HFDU fluids, or hardly flammable fluids, are used in hydraulic systems that have a high risk of fire due to exposure to high temperatures, incandescent surfaces, open flames, etc.
The purpose of analyzing these products for predictive maintenance is to periodically check their efficiency, degree of aging, and pollution by foreign elements (water, dust, etc.).
The control of these fluids is essential because the ester base (often of vegetable origin) used in their formulation, in addition to the advantage of having a higher flash point than that of classic mineral hydraulic oils, also has disadvantages linked to the product chemistry – often sensitive to the presence of humidity in connection with high temperatures.
The need to avoid the formation of sludge and lacquers that could lead to valve blockage, and machinery interruption in general, requires close monitoring of these fluids by an expert laboratory.
Many companies working in the steel industry, from steel or aluminum processing to die-casting, fluids called HFCs are often used in hydraulic systems. Due to their non-flammability, because mixed with water, they guarantee greater operational safety.
As with classic standard hydraulic oils, these types of products also require periodic efficiency checks to ensure their anti-corrosive properties, which are essential given the presence of water that could cause rust, and against solid pollution from environmental dust.
Because of their versatility, transmissions are essential in any type of production process for small and large companies.
Their efficiency and service life are closely linked to the characteristics and performance of the lubricants used to protect them against wear, corrosion, and possible sources of environmental pollution.
Predictive maintenance, through periodic lubricant analysis, is the quickest and safest way for maintenance managers to check the efficiency and residual effectiveness of the oil charge, and to assess the incidence of wear by analyzing the quantity, type, and shape of metal particles in order to focus their interventions on the key problems while keeping the entire production chain under control.
The need in various sectors, especially those related to the food industry, to store products at low temperatures has led to the widespread use of these machines.
The efficiency of the lubricant for these compressors is fundamental to guarantee the operation and continuity of the production processes.
Compared to conventional compressed air compressors, the work of lubricants in refrigeration compressors is further complicated by contact with refrigerant gases (e.g. ammonia), which can cause oil aging over time.
For this reason, NILS and its laboratory have developed many years of experience in compressor management and, through predictive maintenance analysis, have demonstrated the effectiveness of regular, professional monitoring to save in operating and production costs.
The quality of diesel fuel is fundamental in automotive, transport, and marine applications.
Stored in tanks for very long periods, it can undergo degradation, especially in the presence of water, thus creating important and often sudden problems to the engine.
Our laboratory performs, among other things, analyses on the diesel fuel quality and its degree of pollution (from solid dust, humidity, algae, etc.), along with sulfur or biodiesel content determinations to verify compliance with legal regulations.
The importance of grease in production processes is evident to almost every company with a manufacturing operation.
At NILS s.p.a., we have been studying its use for many years: from greases exposed to extreme temperatures, to greases suitable for heavy loads (“extreme pressure”), water-repellent greases, biodegradable greases, greases for the food industry, etc
Like lubricating oil, grease is a vehicle of information on the system’s efficiency and degree of wear. Residues of metal particles together with their shapes and sizes can signal wear and allow us to intervene effectively before possible breakdown and subsequent damages, variations of consistency can indicate pressures that are excessive for the type of grease in use, and the presence of water or solid pollutants in the lubricant can indicate conditions of use for which more frequent lubrication is required.
This and other information can be provided by our laboratory through the screening of a sample of lubricating grease and can be useful for implementing corrections or prompting timely maintenance.
Transformers play an important role in the production chain of companies whose electrical voltage must be managed according to their needs.
A failure in these systems would have serious consequences, as the power supply needed for production would likely fail.
The function of the transformer’s internal oil is to electrically insulate and cool the system. As it is exposed to very high local temperatures, it is essential to check its condition with appropriate analyses.
It is possible to check oil and transformer conditions using standard viscosity tests, acidity and water content analysis, as well as more specific tests for insulating capacity (e.g. dielectric strength), the presence of corrosive sulfur, or paper degradation by checking for furans. The analysis of gases dissolved in the lubricant, which are taken using special syringes, allows us to check for malfunctions and trace their causes.
For older transformers, it is often necessary to check PCBs, which are hazardous to health and the environment, in order to comply with legal requirements.
While hydraulic systems allow the transmission of motion and force, diathermic systems are the means of heat transmission in many production areas.
The main stresses to which these systems (boilers, pumps, expansion tanks, coils, etc.) are exposed are due to the high temperatures involved (typically greater than 200°C) and the long periods of use.
Under such conditions, the thermal oil gradually loses its functions and, if not carefully monitored, can lead to increased running costs, system deterioration, and, ultimately, breakdowns and accidents.
With regular sampling and analysis, all these aspects are kept under constant control to ensure that companies operate their plants correctly and optimally, saving on maintenance and improving internal safety standards.
The engine is the first mechanical device thought of in terms of lubrication.
There are multiple functions of engine oil: protection against contact and sliding wear, the cooling action that oil has on the engine, and detergency and protection against oxidation.
Regular and constant engine monitoring, not only for motor vehicles but also for earthmoving or nautical vehicles, combines professional use with the security derived from having a mechanical device in a controlled and safe service state.
The onset of wear particles is detected promptly by our diagnostic instruments, making it possible to monitor the growth trend and allowing planned action to be taken before any breakage occurs which may cause sudden failures with major economic consequences.
To keep an engine in perfect working order additives, condensation, soot, antifreeze, fuel and the state of oxidation must be regularly monitored.
The increased demand from companies for large quantities of compressed air has led to the widespread use of these machines. Vane, rotary, or piston compressors represent one of the most common components of both industrial and non-industrial sectors.
Lubricant efficiency in this sector is essential to ensure the operation and continuity of production processes.
From the use in the artificial snowmaking field to that in the earthmoving and industrial sectors, NILS and its laboratory have developed many years of experience in compressor management and, through predictive maintenance analysis, have demonstrated the effectiveness of periodic and professional inspections leading to concrete savings in management and production costs.
