Generating electricity from methane-powered biogas engines comes with a major hurdle: the cleanliness and quality of the gas significantly impact the performance and lifespan of lubricating oil.
The Downside of Traditional Lab Oil Analysis
To prevent catastrophic failures, operators have traditionally relied on regular oil sampling. However, delays in receiving laboratory results often force operators to adopt a conservative maintenance approach, meaning they frequently miss out on key operational efficiencies.
The Real-Time Solution
To overcome the limitations of traditional lab testing, a trial was conducted using the Tan Delta Oil Quality Sensor (OQSx). The Tan Delta Express Kit was installed on a set of Jenbacher 320 gas engines and monitored over three complete oil change cycles. During this time, traditional lab samples were also taken to correlate the data. The results were remarkable: the OQSx sensor perfectly tracked the laboratory analysis from the moment the oil was clean right through to the end of its life. This high degree of accuracy is powered by Tan Delta's Full Spectrum Holistic (FSH™) technology, which ensures that any contamination or wear is detected, quantified, and reported in real-time so that nothing is missed.
The ROI and Operational Benefits
Implementing this real-time monitoring solution across a fleet of 35 engines delivered massive commercial and operational wins:
- Massive Cost Savings: The fleet realized savings of £125,000 per year.
- Plummeting Failure Rates: The real-time data led to an 80% reduction in catastrophic engine failures.
- Optimized Maintenance: By having the ability to see oil conditions in real-time, operators could safely increase oil change intervals and reduce the number of laboratory samples needed. Less downtime directly translated to significantly lower operating costs.
- Environmental Conservation: The facility successfully eliminated unnecessary oil waste by only changing the oil when it truly needed to be changed, reducing overall consumption and helping the environment.
- Improved Workplace Safety: Because the technology ensures that equipment is consistently kept in optimal condition, it creates a much safer working environment for staff.
Ultimately, this case study proves that utilizing robust technology designed for harsh industrial applications doesn't just prevent breakdowns—it actively optimizes equipment productivity and slashes ongoing costs