Professional Documents
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Shell
Standard
LubeAnalyst R 199
G 79
B 79
Shell
Websafe
LubeAnalyst R 153
G 51
User Guide B 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
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.
As a new
customer tick
this box
Write your
If you want to detailed address
change your here
address details tick
here and write your
Internet Login
here.
Decide how to
receive your sample
results; the best way is
If a colleague
by e-mail.
should also get
sample results,
write their e-
mail address
here.
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 well also need to register your Equipment/vehicles.
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.
What type of
Equipment or vehicle?
Typical industry Equipment Typical Transport vehicles This is a very easy to use
includes machines like turbines, include cars, buses, and part of the Shell
industrial gears, hydraulics, gas- passenger/freight units and LubeAnalyst service. For
engines, circulating systems, their associated engines, any Equipment/vehicle,
heat transfer systems, gearboxes, transmissions, whether registered with
transformers, and compressors. axles and final drives. For Shell LubeAnalyst or not,
For Marine this includes large Construction this includes you can send in one-off, or
slow/medium speed diesel building and surface mining ad-hoc, samples to help
engines. Equipment. analyse a specific problem,
i.e. an unusual or
unexpected
When registering Equipment or vehicles please remember that
Equipment/vehicle
the more information that is given, the better and more detailed
condition. The analysis and
and accurate the diagnoses will be about the lubricant and your
diagnosis will only be
Equipment/vehicle. This is the best way for Equipment
completed for that sample.
condition monitoring!
No Equipment/vehicle
You should also detail maintenance/lubrication information
sample history will be used
when sending in new samples.
and please note the
The benefit is a more detailed, trended diagnoses including
diagnoses are not as good as
graphs for the important properties of the oil and
for registered Equipment!
wear/contamination graphs indicating Equipment/vehicle
An ad-hoc sample is not a
condition.
faster service.
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.
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.
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.
If you are already
registered as a
Customer write the
Shell LubeAnalyst
Customer registration
number here.
Write the name of the
your company here.
If it is an existing
vehicle, dont forget
If registering a new to write the Shell
vehicle tick here. LubeAnalyst
If modifying an registration number
existing Shell here.
LubeAnalyst machine
tick here. Write in here your
own vehicle
description and
Write the reference id, these
manufacturer and will be printed on the
model details here. sample report along
This is vital for with the sample
accurate diagnosis. number.
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.
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.
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.
ShellLubeAna lyst
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.
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.
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.
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.
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 PE TROL OR DEGREASING FLUID.
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.
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.
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.
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.
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.
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 alu minium 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 cant 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.
Critical Information:
Sample date
Shell LubeAnalyst number
Lubricant & Lubricant Life
Equipment Information
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.
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 its 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.
Sample Shell
registration LubeAnalyst
number. registration
number for the
component.
Customer contact
Equipment information.
registration
information.
Diagnosis with
possible causes
and solutions.
Analysis
results for the Trended graphs
last three showing critical
samples. diagnosis areas
for lubricant and
component
failures and
properties.
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.
Sample status
indicator for
Equipment
User ID for condition.
web access.
Shell
Sample LubeAnalyst
registration registration
number. number for the
component.
Customer contact
information.
Equipment
registration
information.
Diagnosis with
possible causes
and solutions.
Trended graphs
showing critical
diagnosis areas
for lubricant and
component
failures and
properties.
Sample status
indicator for
Equipment
condition.
User ID for
web access.
Shell
LubeAnalyst
Sample registration
registration number for the
number. component.
Customer contact
information.
Equipment
registration
information.
Diagnosis with
possible causes
and solutions.
Analysis
results for the
sample.
(The navigation menu has been shown fully expanded normally this would not happen.)
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
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
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.