Types of water contamination in oil

Team Minimac

Feb 24, 2022 · 2 min read

In our last #knowyouroil segment, we had discussed about Particle Contamination and its effect on the life of rotating parts. Companies spend a lot of money on installing

Types of water contamination in oil

Team Minimac

Feb 24, 2022 · 2 min read

In our last #knowyouroil segment, we had discussed about Particle Contamination and its effect on the life of rotating parts. Companies spend a lot of money on installing filtration units to counter particle contamination but never take preventive measures towards water contamination. Water is a worse and silent killer for the life of machinery as it slowly degrades the oil properties and one only gets to know about it when the machine fails pre-maturely.

In this article, we will try to understand the basics of Water Contamination. We will also try to answer the following questions.

What water does to oil properties?
Can we see water contamination as soon as it starts?
What to do if our oil is contaminated?

To check your machine's, follow: https://www.linkedin.com/company/minimacsystemsprivatetlimited There are three phases in which water can exist in oil i.e. dissolved water, emulsified water, and free water.

Dissolved Water: It is characterized by individual water molecules dispersed throughout the oil. Water can remain in a dissolved state and hence difficult to understand the contamination at this stage.
Emulsified Water: When the oil gets saturated with water it starts to exist as a suspension in oil like microscopic droplets giving oil a milky appearance and is called emulsion.
Free Water:When the level of oil in water increases further it leads to separation of oil and water called Free water.
For a lubricant, the most important property is its viscosity. As the water starts to mix with lubricant it starts to alter the viscosity and hence impacts the film strength which is essential in maintaining equipment reliability by keeping moving parts away from each other. Water contamination also impacts the chemical properties of the base oil by acting as catalyst oxidation and aeration. This also leads to the appearance of sludge and varnish which leads to premature failure.

Water contamination also leads to Hydraulic Pump Cavitation in machines: Pitting inside of the machine; as the water droplets burst under pressure and high temperature creating microfractures on the machine’s surface.
If you see the signs of water contamination in your oil, what should you do?

Not to change oil as changing oil is not the only option. This is because once the oil is drained the impurities still remain in the system until they are flushed. If new oil is introduced without cleaning the system it leads to contamination of the new oil leading to no change in the premature breakdown situation.
Flushing of the system
Check the internals of the system to check for any damage
Filter the new oil to ensure no moisture is available in the oil
Skip all four steps and call Minimac (+91 7030901266)

We at Minimac Systems Pvt Ltd. not only design a maintenance schedule for the lubrication oil but also provide OIL TESTING and FILTRATION services as per the ISO standard of Super Clean Oil. Minimac stands for MINImum MAChinery Maintenance.

WHAT ARE BYPASS FILTERS?

A bypass filter, also known as a pressure relief valve, is a very important part of an oil filter. When oil is too thick or the filter is clogged, the valve opens. If the valve doesn’t open then the filter may eventually

WHAT ARE BYPASS FILTERS?

A bypass filter, also known as a pressure relief valve, is a very important part of an oil filter. When oil is too thick or the filter is clogged, the valve opens. If the valve doesn’t open then the filter may eventually burst.

Bypass filters are designed to remove fine organic and inorganic particles. It also increases the total volume of oil used. Thus, if you have contamination issues and want to extend operating equipment life, extend lube oil & service intervals, and consider adding bypass filters. We can say that Bypass filtration can be considered another aspect to save money and downtime.

Most of the existing manufacturers use ‘full-flow’ oil filters which are designed to protect the component from large particles but they cannot remove soot, water, or silt. Full-flow filters alone cannot keep oil clean for a long-term period. The fine particles which account for most of the contamination can be removed by the bypass filters.

It is advised to do the homework before buying a bypass filter. Some important factors to consider are:

Capture efficiency - The higher the beta ratio, the better will be the capture efficiency. A good beta ratio selection can control the escape of particles through the element. It is just like a good shepherd keeping the flock of sheep in a controlled and organized manner in the field.

Pressure/flow - Suitably designed filter element has calculated flow and velocity of oil through its microvoids. It is as important as keeping the water stream in a controlled way for gardening purposes. Else, it may spoil the sole purpose of watering.

Dirt Holding Capacity - It is not only necessary to have high capture efficiency but also a good filter element capacity is a must-have to retain the collected contamination. A well-engineered element has dedicated space to imprison the unwanted contaminants.

Heating element (to eliminate solid and liquid contaminants) - An elevated temperature helps to dislodge the solid contaminants and accelerates the rate of removal of volatile impurities.

Type of filtration media - Filter media varies with grade and type of oil widely. This may be a fine filter paper to absolute and depth filter media.

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Compatibility of fluid - Not every filter element can be used with any grade of oil. A small mistake in element selection can destroy the element as well as may cause a collapse of the entire system.

Surface area for the filtration – The higher surface area will give a lower pressure drop across the filter and also helps to achieve higher flow rates.

Compact in size - Reduction of size in regards to the filter elements and housing gives us multiple benefits like space and cost-saving, aesthetic look, better maintainability, low recurring expenditure, etc.

Inexpensive to use and install - At the end of every engineering and calculation, economics comes into the picture. It is always suggested to go with optimized design and correct sizing to overcome financial constraints.

We don’t need any additional setup to establish a Bypass filtration system; it can be done within the existing skilled limits. Please note that a bypass filtration system can be of great benefit if installed and maintained appropriately and it helps to prevent post-filtration fugitive contamination ingress into the system.

We will be happy to help you in the entire journey of the right filter selection. Contact - enquiry@minimac.in or WhatsApp us at +91 7030901267.

Do you know?

Did you know that how we maintain our machines can be classified in various types and what is interesting to note is each technique has some benefits and some consequences.

In this article, we will understand different types of

Do you know?

Did you know that how we maintain our machines can be classified in various types and what is interesting to note is each technique has some benefits and some consequences.

In this article, we will understand different types of maintenance techniques their pros and cons along with a brief guideline on how they impact a company’s cost structure with some interesting facts. Contact Minimac to schedule maintenance: +91 7030901266

There are four types of maintenance strategies:

Reactive Maintenance: Maintenance is scheduled in response to operational failure. This type of maintenance is very useful for lowering initial cost, reducing manpower cost as you need fewer staff members and doesn’t require any planning. On the contrary, this strategy compels you to keep more inventory to brace for unexpected failure. This not only leads to a higher cost but also makes the project budgets unpredictable.
Preventive Maintenance: Maintenance is scheduled according to historic trends, experience or reliability data considerable guesswork is required.
Preventive maintenance helps plan operations better and provides a better grip on the project budget as you don’t have to keep a lot of inventory on the shelf. However, sometimes we end up sending parts that do not require maintenance which leads to unnecessary expenditure and work.
Predictive Maintenance: Progression of failure is monitored. Machine repair is scheduled prior to a catastrophic breakdown.
Reduction in maintenance costs, reduction in repair and Overhaul time and reduction in spare part inventory are some of the advantages of this technique, however high implementation cost, expense on manpower training and increased manpower are some of the downsides.
Proactive Maintenance: Ahead of the first initiation of failure, not in response to failure. Focused on the root cause.
This is one of the superior types as the elimination of the cause of failure saves a lot of costs and contributes to the project’s profitability. However, this can be only applied if the manpower has greater diligence and are consistent with observing and recording their feedback. Also, read https://www.linkedin.com/pulse/functions-hydraulic-oil-reasons-its-contamination-anshuman-agrawal/

We at Minimac Systems Pvt Ltd. not only design a maintenance schedule for the lubrication oil but also provide a range of OIL PURIFICATION SYSTEMS & FLUSHING SYSTEMS. Minimac stands for MINImum MAChinery Maintenance.

Minimac accepted the challenge to filter 72 kiloliters of Oil within 72 hours

Challenges and Problems are the fuel of Success. Such a challenging problem was faced by the UMPP (Ultra Mega Power Project) 2*800MW thermal power plant.

In 2021, the plant

Minimac accepted the challenge to filter 72 kiloliters of Oil within 72 hours

Challenges and Problems are the fuel of Success. Such a challenging problem was faced by the UMPP (Ultra Mega Power Project) 2*800MW thermal power plant.

In 2021, the plant called an annual shutdown, just before unit start-up, they found oil quality is not up to the mark to circulate it within the system. They had to run the plant within 3 to 4 days after cleaning 72 thousand liters of Oil to maintain the quality as per standard. The head of maintenance of the unit searched for a reliable and trustworthy name in the market for the task and then contacted Minimac Systems Pvt. Ltd. for the rescue.

Minimac is involved in manufacturing, supplying, exporting, and trading a range of oil purifications and reconditioning plants, allied machines, and laser particle counters. The Minimac team accepted the challenge to filter 72 kiloliters of Oil within 72 hours. The team knew its skills, but the enormous provocation was to transport the machine to the site and complete the task within time. They shipped the machine and later transported it with their personal vehicles. It took 8 hours to install the equipment, and they were ready to achieve the milestone.

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The oil was tested and found NAS10 before they started filtering the oil. At an interval of 18 hours, the oil samples were getting checked for work progress, and after the 3rd round of the quality test, the Minimac team achieved the target and got a favorable result of NAS6. Further, the machine was run to achieve NAS5. Minimac had to finish the task much before 72 hours and it was done only in 40 hours.
This was a challenging task for the team, nearly like a world record if they could filter 72 thousand liters of oil in 40 hours using a compact size filtration trolley.

We used only a single set of correct filters i.e., the MR series filter element to achieve the goal. We did it with 2X FS-150-2S-H-V to get a favorable result for the client satisfaction to meet the standards.
Nothing is impossible if we take up the challenge with great zeal and passion. This synergy happened because of the perfect combination of methodology and technology. Completing the task within the timeline was a challenge, but as it is often said and we strongly believe "hard work always pays off".
Minimac is on a mission to change the way lubrication is being performed in the core sector's industrial plants. We strive to provide better machine efficiency and reduce the cost of maintenance and downtime by promoting Zero Mechanical Breakdown in rotary and hydraulic equipment through lubrication management.

Connect with our experts today to optimize the operational life of your equipment - Drop an Inquiry

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Understanding of the BETA factor

We concluded in our last article on Beta Factor. In this article, we will talk more about BETA Factor for buying new filters.

What is the Beta Ratio?
The beta ratio refers to the efficiency in which a given filter

Understanding of the BETA factor

We concluded in our last article on Beta Factor. In this article, we will talk more about BETA Factor for buying new filters.

What is the Beta Ratio?
The beta ratio refers to the efficiency in which a given filter element removes the particle of a given size. The Beta Ratio is calculated using the ISO multi-pass test standard 16889:1999.

How is it measured?
The test involves adding particles of a known size to the test fluid until the fluid reaches a saturation point and then bringing the filter online to remove particles in one pass through the element. It is important to consider that the beta ratio is valid for a particular size of the particle. For Example for a 5-micron filter, how many particles are above 5-micron mark in upstream of the filter and how many are downstream is measured. And then by using the below formula, the Beta Ratio is calculated.

Each Beta factor corresponds to an efficiency of the filter, the same can be matched as per the below chart.

Get your filter check today, Call +91 7030901266

So, to purchase a filter with a beta ratio of 2-10 is considered poor, it is advised to use filters with at least a Beta factor of 75 and 98.7% effectiveness. High quality, efficient filter assemblies can achieve 200 to 2000 Beta Ratio for given particle size and should be ideal to achieve a low level of contamination.

Also read: https://www.linkedin.com/pulse/you-buying-right-oil-filter-anshuman-agrawal-mlt-1-/

We at Minimac Systems Pvt Ltd. provide services of Total Lubrication Management and Lubrication Consulting that helps you optimize your Lubrication needs. Minimac stands for MINImum MAChinery Maintenance.

Importance of Filter Carts and how to select the right one?

A lubricant filter cart is an important tool that can be used in many ways. From filtering all types of new and used oil to taking samples and transferring oil, filter carts are considered to

Importance of Filter Carts and how to select the right one?

A lubricant filter cart is an important tool that can be used in many ways. From filtering all types of new and used oil to taking samples and transferring oil, filter carts are considered to be a must-have for an effective lubrication program. Oil filter carts have many benefits; they can be customized to fit any plant as per the uses and specifications. If designed, it can also give a warning if the unit needs servicing.

The uses and importance of filter carts are as follows
For cleaning the lubricants stored
For transferring the filtered oil to a machine or containers
For reconditioning of oil (currently in use)
For flushing (power, line, wand, etc.)
For contamination control functions (hose cleaning)
For meeting cleanliness standards
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How to select the right filter cart?
If you don’t want your money to get wasted, select the right filter cart considering the below check-points:

Check the type of oil before buying a filter cart because carts are designed as per the viscosity levels. If a plant uses different types of oil then multiple filter carts are to be used.
Choose a filter cart that can be carried easily to the place of its application. Here, you have to consider the source of power as well.
Knowing your oil cleanliness target is very important before you buy filter carts. Don’t depend on the ISO standards entirely to evaluate used oil. Considering the specification of the type of oil is vital. We know that when viscosity increases, the cleanliness level decreases.
Check the oil flow rate. Powerful carts will cost you more, so it’s very important to know the filter’s flow rate before buying.
Customization of filter cart can be done, check before you buy if it matches your requirements or not. For example, the installation of bypass valves, dual filters, etc.
It is always better to take a second opinion than to stick with a single thought. It’s advisable to have a discussion with your filter distributor or manufacturer to find the best option. Remember that the filter cart must be chosen carefully and effectively to meet the cleanliness goals.

Reach us anytime to find the right Filter cart for your Plant - enquiry@minimac.in or +91 70309 01267

Case Study

Place: A steel plant in Rourkela with production capacity - 4.5 MTPA

Date of Execution: 20th July 2019

Equipment Criticality: High

Background:
A Steam turbine blower was to be commissioned in a steel plant by a leading EPC company, the

Case Study

Place: A steel plant in Rourkela with production capacity - 4.5 MTPA

Date of Execution: 20th July 2019

Equipment Criticality: High

Background:
A Steam turbine blower was to be commissioned in a steel plant by a leading EPC company, the pipelines were erected on the site and as per the Standard Operating Procedure listed by the Steel Plant Owner Company the flushing was completed with a single auxiliary pump at 1500 LPM. However, during the trial run of the turbine, the inline lube oil filters would clog very frequently and lead to halted operations.

Problem Statement:
Frequent clogging of inline lube oil filters were hindering the operations and delaying the steam turbine commissioning project

Underlying Issues:
On inspection, a root cause analysis was done and the required rate for effective flushing was calculated as 3500 LPM. The Particle contamination level was also found to be NAS 10. Hence following things were concluded:

The rate at which flushing was done was too low and lead to ineffective flushing, leaving a lot of debris and scale inside the pipeline.
Absence of a System other than the inline filters to arrest the particles which would come along with the flushing flow.
The maximum flow rate that could be achieved on-site was 3000 LPM.

What Minimac did:
The calculated effective rate for flushing was 3500 LPM, but as only 3000 LPM was achievable on-site, the temperature of the fluid was increased by regular heating arrangement to bring down the required flowrate requirement to 2500 LPM.
Both the auxiliary pumps were employed for flushing activity and a separate filtration skid was offered which could handle the full flow volume that was getting generated.
Duplex type filtration housing on the lube oil return side was also provided to arrest any future debris. Subsequently, turbine governing and Heat Exchanger were also taken online to clean the system in totality.
Result achieved:
The Lines were successfully flushed and a NAS 5 lube oil cleanliness level was achieved.

We at Minimac Systems Pvt Ltd. provide services Oil Purification, Oil Flushing, Oil Condition Monitoring that helps you reduce downtime and increase machine reliability.

13 test parameters to test turbine oil, as per standards

*Test Parameters:

Viscosity
Viscosity Index
Flash Point
Pour Point
Demulsification
Copper Corrosion
Acid Number
Foam Characteristics
Oxidation Characteristics
Water Separation
Rust

13 test parameters to test turbine oil, as per standards

*Test Parameters:

Viscosity
Viscosity Index
Flash Point
Pour Point
Demulsification
Copper Corrosion
Acid Number
Foam Characteristics
Oxidation Characteristics
Water Separation
Rust Prevention
Cleanliness
*Oxidation Stability Test : Turbine Oil Oxidation Stability Test (TOST) is a valuable tool in order to indicate oil life for lubricants that are continuously exposed to gross water contaminations, high temperatures, and air entrainment in field service.

ASTM D943 commonly referred to as Turbine Oil. Oxidation Stability Test (TOST), is widely used in the lubrication industry to evaluate the oxidation stability.

*Best Practices for Steam Turbine Lubrication:

Keep Oil Clean, Cool and Dry
Install High Capture Efficiency Breathers to your Oil Respective Oil Tanks
Monitor returning bearing oil temperature regularly
Maintain proper alignment
Inspect for signs of foaming and/or Air Entrainment
Install primary (return line) and secondary sampling points
Perform regular oil analysis
Routinely inspect sight glasses for level, foam, and water
Keep tank headspace dry using blowers, condensers or instrument air
Drain accumulated water regularly
Use offline fluid conditioning for precision contamination control
Regularly inspect for varnish, especially in gas turbines
Protect against water and or detergent ingress during wash-down
Inspect bulk delivery of new oil before acceptance
Also Read: https://www.linkedin.com/pulse/standards-related-turbine-oil-anshuman-agrawal-mlt-1-/

We at Minimac study your maintenance needs and provide the best solution. We believe in Discern, Design & Deliver.

Call +91 7030901266 for Mechanical Maintenance & Oil Check.

Understanding the Pareto principle in terms of maintenance

In our previous segments, we have discussed several aspects of Lubricant contamination and ways to prevent or treat that contamination. But, as we all know that for every company the

Understanding the Pareto principle in terms of maintenance

In our previous segments, we have discussed several aspects of Lubricant contamination and ways to prevent or treat that contamination. But, as we all know that for every company the maintenance budget is limited so focusing on all the factors is not possible.

In such cases, The Pareto Principle comes handy.

The Pareto Principle (also known as the 80/20 rule ) states that, for many events, roughly 80% of the effects come from 20% of the causes. In terms of maintenance, it can be reflected upon as 20% of Machines cause 80% of the Downtime.

Few key causes that constitute this 20% are:

Particle Contamination
Moisture Contamination
Wrong/Degraded Lubricant
Misalignment
Imbalance
High Temperature

We at Minimac study your maintenance needs and provide the highest quality & service quality solutions. Call +91 7030901266 for Mechanical Maintenance & Oil Check.

Mandatory properties for steam & gas turbine oil

1. Steam Turbine Oil

Good Demulsibility: Means the ability to release water, This is important when the equipment is operating in humid climates or in a plant atmosphere that is wet or humid.
Foam

Mandatory properties for steam & gas turbine oil

1. Steam Turbine Oil

Good Demulsibility: Means the ability to release water, This is important when the equipment is operating in humid climates or in a plant atmosphere that is wet or humid.
Foam Suppression and Air Release: Foam is used whenever there is a possibility of liquid fire. The Foam will mix with water and then expand over the liquid that is on fire, cool the fire, and will finally suffocate it.
Anti-rust protection: Rustproofing is the prevention or delay of rusting.
Anti-wear protection (Certain Cases): Antiwear additives (AW additives) are lubricant components that chemically react with Oil to protect metal-to-metal contact between parts of gears.

2. Gas Turbine Oil
Anti – Corrosion Protection: Help protect the base oil from oxidation and the metal from damage by corrosive acids.
Anti – Scuff (Certain Cases): Anti-scuff additives are designed to react with the parent metal surfaces to provide protection under severe loads and high temperatures where the oxide layers and chemically adsorbed anti-wear films on metal surfaces are disrupted.
Thermal Stability: Thermal stability is the stability of a molecule at high temperatures; i.e. a molecule with more stability has more resistance to decomposition at high temperatures. Thermal stability also describes, as defined by Schmidt, the stability of a water body and its resistance to mixing.
Also Read: https://www.linkedin.com/pulse/what-varnish-its-effects-anshuman-agrawal

We at Minimac study your maintenance needs and provide the best solution. We believe in Discern, Design & Deliver.

Call +91 7030901266 for Mechanical Maintenance & Oil Check.