Executive Summary
Implementing a new fluid sampling program can be a big challenge. Readers identify technical challenges such as developing effective methods and sampling locations, as well as operational barriers such as costs and training. While some readers report that they already utilize a successful fluid sampling program, most report that they would like to implement new features in the upcoming months, including new sensors and automation.
Q.1. What is the most challenging part about implementing a new fluid sampling program?
Developing microfluidic scale high-throughput screening assays that have been validated.
Finding a sampling location that gives the most representative sample.
Setting up the program itself, i.e., how the result will be digitally delivered and archived. In addition, who manages the platform—third party or internal employees.
Ensuring that the same consistent procedure is followed.
Getting samples pulled regularly and going through reports and making implementations on the results. It has to tie to maintaining the systems!
Selling the return on investment (ROI) to management that this is not just another expense and can have a great impact on reducing downtime by being proactive.
If trying to implement in situ, onboard continuous monitoring, it is difficult to understand all the variability that is normal versus what is interesting data. If doing it with intermittent sampling, it is invasive and difficult to get an owner/operator to do this consistently and without adding in confounding factors like contaminants.
Getting the customer to properly identify their equipment and then to include this information on the paperwork going to the laboratory.
Taking representative samples on a regular basis.
Educating the folks taking the samples regarding best technique.
Cost justification.
Rolling over historic data from previous sampling results.
Training personnel on proper sampling techniques and gaining ownership of the program for putting the results into the facility’s computer maintenance management system (CMMS) program to document the long-term health of the machine, which is critical for root cause analysis for any failure. I also help our customers to properly interpret oil analysis results, which requires training and years of experience. The oil analysis lab’s algorithms and recommendations only get you in the “ballpark” many times.
Full characterization of the fluid samples is often times challenging due to desired applicability in different operational mediums.
Getting a representative sample.
Training.
Ensuring all the data required is collected and centralized into a single database.
Training employees on the new procedures and ensuring long-term sustainment of the program.
Convincing the customer that the cost benefit is there.
I would say, if we were to attempt that, most likely end-user buy-in for training time.
Accurate labeling.
Knowing where to sample, how often and which testing for each machine.
People.
Making sure the samples are taken correctly and in a timely manner. Also making sure they are registered and sent into the lab.
Training everyone in how to take a proper, representative sample.
Making sure each person knows their role and understands what they are accountable for.
Cost of equipment.
The most demanding part is to deal with machines without the appropriate sample port location.
Training customers to correctly sample, label and ship samples for analysis.
Providing an appropriate sampling location and preventing substances/dust from entering the liquid from outside. It also is important to ensure a limited temperature range of the samples taken.
Staff and ROI.
Determining the test slate and frequency of sampling.
Explaining and convincing management the value of the program.
In my area, selling people and convincing them to put sampling into their maintenance program. Making sure it’s done correctly and not overlooked because of time constraints. People are used to being reactive, not proactive.
Establishing organizational job description, sampling route planning and controlling the sample data and follow up actions.
Resistance from employees; anytime that there is a change there is resistance.
Would you say your organization is at the leading edge with its fluid sampling program and technology?
Yes
47%
No
53%
Based on an informal poll sent to 15,000 TLT readers.
The biggest challenge in the implementation of an oil sampling program would be in getting everyone’s active participation and commitment to remaining consistent to the program, as its success will be dependent upon the level involvement, priority and dedication being provided to proactively collecting the samples to be able to trend and analyze data.
Market acceptance and comparability of analysis results.
How to handle the increasing data amounts. Evaluation and documentation are important.
Establishing a baseline, and getting all stakeholders involved.
Cultural change within the organization at all levels.
Several things: Convincing people that it’s the right thing to do. Getting them to do it properly. Poor sampling technique = poor results. Getting them to do it at regular time intervals. And, most of all, getting them to act on the results when and where it is warranted to do so.
Keeping the customer focused on extracting the samples consistently. Just like all habits, it takes time to build a new habit.
Getting consistency in sample collection.
Getting buy-in from upper management and training technicians.
Having the buy-in from management to the maintenance personnel on the floor.
Navigating a lab’s webpage. All labs seem to have difficulty navigating web platforms.
Conditions for taking samples, easy access to the oil, regularity of taking and change of consciousness in the operators so that they give the analysis the seriousness and importance it deserves.
It is setting a sampling procedure which gives continuously fully representative fluid sample.
To get the commitment of maintenance technicians.
Appreciating the benefits by the staff and decision makers.
Ensuring that the instructions are clearly defined for each specific application and that expectations are realistic about what can be delivered.
Taking representative samples.
Construction of a sampling point if necessary.
Changing people’s perceptions and work habits—getting people to embrace a new program and understand how important their part in the program is, why they need to take the time do their job right, take a good quality sample, submit the sample promptly and include all relevant information.
Preparation: A pristine database with every asset fully cataloged: What is being sampled, manufacturer, model, lubricant description, sump capacity, other as necessary, e.g., age).
Accurate baseline data, proper training, data interpretation.
Q.2. What new sampling or analysis techniques, technologies or processes do you intend to implement in the coming months or years, and why?
Microfluidic scale high-throughput screening assays to screen ingredient properties for food pharma and cosmetic applications.
Not many currently—system already needs upgrades.
On site.
Building a new lab to be on site at the customer so we get instantaneous data back to them for their processes.
Inline sampling due to skilled labor shortage.
Fluid quality sensors have not been proven to be dependable enough, so the attention is more on just understanding fluid levels, but in transient states even that is difficult to understand what is important and what are just noise factors.
We follow the test laboratory guidelines for their premium laboratory analysis program.
We intend to implement an online infrared (IR) sensor for determining the oil composition (additives), to have data available on an hourly base (and not on a daily or weekly base) and to be able to better stabilize the process.
Drain valve that incorporates sampling ports.
Plan on sampling more machinery as our expansion comes online.
Remote oil monitoring sensors and needle valve installation for ease and repeatability of pulling samples consistently.
Manual sampling: Using sealed vacuum sample bottles for taking particle count samples of critical equipment. Auto sampling: Installing inline particle counters for large/critical hydraulic systems and wind turbine gearboxes, etc. It’s kind of expensive but has a short ROI compared to a day or week of down time.
None at this time—maintain training and help customers stay on track with their scheduled sampling.
Continued deployment of sampling ports on equipment to standardize sampling and deployment of sensor technologies on critical equipment.
Understanding and leveraging how machine learning can be used and applied to data collection and analysis.
No changes currently being looked at. Advanced fluid sampling is sent to a third-party provider.
None. Current method is quick and inexpensive.
Readers online installed nearby of the main points from lubricants oils.
Would you say your organization is generally open to trying new technology and processes related to fluid sampling and analysis?
Yes
85%
No
15%
Based on an informal poll sent to 15,000 TLT readers.
Data standardizing.
If we can train the new generation to take use the old tools to get the right sample, we are lucky.
Using live sample port to take representative samples.
It isn’t new, but we need to keep the front line people attentive to changes in color, odor, clarity and temperature. They don’t necessarily signal problems, but are a sign that more sophisticated testing may be required.
Exploring acoustic imaging, vibration analysis and thermography.
Gas chromatography analysis of color.
None, possibly a magnetic plug/sample port combo.
None planned presently, but always open to new labs and methods.
Use of a device similar to a turbo-syringe in conditions of controlled temperature of liquid samples taken by thermocouples.
Instead of vain pump use an electrical pump for reduce preventative maintenance time.
Inline oil analysis for critical equipment. Automatic alert limits and no delay in corrective action.
Analytical process control that tracks the process either reactive or non-reactive blends.
X-ray florescence (XRF).
Online oil condition monitoring, sensor data connected to distributed control system (DCS) and CMMS to produce corrective work order.
I think one of the most simple yet overlooked processes in the automotive fleet environment would be testing and analyzing for cleanliness control. I believe that any lubrication program should begin with the prevention of contamination. Testing new delivered product, I believe, adds another level of prevention, by proactively mitigating issues from the start. Contamination control is just as important, and for that reason a technique that seems to be very appealing is the membrane patch colorimetry (MPC) varnish test. In general, for quick on the field there are various other tests that we plan on having included such as the metallurgy and other elementals. Additionally, filter media analysis does seem to also provide a lot of insight into what could be happening within an engine in relation to metal friction and wear. Clearly, there are very good options, and with today’s more advance light weight mobile technology and the possibility for getting more high tech devices to test first hand on the field are always available.
Combining sample analyses at laboratory with sensor analyses on site.
1.) Automated and remote sampling systems. Why: Automated and remote sampling systems reduce the need for manual intervention, 2.) Real-time monitoring and analysis. Why: Real-time monitoring and analysis allow for immediate detection of changes or anomalies in fluid composition, enabling quicker decision making and more responsive management of the system.
Currently none—our laboratory is up to date with most analyses.
Sample automation—sample preparation takes a lot of time and needs to be optimized.
Ultrasound and vibration analysis for in depth insights in lubricated components.
Ultrasonic evaluation of optimal greasing volumes/frequencies—plus a shift from condition-based maintenance (CBM) to asset condition management, which pairs up the notion that condition data supplemented with lubrication best practices from selection, delivery, receipt, storage, logistics, deployment management and disposal/reuse.
We are involved in setting up sampling programs for many of our customers and have set up a portal where they have access to the results, which we can then discuss and comment jointly, as well as agree on the most appropriate course of action when required.
Just trying to get consistency in our sampling program.
Grease sampling of used grease out of roller bearings.
Increasing the ASTM procedures for high end analysis.
App-based submissions. Encouraging customers to use/install oil sample ports.
Techniques for practicality of taking, cleaning and results in the field immediately, as well as the possibility of using software that allows you to access results and request recommendations.
It is automatic sampling driven by fluid sensors warning signals.
New techniques for oil aging, oxidation due to the more limited accuracy of current methods with upcoming formulations.
Establishment of sampling points for reliable process monitoring.
Inclusion of real-time sensors with offsite analysis results in a common reporting program.
There are appropriate sampling valves for most asset types that allow circulating the fluid for best representation. Avoid vacuum sampling when possible. I recommend that labs be on site for best outcome: fast data rather than remote lab delays, also added wisdom from shop floor technicians, and it’ll eventually be more economical in the long run.
Innovative tribometer methodology, using for screening new update tribometer to characteristics of tribology property.