Keeping your lubrication system as free of water as possible is essential to an effective maintenance program. Water is a costly and destructive contaminant that results in premature component wear and accelerated lubricant degradation. Following best practices for storage, along with installing adequate moisture prevention and removal equipment, ensures the water saturation level in your system remains low.
The first step to moisture contamination prevention is understanding and recognizing the states in which water is present in your system.
Free and emulsified water are the most destructive to machinery and lubricants. Water compromises the performance of lubricants through altering the oil's viscosity and load carrying capacity. Oil oxidation rates also can change, leading to increased oxide deposition that further contaminates the system with particulates. Additionally, excess moisture washes out additive constituents, leading to premature additive depletion.
The resulting damages to internal components can include:
It is difficult to completely eliminate water from your lubrication system, therefore, the goal is to keep the moisture level as low as possible. Contamination prevention begins with resolving condensation, humidity, and ingress issues. Environmental moisture, leaking seals and covers, and inappropriate or compromised storage containers are all avenues of moisture contamination. Common best practices for lubricant storage are:
Adequate monitoring of water saturation levels is essential in avoiding unseen interior component wear that can lead to sudden, unexpected equipment failure. Three common water measuring methods are:
Crackle testing – A means of roughly determining water saturation level by correlating the amount of bubbling of a drop of oil when it's applied to a hot plate. This method does not offer a precise measurement but is a quick test for an on-the-spot assessment.
Capacitive water sensor– A real-time measurement of water saturation levels via analyzing capacitance variation of a substrate, as influenced by the transmission of water through an adjacent dielectric layer. This method is precise and can also be utilized as a water saturation control device.
Titration or Karl Fischer moisture test – A measurement of absolute water content that gives the most precise assessment. However, this method is not appropriate for time sensitive applications as there is a longer wait time for saturation level results.
When prevention of water contamination of lubricants isn't enough, there are several effective options available for removing moisture from your system.
Preventing water contamination of lubricants extends the life of oils, additives, and machinery. Regular monitoring and testing of moisture levels can reduce the frequency of equipment failure and downtime. When water saturation levels peak, removing that moisture from your system as soon as possible is critical for maintaining efficient production.
Reduce your facility's operating expenses and make your lubrication maintenance job easier by consulting with us for effective water contamination prevention and removal strategies.