There’s a major difference between Shelf life and Service life especially when it concerns lubricants!
No one wants to put expired lubricants into their equipment! This can cause unexpected failures which can lead to unplanned downtime which can continue to spiral down the costly path of unproductivity!
The Shelf life is usually what is stamped by the Manufacturer indicating the length of time the product can remain in its current packaging before being deemed unsuitable for use. These can typically be found on the packaging.
The Service life however is determined by the application and conditions under which the lubricant is being used. Usually, estimated running hours / mileage are given by the equipment manufacturer in the maintenance section of the manual. (Condition monitoring can also be used to determine appropriate service intervals.)
However, how will someone know if the product has deteriorated while still in its original packaging? What should someone typically look for?
Above are some tips for identification of deterioration in lubricants. Take a note of these for the next time you are unsure of the integrity of your lubricants.
How are your lubricants currently stored? Are you storing lubricants under the correct conditions? What conditions affect lubricants?
These questions have come up a dozen times during audits and countless warehouse meetings. To answer these questions, there are five main conditions that can affect lubricants. We have detailed them below along with the effects of these conditions on the lubricant.
Temperature – if incorrect can lead to oxidation. For every 10C rise in temperature above 40C the life of the lubricant is halved.
Light – too much can lead to oxidation especially for light sensitive lubricants such as transformer oils. Hence the reason that most packaging is opaque.
Water – this usually works with additives to cause their depletion or contamination of the product. Water in any lubricant is bad (especially for transformer oils as they are involved in the conduction of electricity.
Particulate contamination – contamination can occur by air borne particles if packaging is left open or if dirty containers/vessels are used to transfer the lubricant from its packaging to the component.
Atmospheric contamination – this affects viscosity and promotes oxidation and can occur if packaging is left open. For instance, if a drum is not properly resealed or capped after usage or the most common practice of leaving the drum open with the drum pump on the inside.
Different types of lubricant degradation
Why is it important to know the types of lubricant degradation? It’s important since it helps us to figure out why or in some instance how, the lubricant degraded! Usually degradation is the change that occurs when the lubricant can no longer execute its five main functions:
the reduction of friction
minimization of wear
distribution of heat
removal of contaminants and
improvement of efficiency.
There are 6 main types of Lubricant Degradation as detailed below. Each type produces various by products which can enable us to understand the reason for the degradation and eliminate that / those reasons.
Here are the 6 main types of Lubricant Degradation:
One of the major types of oil degradation is Oxidation. But what is it exactly, as applied to a lubricant?
Oxidation is the addition of oxygen to the base oil of the
lubricant to form either of the following:
Wow… too many chemical names right?! These help to pinpoint the conditions responsible and then we can address them accordingly. Each of these by products are produced by different types of reactions or in some cases different stages of the oxidation process. It is key to note the type of by product as it gives us a clue to the root of the issue through which oxidation occurs.
For instance, the presence of Carboxylic acids can result in the formation of Primary Amides which can lead to heavy deposits. Early detection of the Carboxylic acids can help us prevent this. Once we determine the source of oxidation to produce the carboxylic acids, we can in turn remove this from the system.
Oxidation does not happen in an instant. Usually, it follows a series of events which eventually lead to oxidation. Like any process in life, there are different stages for Oxidation:
Initiation – Production of the free radical via the lubricant and catalyst.
Propagation – Production of more free radicals via additional reactions
Termination – Continuation of oxidation process after the antioxidants have been depleted or the antioxidant stops the oxidation process.
Results of Oxidation
Why is Oxidation bad for the lubricant? What can it ultimately result in?
Well, oxidation can result in the formation or lead up to
Loss of antifoaming properties
Base oil breakdown
Increase in viscosity
None of these are good for the lubricant!!!!!!!!! If you see any of these signs be sure to test for oxidation and identify the root cause for the introduction of oxygen in your system.
Now that we know more about oxidation… what tests can be performed to prevent it?
There are 6 main tests that can be performed:
RPVOT (Rotating Pressure Vessel Oxidation Test)
RULER (Remaining Useful Life Evaluation Routine)
MPC (Membrane Patch Calorimetry)
FTIR (Fourier Transform Infrared)
Colour (ASTM D1500)
Acid Number (ASTM D974)
One must be careful in selecting which test to apply, this is heavily dependent on the type of lubricant and its application.
For instance, if we perform the RULER test and the antioxidant levels have depleted significantly, we can suspect that oxidation is occurring or has stopped. Charting the rate of antioxidant depletion, can determine the rate of oxidation. This can assist us to forecast the time remaining before antioxidants have been depleted and can no longer protect the base oil.
What’s the difference between Thermal Degradation as
compared to Oxidation of a lubricant?
The two major differences are the contributory factors and
the by products that are produced.
For oxidation, both oxygen and temperature are critical to the degradation of the lubricant however, in thermal degradation, the temperature of the lubricant exceeds its thermal stability (usually in excess of 200°C).
Oxidation usually occurs through the release of free radicals which deplete the antioxidants however, Thermal Degradation consists of polymerization of the lubricant.
Oxidation produces aldehydes, ketones, hydroperoxides, carboxylic acids varnish and sludge. On the other hand, Thermal Degradation produces coke as the final deposit.
Electrostatic Spark Discharge is real and extremely common for turbine users! Static electricity at a molecular level is generated when dry oil passes through tight clearances. It is believed that the static electricity can build up to a point whereby it produces a spark. There are three stages of ESD.
1. Static Electricity builds up to produce a spark – Temperatures exceed 10,000°C and the lubricant begins to degrade significantly.
2. Free radicals form – These contribute to the polymerisation of the lubricant
3. Uncontrolled polymerisation – Varnish and sludge produced (some may remain in solution or deposit on surfaces) which can also result in elevated fluid degradation and the presence of insoluble materials.
Quite often, when lubrication failures occur, the first recommended action is to change the lubricant. However, when the lubricant is changed, the real root cause of the lubricant failure has not been solved. As such, the cause of lubrication failure will continue to be present and may escalate further to develop other problems.
Essentially, this can cause catastrophic future failures simply because the root cause was not identified, addressed and eradicated. Moreover, the seemingly “quick fix” of changing the lubricant, is usually seen as the most “cost effective” option. On the contrary, this usually becomes the most expensive option as the lubricant is changed out whenever the issue arises which results in a larger stock of lubricant, loss in man hours and eventually, a larger failure which can cost the company at least a month or two of lost production.
In this article, we investigate lubricant failures in Ammonia plants and their possible causes. Some Ammonia plants have a developed a reputation for having their product come into contact with the lubricant and then having lubrication failures occur. As such, most Ammonia plant personnel accept that the process materials can come into contact with the lubricant and usually change out their lubricants when such issues occur. However, there are instances, where the ammonia is not the issue and plant personnel needed to perform a proper root cause analysis to determine the root cause and eradicate it. Here are a couple of examples of such instances.
Livingstone (1) defies the Lubrication Engineers Handbook in their description of ammonia as an inert and hydrocarbon gas that has no chemical effect on the oil, stating that this is incorrect. Instead, Livingstone (1) lists the number of ways that Ammonia can react with a lubricant under particular reactions such as;
ammonia being a base that can act as a nucleophile which can interact with any acidic components of the oil (such as rust/corrosion inhibitors)
reaction of ammonia with carboxylic acids (oil degradation products) to produce amides which cause reliability issues
transesterification of any ester containing compound to create alcohol and acids and the reaction of ammonia with oxygen to form NOx which is a free radical initiator that accelerates fluid degradation.
As such, one can firmly establish that ammonia influences the lubricant and can lead to lubrication failures should that be the cause of the lubricant failure.
The Use of Root Cause Analysis
Van Rensselar (2) quotes Zhou as saying the best method for the resolving varnish is to perform a root cause analysis. Wooton and Livingstone (3) also advocate for the use of root cause analysis to solve the issue of varnish. They go on to explain that the characterization of the deposit aids in determining the root cause of the lubricant degradation. As such, Wooton and Livingstone (3) have developed a chart to assist in deposit characterization as shown below.
Wooton and Livingstone (3) discussed that with the above figure, once the deposit can be characterized then the type of lubricant degradation can be more accurately identified. As such, the root cause for the lubricant degradation can now be firmly established thereby allowing solutions to be engineering to control and reduce / eliminate lubricant degradation in the future.
A case study from Wooton and Livingstone (3) was done with an Ammonia Compressor in Romania which experienced severe lubricant degradation. In this case study, they found that when the in-service lubricant was subjected to two standard tests namely MPC and RULER, both tests produced results within acceptable ranges. As such, there was no indication from these tests that the lubricant had undergone such drastic degradation as evidenced by substantial deposits within the compressor. Thus, it was determined that the deposits should be analysed as part of the root cause analysis.
For the deposits from the Ammonia compressor, Wooton and Livingstone (3) performed FTIR spectroscopy to discover that its composition consisted of mainly primary amides, carboxylic acids and ammonium salts. It was concluded that the carboxylic acids formed from the oxidation of fluid while in the presence of water.
In turn, the carboxylic acids reacted with the ammonia to produce the primary amides. These amides consisted of ammonium salts and phosphate. As such, the onset of carboxylic acids within the system eventually leads to the lubricant degradation. Thus, an FTIR analysisfor carboxylic acids was now introduced to this Ammonia plant as well as MPC testing to monitor the in-service lubricant.
Additionally, chemical filtration technology was implemented to remove carboxylic acids within the lubricant. These two measures allowed for the plant to be adequately prepared for lubricant degradation and avoid failures of this type in the future.
Another case study was done in Qatar with an ammonia refrigeration compressor which was experiencing heavy deposits due to lubrication degradation. For this Ammonia plant, high bearing temperatures and deposits were found on the bearing.
Upon investigation, it was realized that the lubricant had been contaminated externally and there was restricted oil flow to the bearings. After a FTIR was performed it was deduced that that the deposits were organic in nature and there were several foreign elements including high levels of carbon and primary amides.
From further root cause analysis, it was determined that the high temperatures observed were due to the lubricant starvation. Due to these high temperatures, oxidation initiated and with the high levels of contamination (mainly from ammonia within the process) this lead to degradation of the lubricant in the form of heavy deposits.
The bearing oil flow was increased and reduction in external contaminants were implemented. Oil analysis tests of Viscosity, Acid Number, Membrane Patch Calorimetry and Rotating Pressure Vessel Oxidation tests were also regularized in the preventive maintenance program. Thus, for this failure, some operational changes had to be made in addition to increased frequencies of testing. With these measures in place, there would be a reduced likelihood of future failures.
From the case studies mentioned, it can be concluded that ammonia systems have a higher possibility of undergoing lubricant degradation due to the contamination of the lubricant by ammonia gas / liquid due to its properties. However, it must also be noted that the ingression of ammonia into the lubrication system is not the only cause for lubrication failure.
Therefore, it is imperative that a proper root cause analysis be carried out to determine the varying causes for lubrication failure before the ingression of ammonia accepts full responsibility for any such failure.
Livingstone, Greg (Chief Innovation Officer, Fluitech International, United States America). 2016. E-mail message to author, March, 08.
Van Rensselar, Jeanna. 2016. “The unvarnished truth about varnish”. Tribology & Lubrication Technology, November 11.
Wooton, Dave and Greg Livingstone. 2013. “Lubricant Deposit Characterization.” Paper presented at OilDoc Conference and Exhibition Lubricants Maintenance Tribology, OilDoc Academy, Brannenburg, Rosenheim, Germany, United Kingdom, January 22-24, 2013.
When failures occur in industrial plants, the first culprit to be suspected is usually the lubricant. However, should this be the first area that one looks at and what are the main causes of the lubricant failing? To understand this, I’ve taken a look at lubrication failures in industrial plants both globally and locally to understand the impact that they have on the sector.
Van Rensselar(1) explained that a recent study conducted by ExxonMobil Lubricants & Specialities of 192 US based power plants, 40% of these have reported issues of varnishing within their facilities. On the other hand; Livingstone, Prescott and Wooton(2) describe a study carried out by EPT Inc which document 44% lubrication failure of gas turbines (not including GE Frame 7FA & EA). It is therefore clear to see that there exists a prevalent issue of lubrication failure within the industry.
When a lubrication failure occurs, it costs an estimate of USD100,000 per trip in a power plant(1). As such, lubrication failures are costly within the industry and methods to reduce issues relating to these types of failures should be explored. Van Rensselar(1) also interviewed Joe Z. Zhou senior research chemist for Chevron Lubricants in Richmond California who explained that one of the main causes of varnish is the primarily oxidized hydrocarbon molecules which undergo surface aggregation and further surface reaction to produce the varnish. However, Livingstone and Oakton(3) add to this description of the main causes of varnish as the oxidation of the oil whereby there is a loss of electrons from the molecules within the lubricant. They go on to state that hydrolysis and thermal degradation are also leading factors for the degradation of the lubricant.
Van Rensselar(1) explored the main cause of such increased volumes of varnish cases in recent times and found that due to changes in turbine designs to allow for reduced operating and capital costs, the clearances have become smaller, operations are now continuous and a common lubricant for both bearings and controls is now being used. With the reduced clearances, the lubricant can now heat up faster and allow for quicker oxidation occurrences thus leading to varnish. Additionally, with the use of a common lubricant for bearings and control functions, there are significantly different levels of filtration required. Bearings allow for at least a 200-micron filtration system whereas servo valves will accept nothing less than 3-micron filtration(1). As such, it has now become easier for servo valves to become clogged due to varnish as compared to instances in the past.
Johnson, Wooton, and Livingstone(4) describe a case study on a power plant in Arizona, USA where a failure occurred during a routine test. Upon inspection, soft varnish/sludge was found on the trip valve piston. The varnish/sludge was analysed using FTIR testing and its chemical properties suggested the presence of carboxylic acid, primary amide and methacrylate ester. Further investigations revealed that the varnish had accumulated in a uniformed fashion. However, MPC testing did not reveal significant varnish accumulation since these tests were conducted monthly and the varnish had accumulated significantlyduring that time. Upon performing a root cause analysis, it was discovered that a steam leak containing hydrazine gave rise to the presence of ammonia in the system which reacted with the carboxylic acids (produced from oxidation of turbine oils) to form varnish within the system. It was then decided that lower MPC levels were needed to manage the volume of varnish within the system and reduce the steam leaks into the oil. These actions were taken to ensure that the varnish levels could be managed such that there would be no future trips as a result of this issue.
Wooton and Livingstone(5) conducted another case study on a combined cycle power plant in the US which experienced a type of lubrication failure. The plant had been shut down during an outage and it was noticed that when the lubricant storage tank cooled past 32°C large black tar balls formed and floated at the surface of the tank. The filters appeared to contain the black tar when in a liquid form but when allowed to cool, the tar turned into a black / brown solid. FTIR testing on the deposit revealed decomposed amine antioxidant, an ester and an additive not characteristic of the lubricant in service. The non-characteristic additive was identified as a foam inhibitor which was not found in the lubricant in service. It was then concluded, that an incompatible fluid was mixed with the in-service lubricant. A quality control program was implemented to ensure that all the incoming fluids are compatible with the in-service lubricant. As such, for this case study, lubricant degradation occurred due to contamination.
Trinidad & Tobago
After conducting a lubrication survey with turbine users for the period 2014-2015 and it was found that within Trinidad & Tobago, turbine users can be classified into three main categories namely; Power generation, Oil & Gas and Petrochemical. It was found that internationally, there is a greater focus on the Power Generation sector in research regarding lubrication failures. However locally, Power Generation represents 40% of turbine users while Petrochemical represents 34%. On the contrary, it was found that the Petrochemical sector suffered more lubricant degradation issues as compared to the Power Generation sector from this study. Overall, the Petrochemical industry experienced the highest volume of lubricant failures.
Overall, it appears that while Power generation sector has a higher percentage of turbine users, locally the Petrochemical sector emerges as the larger shareholder of lubrication failures in the industrial sector. Given that most of the lubrication failures occurred via oxidation and contamination (both locally and internationally), one can only conclude that within the industrial sector a greater emphasis should be placed on the monitoring of the condition of the lubricants especially for critical equipment. When lubrication failures occur, they can be very costly, as such greater emphasis should be placed on the monitoring of these lubricants in service.
1 Van Rensselar, Jeanna. 2016. “The unvarnished truth about varnish”. Tribology & Lubrication Technology, November 11.
2 Livingstone, Greg, Jon Prescott, and Dave Wooton. 2007. “Detecting and Solving lube oil varnish problems”. Power Magazine, August 15.
3 Livingstone, Greg and David Oakton. 2010. “The Emerging Problem of Lubricant Varnish.” Maintenance & Asset Management, Jul/Aug.
4 Johnson, Bryan, Dave Wooton, and Greg Livingstone. 2013. “Root Cause Determination of an Unusual Chemical Deposit on a Key Oil Wetted Component.” Paper presented at OilDoc Conference and Exhibition Lubricants Maintenance Tribology, OilDoc Academy, Brannenburg, Rosenheim, Germany, United Kingdom, January 22-24, 2013.
5 Wooton, Dave and Greg Livingstone. 2013. “Lubricant Deposit Characterization.” Paper presented at OilDoc Conference and Exhibition Lubricants Maintenance Tribology, OilDoc Academy, Brannenburg, Rosenheim, Germany, United Kingdom, January 22-24, 2013.
This question has caused many sleepless nights and initiated countless discussions within the industrial and even transportation sectors. Before examining the causes for lubrication failure, one must first consider the definition of lubricant failure.
The composition of a liquid lubricant can be described as a combination of base oil and additives (Menezes, Reeves and Lovell 2013, 295). These two components work in tandem to define particular characteristics of the lubricant to perform its functions. According to Menezes, Reeves and Lovell (2013, 296) the five functions of a lubricant include;
the reduction of friction
minimization of wear
distribution of heat
removal of contaminants and
improvement of efficiency.
As such, lubrication failure can then be described as the failure of a lubricant to adequately perform any or a combination of its five functions as a result of the degradation of any of its two components; namely the base oil or additive package. Thus, it can be deduced that lubrication failure is as a result of lubricant degradation.
Now that we understand that a lubricant fails when it undergoes degradation which by extension results in the lubricant not being able to perform any of its functions properly, we need to explore further on the types of degradation that exist. Only then can we really answer the question of how a lubricant can fail.
Barnes (2003, 1536) focuses on three main mechanisms of lubricant degradation namely;
Compressive Heating (Microdieseling).
One may argue that these three types form the basis of all mechanisms of lubricant degradation however, Livingstone, Wooton and Thompson (2007, 36) identify six main mechanisms of degradation namely;
Electrostatic Spark Discharge and
In this instance, the six identified mechanisms all produce varying identifiable characteristics which lend to these six forming the foundation of identification of lubricant degradation mechanisms. With these six in mind, one would need to be able to determine which degradation mechanism is at work in their facility. Afterwards, methods to treat with these mechanisms must be administered. Firstly, let’s understand each mechanism.
This mechanism involves the reaction of oxygen with the lubricant. According to Livingstone, Wooton and Thompson (2007, 36) oxidation can result in the formation of varnish, sludge, increase in viscosity, base oil breakdown, additive depletion and loss in antifoaming properties of the lubricant.
Barnes (2003, 1536) refers to this phenomenon as the addition of oxygen to the base oil to form aldehydes, ketones, hydroperoxides and carboxylic acids.
On the other hand, Wooton (2007, 32) explains that there are three main stages of oxidation namely initiation, propagation and termination. Fitch (2015, 41) explains that:
Initiation entails the production of a free radical via the lubricant and a catalyst.
Propagation involves the production of more free radicals via additional reactions.
Finally, termination entails either the continuation of the oxidation process after the antioxidants have been depleted or the antioxidant stopping the oxidation process.
This mechanism is largely dependent on temperature as one of its contributory factors even though dissipation of heat was highlighted above as one of the functions of a lubricant. However, during the operation of machinery particular components tend to develop increasing temperatures.
As described by Livingstone, Wooton and Thompson (2007, 36) once this temperature exceeds the thermal stability point of a lubricant, the consequences can include shearing of the molecules. This phenomenon is also called the thermal cracking of the lubricant which can result in the production of unwanted by products, polymerization and decrease in viscosity.
Subsequently, Barnes (2003, 1536) explains that thermal degradation usually occurs when the lubricant experiences temperatures in excess of 200°C. He also states that the by-products of thermal degradation differ from that of oxidation.
Wooton and Livingstone (2013) state that there are two main actions that can occur once a lubricant is thermally degraded.
Either the small molecules will become cleaved off and volatize from the lubricant. This does not leave any deposit in the lubricant.
On the other hand, there is the condensation of the remainder of the molecule in the absence of air thus dehydrogenation also occurs. Consequently, coke is formed as the final deposit with numerous types of deposits forming between the start of the condensation to its final deposit of coke.
The main contributing factor for thermal degradation can therefore be linked to dramatic increases in temperature or constant high temperatures.
Livingstone, Wooton and Thompson (2007, 36) have characterized Microdieseling as a form of pressure induced thermal degradation. They describe it as the transition of entrained air from a low pressure to a high pressure zone which results in the adiabatic compression.
This type of compression results in localized temperatures almost on excess of 1000°C.As such, the lubricant undergoes dramatic degradation. Wright (2012, 14) explains that because of these high temperatures, the bubble interface becomes carbonized. As such, carbon by products are produced and the oil undergoes oxidation.
Wooton and Livingstone (2013) indicate that additive depletion can result in either organic or inorganic deposits. The nature of the deposit is dependent on the type of additive that has been depleted and its reaction with other components in the oil.
For instance, if the rust and oxidation additives drop out of the oil, they typically react to form primary antioxidant species thus producing organic deposits. However, as Wooton and Livingstone (2013) explain, inorganic deposits can also be formed from additives that have dropped out of the oil but did not react with anything. This unresponsive reaction is typical of ZDDP (Zinc dithiophosphate) which is an additive that assists with reducing wear in the lubricant.
In cases of additive depletion, the FTIR test seeks to identify spectra relating to the reacted or unreacted additive packages for the lubricant in use (Wooton and Livingstone, 2013).
Electrostatic Spark Discharge
Livingstone, Wooton and Thompson (2007, 36) describe this phenomenon as the generation of static electricity at a molecular level when dry oil passes through tight clearances. It is believed that the static electricity can build up to a point whereby it produces a spark. This spark can induce localized temperatures in excess of 10,000°C which can significantly degrade the lubricant at an accelerated rate.
Van Rensselar (2016, 30) also advocates that Electrostatic Discharge contributes to the formation offree radicals in the lubricant which subsequently results in uncontrolled polymerization. This polymerization of the lubricant gives rise to the formation of varnish and sludge which may deposit on the surface of the equipment or remain in solution. Van Rensselar (2016, 32) indicates that the most common result of Electrostatic Discharge is an elevated rate of fluid degradation and the presence of insoluble materials.
This mechanism of degradation can include foreign material entering the lubricant and being used as catalysts for degradation mechanisms listed above. Contaminants can include a variety of foreign material, however Livingstone, Wooton and Thompson (2007, 36) have narrowed the list to metals, water and air. These main contaminants can significantly contribute to the degradation of the lubricant by oxidation, thermal degradation or compressive heating.
From the above, we can summarize these lubricant degradation mechanisms into the following table:
From this summary, we can now assess the methods in which a lubricant can fail. While this article may serve as a guide in determining various lubricant degradation mechanisms, each mechanism must be treated differently depending on the conditions (environmental and operational) that exist during the lubricant failure. A proper root cause analysis should always be done when investigating any type of failure.
1 Livingstone, Greg, Dave Wooton, and Brian Thompson. 2007. “Finding the Root Causes of Oil Degradation.” Practicing Oil Analysis, Jan – Feb.
2 Barnes, M. 2003. “The Lowdown on Oil Breakdown.” Practicing Oil Analysis Magazine, May-June.
3 Livingstone, Greg and David Oakton. 2010. “The Emerging Problem of Lubricant Varnish.” Maintenance & Asset Management, Jul/Aug.
4 Wooton, Dave and Greg Livingstone. 2013. “Lubricant Deposit Characterization.” Paper presented at OilDoc Conference and Exhibition Lubricants Maintenance Tribology, OilDoc Academy, Brannenburg, Rosenheim, Germany, United Kingdom, January 22-24, 2013.
5 Van Rensselar, Jeanna. 2016. “The unvarnished truth about varnish”. Tribology & Lubrication Technology, November 11.