When labeling oil sample bottles, consider labeling the bottle cap also. If you mistakenly place a cap from a bad sample onto a bottle containing a good sample, the sample is cross-contaminated. Testing of this cross-contaminated sample will yield false data. Labeling both the bottle and its cap will prevent this problem from occurring.

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Begin by learning how lubricants and machines reveal problems. Unlike people who have verbal skills, machines use "sign language" to communicate what hurts or what has invaded their system. Recognizing the "signs" or symptoms that the machine conveys is a required skill for those who work with machines and are responsible for their care and feeding. This involves training, practice and motivation.

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"We suspect that we have an air contamination problem in one of our hydraulic systems. What types of problems can air contamination cause?"

Air contamination can cause a great deal of harm to hydraulic systems. Unfortunately, unless the machine is foaming, with oil spewing from the top of the reservoir, we sometimes overlook this potentially devastating contaminant. Here are a few ways in which air contamination can undermine your reliability effort:

Spongy hydraulics – Air is compressible. This loss of control can slow throughput, increase the percent defective rate, and, in some cases, cause injury or death.

Gaseous cavitation – Some references say gaseous cavitation causes wear, others say it just makes noise. Play it safe and keep as much air out of the oil as possible.

Oxidation – The rate of oxidation is affected by a number of factors, but all else held equal, it is proportional to the amount of oil in boundary contact with air (which, of course provides the oxygen).

Thermal degradation - Did you know that compressing an air bubble from ambient pressure to 3,000 psi increases the bubble's temperature to more than 2,000 degrees F? This is hot enough to thermally degrade oil at the boundary contact between the air and the bubble, which darkens the oil, sometimes giving it a sooty appearance causing varnish to build up on component surfaces.

So, watch for signs of air entrainment or foaming, and take occurrences seriously. Also, periodically test your oil's ability to release air and its tendency to maintain stable foam. If you have recurring problems, evaluate the lube specification and the tank design, and check for low levels and signs of a suction line leak.

Drew Troyer, Noria Corporation

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APRIL 2007

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