What Is Contamination?
Contamination is anything that is foreign to the environment. For machinery lubricants, these are usually classified in three main groups: Gases, liquids and solids. When speaking about gases, this can be air or other gases (such as ammonia or methane) that encounter the lubricant. For liquids, this includes water, fuel or any other liquid that can enter the lubricant, particularly other lubricants or liquids that can be added knowingly or unknowingly. Lastly, solids can mean dirt (from outside the process), metals (from inside the machine) or any other solid particle in the lubricant.
Gases
Gases are the most unsuspected forms of contamination since many people believe that a gas will not affect the lubricant or by extension the machine. However, if air gets trapped in a closed loop system, this can lead to foaming (if the oil makes its way to the surface) or to microdieseling if it remains entrained in the oil.
With foaming, this typically occurs in gearboxes or equipment that are subjected to high churn rates of oil. Foam can settle at the top of the oil and cause the lubricant to not form a full film to separate the contacting surfaces. As such, this can lead to wear of the equipment.
On the other hand, microdieseling or the entrainment of air in the system can also prove to be dangerous because the trapped air bubbles can give rise to temperatures in excess of 1,000°C if they move between different pressure zones. This will lead to oil degradation, often producing some coke or tar insoluble as final deposits. Additionally, this trapped air/gas can also advance to cavitation inside the equipment.
Additionally, if the gas trapped is not air but a catalyst to a chemical reaction, this can incite further or more rapid degradation of the oil making it no longer able to protect the equipment. Therefore, identifying the presence of unwanted gases in your lube oil systems or preventing their entry in the first place is important.
Liquids
Liquids are trickier than gases because they somehow seem to enter the lubricant more easily or get mixed in unknowingly. When a liquid enters a lubricant, it can directly impact the viscosity of the lubricant, either increasing it or decreasing it. In either of these cases, this can be detrimental to the equipment.
If the lubricant’s viscosity increases above the essential value, then the machine will demand more energy to execute its required functions. This will directly impact its efficiency and energy consumption. On the other hand, if the lubricant’s viscosity decreases outside of the essential value, then the lubricant may not be able to adequately protect the contacting surfaces. Therefore, this increases the amount of wear that may occur on the inside of the machine.
Typically, water and fuel are the most common culprits of liquid contamination. These can easily get into your lubricants through poor storage and handling practices. Water can increase the viscosity of your lubricant and cause some additives to drop out of it, reducing its level of protection. Fuel will decrease the viscosity and possibly add to the fire risk of the system. Both can severely damage your equipment.
Another common culprit is the mixing of different types of oil. On an average day, things are busy, and people can get confused and pick up the wrong oil to perform a top up on a system. If we add gear oil or hydraulic oil to an engine oil system, we can have a catastrophe! These oils would have different viscosities, and their additive packages (or even base oils) may not be compatible. This can cause the equipment to stop working, leading to unplanned downtime and then exorbitant resources to get the machine operating again.
Solids
Solids can easily get into our equipment either from the outside or the inside. If there are openings to allow solids to enter then they will. However, sometimes solids enter our lubrication systems without us knowing. This can happen through poor storage and handling practices.
Once solids enter the system, they can:
- Increase the viscosity of the oil
- Increase the amount of wear occurring inside the equipment
- Act as a catalyst (depending on their nature)
- Block smaller clearances causing unwanted downtime in the equipment
Typically, solids are usually dirt, which can enter from outside the equipment. However, these hard particles can cause some metal to be damaged on the inside the equipment which can then lead to the metal being a catalyst for another degradation mode.
Some solids are formed inside the equipment as deposits. These deposits can occur if another contaminant (liquid, gas or another solid) enters the system and reacts with the oil to produce them. As such, these deposits may clog injectors, other valves or tight clearances causing the equipment to malfunction.