Ultrasonic Flowmeters
Water in Oil Monitors
Water in Fuel Monitors
BS&W Water Cut Meters
Inline Static Mixers
Water/Oil Measurement Systems
BS&W Analysis
Oil Centrifuge/Purifier Monitors
Site map / Archive
Research and Development
Articles
News
Home page
corporate solitications
Becoming a distributor or Factory visit
click here>>

Pressure Equipment Directive
   
WATER THAT FORGOTTEN CONTAMINENT IN OIL !

EESIFLO's EASZ-1 measures water in all forms and can report total water contamination at start up and throughout your system's life without changing sensors.

Dissolved water , Emulsions or Free Water. The EASZ-1 water in oil sensor knows where its at!

Whether you are measuring dissolved water in oil i.e water with no visible indication of its presence in an oil or emulsions or free water , the EASZ-1 can report water in all forms because it is an instrument that measures total water contamination.

Most brand new industrial oils such as hydraulic fluids, turbine oils can hold as much as 0.02 to 0.08% of water at start up . This of course is a general figure and depending on the temperature and age of the oil -the aged oils are capable of holding three to four times more water in the dissolved state than new oil.

 WATER - THAT FORGOTTEN CONTAMINENT IN OIL !

The EASZ-1 measurement cell

Should you exceed your normal water in oil levels, the EASZ-1 will keep working up to 25% water in oil without changing /drying sensors. The addition of more water to an emulsified oil/water mixture will lead to a separation of the two phases producing a layer of free water as well as free and/or emulsified oil.. Free water layer is found on the bottom of tanks and sumps. Condensation is always a problem for oil and water is unavoidable . This has led to whole schools of technologies using different principles to remove water normally from the percentage stage down to ppm levels.

This gives enough cause for a device that is able to work within all these parameters whether in higher or lower levels to actually test that a removal system is actually able to work to its specification in real time. The EASZ-1 is a great plus to water removal system manufacturers because it can actually prove that large amounts of water are actually being removed down to lower ppm levels. The sensor cell reacts to changes within seconds and measurements are not highly damped so that it is possible to view tiny intermittent "slugs" of free water in oil that were previously undetectable. The sensor cell has a large surface area and most of the process flow running through it which increases sample area and thus ultimate accuracy.

The EASZ-1 is a measuring device that relates to the permittivity of oil . Although this is not a new concept, it has been possible to greatly improve accuracy and reliability of this technology by using modern day increased stabililty electronics. The problems associated with instability in older technology designs have been overcome through extensive research and development and the total power consumption of the units have been drastically reduced so that it is possible to manufacture a new generation loop powered instrument.

Each unit is normally individually tested with a reference oil before shipment but should site conditions prove otherwise, it is possible to adjust the measurement to a true zero offset with oil of no water content or known water content from Karl Fischer laboratory examinations.
A word about how temperature affects accuracy!

The temperature coefficient is the relationship between temperature changes and capacitance for dry oil or contaminated oil. The coefficient is applied to the measured capacitance per degree Celsius of temperature change. With a built in temperature sensing element, the EASZ-1 is able to detect changes in temperature and compensate values using built in table values within its electronics . This enables the EASZ-1 to maintain its accuracy throughout operating temperature , even if they fluctuate from time to time.

It is always good to take samples and to send them for lab testing. The very fact that most people are still sending oil for water testing through Karl Fischer methods e.g http://www.metrohm.com/ shows that sampling will be around for a long time to come. The day where 100% reliance on online instruments to detect and analyze all the constituents in a process oil has not yet come and probably won't in our lifetime for various reasons which old timers in the industry are well aware of .

WATER - THAT FORGOTTEN CONTAMINENT IN OIL !

There is however a basic need for online reporting of water in oil. Some companies paranoid about water contamination due to uncertainties regarding actual water content have resolved to change oils more often than needed. Regimes to save costs in excessive purchasing new oil and also impending environmental legislations justify the need for online measurements.

Below is a recommendation of oil sampling frequencies. An online water in oil sensor that is economical, accurate and robust, that does not require any maintenance except for possible cleaning over extended periods gives added insurance and peace of mind to end users wishing to report or identity possible sources of problems in lubrication or hydraulic systems.

The online water in oil measurement system gives end users and maintenance personnel added value information of the moisture or water status of the oil between sampling periods since it is not possible to know if a sample has been mishandled by personnel, whether the sample is truly representative or if the lab reports are to be the sole basis of the condition of the oil at all times. It is important to remember that it is probably not prudent to rely only on a "spot sample" taken at one point within an oil system will be able to represent the condition of all the oil that has run through the process at all times. Online sampling/analyzing is becoming more important in all industries as cost savings, preventative maintenance and environmental concerns become the topic of the day.

EQUIPMENT TYPE

TEST PACKAGE

RECOMMENDED SAMPLING FREQUENCY

 

 

 

Diesel engines

Basic with TBN

100 - 500 hours, 3500 - 20,000 miles

Gasoline engines

Basic with TBN

50 - 200 hours, 2000 - 7500 miles

Transmissions

Basic with TAN

30,000 - 100,000 miles

Gears, differentials, final drives

Basic with TAN

30,000 - 100,000 miles

 

 

  Normal Use        Intermittent Use

Hydraulics

Basic with TAN

750 hours or monthly     Quarterly        

Gas turbines

Basic with TAN

750 hours or monthly     Quarterly        

Steam turbines

Basic with TAN

1500 hours or bimonthly Quarterly          

Air or gas compressors

Basic with TAN

750 hours or monthly     Quarterly        

Refrigeration compressors

Basic with TAN

Quarterly                           

Natural gas engines

Basic with TAN

750 hours or monthly                            

Gears and bearings (industrial)

Basic with TAN

1500 hours or bimonthly Quarterly         

Fig. 1.1 Typical Frequency for sampling of oil

In a lubricating system, the two most harmful phases of water are free water and emulsified water. It is reported that little as one percent water in oil can reduce the life expectancy of a bearing by as much as 90 percent. Under certain conditions, water molecules can be ripped up into their constituent oxygen and hydrogen atoms as a result of the high pressures generated in the load zone of a rolling element bearing. Due to their relatively small size, the hydrogen ions produced by this process can absorb onto the surface of the bearing raceway resulting in a phenomenon known as hydrogen embrittlement. Hydrogen embrittlement is caused by a change in subsurface bearing metallurgy.

This change causes the bearing material to become weak or brittle and prone to cracking beneath the surface of the raceway. When these subsurface cracks spread to the surface, the result can lead to pitting and spalls. The effects of free and emulsified water are more harmful compared to dissolved water, a general rule of thumb is to ensure that moisture levels remain low and every reasonable effort should be made to keep water contamination as low as possible.

Measuring online Water in Oil with the EASZ-1

Whatever method you use to determine water levels, one thing is certain that water is a major cause of lubricant failure, component failure and poor machine reliability. Like all contaminants, it is important not only to recognize its presence, but also to take steps to control or eliminate the source of water ingression. If possible, water levels in all equipment should be kept as low as possible .Whether you choose to install desiccant style breathers, improve seals, or to use a centrifugal filter or a large vacuum dehydration unit, reducing the level of water in all types of equipment can dramatically extend the life of the lubricant and the machine.

We would like to hear from you and are happy to see how the EASZ-1 fits into your maintenance and reporting plans .For more information on EESIFLO's EASZ-1 water in oil monitor please contact your local EESIFLO distributor or log onto www.eesiflo.com

Vehicle Lubricants Commercial & Industrial Lubricants Automotive Chassis/Bearing Greases Barrier Seals Chain Oils Commercial Vehicle Chassis/Bearing Lubes Compressor Oils Coolants Coupling Lubes Cutting Fluids Electric Motor Lubes Engine Oils Automotive Engine Oils-Diesel Gear Lubes General Purpose Greases Heat Transfer Oils Heat Treating Oils Hydraulic Oils Machine Tool and Way Oils Mist Oils Mobile Equipment Chassis/Bearing Greases Oil Filters - Diesel Engines Oven Lubes Paper Machine Lubes Pneumatic System Oils Pump Lubes Railroad Lubes Refrigeration Oils Rolling Mill Oils Rust Preventives Saw Guide Oils Spindle Oils Steam Cylinder Oils Transmission, Differential & Final Drive Oils Turbine Oils