Could You Benefit From A Fresh Oil Sampling Approach?
Oil analysis is dependent on the small oil sample submitted to the lab. This sample must represent the often very large volume within the entire system. To provide the most complete picture of operating conditions it must accurately reflect a variety of characteristics. This might include the development of critical wear elements, potential varnish contamination or the depletion of a key additive.
The method and care in taking the sample is fundamental and important but, some companies are still missing less than a complete story. Consider using a sampling method that allows you to:
- Sample quickly while the equipment is running, while the lubricant is thoroughly mixed - Sample from the same location each time so trending is possible - Reduce the chance for outside or cross-contamination
Dedicated oil sampling valves make it possible to take reliable oil samples safely, while the equipment is running. This ensures that the sample is a direct representation of the equipment's condition. The sampling valves are installed into the equipment, ensuring each active oil sample comes from the same spot, every time. The location of the sampling valves guarantees that the sample pulled will contain hot, information-rich oil that can be trended against previous samples to show the condition of your equipment. Sampling valves typically can collect the sample faster and cleaner way compared to other sampling methods.
With dedicated sampling valves you'll get more sampling compliance, better oil analysis results and increased program savings from:
1) Decrease Time Spent Sampling
The most valuable, immediate benefit from customer feedback is a reduction in sampling time. Here are some examples:
- A company with 9 rotary screw compressors was taking 30 minutes per compressor to draw sample via drop tube (4.5 hours spent sampling in total). This company wanted to reduce that sampling time. Their solution was a simple pushbutton sampling valve. After installing the KP Pushbutton valve they reduced their overall sampling time to 30 minutes total for the 9 compressors
- A company with refrigerant compressors found that the KP Pushbutton valves saved them 20 minutes sampling per compressor
- A North American mail hauler installed KP Pushbutton valves onto their Cummins X15 engines.
By switching from drain sampling to the KP Pushbutton they were able to reduce their sampling time from 18 minutes to 3 minutes.
- A company spent 24 hours sampling their hydraulic reservoirs. The lack of consistent sampling method led them to install the LT Series. With the LT Series installed they were able to develop a consistent sampling procedure and reduce their sampling time to 16 hours.
Here are the potential savings you could see at your facility. If we take the information from the first example:
- 9 compressors, sampled every quarter
- Before valves it would take 4.5 hours (270 minutes) to sample, with two technicians
- Now it only takes 30 minutes to sample, with one technician
The time savings converted to cost-benefit can be significant after the 1st year. But what people forget to see is how that significant cost-benefit continues year after year, typically until the equipment is retired. This time savings allows teas to systematically troubleshooting or fixing minor day-to-day problems, saving larger repairs for later.
2) Decrease Spending And Time On Unnecessary Maintenance
What happens when your oil analysis report says there is a problem with your equipment? You fix it. You're relying on that oil analysis report to be accurate. Sometimes the oil sample is not reflective of the condition of the machine, this could be due to cross contamination, or pulling a sample from too close to the side or bottoms. This can happen more often than you think. Take these cases into consideration:
- A pulp and paper company with a set of HPU pumps found that their oil sampling reports frequently indicated elevated wear particles on the pump set, requiring replacement. Since the sample was only coming from the shared reservoir, they did not know which pump needed to be replaced out of the set. So, they would just replace the set - an $8000 cost. As this became frequent, the reliability engineer thought their sampling method could be the culprit. They installed sample valves separately on each pump's return line so they could tell which pump might be failing out of the set. The subsequent sampling reports reinforced that the pumps were fine, and that they could now trend how each pump was operating.
- A marine company in the Pacific Northwest suspected a problem when their main engine's oil analysis report continuously came back indicating coolant was in their system. They would drain the engine, inspect and see nothing wrong. It wasn't until they switched their sampling method to the Checkfluid LP & KP Pushbutton valves that the real problem was discovered. The company originally switched their method because they no longer wanted to the purchase plastic tubing needed for drop-tube sampling. The Pushbutton valves would allow them to get their oil samples, by simply pushing a button, no tubing required.
Sampling valves provide a true representative sample that could help you avoid pulling apart a piece of equipment that's just fine. Here are the potential savings you could see at your facility, taking the information from the first example:
- 1 HPU Pump Set
- Cost to replace $8000
- Not accounting for:
- The time to pull apart and replace the pump set
- The lost production time replacing the pump set
- The regained confidence in their oil analysis program
Looking Beyond Sampling - Condition Based Monitoring Tools
Incorporating other condition based monitoring tools in with your oil sampling valves will only help you increase savings. Condition-based maintenance (CBM) is a maintenance strategy that monitors the actual condition of an asset to decide what maintenance needs to be done. Other CBM tools such as visual oil analysis or desiccant breathers can be easily incorporated alongside sampling valves.
Example 1: A plastics manufacture wanted to be able to sample and filter without shutting down and impacting production. By installing the Checkfluid CORE Solution they were able achieve that goal. They also discovered that with improved sampling reports and filtering they learned they could extend out their drain intervals; saving them thousands on oil disposal costs.
See, prior to 2012 this company's preventative maintenance strategy consisted only of two semi-annual oil changes. For 12 pieces of equipment, they were throwing away, on average: 954 gallons per year, costing them $12163.50. By the time their sampling and filtering program was set up in 2017 they had 28 pieces of vital equipment being maintained. By filtering through 1856 gallons of oil, they were able to retain 1293 gallons in the machines and only had to change out 563 gallons. In 2018 the number of equipment drop to 25 pieces being maintained. They filtered through 1510 gallons of oil, retaining 1350 gallons, and changing out 160 gallons. This optimization has saved they thousands in oil disposal costs over the years.
Reducing lubricant waste was a KPI for this company. From 2017 to 2018 the company increase the amount of oil they were able to filter and retain in their machines by 27.4%. This reduction saved this company thousands in oil disposal costs. in 2018 they only spent $1200 on oil disposal costs, compared to $4222 in 2017. The company was able to reduce their CO2 Emissions from 22533.48 pounds of CO2 in 2012 to 3779.2 pounds of CO2 in 2018, an 83% decrease in emissions by switching to a CBM program.
Example 2: A company focused on creating household consumer goods started their oil analysis program with a goal in mind, they wanted to extend their drain intervals beyond the established 1-year mark. To do this they needed a way to cleanly sample the oil at least once every three months. A reliable sampling method was needed. After trying several different types and brands of sampling valves including some self-made options they discovered Checkfluid's CORE Solution. The CORE Solution would allow them to sample, filter, visually inspect, drain and top-up the gearboxes from a closed system. Being able to maintain a closed system greatly reduces the risk of contamination.
Since installing the CORE Solution the facility has been able to extended out the drain intervals based on the oil's condition, rather than a time-based changed. They are now able to perform condition-based change-outs at 1.5 years. Since their manufacturing process requires the use of expensive food-grade lubricants, the lubrication team estimates that with this increase of 6 months, they can save $10,000 on lubrication change-out costs.
Potential Impact: Here is some potential impact you see by reducing your facility's oil waste:
- By 10 gallons = 236.2 pounds of CO2
- By 50 gallons = 1181 pounds of CO2
- By 75 gallons = 1171.5 pounds of CO2
- By 100 gallons = 2362 pounds of CO2
In Summary
The success of an oil analysis program begins with the oil sample sent into the lab. That very small 3 oz (70 mL) sample represents all the oil in your system at the time that sample was taken. That sample must represent the actual condition of the all oil in the machine. Therefore entire oil sampling process should be focused on ensuring the oil entering the bottle contains complete information. Changing sampling methods to best practice valve sampling can have a significant impact on corporate profitability. Incorporating condition monitoring alongside valve sampling has shown to contribute to more compliance, better oil analysis results and increased program savings through:
- Decreasing time spent sampling - Decreasing spending on unnecessary maintenance - Optimizing drain intervals - Improving your carbon footprint
