How to Perform the ASTM D1160 Test Correctly (With Common Mistakes to Avoid)
Getting accurate results from crude petroleum testing takes more than just following the basics. The ASTM D1160 test is used when high temperatures under normal pressure could damage the sample, so precision is key.
Knowing how to perform the ASTM D1160 test correctly (with common mistakes to avoid) helps improve consistency, reduce errors, and protect both your data and your equipment. Even small oversights can throw off your results.
This blog breaks down how the test works, what to watch out for, and why it’s still a critical method for analyzing petroleum products under reduced pressure.
Key Takeaways
- Small mistakes in D1160 testing can throw off big results—precision matters.
- When physical boiling data is critical, ASTM D1160 still outperforms faster GC methods.
- The right equipment, clean process, and expert support help you get consistent, complete data every time.
Why ASTM D1160 Still Sets the Standard for Vacuum Distillation
When working with petroleum products that can’t handle high heat, ASTM D1160 offers a reliable solution. This standard test method uses reduced pressure to distill crude oil, biodiesel, and similar materials without damaging their components.
Instead of simulating results like D2887 or relying on atmospheric conditions like D86, this method provides real boiling data through a controlled, physical process. That accuracy is key for labs focused on performance, product consistency, and quality control.
ASTM D1160 helps identify critical boiling points, supports regulatory compliance, and improves how systems handle oil samples with varied compositions. It’s a simple but powerful way to reduce risk and keep test results consistent.
When to Use ASTM D1160 (and When Not To)
ASTM D1160 is the recommended test method when working with crude oil or petroleum products that can’t be distilled under standard conditions without risk.
It’s designed for high-boiling-point fractions and materials that might decompose if exposed to high temperatures at atmospheric pressure. Using reduced pressure allows these components to vaporize without damage, preserving their chemical integrity and giving you reliable analytical data.
Operating conditions and limits
This method typically runs at reduced pressures between 0.1 and 10 mmHg, with oil sample temperatures reaching up to 400°C. It’s a strong fit for applications that require accurate volume recovery, boiling range identification, and consistent performance across varied hydrocarbons.
D1160 is often used in quality control labs, research settings, and systems where detailed distillation data is critical to process efficiency.
When other methods make more sense
ASTM D86 may be better for lighter petroleum fractions where standard conditions won’t affect the results. For high-throughput labs or when only a small sample is available, ASTM D2887 offers a simulated distillation using gas chromatography.
While faster, GC-based methods don’t always provide the complete physical behavior of complex or heavy samples. In those cases, ASTM D1160 remains the method of choice for reducing risk, maintaining accuracy, and avoiding data gaps.
Step-by-Step: Performing the ASTM D1160 Test the Right Way
Getting reliable test results starts with using the right setup and following a method that limits errors. ASTM D1160 is a standard test method that requires specific conditions to be effective, especially when working with crude oil or petroleum products sensitive to heat.
Here’s how to run the test properly from start to finish.
1. Start with the right equipment
Use a calibrated vacuum distillation system with precise pressure and temperature controls.
You’ll need a distillation flask, condenser, cold trap, and a vacuum pump capable of reaching 0.1 to 10 mmHg. Systems like the DIST D-1160 CC offer advanced features that simplify the process and improve reliability, from automatic shutoffs to real-time data logging.
A stable, well-maintained system plays a key role in avoiding deviations and maintaining accurate results.
2. Prepare the sample correctly
Each oil sample should be clean, homogeneous, and measured at the recommended volume—typically around 200 mL.
Inconsistent sample prep can lead to problems like incomplete vaporization, erratic boiling behavior, or recorded data that doesn’t reflect true product performance. Avoid combining incompatible materials, and reject any sample that shows signs of contamination.
3. Calibrate and check for leaks
Before starting the test, confirm that all pressure sensors are calibrated. Perform a full leak check on the system to prevent outside air from affecting the vacuum. Even a small leak can reduce test efficiency, alter the distillation curve, or lead to inaccurate boiling point data.
This step is critical and should be repeated before each test cycle.
4. Control the heating process
Bring the temperature up slowly to prevent overheating and to avoid damaging sensitive hydrocarbons. The test method requires a steady, controlled ramp that supports gradual vaporization.
Monitor the temperature closely throughout the test and adjust as needed to maintain consistency. Sudden spikes in heat can affect distillation performance and impact the final results.
5. Record and review the data
As distillation progresses, measure the volume percent recovered at each temperature point. Data should be recorded in real-time to track the boiling curve accurately.
Key parameters include actual boiling temperatures and atmospheric equivalent temperatures. These values are critical for product classification, research comparisons, and system performance analysis.
6. Clean and shut down properly
After the test is complete, allow the system to cool down fully before disassembling. Clean each component thoroughly to remove residue that could affect the next oil sample. Proper shutdown also helps extend the life of the equipment and minimizes exposure risks during maintenance.
Consistent cleaning between samples supports long-term reliability and reduces the chance of introducing unwanted variables into future tests.
By following these steps, you minimize errors, improve accuracy, and get consistent results that help identify critical differences between materials. The right method, combined with proper setup and attention to detail, makes all the difference in quality control and research outcomes.
Avoid These Common Mistakes (They’ll Cost You Accuracy)
Even with a reliable system and a well-defined test method, errors can still occur. They affect data quality, reduce system efficiency, and compromise your understanding of how the sample behaves.
Here are the most common problems that lead to inaccurate results during the ASTM D1160 test and how to prevent them.
Skipping vacuum leak checks
Not checking for leaks is one of the fastest ways to introduce variability into your test. When the system isn’t properly sealed, pressure loss can occur, affecting the way hydrocarbons vaporize. This may lead to boiling points being recorded incorrectly or, worse, incomplete distillation.
Every test should start with a full seal check.
Overheating the sample
Heating crude oil or other petroleum materials too quickly can cause thermal decomposition. This alters the test results and leaves residue in the system, creating problems for the next sample.
A gradual temperature increase gives you better control and helps prevent damage to sensitive components.
Poor temperature ramp control
An inconsistent temperature ramp affects how the distillation curve develops and makes it harder to compare one test to the next. The heating rate should follow the ASTM D1160 guidelines, maintaining a controlled increase that supports the complete vaporization of the sample.
Ignoring calibration
If your pressure or temperature sensors aren’t calibrated regularly, you risk collecting data that looks fine on paper but doesn’t reflect real-world behavior.
Calibration is critical to avoid inaccurate volume measurements and test results that misrepresent the material’s true performance.
Cleaning lapses between runs
The residue left behind from previous tests, especially when biodiesel or heavier crude is involved, can affect the next sample. Incomplete cleaning introduces contamination, which can cause unexpected reactions or skew your recorded values.
Cleaning the system thoroughly between each test helps maintain reliability and reduces long-term maintenance problems.
Using the wrong conditions
Every product group is different, and not all petroleum samples respond the same way. Running a test outside the recommended pressure or temperature range can lead to unreliable data or damage to the equipment.
Be sure the test conditions match the specific requirements of the oil being tested to avoid unsuitable results.
Avoiding these issues saves time, reduces rework, and keeps your test method consistent. Every step in ASTM D1160 has a purpose, and skipping just one can affect the outcome.
By following the right guidelines and staying consistent, you’ll get complete, accurate data every time.
Manual vs. Automatic: Which Method Fits Your Lab?
The ASTM D1160 test method can be carried out using either manual or automated systems. While both follow the same standard, the way each method is conducted impacts the test’s accuracy, speed, and how much operator effort is required.
Manual testing
Manual testing puts the operator in charge of every part of the process, from regulating pressure and adjusting temperature to logging the data. This method is often preferred in situations that call for detailed oversight or hands-on control, such as troubleshooting or research.
Benefits:
- Direct control over all testing steps
- Useful for R&D, pilot testing, and procedural validation
- Often relied on for referee testing due to operator oversight
Limitations:
- Time-consuming and labor-intensive
- Requires experienced personnel to maintain precision
Automated systems
Automated D1160 units, like the DIST D-1160 CC, handle most of the test process with built-in controls and software. These systems regulate pressure and temperature automatically, record data in real-time, and are equipped with safety features that reduce manual handling.
Benefits:
- Consistent test conditions with automated control
- Real-time data tracking and fewer manual steps
- Faster test cycles and improved safety
- Well-suited for high-throughput labs
Limitations:
- Higher upfront cost
- May require additional validation in regulated environments
Choosing the right fit
Manual setups are ideal when you need flexibility, detailed observation, or a referee method for confirming test results. If you’re running frequent or large-volume tests and want to reduce exposure and manual effort, automated systems offer speed and consistency with less hands-on time.
Both methods, when conducted properly, produce valid and reliable results under ASTM D1160. The best approach depends on your testing needs, lab capabilities, and how you prioritize control versus efficiency.
ASTM D1160 vs D2887: Industry Trends and Tradeoffs
ASTM D1160 is still a key method for testing heavy petroleum fractions and crude oil that require physical distillation under reduced pressure. However, many labs are turning to simulated distillation methods like ASTM D2887 to speed up testing and reduce sample size.
D2887 uses gas chromatography to estimate boiling ranges with as little as 1 mL of sample and allows for much higher throughput. While efficient, it doesn’t capture the same level of detail as D1160, especially for complex hydrocarbons or product development.
Labs like Albemarle now use D2887 for most routine testing but still rely on D1160 when accurate physical data is critical. It’s a shift toward balancing speed with precision—using SimDists for screening and ASTM D1160 for deeper analysis.
Key Data Outputs You’ll Get (and How to Use Them)
The ASTM D1160 test delivers a complete boiling range curve—showing temperature versus percent volume recovered—which helps characterize how crude oil and other petroleum materials behave under reduced pressure. This curve offers insight into how different hydrocarbons distill and at what temperature ranges.
Engineering design
This data is commonly used to size and configure distillation systems. The boiling curve helps engineers identify temperature thresholds for efficient separation, supporting system development that minimizes exposure and maximizes performance.
Regulatory compliance
D1160 results are frequently used to confirm that a product meets regulatory standards. With clearly recorded temperatures and volumes, the data helps support audits, safety documentation, and quality control processes.
Feedstock selection
Labs use D1160 data to evaluate crude oil or other feed materials before they enter production. Understanding how each sample behaves during distillation helps eliminate unsuitable options early and reduces the risk of costly process disruptions.
Blend optimization
The test also supports product formulation by helping teams adjust component volumes to meet specific targets. Whether you’re managing fuel specs or refining lubricants, having accurate boiling range data allows for smarter blending with fewer variations.
Material insight
Results from ASTM D1160 also provide insight into viscosity, vapor pressure, and molecular weight—all key indicators of how a material will perform. These values are especially important when working with unique products or developing new applications where reliability matters.
With this level of understanding, labs can reduce errors, optimize testing strategies, and make better decisions from start to finish.
How Performance Distillation Solutions Helps You Get It Right
Performance Distillation Solutions is the exclusive North American representative for ILUDEST Thermal Process Equipment, offering fully automated, computer-controlled units like the ASTM D1160 systems with precise vacuum and temperature control.
We provide D1160 testing services, equipment consulting, and turnkey distillation solutions tailored to your application—whether you’re working with crude oil, refining product blends, or troubleshooting system performance.
We also supply Pro-Pak® random column packing and column internals to improve efficiency and flow in lab, pilot, or small-scale production setups.
Want expert guidance for your next D1160 setup or test? Give us a call today.
Conclusion
ASTM D1160 remains an important method for crude oil and heavy petroleum fractions, especially when accurate distillation data is critical. When done right, it delivers a complete profile that supports blend optimization, process decisions, and compliance.
Avoiding small mistakes like pressure leaks, overheating, or inconsistent cleaning helps protect your results and equipment. These variations may seem minor but can lead to inaccurate data and wasted time.
If you have questions or want to optimize your setup, partner with experts like Performance Distillation Solutions. We’ll help you apply the method correctly and keep your system performing to standard.
Frequently Asked Questions
How do you test for ASTM water pressure?
This test checks if a system can hold specific pressure levels without leaking. While not part of ASTM D1160, it’s often used to confirm vacuum integrity before running reduced-pressure oil distillations and helps ensure reliable results.
What is the process of the distillation test?
In ASTM D1160, the distillation test heats an oil sample under reduced pressure to separate components by boiling point. It produces a complete boiling range curve used to analyze composition and improve process efficiency.
What is the ASTM D790 test method?
ASTM D790 measures the flexural strength of plastics—not related to oil testing. It evaluates how materials bend under stress, making it useful for quality checks in unique non-metal materials.