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Why Sample

Introduction

Industries have been practicing oil and fluid analysis for the past several decades as a means of determining the cleanliness of system fluids and the condition of components such as pumps, bearing, motors, valves, and cylinders within a hydraulic system. Fluid sampling allows maintenance managers and fleet operators to examine the components of a hydraulic system on their equipment without having to physically disassemble the system to inspect components for wear. Oil analysis has been proven to reduce maintenance and operating costs and increase both equipment reliability and productivity. The following are some of the benefits resulting from installing fluid sampling valves and implementing a fluid analysis program.

 

Don’t risk one bad sample

The cost of taking bad samples is often overlooked and goes unnoticed. Bad samples are samples that do not truthfully reflect the condition of the system and are caused either from less than ideal sample location or poor sampling procedures. Taking an oil drain sample for example could show elevated amounts of wear metals or contamination and lead to unnecessary repairs resulting in lost productivity and higher maintenance costs. On the other hand, a sample taken unknowingly downstream of a filter will indicate that the system and components are in good working condition even thought this may not be true, resulting in unexpected break downs and lost productivity. The cost of diagnosing false fluid data can quickly escalate and become more costly than installing a proper sampling valve and maintaining good sampling practice.

 

Sample from a Closed System

Being able to draw a sample from a system without exposing it to the atmosphere eliminates the possibility of airborne particles and water vapor from entering the system. Particulate matter is a primary culprit of increased rates of wear and surface damage on components. Particulate matter can enter a system in a variety of ways such as worn seals, removing the fill cap to add new fluid, and particles not filtered out by breathers. Surface abrasion and damage are prime areas for metal corrosion to form and where the majority of wear metals originate. Water contamination in oil is a main contributor to surface corrosion in pumps, bearings, cylinder, valves, and motors. Equipment operating in sub-zero temperatures can be at risk of developing ice within the hydraulic system if the oil is saturated with water and the equipment is not in operation. Sampling from a closed system greatly reduces the chances of fluid contamination in dirty and outdoor environments.

 

Sampling Valve Locations  


  A. In-line Sampling

Installing in-line sampling valves are the easiest and most convenient method for sampling oils, lubricants, and coolants while providing consistently clean fluid samples. Sampling valves should be installed in turbulent areas of the system, such as in elbow connection or sharp bends to ensure particles are thoroughly mixed in the fluid. Primary sampling valves are typically located on the return line before the reservoir where it can capture oil after passing through the entire system. Primary sampling valves are where the majority of fluid samples should be taken.  Secondary sampling valves should be located downstream of critical components and upstream of any filters in order to monitor the wear of individual components. In the event that high levels of wear metals are found from primary sampling valves, sampling from the secondary sampling valves can identify which component is producing excessive wear. Sampling valves may also be used to monitor the effectiveness of filters. Installing a sampling valve before and after the filter allows fluid to be analyzed from each valve to identify the filter efficiency and whether servicing is required.


  B. Reservoir Sampling

Sampling from a reservoir should be avoided, but if necessary, it is recommended to use a tube extended valve. Ensure the tube is positioned to draw active oil and avoid sampling oil from the top, sides, and bottom surfaces of the reservoir as this oil is less active and could result in false readings. Positioning the tube to draw oil close to the inlet will help capture the most representative oil.


  C. Remote Access Sampling

On large equipment or for added safety and convenience, install a remote access kit to allow sampling from a more practical location while still able to sample from the desired port. Remote access sampling valves allow sampling to be performed by a single individual in a fraction of the time compared to sampling from hard to reach valves located close to hot, sharp, or moving objects. Safe, convenient, and easily accessible sampling valves translates into a more effective sampling program that requires less time and optimizes productivity.

 

 



In-Field Sampling

Fluid samples can be taken while the equipment is operating on the job site which saves time and reduces lost productivity. In-field sampling ensures the most representative fluid samples are analyzed to reflect the most accurate condition of the system. Sampling fluid in between scheduled services allows minor issues to be noticed and corrected to reduce the amount and severity of breakdowns.


 

Maintenance Scheduling   

Oil analysis allows maintenance managers to track the condition of components by trending particle counts, wear metals, or element levels in the fluid sample and tracking the rates-of-wear of critical components. The ability to track the rate-of-wear of pumps, motors, bearing, and valves allows maintenance managers to predict when a component could potentially fail and schedule the equipment for repairs prior to component failure. Scheduling service times allows managers to schedule a replacement unit to provide support while maintenance service is performed. Fluid analysis data trending also allows managers to schedule maintenance service that best suits the the company and productivity to less the impact of having proactive maintenance performed on equipment. Accurate fluid data can be used to determine when oils and coolants require changing and can be used to extend service intervals which in turn reduces maintenance costs, unnecessary oil changes, decrease oil and fuel consumption, and increases productivity and reliability.

    

A study conducted in Canada’s public and private sectors concluded that businesses spend approximately five billion dollars per year on unresolved equipment issues related to excessive friction, insufficient lubrication, and component wear. (Manitoba Hydro)

 

Increase Resale Value and Equipment Life

Companies that regularly sell and replace equipment and ones that prefer to keep equipment for much longer periods of time can both benefit from a fluid analysis program. A fluid analysis program can increase resale value, provide a record of maintenance services, and enables companies to extend the service life of equipment. Fluid sampling is highly recommended in dirty and harsh environments to monitor fluid contamination and to ensure greater reliability.

 

Things to Avoid

In order to have an effective and representative fluid sampling program here are a few situation to avoid that could compromise the fluid analysis results.

1.    Avoid sampling downstream of filters as filters will rid the oil sample on the useful particles intended to be captured for analysis.

2.    Sampling upstream of critical components will not provide condition and data of the component that is downstream of it.

3.    Avoid sampling from reservoir bottoms or sumps as this is where the particles settle and can result in elevated levels of wear particles and prompt unnecessary equipment maintenance.

4.    Sampling dead or static fluid should be avoided as this oil does not circulate through the system as often as oil in the active zones and can result in fluid readings that do not reflect the true condition of the system. This is way it is important to properly purge the valve of static fluid before capturing the sample for the lab.

5.    Sampling cold fluids is not recommended as this does not reflect the condition of the system at operating conditions and if the system has not been running, the debris can settle from the static fluid resulting in an unrepresentable fluid sample.

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