Shell Lube Analysis guide

User Guide

Shell

LubeAnalyst

Shell

LubeAnalyst

Shell

LubeAnalyst

Pantone 7418

4 colourC 0M 70Y 60K 5

StandardR 199G 79B 79

WebsafeR 153G 51B 51

Shell LubeAnalyst User Manual

Table of Contents Introduction to Shell LubeAnalyst. ................................................................ 3 Registering with Shell LubeAnalyst................................................................ 4

Registering as a New Shell LubeAnalyst Customer. ...............................................4 Registering or Modifying Equipment/Vehicle Information. .....................................5

Register/Modify Equipment for Industry and Marine..............................................................6 Register/Modify Vehicles for Transport and Construction. .....................................................7

Ordering Materials from Shell LubeAnalyst. ...........................................................8 Choosing a Shell LubeAnalyst Test Suite....................................................... 9

Standard Test Suites using Pre-paid Test Kits. .......................................................9 Standard (K1) - Transport & Construction..............................................................................9 Standard (K2) - Industry & Marine. ...................................................................................... 10

Advance Test Suites using Post-paid Test Kits..................................................... 10 Tailor-made Equipment Specific Test Suites. ....................................................... 10 Shell LubeAnalyst Test Suites............................................................................... 10 Shell LubeAnalyst Optional Test. .......................................................................... 12

Registering Oil Samples with Shell LubeAnalyst........................................... 14 Why correct oil sampling is important. ................................................................. 14 General instructions for correct oil sampling. ....................................................... 14

Ensuring Health and Safety conditions................................................................................... 14 Ensuring the quality of the sample......................................................................................... 14 Avoiding contamination of the sample. .................................................................................. 14

How to take a good sample................................................................................... 14 Drawing a sample with a sample pump. ................................................................................ 14 Sampling from circulation systems. ....................................................................................... 15 Sampling from reservoirs, sumps and tanks. .......................................................................... 15 Sampling from splash, slinger-ring and flood lubricated components. ..................................... 15 Vacuum pump thief sampling. ............................................................................................... 15 Sampling from a heat transfer system. ................................................................................... 16

Shell LubeAnalyst Sample Label Forms. ..................................................... 17 Sample Label for Standard Pre-paid Test Kits. ..................................................... 17 Sample Label for Post-paid Advanced Test Suites................................................ 17 Completing the Sample Label................................................................................ 18 Keeping Track of Shell LubeAnalyst Oil Samples. ................................................ 18

Interpreting the Shell LubeAnalyst Sample Reports. ..................................... 19 The Standard Report (K1 & K2 Test Kits). .......................................................... 19 The Advanced Report ........................................................................................... 20 The Ad-hoc Report ............................................................................................... 21 The Annual Report................................................................................................ 21

Receiving the Shell LubeAnalyst Sample Reports......................................... 22

The Internet Sample Reports ................................................................................ 22 The Email Sample Report ..................................................................................... 22 The Fax Sample Report ........................................................................................ 22 The Post Sample Report ....................................................................................... 22

Using the Shell LubeAnalyst Web based Software....................................... 23 Internet access...................................................................................................... 23 Navigating through the Shell LubeAnalyst application........................................... 23

Equipment Management Section............................................................................................ 23 Sample Management Section. ................................................................................................ 24 Management Results Section................................................................................................. 25 Registration Section............................................................................................................... 25 Order Section ........................................................................................................................ 25 Miscellaneous Sections.......................................................................................................... 25

Invoicing for Shell LubeAnalyst Samples ..................................................... 26

Introduction to Shell LubeAnalyst. Welcome to Shell LubeAnalyst, the leading global oil and Equipment condition monitoring service Shell LubeAnalyst is like a health check for your oil and Equipment. It is a condition monitoring service, which helps to keep your business running smoothly. Why Shell LubeAnalyst can help you improve Equipment reliability and save money on your maintenance? The Shell LubeAnalyst system has been designed as an early warning system that identifies signs of increased wear and evidence of unwanted contaminants or lubricant degradation. This condition monitoring service enables preventative and predictive maintenance. Lubricants are designed to perform many functions: reduce friction and wear, transfer power, remove and control contaminants to name just a few. Consequently, the analysis of used lubricants can reveal important information about the condition of machinery and the ongoing serviceability of the lubricant. In many applications, an aged lubricant can begin to cause damage to machinery rather than protect it. Whether this is due to excessive contamination or chemical degradation, oil analysis is the most effective means of detecting this common problem and optimising service intervals. Oil analysis is also one of the most effective ways of trending wear and identifying wear behaviour, whether this is via time based trending of wear or the morphological study of individual wear particles. Five simple steps to the Shell LubeAnalyst Equipment condition monitoring service Register your customer details and Equipment with Shell LubeAnalyst Collect the oil sample Label the oil sample Send the oil sample Read the lab report with the diagnosis and recommendations. How do I get the most out of Shell LubeAnalyst? Define your goals clearly, so that the tests performed fit the application. Take the time to complete the sample registration process to determine true conditions and ensure accurate testing. -------- Please note that the assessment of lubricant condition is a complex task. Shell and its related bodies corporate have prepared this document as a guide only, to assist you in using the Shell LubeAnalyst service. It should not be regarded as an authoritative for all machinery, in all circumstances. If in doubt about a particular aspect of testing, contact the Equipment manufacturer or your local Shell representative. This document is provided on the condition that neither Shell nor its related bodies corporate shall be liable for any loss, damages, costs and expenses (including loss of profits, business or anticipated savings or any direct or consequential losses of whatever kind) incurred by customers or any other person or entity arising out of reliance on, use or communication of this document. Shell outsource some aspects of the Shell LubeAnalyst Condition Monitoring Service to third parties.

Registering with Shell LubeAnalyst. Registering as a New Shell LubeAnalyst Customer. You may obtain the following Shell LubeAnalyst Customer Registration and Material Order Form from your Shell LubeAnalyst contact. Please complete this form as detailed below.

After putting in all the relevant information, please forward it to your Shell LubeAnalyst focal point; they will then use the details to register you onto the Shell LubeAnalyst condition-monitoring programme. Along with this form we’ll also need to register your Equipment/vehicles.

Decide how to receive your sample results; the best way is by e-mail.

As a new customer tick this box

Write your detailed address here

If a colleague should also get sample results, write their e-mail address here.

If you want to change your address details tick here and write your Internet Login here.

Registering or Modifying Equipment/Vehicle Information. To get the best out of the Shell LubeAnalyst condition-monitoring programme each Equipment/vehicle needs to be registered with a unique Shell LubeAnalyst LubeAnalyst number. This number must then be quoted on every sample label submitted. The Shell LubeAnalyst diagnostician can then spot trends in the test results thereby helping to predict Equipment/vehicle potential failures. Registering your Equipment/vehicle information is easy. However, the more information given, the better able the diagnostician to advise you on the condition of your lubricant and Equipment/vehicle. It is important to note that a separate form is required for every Equipment/vehicle that condition monitoring is to be undertaken for. When submitting ad-hoc samples, simply use the sample label and tick the relevant box. To order sampling materials and pre-paid kits see below.

What type of Equipment or vehicle?

Industry & Marine Equipment Transport & Construction Ad hoc Equipment

Typical industry Equipment includes machines like turbines, industrial gears, hydraulics, gas-engines, circulating systems, heat transfer systems, transformers, and compressors. For Marine this includes large slow/medium speed diesel engines.

Typical Transport vehicles include cars, buses, and passenger/freight units and their associated engines, gearboxes, transmissions, axles and final drives. For Construction this includes building and surface mining Equipment.

When registering Equipment or vehicles please remember that the more information that is given, the better and more detailed and accurate the diagnoses will be about the lubricant and your Equipment/vehicle. This is the best way for Equipment condition monitoring! You should also detail maintenance/lubrication information when sending in new samples. The benefit is a more detailed, trended diagnoses including graphs for the important properties of the oil and wear/contamination graphs indicating Equipment/vehicle condition.

This is a very easy to use part of the Shell LubeAnalyst service. For any Equipment/vehicle, whether registered with Shell LubeAnalyst or not, you can send in one-off, or ad-hoc, samples to help analyse a specific problem, i.e. an unusual or unexpected Equipment/vehicle condition. The analysis and diagnosis will only be completed for that sample. No Equipment/vehicle sample history will be used and please note the diagnoses are not as good as for registered Equipment! An ad-hoc sample is not a faster service.

Register/Modify Equipment for Industry and Marine. You may obtain the following Shell LubeAnalyst Equipment Registration Form from your Shell LubeAnalyst contact. Please complete this form as detailed below. Alternatively you can register new Equipment using the Shell LubeAnalyst web based software.

After putting in all the relevant information, please forward it to your Shell LubeAnalyst focal point; they will then use the details to register your Equipment onto the Shell LubeAnalyst condition-monitoring programme. Please note that separate forms are required to register every piece of Equipment that will be regularly sampled. This is usually critical or important plant Equipment.

Write the name of your company here.

If registering a new machine tick here. If modifying an existing Shell LubeAnalyst machine tick here.

If it is an existing machine, don’t forget to write the Shell LubeAnalyst number here.

Write in here your own machine description and reference id, these will be printed on the sample report along with the sample number.

Write the manufacturer and model details here. This is vital for accurate diagnosis.

How much time per day do you use your machine?

Detail the type of component here and give us the necessary information using the tick boxes.

If you do not want to do a standard test only, then write here the additional test codes for the options. Additional tests can only be added to the advanced post-paid service. The pre-paid kits have standard test suites that cannot be changed or added to.

If you are already registered as a Customer write the Shell LubeAnalyst Customer registration number here.

Register/Modify Vehicles for Transport and Construction. You may obtain the following Shell LubeAnalyst Vehicle Registration Form from your Shell LubeAnalyst contact. Please complete this form as detailed below. Alternatively you can register new vehicles using the Shell LubeAnalyst web based software.

After putting in all the relevant information, please forward it to your Shell LubeAnalyst focal point; they will then use the details to register your vehicle onto the Shell LubeAnalyst condition-monitoring programme. Please note that separate forms are required to register every vehicle and component that will be regularly sampled.

Write the name of the your company here.

If registering a new vehicle tick here. If modifying an existing Shell LubeAnalyst machine tick here.

If it is an existing vehicle, don’t forget to write the Shell LubeAnalyst registration number here.

Write in here your own vehicle description and reference id, these will be printed on the sample report along with the sample number.

Write the manufacturer and model details here. This is vital for accurate diagnosis.

How much time per day do you use your machine?

Detail the type of component here and give the necessary information using the tick boxes.

If you do not want to do a standard test only, then write here the additional test codes for the options. Additional tests can only be added to the advanced post-paid service. The pre-paid kits have standard test suites that cannot be changed or added to.

If you are already registered as a Customer write the Shell LubeAnalyst Customer registration number here.

Ordering Materials from Shell LubeAnalyst. You can order materials when registering as a new customer. To re-order materials for ongoing sampling, the form is the same as the customer registration form. When you are a new Shell LubeAnalyst customer, your focal point will advise what kind of material you need and will send it after you are registered. Thereafter simply order materials as required. Please complete this form as detailed below. Alternatively you can order new materials using the Shell LubeAnalyst web based software. After putting in all the relevant information, please forward it to your Shell LubeAnalyst focal point; they will then use the details to register your order onto the Shell LubeAnalyst condition-monitoring programme, which will then be sent to you by post.

Tick here if you are an existing Shell LubeAnalyst customer.

Tick here for ordering materials.

Give us your Shell LubeAnalyst customer number and the name of the company for identification.

If you need a purchase number on the bill, please write it here.

If you are using the standard service, choose the industry or transport pre-paid kits and how many you need. These are standard kits that include everything you need for up to 10 samples.

If you using the advanced service, plus any optional tests, then choose exactly which kind of bottle sets you need. You will receive the bottles, the sample card, and a posting package. The advanced service is a post-paid service only, paid per sample.

For additional materials detail here what you need. These will be paid for it separately.

Choosing a Shell LubeAnalyst Test Suite. Shell LubeAnalyst offers two levels of predefined testing packages developed to identify known Equipment/vehicle failures. These are Standard and Advanced. Your choice of test suite will vary according to the type of Equipment/vehicle used, how mission-critical it is, and the type of failure or problems you may have. The Standard test includes the standard areas of inspection to identify typical Equipment/vehicle failures and problems. If you require more enhanced results, you should opt for the Advanced test. Shell LubeAnalyst also offers optional tests that can be tailor-made to your individual situation. This option makes it possible to help identify problems specific to your Equipment. Standard Test Suites using Pre-paid Test Kits. This is the standard level of testing, which is suitable for non-mission-critical Equipment. Used on a regular basis it can help you detect the most common types of Equipment/vehicle irregularities. Test results and diagnoses are trended, with reports showing graphical output for key diagnosis identifiers.

ShellLubeAna lyst

ShellLubeAna lyst Standard/Advanced Test Suites

Seal SystemsHeat Transfer SystemsRefrigeration SystemsAmmonia CompressorsTurbo CompressorsGreasesEDM FluidsFire Resistant FluidsTransformersFuel TestingCoolant Testing

Marine/Medium Speed DieselsIndustrial GearsHydraulicsTurbinesGas EnginesCirculating SystemsAviation Piston EnginesCompressors

Engines (Diesel & Gasoline)GearboxesTransmissionsAxlesHydraulicsConstruction Gears

AdvancedPost Paid Sampling

StandardPre-Paid Sample Kit

Equipment/Vehicle Type

Standard (K1) - Transport & Construction.

This test kit covers test suites for engines, gearboxes, transmissions, construction gears, axles and basic hydraulics. The kit contains sufficient sampling materials for up to 10 samples. This kit is pre-paid and the test suites are standardised and non-variable. Standard (K2) - Industry & Marine. This test kit covers test suites for Marine diesel engines, Aviation piston engines, and Industrial gears, hydraulics, turbines, compressors, gas engines, and circulating systems. The kit contains sufficient sampling materials for up to 10 samples. This kit is pre-paid and the test suites are standardised and non-variable. Advance Test Suites using Post-paid Test Kits. This level of testing is more complex and can be tailor-made for special machines and mission-critical Equipment/vehicles. It offers you a vast range of optional tests that are available and can be performed depending on specific Equipment/vehicle duty cycles and requirements. If used on a regular basis, this enhanced testing can give you a more accurate diagnosis on your Equipment/vehicle. It can also make your machine maintenance more reliable. This service covers advanced test suites for the pre-paid kits for engines, gears, hydraulics, etc, to provide more accurate and detailed diagnosis. It also covers Equipment such as heat transfer systems, compressors, seal systems, gas engines, refrigeration compressors, ammonia compressors, and turbo compressors where identification/diagnosis of Equipment failures is more complex. Also, optional tests like fuel, coolants, fire resistant fluids, transformer oils, heat transfer systems and advanced turbines are available. Tailor-made Equipment Specific Test Suites. This is a tailor-made service for special machines and extremely mission-critical Equipment. It offers a vast range of optional tests that are available to help diagnose on specific Equipment requirements. Shell LubeAnalyst Test Suites.

Test Groups Application Standard Advanced Options

Manual & Automatic Transmissions & Gearboxes • Appearance (Special) • Metals/ICP (SPEO) • VK 100°C (V10O) • Water Content (OQO)

Manual & Automatic Transmissions & Gearboxes • Standard plus • Optional tests

• Wear Index (WPIO) • Wear Severity Index (ISUO) • Millipore Sludge 5µ (G5O) • TAN (TANO)

Construction Equipment Gears & Hydraulics • Metals/ICP (SPEO) • VK 40°C (V40O) • Water Content (OQO)

Construction Equipment Gears & Hydraulics • Standard plus • Optional tests

• Wear Index (WPIO) • Wear Severity Index (ISUO)

Transport & Construction Kit 1 (SEK2) Pre-paid Box of 10

Diesel & Gasoline Engines • Blotter Spot (TACO) • Flash Point (FLGO) • Metals/ICP (SPEO) • VK 100°C (V10O) • Water Content (OQO) • TBN (TBNO)

Diesel & Gasoline Engines • Standard plus • Water Glycol (GOLO)

• Fuel Dilution Diesel (DILO) • Fuel Dilution Gasoline (DIEO)

Industrial Gears, Circulating Systems • Standard plus • Colour Option (CO) • Wear Severity Index (ISUO) • Millipore Sludge 5µ (G5O)

• Analytical Ferrography (FEO) • pH Option (PHO) • For PAG use (G5TO)

Industry Kit 2 (SEK2) Pre-paid Box of 10

Compressors, Circulating Systems, Hydraulic Systems, Industrial Gears, EDM, Turbine Systems • Appearance (Special) • Metals/ICP (SPEO) • TAN (TANO) • VK 40°C (V40O) • Water Content (EAUO) • Water Content (OQO)

Compressors, Hydraulics • Standard plus • Colour Option (CO) • Particle Count (PCO)

• Analytical Ferrography (FEO)


• Millipore Sludge 0.8µ (G08O)

Marine Diesel Engines • Blotter Spot (TACO) • Flash Point (FLGO) • Metals/ICP (SPEO) • TBN (TBNO) • VK 100°C (V10O) • Water Content (OQO)

Aviation Piston Engines • Fuel Dilution Gasoline

(DIEO) • Metals/ICP (SPEO) • VK 100°C (V10O) • Water Content (OQO)

Aviation Piston Engines • Standard plus • Optional tests

• Oxidation (OXNO) • TAN (TANO)

Gas Engines • Metals/ICP (SPEO) • Oxidation (OXNO) • TAN (TANO) • VK 100°C (V10O) • Water Content (OQO)

Gas Engines • Standard plus • TBN (TBNO)

• Initial pH Jenbacher (IPHO) • Chlorine Content (CLO)

Heat Transfer & Seal Systems SEAD

• Appearance (Special) • Flash Point (FLEO) • VK 40°C (V40O) • Water Content (EAUO) • TAN (TANO)

• Flash Point (FLMO) • Colour Option (CO) • Metals/ICP (SPEO) • Millipore Sludge 0.8µ (G08O) • Millipore Sludge 5µ (G5O)

Heat Transfer & Seal Systems (German Mrkt) HTAD

• Appearance (Special) • Flash Point (FLMO) • VK 40°C (V40O) • Water Content (EAUO) • Conradson Carbon (RCOO)

• Colour Option (CO) • Metals/ICP (SPEO) • Millipore Sludge 0.8µ (G08O) • Millipore Sludge 5µ (G5O)

Coolant Systems LRCO

• Appearance (Special) • Density (MVO) • pH Option (PHO) • Water Content (Special) • Metals/ICP (SPCO)

Diesel Fuel FOAD

• Density (MVFO) • Micro-organism (BACO) • Millipore Sludge 0.45µ

(G45O) • Sulphur (SUO) • Water Content (EAUO)

Transformer Test ELCO

• Appearance (Special) • Dielectric Strength (RDIO) • TAN (TANO) • VK 40°C (V40O) • Water Content (EAUO)

• Power Factor (PFO) • Gases (GAZO) • Furans Compounds (FUO) • PCB’s

Grease Lubricated Bearing GRCO GRAD

• Appearance (Special) • Metals/ICP (SPGO)

• Appearance (ASCO) • Penetration (PWO)

Fire Resistant Hydraulic HFB HFC

• Appearance (Special) • Metals/ICP (SPEO) • TAN (TANO) • VK 40°C (V40O) • Water Content (Special) -

HFB • Water Content (EAUH) -

HFC

• Optical Particle Count (OPC)

Refrigeration Compressor RCAD

• Appearance (Special) • Metals/ICP (SPEO) • TAN (TANO) • VK 40°C (V4DO) • Water Content (EAUO) • Colour Option (CO) • Wear Severity Index (ISUO) • Millipore Sludge 0.8µ

(G08O)

Refrigeration Ammonia Compressor RAAD

• Appearance (Special) • Metals/ICP (SPEO) • TBN (TBDO) • VK 40°C (V4DO)


• Water Content (EAUO) • Colour Option (CO) • Wear Severity Index (ISUO) • Millipore Sludge 0.8µ

(G08O) Turbo Compressors TOAD

• Appearance (Special) • Metals/ICP (SPEO) • TAN (TANO) • VK 40°C (V4OO) • Water Content (EAUO) • Colour Option (CO) • Millipore Sludge 0.8µ

(G08O)

Turbine TBCO

• Appearance (Special) • Metals/ICP (SPEO) • TAN (TANO) • VK 40°C (V4DO) • Water Content (EAUO) • Colour Option (CO) • Millipore Sludge 0.8µ

(G08O) • Air Release (AREO) • Particle Count (PCO)

Gas Turbines • Foaming (1+2+3) (MO2O) • RBOT (RBOO) Steam Turbines • Water Separation (WSO) • Foaming (1+2+3) (MO2O) • RBOT (RBOO) Water Turbines • Foaming (1+2+3) (MO2O)

Shell LubeAnalyst Optional Test. Test options Test Method Terminology DESCRIPTION Test

Code STANDARD Vol

Air release Characteristics (IP 313) Air release Option AREO IP 313 250 ml Rust Preventing Characteristics (ASTM D 665) Anti Rusting Option (fresh water) ARO ASTM D 665 400 ml

Anti Rusting Option (salt water) AROS ASTM D 665 400 ml ASTM Colour (ASTM D 1500) Appearance + Colour Option ASCO ASTM D 1500 50 ml

Asphaltenes Option ASPO IP 143 20 ml Blotter Spot Test Blotter Spot Option TACO In House 1 ml Determination of Carbon (residue micro method) (ASTM D 4530)

Carbon Conradson Option RCOO ASTM D 4530 20 ml

CFPP option CFPO EN 116 80 ml Chlorine Content (DIN 51 408/2) Chlorin Content Option CLO DIN 51 408/2 10 ml

Conductivity COND In House (D 2624)

50 ml

ASTM Colour (ASTM D 1500) Colour Option CO ASTM D 1500 50 ml Density Pyknometer (IP 189/190) Density Option Lubricant MVO IP 189/190 30 ml

Density Option Fuel MVFO IP 189/190 30 ml Water Separability (ASTM D 1401) Desemulsibility Option DESO ASTM D 1401 100 ml

Dielectric strength (Breakdown voltage)

RDIO IP 295 400 ml

Fuel content by gas chromatography (ASTM D 3524) (not for bio diesel)

Diesel Dilution DILO ASTM D 3524 20 ml

Analytical Ferrography Ferro (Analytical) Option FEO In House 20 ml Wear Severity Index Ferrography Wear Severity Index ISUO In House 20 ml

Filterability with water FO57 ISO 13357-1 300 ml Filterability without water FI57 ISO 13357-2 300 ml Filterability Index with water FIWO E 48690 300 ml Filterability Index without water FIO E 48690 300 ml

Flash point, closed Cup (SETAFLASH) Flash Exact Option FLEO SETAFLASH 50 ml FTIR (Oxidation / Nitration / Insolubles / Gycol / Water / soot etc)

FTIR

Furanic derivative (used on transformers to estabish the condition of the paper elements in the condensators)

Furanic compounds FUO ASTM D 5837-99

600ml

Pensky Martens Closed Cup Flash Point (ASTM D 93) Flash Pensky Maertens Option FLMO ASTM D 93 100 ml Flash point (Go/No Go) (ASTM D 3828) Flash Point (Go/no go) FLGO ASTM D 3828 10 ml Foaming Characteristics (ASTM D 892) Foaming (1+2+3) Option MO2O ASTM D 892 400 ml Foaming Characteristics ASTM D892 @ 24 c Foaming (1 sequence one only) MO10 ASTM D 893 200ml Gasoline Dilution by Distillation (ASTM D 322) Fuel dilution Option DIEO ASTM D 322 30 ml Gas in oil test used on transformers (type 1) Gas in Oil Option (9 gases) GAZO In House 300 ml Gases test as above but from gas sample (requires special on site sampling Equipment) (Type 2)

Buchholz gas analysis GAZO ASTM D 3612-01

See note

Glycol option GOLO In House 10 ml Insolubles N-Heptane INHO ASTM D 893 A 60 ml

Test options Test Method Terminology DESCRIPTION Test

Code STANDARD Vol

Ionol content % IONO In house 10 ml Initial pH (Jenbacher) IpH (Jenbacher) IPHO Jenbacher 20 ml Infra Red Analysis IR Spectrum Option IRO In House 10 ml

IR Special Option IRSO In House 10 ml Metals by ICP (ASTM D 5185) Metals/ICP (LUB) Option SPEO ASTM D 5185 10 ml

Metals/ICP (Coolant) Option SPCO ASTM D 5185 10 ml Metal/ICP Grease SPGO ASTM D 5186 10ml

SPPO is a standalone option only Additive metals in ppm SPPO ASTM D 5185 10 ml Bacteria Test Micro-organisms Option BACO MICRO TEST 10 ml Millipore Solids 8m Millipore sludges 0.8 µOption G08O In House 50 ml Millipore Solids 5m Millipore sludges 5 µ Option G5O In House 40 ml

Millipore sludges 0.45 µOption G450 In House 40 ml Millipore Filtration Teflon G5TO In House 40 ml

Nitrite Analysis Nitrite (go/no go) Option NITO In House 40 ml Oxidation/Nitration by FTIR Oxydation Nitration Option OXNO FTIR 10 ml Automated Particle Counting (NAS 1638 & ISO 4406) Particle Counting Option PCO NAS 1638 &

ISO 4406 60 ml

Automated Particle Counting (New ISO 4406 3 digit code) Particle Counting Option PC9O ISO 4406 60 ml Particle Counting by Microscopy Particle Counting Visual OPCO Microscope 100 ml PCB Analysis (ISO C 27234) PCB Option PCBO ISO C 27234 50 ml

Penetration (unworked) Option PUNO ASTM D217 600 g Penetration (worked) Option PWO ASTM D217 600 g

pH Determination (Jenbacher) pH Option PHO Jenbacher 20 ml Power factor Option PFO ASTM D 924 600 ml

RBOT (ASTM 2272) RBOT Option RBOO ASTM 2272 200 ml SAN (ASTM D 664) SAN Option SANO ASTM D 664 40 ml Sulphur by IPC (ASTM D 5185) Sulfur for Diesel Fuel SUO ASTM D 5185 10 ml TAN (ASTM D 664) TAN Option TANO ASTM D 664 10 ml TBN (ASTM D 4739) TBN Option TB4O ASTM D 4739 10 ml TBN (ASTM D 2896) After degazing TBN Option - after degazing TBDO ASTM D 2896 60 ml TBN (ASTM D 2896) TBN Option TBNO ASTM D 2896 10 ml Kinematic Viscosity (VK) 40°C after Degas Visco 40° Option after degazing V4DO In House 10 ml

Viscosity Index (Calculation) VIO ASTM D 2270 NA VK 100°C VK 100° Option V10O ASTM D 445 10 ml VK 40°C VK 40° Option V40O ASTM D 445 10 ml

Water content OQO Aquatest 10 ml Water Content HFC Water Content in HFC EAUH In House 10 ml Water content Karl Fischer Water Content Option EAUO K F 10 ml Steam demulsibility Water Separation WSO IP19 100 ml Wear Index Wear Index WPIO PQ 60 ml Notes: 1. Options should be available to add to any test suite or as stand alone / grouped and will be paid as an addition post paid item. 2. For Buchholz gas analysis you need a gas sample and therefore special Equipment and containers; sampling Equipment costs €300 and sample bags cost €230 per pack of ten + the testing costs.

Registering Oil Samples with Shell LubeAnalyst. Why correct oil sampling is important. Most lubricant condition monitoring services use an oil sample of only 100ml to represent a system that may hold hundreds or thousands of litres of oil. The importance of taking a representative sample cannot be over-emphasised. From the very first sample you begin investing in a valuable condition monitoring programme. But this will only be achieved if every sample contributes to building an accurate history from which trends in wear, contamination, and degradation can be determined. General instructions for correct oil sampling. Ensuring Health and Safety conditions. Always observe safety rules. Take particular care with high-pressure piping and thermal systems and any sampling close to electrical Equipment or when sampling from a drain line. If in doubt, please contact your Technical Advisor. Ensuring the quality of the sample. We recommend a consistent method of taking a sample. Always take the sample at the same point, in the same way and after the same amount of time. For example, if you previously took the sample half an hour after the machine has been started, please make sure that the next sample is taken half an hour after the start of the machine as well. We recommend that you sample a component while it is running (if it is safe to do so) or within 30 minutes after shutdown. Always keep in mind to refrain from sampling right after a large volume of lubricant has been added.

Always be sure to draw sufficient of the sample to fill the bottle. 80% full is a good level to aim for as this will ensure that there is adequate sample to complete all tests and will ensure adequate ullage to allow sample agitation by the laboratory. Avoiding contamination of the sample. Areas where lubricant flow is restricted or where contaminants and wear products tend to settle/collect should be avoided as sampling points. Always take the sample in the most hygienic of conditions. In this way, you can avoid contaminating the sample, which could lead to an incorrect analysis. Always use the right sampling Equipment and the bottles supplied by Shell and make sure that they are unopened, unused and clean. Always clean the sampling kit immediately after use. After taking the samples, check to make sure that the bottles are tightly closed. It is important that the gun/bottle assembly is kept upright while in use to prevent oil entering the gun. Should this occur, disassemble it immediately and flush thoroughly with white spirit or kerosene. Dry before reassembling. DO NOT FLUSH GUN WITH PETROL OR DEGREASING FLUID. How to take a good sample. Drawing a sample with a sample pump. 1. Use a Shell LubeAnalyst sample bottle; remove the cap and screw into the pump body. 2. Using a new length of tube for each sample, push the tube through the top of the pump until it

appears half way down the sample bottle. Please make sure to tighten the thumbscrew to secure the tube.

3. Place the end of the tube into the sampling point.

4. Ensure that the sample bottle is vertical throughout the sampling operation and that it is not overfilled.

5. Unscrew the bottle and immediately screw on the cap to avoid any contamination. 6. Complete the sample label and send the sample and sample label to the laboratory.

Sampling from circulation systems. For circulating systems one of the best sampling locations is a live zone upstream of filters where contaminants and wear debris are the most concentrated. Usually, this means sampling from fluid return lines or drain lines. For systems where oil drains back to a sump without being directed through a line (such as engines), draw from the pressure line down-stream of the pump (before the filter). Permanent sampling points should be at elbows in pipe runs in preference to straight sections. This will help to ensure that the flow regime at the sample point is turbulent and that wear and contaminant particles do not ‘drop out’ of suspension. Sampling from reservoirs, sumps and tanks. Avoid sampling from dead zones of static tanks and reservoirs. In particular, sampling from the bottoms of sumps should be avoided because the wear debris and contaminants collected are likely to be the results of build up over time and may not represent current operating conditions. The sample point should be near the mid-point between the surface of the oil and the floor of the tank/sump and away from walls. Sampling from splash, slinger-ring and flood lubricated components. Splash, slinger-ring and flood-lubricated components are best sampled from drain plugs but only after considerable flushing. In a similar manner, permanent valves should be wiped clean and then flushed prior to sampling to ensure that any ‘dead-leg’ debris is excluded from the sample. Vacuum pump thief sampling. For thief sampling the Shell LubeAnalyst operator should follow the recommended instructions in order to ensure that representative samples are taken. Thief sampling utilises a vacuum pump and plastic tubing in order to draw samples via points such as dipstick tubes and filler plugs on gearboxes and transmission.

When using a vacuum pump the oil does not make contact with the gun, consequently vacuum pumps are preferred over syringes. By comparison, syringes must either be flushed or replaced between samples in order to prevent cross-contamination. Tips for Successful Thief Sampling – Tip 1: Cutting the bottom of the tubing at an angle of 45 degrees reduces the likelihood of drawing sludge from the bottom of sumps and tanks; Tip 2: Plastic tubing can be difficult to control once it enters a system via a filler plug. In order that the tube end does not draw oil from the sides or bottom of systems it may be necessary to use a custom made dipstick such that the tubing is clipped to the dipstick and the dipstick / tube combination is inserted into the system to be sampled. This should also prevent the uncontrolled sampling tube being fed into the path of meshing gear teeth. Care must be taken to ensure that the dipstick is thoroughly cleaned prior to sampling. Sampling from a heat transfer system. Please take note that for safety reasons taking oil samples from the heat transfer system it is important to note that the temperature of the oil could be over 100 degrees Celsius. If the correct guidelines are not followed it will be impossible to make a correct diagnosis. Always make sure that the oil has cooled before taking the sample. Always use aluminium bottles for taking the oil sample. Plastic containers are not appropriate because they tend to melt due to the high oil temperature. Always cap the bottles directly, so that the gases can’t leak.

Shell LubeAnalyst Sample Label Forms. There are two types of sample labels; one for pre-paid standard kits (Industry and Transport) and one for Advanced, post-paid, test suites and optional testing. Sample Label for Standard Pre-paid Test Kits.

Sample Label for Post-paid Advanced Test Suites.

Critical Information: Sample date Shell LubeAnalyst number Lubricant & Lubricant Life Equipment Information

Advanced Test Suite Sample Label Critical Information Sample date Shell LubeAnalyst number Lubricant & Lubricant Life Equipment Information Component Information Sample Details Maintenance Interventions

Completing the Sample Label. Some information on the labels is mandatory in that without this information it may not be possible to process or diagnose the sample. Critical information is – Sample Date, Shell LubeAnalyst number; Lubricant & Lubricant Life; Equipment/Vehicle Life. For Advanced Test suite samples a more detailed sample label is used where more detailed information is required. Missing information on the label could lead to delays or to the sample not being analysed. Please complete Steps 1 - 4 as follows paying particular attention to the mandatory fields. Step 1: Enter the 12 digit alphanumeric Shell LubeAnalyst number for the Equipment / component that is to be diagnosed. The Shell LubeAnalyst number is given on the top right hand side of your Shell LubeAnalyst report for the Equipment / component. If you do not have this number ask your Shell LubeAnalyst representative to supply it to you. Step 2: Enter your Company Login Number, and Company name, plus any other contact details as per the sample label used. Step 2A: For Ad Hoc samples only, you need to provide the following information. • Equipment Number: Your Equipment / part identification number. • Equipment Description: Your description of the Equipment. • Equipment Location: Your location of the Equipment. • Your Component Type: Tick the appropriate box. Step 3: Enter your sample details as follows: • Lubricant in use: Confirm the current lubricant used in the Equipment/Vehicle • Oil Life: The age of the oil since last changed (i.e. running hr; miles/km). • Date sample taken: Day/month/year. • Component Life: as appropriate. • Oil top up volume: added since last sampling. • Test suite: required for Ad Hoc samples only. • Additional test options: Any extra tests other than those registered. Step4: Enter any Maintenance (for Advanced only) carried out on this Equipment/Vehicle since the last sample. Keeping Track of Shell LubeAnalyst Oil Samples. After the samples have been taken, they will need to be sent to the laboratory for analysis in the pre-paid envelope provided in the sample kits. Before posting your sample, please check to make sure that the bottle is tightly closed and that the bottle label has been stuck on the sample bottle. Put both the sample bottle and the rest of the label into the pre-paid envelope provided. If your sample is urgent please contact your Shell LubeAnalyst Support Manager who will arrange for a courier to pick up your sample (there is an extra charge for this service). If you want to keep track of your sample while it’s being processed, the best way you can do so is by using the Shell LubeAnalyst website: www.shell-LubeAnalyst.com. Alternatively contact the local Shell LubeAnalyst Focal Point.

Interpreting the Shell LubeAnalyst Sample Reports. This section explains the different types of reports available, plus how to interpret them. The three main sample reports are all similar in that diagnoses, sample status (Red, Amber and Green), and test results are all shown. In addition for both Standard and Advanced reports trended graphical output showing key diagnosis areas are also shown, (note that two or more samples per Equipment/vehicle component are required. The Advanced report shows test results for the last six samples and is produced on two pages as a result. The Ad-hoc report is a single sample report and does not contain graphs or trended test results. The Standard Report (K1 & K2 Test Kits). For all standard tests for both Transport and Industry. This report has one page and shows the last 3 analysis results plus graphs on oil properties, wear and contamination. It also includes comments and recommendations from the diagnostician.

User ID for web access.

Sample registration number.

Equipment registration information.

Diagnosis with possible causes and solutions.

Analysis results for the last three samples.

Sample status indicator for Equipment condition.

Customer contact information.

Trended graphs showing critical diagnosis areas for lubricant and component failures and properties.

Shell LubeAnalyst registration number for the component.

The Advanced Report For all advanced test suites across both Transport and Industry, and including and specialised Equipment specific test suites. This report has one page showing comments and recommendations from the diagnostician, plus graphs on oil properties, wear, contamination and additives. The second page includes all test results for the last 6 samples.







Trended graphs showing critical diagnosis areas for lubricant and component failures and properties.


Analysis results for the last six samples, current sample is shown in bold highlight.

The Ad-hoc Report This report is similar to the Standard report but the diagnosis section is without graphs, since there are no other samples for comparison.

The Annual Report Shell LubeAnalyst also offers the possibility of receiving an Annual report in addition to the standard sample reports. The Annual report enables you to obtain a complete view of how your machinery has performed throughout the year, along with its annual trend. It also offers you the possibility to compare your test results against the data we have within our database. For more information please contact your Shell LubeAnalyst Focal Point or Shell Representative.





Analysis results for the sample.




Receiving the Shell LubeAnalyst Sample Reports The reports can be received in four different ways: The Internet Sample Reports You will be able to view your own report in full colour, or create a pdf version to print, e-mail or fax. There is no need to keep hard copies, or any other electronic copies, as it is possible to view sample reports for the entire Shell LubeAnalyst sample history for the component. These reports are instantly available immediately after the diagnostician has completed the sample diagnosis. To have this facility it is necessary to register to use the Shell LubeAnalyst web based software. The Email Sample Report This report is sent via email as an attachment. The email subject line will include the sample number and sample status making it easy to quickly identify critical samples. The attachments are a full-colour report, either as a pdf or excel file, which you can then print/email yourself. This is the preferred option, if not using the web based software, as emails are sent immediately after the diagnostician has completed the sample diagnosis. The Fax Sample Report This report is normally a black/white version of the sample reports (standard, advanced or ad-hoc) but sent via fax. Faxes are sent immediately after the diagnostician has completed the sample diagnosis. In this instance hard copy reports will need to be retained but should you decide later to use the web based software then all faxed reports will still be available online. The Post Sample Report You will receive all sample reports, in full colour, via the post. In this instance there will be a postal delay once the diagnostician has completed the sample diagnosis. Again a hard copy reports will need to be retained but should you decide later to use the web based software then all faxed reports will still be available online.

Using the Shell LubeAnalyst Web based Software Internet access

The aim of the Shell LubeAnalyst web site is to give you direct access to your results so that you can take action as soon as possible. The Internet application also gives you a new way to communicate with Shell. In order to access the Shell LubeAnalyst web site www.shell-LubeAnalyst.com you will need to enter your user ID and password. Shell will provide you with both of these when you register. If you would like access at a later date please contact your Shell representative.

Navigating through the Shell LubeAnalyst application. Upon accepting your user ID and password, the system will take you to the main menu. The left-hand side of the screen always displays the menu in the following way: • Equipment Management: all information related to your Equipment. • Sample Management: all information related to your samples. • Statistics: statistics on your results history. • Miscellaneous: access and administration for ordering materials. Clicking on any of the menu options will take you straight there. (The navigation menu has been shown fully expanded normally this would not happen.) Equipment Management Section.

To manage all the Equipment/vehicles that are registered within Shell LubeAnalyst, click Equipment Management, then View option and the screen lhs will appear. Click on either List of Equipment or List of Components to show a complete list of all registered Equipment/Vehicles or Components; or click on Search on Equipment or Search on Component to search for specific information. Either option then produces a list, click on the magnifying glass to view the Equipment/Vehicle or Component. From either the Equipment Details or Component Details use the various options to

modify any details, enter feedback from maintenance or sample reports, register new Equipment/Vehicles or Components, and register new samples prior to posting.

Sample Management Section. This screen opens when first entering the system. From here it is possible to search for sample results (see opposite), click on the sample status icon to view all reports since the previous session. Alternatively search for sample reports for specific Equipment or periods, click See Results and then click the sample status icon to see the report. To track samples that have been sent for diagnosis click on Sample Management / Tracking. This opens a similar search screen; click See Results to see where samples are.

To register new samples click on Sample Management / Register, choose whether Standard or Advanced and whether Industry or Transport on the Shell LubeAnalyst online Sample Label appears. Enter in the relevant details and this will tell the laboratory that a sample is in the post. To search for specific sample reports click on Sample Management / Results. Complete the search criteria and then click See Results; this will create a list of samples as above. Click on the sample and this will take you to a screen showing the report details (see following).

Management Results Section This section provides two additional standard reports; there are the traffic light reports and the failure type report. To produce either report first enter the relevant criteria and click See Results. The Traffic Light Report produces details for the number and percentage of Red, Amber and Green samples for the chosen criteria, plus the number of Equipment/Vehicles and Components they relate to. The Failure Type Report (shown opposite) produces a table showing the various failure types and the number of samples against the relevant failure type. A pie chart, from which it is possible to copy into a document, follows showing graphically the same information. Registration Section This section enables new Equipment/Vehicle and Components to registered, register new samples, download the various registration forms. The application opens the online registration forms but in this case no details are pre-completed. The password option allows you to change your user access password to the Shell LubeAnalyst Web Site. The Customer Registration option allows you to modify your customer details. Order Section This section enables ordering of materials for samples. Miscellaneous Sections Here is it possible to download user guides, brochures etc. as well as who to contact in case of a problem.

Invoicing for Shell LubeAnalyst Samples After samples have been analysed and reports have been sent, an invoice will then follow. The invoice will be the same format as the current invoices received from Shell. Information contained on the invoice will be: 1) Invoice address details. 2) Order/customer number. 3) All samples that have been analysed and reports sent in the last month. 4) Any services you have used in the last month. 5) Contact details. 6) Payment details Please note that: • You will not be charged for your Shell LubeAnalyst samples along with your lubricant and fuels

orders, these will be invoiced separately. • You will receive your invoice on a monthly basis. If you have any problems relating to your invoice, the address or amount etc, please contact the Shell LubeAnalyst Service Manager.

Documents

Shell Lube Analysis guide