Fluid Sampling

All fluid sampling services provided by Texas Emergency Power Generation is performed by an independent outside laboratory to provide your company the greatest assurances that results are accurate and timely. 

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Oil Sampling

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Performing an oil sample is part of every Texas Generation Engine Service, and should be performed at a minimum of an annual basis for most generators.  However, some customers may want their equipment sampled and receive results frequently based on internal maintenance requirements or annually accumulated hours.  

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Oil sampling checks for several different contaminants including:

 

• Diesel Fuel - Presence of diesel fuel in the oil can be an indicator of a failed fuel injector(s) or a malfunctioning injection pump and in extreme cases can result in an oil pan fire. 

• Glycol/Coolant - Can be an indicator of a failed head gasket, cylinder head, cylinder jacket, or water pump.

• Water - Presence of water can occur by condensation from too long an interval between oil changes, or in severe cases, is caused by outside contaminants like rain reaching the oil pain.

• Silicates - Typically the presence of silicates are caused by outside elements as a result of dust, dirt or debris contaminating the oil reservoir which are typically captured by an oil filter.  This could mean oil filter failure or an improperly sealed crankcase.

• Heavy Metals - Testing for the presence of heavy metals is for the purpose of tracking engine wear and signs of potential component failure.

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Oil sampling also tests for the following conditions that can occur as a result of abnormal engine operation:

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• Fuel Soot - Occurs a result of poor combustion and can lead to oil gelling or sludge in the engine.

• Oxidation Levels - An high or increased oxidation level can be an indicator of overheating or going too long between oil changes

• Nitration - In emergency generator applications, this typically occurs when there is excessive blow-by (exhaust gases passing the cylinder rings and reaching the oil pan) or an over-extended oil change interval.  

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Diesel Fuel Sampling

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Diesel fuel in emergency generators tend to sit for much longer periods of time than in, for example, a tractor trailer or a diesel pickup.  Because of this, diesel fuel is susceptible to contaminants and degradation over time.  When performing fuel sampling, testing is performed to check not only for contaminants, but for the quality in the fuel as well.

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When checking for contaminants, we are looking for the following items:

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• Debris/Silicates - Diesel fuel cells, especially modern ones, are required to be vented to outside are.  This means tanks are open to outside contaminants which can reach the internals of the tank.  

• Fungi/Algae/Biological - Similar to dust/debris, outside air also brings outside biological components, one of which can result in algae or fungus that grows on the water layer (see below) at the bottom of the tank and feeds on the diesel fuel above it.  This algae/fungus, if picked up, can clog filters and reduce fuel flow causing engine failure.

• Water - Typically water contamination is the result of condensation which is caused by not maintaining proper fuel levels in the tank (>90% at all times).   If picked up, water can lead to failed injectors due to rusting, failed injection pumps due to seal failure and many other engine maladies.

• All of the above contaminants reside at the bottom of the tank and fuel should be sampled at bottom of a tank utilizing a fuel "bomb"

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When checking for quality or fuel deterioration, labs are  testing for fuel degradation due to long-term (>6 month) storage:

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• Cetane Rating - Since diesel engines operate on compression only for combustion (they have no spark plugs), diesel fuel must ignite as quickly as possible once the fuel is injected in the cylinder.  The cetane rating measures the speed at which diesel fuel will combust once injected into the cylinder.  Running an engine on diesel fuel with too low a cetane number can result in decreased power, rough running and incomplete combustion (see fuel soot in oil contaminants).

•  Cloud Point - Diesel fuel contains waxes and in colder weather when operating with no additives to reduce or decrease the cloud point, that wax begins to get cloudy once it drops to around freezing (32F).  If it drops further, (around 10F-15F) it begins to gel which can lead to clogged fuel lines and filters, starving the engine of fuel.

• Density/Specific Gravity - Density is the measure of potential energy of diesel fuel and engines are designed to operate with fuel in an optimal range (~0.80-0.95 @ 60F).  If over time diesel fuel, as a result of repeated refueling or bad fuel, has a drop in density it restricts engine power.  Conversely, too high a density results in incomplete combustion of fuel and black smoke.

• Viscosity - The measurement of a fluid to "flow", viscosity in diesel fuel is important to ensure proper engine function.  Too low, (think molasses) and the diesel fuel lacks the ability to lubricate engine components and seals.  Too high a viscosity, (think water) and the fluid can lead to damage and premature failure ofthe fuel pump.

• All of the fuel quality items above are not considered "bottom" contaminants and sampling should occur at mid-level of the tank. 

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Engine Coolant Sampling

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Engine coolant, whether standard coolant or Extended Life Coolants (ELCs), will degrade and lose the ability to protect an engine.  While the life of the coolant is dependent on the type of coolant used and additives included, routine sampling will not only monitor your cooling system for optimal performance but help ensure the longevity of the equipment as well.

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• Freeze Point - Freeze point (and conversely related boiling point), is the measure of the ability of the coolant to protect your engine in extreme temperatures.  If the freeze point is to high, in cooler temperatures it can freeze and expand and can lead to failed components and even cracked engine blocks!

• pH - pH is the measure of acidity or basic nature of the coolant.  Too low (acidic) and it can lead to a buildup called scale (especially when combined with contaminant elements below) which can restrict or blocking the radiator leading to overheating and localized "hot spots" resulting in component failure.  

• Corrosion Elements - The presence of Iron, Copper, Aluminum, Silver, Lead, Tin and Zinc are often the result of the corrosion of engine and cooling system components and can be indicators of potential failure.  Recommendation will be for an immediate flush and refill to prevent further damage.

• Contaminant Elements - Calcium and Magnesium are present in hard or untreated water and can result in scale build up.  Recommendations may be to treat or to drain and refill cooling system with fresh coolant.

• Additive Elements - Phosphorus, Boron, Molybdenum, Silicon, Potassium and Sodium are present in coolant and Supplemental Coolant Additives (SCAs).  If levels drop too low, a recommendation for adding SCAs may be issued, however, care should be taken to add the appropriate type and not to mix.

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