Oil analysis specialists WearCheck’s on-site sampling has received a vote of confidence from the Mpumalanga Mining fraternity since the service’s introduction a year ago, with several large mines signing up.

Trained WearCheck technicians travel to the mines to take samples from mining machinery on site.

Customers have the option of either basing WearCheck personnel on their site, or WearCheck can provide daily sampling services to mines where the workload does not require a full- time mine employee to do the actual sampling.

During an intensive three month training course, the specialised sample technicians pass an obligatory “induction”, which qualifies them for sample collection, both underground and on machines that are brought to the surface for routine maintenance.  

Once samples are taken, they are delivered directly to the nearest WearCheck laboratory for testing, analysis and diagnosis, and where necessary, clients are then alerted to potential machine component concerns.

Neil Robinson, managing director of WearCheck, believes that investing in this service saves mines time and money.

‘Historically, companies who invest in our oil analysis service have reported a return-on-investment ratio of approximately 1:10, with massive financial savings through the early detection of component wear, which in turn avoids costly, unscheduled downtime.’

‘By using our resources to do the sampling, it removes responsibility from the site engineer and his team, thus enabling our clients to remain focused on their core business, which is mining,” he said.

‘Another benefit is the increased consistency it brings to the sampling process by reducing the inevitable variables that occur when there are multiple “sample takers”, and this can assist in optimising the accuracy and validity of the analysis.

WearCheck’s Chis Hattingh, who provides operations/technical support for the on-site service in the region, takes up the story:

‘On one of our coal mine contracts, we invested in a specially-modified vehicle that complies with mining regulations. This vehicle is certified to navigate underground in a coal mine, collecting samples as per the mine maintenance schedule. Without the vehicle, the sample technician would be required to walk up to 8 kms to collect the samples.

‘Our technicians take samples from any mining machinery with oil-wetted components, including CMs (continuous miners), shuttle cars, roof bolters, feeder breakers, crushers, conveyor gearboxes, LHDs (load haul dumpers), tractors and stone dusters.

‘We are currently servicing several large mines, including BHP Billiton’s Khutala Mine and Samancor’s underground chrome mines.  These include the Doornbosch, Lannex and Tweefontein sites.’

In addition to their mining focus, WearCheck provides on-site sampling service to a wide variety of industries, including oil refineries, sugar mills, aluminium mills, factories, process plants, paper mills and the petrochemical industry.

A new dimension to WearCheck’s traditional oil analysis service brings relief for customers with troublesome components, through the introduction of a mobile troubleshooting service.

Until recently, customers sent oil samples to WearCheck for analysis and diagnosis.  A normal result meant operations continued uninterrupted.

However, reports indicating abnormal symptoms meant customers had to investigate and fix the source of the problem, which caused difficulties for operations without the necessary resources to conduct the repairs.

Now, a specially-trained WearCheck technician with a diagnostic toolkit can be called on-site to investigate, identify and evaluate problems.

Technical support consultant for WearCheck, Herman Geldenhuys, who developed the troubleshooting toolkit, explains, ‘Typical customer reactions to problematic reports were: “What do we do? How do we do it? We don't have the skills - the tools - the knowledge - we need help!”  The mobile troubleshooting clinic evolved in response to these calls for help.

‘Our on-site diagnostic equipment identifies symptoms such as blow-by, low oil pressure, coolant leaks, crank shaft float, exhaust pressures and abnormal operating temperatures. An evaluation report then equips the customer’s technicians to isolate and rectify the faults.’

Geldenhuys believes the new service has additional benefits. ‘Prior to purchasing pre-owned equipment, WearCheck’s mobile troubleshooter can test, evaluate and verify the quality of the unit.

‘Furthermore, the troubleshooting service can determine the necessity (or not) of conducting costly periodic machine overhauls or re-builds.

Says Geldenhuys, ‘Sometimes, customers do not gain the true potential savings of an effective oil analysis program due to skills or equipment shortage. The new mobile troubleshooting service aims to address this, and take traditional diagnostic oil analysis to the next level by extending condition monitoring to incorporate an on-site repair dimension.’

For more information, please visit www.wearcheck.co.za, or call WearCheck on (011) 392-6322 or Herman Geldenhuys on 083 628-9404.

It is with great sadness that I write to inform you of the passing of Gary Brown.
Gary passed away peacefully on Saturday the 3rd of March 2011 after losing his fight with cancer.

As most of you are aware, Gary was one of the founders of WearCheck nearly 40 years ago
and was responsible for creating the foundations on which the success of WearCheck stands today.

Bernard of Chartres used to say

Gary is survived by his wife Jenny, daughters Jill and Brigette, son Quentin and his five grandchildren.
I'm sure you will join me in sending our condolences to the Brown family at this sad time.

Neil Robinson

The presence of silicon, its compounds or its alloys in lubricants has long been considered an indicator of wear and / or contamination. However, this can be misleading.

For an accurate understanding of the implications of the detection of silicon in oil, it is essential that the interpretation of oil analysis results is conducted holistically, and all results are diagnosed in relation to each other by highly skilled and experienced diagnosticians.

In the latest Technical Bulletin, WearCheck’s Diagnostic Manager John Evans discusses the various sources of silicon and what it means when present in oil.

Click here to download Technical Bulletin 53 (1.5MB)

The 2012 Super 15 rugby tournament kicks off in just 3 days!

Make sure you don’t miss your team playing by downloading the WearCheck Viewing Schedule which highlights all the matches and times taking place over the 24 week long tournament.

Click here to download (1.5MB)

The official opening ceremony for WearCheck’s 6th world-class oil analysis laboratory - situated in Kitwe, Zambia - took place last month, and was attended by various key players in the mining, earth moving industry and petro-industries.  Guests were treated to music, a sit down lunch and a detailed tour of the laboratory.

WearCheck managing director Neil Robinson praised the Kitwe laboratory project team at the launch. ‘The fact that the laboratory was able to process in excess of 1500 samples in the days before the official opening ceremony is testament to the demand for a reliable oil analysis service in the region, and we are grateful for the support from Zambian businesses.
The new state-of-the-art laboratory effectively doubles WearCheck’s Zambian presence as it joins the already successful laboratory at the Lumwana copper mine, both of which boast a 24-hour sample turnaround time.
 
Robinson added that a fuel and transformer oil testing laboratory will be introduced to the Kitwe laboratory later this year.
We wish the entire WearCheck Zambia team every success and congratulations on a great start - may you continue to grow from strength to strength!

Despite difficult global trading circumstances, WearCheck enjoyed a successful and busy year in 2011 with lots of ‘firsts’ and other highlights, including many exciting new services and tailored tests, new laboratory instruments and a presence in several new countries.

Reliable, world-class oil analysis service from a highly experienced team is supported by state-of-the-art laboratory equipment and well-trained back-up staff.  This, coupled with WearCheck’s structured expansion has seen the company show steady growth in both the domestic and international markets, entrenching its position as one of the global leaders in the oil analysis industry.

Some of the 2011 milestones are:

• A brand new, state-of-the-art Perkin Elmer gas chromatograph for determination of fuel dilution was installed in WearCheck’s Middelburg laboratory, bringing its analysis capabilities in line with WearCheck’s other laboratories.

• WearCheck entered the market in Namibia, with the opening of sales and support branches in Windhoek and Swakopmund.

• WearCheck's India laboratory was officially opened in July, expanding the WearCheck network from southern Africa to the Middle East and across to India. WearCheck India aims to service the burgeoning local wind turbine industry.

• The planning and groundwork for the January 2012 opening of WearCheck Kitwe progressed throughout 2011, culminating in the opening of our doors on the January the 20th.

• Each month, ongoing specialised staff training and upgrading of laboratory equipment took place, keeping WearCheck at the forefront of technological innovation.

• Service levels reached new heights with the launch of the first underground sampling facility for the mining industry, boosting WearCheck’s range of on-site sampling services. This was in conjunction with the expanded sampling service offered in the Steelpoort area with the purchase of a second vehicle and recruitment of additional sampling staff.

• Adding to WearCheck’s tailored product range of fluid analysis tests for specific industries was the introduction of the comprehensive and sophisticated heat transfer and turbine oil analysis kits. 

• The online reporting system was formally introduced and has become increasingly popular, with many customers preferring this method of receiving their test results.

• WearCheck workers showed their hearts by partnering with the company in several community upliftment initiatives. During 2011, the children at St Vincent’s orphanage received gifts, treats and two wonderful parties, the U13 Highway soccer team sported new sponsored uniforms; and the education of 700 adults at the Thuto-Mfundo Adult Centre was boosted through the donation of a new computer laboratory and sewing machines.

• A daring team of WearCheck and Set Point staff took part in the popular, but daunting, 94.7 cycle race. All participants agreed that training and racing together was a great team-building exercise, and went a long way towards boosting fitness levels, improving motivation and setting and achieving goals.

• A feather in WearCheck’s cap, and further confirmation of their strong service excellence ethic, was having several SABS audits conducted throughout 2011 without any major findings.

• The annual WearCheck International (WCI) conference was hosted by WearCheck’s Pinetown branch in 2011. WCI members from seven countries met to discuss the latest oil analysis developments and share their experiences, technical research and skills.

• And a real achievement for 2011 is the increase in the number of samples processed per year - now in excess of 600 000 annually - a statistic that entrenches WearCheck’s position as the leaders in oil & fuel analysis!