Mining assets operate in extreme environments under continuous load — and when a haul truck engine or hydraulic system fails, it costs thousands per hour in lost production. FluidInspectIR® monitors oil condition continuously across engines, hydraulics and compressors, enabling condition-based maintenance decisions that reduce failures and extend asset life.
Mining operations rely on fixed-interval oil change schedules that ignore what's actually happening inside the machine. A conservative 250-hour engine oil change interval means over-maintenance on assets running in good conditions, and under-protection on assets where oil is degrading faster.
Periodic lab sampling provides 4 data points per year. FluidInspectIR® provides over 8,000 — giving maintenance teams a real operational baseline and the ability to identify deviating assets before they fail.
Monthly oil changes at $33,222 per engine are scheduled without reference to actual oil condition — most oil is being changed well before its useful life is exhausted.
With only 4 lab samples per year, there is no way to define what "good" engine behaviour looks like — or to identify which assets in the fleet are deviating.
Catastrophic breakdowns in remote mining operations cost $50,000–$1M+ in lost production and emergency repairs — and they arrive without warning under current monitoring approaches.
Collecting oil samples from hot, remote, or elevated machinery exposes technicians to H&S risks — and sampling quality is often inconsistent, reducing lab result reliability.
A single in-cabin control unit manages up to three FluidInspectIR® sensors sequentially — engine, hydraulic, and compressor — on a single haul truck or excavator. IP67 rated, no consumables, 3–4 year operational life.
FluidInspectIR® tracks TAN, TBN, soot, oxidation and viscosity in real time. When data shows oil is still performing within spec, the drain interval is extended safely — halving oil spend and maintenance stops.
DataInspectIR® plots each engine's oxidation slope across multiple oil drain intervals, projecting exactly when the OEM limit will be reached. All assets are compared side-by-side to identify deviating machines instantly.
Thousands of data points per year replace 4 lab samples — giving you the real operational baseline to define what good engine behaviour looks like and replicate best-asset practices across the fleet.
FluidInspectIR® sensors have passed military-grade certification (combat tanks) — designed to withstand the vibration, shock, and environmental extremes of open-pit and underground mining operations.
FluidInspectIR® Portable delivers on-site oil analysis in under 3 minutes — no external lab required. Results upload to DataInspectIR® for a unified fleet view alongside inline data.
Monthly oil change cost falls from $33,222 to $7,706 per engine. Less oil consumed, lower CO₂ footprint, fewer maintenance stops — and reduced risk of costly unplanned failure.
In a validated biogas engine deployment, FluidInspectIR® extended oil drain intervals from 600 hours to 1,400 hours — targeting 1,800 hours. The same principle applies directly to mining engine and hydraulic applications.
Versus 4 lab samples from traditional sampling. Trend analysis of each engine across multiple oil drain intervals projects when OEM limits will be reached — enabling condition-based, not calendar-based, decisions.
48–72 hours advance warning from slope trend monitoring converts catastrophic breakdowns into planned interventions. Each avoided failure in a remote mining operation saves tens to hundreds of thousands in lost production and emergency repairs.
Mining customers typically deliver four or more of these pillars simultaneously — with payback periods measured in months.
Extend engine oil from 250 hrs to 500–750 hrs and hydraulic oil from 2,000 to 4,000+ hrs. Monthly oil change cost falls from $33,222 to $7,706 — a 77% reduction in oil and filter spend.
Early slope alerts give advance warning before a failure. Convert catastrophic breakdowns into planned interventions. Each avoided event in mining saves $50k–$1M+ in lost production and emergency repair.
Tight oil condition control reduces internal wear rates. Engine life extension of 20–30% reduces rebuild frequency and capital replacement cycles — critical for high-value mining assets.
Each oil change on a large mining truck generates 15–50 kg CO₂e. 50% fewer changes across a 20-vehicle fleet avoids 1.5–5 tonnes CO₂ per year — supporting ESG and emissions reporting.
Inline monitoring removes technician exposure to hot oil, elevated machinery, and remote harsh environments. Reduces H&S incidents, PPE costs, and regulatory risk across the fleet.
Continuous DataInspectIR® records provide objective evidence of oil condition history for OEM warranty claims and regulatory compliance — replacing subjective paper-based logs.
Rising TAN indicates combustion acid build-up — the primary driver of engine oil degradation in mining diesels and gas engines.
TBN depletion signals loss of acid neutralisation reserve — the key indicator for engine oil change timing on heavy mining equipment.
Viscosity monitors fuel dilution, thermal breakdown, and oil mixing — critical in both engine and hydraulic circuits on mining assets.
Combustion soot in mining diesel engine oils — leading indicator of ring and seal wear and combustion inefficiency.
Real oxidation slope measured directly against OEM limits — projects exactly when the oil drain is required, enabling condition-based scheduling.
4, 6 and 14 µm particle counts for hydraulic and compressor circuits — detects wear debris, seal failure, and contamination ingress.
Water ingress from failed seals or cooler leaks — detected in real time before it causes bearing damage in hydraulics and engines.
Detects fuel dilution from injector leaks — a major cause of viscosity drop and premature oil degradation in mining diesel engines.
Monthly oil change cost fell from $33,222 to $7,706 per engine by switching to condition-based drain intervals. Trend analysis of each engine across multiple oil drain intervals allows maintenance teams to project exactly when the OEM limit will be reached. All assets are compared side-by-side in DataInspectIR® to identify deviating machines instantly and replicate best-asset practices across the fleet.