Oil is what keeps equipment running like, well, a well-oiled machine, but the cleanliness of that oil is crucial to reliability and performance. Even the smallest amount of contamination can impact the oil’s effectiveness and result in corrosion, abrasion, and wear that may not only reduce the lifespan of your machinery, but also increase maintenance costs, and cause inefficiencies and unplanned interruptions. To keep things running smoothly, it is critical to know all you can about contamination, how it can occur, and what you can do to prevent it.
Common Types of Contaminants
- Dirt, Dust & Soot – whether from outside environment or internal processes, these can have ill effects on oil’s viscosity.
- Metal particles – wear and tear and friction from machine components sliding or rubbing together can lead to small metal pieces breaking off into abrasive debris.
- Water or Gas – heat can result in condensation and release of gases which dilute the oil making it difficult to do its job.
How Oil Becomes Contaminated and the Damage that can Occur
Any of the above contaminants can enter oil through leaks, unfiltered air intake, cross-contamination with other lubricants, improper storage and dispensing, or internal factors such as oxidation over time. This can significantly affect pumps, valves, hoses, cylinders, pistons, bearings, seals, and hydraulic systems in several ways. For instance, contamination in oil can cause surface damage, increased friction, and premature wear of bearings, reducing their lifespan. The integrity of seals can be compromised, allowing additional contaminants in and oil to leak out. Contaminants in hydraulic systems can lead to fluid degradation, wear, and even system failures.
With the following guidelines, however, you can significantly reduce the risk of contamination and ensure the longevity, reliability, and efficiency of your machinery, maximizing your equipment life as well as your bottom line.
Preventing Contaminants in Oil
Clearly, oil cleanliness is of the utmost importance in avoiding costly repairs, replacement, and downtime. Fortunately, there are ways you can steer clear of contamination, such as maintaining a clean environment and implementing regular maintenance inspections. It’s also helpful to know warning signs that can assist you in catching contamination issues early and mitigate further damage.
Indicators of Oil Contamination
- Increased system temperatures
- Leaking components
- Inconsistent equipment behavior and inefficiency
- Appearance of foam in fluid reservoirs
- Strong burning smell
- Thick, dark, milky, or frothy oil
- Unusual noises
Best Practices to Avoid Contamination in Oil
To prevent oil contamination, keep an eye out for the warning signs above, ensure responsible management practices before, during, and after working with oil, and follow these best practices and proactive strategies:
- Perform regular maintenance and inspections
Check all equipment for leaks, corrosion, damage, and any of the warning signs listed above on a regular basis and keep a maintenance log to help track equipment condition.
- Use effective filtration systems
Filtration systems remove contaminants and help create optimum conditions to keep oil clean. Be sure to opt for filters that meet OEM specifications and replace them when necessary.
- Maintain proper storage
It’s essential to use properly sealed containers in good, clean condition that are specifically designed for oil storage. Also, make sure to store oil in clean and dry environments.
- Adhere to proper cleaning standards
Keep work and storage areas clean. Empty any residual oil from dispensers and remove residue, scrub with warm water and dish soap, rinse and dry thoroughly.
- Label containers clearly
Label containers and include handling instructions to prevent accidental misuse or mishandling of oils.
- Implement employee training
Training sessions ensure all team members are aware of proper procedures to handle oil safely and avoid contamination.
- Regularly monitor oil cleanliness and perform routine oil analysis
Regularly analyzing oil samples can help detect contamination early so you can take corrective actions before it impairs operations.
Key Methods for Measuring Oil Cleanliness
When analyzing oil samples, it is essential to have an understanding of ISO cleanliness codes. Here is a rundown of the types of ISO codes and what they measure:
- ISO 4406 – measures number of particles greater than 4, 6, and 14 microns per milliliter of fluid.
- ISO 4407 – counts particles between 5 and 15 microns using an optical microscope to find the particles and a fine filter patch to capture them.
- ISO 11500 – uses an optical particle counter to measure particles as they pass through a capillary detection zone.
You can also use tools like Noria’s Oil Target Cleanliness Calculator, which can help you determine your ideal cleanliness target based on your machine type, downtime risks, and other operational factors. By setting a good beginning target for contamination levels in your fluids and frequently measuring samples, you can control and maintain clean, thus well-performing and long-lasting, machinery and equipment.
Besides starting with an ideal cleanliness target, it’s also important to start with high-quality fluids in the first place. That’s where Keller-Heartt can help. As a family-owned company for over 80 years, we’ve built a reputation as one of the leading distributors of bulk oil solutions in the country and have leveraged our long history of distributor partnerships to provide low wholesale prices on top, quality brands.
To keep contamination problems at bay, keep the tips provided here in mind, and call Keller-Heartt at 1-800-423-7513 or visit us online at kellerheartt.com for the best products, prices, and service around. For quality oil and lubricants, you can count on Keller-Heartt. Request a quote today.
