.jpg)
Image Credit: 3dmotus | Shutterstock.com
Typically, oil is only thought about when it is initially used or at the moment that a breakdown could occur.
Conducting regular oil analysis is a proactive approach to mechanical lubrication, and will provide additional information about the oil being used. Through an oil analysis, a lubricant’s performance can be assessed, a more accurate and cost-benefit analysis can be performed, repairs will be reduced and downtime eliminated, ultimately saving money.
Proper Sampling
An oil analysis is conducted on a sample of oil extracted directly out of a part or machine during routine maintenance.
Sampling is crucial to an accurate analysis. If oil is improperly sampled, the wrong conclusions might be drawn about the lubricant’s performance – undermining the purpose of the analysis. It is important that an organization use a standard procedure to sample oil. This consistency will provide a more accurate comparison over time and better trend spotting.
Oil sampling should aim to maximize data density, meaning a sample should provide the maximum data per drop. This can be done by getting a representative sample or samples from locations of interest in order find the most relevant information.
A sampling procedure should also reduce any noise, disturbances, or potential factors that might skew analysis results. This means certain measures should be taken, including oil not being allowed to settle for too long before sampling, using clean instruments for each sample, and not exposing samples to the environment for too long.
Sampling procedures should also be based on the goal the analysis is trying to achieve. For instance, the goal of an analysis could be to assess the effectiveness of a system filter or determine the optimal length between oil changes.
.jpg)
Image Credit: zhengzaishuru | Shutterstock.com
Effective Oil Analysis Program
The goal of a program will dictate more than just sampling procedures. It will inform just about every decision made in respect to an oil analysis program, like sampling location(s), frequency, and method.
It may take some experimentation to determine optimum sampling locations, and once they have been determined they need to be clearly identified on a schematic, photograph or other visual aid. Clearly-marked images help to minimize confusion and ensure consistency.
In addition to location, sampling frequency should also be provided on documentation. The interval at which samples are taken should also be discovered through experimentation. Over sampling can unnecessarily increase costs, while under sampling can reduce the overall effectiveness of the analysis.
The sampling technique should describe the materials needed for sampling, like bottles and sample extraction tools. The sampling method should offer straightforward, step-by-step instructions to pull a sample. The method may vary based on sampling location and process. Graphics or photographs can help visually demonstrate the proper method.
The program should also point out some possible sources of interference with a given sampling technique or location. By doing this, a technician can be on the lookout for these stumbling blocks, lowering the chance that oil investigation outcomes will be compromised. This becomes particularly crucial when the sampling point or necessary sequence is less than ideal, as a result of the location of the machine or operation-related limitations.
While a program goal will dictate what an analysis should test for, most analysis should look at viscosity, total acid number, water, elemental content and particle count. Tested at 40 degrees and 100 degrees Celsius, viscosity of a sample will reveal if the oil has maintained its integrity, as will total acid number. Water, elemental content and particle count results will all show if the oil has been contaminated.
The return-on-investment of an oil analysis program is dependent on what a company or organization does with the results. Not basing maintenance actions on test results could mean either insufficient or excessive maintenance, both of which are a drain on ROI.
Most reports will contain recommendations on how to take maintenance actions that minimize costs while providing the most benefit.
References and Further Reading
Disclaimer: The views expressed here are those of the author expressed in their private capacity and do not necessarily represent the views of AZoM.com Limited T/A AZoNetwork the owner and operator of this website. This disclaimer forms part of the Terms and conditions of use of this website.