industrial
Category / Component / Test Kit / Interval / Comments
Turbines / Natural Gas / IND 3 / 3 mon / 1500 hr / Test kit includes ferrography to monitor for rapid system failures (e.g. rolling element bearings), particle counting to monitor fluid cleanliness, and TAN to monitor fluid degradation.
Steam / IND 3 / 3 mon / 1500 hr / "
Blowers / Blower / IND 3 / 1 mon / 500 hr / "
Hydraulics / Hydraulic System / IND 2 / 1 mon / 500 hr / Test kit includes particle counting to monitor fluid cleanliness, and TAN to monitor fluid degradation.
Extruder / IND 2 / 1 mon / 500 hr / "
Press / IND 2 / 1 mon / 500 hr / "
Compressors / Refrigeration Comp. / IND 2 / 1 mon / 500 hr / Includes Karl Fischer to monitor fluid cleanliness levels, and TAN to monitor fluid degradation.
Chillers / IND 2 / 1 mon / 500 hr / Includes Karl Fischer to monitor fluid cleanliness levels, and TAN to monitor fluid degradation.
Air and Gas Comp. / IND 2 / 1 mon / 500 hr / Includes Karl Fischer to monitor fluid cleanliness levels, and TAN to monitor fluid degradation.
Gears / Gearbox / IND 1 / 1 mon / 500 hr / Routine analysis kit.
Worm Gear / IND 1 / 1 mon / 500 hr / Routine analysis kit.
Bevel Gear / IND 1 / 1 mon / 500 hr / Routine analysis kit.
Reduction Gear / IND 1 / 1 mon / 500 hr / Routine analysis kit.
Differential / IND 1 / 1 mon / 500 hr / Routine analysis kit.
Final Drive / IND 1 / 1 mon / 500 hr / Routine analysis kit.
Gear Extruder / IND 2 / 1 mon / 500 hr / Includes particle count to monitor fluid cleanliness levels, and TAN to monitor fluid degradation.
Engines / Diesel Generators / IND 1 / 1 mon / 500 hr / Routine analysis kit.
Fluids / New Unused Oil / IND 1 / every oil shipment / Establish baseline for your oil.
Thermal Oil / IND 2 / 3 mon / 1500 hr / Test kit includes flash point.
Special Sampling Considerations
Follow up on abnormal samples / IND 3 / WearCheck advises that ferrographic analysis be performed with resamples on equipment that tested abnormal. Filter analysis allows the diagnostician to locate and detect major wear situations.
Extended oil drain intervals / IND 2 / Any equipment that is undergoing extended oil drain interval testing should use MOB 2 test kits. These kits include TAN testing to monitor the degradation of the oil, as well as the build up of acids in the oil. Oils with high TAN levels generally experience oil thickening, sludging, improper oil flow, and corrosion of components.
Critical Systems / IND 3 / IND 3 kits include the most comprehensive battery of tests to monitor the oil condition, wear condition, and contamination levels of the system.
IND 1 - Basic Industrial Oil Analysis Test Kit
Uses
Non-critical gearboxes, Reduction gears, New (unused) oil for baseline
Wear
ASTM D5185 / ICP Spectroscopy
WC Method / *Particle Debris Filter
Contamination
ASTM D4377 / *Karl Fischer Water Determination
ASTM D445 / †Kinematic Viscosity (40°C)
WC Method / *Particle Debris Filter
Fluid Degradation
ASTM D445 / †Kinematic Viscosity (40°C)
* - generally this testing is only performed when other routine testing warrants.
** - this test is performed on filtered systems only or by special request.
† - this test is performed on non-engine samples only.
‡ - this test is performed on engine samples only.
IND 2 - Routine Industrial Oil Analysis Test Kit
Uses
Hydraulic systems, Injection-moulding machines, Presses, Air compressors, Refrigeration compressors, Bearing reservoirs, Thermal Oils
Wear
ASTM D5185 / ICP Spectroscopy
WC Method / *Particle Debris Filter
Contamination
ISO 4406 / **Particle Count
ASTM D4377 / *Karl Fischer Water Determination
ASTM D445 / †Kinematic Viscosity (40°C)
WC Method / *Particle Debris Filter
Fluid Degradation
ASTM D974 / †Acid Number (TAN)
ASTM D445 / †Kinematic Viscosity (40°C)
* - generally this testing is only performed when other routine testing warrants.
** - this test is performed on filtered systems only or by special request.
† - this test is performed on non-engine samples only.
‡ - this test is performed on engine samples only.
IND 3 - Advanced Industrial Oil Analysis Test Kit
Uses
Natural gas and steam turbines, Blowers, Critical systems
Wear
DR-Ferr / Direct-Reading Ferrography
A-Ferr / Analytical Ferrography
ASTM D5185 / ICP Spectroscopy
WC Method / *Particle Debris Filter
Contamination
ISO 4406 / **Particle Count
ASTM D4377 / *Karl Fischer Water Determination
ASTM D445 / †Kinematic Viscosity (40°C)
WC Method / *Particle Debris Filter
Fluid Degradation
ASTM D974 / †Acid Number (TAN)
ASTM D445 / †Kinematic Viscosity (40°C)
* - generally this testing is only performed when other routine testing warrants.
** - this test is performed on filtered systems only or by special request.
† - this test is performed on non-engine samples only.
‡ - this test is performed on engine samples only.
/ Oil Analysis Sample Taking Methods
Take Samples
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There are different methods and tools employed to take a sample of oil from machine compartments. The most common methods are the vacuum pump method, drain stream method, and guage plug method. A WearCheck oil analysis course will provide more detailed information on taking oil samples. For information on purchasing sampling accessories contact us.
Vacuum Pump Method
The vacuum pump sampling method is the most popular method for sampling the various compartments of mobile equipment. Samples may be taken from transmissions, engines and other machine compartments by putting the plastic tubing into the dipstick or oil access opening and using a vacuum pump to draw oil into the sample bottle.
Figure 1 - A typical vacuum pump.
Sampling Procedure (Vacuum Pump)
- With the engine shut off, insert the two (2) meter piece of clean plastic tubing through the head of the sampling gun.
- The tubing should be cut at a 45° angle for easy insertion through the cap.
- Next, tighten the sampling bottle onto the cap of the vacuum pump.
- For compartments with a dipstick, the tubing should be cut to the length of the dipstick.
- For compartments without a dipstick, such as gearboxes, final drives and other fixed or mobile equipment, the tubing should be cut to length as necessary.
- Several light pulls of the handle will fill the bottle.
- In order to obtain a homogenous sample it is essential that the oil be at operating temperature.
- The tubing must be used only once and then discarded.
- When you discard the tubing, do not pull the tubing back through the top of the pump, as this could contaminate subsequent samples. Instead, cut the tubing just above the top of the pump, and then pull the remaining piece (that was in the bottle) from the bottom of the pump.
Figure 2 - Plastic tubing used for taking samples with a vacuum pump.
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Drain Stream Method
This method requires care on the part of the serviceman, as external dirt entry is a likely possibility. An incorrect diagnosis will be the result.The sample must be taken from the oil when it is hot and well mixed as it flows from the compartment drain. The initial and final parts of the oil stream must not be used, as this oil is not typical of the oil in the system.
Figure 3 - Drain port sampling from a reservoir into the sample bottle..
Sampling Procedure (Drain Stream Method)
- All dirt and debris from around the drain plug must be cleared before the sample is taken. Compressed air can be used for this.
- Remove the drain plug and allow the oil to start draining.
- Once the flow is clear of visible debris the bottle can be placed under the flow and filled to the recommended level.
- This bottle must be capped immediately.
- Do not take the oil sample from the drain container!
Gauge Plug Method
This method is most commonly used in fixed plant applications. It is easier, cleaner and faster than other methods of oil sampling, and it is generally possible to obtain the sample while the machine is running. This produces a fairly consistent and homogenous sample that is representative of the oil in the compartment.
Figure 4 - A typical gauge plug with a dust cap. Guage plugs are available in a variety of configurations, sizes and standard thread types.
Gauge Plug Location
A gauge plug is permanently installed in the oil line or in an oil gallery. The ideal location of the gauge plug will change with the machine model, but in all installations, the gauge plug should be installed in a location where it is easy to access away from any moving parts, protected from damage, and before any in-line filtration system (if applicable).
Figure 5 - A hose assembly for taking samples in conjunction with a gauge plug. The hose pictured here is for low pressure systems. Hose assemblies with a threaded connector are also available for high pressure sampling.
Sampling Procedure (with Gauge Plug)
- Step 1 Remove dust cap from the gauge plug on the machine, and with the engine at low idle, purge the gauge plug by discharging a small amount in a waste container. The sample bottle should not be used for purging.
- Step 2 Push the hose assembly onto the gauge plug and fill the bottle to the indicated level. Disconnect probe and replace the dust cap on the gauge plug. When taking samples from additional equipment ensure that the hose assembly has been thoroughly flushed with used oil from the equipment before taking a representative sample.
- Oil sampling must be done during normal operation of the equipment or within 30 minutes after machine shut down. This ensures that the oil is warm and truly representative of the conditions within the compartment.
- When using the vacuum pump method, ensure that the sample is drawn from about the mid point or within the working level of the oil in the compartment and not from the bottom where sludge accumulates.
- It is important that the sample container is totally clean and free of moisture before the sample is taken.
- The container should be properly sealed to prevent any contamination or loss of oil during transit.
- Ensure the sample information sheet is completely and correctly filled out.
- Courier or mail the sample to the Laboratory immediately, so as to receive the analysis results as soon as is possible.
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