Getting Spot On Oil Samples
Proper sampling procedures build the foundation of an effective oil analysis program. Why? It's because oil analysis depends on a representative oil sample. The results for the tests done durring oil analysis depend on the data contained in the oil sample.
The entire oil sampling process should be focused on ensuring the oil entering the bottle contains complete information. Without good sampling procedures, time and money can be wasted, and incorrect conclusions may be reached based on faulty data. For instance we had a customer sampling marine engines. Their oil analysis reports kept indicating that there was a coolant leak, as coolant kept appearing in the engine's oil analysis. They would drain, flush and inspect the engine only to find no issues, no leaks. This was a recurring $3000 USD cost. Was the analysis wrong? Not quite.
It turned out the tech who was pulling the samples via drop tube neglected to follow proper sampling procedures and would use the same tubing for sampling the coolant and engine. The left-over coolant would show up in the engine's analysis, indicating that there was a non-existent coolant leak. This story is not alone. Over the years we have heard similar stories from customers about non-existent problems showing up in their oil analysis reports, or problems not showing up at all. Typically the reasoning for these issues can be narrowed to the sample submitted to the lab, and more specifically, the sampling method.
Remember not all oil sampling methods are created equal. The goal of oil sampling is to get a data-rich sample. The sampler should aim to maximize data (wear debris, oil quality, contamination) and minimize any disturbances. Not sampling while the machine is running is a common example of a sampler failing to maximizer data. If the sample is taken with the machine off, particles and moisture can settle causing inaccurate particle counts. Likewise, using dirty sampling tools and bottles, failing to purge, and exposing open bottles and caps to the ambient environment cab all disturb the quality of the data contained in the sample. Both drop-tube and drain sampling can impact the data contained in the oil sample. In both cases the machine is required to be shut down in order to sample safely, nor is it coming from the same location each time.
Getting a trendable, data-rich oil sample is one that comes from a machine running at normal operating temperatures. It comes from the same location each time from (or as close to as possible) the active oil flow. Proper oil sampling does not have to be difficult - use dedicated oil sampling valves. There are sampling valves available for both pressurized and non-pressurized systems. Sampling valves eliminate the discrepancies that can happen with other sampling methods.
Spot on samples will result in more sampling compliance. Since no shutdowns, or special circumstances will be needed to samples, oil sampling will be easier and faster, saving you valuable maintenance time and resources. By having oil samples that reflect the true condition of your asset your trending will allow you to save on unnecessary maintenance, optimize drain intervals, and save on equipment life. This will eventually lead to increased program savings.
Ask us today for your own cost savings analysis. See what potential savings you could have by switching your oil sampling method. Request one today.
