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For further information on Oil Sampling and Analysis go to our microsite at www.howcleanisyouroil.com
Oil Sampling & Analysis |
OIL Sampling and Analysis
Whatever the industry, all operators and owners of equipment that use any type of fluid including engine oil, hydraulic oil, gear oil, transmission oil, grease and coolant should know that these products are the lifeblood of their equipment. The oils are there to protect and lubricate, reduce friction, clean vital parts, act as a coolant, maintain compression, lubricate seals and to operate under pressure the hydraulic parts and maintain the life of the components. The grease is there to lubricate and stop wear occurring in bearings, pins and bushes and to ensure all the parts run smoothly and without friction. The coolants are there to keep the equipment from overheating and to protect the metals from distorting under extreme temperatures.
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It is a well known fact that contamination causes over 70% of mechanical failures resulting in expensive repairs and costly machine downtime.
Each moving part in an oil lubricated circuit has a normal wear rate. As these parts wear they introduce particles into the oil, generally these are very small but through an oil sampling and analysis programme these can be monitored. If there is an increase in the amount and size of the particles the analysis will highlight these and be able to pinpoint the source. This gives the owner/operator the opportunity to take preventative action before a failure can occur.
Many machine manufacturers test their products over many years and millions of miles to failure point. During these tests regular oil samples are taken and a complete analysis over the lifespan of the components is built up. This is then broken down into a wear analysis record. This trend is then used by the oil laboratories to be able to monitor the machinery.
Regular oil sampling is a low cost preventative maintenance tool that enables owners/operators to see what is happening inside the machinery. By implementing an oil sampling and analysis programme companies can: |
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- Reduce operating costs.
- Pinpoint potential problems
- Plan manpower and maintenance schedules
- Plan service schedules
- Maintain productivity
- Save downtime costs
- Keep minor repairs from becoming major repairs
- Reduce oil and filter change costs
- Reduce waste products
- Evaluate equipment for purchase or sale
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| Sampling Tips |
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Sample Label
Always supply all the relevant information that is required. Try to provide a sample of new oil or the details of the product. The more information provided to the laboratory the better, hours on meter, miles, oil changed date, machine history, oil added etc.
New Oil Samples
If you change your oil supplier, provide the laboratory with the relevant information and a test sample of the product. Provide the type, brand and classification of the oil.
Avoid Contamination.
When taking oil samples DO NOT take samples from used oil filters, drain stream or a waste oil container.
Sampling Points.
Where possible install oil sampling points on all machinery. This reduces the risk of contamination and maintains consistency in oil sampling. These points are inexpensive and simple to install. Many machinery manufacturers fit these as standard.
Taking a Sample
Always sample oil at normal running temperature, if this is not possible indicate (taken cold) on the sample form. Sample the oil after a minimum of 15 minutes running to ensure the oil is well mixed.
Sample Tubing
Always use a fresh tube for each sample to avoid cross contamination. Cut the tubing into the correct length ensuring it does NOT touch the bottom of the reservoir.
Vacuum Pump.
Make sure the pump is clean after each sample is taken, draw off ¾ of the bottle and discard into a suitable container, then take the sample into a fresh bottle.
Coolant Samples
Use a separate sampling pump for coolants as glycol will give a false reading to oil samples.
Health & Safety
Oils can reach temperatures of 200 deg f particularly in engines so always use protective gear such as gloves and goggles. Oil spillage can be dangerous so keep to hand an oil spill kit in case of an emergency.
Hygiene and Cleanliness
Oil is an irritant and contributes to several medical skin conditions e.g. Dermatitis, eczema. Maintain a strict health and safety policy when handling oil based products. Dispose of all contaminated materials safely and in accordance to government guidelines. |
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| Key Points |
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- Always refer to the machinery manufacturers recommendations for oil types; using the wrong oil type could invalidate a warranty claim.
- Use an independent laboratory for oil analysis. These companies are not there to sell you oil. They give unbiased reports.
- Oil analysis can reveal where wear is taking place and the location by the type of metal accumulation in the oil.
- Regular sampling will build a trend based on hours/miles and enable maintenance staff to plan their schedules.
- Sulphuric acid contamination is caused from excessive amounts of sulphur in diesel fuel combined with water contamination.
- Additional filtration can remove contamination and water therefore prolonging the life of the oil.
- Maintain equipment; use the oil analysis reports to change the oil and filters.
- Change air filters regularly, fit a pre-air cleaner to prolong air filter life.
- Train maintenance staff in correct oil sampling procedures.
- Always sample the oil HOT and from the correct sampling point. Always sample from the same point.
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| Analysis Tests & Reports |
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The oil laboratory is ISO 9002 registered and carries out numerous tests on oils and coolants. Dependant on the initial findings the laboratory interpreters may carry out further tests at their discretion. Microscope photography may be used to provide additional evidence to support and record findings. All analysis reports carry a recommendation from the laboratory interpreter offering information and advice on any actions required. When a sample is received at the laboratory results are available within 48 hours. These are then e-mailed in pdf format direct to the recipient.
The basic tests are for:
WEAR RATE
Full spectrographic analysis of wear metals, oil additives and contaminants by ICP, ASTM D5185 that monitors and tracks metal wear particles, contaminants, and oil additive package elements.
VISCOSITY
Oil viscosity tested in centistokes at 40 deg C, ASTM D445
PARTICLE COUNT
Standard test for hydraulic oils to ISO 4406
KARL FISCHER
This test looks for water contamination
INFRARED
Analysis for engine oils to monitor oil condition and degradation. Reported as % allowable.
OIL CONDITION
Compares used oil to new oil to check the lubrication properties and to see if the oil is providing and maintaining its protective properties.
OIL CLEANLINESS
Determines if abrasive contaminants are contributing to accelerated wear.
GLYCOL, WATER & FUEL TEST
Looks for these contaminants in the oil and can give an early indication of ingress from the cooling or fuel system. |
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| What Fluids Can Be Analysed |
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All types of oils can be tested, mineral, synthetic, bio-degradable, food grade, transmission, hydraulic, gear, transformer, turbine, compressor, heat transfer and quench, neat cutting, soluble, process, aviation, marine etc. etc.
The laboratory also undertakes fuels, coolants and grease analysis.
Automotive and industrial oils from all industries and in all applications including construction plant, mining, quarrying, HGV, marine, production machinery, manufacturing, aerospace, trains, industrial machinery, power stations and many more applications. |
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HOW
CLEAN IS YOUR OIL?
For more information please contact:
info@fa-st.co.uk
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