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OIL ANALYSIS
49
PROGRAMMES START
ISSUE
2
is of vital importance when selecting a disturbance often encountered is the
sampling location. cleaning of sampling equipment and
bottles with diesel or solvents. Even
However, maximising data density is residual amounts of diesel from this
dependent upon the nature of the data cleaning error can be detected by most
you desire. For example, if you want to oil analysis laboratories and mistakenly
assess the effectiveness of a systems diagnosed as evidence of a fueling problem
filter, we must collect a representative on an engine.
sample before and after filtration. The
difference between the two samples By communicating a potential source of
is reflected in the differential particle interference with a given sampling method
count across the filter. Depending on the or location, the diagnostician can be on
results, a decision to retain or change the lookout for these pitfalls, reducing
the filtering practices can be made. the likelihood that the oil analysis results
will be compromised. This is especially
In this instance, maximising density important when the sampling point or
of information requires the analyst required process is less than ideal due to
to obtain two representative samples the location of the machine or operation-
from a specific location to calculate the related restrictions. In the case of a
information required. Different objectives sample bottle washed out with diesel, the
require different sampling procedures. simplest communication by the sample
The objective should drive the sampling taker could avert an overreaction to the
procedure. fuel detected in the sample.
The above example applies to transient The oil sample should be extracted in
properties like measuring particles such a way that the concentration of
(wear and contaminants). Transient information is uniform, consistent and
properties depend upon the location representative. It is important to make
from which the sample is collected. By sure that the sample is not contaminated
contrast homogeneous properties like during the sampling process. At the end
viscosity, TAN (Total Acid Number) and of the day we want to ensure that what
TBN (Total Base Number) tend to remain enters the bottle is both rich in information
constant throughout the oil. Transient and remains undisturbed by the sampling
properties pertain to equipment health process itself. To ensure good data
and contamination while homogeneous density and minimal data disturbance one
properties pertain to the oil and additive should consider the following factors:
health. It is more difficult to maximise sampling location, sampling procedure,
data density of transient properties and, sampling device and sample bottle.
for this reason, effective sampling of
transient properties is essential if reliable As with real estate, one of the most
and trendable data is expected. important aspects of taking an oil sample
is location, location, location. Not all
Data disturbance refers to interference locations in the machine will produce
associated with gathering, preparing and the same data. Some are far richer in
analysing an oil sample. Failing to sample information than others. Some machines
from a running machine, where the oil require multiple sampling locations to
is not hot or well mixed, is a common answer specific questions related to the
source of data disturbance. Ideally the machines health.
machine should be operating at normal
load and speed in its typical environment There are three main ways an oil sample
when taking a sample otherwise particles can be extracted: through the drain plug,
and moisture can settle when the sample using a vacuum pump with a drop tube
is taken, causing data disturbance. and via a dedicated sampling valve.
Using dirty sampling equipment and All three methods can deliver
exposing the open bottles and caps to representative samples but the
the environment disturb the quality of sample valve is preferred. Obtaining a
the data. A common example of data representative sample from drain port or
3
drop tube sampling is influenced by the that the oil is well mixed and will minimise
technical understanding of the potential interference from water condensation.
pitfalls of the process itself. Even though Clean around the drain plug to remove
widely implemented, drain plug and dirt that might contaminate the sample.
drop tube sampling are not considered Remove the drain plug and allow a litre
best practice as the potential for data of oil to drain to waste. This will help
interference is greater given the human prevent bottom debris from the sump
factor. contaminating the oil sample. Fill the
bottle to about the three quarter level
allowing for sufficient ullage for agitation
Why do we sample? in the laboratory. Make sure that waste
oil is disposed of in an environmentally
Lubricant health
sound manner.
Chemical properties
P Physical properties
Pros
Contamination control
Machine health Only a sample bottle is required (and
P Normal/abnormal wear modes maybe a first aid kit if you spill hot oil all
Failure indicators over your hands).
Contamination levels
P Dust/water/other oils etc. Cons
Your sampling strategy (location, tests, frequencies) should The health hazard of burning ones hand
reflect your goals. while trying to take an oil sample that
may be at an operating temperature as
high as 100 C.
4
bottom of the sump. Chamfering the tip Cons
of the tubing helps in this regard.
The tube that is directed into the dipstick
Ideally the sample should be taken from port can be difficult to control. The
the same depth every time to ensure the tubes final resting place can be hard
data is consistent. This can be achieved to predict, resulting in samples being
by measuring the tubing against the taken from different locations within
length of the dipstick. Sizing the tubing the sump.
to the appropriate length will also ensure
the tube does not coil up inside the sump There is always the risk of the tube
above the oil level. As a general rule, thin actually going all the way to the bottom
sampling tubes are for thin (low viscosity) of the sump where debris and sediment
fluids such as engine and hydraulic oils can be picked up.
and the thicker tubing is usually intended
for thicker (high viscosity) fluids such as The possibility of cross contamination
final drive and gearbox oils. Disposable of sampling tubes with another oil that
tubing is also commercially available and, has been sampled at the same time.
while more expensive, will ensure that
cross contamination does not occur The drop-tube method is intrusive.
when more than one sample has to be The intrusion introduces the risk of
taken at a time. contamination while the machine is being
exposed to the environment.
Valve Sampling
5
This might seem like over-kill but
experiments on the influence of
environmental dust on particle counts
have shown ISO codes to increase 2-3
range numbers when a sampling bottle
has been left open for just a few minutes.
So how do you take an oil sample without
opening the bottle to the environment?
I assure you this is not a beer drinking
trick.
6
Sampling best practices in a dusty environment
Zip lock bag
1. Place sealed bottle in a clean zip-lock bag and seal
3. Thread the bottle on to the sampling device without opening the bag
Sampling bottle Cap
Sampling
4. Puncture with the sampling tube probe or pump
5. Recap the bottle after taking the sample without opening the bag
6. Remove the sealed (capped) bottle from the bag, label if needed and
dispose of the bag
7
hardware with which the oil comes into oil analysis is dependent on two aspects
contact is considered dead space and of the whole procedure the customer
must be flushed. controls: how the sample is taken and the
Forward the sample to the oil analysis information accompanying the sample.
lab immediately after sampling. Do not Therein lies the problem: oil analysis is a
wait more than 24 hours to send the holistic process.
sample out. Remember you have taken
a snapshot of the oil at that point in The word holistic can be defined as
time. The health of the component and emphasising the importance of the whole
oil can change dramatically in a short and the interdependence of its parts.
period of time. The earlier a problem The way you take an oil sample and the
is detected the less chance there is of information supplied is part of the whole
catastrophic failure. Oil analysis is a form that is oil analysis.
of predictive maintenance. The whole
idea is to detect potential problems Sending an oil sample to an oil laboratory
before serious consequences arise. with no accompanying information is like
sending an unidentified blood sample to a
At the beginning of this article I made a pathology laboratory and expecting them
statement about how the accuracy of to know what to look for in the blood.
Sending a poorly taken sample to an oil
Summary sampling practices analysis laboratory is like taking a blood
sample from a complete stranger and
High ROI Time and money wasted
expecting the pathologist to diagnose
Sampling from drain what is wrong with you.
P Live zone sampling P port
P Upstream of filters P Sampling cold systems In laymans terms my analysis is only as
accurate as the sample and information
Downstream of Sampling directly
P system P after an oil change you give me. Hopefully from this article you
will see that developing and implementing
Good, repeatable Dirty sampling
P sampling procedures P procedures effective sampling procedures is one of
the most important components of a
P Proper frequency P Cross contamination
successful oil analysis programme. The
Waiting days/weeks bottom line is: what you put in is what
Proper information to
P P before sending you get out. Happy sampling!
accompany sample samples to lab
Short site-to-lab time Drop tube sampling Steven Lara-Lee Lumley
P P instead of using valves
is a diagnostician at WearCheck Africa
Copies of previous Technical Bulletins can be accessed on WearChecks web site: www.wearcheck.co.za
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