Hydraulic systems can be finicky. Without proper care and maintenance, they’re prone to breakdowns or inefficiency. That’s why hydraulic lubrication is so necessary. These lubricants keep the machinery in good working order. But most people find the problem with hydraulic equipment is that it’s operated in dusty, dirty outdoor working conditions. These conditions are the perfect environment for abrasive contaminants to enter into hydraulic lubricants and reduce their effectiveness over time.

To combat this issue, preventing contamination is key, and regular oil analysis should be part of the process. An oil analysis program is the best way to ensure the efficiency of your lubricants and monitor for potential contamination issues that may cause long-term problems. With regular oil sampling, you can collect data on your machinery’s individual lubrication needs, which can help you extend drain intervals, reduce how often you have to change filters, and other routine maintenance tasks. Keeping your hydraulic system clean of abrasive particles has been shown to increase equipment life tenfold.

Establishing an effective oil sampling program
So, how do you get your team onboard with an oil analysis program? It can be challenging to convince your team of the importance of preventing lubrication contamination and the value of establishing an oil analysis program. Here are some tips that may help.

  • Appoint a program champion. You’ll need someone to oversee the program and ensure that your team is up to speed on the requirements for lubricant cleanliness and sampling protocols. Ensure the individual you choose sees the value in lubricant cleanliness and regular sampling and understands how to implement an effective sampling process for your team.
  • Provide oil sampling training. There are many ways to take oil samples effectively, and how your team does it may depend on several factors, including the equipment you use and the data you need to collect. To establish an effective program, your team must be well-versed in proper sampling protocols to ensure they don’t introduce contaminants into the samples during the process.
  • Document your process. The key to an effective lubricant program is documentation. Keeping a record of all your lubricant tasks, including sampling, is essential. As your program progresses, document your sampling data, proactive maintenance recommendations, and savings achieved through your program.
  • Celebrate your team’s successes. As your team becomes more familiar with the sampling process and sees the value in preventing lubricant contamination, they’ll begin to see the value of your efforts and how they help extend the equipment’s life.

Best sampling practices for preventing contamination
As part of establishing your oil analysis program, you must learn proper sampling techniques. The most common tools used are sampling bottles and vacuum pumps. When using these tools, ensure they are always clean, dry, and free from contaminants. Even small amounts of residual oil, dirt, or moisture can alter test results, making it difficult to determine the actual condition of the lubricant.

Use desiccant breathers
A desiccant breather is a device that prevents moisture and contaminants from entering oil and lubricant reservoirs by using silica gel to absorb moisture and a filter to capture particulate matter. It helps extend equipment life and maintain lubricant quality by controlling environmental factors that cause contamination. Commonly used in hydraulic systems, they are helpful when taking samples in a dusty or humid environment. If your equipment has desiccant breathers for sampling, regularly inspect them and replace them when the silica gel changes color so they work effectively.

Avoiding cross-contamination between samples
Another drawback that can occur as you establish a sampling program is cross-contamination between samples. This can happen when residue from previous samples or external contaminants mix with the current sample, distorting the resulting analysis results. To prevent cross-contamination, you’ll need to establish a clear sampling protocol that includes the following:

  • Using dedicated sampling equipment for each lubricant type
  • Thoroughly cleaning tools between uses.
  • Flushing sampling ports or lines before drawing a sample to remove residual oil.
  • If using a vacuum pump, replace or clean the tubing between different sampling points.

Tips for a successful sampling program
The best oil samples should accurately reflect the condition of the oil in operation, which isn’t always easy to do. That’s why your team must figure out the best extraction methods for sampling from active flow areas instead of stagnant zones. These tips can help you get the right kind of samples.

  • Avoid taking samples from the bottom of reservoirs or tanks where settled debris may skew results.
  • Sample from the midpoint of the oil volume, where contaminants are evenly distributed.
  • If using a sampling valve, purge the first portion of the oil to remove any stagnant or previously exposed lubricant.
  • Avoid drain samples. They often contain excessive settled contaminants, which will skew your results.
  • Place sampling ports in high-flow areas for a more consistent and representative sample.
  • If you must use a drain sample, always flush it out before collection to minimize built-up containments.
  • Use clean gloves to prevent dirt, moisture, or skin oils from contaminating the sample.
  • Avoid taking samples in windy, humid or dusty areas. For sampling, try to use a controlled environment like your maintenance shop.
  • Cap sample bottles immediately after filling to prevent airborne contaminants from entering.
  • Use airtight, tamper-proof sampling containers to prevent leaks and exposure.
  • Don’t overfill sampling containers.
  • Wipe the exterior of the bottles to remove any residual oil that could attract dirt.
  • Keep samples at room temperature and out of direct sunlight.
  • Label each sample with key details like equipment ID, date, location, lubricant type, and sampling method.
  • Implement a barcode or digital tracking system to maintain a clear record of sample history.
  • Maintain a log of past results to identify trends and detect early signs of contamination or degradation.

Conclusion
Testing oil samples can give your maintenance team the data they need to detect contamination issues early before equipment damage occurs. Oil sampling is a great way to ensure your hydraulic machinery works well. With an effective sampling program that uses the right equipment and proper sampling techniques, you’ll gain valuable insights into your equipment’s health. These insights can help reduce lubricant costs, extend equipment life, and reduce overall maintenance costs. We offer a fantastic oil analysis sampling program in partnership with Chevron that is an excellent investment for business owners. To learn more about this program and how it can help your business, contact your Greg’s Petroleum representative today!