G2047 - Oil Analyzers Oil Analysis User's Guide
Contents
1. while they are still at operating temperature Although an equipment manufacturer s recommendations provide a good starting point for developing preventative maintenance practices Take samples at regularly scheduled intervals e Take samples from the same sampling point sampling intervals can easily vary How critical a each time piece of equipment is to production is a major Whether you re a seasoned veteran or a first time consideration for determining sampling frequency sampler a well designed quality fluid analysis as are environmental factors such as hot dirty program puts you on track for well managed operating conditions short trips with heavy loads cost effective equipment maintenance and excessive idle times programming Suggested Sampling Intervals amp Methods MOTOR VEHICLES Gas Engines 125 Hours 7 500 miles By vacuum pump through dipstick retaining Diesel Engines 250 Hours 15 000 miles tube or sampling valve installed in filter return Gears By vacuum pump through oil level plug Differentials amp 250 hours or dip stick retaining tube Final Drives Planetaries 250 hours By vacuum pump through oil fill port of system reservoir at mid level By vacuum pump through radiator cap Cooling System 1 000 hours 5 5 Si or fill port of system reservoir at mid level INDUSTRIAL EQUIPMENT Hydraulics 220 50 Hola By vacuum pump through oil fill port of system reservoir at mid level Through sample val2. 5 settings and preferences also gives you the power to put Use a trackable shipping service for sending samples the information you need most in front of you first to the laboratory STEP 4 NOTE When you provide accurate and complete unit and fluid informa tion your laboratory can deliver accurate and complete results and recommendations e Complete and attach the return mailer address label Go to www horizonsignup com to the black shipping container e Ship by trackable mail service such as FedEx or UPS FTE Bae ar L g ele i ja a a e ea Fi i E i jk a je ajsla ale q lajal la elaj rie Jaja jmlirimjn miala a eli ele a fal a fae a epee eae a i ifa fafej F fa Sli e a jejalalmjejaje ja e a pale ul a fuls de leirlniel dele In a Velelelulmln r j j j m a jalalm ja mjaf Jul i lle Im m el m mjadi u inlalnlal m la ee m Ih li DRI co SODOOE ofa pm om oil ele oe nm a m mogn m ilelelel m efne im Teleleiele fell m Te m a Jead gefjefefal a Senf Sr falafefe je fen m DA AA ees a en TGA Fees E Wati 7 mya ai E R E BO ma amaa se i Pheded lee Pade H lee lelalalalealdala IHT Pa ERA Be Ti u a ES EIEISE BEE EB ET EN EIG fafafa aa dada DAWA Ih dee iT if s le PE ae oe siwinjejeisjejeieisiejeie slefa nee ee aibid i oa B f a fii ll m re e m eet ot et ieee
3. een Complete a sample jar label for every sample submitted to the laboratory Be sure to fill out all label information completely and accurately to ensure proper testing and accurate in depth analysis Once complete attach the label to the sample bottle Fill in the unit s ID on the removable tracking number sticker located to the right of the sample label and retain for your records e Fill out the sample jar label completely and accurately e Include all unit and fluid information requested including unit ID type of component and position time on both the fluid and the unit and whether or not fluid has been added or changed e Track sample processing at www trackmysample com I TETEE Fluid Analysis Program Shipping Information Test Reports and Data Management Your FREE online reporting option HORIZON is fast bringing you test results almost immediately after w v processing is complete ec HORIZON Management Reports allow you to affect Salt Lake City positive changes in your daily maintenance practices by e Keeping sampling schedules on track e Identifying bottlenecks in turnaround time that are Houston costing you money e Summarizing unit problems that could influence Complete the mailer return address label for the future purchasing decisions lane nearest yOu o eaa Mon eee ne Control over an extensive host of personal application container affix the appropriate postage and mail s ene
4. reaches shoulder of jar unscrew jar from pump replace jar lid and tighten securely e Unscrew pump locking ring remove tubing and drain excess oil back into reservoir e Discard tubing after each sample to avoid cross contamination e Complete sample jar label and affix to sample jar Oil Analyzers OIL ANALYZERS Fluid Analysis Test Packages OIL ANALYZERS Fluid Analysis provides diagnostic testing designed to evaluate lubricant condition component wear and contamination in mobile and industrial applications with a test report provided by an independent laboratory for each sample submitted Refer to the chart below to determine which combination of tests each component will receive Test Packages Applications Engines Non Engines Purpose Monitors wear amp contamination 24 Metals by ICP Fuel Dilution Soot Water by Crackle Viscosity 40 C if ISO grade fluid Viscosity 100 C O 3 9 if SAE grade fluid Oxidation Nitration By FTIR Total Base Number Total Acid Number To order OIL ANALYZERS Fluid Analysis kits please call OIL ANALYZERS at 800 777 7094 For product information if you have questions regarding the OIL ANALYZERS fluid analysis program or for help in understanding your test reports call 877 458 3315 Coolant Kit Basic Fuel Kit Basic Winter Fuel Kit 17 Metals by ICP pH Glycol Ethylene or Propylene Glycol Freeze Point Boil Poin
5. Grade 40 C Industrial Fluids Min cSt 1 98 2 88 4 14 6 12 9 00 13 5 19 8 28 8 41 4 61 2 90 0 135 198 288 414 612 900 Max cSt 2 42 3 52 5 06 7 48 11 0 16 5 24 2 35 2 50 6 74 8 110 165 242 352 506 748 1100 1650 How to Read the OIL ANALYZERS Fluid Analysis Report Application identifies in what type of environment the equipment operates and is useful in determining exposure to possible contaminants a i E H rum _ aa f Equipment ID is each customer s opportunity to uniquely identify units being tested and their location Ss J T Accurate thorough and complete Unit Type should give as much fluid and equipment information detail as possible What kind of allows for more in depth analysis and ompresenr gearbox engine liminat fusi h etc influences flagging can eliminate confusion when inter parameters and depth of preting results analysis Different metallurgies require different lubrication TRACKING and have great impact on how results are interpreted Lube Manufacturer Type and Grade identify a lube s properties and its viscosity and are critical in determining if the right lube is being used Filter Types and their Micron Ratings are important in analyzing particle count the higher the micron rating the higher the particle count results 12 Fluid Analysis Pr
6. IME missing Mia Laboratory will request additional unit and lube information if incomplete on sample label Fluid Analysis Program Elemental Analysis Elemental Analysis or Spectroscopy identifies the type and amount of wear particles contamination and oil additives Determining metal content can alert you to the type and severity of wear occurring in the unit Measurements are expressed in parts per million ppm Combinations of these Wear Metals can Knowledge of the environmental Additive and Multi Source Metals may turn up in test results for a identify components within the machine that conditions under which a unit variety of reasons Molybdenum antimony and boron are additives are wearing Knowing what metal a unit is operates can explain varying levels in some oils Magnesium calcium and barium are often used in made of can greatly influence an analyst s of Contaminant Metals detergent dispersant additives Phosphorous is used as an extreme recommendations and determine the value Excessive levels of dust and dirt can pressure additive in gear oils Phosphorous along with zinc are of elemental analysis be abrasive and accelerate wear used in anti wear additives ZDDP P a Ti a 8 E B Test Data Test results are listed according to age of the sample oldest to most recent top to bottom so that trends are apparent Significant changes are flagged and printed in the gray areas of the re
7. ding wear metal concentrations The laboratory at which testing was completed is denoted by an for Indianapolis an H for Houston and an S for Salt Lake City The Lab is assigned to the sample upon entry for processing and should be the reference num ber used when contacting the lab with questions concerns or feedback Lube Time is how long the oil has been used Unit Time is the age of the equipment and Lube Added is how much oil has been added since the last sample was taken Data Analysts Initials OlAnaigors C Recommendations A data analyst s job is to explain and if necessary recommend actions for rectifying significant changes in the lubricant or the unit s condition Reviewing comments before looking at the actual test results will provide a road map to the report s most important information Any actions that need to be taken are listed first in order of severity Justifications for recommending those actions immediately follow FLUID ANALYSIS REPORT Check for possible source of ABRASIVES entry such as faulty Alter eements Nibe housing breathers fall points etc Abrasnees Silicon are a a SEVERE LEVEL Lubricant change is suggested F mot done at samping Kirmes Water ie at a MODERATE LEVEL Gear and or bearing metal a a MODERATE LEVEL Aluminen 5 most lieh in the foren of ahumira silice Dirt Poteau i at a MINOR LEVEL BARIUM 15 COMMONML FOUND IN DRILLING MUD init andor lube T
8. m lalnim la in ie im w ze J 4 8 er u hee JE am au a F t CENE rE a es a ee a L stig eh Te rer T a du iit LE Trees en LLLITITIEI 10 Diesel amp Gasoline Engine Oil Guidelines for physical properties contaminants amp degradation Glycol Water Fuel Dilution Viscosity Solids Soot diesel only Oxidation Nitration Total Base Number Total Acid Number industrial Normal Abnormal 0 Trace lt 0 05 0 05 lt 1 0 2 0 in grade or one SAE ISO viscosity grade change lt 1 5 2 0 lt 2 0 3 0 Expressed as absorption units per cm Expressed as absorption units per cm Excessive Trace gt 1 0 3 0 or two SAE ISO viscosity grade change gt 4 0 gt 4 0 50 0 synthetic 30 0 petroleum 50 0 synthetic 30 0 petroleum Change oil when TBN strength diminishes to lt 2 1 3 3 4 SAE Engine amp Gear Oil gt 4 Viscosity Grade 100 C Automotive Fluids SAE Engine Oil Grade 100 20 30 40 50 60 SAE Gear Oil 90 140 250 Min cSt 5 6 oS 12 5 16 3 21 9 Min cSt 13 5 24 0 41 0 Max cSt gt 9 3 gt 12 5 gt 16 3 gt 21 9 gt 26 0 Max cSt gt 24 0 gt 41 0 No Req ISO Viscosity Grade 40 C 2 S 5 7 10 15 22 32 46 AGMA 1 68 AGMA 2 100 AGMA 3 150 AGMA 4 220 AGMA 5 320 AGMA 6 460 AGMA 7 680 AGMA 8 1000 AGMA 8A 1500 ISO Viscosity
9. nalyzers Dil Analyzers What Can the OIL ANALYZERS Fluid Analysis Program Do For You Imagine being able to see exactly what s happening inside an engine a gearbox or hydraulic system OIL ANALYZERS Fluid Analysis is a preventive maintenance tool that provides a picture of both the fluid condition and the internal condition of a component or system without disassembly OIL ANALYZERS Fluid Analysis will Monitoring the condition of the oil optimizes drain intervals so that you get the most out of the fluid you re paying for Fewer oil changes minimize maintenance costs and maximize uptime Monitoring system cleanliness and filtration efficiency allows you to keep your equipment longer and significantly reduce replacement costs State of the art fluid analysis identifies dirt wear particles fuel dilution and coolant contaminants that can cause catastrophic failure or significantly shorten equipment life Testing and analysis ensures that units are up running and making money Analysis results provide valuable sampling history documentation that easily justifies higher equipment resale values Fluid Analysis Program HIGH QUALITY TESTING The OIL ANALYZERS Fluid Analysis Program utilizes independent ISO 17025 A2LA accredited testing laboratories This is the highest level of quality attainable by a testing laboratory backed by the most stringent accrediting body in the industry You can be confident that the results yo
10. ogram Customer Equipment and Sample Information The information submitted with a sample is as important to who is reading the report as it is to the analyst interpreting the test results and making recommendations Properly document your equipment and share this knowledge with your laboratory Implement a sampling process for every piece of equipment in your oil analysis program that can be followed consistently each time the unit is sampled Accurate thorough and complete lube and equipment information not only allows for in depth analysis but can eliminate confusion and the difficulties that can occur when interpreting results Make note of the difference between the Date Sampled and the Date Received by the lab Turnaround issues may point to storing samples too long before shipping or shipping service problems Also noted is testing Date Completed Manufacturer and Model can also identify metallurgies involved as well as the OEM s standard maintenance guidelines and possible wear patterns to expect Severity Status Levels 0 Normal 1 At least one or more items have violated initial flagging points yet are still considered minor 2 A trend is developing 3 Simple maintenance and or diagnostics are recommended 4 Failure is eminent if maintenance is not performed Py PR Oy ph iiih Sump Capacity identifies the total volume of oil in gallons in which wear metals are suspended and is critical to tren
11. ples A Special Testing section of your report systems Oil Analyzers OAI LABORATORIES INDIANAPOLIS 7898 Zionsville Road Indianapolis IN 46268 Phone 877 458 3315 OAI LABORATORIES HOUSTON 10910 W Sam Houston Pkwy N Suite 700 Houston TX 77064 6314 Phone 877 458 3315 OAI LABORATORIES SALT LAKE CITY 3060 W California Avenue Suite B Salt Lake City UT 84104 Phone 877 458 3315 OAI LABORATORIES CANADA 5140 75 St Edmonton ABT6E 6W2 Phone 877 458 3315 Send your samples to the laboratory location nearest you To order OIL ANALYZERS Fluid Analysis kits Visit www WorldsBestOil ca G2047 4 09
12. port Samples are listed by Date Received in the lab Viscosity measures a lubricant s resistance to oldest first They are also assigned a Lab Number flow at temperature and is considered it s most for easy internal tracking Important to also note is important physical property Depending on lube whether or not the Lube has been Changed since grade it is tested at 40 and or 100 degrees the last sample was taken Centigrade and reported in Centistokes sel ee lel ele TTT E E ale Yo feel fee I I I ELEND SBOCBBESBEITHEBENEBERE 1 TEE EEE AH ee ee ees ees ees ees eee ee ee ee eee ee a a TEEN GEN ee VON TEEN ee ERREN eS e ee ee ee ee ee ee ee ee ee ee aE EE ii Fuel and Soot are reported Water in oil decreases lubricity prevents The ISO Code is an index number that represents in of volume High fuel additives from working and furthers a range of particles within a specific micron dilution decreases unit load oxidation Its presence can be determined range i e 4 6 14 Each class designates a range capacity Excessive soot is a by crackle or FTIR and is reported in of of measured particles per one ml of sample sign of reduced combustion volume Water by Karl Fischer ASTM The particle count is a cumulative range efficiency D1744 determines the amount of water between 4 and 6 microns This test is valuable present These results appear in the in determining large particle wear in filtered only on engine oil sam
13. t Nitrite SCA Number Total Dissolved Solids Specific Conductance Total Hardness Visuals color oil fuel magnetic precipitate non magnetic precipitate odor amp foam 24 Metals by ICP Cloud Point Viscosity 40 C Pour Point Calculated Cetane Index Distillation Premium API Gravity Winter Fuel Kit Cloud Point Basic Fuel Kit Pour Point Fuel Contamination Cold Filter Plug Point Water amp Sediment Cold Filter Plug Point can be added to Aerobic Bacteria any fuel test package Sampling Equipment and Supplies Vacuum Pump Plastic Tubing 100 ft roll Plastic Tubing 56 Oil Analyzers A Component Registration Form is included with every sample kit Fill it out only when sampling a component for the first time or to notify the laboratory of a change in component and or fluid information already registered with the laboratory Complete up to date information ensures that you receive the proper testing and an accurate analysis of the results e Fill out the Component Registration Form completely and accurately e Use this form only for first time samples or changes in unit or oil information previously submitted e Include it in the black mailer with the sample jar COMPONENT REGISTRATION FORM ae Tri _ NEEENRERSEEENEEE id en a dep for pet rend Dil Analyzers Size E EN e EEE o CE if Pe ee ee ae ee ee LRHE Dome er be
14. u receive are accurate repeatable and traceable to a standard and that your fluid analysis program is supported by a documented quality system you can depend on to deliver superior testing and customer services INNOVATIVE INFORMATION TECHNOLOGY SOLUTIONS The OIL ANALYZERS Fluid Analysis Program s online reporting software shows you how to get the most from your information Using HORIZON online you receive results fast almost immediately after sample processing is complete The software s management reports can then take your fluid analysis program to the next level by helping you manage your data and your program efficiently and effectively Oil Analyzers Taking Samples OIL ANALYZERS Fluid Analysis will show you how Fluid analysis is most effective when samples are regular sampling and TREND ANALYSIS monitoring representative of typical operating conditions Dirt test data over an extended period of time will system debris water and light fuels tend to separate provide the information you need to continually from the lubricants and coolants when system maximize asset reliability and ultimately increase temperatures cool For optimum results consider company profits Comparing a component s most the following best practices recent samples to its historical data is instrumental e Take samples while systems are operating under in en trends that can pinpoint potential normal conditions or immediately after shutdown problems
15. ve installed upstream Gas Turbines Monthly or every 500 hours of the filter on the return line or out of the system reservoir Through sample valve installed upstream Steam Turbines Bi monthly or monthly quarterly of the filter on the return line or out of the system reservoir Through sample valve installed upstream of the filter on the return line or out of the system reservoir Gas Air Monthly or at Compressors 500 hours quarterly Sampling with a Vacuum Pump A vacuum pump is used to take samples from a dipstick or non pressurized system The pump is attached to the sample jar a tube is inserted into the pump and then into the dipstick retaining tube or oil fill port Activating the pump handle the sample jar should be filled about 3 4 full or to its shoulder When sampling engines e Measure length or depth of fill port tube reservoir or dipstick e Add six 6 inches and mark the measurement on the tubing e Cut the tubing 12 inches beyond this mark e Insert tubing onto top of vacuum pump and tighten lock ring e Remove sample jar lid and attach jar to bottom of vacuum pump and tighten securely e Insert tubing into fill port reservoir or dipstick retaining tube only to the mark on the tubing To avoid drawing settled debris into the sample do not allow contact between tubing and bottom of reservoir e Push and pull vacuum pump plunger until sample jar is 3 4 full e When sample
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