RSA

2003
File No. RSA-006
revision. 0 -7/08/03

Tables on Oil Analysis

All Rights Reserve - 2003

Prepare by : Rolly Angeles

Technical Training

Maintenance Excellence

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RSA
2003

TABLE OF CONTENTS
Table 1 : ISO 4406 Fluid Cleanliness Standard .. 1
Table 2 : Fluid Cleanliness Standard for New Oil ... 1
Table 3 : Sample Standard Base Cleanliness Target . 2
Table 4 : General Water Concentration Limit ... 2
Table 5 : Engine Problems Analyzed Through Oil Analysis ... 3
Table 6 : Recommended Test for Different Applications . 3
Table 7 : Comparing Multi-grade oil properties . 4
Table 8 : Another ISO 4406 Fluid Target Cleanliness Std 5
Table 9 : Commonly Recommended Oil Sampling Frequencies 6
Table 10 : Common Elements Found On Oil. 6
Table 11 : What Different Oil Analysis Test Will Detect .. 7
Table 12 : Limits On Oil Analysis Tests . 7

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2003

Oil Analysis Important Tables

Table 1 : ISO 4406 :99 Fluid Cleanliness Standard

ISO 4406
CODE
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6

Number of Particles
From
To
320,000
640,000
160,000
320,000
80,000
160,000
40,000
80,000
20,000
40,000
10,000
20,000
5,000
10,000
2,500
5,000
1,300
2,500
640
1,300
320
640
160
320
80
160
40
80
20
40
10
20
5
10
2.5
5
1.3
2.5
0.6
1.3
0.3
0.6

Table 2 : Fluid Cleanliness Standard Comparison for New Oil

Without By-Pass
ISO 22/17
> 5 = 29263 ppm
> 15 = 1112 ppm
> 25 =
29 ppm
> 50 =
0 ppm
>100 =
0 ppm

Brand New Oil

ISO 17/14
> 5 = 1292 ppm
> 15 = 119 ppm
> 25 =
19 ppm
> 50 =
5 ppm
>100 =
0 ppm

With By-Pass Filter

ISO 13/10
> 5=
> 15 =
> 25 =
> 50 =
>100 =

55
15
3
0
0

ppm
ppm
ppm
ppm
ppm

Table 13

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2003

Oil Analysis Important Tables

Table 3 : Sample Standard Cleanliness Target for System Applications

ISO RATING

MACHINE / COMPONENT
Roller Bearings
Journal Bearings
Industrial Gearboxes
Mobile Gearboxes
Diesel Engines
Steam Turbine
Paper Machine

16/14/12
17/15/12
17/15/12
17/16/13
17/16/13
18/15/12
19/16/13

Servo-Valve
Proportional Valve

13/12/10
14/13/11
15/14/12
16/15/12
16/15/12
16/15/12
14/13/11
17/15/12

Variable Volume Pump

Fixed Piston Pump
Vane Pump
Gear Pump
Ball Bearing
Turbine

Table 4 : General Water Concentration Limits

H20 Concentration

Action

Status

100 - 300

Alert

Check seals, breathers, coolers, etc., for

ingression sources, watch the trend

300 - 800

Danger

Aggressively investigate and correct the

source of ingression and implement an
effective water removal activities

800 above

Extremely
Danger

Immediate action is required to eliminate

ingression and effect removal of water to
minimize damage to machine and lubricant

Note : Unit of Water concentration in PPM

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2003

Oil Analysis Important Tables

Table 5 : Engine Problems Analyzed through Oil Analysis

Metal Traces

Limit

Engine Problem

What to Check
Air intake system
Oil filter plugging
Oil filler cap and breather
Valve cover

Silicon

10 - 30 ppm

Dirt Ingression

Iron (Fe)

100 - 200 ppm

Wear of cylinder liner

Valve and fear train
Oil pump
Rust in the system

Excessive oil consumption

Abnormal engine noise
Performance problem
Oil pressure
Stuck or broken piston

Chromium (Cr)

10 - 30 ppm

Piston ring wear

Excessive oil blow-by

Oil consumption / degradation

Copper (Cu)

10 - 50 ppm

Bearing / bushing wear

Radiator corrosion

Coolant in engine oil

Abnormal noise on operating
at stall speed

Lead (Pb)

40 - 100 ppm

Bearing corrosion

Extended oil change intervals

Aluminum (Al)

10 - 30 ppm

Piston and piston thrust

Bearing wear

Blow-by gases
Oil consumption
Power loss
Abnormal engine noise

Table 6 : Recommended Test for different applications

Equipment
Engines
Compressor
Gearboxes
Bearings
Hydraulics
Turbines
Motor
Where :

Spectro- Viscosity
Analysis

R
R
R
R
R
R
R

R
R
R
R
R
R
R

FTIR

Particle
Count

Karl
Fisher

TAN

TBN

Rotrode
Filter

R
R
R
R
R
R
R

---A
---A
R
R
----

R
R
------A
R
----

R
---------A
R
----

R
-------------------

A
R
R
R
R
R
R

R - Require Test
A - Advisable, provides extra details

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2003

Table 7 : Comparing Multi-grade Oil Properties

BRAND (SAE 20W-50)

AMSOIL
Castrol GTX
Exxon High Perfmance
Havoline Formula 3
Kendall GT-1
Pennzoil GT Performance
Quaker State Dix
Red Line
Shell Truck Guard
Spectro Golden 4
Spectro Golden M.G.
Unocal
Valvoline All Climate
Valvoline Turbo
Valvoline Race
Valvoline Synthetic

BRAND (SAE 20W-40)

Castrol Multi-Grade
Quaker State Dix

BRAND (SAE 15W-50)

Chevron
Mobile 1
Mystic JTS
Red Line

BRAND (SAE 5W-50)

Castrol Syntec
Quaker State Sunquest
Pennzoil Performax

BRAND (SAE 5W-40)

Havoline

BRAND (SAE 15W-40)

VI

Flash

Pour

% Ash

% Zinc

136
122
119
125
129
120
155
150
130
174
174
121
125
140
140
146

482
440
419
465
390
460
430
503
450
440
440
432
430
440
425
465

-38
-15
-13
30
-25
-10
-25
-49
-15
-35
-35
-11
-10
-10
-10
-40

< 0.50
0.85
0.70
1.00
1.00
0.90
0.90
--1.00
----0.74
1.00
0.99
1.20
<1.50

--0.12
0.11
--0.16
------0.15
0.15
0.13
0.12
0.11
0.13
0.2
0.12

VI

Flash

Pour

% Ash

% Zinc

110
121

440
415

-15
-15

0.85
0.90

0.12
---

VI

Flash

Pour

% Ash

% Zinc

204
170
144
152

415
470
420
503

-18
-55
-20
-49

0.96
--1.70
---

0.11
--0.15
---

VI

Flash

Pour

% Ash

% Zinc

180
173
176

437
457
---

-45
-76
-69

1.20
-----

0.1
-----

VI

Flash

Pour

% Ash

% Zinc

170

450

-40

1.40

---

VI

Flash

Pour

% Ash

% Zinc

135
134
136
--135
135
142
149
146
140
140

460
415
421
417
399
410
440
495
410
--420

-38
-15
-27
-11
-11
-25
-20
-40
-25
-10
-10

<0.50
1.30
1
0.9
0.95
1
1.7
--1
1
0.99

--0.14
--0.14
0.13
0.16
0.15
--0.13
0.15
0.13

BRAND (SAE 5W-30)

VI

Flash

Pour

% Ash

% Zinc

AMSOIL
Castrol GTX
Chevron Supreme
Chevron Supreme Synthetic
Exxon Superflow HP
Havoline Formula 3

168
156
202
165
148
158

480
400
354
446
392
420

-76
-35
-46
-72
-22
-40

<0.50
0.8
0.96
1.1
0.7
1

--0.12
0.11
0.12
0.11
---

AMSOIL
Castrol
Chevron Delo 400
Exxsn XD3
Exxon XD3 Extra
Kendall GT-1
Mystic JT8
Red Line
Shell Rotella w/ XLA
Valvoline all fleet
Valvoline Turbo

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2003

Oil Analysis Important Tables

Table 8 : Guidelines for determining, achieving and maintenance Target Cleanliness
Levels with High Performance Filtration (Beta Ration > 200)

Most Sensitive
System
Components

Low

Medium

High

Pressure

Pressure

Pressure

140 Bar

140 - 210 Bar

210 Bar - up

ISO Target

Micron

ISO Target

Micron

ISO Target

Micron

Levels

Rating

Levels

Rating

Levels

Rating

Fixed External Gears

Vane Pump
Fixed Piston
Variable Piston

21/17/14
21/17/14
20/16/14
19/16/13

25
25
10
6

10
10
6
3

20/16/14
19/16/13
19/15/12
18/14/12

10
6
3
3

Check Valves
Directional (Solenoid)
Standard Flow Control
Cartridge Valve
Proportional Valve
Servo Valve

21/17/14
21/17/14
21/17/14
20/16/14
19/15/12
18/14/12

25
25
25
10
3
3

10
10
10
6
3
3

20/16/14
20/16/14
20/16/14
19/15/12
17/13/11
16/12/10

10
10
10
3
3
3

Cylinders, Vane Motors

Gear Motors
Piston Motors
Swash Plate Motors
Hydrostatic Drives

22/18/15
22/18/15
20/16/14
20/16/14
19/15/12

16
16
6
6
3

19/16/13
19/16/13
19/15/12
19/15/12
17/13/11

6
6
3
3
3

Paper Machine Oils

Steam Turbin Oils
Diesel Engines
Mobile Gear Box
Industrial Gear Box
Journal Bearings
Roller Bearings
Ball Gearings

21/16/13
20/15/12
19/16/13
19/16/13
19/15/12
19/15/12
18/14/12
17/13/11

n.a.
n.a.
n.a.
n.a.
n.a.
n.a.
n.a.
n.a.

n.a.
n.a.
n.a.
n.a.
n.a.
n.a.
n.a.
n.a.

n.a.
n.a.
n.a.
n.a.
n.a.
n.a.
n.a.
n.a.

PUMPS
20/16/14
20/16/14
19/16/13
19/15/12

VALVES
20/16/14
20/16/14
20/16/14
19/16/13
18/14/12
17/13/11

ACTUATORS
25
25
10
10
3

20/17/14
20/17/14
19/16/13
19/16/13
18/14/12

LUBRICATING OILS
n.a.
n.a.
n.a.
n.a.
n.a.
n.a.
n.a.
n.a.

3
3
3
3
3
3
3
3

Severe conditions may include high flow surges, pressure spikes, frequent cold starts, extremely
heavy duty use or the presence of water
Two or more systems filters of the recommended rating may be required to achieve and maintain
the desired Target Cleanliness Level (ISO 4406 : 99)

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2003

Oil Analysis Important Tables

Table 9 : Commonly Recommended Oil Sampling Frequencies

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14

Machine Type

Hours

Diesel Engine
Transmission, differentials, final drives
Hydraulics - Mobile Equipments
Gas Turbines - industrial
Steam Turbines
Air / Gas Compressors
Chillers
Gear boxes - high speed / duty
Gear boxes - low speed / duty
Bearings - journal and rolling elements
Aviation reciprocating engines
Aviation gas turbines
Aviation gear boxes
Aviation hydraulics

150
300
200
500
500
500
500
500
300
1000
25 - 50
100
100 - 200
100 - 200

Table 10 : Commonly Elements Found On Oil

Item
1
2
3
4
5
6
7
8
10
11
12
13
14
15
16

Element
Iron
Copper
Chromium
Tin
Aluminum
Lead
Silicon
Sodium
Boron
Calcium
Magnesium
Zinc
Phosporous
Molybdenum
Potassium

Symbol
(Fe)
(Cu)
(Cr)
(Sn)
(Al)
(Pb)
(Si)
(Na)
(B)
(Ca)
(Mg)
(Zn)
(P)
(Mo)
(K)

Maintenance Excellence

Wear
x
x
x
x
x
x

Contam
x
x

Additive
x

x
x
x
x
x
x

x
x

x
x
x
x
x
x
x
x

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2003

Oil Analysis Important Tables

Table 11 : What Different Oil Analysis Test Will Detect

Ferrous Density
Analytical Ferrography

P
S

P
S
P

Corrosive Condition

Thermal Failure

Soot Load
S

Moisture Tester

P
S

Flash Point Test

P = Primary Indicator

P
S

S
P

S
P

P
S

S
S
P

S = Secondary Indicator

Table 12 : Limits On Oil Analysis Tests

Oil Analysis Test

Caution

Critical

Shell Limits

Cleanliness
Dryness
TAN
Fuel
Glycol
Soot
Viscosity
RPVOT
FTIR (Ox)
Zinc
Calcium
TBN
Water

ISO 14/11
200
0.2
1.50%
200 ppm
2%
+5%
- 30 %
0.3
-15 %
-10
- 50%
100 - 300 ppm

ISO 16/13
600
0.4
5%
400 ppm
5%
+ 10%
- 60 %
1
- 30 %
20%
- 75 %
above 300 ppm

no data
no data
no data
no data
no data
no data
+/- 20 %
no data
no data
no data
no data
2 mg KOH min
0.10% by vol.

- Iron (Fe)
- Silicon (Si)
- Chromium (Cr)
- Lead (Pb)
- Aluminum (Al)
- Copper (Cu)

100- 200 ppm

10 - 30 ppm
10 - 30 ppm
40 - 100 ppm
10 - 30 ppm
10 - 50 ppm

Metals

Maintenance Excellence

P
S

S
P

RPVOT
Elemental Spectroscopy

Wrong Oil

Fuel Dilution

S
P
P

Alkalinity Reserve

FTIR Spectroscopy

S
P

Glycol Contamination

P
S
S

TAN / TBN

Oxidation Stability

Additive Depletion

Moisture Contamination

Viscosity

Abnormal Viscosity

Wear Debri Analysis

Particle Count

Wear Debri Detection

OIL ANALYSIS Test

Particle Contamination

LUBE MACHINE CONDITION

Shell Limits
above 200 ppm
above 30 ppm
above 30 ppm
above 100 ppm
above 30 ppm
above 50 ppm

3 - 150 ppm
1 - 15 ppm
0 - 20 ppm
3 - 50 ppm
2 - 20 ppm
- 5 - 65 ppm
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