Below are eight quick lubricant inspections for the Condition Monitoring Pod. They include guidelines on possible causes and corrective actions.
| Observation | Possible Cause(s) | Corrective Action |
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1. Note Oil Level - Observe oil level in sight glass during normal operation and running temperature.
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| A. At cross hairs |
Correct oil level |
No action required |
| B. Above cross hairs |
1) Excessive makeup oil introduced; 2) Slow internal leakage; 3) water contamination/in-leakage; 4) entrained air |
Confirm cause, correct contributing condition and adjust oil level |
| C. Sight glass flooded |
1) Large internal leakage of coolant, other lubricant or process chemical; 2) gross water contamination; 3) entrained air/foam |
Confirm cause, correct contributing cause, drain and flush as needed |
| D. Below cross hairs |
1) Oil leakage; 2) excessive oil volatilization; 3) high oil temperature; 4) too low oil viscosity |
Confirm cause, correct contributing condition; correct oil level |
| E. No oil in sight glass |
1) Gross oil out-leakage; 2) gross oil internal leakage |
Confirm cause, correct contributing condition; correct oil level |
2. Observe Oil Color - Observe oil color using a bright flash light. Compare to new oil color.
| | |
|---|
| A. Same or slightly darker than new oil |
Correct oil color is observed |
No action required |
| B. Considerably darker |
1) Oil contamination with chemical or process fluid; 2) thermal degradation (hot conditions); 3) oil oxidation; 4) photo catalytic reactions (sun light exposure) |
Confirm cause with oil analysis, correct contributing cause, refresh or change oil as needed |
| C. Completely different color |
1) Wrong oil in use; 2) process chemical contaminating oil; 3) thermal reaction with antioxidant additive (oil is red or purple); 4) glycol contamination |
Confirm cause with oil analysis, correct contributing cause, refresh, flush and/or change oil as needed |
| D. Black (opaque) |
1) Soot (engine oil); 2) Thermal degradation (hot conditions); 3) advanced oil oxidation |
Confirm cause with oil analysis, correct contributing cause, refresh, flush and/or change oil as needed |
| E. Clear and watery |
1) water contamination; 2) wrong oil; 3) chemical contamination |
Confirm cause with oil analysis, correct contributing cause, refresh, flush and/or change oil as needed |
3. Observe Oil Clarity - Observe oil clarity using a bright flash light and/or a laser pointer. Compare to new oil.
| | |
|---|
| A. Oil is clear and bright, same as new oil |
Correct oil condition |
No action required |
| B. Oil has a slight hazy appearance |
1) Entrained air; 2) emulsified water; 3) additive precipitation (dead or insoluble additives); 4) waxy floc; 5) cross contamination (mixed oils) or other contaminants |
Confirm cause with oil analysis, correct contributing cause, refresh, dehydrate, flush and/or change oil as needed |
| C. Oil is cloudy |
1) Entrained air; 2) emulsified water; 3) waxy floc; 4) cross contamination (mixed oils) or other contaminants |
Confirm cause with oil analysis, correct contributing cause, refresh, dehydrate, flush and/or change oil as needed |
| D. Oil is milky |
1) Entrained air; 2) emulsified water; 3) glycol contamination |
Confirm cause with oil analysis, correct contributing cause, refresh, dehydrate, and/or change oil as needed |
| E. Oil appears layered (stratified) |
1) Free water contamination; 2) chemical contamination; 3) glycol contamination; 4) sludge; 5) microbial contamination |
Confirm cause with oil analysis, correct contributing cause, refresh, dehydrate, flush and/or change oil as needed |
4. Appearance of Aeration and Surface Foam - Observe using a bright flash light.
| | |
|---|
| A. No appearance of aeration or foam |
Correct oil condition |
No action required |
| B. Slight to moderate aeration |
1) Wrong oil level; 2) mechanical aeration condition; 3) plunging oil return; 4) excessive tank agitation; 5) suction line leak; 6) poor oil air release properties (oil degradation or contamination) |
Inspect machine for mechanical or operational causes. Inspection oil for oil quality or contamination causes. Correct contributing cause. |
| C. Aeration and moderate foam |
1) Wrong oil level; 2) mechanical aeration condition; 3) plunging oil return; 4) excessive tank agitation; 5) suction line leak; 6) poor oil air release properties (oil degradation or contamination); 7) poor oil foam suppression properties (oil degradation or contamination) |
Inspect machine for mechanical or operational causes. Inspection oil for oil quality or contamination causes. Correct contributing cause. |
| D. Sight glass has thick layer of foam |
A combination of machine and oil condition is occurring. Machine conditions include mechanical agitation, plunging returns, excessive tank turbulence and suction line leaks. Oil conditions include degraded oil properties and contamination (water, chemicals, etc.) |
Inspect for contributing machine conditions. Inspection oil for oil quality or contamination causes. Correct contributing cause. |
| E. Sight glass is full of foam only |
A combination of machine and severe oil condition is occurring. Machine conditions include mechanical agitation, plunging returns, excessive tank turbulence and suction line leaks. Oil conditions include degraded oil properties and contamination (water, chemicals, etc.) |
Inspect for contributing machine conditions. Inspection oil for oil quality or contamination causes. Correct contributing cause. |
5. Rust on Steel Corrosion Gauge - Observe through sight glass using a strong flash light. Rotate sight glass so that corrosion gauge tip is out of the oil for easy inspection.
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| A. No evidence of rust or corrosion |
Oil has healthy rust suppression properties and/or the presence of water and other corrosive agents do not exist |
No action required |
| B. Light rusting (few very small rust spots) |
1) Water contamination; 2) salt water contamination; 3) water and acids. PLUS impaired rust suppression properties of the oil |
Use oil analysis to determine contamination and rust suppression properties. Decontaminate and restore oil properties as required. |
| C. Moderate rusting (numerous and larger rust spots) |
1) Water contamination (mostly free and emulsified); 2) salt water contamination (mostly free and emulsified); 3) moderate water and acids. PLUS moderately impaired rust suppression properties of the oil |
Use oil analysis to determine contamination and rust suppression properties. Decontaminate and restore oil properties as required. |
| D. Severe rusting (greater than 10% of the rods surface is covered by rust) |
1) Water contamination (mostly free and emulsified); 2) salt water contamination (mostly free and emulsified); 3) moderate water and acids. PLUS severely impaired rust suppression properties of the oil |
Use oil analysis to determine contamination and rust suppression properties. Decontaminate and restore oil properties as required. |
6. Tarnish on Copper Corrosion Gauge - Observe through sight glass using a strong flash light. Rotate sight glass so that corrosion gauge tip is out of the oil for easy inspection.
| | |
|---|
| A. No evidence of copper tarnish or corrosion |
Oil has healthy corrosion suppression properties and/or the presence of corrosive agents do not exist |
No action required |
| B. Slight tarnish |
Trace amounts of 1) Active sulfur in base oil and additives (e.g., AW and EP additives); 2) acids and other corrosive agents. PLUS impaired corrosion suppression properties of the oil |
Use oil analysis to determine contamination and corrosion suppression properties. Decontaminate and restore oil properties as required. |
| C. Moderate tarnish |
Moderate amounts of 1) Active sulfur in base oil and additives (e.g., AW and EP additives); 2) acids and other corrosive agents. PLUS moderately impaired corrosion suppression properties of the oil |
Use oil analysis to determine contamination and corrosion suppression properties. Decontaminate and restore oil properties as required. |
| D. Dark tarnish |
Severe amounts of 1) Active sulfur in base oil and additives (e.g., AW and EP additives); 2) acids and other corrosive agents. PLUS severely impaired corrosion suppression properties of the oil |
Use oil analysis to determine contamination and corrosion suppression properties. Decontaminate and restore oil properties as required. |
7. Varnish on Corrosion Gauge or Sight Glass - Observe through sight glass using a strong flash light. Rotate sight glass so that corrosion gauge tip is out of the oil for easy inspection of varnish and deposits.
| | |
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| A. No evidence of varnish or sludge |
Oil is not producing deposits or varnish on machine surfaces. No varnish producing conditions with machine or lubricant. |
No action required |
| B. Slight varnish on corrosion gauge and/or slight glass |
Early stage of 1) oil oxidation; 2) microdieseling; 3) electrostatic discharge; 4) additive dropout; 5) thermal degradation; 6) contamination |
Use oil analysis to confirm varnish potential. De-varnish oil and machine as required. Remediate root cause conditions. |
| C. Moderate varnish on corrosion gauge and/or slight glass |
Moderate stage of 1) oil oxidation; 2) microdieseling; 3) electrostatic discharge; 4) additive dropout; 5) thermal degradation; 6) contamination |
Use oil analysis to confirm varnish potential. De-varnish oil and machine as required. Remediate root cause conditions. |
| D. Heavy varnish on corrosion gauge and/or slight glass, possibly including bathtub rings about oil level |
Advanced stage of 1) oil oxidation; 2) microdieseling; 3) electrostatic discharge; 4) additive dropout; 5) thermal degradation; 6) contamination |
Use oil analysis to confirm varnish potential. De-varnish oil and machine as required. Remediate root cause conditions. |
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8. Wear Debris on Magnetic Plug - Observe oil level in sight glass during normal operation and running temperature.
| | |
|---|
| A. Magnet is clean |
No visible wear debris |
No action required |
| B. Slight “peach fuzz” wear debris on magnet |
Normal to moderate wear from various causes. Depends on machine and application. |
If accumulation is abnormal examine particles on magnet in laboratory for characterization (type, cause, severity). Look for mechanical causes. Perform oil analysis for various contributing conditions. |
| C. Moderate “whisker” accumulate on magnet |
Moderate to severe wear from various causes. Depends on machine and application. |
If accumulation is abnormal examine particles on magnet in laboratory for characterization (type, cause, severity). Look for mechanical causes, hot spots, and vibration. Perform oil analysis for various contributing conditions. |
| D. Heavy debris clumping on magnet |
Severe to critical wear from various causes. Depends on machine and application. |
Examine particles on magnet in laboratory for characterization (type, cause, severity). Look for mechanical causes. Perform oil analysis for various contributing conditions. |
| E. Heavy debris and large particle clumping on magnet |
Critical wear condition |
Examine particles on magnet in laboratory for characterization (type, cause, severity). Look for mechanical causes, hot spots, and vibration. Perform oil analysis for various contributing conditions. |
