How to Prevent Failures in the Railway Industry (A Guide to Laboratory Testing)

Key areas of oil analysis in the railway sector and a clear overview of the most important laboratory tests for the railway industry, broken down into: gearboxes and bearings, hydraulics, fuels, and transformers.

How to prevent failures and downtime in railway rolling stock?

Oil diagnostics is one of the key elements of modern maintenance in the railway industry. Regular oil analysis enables early detection of component wear, assessment of lubricant condition, and identification of contaminants affecting system performance.

As a result, it is possible to reduce the risk of failures, extend equipment lifespan, and optimize operating costs. Oil diagnostics provides insight into the actual technical condition of systems operating in railway rolling stock – from engines and gearboxes to hydraulic systems and transformers.

It helps answer three key questions:

1. Mechanical wear

Is a failure developing within the system?

  • ICP / RDE – wear metal analysis
  • PQ Index – ferromagnetic particles
  • PSC – wear characterization

2. Oil condition

Is the oil still providing proper protection?

  • water content (Karl Fischer)
  • kinematic viscosity
  • acid number (TAN) / base number (BN)
  • IR spectroscopy

3. System cleanliness

Is the system operating reliably and without disturbances?

  • oil cleanliness class
  • filterability
  • foaming tendency and air presence

Full list of tests for the railway industry

Oil diagnostics for the railway sector involves a wide range of laboratory tests, including analysis of the physicochemical properties of oil, the level of component wear, and the presence of contaminants.

Gearboxes and bearings – testing and benefits

test

benefit

link

Elemental analysis using the ICP (Inductively Coupled Plasma) method

👉 Early detection of wear and tear on gearbox components and bearings – reducing the risk of serious breakdowns

PQ Index – measurement of particle content

👉 Rapid identification of severe mechanical wear – enabling an immediate service response

Infrared (IR) spectroscopy

👉 Monitoring oil degradation and detecting contaminants – extending the service life of the oil and components

Determination of the total acid number (TAN) of oil

👉 Monitoring oil degradation – optimising the timing of oil changes

Kinematic viscosity – the Stabinger method

👉 Assurance of proper lubricating properties – smooth gearbox operation

Kinematic viscosity – capillary method

👉 Checking that the oil meets the manufacturer’s specifications – reducing the risk of inadequate lubrication

Water content in oil (Karl Fischer) – coulometric method

👉 Elimination of one of the main causes of degradation – protection against corrosion and cavitation

Oil purity class

👉 Monitoring of contamination levels – extending the service life of bearings and precision components

Melting point

👉 Guaranteed performance at low temperatures – reliability in winter conditions

Flash point in an open cup – Cleveland method

👉 Detection of oil dilution and degradation – improved operational safety

Hydraulics – research and benefits

test

benefit

link

Elemental analysis using the ICP (Inductively Coupled Plasma) method

👉 Early detection of wear and tear on hydraulic system components – preventing pump and valve failures

PQ Index – measurement of particle content

👉 Quick identification of excessive wear on components – reducing the risk of system failure

Infrared (IR) spectroscopy

👉 Detection of oil degradation and contaminants – maintaining stable hydraulic system performance

Determination of the total acid number (TAN) of oil

👉 Monitoring oil ageing processes – preventing corrosion and system degradation

Kinematic viscosity – the Stabinger method

👉 Ensuring the system operates correctly – maintaining the correct pressure and lubrication

Kinematic viscosity – capillary method

👉 Verification of oil compliance with requirements – stable and safe system operation

Oil purity class

👉 Protection of precision hydraulic components – extending the service life of valves and actuators

The colour of the oil

👉 Rapid identification of anomalies – an early warning of degradation or contamination

Water content in oil (Karl Fischer) – coulometric method

👉 Elimination of the risk of cavitation and corrosion – improved reliability of the hydraulic system

fuels – research and benefits

test

benefit

link

Cleanliness class

👉 Reduced risk of fuel system contamination – protection for injectors and filters

Oil cleanliness class – microscopic method

👉 Identifying the type of contamination – more effective resolution of the root causes

Water content in oil (Karl Fischer) – coulometric method

👉 Elimination of the risk of corrosion and fuel system failure – improved engine reliability

Fractional composition

👉 Optimisation of the combustion process – improved efficiency and reduced fuel consumption

Oil density

👉 Fuel quality control – detection of adulteration or non-compliance with standards

Kinematic viscosity – the Stabinger method

👉 Ensuring proper fuel atomisation – smooth engine running

Kinematic viscosity – capillary method

👉 Checking fuel performance parameters – reducing the risk of injection problems

Cold Filter Plugging Point / Cloud Point (CFPP)

👉 Reliable starting in cold weather – no fuel flow issues in winter

Flash point in a closed cup – Pensky-Martens method (manual)

👉 Detection of contaminants and dilution – improving operational safety

Flash point in a closed cup – Pensky-Martens method (automatic)

👉 Precise fuel quality control – reducing the risk of incomplete combustion

Corrosion on copper plates

👉 Fuel aggressiveness assessment – protecting fuel system components from damage

transformers – testing and benefits

test

benefit

link

Water content (Karl Fischer method)

👉 Protection of oil-impregnated paper insulation – slowing down the degradation process of the transformer

Phase-to-phase voltage

👉 Early detection of oil degradation – a swift response before a breakdown occurs

Breakdown voltage

👉 Insulation safety assessment – minimising the risk of electrical breakdown

Resistivity / dielectric loss factor

👉 Oil insulation quality control – ensuring stable transformer operation

Dissolved Gas Analysis (DGA)

👉 Early detection of internal faults – diagnosis of overheating, short circuits and breakdowns

Furan content

👉 Assessment of the degree of degradation of insulating paper – prediction of the transformer’s service life

Cleanliness class

👉 Minimising the impact of contamination on the insulation system – improving operational reliability

Determination of the total acid number (TAN) of oil

👉 Monitoring oil ageing – monitoring the degradation process of the insulating medium

The colour of the oil

👉 Quick assessment of changes in the oil – an early indication of oxidation and contamination

Oil density

👉 Detection of oil contamination or degradation – quality control of the insulating medium

Flash point in a closed cup – Pensky-Martens method (manual)

👉 Operational safety assessment – identification of dilution and thermal risks

Flash point in a closed cup – Pensky-Martens method (automatic)

👉 Precise quality control of insulating oil – improving workplace safety

Kinematic viscosity – the Stabinger method

👉 Ensuring proper airflow and cooling – stable transformer operation

Kinematic viscosity – capillary method

👉 Checking the oil’s performance parameters – protecting the insulation system

Oil diagnostics is used in:

  • diesel locomotives
  • electric multiple units
  • gearboxes and running systems
  • hydraulic systems
  • traction transformers

contact

Would you like to introduce or expand oil analysis within your rolling stock fleet?

Please feel free to contact us – we’ll help you choose a range of tests tailored to your fleet.

Brak połączenia z internetem

Nie udało się nawiązać połączenia z siecią. Upewnij się, że masz dostęp do internetu, a następnie odśwież stronę, aby kontynuować korzystanie z serwisu.