WearCheck | News Blog

Precision in every drop – powered by ICP technology

2025-10-30T12:23:27+00:00

Inductively Coupled Plasma – Optical Emission Spectroscopy (ICP-OES) turns a small oil sample into clear maintenance intelligence. The sample is nebulised into an argon plasma, where atoms are excited and then emit light at element-specific wavelengths in the UV/visible range. The intensity at those wavelengths is proportional to concentration, which means that metals and additives can be quantified precisely against calibration curves.

In the latest high-tech ICP instruments at WearCheck, modern Echelle optics with CCD/CID detectors capture many wavelengths at once, enabling fast, simultaneous multi-element analysis with excellent sensitivity and selectivity. Rigorous calibration underpins accuracy: certified reference materials, tight linearity (very high R² values), daily calibration checks, scheduled services and periodic method validation keep results reliable across different lubricant types.

High-throughput autosamplers enable us to process 100+ samples per hour, with multiple rapid reads per sample to strengthen precision. Automated quality controls pause analysis if anything falls out of spec. Aligned to recognised methods (such as ASTM D5185), this approach provides consistent insight into additive health, contamination and component wear, helping teams decide if oil is fit for service, spot abnormal wear early and plan interventions before minor issues become failures. In short, WearCheck offers faster turnaround, lower detection limits and data you can trust.

For a deep-dive into our ICP offerings, you can read our latest Technical Bulletin 94, which can be downloaded here.

Our latest Monitor newsletter is ready!

2025-08-21T12:45:24+00:00

Dissolved gas analysis, rheology, advanced legionella testing, top transformer tips and even a chance to win a prize worth R6,000 – these are just some of the stories featured in the latest WearCheck Monitor newsletter.

We also bring you news of international and local expos and conferences where WearCheck was present, and a heartwarming story about some very special blankets, which were knitted by one group of grannies and donated to another group of grannies.

Technical training for maintenance staff is an investment which yields excellent returns. Check out our latest schedule of upcoming customer training courses, which focus on more than 12 different areas of condition monitoring.

You can read Monitor 97 here: WearCheck Monitor 97

ANTIOXIDANT ADDITIVES – the anti-ageing additive in your oil

2025-07-16T12:09:53+00:00

Calling all pop quiz hot shots - what do blueberries, a jar of the most expensive face cream in the world and a drum of new engine oil have in common? They are all jam packed with oxidation inhibitors, or antioxidants, as they are also known.

In this instalment of the lube series, we are going to unpack the oxidation process and explore how antioxidants keep your oil young at heart.

Oxidation is perhaps the most common chemical reaction, not just in lubricant chemistry, but also in everyday life. Oxidation reactions take place during the combustion of fuel, when metal surfaces rust, when cleaning wounds with hydrogen peroxide and even when a cut apple turns brown.

Here’s a bit of trivia - once exposed to oxygen, enzymes in your apple begin converting natural chemicals called polyphenols into melanin that gives the flesh a brown, rusty colour.

In a nutshell, oxidation is the loss of electrons or the increase in oxidation state of a molecule, atom, or ion in a chemical reaction. When it comes to lubricating oils, oxidation results in the sequential addition of oxygen to the base oil molecules, producing a number of different chemical species, including aldehydes, ketones, hydro-peroxides and carboxylic acids.

Oxidation is the primary cause of oil degradation, and it occurs at all temperatures, but is accelerated at higher temperatures. Like many chemical reactions, oxidation rates increase exponentially with increasing temperature due to the Arrehenius rate rule. For most mineral oils, a general rule of thumb is that the rate of oxidation doubles for every 10°C increase in temperature above 75°C. Oxidation is further accelerated by the presence of contaminants like water, and wear metals like iron and copper, which act as catalysts.

Oxidation in lubricants takes place through a complex series of chain reactions that consists of three key stages - initiation, propagation and termination.

In the initiation stage, one of the external factors (temperature, contaminants, wear metals etc) causes a free radical (or unpaired electron) to be generated in one of the organic species that is part of the lubricant. This process involves breaking a bond with a hydrogen atom.

The free radical is a highly reactive species that can react with oxygen to form a peroxide radical, that can generate additional radicals through reaction with more components in the lubricant. This step is known as propagation and leads to further decomposition of the lubricant.

Eventually two of the radical species combine and form a stable compound. This is the termination step, because it removes free radicals from the system. However, the termination step is only effective in stopping the process if no more free radicals are formed during initiation.

In terms of its effects, oxidation typically results in impaired chemical and physical properties of the base oil and additives – increases in viscosity and organic acids, the formation of sludge and varnish, additive depletion - all of which, in turn, will have a detrimental effect on the system being lubricated.

It stands to reason that improving oxidation resistance is critical to improving lubricant stability and the operational life of the lubricant which, in turn, allows for extended oil drain intervals.

So, now for the start of the show. Antioxidants are used to extend the operating life of your lubricant, and these days, nearly all lubricant formulations contain some kind of oxidation inhibitor in some concentration.

They function by interrupting the three-step oxidation process either through reaction with free radicals or decomposing peroxide radicals.

There are two main types known as primary and secondary antioxidants. The former inhibits oxidation by reacting with chain-propagating free radicals to form stable molecules. Primary antioxidants are basically free radical scavengers made from compounds like aromatic amines and hindered phenols.

The latter, secondary antioxidants, are peroxide decomposers that consume unstable hydrogen peroxides to form stable alcohols. It is for this reason that secondary antioxidants are also known as peroxide decomposers. These peroxide decomposers are made from phosphorus- and sulphur -containing compounds that include sulphides, phosphates and - my personal favourite - zinc dialkyldithiophosphates, or ZDDPs.

Besides functioning as an antioxidant, ZDDPs are also a very effective anti-wear agents in many applications. ZDDPs have been a mainstay of diesel engine oil formulation and performance for over 60 years, and with good reason – no single additive provides the same benefit as cost effectively as ZDDPs.

However, The Times, They Are a-Changin’. With new engine designs and the addition of emission-control technologies, come changes to oil formulations and, needless to say, additive selection.

With the restriction in phosphorus-containing additives like ZDDPs and increased oxidation-control requirements, formulators are increasingly turning to incorporating higher levels of ashless antioxidants in their blends. Adieu ZDDPs!

WEARCHECK WATER EARNS ACCREDITATION FOR MICROBIOLOGICAL TESTING

2025-04-14T11:11:47+00:00

Great news from the WearCheck Water team — our Johannesburg lab has just earned ISO/IEC 17025 accreditation for testing Total Coliforms and E. coli in water. This follows a detailed audit process and adds another feather to our cap when it comes to delivering top-quality testing services.

What It Means for Our Customers

This new accreditation gives our clients — both in South Africa and beyond — even more confidence in the work we do. It proves our team is working to the highest international standards when it comes to microbiological testing.

WearCheck Water is part of WearCheck, a specialist condition monitoring company. We’re proud to be the only oil analysis company in Africa with ISO 9001 (quality), ISO 14001 (environmental), and ISO/IEC 17025 (lab quality) certifications — and now our water division is even stronger with this latest win. We also recently received SANAS accreditation for testing AdBlue®/DEF (diesel exhaust fluid).

Why This Testing Matters

General Manager of WearCheck Water, Thelma Horsfield, explains:

“It takes months of hard work to develop the testing method and get it up to standard for SANAS approval. This accreditation confirms our lab’s ability to carry out precise and reliable water-quality testing.”

The method we use — membrane filtration — is a well-respected technique in water testing. It helps us identify and count total coliforms and E. coli in water samples.

Coliforms are bacteria often found in soil, plants, and surface water. Most are harmless, but their presence in drinking water could signal other dangerous contaminants. E. coli is a specific type of coliform found in the intestines of warm-blooded animals, and some strains can cause serious illness — so accurate detection is crucial for public health.

Celebrating Our People

A big shout-out goes to our lab assistant Khensani Mbuli, who played a key role in securing this accreditation. Thanks to her dedication and skill, she’s now been appointed an ISO/IEC 17025 Technical Signatory — a huge achievement in the world of lab testing!

Thelma explains: “Becoming a Technical Signatory is no small task. It takes deep knowledge, hands-on experience, and loads of training. TSs have the final say when it comes to signing off test results, so it’s a position of real trust and responsibility.”

Khensani joins six other senior Technical Signatories in our team: Moses Lelaka, Thelma Horsfield, Lerato Letsoalo, Lorato Hotane (our nominated rep), Katlego Mokoroane, and Michelle Wium.

Supporting a Range of Industries

WearCheck Water offers professional water analysis services across a variety of sectors — from mining and agriculture to manufacturing and fleet management. This latest accreditation is just one more way we’re proving our commitment to quality, reliability, and keeping water safe.

Crude awakening – part 1 of 4

2025-02-25T17:24:53+00:00

You’re in for a ‘crude awakening’ when you download WearCheck’s latest Technical Bulletin! You will be treated to an in-depth explanation of the processes of producing oil, fuel and other petrochemical wonders that power our modern lifestyle. The epic tale about this almost magical process begins with the formation of the crude oil millions of years ago, and flows through all the stages of extracting, distilling, cracking, coking, refining and blending it into consumer-friendly products.

If you’d like to join us as we explore the molecular magic and unpack the chemistry behind crude oil, please download Technical Bulletin 92 here.

SAMPLING TINS AND BEST PRACTICES IN TRANSFORMER OIL ANALYSIS

2025-01-29T10:58:36+00:00

Transformer oil analysis is a crucial aspect of electrical maintenance, ensuring the reliability and efficiency of oil-filled electrical equipment. However, the accuracy of this analysis begins long before the laboratory testing process—it starts with proper sampling. The choice of container and adherence to best practices play a significant role in obtaining reliable results.

The Importance of Proper Sampling

Laboratories follow strict procedures and standards to maintain compliance with industry certifications and requirements. However, even the most advanced laboratory can only provide accurate results based on the quality of the sample it receives. If a sample is taken incorrectly, stored improperly, or collected in a contaminated container, the results may be compromised. This can lead to incorrect diagnoses and costly maintenance decisions.

Recommended Sampling Containers

In South Africa, the standard container for transformer oil sampling is a one-liter tin. However, alternative containers may be used under specific circumstances:

1. Glass Bottles

Certain mining operations require the use of clear glass bottles for security reasons. While glass is suitable for sampling, it presents safety risks due to its fragility. Breakage during transport or handling can pose hazards to both field personnel and laboratory staff.

2. Plastic Containers

Plastic containers are generally discouraged because they can interfere with most laboratory tests. However, they are acceptable for Polychlorinated Biphenyls (PCB) analysis. For this purpose, WearCheck provides 100 ml single-use plastic bottles, which are responsibly discarded after testing to ensure environmental compliance.

3. Gas-Tight Syringes

For Dissolved Gas Analysis (DGA), gas-tight syringes offer excellent repeatability, particularly for transformers with high gas levels, such as those in wind and solar farms. However, these syringes hold only 30 or 50 ml of oil—insufficient for comprehensive testing—and are more expensive than tins. They are also fragile and prone to breaking during sampling, transport, or handling in the laboratory.

Why New Tins Matter

WearCheck strongly recommends using new tins for each sample. While this increases sampling costs, it helps prevent contamination-related issues. A recent case study illustrates the risks of reusing tins: a client noticed a slight increase in PCB values, which was traced back to a second-hand tin. The history of reused tins is often unknown, and residual contaminants can skew moisture and dielectric readings. This can lead to unnecessary oil purification or replacement, costing clients significant amounts of money.

Best Practices for Transformer Oil Sampling

To ensure accurate results, the sampling process must be conducted with precision. Here are some key best practices:

1. Clean the Sampling Container with Transformer Oil

A client in the Northern Cape reported finding water in the flanges from which samples were taken. This underscores the importance of flushing the sampling container with oil from the transformer to remove potential contaminants.

2. Avoid Reusing Sampling Tubes

Residual water or PCB contamination from previously used sampling tubes can compromise results. Clients should work with reputable service providers who follow stringent protocols to prevent cross-contamination.

3. Rely on Trained Technicians

Improper sampling techniques, even minor mistakes, can lead to incorrect diagnoses and costly consequences. Engaging trained professionals ensures that samples are taken correctly, stored properly, and handled according to industry best practices.

Conclusion

Proper sampling is the foundation of accurate transformer oil analysis. By using the correct containers, maintaining cleanliness, and ensuring trained professionals conduct the sampling, clients can trust the integrity of their oil analysis results. Cutting corners in the sampling process can lead to misdiagnoses, unnecessary maintenance, and financial losses. Investing in proper sampling practices is an essential step toward effective transformer maintenance and long-term operational reliability.

ADBLUE AND ACCREDITATION: WHY IT MATTERS?

2025-01-22T13:01:17+00:00

At WearCheck, we’re thrilled to share some exciting news—our Water division has become the first laboratory in Africa to achieve ISO17025 accreditation for testing AdBlue®/DEF (Diesel Exhaust Fluid)! This certification, granted by the South African National Accreditation System (SANAS), is a major milestone that reinforces our commitment to quality and precision.

Why Is Accreditation Important?

Accreditation isn’t just a fancy certificate on the wall—it’s proof that a laboratory meets strict international standards. With this new ISO17025 accreditation, WearCheck can now officially test AdBlue®/DEF to ensure manufacturers meet the ISO 22241 requirements. This is essential for AdBlue® producers, fleet managers, fuel depots, and original equipment manufacturers (OEMs) who rely on high-quality DEF to keep their diesel engines running cleanly and efficiently.

What Is AdBlue® and Why Does It Matter?

AdBlue® (also known as DEF) is a key player in reducing vehicle emissions. It’s a non-toxic, colorless liquid made of 32.5% high-purity urea and de-mineralized water. When injected into the exhaust system of vehicles with Selective Catalytic Reduction (SCR) technology, it helps break down harmful nitrogen oxides (NOx) into harmless nitrogen and water vapor. The result? Cleaner emissions and a healthier environment.

The Science Behind AdBlue®

Vehicles with SCR technology have a separate AdBlue® tank, which feeds the fluid into the exhaust stream. When heated, AdBlue® decomposes into ammonia and carbon dioxide. This ammonia reacts with NOx in the catalyst, converting it into nitrogen and water—substantially reducing air pollution. But for this process to work efficiently, AdBlue® must be produced to exacting ISO 22241 standards, ensuring it doesn’t harm engines or emission systems.

How WearCheck Ensures AdBlue® Quality

At our Johannesburg laboratory, we conduct a range of tests to verify AdBlue® quality, including:

Titrimetric Testing: Checking alkalinity levels.
Gravimetric Testing: Identifying insoluble matter.
Colorimetric Testing: Measuring biuret and aldehyde content.
Ionisation Testing: Detecting metal contamination.

We’ve also invested in a state-of-the-art refractometer to enhance our testing capabilities. And soon, we’ll be expanding this service to our Cape Town laboratory!

How to Take a Proper AdBlue® Sample

To get an accurate test result, sampling must be done correctly. Here are some tips:
Use only high-density polyethylene (HDPE) or stainless steel containers.
Ensure containers are free from chemical residues—rinse them with distilled or deionized water before use.
Take a representative sample—avoid areas with sediment or contamination.
Flush the sampling point by allowing a few liters to flow out before collecting the sample.
Seal and label the container properly, then store it in a cool, dry place until testing.

Need Your AdBlue® Tested?

If you manufacture, distribute, or rely on AdBlue®, WearCheck’s analysis services ensure that your product meets ISO 22241 standards. Contact us today to learn more!

Visit: www.wearcheck.co.za / Call: (021) 001 2100/ Email: mosesl@setpoint.co.za.

Stay ahead with WearCheck—your trusted partner in fluid analysis!

UNLOCKING LUBRICANT LONGEVITY: THE POWER OF RPVOT TESTING

2025-01-09T16:07:45+00:00

There are multiple degradation pathways that turbine oil faces under operational stress, but the dominant failure mode in an operating system is oxidation, one of the primary causes of lubricant degradation.

Simply put, oxidation occurs when oxygen reacts with the hydrocarbon molecules in the base oil of a lubricant. The oxidation process is significantly accelerated by heat, with a 10°C increase in oil temperature effectively doubling the oxidation rate. Contaminants such as water, and metallic wear particles containing copper or iron, act as catalysts, further speeding up oxidation.

As oil oxidises, it forms acids and insoluble oxidation products, which can lead to formation of sludge or varnish. These degradation products can coat bearing and oil-cooler surfaces, preventing adequate cooling of the bearings. Areas with tight tolerances such as hydraulic control valves can also become coated, causing operational issues. What’s more, as the oil oxidises, its foam control, demulsibility and air-release characteristics will likely deteriorate.

In a nutshell, poor oxidation resistance shortens the oil’s service life.

All turbine oils contain antioxidants, which serve as the base oil’s first line of defence against oxidation. However, like all additives, antioxidants are sacrificial in nature and must be monitored through advanced oil analysis to determine the oil’s remaining life. This allows for proactive planning of oil replenishment and maintenance activities.

One such advanced oil analysis technique is the Rotating Pressure Vessel Oxidation Test (RPVOT).

The RPVOT is an essential tool in the lubricant industry for evaluating a lubricant’s oxidation resistance, particularly for turbine oils, hydraulic fluids, and other industrial lubricants. This test is crucial for ensuring that lubricants can withstand the oxidative stress encountered during operation, thereby extending their service life and protecting machinery from premature wear.

Let’s take a closer look at how WearCheck performs RPVOT analysis using ASTM D2272 – Method B.

The test begins by placing a predetermined amount of the lubricant sample, along with distilled water and a copper catalyst coil, into a glass container. This container is then sealed and placed inside a rotating pressure vessel, which is filled with oxygen to a specified pressure and heated to a standardised temperature (typically around 150°C).

Initially, the antioxidant additives in the oil resist oxidation. However, once these additives are depleted, the oil starts to oxidise, leading to a pressure drop within the vessel. The test continues until the pressure drops by a predetermined amount, with the time taken for this drop indicating the oxidation stability of the sample.

Depending on the condition of the sample, the test duration can range from 200 minutes to over 3,000 minutes. The result is reported as the time, in minutes, required for the pressure drop to occur. A longer RPVOT time suggests better oxidation stability, indicating that the lubricant is more robust and capable of performing well under oxidative stress.

For industries where equipment reliability is paramount, performing regular RPVOT analysis is invaluable, as it provides an early warning of potential lubricant degradation issues that can escalate to unplanned downtime. The cost of changing the oil in an industrial turbine is substantial, so maximising lubricant life is key. However, the greatest financial benefit of advanced oil analysis techniques like RPVOT is improved machine reliability and overall operational integrity.

Enter WearCheck’s world of condition monitoring, and more …

2024-12-13T06:46:34+00:00

You will find the magic worked by Extreme Pressure (EP) additives on metal surfaces, sustainable water-saving tips, useful transformer maintenance advice, a discussion on the power of RPVOT testing – these stories and loads more await you in our latest Monitor newsletter.

Looking to upskill? You can select your team’s 2025 training courses, and even sign up for our free monthly Toolbox Training sessions!

Explore Monitor 95 here.

SLIDING THROUGH TIME - part 4 of 4

2024-10-17T12:19:35+00:00

Technical Bulletin 91 just slid onto our website! In this final part of the epic story spanning the progressive development of lubrication from Stone Age to Modern Age, we begin in the early 20th century. Here, the enthralling tale of how scientific progress in both North America and Europe had a major impact in the outcome of World War II is told. We are taken from the battlefields in Germany, to various laboratories and even a captivating court case in the USA between two of the world’s major oil giants.

We invite you to embark on the final chronicle of how a simple substance, oil, has propelled civilisation. Click here: https://www.wearcheck.co.za/shared/TB91.pdf