Oil Analysis Training Videos

Title: Oil Analysis Introduction: Why Oil Samples Are Taken

Duration: 2:21 minutes

Description:

Training video featuring Shell Technical Advisor Brent Warr (KGHM / Nevada & Winnemucca projects) about the benefits of oil analysis.

 

Oil Analysis Introduction: Why Oil Samples Are Taken Transcript

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Oil Analysis - Introduction to Why Samples are Taken

Interview with Brent Warr

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Brent Warr, Shell Technical Advisor

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Brent Warr standing in a warehouse of Shell oil drums.

[Brent Warr]

Why is it important to have a good oil analysis program?

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Headline: Importance of Oil Sampling

·       Validating preventative maintenance schedules

·       Monitoring equipment and oil condition

·       Improving Oil Cleanliness by controlling contamination

[Brent Warr]

Some of the benefits include: validating preventive maintenance schedules, monitoring equipment and oil condition and for controlling contamination. By validating preventive maintenance intervals, sampling can show if operators are maximizing their oil life or if they are overextending the use of their oil. Oil analysis is used to monitor for wear and abnormal conditions, which can help identify potential failures before they occur, avoiding costly downtime if timely repairs are made. Oil analysis is used to monitor the condition of the oil itself, to ensure the oil remains suitable for use, or if it needs to be changed. Oil analysis is also used to check for contaminants, such as dirt, water, coolant or fuel.  It is used to verify if the correct lubricant is being used, or if incorrect lubricants have been mixed.

[Video footage]

Brent walking up to hauler. Placing tubing into dipstick slot. Brent using a vacuum pump. Closeup of vacuum pump. Brent sealing a sample bottle. Brent filling inserting needle probe into sample bottle. Closeup of filling sample bottle. Dirt falling into sample bottle. Brent underneath hauler.

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Good Oil

Analysis Program

[Brent Warr]

A good oil analysis program will help determine the proper corrective actions. However, a good oil analysis program can only be as good as the sampling practices utilized when collecting samples. When taking samples, it is important to avoid any solid, water, or chemical contamination to achieve a representative sample. For example, an improper sample may make oil appear in better condition than it really is, which can give a false indication when there is actually something wrong. Or, it may make the oil appear in worse condition than it is, which can lead to unnecessary repairs and increased maintenance costs. Effective oil samples can help operators tailor maintenance schedules to each piece of equipment. This can result in extended intervals between drains and reduce maintenance expenses without compromising equipment life. It is also important that maintenance personnel properly fill out paperwork when taking oil samples. This will assist the analyst in interpreting the data and making maintenance recommendations. Following effective oil sampling practices is key to having a good oil analysis program. This can extend equipment life, improve equipment uptime and reduce the total cost of ownership.

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Headline: Oil Sampling Can

·       Extend Equipment Life

·       Improve Equipment Uptime

·       Reduce Total Cost of Ownership

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© Shell International Limited 2018

Title: Oil Analysis: Overview of Equipment | Shell Lubricants | Services

 Duration: 1:51 minutes

Description: training video featuring Brent Warr (KGHM / Nevada & Winnemucca projects) detailing equipment needed for oil analysis.

Oil Analysis Equipment Overview Transcript

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Oil Analysis - Overview of Equipment

Interview with Brent Warr

[Title]

Brent Warr, Shell Technical Advisor

[Video Footage]

Oil sampling can be done with several different types of equipment. In this video, we will look at the equipment needed for various sampling methods. Regardless of what type of oil sampling you do, you need personal protective equipment, a clean work area and a sample kit.

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Equipment

●      Personal Protective Equipment

●      Clean Work Area

●      Sample Kit

[Brent Warr]

Protective equipment, includes gloves, safety glasses and cleaning supplies.

When taking a drain sample, remember to be cautious of the hot oil, only pulling the sample when it is safe to do so. A clean work area prevents outside contaminants from being introduced into the sample. Using lint-free rags and oil-absorbing pads will also reduce the chances of contamination.

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Closeup of gloves. Safety glasses. Cleaning supplies. Technician and clean work area. Oil absorbing pads.

[Brent Warr]

Every sampling kit should include: A clean bottle for collecting the sample. A sample registration form or an online sample registration. And a mailer to send the sample to the lab. For most sampling methods, you will need a separate container to collect the waste oil that you flush from the system. If you have a probe-style sample port, you will need to order needle probes that fit into the valves. You will also need a vacuum pump and clear, clean tubing. Never reuse tubing because it will contaminate future samples.

Ideally vacuum pumps should be dedicated for each product and stored appropriately to minimize the chance of cross contamination.The tubing should be cut to the length required to reach the midpoint of the oil in the reservoir. If the equipment’s sample port has a push-button valve the sample can be taken directly into the bottle after flushing the valve and the bottle. Similarly, if you are taking a bottom drain sample, you will need a waste oil container and a sample bottle. It is important you have all your necessary equipment before you take your sample.

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Clean sample bottles. Sample registration form. Mailer envelope. Waste oil container. Probe-style sample port. Needle probes. Vacuum pump. Clear, clean tubing. Brent cutting tubing. Closeup of push-button valves. Technician flushing valve.

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Shell Lubricants, Together Anything Is Possible logo centered on a white background

Title:  Oil Analysis Sampling Procedures

Duration: 3:40 minutes

Description:

Training video featuring Brent Warr (KGHM / Nevada & Winnemucca projects) about oil analysis sampling procedures.

Video outlines the procedures that need to be followed to take a proper oil analysis sample. At first the proper steps are listed.  After this the importance of taking a sample the same way each time is explained.

The video shows how to properly take an oil analysis sample and explains which sample locations are the most reliable.

Oil Analysis Sampling Procedures Transcript

 

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Follow These Sampling Procedures

●        Same way each time

●        Equipment should be at operating temperatures

●        Purge Ports and Valves of Contaminants

●        Sample from dedicated ports or use a vacuum pump with tubing

●        Bottom drain samples are least reliable

[Brent Warr]

[Title]

Brent Warr, Shell Technical Advisor

To get the best results from an oil analysis program, it’s important to follow proper procedures and remember to take the sample the same way each time. This will ensure consistent results. Equipment should be at operating temperatures before sampling.

Take samples while the lubricant is still circulating, or within 30 minutes of shutting down the equipment. It is best to sample from dedicated ports. If that’s not possible, then a vacuum pump with tubing can be used to take the sample from the reservoir. Bottom drain samples are the least reliable and can be easily contaminated by sediment and other particulates that accumulate at drain ports.

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Driver turning hauler’s ignition key. Shot of driver through windshield. Overhead shot of driver inside cab. Lubricant port. Vacuum pump. Oil with sediment in it being drained.

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Sampling Method #1:

Probe and Push Valve Ports

[Brent Warr]

Wipe the port valve with a clean, dry, lint-free cloth. Hold a separate waste container under the probe and cap assembly. Then, insert the needle probe into the valve. Flush the fluid in the valve into the waste container for a few seconds to purge any stagnant oil, water or debris. Remove the needle probe to stop the flow and set the waste container aside. Now, remove the cap from the sample bottle and place the probe and cap assembly into it, securing it firmly.

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Close-up of port being wiped with a cloth. Brent holding a waste container. Brent inserting a needle probe into the valve. Brent setting the container aside. Brent removing cap from sample bottle and placing probe assembly into it.

[Brent Warr]

Take the sample bottle with the probe and cap assembly and insert the needle probe into the valve. Fill three-fourths of the bottle. Remove the needle probe to stop the flow. Place the cap onto the sample bottle and place the protective cap back on the valve.

[Video footage]

Brent inserting needle probe into valve and filling bottle. Brent removing probe. Brent placing cap back onto sample bottle. Closeup of cap being placed back on the valve.

[Brent Warr]

Discard the probe and cap assembly in a safe manner. If the equipment has a push-button style sample port, no needle probe is required. But you still need to press the button on the port for a few seconds to clear and drain the fluid into a waste container, to ensure you get a clean sample.

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Brent pushing port button.

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Sampling Method #2:

Using Vacuum Pumps

[Brent Warr]

When taking an oil sample with a vacuum pump, make sure you use new tubing to prevent contamination. Measure and cut the tubing to the length required to reach the midpoint of the reservoir. Next, assemble your vacuum pump by pushing the tubing through the head one inch and tightening the retaining nut. Insert one end of the tubing into the dipstick tube. Screw on the sample bottle. Insert the other end of the tubing into the pump. Make sure the sample is taken from about halfway up the reservoir. Do not allow the tube to reach the bottom of the reservoir.

[Video footage]

Brent taking an oil sample. Brent measuring and cutting tubing. Assembling a vacuum pump. Inserting tubing into dipstick tube. Brent screwing on sample bottle. Sample flowing into the bottle.

[Brent Warr]

Keep the sample gun level so that the used oil doesn’t contaminate the gun. Pump the handle to create a vacuum. Fill the bottle half way to purge the tubing and dump the oil in a waste bucket. Fill the bottle to the fill line, or, three-fourths full if there isn’t a fill line, ensuring the oil doesn’t touch the tubing. If the oil does touch it, push the tubing through and cut it off before removing it. This will avoid contaminating the vacuum pump.

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Brent pumping the handle. Dumping oil in waste bucket. Filling the bottle. Measuring and cutting the tubing.

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Sampling Method #3:

Drain Plug Samples

[Brent Warr]

Drain plug sampling is the least effective sampling technique. We recommend avoiding this type of sampling, as it cannot be done consistently. After the sample has been taken, it is important to ensure the right test is performed on the sample and the right information is captured.

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Sample bottle being labeled.

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Follow these sampling procedures

●        Same way each time

●        Equipment should be at operating temperatures

●        Purge ports and valves of contaminants

●        Sample from dedicated ports or use a vacuum pump with tubing

●        Bottom drain samples are least reliable

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Title: Oil Analysis: Sources of Contamination | Shell Lubricants | Services

Duration: 2:36 minutes

Description: Training video featuring Shell Technical Advisor Brent Warr (KGHM / Nevada & Winnemucca projects) about oil analysis and sources of contamination.

Oil Analysis Sources of Contamination Transcript

Oil Analysis: Sources of Contamination | Shell Lubricants | Services Transcript

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Oil Analysis - Sources of Contamination

Interview with Brent Warr

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Brent Warr, Shell Technical Advisor

[Video footage]

When collecting oil samples, it’s important to avoid outside contamination, which can lead to unrepresentative results. For example, a sample contaminated by an unclean work area may make oil appear dirtier than it is, leading to unnecessary maintenance and increased costs. Likewise, a sample taken in a reused bottle may give incomplete results or mask the issues that can lead to premature equipment failure. Let’s look at three major types of sampling contamination that can mislead our results:  

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Shots of dirty work area. Reused sample bottle.

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Solid Contamination

[Brent Warr]

Solid contamination typically refers to dirt or other abrasives that can get in the sample from an unclean work area, equipment or sample port. Samples can also become contaminated by lint or stray threads from cleanup rags. Be sure to clean around the sample port or drain plug with a lint-free rag before taking a sample. When using a vacuum pump, contaminants can remain in the pump or the tubing. That’s why it’s important to use fresh tubing for each sample. Ideally vacuum pumps should be dedicated for each product and stored in clean, clearly labeled cases. This minimizes the risk that future samples will be contaminated. Drain plug samples are particularly vulnerable to contamination because of sediment and other particulates that can accumulate around drain ports.

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Dirt being knocked into bottle. Box of cleanup rags. Worker cleaning sample port with rag.Vacuum pump in box. Labeling case. Putting pump in case. Bottom drain valve being turned and oil drained.

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Water Contamination

[Brent Warr]

We all know that water and oil don’t mix. It’s important to take samples in a work area that is not only clean but also dry. Do not allow any water to come in to contact with the sample area. Make sure all sample ports, tubing,  bottles, and equipment are free of water before taking a sample. Purging may be necessary to remove water build up. If a little water gets in the sample, it leads maintenance personnel to believe there is a lot of water in the system. This could potentially lead to a premature oil change.

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Shot of clean, dry work station. Technician laying out tubing and tools. Pressing valve button to release water.

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Chemical Contamination

[Brent Warr]

Chemical contamination can come from brake cleaner, degreasers, other oils, and any other chemical found on site. Avoid using degreasers on sample ports and around sampling equipment as it leaves a residue. Also avoid brake cleaner if possible. However, brake cleaner is the most acceptable solvent if equipment needs to be cleaned thoroughly. It is important to allow enough time for the brake cleaner to evaporate completely before taking your next sample.

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Bottle of degreaser. Can of brake and parts cleaner.

[Brent Warr]

Always use new, clean, sample bottles, supplies and tubing to prevent any cross contamination from the last sample. Contaminating a sample with different types or grades of oil can distort sample results, potentially leading to a change of perfectly good oil. By taking these precautions to avoid sample contamination, you can help ensure accurate oil sampling results.

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Closeup of new, clean bottles and supplies. Racks of oil buckets. Sealed bottle with clean sample.

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Shell jingle

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Shell Lubricants, Together Anything Is Possible logo centered on a white background