Proper
sampling is critical to an effective analysis program. Follow these tips
when collecting a representative sample to ensure analysis produces
ongoing and accurate Statistical Process Control.
1) Machines should be running in application during sampling. That means
samples should be collected when machines are at normal operating
temperatures, loads, pressures and speeds.
2) Always sample upstream of filters and downstream of machine
components such as bearings, gears, pistons, cams, etc. This will ensure
that no data, such as particles, is removed by filters or separators. If
you want to access the efficiency of a filter or separator then sample
before and after.
3) Create specific written procedures for each system sampled. This
ensures that each sample is extracted in a consistent manner.
4) Ensure that sampling valves and sampling devices are thoroughly
flushed prior to taking the sample. Vacuum samplers and probe-on
samplers should also be flushed. Our sample bottles are supplied in a
sterile condition so do not open until ready to sample.
5) Make sure that samples are taken at proper frequencies and that the
frequency is sufficient to identify common and important problems.
Record the hours on the oil where possible, especially with crankcase
and drive train samples. Record any additional information e.g. If there
has been any 'topping up' or any change to the oil such as the addition
of additives, a partial drain or anything relevant to the equipment.
6) We will issue reports on samples within a maximum of 36 hours of
receipt. The properties of the oil in the bottle and the oil in the
machine begin to drift apart the moment after the sample is drawn.
Quickly analyzing the sample ensures the highest quality and timely
decisions.
Once the sample arrives at the lab, it will be registered, analysed by a chemist who works to defined procedures and reports facts based upon test results.
A string of standard tests are undertaken to determine the physical condition and contamination type and levels of the sample.
The report is compiled by an engineer who may have a working knowledge of the system where the sample came from. The engineer will interpret the facts from the chemist and compile a diagnosis report which will contain relevant and meaningful comments and suggestions. We prefer to email reports for speed, ease of dissemination and action. In any case where a particular problem is identified from the analysis the engineer will also telephone predetermined contact's to discuss further.
The reports are colour coded for initial visual check, white/green = normal, yellow = caution, red = serious
The
original equipment manufacturers filter elements on plant and equipment
may not be sufficient to remove particle contamination and more than
likely will be unable to remove water contamination. For companies who
wish to undertake their own maintenance tasks we supply static or
mobile, off line, dialysis type, filtration systems for sale or hire
which will be technically specified to suit your needs. These units will
remove any contamination identified from the sample's and will return the fluid to a 'better than manufactured' condition. We
can also advise and supply alternative filter elements which offer
increased technical capability and reduced cost over the OEM's
specification.
With our Total Cost of Ownership Program we will take care of machinery filtration requirements from supply of filter elements to carrying out element changes, sampling and oil analysis and contamination control ensuring best practice is carried out and target ISO codes are implemented and adhered to. This is a bespoke service specifically designed to suit needs and can contain as many elements as required.
Typically with a TCO program we offer a fixed price defined service arrangement where we all focus on the ISO cleanliness codes for each part of the plant and implement strategies to maximise the maintenance-free period ensuring cost reductions are delivered and reliability is increased.
For companies who wish to focus more on their core activities our Fully Managed Services may be of benefit.