How is tribology different from vibration monitoring?

Vibration captures mechanical symptoms on the casing; oil analysis shows internal gear, bearing and hydraulic condition via particles and wear metals. Both complement each other on the P-F curve.

How often to sample a conveyor gearbox?

Critical no-spare drives — every 3 months; class A with spare — every 6 months. First three samples after startup or overhaul establish the baseline trend.

Do we need an on-site laboratory?

For 20+ class A assets a field lab often pays back in 12–18 months by avoiding unplanned stops. Smaller fleets can use an accredited external lab with a KEG TRK sampling procedure.

Is this the same as transformer oil analysis?

No. Tribology covers lubricating and hydraulic oils for gearboxes and hydraulics. Transformers use DGA, headspace oxygen and Rapidox — a separate section.

Mining · metals · power · gearboxes & hydraulics

Oil analysis & tribology

Laboratory and field monitoring of lubricants and hydraulic fluids: ISO 4406 cleanliness, Fe/Cu/Al wear metals, viscosity, water and full programs for auxiliary equipment.

KEG TRK supplies instruments, helps launch sampling programs and interprets trends at mining, metals and power sites across Kazakhstan.

Field laboratory →Article: oil analysis at mines →

Tribology equipment

Cleanliness & particles

Online oil particle monitor

Continuous in-line particle monitoring for critical no-spare gearboxes — real-time ISO 4406 trending

KEG TRK

Portable particle counter ISO 4406

Laser particle counter for lubricant and hydraulic oil cleanliness per ISO 4406 / NAS 1638 in the field

KEG TRK

Wear & spectrometry

Wear debris spectrometer

Atomic emission or ICP spectrometer for quantitative Fe, Cu, Al, Cr and other wear metals in oil

KEG TRK

Physical-chemical properties

Karl Fischer water-in-oil analyzer

Titrimetric water content in oil and hydraulic fluids — critical for gearboxes and hydraulics

KEG TRK

Oil viscosity analyzer

Kinematic viscosity at 40 °C and 100 °C to detect oxidation, dilution and oil grade mismatch

KEG TRK

Field laboratory

Field oil analysis laboratory

Instrument kit for mine, metals and power tribology: particles, wear, viscosity and water in one route

KEG TRK

Spectro MiniLab 153 — on-site oil analysis lab

AMETEK Spectro integrated field lab: wear (RDE-OES), particles, viscosity and oil chemistry in ~20 minutes with TruVu 36...

Spectro Scientific

Oil sampling

Oil sampling system

Sample valves, tap points, bottles and consumables for representative industrial oil sampling

KEG TRK

What does oil analysis provide?

Oil in a gearbox or hydraulic tank is a liquid archive of machine condition. Metal particles, water and viscosity loss appear before mechanical failure.

•Particle counters and online monitors — ISO 4406 / NAS 1638 cleanliness
•Spectrometry — chemical wear fingerprint (Fe, Cu, Al, Cr)
•Viscosity and Karl Fischer — oxidation, dilution, water ingress

For transformer oil, headspace oxygen and DGA companion see Rapidox.

Where tribology is applied

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Conveyor and crusher gearboxes

Fe and PQ trends — planned inspection before failure

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Hydraulic systems

Water, particles and viscosity — cavitation and cylinder wear

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Mining and mineral processing

Dust, overload and harsh media accelerate oil degradation

🔥

Metals industry

Roll tables, conveyors, gas-cleaning drives

⚡

Power plants and auxiliaries

Lube oil systems, feeder and PA fan gearboxes

🧪

Field laboratory

Route-based testing without waiting for external lab results

Benefits of an oil analysis program

📈

Trend beats a single sample

Three baseline samples set the line; +20% Fe in a quarter triggers inspection

🔬

Early gear and bearing wear

Spectrometry sees micropitting before GMF rises in vibration

💧

Water control in hydraulics

Karl Fischer catches seal ingress before cylinder seizure

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Field laboratory

Modular kit for conveyor and hydraulic fleets on one site

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Part of integrated PdM

Complements vibration, alignment and thermography on auxiliary assets

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KEG TRK in Kazakhstan

Supply, sampling procedure, training and report interpretation

Tribology resources

Four Predictive Maintenance Methods for Auxiliary Equipment: Alignment, Balancing, Oil, Thermography | KEG TRK →Laser Alignment of Auxiliary Equipment in Metallurgy, Ore Processing and CHP Plants | KEG TRK →Field Balancing of Fans and ID Fans in Metallurgy and Power Plants | KEG TRK →Laboratory Oil Analysis for Gearboxes and Hydraulics at Mines and Steel Plants | KEG TRK →Thermal Imaging Inspection of Auxiliary Equipment at CHP Plants, Mining and Metallurgical Sites | KEG TRK →Gearbox Diagnostics: Tooth Wear, Pitting and Misalignment Before Shutdown →Predictive Maintenance of Metallurgy Gearboxes: Spectral Analysis | Bently Nevada — KEG TRK →

Oil analysis FAQ

Start a tribology program

We will recommend instruments and sampling intervals for your gearbox, hydraulic and pump fleets.

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