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Measuring
Varnish Potential
Leading
Edge Lubrication Technology Questions & Answers by
Terrence O'Hanlon, Reliabilityweb.com and Michael
Forgeron, Analysts Inc.
Analysts,
Inc. recently introduced a new predictive technology
called Quantitative Spectrophotometric Analysis or QSA.
This exciting new testing methodology identifies and
measures the specific contaminants that promote the
formation of varnish deposits in lubrication and
hydraulic systems. Analysts, Inc. presented an excellent
overview of QSA at
IMC-2004 the 19th International Maintenance
Conference. We decided to catch up with Michael
Forgeron, President of Analysts Inc. to learn more.
1)
How did
Analysts Inc develop this new method for detecting
varnish potential?
QSA combines a number of
varying approaches to determine the sludge and varnish
potential of lubricants. Led by Brian Thompson from our
Louisville, Kentucky laboratory, Analysts has
independently researched this problem for a number of
years. Over time we identified other organizations
including oil companies, filtration companies and many
end users that were also concerned about the problems of
varnish build-up and the inability to identify its
presence with traditional laboratory testing. These
companies, including Clarus Technologies, Shell Oil,
ChevronTexaco, Kleentek, and a number of plastics
manufacturers and power producers were very helpful in
our developmental work on QSA.
2)
What makes
this testing different?
QSA testing
protocol was purposely designed to isolate, identify and
measure the specific degradation by-products responsible
for the formation of sludge and varnish, there is no
other commercial technology like QSA offered in the
marketplace. QSA does not use traditional oil analysis
methods or instruments. Through field research, we
developed the Varnish Potential Rating (VPR), in which
severity levels are application specific. Until QSA was
developed, there never was a VPR.
3)
Why is it so
difficult to detect varnish potential with traditional
fluid analysis techniques?
This will
get a little technical, so bear with me.
Let’s start
with a brief explanation of what varnish is made of and
how it forms. Varnish deposits are made up of lubricant
degradation by-products. Lubricant degradation occurs
from oxidative, thermal or chemical attack on the
building blocks of the lubricant – the hydrocarbon
molecule. Hydrocarbon degradation is a complex process
where normal oil molecules transform into a wide variety
of harmful intermediaries. These intermediaries are
highly reactive and easily transform into new compounds.
As these reactions continue or propagate, new polymers
of increasing molecular weight form. Many of these
compounds or by-products are insoluble. Simply put,
varnish is composed of these organic polymers.
Conventional
laboratory test methods are not intended to identify
these by-products. What conventional oil analysis does
do is identify the end result of certain physical
properties, contamination and component wear.
QSA focuses
specifically on the chemical and physical signatures of
the particular types of degradation by-products that
have a high tendency to deposit on surfaces.
QSA, is
concerned with elements in transition, degradation
by-products that are on the way to becoming something
else – varnish. Finding those elements in the oil is a
complex and difficult task. One way to look at it is
this is a natural evolution of the science of
lubrication analysis and we are the laboratory at the
leading edge of the research.
4)
Does QSA replace the
traditional used oil analysis programs?
No, not at
all. QSA combined with a solid oil analysis program
will broaden the spectrum of information that the users
can utilize to make the most informed decisions from
their analytical test programs. QSA focuses on
lubricant properties that traditional oil analysis
testing methodologies do not. QSA addresses sludge and
varnish build-up. Proper routine oil analysis addresses
component wear, sources of contamination and changes in
the physical properties of the lubricant. Both are
important players in the fight for increased equipment
reliability.
5)
How is the information
reported?
Each client
receives a customized report that includes the VPR, a
severity scale that depicts where the result lies
between normal and critical, a digital image of the
separated contaminants, and a written interpretation of
the laboratory results.
For a first
time sampler, the easy-to-understand severity scale
allows the user to quickly determine their risk for
developing varnish related problems. We also include a
historical graph of the VPR to assist in trending.
Sample
QSA Report
6)
How was
varnish detected prior to this technology?
Prior to the
development of QSA, there was virtually no mechanism to
provide an early warning of an impending varnish
problem. Historically, the most common way of detecting
varnish was by visual observation of easily viewed
surfaces in the system. Unfortunately, dirty sight
glasses and “bathtub rings” in lubricant reservoirs
often do not show up until the contamination level has
reached critical stage. All too often, unexpected
varnish deposits were observed on internal components
such as valves, bearings and gears during unscheduled
and costly shutdowns or failures.
7)
What kind of
impact does this test have on overall plant and
machinery reliability?
By
monitoring those contaminants responsible for sludge and
varnish, maintenance planners can properly schedule
service and/or implement appropriate corrective actions
before costly damage occurs and unnecessary downtime is
experienced. QSA will develop into a useful tool in root
cause analysis. By controlling factors that influence
or promote lubricant degradation, machine reliability
and availability increases. This has a significant
impact on industry.
8)
Do you find
you have to educate potential customers as to how and
why they might benefit from detecting varnish potential?
Not really.
Varnish is a widespread problem that challenges many
industries. We have found that almost everyone involved
in maintenance, production, and reliability encounter
some degree of problems associated with varnish. Most
already understand the benefits of early detection.
Some of the
most common problems related to sludge and varnish
build-up that these professionals face are sticking
servo control valves, elevated operating temperatures,
accelerated wear and filter plugging. We have found
that the marketplace is hungry for an effective
predictive tool that can be used to monitor the
otherwise missed varnish precursors in used
lubricants.
9)
What are your
future plans and goals for this new test?
We officially introduced QSA
to the marketplace at IMC 2004. Our immediate goal is
to have our sales department actively introduce the
technology directly to the industrial sector.
Additionally our co-workers have written papers to
present this technology at additional forums including
the upcoming annual STLE meeting and other industry
related conferences.
While the
existing technology is solid and provides tremendous
returns for our customers, we are continuing our
research, particularly in areas such as contaminants
versus lubricant performance.
10)
What is the
best success story you can share about detecting varnish
potential?
QSA is now
used extensively in the power generation and industrial
hydraulic market.
We have
identified dangerous fluid conditions at numerous
facilities during the past year. These alerts have
allowed our clients to implement appropriate corrective
actions and investigate root cause before an unscheduled
shutdown or worse.
One specific
case involved a base load power plant. Our laboratory
identified a very high VPR. Based on the QSA results,
the plant initiated a corrective action utilizing
electrostatic filtration as well as continued sampling.
Over the course of the next few months QSA showed a
gradual decrease in the VPR. When the plant shut down
for planned maintenance they found the valves and
filters were clean with no varnish related problems.
The savings were in the tens of thousands of dollars.
11)
Where can
people go to learn more?
To
learn more about QSA and its benefits people can visit
our website at
www.analystsinc.com
where we have excellent
information on the technology. From the website they
can also request additional information about our
services or to have a representative contact them.
To learn
more about sludge and varnish and their effects on
machinery there are a number of very well written
educational papers that have been published. An
internet search, or call to Analysts at 800-655-4473
will get them details on this area.
Editors
Note: Research does not always near fruit as meaningful
as QSA. Investing in uncertain outcomes requires
leadership and the ability to absorb risk. Companies
like Analysts Inc., should be congratulated for taking
that risk and bringing new tools to support reliability
rather than being satisfied with business as usual. It
was exciting to being somewhat plugged in as Mr.
Thompson and others worked to bring this technology to
the world last December at IMC-2004 and will also be
reporting an exciting case study at
LubricationWorld, December 6-9, 2005 in Tampa Florida.
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