounding Board, nor does inclusion of a comment represent an endorsement of the technology by STLE.