Extend Machine and Lubricant Life
   Through Contamination Control
October 20, 2005

Inspecting Debris from Used Oil Filters

"I was told that a good way to monitor the health of your machines is to routinely inspect used oil filters when they are changed. How is this done?"

For many machines the filter is the final resting place for contaminant and wear particles. As such, there is somewhat of a recorded history that is captured within the filter. To get these particles in a suitable visible form, cut a section of the filter media, approximately four square inches. Always take this section from the same place on the pleated element.

Next, place the section of used filter media in a small beaker of superclean solvent, such as mineral spirits or kerosene. Place the beakerin an ultrasonic bath for four minutes. The membrane should be carefully lifted using laboratory forceps, shaken in the solvent several times and then removed (leaving the particles behind in the solvent). Next, follow the procedure described in these articles (article 1, article 2) to prepare a patch for analysis of the particles under a common microscope:

In addition to microscopic analysis, the patch with the particles can also be examined by XRF spectroscopy. In examining the particles on the patch consider the hours/months the filter was in service, amount of makeup oil added, timing of last oil change, quality of system filtration, and machine application. One unique advantage of examining wear particles deposited on a used filter is the fact that most of these particles are in their original shape; that is, they haven't been reworked (crushed, etc.) by the machine's working surfaces and frictional contacts.

Practice makes perfect. By using this method routinely on critical equipment, it is possible to quickly identify abnormal wear conditions that may be occurring.

How to Implement Proactive Maintenance

"I've heard the term 'proactive maintenance' used in relation to maintaining lubricants. Can you explain how to implement a proactive maintenance program for lubricants?"

When this approach is applied diligently, proactive maintenance offers the biggest "bang for the buck" when trying to extend lubricant and machine life. We explain this strategy in greater detail in our training courses, but here's a basic explanation:

Proactive maintenance can be accomplished in three steps. The first step is to set a target or standard associated with each root cause of failure. These targets help maintain an environment conducive to prolonged lubricant and machine life.

In lubrication, root causes of greatest importance relate to fluid contamination (particles, moisture, heat, glycol, etc.) and additive degradation. However, the process of defining precise and challenging targets (high cleanliness) is only the first step. Control of the fluid's conditions within these targets must be achieved and sustained. This is the second step and often includes an audit of how fluids become contaminated and then systematically eliminate these entry points.

The third step is equally vital and is the action element of an oil analysis program. Specifically, control over these root causes within the targets is ensured only when constant feedback is supplied. Monitoring the oil with an oil analysis program provides this feedback.

Diligent application of proactive maintenance can extend oil and machine life by up to 10X. Further reading about proactive maintenance.


Detecting Water Contamination Problems in Reservoirs

From the book "The Lubrication Field Test and Inspection Guide"

The headspace of many tanks maintains a continuous moist fog. This can lead to a buildup of water in the oil, especially accumulations at the tank floor. The moisture in the headspace typically condenses on the ceiling then drips or runs to the bottom, forming puddles. Tanks like this are referred to as "rainmakers." This can be observed by touching the inside ceiling with your fingers. If moisture is picked up (sometimes rust as well), the risk of water accumulation is great.

Heavy varnishing sometimes occurs inside tanks and reservoirs. The appearance can range from gold-colored tank walls to thick dark deposits. Occasionally, the "Fruit Roll-up" effect is observed when a putty knife is used to peel away a tarry adherent film. A varnish gauge can be used to rate the severity.

More about The Lubrication Field Test and Inspection Guide

Resources

 


See What's In Your Oil
Microscopic photos of your oil sample on every oil analysis report make interpretation quick and easy. Ask about our one-micron bypass filters.

 


On-site high-speed purification and drying of contaminated lube systems.
Flow rates up to 5,000 gallons/hr. No downtime – we clean while you run!

 


Join Jim Fitch, Noria Corporation for Effective Contamination Control
Learn how to systematically reduce lubricant contamination and extend machine and lubricant life by up to 10X.
Cleveland, OH - Jan 24-26


Training Calendar

OCTOBER 2005

Machinery Lubrication I
24-27 Jwaneng Mine, Botswana
26-27 Buenos Aires, Argentina

Machinery Lubrication II
20-21 Gdansk, Poland
26-27 Houston, TX
Oct 31 – Nov 1 Sydney, Australia

Machinery Lubrication Basics
25 Midrand, South Africa

Mobile Equipment Lubrication Basics
26 Midrand, South Africa

Oil Analysis I
24-25 Antofagasta, Chile
25-27 Houston, TX

Oil Analysis II
19-20 Valencia, Spain
26-27 Antofagasta, Chile

NOVEMBER 2005

Analisis de Aceite para Equipo Móvil
8-9 México, D.F., Mexico

Machinery Lubrication I
7-8 Bilbao, Spain
7-9 Perth, Australia
15-16 Midrand, South Africa
21-22 Santiago, Chile
23-25 São Paulo, Brazil

Machinery Lubrication II
9-10 Bilbao, Spain
14-17 Jwaneng Mine, Botswana
15-17 Daegu, Korea
17-18 Gdansk, Poland
17-18 Midrand, South Africa
23-24 Buenos Aires, Argentina
23-24 Santiago, Chile

Mantenimiento Proactivo y Análisis de Aceites I
16-17 Santa Cruz, Bolivia

Oil Analysis I
2-4 Sydney, Australia
7-8 Lima, Peru
16-17 Santa Cruz, Bolivia
21-22 Madrid, Spain

Oil Analysis II
9-10 Lima, Peru
23-24 Madrid, Spain

Técnicas de Lubricación
10 México, D.F., Mexico

Effective Mobil Equipment Lubrication
2-4 Midrand, South Africa

Filtration Tips is published twice a month by:
Noria Corporation, 1328 E. 43rd Court, Tulsa, OK 74105 USA. (918) 749-1400

Because results will vary widely based on a number of factors, Noria Corporation cannot warrant the results of any information within this e-mail.

© 2005 Noria Corporation

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