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"The First In Synthetics"® |
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Maximize
Productivity - Minimize Wear
Right now, the oil working in your crankcase, gearbox or sump contains information that could be vital to the performance and productivity of your engine or equipment. Contaminants that can indicate wear or cause serious equipment damage such as metals, water, raw fuel, acids, fuel soot and other solids collect in your lubricant. Using oil analysis to evaluate these contaminants is a scientific approach to predictive maintenance, allowing you a look inside your machinery to spot mechanical wear and contamination in its early stages. You’ll extend machine life, head off major maintenance costs and prevent catastrophic failure that can shut you down or leave you stranded, and you’ll maximize lubricant life. Oil Analysis - A Proven Industry Standard Maintenance Tool Used oil analysis has existed as long as lubricants have been around. In the 1940s, the railroad industry began to analyze their lubricants for the various metals found in specific components of the engine. By tracking wear rates and trends from one sample to the next, maintenance could be anticipated and scheduled before component failure resulted in downtime and the loss of equipment productivity. This data allowed railroads to schedule teardowns when they were necessary, rather than after an arbitrary number of operating hours. The advent of spectrometric metals analysis gave rise to the practice of “predictive maintenance” which continues to be more cost effective than the standard of preventive maintenance. The oil analysis process consists of (1) lubricant sampling, (2) laboratory analysis and (3) interpretation of the results to determine the condition of the fluid and the machinery from which the sample was taken. Oil Analysis Provides a Big Return for Your Small Investment by:
· Extending equipment life by preventing premature component failure · Reducing maintenance costs by eliminating unnecessary component changes and decrease in downtime due to premature scheduled maintenance · Enabling calculation of optimum drain intervals that will reduce lubricant costs and assure maximum equipment protection · Eliminating complete teardowns based on guesswork · Reducing unscheduled maintenance - keeps equipment up and running · Enabling better assessment of equipment performance
Who is Using Oil Analysis? An oil analysis program can provide critical information for any equipment requiring lubricants - both gasoline and diesel engines, transmissions, gears, bearings, and hydraulic systems. It’s useful for owners of passenger cars, over-the-road fleets, off-highway equipment, boats, or high performance vehicles. It’s also right for any industrial business that focuses on managing plant equipment and maintenance costs. As a matter of fact, as many as 70 percent of today’s construction equipment operators use professional oil analysis to assess equipment and lubricant condition. Forty percent of all transportation fleets and 20 percent of industrial plants also rely on lube testing as an integral part of predictive/preventative maintenance. These businesses know that oil analysis replaces the guesswork in predicting equipment wear and scheduling optimum drain intervals. The data provided by oil analysis enables them to maximize equipment profitability by minimizing maintenance downtime. The Oil Analysis Program from Oil Analyzers, Inc. Make the decision to use Oil Analyzers, Inc. (OAI) to test the lubricants in your equipment or fleet and you'll be partnering with the most advanced computerized testing laboratory today’s technology has to offer. Simply collect your samples using our sampling kits and mail them in our pre-addressed packages to our lab. Our technical team will do the rest. They combine their years of analytical experience with state-of-the-art instrumentation to produce reliable, meaningful results from your samples. Testing is typically completed by the end of the business day following receipt of your sample. Results are reported by fax, mail, or in the case of an impending equipment failure, by telephone. Reports are easy-to-read and include interpretation and recommendations. And because the tests performed on your samples are tailored to your machinery, you'll get data that applies directly to your equipment and maintenance decisions. Our technicians are available to answer your questions ranging from sampling procedures to the test results and maintenance recommendations. Also, your reports are kept on file at the lab to enable monitoring of trends and detection of subtle changes in the condition of your equipment. How the Oil Analysis Program (OAP) Works OAP is a 4-step process: (1) Registration (2) Sampling (3) Analysis (4) Diagnostic Reporting
Step 1 – Registration 1. Begin the OAP process by purchasing a sampling kit. Simply call Oil Analyzers Inc. at (715) 395-0222 for pricing information or to order kits (and a sample pump if desired). You may purchase kits singly or in quantities of 10, 25, 50 or 100, with lower per-kit prices for larger orders. 2. Upon receipt of your order, OAI will immediately send out your sample kit, which includes sample container, sample information form, mailer and complete sampling and mailing instructions.
Step 2 – Sampling 1. Read the Oil Sampling Procedures included in the kit. 2. Fill out the Sample Information Form completely. 3. Take a sample (minimum: 2 to 3 oz) using the convenient instructions included in your kit. See page 7 of this brochure for more information on sampling. 4. Close and seal sample container tightly. 5. Using the mailing instructions included in your kit, send the filled sample container and the Sample Information Form to OAI in the supplied mailer.
Step 3 – Analysis Upon receipt of your sample at the Oil Analyzers Inc. laboratory, all requisite testing will be performed. All analyses include determination of viscosity, fuel dilution (if applicable), water, dirt content, fuel soot contamination (if applicable), plus spectrochemical analysis for 21 trace elements to determine component wear, airborne dirt, anti-freeze contamination (if applicable), and oil additive concentrations. The analyses also include a neutralization value determination - Total Base Number, TBN (primarily for gasoline and diesel motor oils) or Total Acid Number, TAN (non-crankcase lubricants). Oxidation values and nitration values (if applicable) are also determined. Step 4 – Reporting 1. OAI will mail your analysis report on the business day following receipt and testing of your sample. For even faster results, simply request on the Sample Information Form that your report be faxed to you. Be sure to include your fax number. 2. If your analysis uncovers a critical problem, such as pending equipment failure, a technician will telephone you directly to advise you of the situation and recommend a course of corrective action. The Sampling Process Trend Analysis A single sampling analysis is useful in providing information when critical failure conditions exist. However, trend analysis is a better tool for estimating the useful life or overall condition of your engine or equipment. Trend analysis samples are taken and analyzed at regularly scheduled intervals. Comparing the most recent analysis to previous reports on a given machine shows the development of trends. Monitoring these trends enables early detection of internal abnormalities. Tested values falling within acceptable limits may show a pattern of subtle variance, which could signal a developing problem. Machines of the same type will accumulate contaminants and wear at different rates. Performing trend analysis on each machine is the most effective method of giving you an internal look at your equipment and enabling you to deal with developing problems before they become catastrophic situations.
Sampling Frequency The frequency of sample analysis from your equipment depends on the machine type, machine application and condition, operating environment and other variables. For example, many machines that operate in harsh environments, such as heavy equipment in mining or construction, require short oil sampling intervals - every 100 to 300 operating hours. However, certain power transmission systems, such as gearboxes and hydraulic systems used inside manufacturing and production facilities, require no more than quarterly sampling intervals. The following table lists generic sampling frequencies for common equipment types, and is provided as a guideline only. Additional information is available from Oil Analyzers Inc., your lubricant supplier, and the equipment manufacturer. Collecting a clean and representative oil sample is critical to the oil analysis process. Put simply, an oil analysis is only as good as the sample taken. The accuracy and reliability of the data produced by an analysis hinges on receiving a representative sample from the equipment to be tested. To assure that the sample extracted is representative of the system, always follow proper sampling procedures.
Sampling Methods
1. The component sampled should be brought to operating temperature prior to sampling. This will assure that the insoluble and semi-soluble material is suspended evenly throughout the system. Samples taken from components that have been inactive for long periods are not representative. 2. Sample should always be taken in the same manner and from the same point. 3. Do not sample a component directly after an oil change or after a large amount of makeup oil has been added. 4. Use a clean, dry, unbreakable container. Never reuse containers or sampling tubing. Collect your sample using one of the three following methods: 1. Sample Pump Method Request a sample pump when ordering your sample kit. The pump will come with complete instructions and will enable you to draw a sample quickly and easily. Seal the bottle tightly. 2. Sample Valve/Petcock Method The valve should be wiped clean and any stagnant oil should be drained prior to catching a sample run. Seal the bottle tightly. Wipe bottle clean. 3. Oil Drain Method Clean the area around the drain plug thoroughly to avoid sample contamination. Allow oil to drain for three to five seconds prior to catching a sample. Place a clean, dry sample bottle in the oil stream and fill to within 1Ú2 inch of the top. Seal bottle tightly. Wipe bottle clean. Sampling Tips · For best results, oil samples should be taken immediately after equipment shutdown, while the equipment is still at operating temperature. Never sample a cold engine and always make sure the oil has been well circulated before taking a sample. Dirt, water and other debris tend to settle to the bottom of the reservoir while light fuels tend to float. This separation will compromise your analysis. · Good locations for sampling include an oil gallery, the engine crankcase, the drain plug or dipstick tube and the equipment reservoir or sump. · When taking oil from industrial machinery through a bottom drain, be careful to draw oil until your sample has a uniform, representative appearance. · Use samples from the drain pan or oil filter only as a last resort. For a failed engine that has had the oil drained, a drain pan or oil filter sample may help detect the cause of the failure. • Avoid prolonged skin contact with used oil. Wash exposed skin with soap and water after exposure.
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(317)501-5133 |
©Copyright 2005 by SBS Synthetic, LLC. All rights reserved. Duplication, reproduction or use of any material within this site, in any way, without the expressed authorized permission of SBS Synthetic Oil is prohibited. SBS Synthetic Oil is an authorized dealer of AMSOIL® products. ____________________________________
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