by 凯德Gulledge, 工业 Solutions Engineer | 猪油公司

对于许多, 石油分析是一种“检查框”活动——从最容易的地方抽取样本，把石油装进瓶子里, and checking the report when there’s an “alert”, 如果有的话. But major financial decisions are often made from these results, so it pays to make sure you’re doing it right.

Here are 3 keys to ensuring quality insights from Oil Analysis:

1.)   选择正确的采样点.

你要问自己的第一个问题是:“我想从中获得什么见解??” This is an important question that’s often overlooked. 不管你的答案是什么, 您在油分析报告中看到的数据取决于您提取的样品的质量. Whether the asset is 12 gallons or 12,000加仑, 你只有大约4盎司/ 125毫升来获得洞察力-所以你会想让样本计数.

Whether the asset is 12 gallons or 12,000加仑, 你只有大约4盎司/ 125毫升来获得洞察力-所以你会想让样本计数

If you want to check the cleanliness of the oil on its way to the bearing，则应将样品拉到过滤器下游的供应线上:

If you want to check for signs of varnish or deposits, the oil drain port on the cooler is a great spot to pull from:

常规油取样, most of the time you’re looking for signs of wear and impending failure. 在这种情况下, 你应该尽可能从离它刚刚润滑过的地方最近的地方收集样品. My hierarchy of sample points are as follows:

Routine Sample Points for Circulating Systems

1:共回线

这是你最有可能得到最具“代表性”样本的地方——把你希望在结果中看到的所有相关成分都装进一个4盎司的瓶子里. 如果有磨损发生, oil reaching the end of its life, or any other alarming phenomena, 你会在这里感染的.

寻找“点”:

• 返回线上未使用的端口. 湍流就是你要找的——任何悬浮在油中的物质的均匀混合物.
• P/T Gauges (w/o thermowells) to tee off of. 市场上的许多样品阀允许您弯曲和切割刚性管进入湍流区. 即使一个端口被占用了，你通常也可以用这些样管中的一个来“开球”.
• 排水管道或“狗腿”. All large circulating systems have these somewhere. 你要找的是一条在公共线路上的线——在单行馈线的下游, 不是所有的系统都有. These are usually within a few feet of the reservoir. 在取实际样品之前，一定要“冲洗”滞留油的体积.

例子:

2nd: On Reservoir Near Return Outlet

当没有地方提取样品的共同回报，这是你的次佳选择. 按照上面的逻辑, 你要找一个靠近回流出口的地方提取样本. 要做到这一点，可能需要绘制或图片显示水库的内部管道.

寻找“点”:

• 未使用的端口 在储液器的顶部或侧面，刚性油管可以在回流出口附近弯曲.
• 呼吸的港口 or gauges to adapt with rigid tubing to extend to the active zone.

例子:

3rd: Supply Line Upstream of Filters

下一个最好的选择(绝不是坏的)是在悬挂组件被过滤掉之前在供应线上. While you may not be getting the oil as it just left the load zone, spectroscopy is measuring materials smaller than around 10 microns, 有可能有些在通过润滑油泵循环时仍处于悬浮状态. This is especially true if the reservoir is smaller than 500 gal or so.

寻找“点”:

• 未使用的端口 upstream of filters. Even if occupied by a gauge, you can tee off of it as before. 取决于你的设计, 如果供应管道本身没有可用端口，热交换器通常具有可用端口.
• Supply line or kidney-loop filter housing. 只要确定你选择的端口-检查图纸或旁路，并放下过滤器检查哪个端口是上游.

例子:

Routine Sample Points for Gearboxes

1st: Dipstick or Other Unused Port

If your gearbox is critical enough to warrant sampling, 然后，关键是要给它配备一个合适的视镜，把油尺扔掉. 油尺端口通常是一个伟大的位置，因为你可以接近齿轮没有咀嚼管，因为你在下降.

笔记:

• Utilize a sight glass to check oil level and condition
• 用靠近配合齿轮弯曲的刚性管样阀替换油尺端口

例子:

2nd: Drain Port with Tubing Bent Close to Gears

笔记:

• 使用包含旋转功能的样品阀，以确保管的末端在拧紧时保持放置
• 关闭主排水管的三通管，或者利用次级排水管口，这样在需要的时候，你仍然可以排油

例子:

抽样过去的机器防护

2.)保持一致

The value of oil analysis typically isn’t recognized overnight. 这是因为高质量的洞察不是来自单个数据点，而是来自趋势.

Quality insights don’t come from single data points, they come from trends.

坚持以下做法，以确保你的趋势是准确的:

• Identify your sample point, label it, and always pull from that point. 这可以更进一步，结合QR码等技术，从现场提交样本并查看以前的样本结果:

• Try to pull samples at consistent time intervals when the equipment is running.
• Always flush any “trash” that has accumulated at the point. 一个好的做法是冲洗至少要收集的样品的体积. 一个更好的做法是冲洗停滞“区域”的体积，以确保你送出的油是通过管道循环的油的代表.

• 必要时更换油管. Some say to replace the tubing between each sample. 如果你冲洗得当的话, 您可能只需要在采样不同的油之间更换油管，或者如果先前的样品被严重污染.
• Only take the cap off when you’re ready to pull the sample, and put it back on as soon as the bottle is full. 不要让任何不是来自石油流的东西最终进入瓶子.
• Utilize valves that are meant for sampling lube oil. 传统的球阀或打开现有管线可能会造成混乱，导致石油泄漏, and oil sampling valves are usually cheaper than a DIY valve. Using the right valve can help to eliminate misleading results.

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3.优化频率

The overall goal of oil analysis is to mitigate failures. You do this by capturing the data between a problem and the onset of failure. 而更频繁的采样则增加了捕获该事件的可能性, the costs of testing and labor have to be accounted for. 考虑以下因素和行业标准来优化您的样本间隔:

• 临界 -如果该资产发生故障并导致停机，则需要更频繁地采样.
• 糟糕的演员 -应根据问题发生的频率和您计划采取的措施对有问题的资产进行抽样. 例如, if an asset is known to have misalignment or undergo abnormal loading, 更频繁地对其进行采样以估计故障时间线，并查看它是否能够执行下一次计划的停机，这是有意义的. 相反, 如果一项资产已知有持续的水侵入，而你没有用脱水器或其他方法去除它, there is little value to gain by sampling it more frequently.
• “Replaceablility” -这些部件的可用性? Do you have extras on the shelf, or is this the only one like it in the world?

When in doubt, the following standards are a safe guideline:

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The bottom line is that you should understand 为什么 you’re doing oil analysis before gathering and sending off samples. 这通常需要深入实地调查和了解每个资产的细微差别.

当然(销售)，时间就是金钱，我们有大量的经验 油品分析调查s as a service, among other on site services in our portfolio.

因此，如果您对本文中展示的概念、产品有任何疑问，或者对 油品分析调查 或其他现场365怎么买球, feel free to message me directly via LinkedIn or email at cgulledge@haianib.com.