From the Expert: Effects of Varnish

Varnish is a gel-like substance that adheres to metal surfaces and can cause hot spots, increase in machine temperature and can result in filter plugging, micro-dieseling and can cause catastrophic failure. It’s important to test for varnish on turbines, compressors, hydraulics and large circulation and lube systems. We’ve turned to our expert, CLS and OMA I certified Data Analyst, Elaine Hepley, to explore varnish and the Membrane Patch Colorimetry (MPC) test conducted to detect it as well as two other tests that can help identify varnish formation potential.

  • Membrane Patch Colorimetry (MPC) ASTM D7843
    • MPC is a test designed to capture any presence of varnish that is soluble with the oil. This test is performed by heating the sample to 60 to 65 degrees Celsius for 23 to 25 hours. The sample is then placed in the dark away from UV light for 68 to 76 hours. After the incubation period, the sample is mixed with Petroleum Ether and stirred for 30 seconds to allow a complete mixture and then filtered onto a 47mm, 0.45-micron-size membrane patch.
    • The patch is placed in a location free of dust and heat and air-dried for about 3 hours. Once the patch has been dried, a colorimeter is used to detect the color of the patch and the CIE Lab ΔΕ and L*a*b* calculations are used to report the color of the patch. The color and severity scale is as follows:
      • 0-14.99: Severity 0 – Very low potential for varnish formation
      • 15-19.99: Severity 1 – Minor potential for varnish formation
      • 20-29.99: Severity 2 – Moderate potential for varnish formation
      • 30-39.99: Severity 3 – Significant potential for varnish formation. Preventative measures should be taken to stop the continuous formation of varnish
      • >40: Severity 4 – Severe and evident formation of varnish in system, and action must be taken to remove varnish.
    • The lighter (whiter) the color of the patch, the lower the MPC value and the darker (amber) color of the patch, the higher the MPC value.
    • PLEASE NOTE: Gray discoloration of the patch can be attributed to micro-dieseling or static discharge in the filters.
    • MPC testing can be performed on turbines and other unit types such as compressors, hydraulics, large circulation and lube systems.
  • Linear Sweep Voltammetry (LSV) ASTM D6971
    • LSV uses a voltage reading to detect the presence of anti-oxidants amines and phenols. The test is performed using an alcohol/acetone based solution (yellow or green) to help draw out the anti-oxidants from the oil. An electrical current is introduced to the sample and reveals the presence of amines and phenols in a matter of seconds. The results of the used oil are compared to a standard (new lubricant levels) and the differences/changes in the anti-oxidants in percentage are reported.
    • Some formulations are composed of amine, phenols or both. Phenols are considered to be the “sacrificial anti-oxidant” when formulated in conjunction with amines. The role that the phenols have is to be the first to deplete. This leaves behind amines to stabilize and keep the potential for varnish at bay.
    • That is not to say that phenols are a weak anti-oxidant. In a phenol-only formulation, the phenol is formulated to hold its presence and not deplete as rapidly when formulated with an amine. The same rule would apply to an amine-only formulation. These anti-oxidants help keep the free radical oxides from taking over the system and creating “varnish”. Anti-oxidants help sustain a healthy operational life for the equipment.
    • It has been discovered that as these anti-oxidants deplete, the potential for varnish is eminent and action should be taken to help remove the varnish from the system entirely.
  • Rotating Pressure Vessel Oxidation Test (RPVOT) ASTM D2272
    • RPVOT was designed to measure the oxidation stability of a turbine oil in minutes. The lubricant is placed in a vessel containing a polished copper coil. The vessel is charged with oxygen and then placed in a bath heated to a constant temperature of 150 °C. The vessel rotates while submerged in the bath and will stop once a drop of 25.4 psi is reached from maximum pressure.
    • When the test is complete, the RPVOT results are divided by the starting value RPVOT of the new lube to calculate the overall percentage of remaining useful life.
    • Calculation %=RVOT test result ÷ RPVOT new lube
      • Values of >55% are within the acceptable limits for the method and no action is needed.
      • Values of 55-45% are approximately half of the products starting life and sweetening is recommended.
      • Values of 44–26% indicate low oxidative stability. The possibility for sludge formation and discoloration is likely, and sweetening the sump is recommended.
      • Values of <25% is an indication the oxidative stability is extremely low and change of lubricant is advisable.
    • RPVOT testing is essential to for turbine oils this test helps determine when to schedule downtime and maintenance actions.

It is believed that as the antioxidants deplete, there is an increased potential for varnish formation. LSV Ruler testing is recommended to help monitor the antioxidant properties as well as the presence of varnish formation via MPC. As these antioxidants deplete, the presence of varnish forming can be captured on the MPC. These two tests can be used to help correlate any decreases or increases in antioxidants and monitor any changes/improvements with the presence of varnish. The same correlation can be used with RPVOT as the values decrease or are <44% the potential for varnish formation.

Click here for a complete list of testing performed by POLARIS Laboratories®

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Published May 1, 2018

8 Tips for Setting Flagging Limits

Our customers often ask us to display the condemning limits for the tests performed on their sample, on the actual sample report they receive. Believe it or not, there is a reason why we exclude the limits from the report. It’s not a simple case of we are unable to, or we do not want to. The real reason relates to the complexity of using the correct limits for each parameter, based on several pieces of equipment and application information; as well as looking at trends of historical samples from the same unit, rate of change and any other applicable information relating to the sample and component. These differentiating factors result in limits changing dynamically on a sample by sample case, dependent on this information.

When setting limits, the following information must be taken into consideration on each sample, below are some examples:

  1. Equipment Type: (e.g. hydraulic)
  2. Specific Application: (e.g. Injection Moulding Machine)
  3. Equipment Manufacturer: (e.g. ARBURG)
  4. Equipment Model: (e.g. 1120H)
  5. Industry Type: (e.g. industrial manufacturing)
  6. Filter Type: (e.g. INLINE)
  7. Filter Micron Rating: (e.g. 10 micron)
  8. Sump Capacity: (e.g. 1000 litres)

Once limits are set, it’s best not to use them exactly. If for example, the iron ppm condemning limit for a hydraulic oil sample is set at 30ppm, customers may not expect the iron result to be flagged until it exceeds 30ppm. However, if historical samples from the same unit have consistently shown iron results of less than 5ppm, and on the latest sample the results are 22ppm, this is considered an abnormal trend, and exceeds expected Rate of Change values. In this instance, the result of 22ppm would be flagged as abnormal for these reasons, but is still below the statistical condemning limit level of 30ppm. So, if we did display this limit of 30ppm on the sample report, the customer may ask why the result has been flagged at 22ppm as it is under the threshold, which would in turn lead to more confusion and questions. Another important point to note is that combinations of metals present also affect the limits used, as they may indicate abnormal wear to a specific component.

Most OEM’s will provide some form of condemning limits in their technical bulletins or operational guides, but often come with the caveat that ‘these fixed limits should only be used if the laboratory cannot provide limits based on robust statistical analysis of previous results’, which further confirms the need for an accurate statistical model to be used on all samples tested.

Click here to read more information on setting limits. 

 

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Published April 24, 2018

Fluid Analysis 101: 5 Tips to Collect the Best Sample

Obtaining a truly representative fluid sample from your equipment or machine is the most critical part of a successful fluid analysis program. Without a true, accurate representation of what is going on inside your equipment, the analysis conducted may prove to be of little value in determining the condition of the machine at the time of sampling.

The particles and elements of wear, corrosion, fluid degradation and contamination provide the necessary diagnostic information concerning both the fluid and the machine. These particles can settle or separate out from the fluid, causing an uneven distribution throughout the system. So, choosing the right sampling point is very critical. Below are five tips to follow to ensure you collect the best sample possible.

  1. Take the sample from a point that provides plenty of turbulence in the fluid to ensure the particles are well mixed. 
  2. If you’re sampling from a filtering device, samples should be taken upstream.
  3. For trending, it is best to take the sample from the same location, depth etc. on the equipment – every time.
  4. Where possible, take the sample while the equipment is in operation or within 30 minutes of shut-down.
  5. The best sample points to collect the fluid are different depending on the type of equipment. The chart below outlines some of the best sample points:

To achieve a successful, effective fluid analysis program, the sample has to be truly representative of the equipment or fluid condition. This can only be accomplished if samples are taken from the same proper sampling points each time – this also helps to establish maintenance trends. To ensure you get the most value from your fluid analysis program – and to experience increased uptime and cost savings – follow these easy sampling tips.

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Published April 3, 2018

Elevate Your Fluid Analysis Program and Save More Equipment

Four years ago, several of my colleagues presented a proposal that could simply be billed “if you build it, they will come”. This proposal involved building a groundbreaking, customer-focused event hosted by an independent fluid analysis laboratory. What started as a cautious experiment in 2015 to educate and train our customers on the strategic value of an effective fluid analysis program has grown into a mainstay that brings together more and more customers each and every year. It’s our Customer Summit.

In past years, we’ve focused on issues that matter most to maintenance professionals and fluid analysis leaders. Driving Action. Champion Impact. Connected Performance. Now in 2018, we bring you a summit that focuses on Elevate. Our fourth annual Customer Summit is set for November 5-7, 2018, at the Alexander Hotel in downtown Indianapolis.

Elevate will help our customers sharpen their focus and take their fluid analysis program to the next level. With a dynamic and diverse speaker lineup in the works, we are committed to helping you close the gap and build a fluid analysis strategy for the future.  We’ve structured this summit to be for maintenance professionals by maintenance professionals. We simply provide a platform for key players at companies like yours to learn through peer-to-peer conversations. In turn, our customers leave with a better understanding about what needs to be improved, accelerated and leveraged the most in their programs. You can’t afford not to engage in these conversations – so we encourage you to come experience it first-hand at the 2018 Customer Summit this November.Building on past feedback from nearly 200 customers across more than 90 companies, the 2018 summit will provide greater variety and depth in the content we share. This is a must-attend for new and returning customers. Specific content will include new insights on:

  • Expanding and maximizing your program
  • Securing greater executive support
  • Importance of proven impact, uptime and savings
  • Contamination control
  • Business impact initiatives to improve fluid analysis
  • Innovative technological solutions to maximize your program
  • Optional lab tours before and after the summit schedule

Mixing work with some memorable fun and networking is how we do it. What’s more, we do it in a way that is affordable for multiple members of your team to attend.

Are you ready to take the next step elevate your fluid analysis program? Then clear your calendar in November and join us in Indianapolis at the 2018 POLARIS Laboratories® Customer Summit. We’ll circulate more details when registration opens in late April! Click here to be notified when the 2018 summit registration process opens.

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Published March 27, 2018

One Lab, Multiple Locations

POLARIS Laboratories® constantly strives to meet our customers needs and expectations. Due to a high number of North American customers with locations throughout Europe, and with increasing shipping costs, in 2013 we decided to establish a laboratory facility in Europe to meet our customers needs on a global scale. This meant reduced shipping costs and much shorter turnaround time for samples for customers.

As a laboratory with locations worldwide, we operate on the idea of “one lab, multiple locations”, meaning our customers can be confident their samples will go through the same processing, testing and analysis, no matter what laboratory location their sample is sent to. But, achieving this idea within our international laboratories does come with its challenges. Even though all our laboratories operate under the same quality and laboratory standards, there are many differences within the labs:

Time difference

  • By having a laboratory in Europe – we moved to the same time zone as our global customers (instead of being 5-6 hours behind). This has helped us establish timely customer service and order and sample processing, resulting in the customer receiving assistance and orders faster – and cheaper.

Test methods

  • After some time, we also have realized expectations of our European customers may be different from what we, as a company, were accustomed to while operating only in North America. For example – one of the tests required by Natural and Biogas Engine OEMs in Europe is Base Number according to ASTM D2896 (to read more about ASTM D2896, read Battle of the Base Number Testing: D2896 vs. D4739) To meet our customers’ needs and expectations – we introduced this test in our Poznan, Poland laboratory location, in 2015. This test method is largely conducted for gas engine oil samples but also occasionally for diesel engine oils and research purposes for testing oil/fuel additives.

Sample volume by industry

  • When we break the sample volume per laboratory location into various industries – we’ve found European samples come mainly from industrial applications. 40 percent of the samples processed in our Poznan, Poland laboratory are from the industrial industry. Due to a large quantity of samples sent to the Poznan laboratory which require Membrane Patch Colorimetry (MPC), a test performed on industrial equipment – currently only being conducted at our Indianapolis laboratory – we are adding MCP to testing capabilities in our Poznan laboratory.

Reporting the numbers

  • It’s safe to say not many people on this side of “the pond” would be able to easily tell a gallon from a quart, or an inch from a foot – but no matter what type of units of measure we use – it is important to provide this information with the sample.
  • Operating time is one of the most important pieces of information in fluid analysis. Whether it is reported in miles, kilometers or hours – it is vital for determining severity of contamination or wear and if any maintenance actions need to be taken. Read more in The Importance of Lubricant Time for Proper Oil Analysis.

Whether your samples are sent to our laboratory in Poznan, Guatemala or Salt Lake City, as a global fluid analysis provider, we continue to operate as one laboratory. From processing your sample, to conducting the testing in the laboratory to delivering results and maintenance recommendations, our customers can count on receiving the same quality standard of services from all laboratories. At POLARIS Laboratories®, we offer not only state-of-the-art testing and analysis, but a partnership with our customers and strive to provide innovative solutions and improvements to meet their needs at every step of the fluid analysis journey.

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Published March 6, 2018

A Closer Look at ISO Codes

As industry maintenance practices continue to evolve and maintenance professionals realize the substantial cost saving benefits of contamination control efforts and fluid cleanliness, we find ISO codes entering our daily conversations more often. Cleaner fluids translate to reduced wear and longer component life. ISO codes are simply a ‘shorthand’ method of quantifying fluid cleanliness.

Language of Cleanliness

Fluid analysis laboratories measure fluid cleanliness with specialized equipment that categorizes particles in the fluid by size and counts the number of particles per volume of the sample in each category or size range. The sample report shows the absolute number of particles equal to or larger than each of the following sizes: 4, 6, 10, 14, 21, 38, 70, and 100 microns.

That’s a total of 8 different numbers to describe fluid cleanliness, which makes it cumbersome to compare and discuss results.

Translating Codes: What Do They Mean?

The ISO 4406 standard simplifies that data by only looking at three size ranges (4, 6, and 14 microns). It further simplifies the data by assigning codes to correspond to a range of particle counts. For example, rather than saying there are 1,890 particles 4 microns or larger, the standard assigns a ‘code’ of 18 (which includes particles counts from 1300 to 2500). A similar code is assigned for the 6 and 14 micron size range. So now the fluid cleanliness is reduced to three numbers (or codes). For example, 18/15/13. That is a much easier way to include fluid cleanliness in our comparisons and discussions.

But, this also means that without a thorough understanding of what those codes mean, we can easily jump to poor conclusions. In a simple example, a change in ISO code from 18/15/13 to 19/15/13 might lead to the assumption that the number of particles between 4 and 6 microns has doubled (since each increase in ISO code doubles the upper and lower range of the previous code). Consider if the actual particle counts at 4 microns were 2485 initially and increased to 2510; the code assigned does indeed increase from 18 to 19, but the absolute particle count is nowhere close to doubling. Conversely, if the initial count was 1310 and the next sample increased to 2490, the number of particles has indeed nearly doubled, but the ISO code has remained at 18.

Understanding ISO Code Shorthand

ISO codes are a great way to simplify our comparisons and discussions on the important topic of fluid cleanliness. But having a thorough understanding of what that ‘shorthand’ notation means, can also save us from overlooking the more subtle picture of what is happening to our fluids.

Click here to read more information on ISO codes and fluid cleanliness.

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Published February 20, 2018

Fluid Analysis: A Safe Bet

Unexpected Equipment Repairs

Equipment failing unexpectedly results in downtime, repairs and unsafe work conditions can occur. With sudden downtime comes the need for rushed repairs in order to get the equipment back up and running. When machine or equipment operators or maintenance technicians perform unexpected equipment repairs quickly and often times, in an unsafe manner, the risk of a serious injury increases.

So, choose predictive maintenance over corrective maintenance. 

Fluid Analysis: A Safe Bet

When you can predict equipment failure through oil, coolant or diesel fuel analysis, the risk of your operators and maintenance technicians injuring themselves decreases significantly. Downtime can be scheduled in advance, eliminating the need to rush to repair the equipment.

Your maintenance team keeps your equipment up and running so you can stay on schedule and keep your business on the road to success. So, keep your operators, maintenance technicians and other team members safe by eliminating the need for rushed repairs and participating in a fluid analysis program.

 

 

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Published February 6, 2018

4 Tips for Shipping Success

Whether you’re submitting oil, coolant or diesel fuel samples for testing, mailing the samples can be tricky, especially if the sample jar lid is not tightened securely onto the sample jar. Loose lids can cause leakage and delay the processing of your sample. Here are some helpful tips to not only ensure your samples arrive at our laboratories in a timely manner, but improve your testing experience too.

1. Secure Sample Jars

Make sure the sample jar lids are closed tightly. Fluid pulled from equipment will likely be hot, and this may cause the lid to loosen after the fluid cools down. Also, too much fluid in the neck of the bottle will also cause the lid to loosen as well. Be sure to only fill the sample bottle to the designated Fill Line and make sure the jar is closed tightly by re-tightening the lid by hand until snug. You may also use a strip of silicone tape to secure the lid, but it is not required.

2. Shipping Container

If a hard or soft plastic mailer was provided with the sample jar, place the sample jar inside it and close it securely. The sample can be shipped in that container or protected further by placing it inside a box. Insert packing material to make sure the samples do not shift during the shipping process.

             

3. Commercial Invoice

International shipments to the United States require a commercial invoice to categorize the items being shipped. Oil and coolant samples should be categorized as Non-hazardous lubrication oil/coolant samples. Tested to destruction. Not Restricted by I.A.T.A. No commercial value. Flash Point >200°C. It is recommended to declare the value of the entire shipment as $10.00. Below is a sample of a commercial invoice.

 4. Shipment Services

Listed below are some of the more common shipping carriers that deliver packages to our testing laboratories. In order to receive your results back in a timely manner, we recommend using services that can track the location of your package so you are able to track down your sample if shipping errors occur.

  • Canada: Canada Post, Loomis, FedEx, UPS and independent couriers
  • Guatemala: DHL, FedEx, Guatemalan Post, UPS and independent couriers
  • Poland: DHL, FedEx, Polish Post, UPS, and independent couriers
  • United States: DHL, FedEx, UPS, United States Postal Service (USPS) and independent couriers

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Published January 30, 2018

Compliance is Key

Being compliant is not only important to properly manage your PM’s, but also to uncover issues within the equipment before it becomes catastrophic. Compliance is key when it comes to managing an effective fluid analysis program.

Not taking a timely sample from each actively-used equipment will lead to performance issues and potentially downtime, which will result in more expensive repair costs and lost revenue.

Samples should be taken on time and while the equipment is in use to get the most accurate assessment of the overall health of the equipment. This will lead to extended equipment lifespans and more uptime and savings, increasing your overall ROI.

One way to ensure your program is compliant and you’re getting the most out of your ROI is by participating in a Program Review. We take your existing data and compare it to our recommendations and industry averages to give you a clear look at the compliance of your program.

The Program Review looks at:

  • Component Compliance – How many components do you have on file and, of those, how many are you actively sampling?
  • Frequency Compliance – How frequently are you submitting samples?
  • Sample Severity – How many of your samples fall into a high-severity ranking?
  • Shipping Time – What is the average time it takes for us to receive your samples?
  • Goals, Tools and Training – Are you getting the most out of the available trainings and technology?

For more information, check out our Blog on Program Reviews.

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Published November 28, 2017

 

Battle of Base Number Testing: D2896 vs. D4739

We have two ASTM Base Number analysis testing methods: D2896 and D4739. D2896 measures the Total Base and includes all sources of Base Number including detergent, dispersant, antiwear and antioxidant additives. On the other hand, D4739 measures the ‘hard base’ such as that from over-based detergents.

What’s the difference?

In addition to ASTM D2896, the Total Base Number of a lubricant can be tested by the procedure detailed in ASTM D4739. There are subtle, yet important differences to consider when looking at Total Base Number data from each. 

Click here to learn more.

 

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Published November 21, 2017