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Outsmarting Varnish Whitepaper PDF
Outsmarting Varnish Whitepaper PDF
Page 1 www.testoil.com
Varnish: The Elusive Enigma
Whether tending to a gas turbine or a large potential has remained elusive in routine “It’s very important that a gas
turbine and the hydraulic system
hydraulic system, the mere mention of testing.
work every time you start up or
varnish can cause alarm and an immediate
make changes. The cost of not
call to action. “We work with power plants all over the starting up when required, or
country and their number one concern is causing shutdowns, can cost in the
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Measuring Varnish Potential
within machinery and a loss of heat transfer
due to thermal insulating. As more A varnish potential analysis is used to signal
operators face the prospect of varnish in the development of lube oil varnish
their lube oil systems, they are turning to oil potential. This analysis combines multiple
analysis labs for answers. testing technologies to measure a
lubricating oil's propensity to create varnish
Varnish potential, or the measure of a deposits.
View a sample report:
lubricant's tendency to form varnish Varnish Potential Analysis
Page 3 www.testoil.com
Membrane Patch Colorimetry (MPC) The test is designed to identify soft higher the L value, the higher
In this method insoluble contaminants are contaminants directly associated with oil the concentration of black
extracted from a used oil sample, followed degradation. This test is considered to be particles in the oil. Black
by spectral analysis of the separated highly sensitive and reliable for detecting color can be due to soot
material. The process of making a patch subtle changes in insoluble levels. particles, which can point to
isolates and agglomerates insoluble by‐ As part of the MPC the L, a, b color values micro‐dieseling, spark
products associated with varnish. The color are also documented. The L, a, b values discharge, or hot spots. The a
of the membrane patch provides a provide additional information on the value is a red to green scale.
guideline to the extent of varnish potential. particular varnish degradation mode and The higher the a value, the
With MPC, a direct correlation is made offer clues about the effectiveness of greater the danger of sludge‐
between the color and intensity of the filtration targeting specific varnish modes. building corrosive particles
insoluble contaminants and oil degradation. The L value is a black to white scale. The or diminished extreme
pressure (EP) additives.
Lastly, the b value is a yellow
to blue scale. The higher the
b value, the more susceptible
the oil is to sticky deposits.
Particle Count
Particulate contamination is
This MPC test depicts a color value of 51, which is above the critical limit of 50, indicating a high‐level of
insoluble degradation products associated with varnish. The increasing the value also suggest the presence of tested using two methods,
degraded antioxidants
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optical and pore blockage. Optical particle
count passes the oil through a beam of
light. Anything in the oil that interrupts the
beam is counted as a particle. This method
will count soft (varnish) particles. Pore
This example shows a sample has a UC value of 5, which is above the acceptable
limits. These
blockage particle count passes the oil results correlate with the elevated MPC value (shown above) and indicate the presence of an
elevated level of degradation byproducts associated with varnishing.
through a calibrated mesh screen that
captures only hard particulates. A
testing. The amount of the agglomerated Karl Fischer Method
significant difference in the two results may
material is compared to a rating scale to This water determination
be due to the presence of water, soft
derive the UC value (1‐8). This test is test quantifies the amount of
contaminants, or insoluble contaminants.
considered an excellent indicator of varnish water in the lubricant. A
potential. reagent is titrated into a
Ultra Centrifuge
measured amount of sample
A small amount of oil in a test tube is run
Acid Number and reacts with the OH
for 30 minutes at 18,000 RPM in an ultra
A significant increase in the acid number molecules present in the
centrifuge. By subjecting the sample to
could be indicative of rising carboxylic acids sample. Results are reported
significant G‐forces, we are able to extract
associated with an oxidation condition. as either % water or ppm
oil‐degraded insoluble contaminants that
Monitoring the acid number alerts us to an percentage (1% =10,000ppm).
are associated with varnish potential.
increasing risk of oxidation. A rapidly rising Increased water
Insoluble contaminants tend to have a
acid number indicates antioxidant depletion. concentrations indicate
higher density and will drop out during
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possible condensation, coolant leaks, or degradation. Ester, aromatic additive and relative concentrations of
process leaks around the seals. base oil aromatic provide formulation antioxidants in
information and should correlate with new oil new and used oils in order to
IR Spectroscopy data. Amine antioxidants and phenolic monitor the depletion rates
The FTIR covers the monitoring of base antioxidants are oxidation inhibitors with data of the antioxidant protection
stock degradation, oxidation and additive expressed in indexing numbers. package in the oil. Hindered
depletion in machine lubricants, hydraulic phenols and aromatic amines
fluids and other fluid types. This test is Remaining Useful Life Evaluation Routine are primary antioxidants
based on trending of different parameters The RULER® test uses linear sweep used in many industrial oils
in various oils and fluids. For the turbine oil voltammetry to measure hindered phenolic and turbine oil applications.
method, thermal event acid and acid and aromatic amine antioxidant content. By measuring the depletion
oxidation are indicators of lubricant The RULER quantitatively analyzes the and available reactivity of
these antioxidant
compounds while conducting
The ruler measures
the remaining active other routine performance
antioxidants in the
tests, the service life of used
lubricant. This
example shows that lubricants can be effectively
the level of amine
antioxidants is 79%, monitored.
and the level of
phenolic antioxidant
is 15%, of the new oil
level. These results
suggest a lubricant is
at risk for varnish
formation.
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Fighting Back Against Varnish
Varnish potential analysis should be considered a mandatory tool for any lube system that is prone to varnish. By controlling
factors that influence or promote lubricant degradation, machine reliability and availability increases. By monitoring the
contaminants responsible for varnish, reliability managers and maintenance planners can implement appropriate corrective
actions before costly damage occurs and unnecessary downtime is experienced.
View a sample Varnish Potential Analysis Report at http://www.testoil.com/pdf/vpaw1.pdf
Contact Us About TESTOIL
Call: 216‐251‐2510 TESTOIL is a full service oil testing laboratory owned by Insight
Email: info@testoil.com Services. Since 1988 the laboratory has been providing fast
and reliable oil analysis results across all industries throughout
Visit our website: www.testoil.com the Americas.
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The firm’s comprehensive range of oil analysis services assists
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reliability engineers with condition monitoring and
identification of machine wear.
TESTOIL employs a sophisticated diagnostic technology that
assists their Machine Condition Analysts in making equipment
and lubrication condition assessments.
Page 7 www.testoil.com