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It also helps to know the metallurgical makeup of the engine. "Many engines are similar, but some are different," Silveira comments. "As we go to newer technology engines, [it helps to know] if it is babbit or bearing wear vs. liner wear vs. ring wear... In many cases, the OEM can provide you with [the information] to assess where those metallurgical families line up with the engine. You may be able to diagnose something sooner than later."

You also need to understand what drives failures. "In the past, we always just looked for wear metal. What we are finding is that wear metal is really the result of other things, it is not the cause," explains Wacaser. "So now we look at the quality of the oil, the mixing of the oils and how long it has been in the machine... We are trying to get back to causes, not react to wear."

Consider the oil's viscosity, as well as the Total Base Number (TBN), which is the reserve capacity for acid neutralization. "You can look at that and you know how many hours you can run that oil without doing any damage whatsoever," says Wacaser.

Oil analysis can also be used to spot when the wrong products end up in a certain component. "Some people are taking it to the next level, where they are watching the additive concentration in oils," says Silveira. "Depending upon the additive makeup of the oil you are using, it helps you determine if the oil was contaminated." For example, say the oil doesn't contain zinc, yet it shows up in the oil analysis report. "Somebody may have topped off with a different oil, like a hydraulic oil."

Costs vs. benefits of extended drains
"Condition-based maintenance requires a very structured testing program to ensure you are doing the correct testing at the correct time," says Jason Papacek, data analysis manager and certified lubrication specialist, POLARIS Laboratories. "You also have to consistently review your reports, read the recommendations and take action when necessary. A reporting software application can help you manage the data across your fleet, as opposed to one report or unit at a time. How effectively you sample and react to data will determine how much you can benefit from a condition-based approach to maintenance."