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Oil Conductivity
The more polar a lubricant is, the less refined and more conductive it is. Based on the manufacturing method
and level of refining, the American Petroleum Institute (API) has classified base oils into five groups (see Table
1).
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The lightly refined, mineral-oil-based base oils of Group I represent the simplest option and previously
accounted for the largest proportion of lubricant production. Over the last few years, that proportion has been
in steady decline, as the more refined base oils of Groups II, III and IV are increasingly being utilized for
modern lubricants.
This trend of using more refined base oils and synthetic alternatives is based on the fact that they generally
have better characteristics such as higher aging stability. However, while the higher-quality base oils have
many advantages, there are concerns over some of their changed properties, which can lead to problems,
especially when unfavorable combinations occur.
One such consequence is varnish, which can be due to the base oil’s altered dissolving performance with
regard to aging and reaction products. Another consideration is component and lubricant damage, which can
be caused by electrostatic discharges. The lubricant’s conductivity is an important factor in the charge buildup,
and conductivity is dependent on the type of base oil used (see Table 2).
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Along with the base oil, additives have a significant effect on an oil’s conductivity. The higher the proportion of
metal-organic additives, the higher the lubricant’s conductivity. A prime example would be metal-organic
additives such as those frequently used in zinc dithiophosphate (ZnDTP). As a proven multi-purpose additive
in engine and hydraulic oils, ZnDTP improves wear and corrosion protection while simultaneously functioning
as an antioxidant.
However, zinc is considered to have dangerous health implications, so ZnDTP should be largely avoided. This
means that the oil’s conductivity decreases and the risk of static charging increases.
A lubricant’s conductivity not only is influenced by the base oil and the additive package but also depends on
temperature. The higher the temperature, the higher the oil’s conductivity. Unfortunately, there is no linear
correlation between the two parameters, as each oil type has its own conductivity/temperature relationship.
Furthermore, at a constant temperature, conductivity still changes during operation due to additive reactions,
wear metals, reactions with metal surfaces, water and the formation of aging and oxidation products.
Electrostatic Charges
Although monitoring conductivity so far has been unable to achieve much success in the area of sensor
technology, it is gaining significance with regard to electrostatic charges and discharges in lubricant and
hydraulic systems.
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In oil-circulating systems, electrostatic charges generally can occur if there is friction in the flow between the oil
and the surfaces surrounding it. The strength of the static charge depends on many different and partly
interconnected factors.
The energy density, which builds up in the system and leads to subsequent discharges, is contingent on the
oil’s conductivity and volume flow. The more oil that flows through a circulation pipe and the lower the oil’s
conductivity, the greater the potential for an electrostatic charge.
If the charge is high enough, the discharge could be repeated several times in quick succession. Discharges
primarily take place in areas with vastly different material combinations. Modern filters with a high proportion of
plastic are often affected.
The microsparks caused by a static charge can lead to temperatures approaching 1,000 degrees C. This can
be extremely dangerous if the fluids are even slightly flammable. In addition, if hydrocarbon vapors have
formed in the tank ventilation area, the system could spontaneously combust.
However, when discharge sparks occur within a turbine or hydraulic oil-circulation system, they are normally
smothered very quickly by the oil. Nevertheless, these mini-explosions can burn holes in filters or even
seriously damage the oil due to increased sludge buildup.
Modern hydraulic fluids and turbine oils have become increasingly less conductive because of the global
trend to use modern base oils and additives. Previously, turbine oils were based on relatively conductive,
lightly refined Group I base oils. Currently, more oxidation-resistant, better refined Group II base oils or
even partly synthetic Group III base oils are being used, especially for gas turbine oils. These oils are
considerably less conductive. In addition, turbine oils normally contain very few metal-organic additives,
which help to prevent the formation of unwanted deposits (varnish).
New systems feature a more compact design with a considerably smaller tank capacity and a
proportionally larger displaced volume.
Oil purity requirements have increased. This in turn has led to higher filtration rates.
The filtration intensity and electrostatic charge properties of the oil (resulting from filtration) have
increased.
The oils’ low conductivity, which often is far below 1,000 pS/m in certain conditions, has resulted in an
increased tendency for electrostatic charging.
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As mentioned previously, oil’s conductivity value is measured in pS/m. If the conductivity is more than 400
pS/m at 68 degrees F (20 degrees C), there is little risk of damage to the oil or the system from electrostatic
charges. However, if the value is lower, there is a very real possibility that the phenomenon could occur.
If an oil with an increased ESD risk is being used, grounding the entire system is not a viable option. The
voltage inside the system cannot be discharged through a grounding wire. Fortunately, there are several other
approaches for prevention.
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