s Defense Technical Information Center oR Compilation Part ...

1 S Defense Technical Information CenteroR Compilation Part Notice4fTMENT o-This paper is a part of the following report:STitle. Technology Showcase: Integrated Monitoring, Diagnostics and& of a Joint Conference, Mobile, Alabama, April 22-26, 1996."* To order the complete Compilation report, use: AD-A325 558 The component part is provided here to allow users access to individually authored sectionsof proceedings, annals, symposia, etc. However, the component should be considered withinthe context of the overall Compilation report and not as a stand-alone Technical S-atement A:This document has been approved for publicrelease and sale, its distribution is 711iaon or The Dtfense_9712 w3 iESTIMATING WATER CONTENT IN OILS:MOISTURE IN SOLUTION, EMULSIFIED WATER, AND FREE Ray Garvey and Grahame FogelComputational Systems Incorporated, 835 Innovation Dr, Knoxville, TN 37932 Abstract: This paper discusses the detrimental effects of moisture in lubricants, hydraulics, andtransformer oils.

2 It describes a means for automatic estimation of moisture content in lubricatingoils, hydraulic fluids, and transformer oils. This is a field test method, used as an alternative whenit is not convenient to measure water content by the Karl Fisher test or another analytical total moisture content is found to be the sum of three separate measurements: moisture insolution, water, and free water. A single capacitive sensor is used to mak all threemeasurements. Moisture in solution is instantaneously measured from a well mixed contaminatedoil sample as compared to a similar measurement for a clean reference oil sample. Emulsifiedwater is measured by determining the median-average rate of change in sensor output over water is measured by determining the accumulation of step changes in sensor output overtime.

3 The capacitive sensor is also used to identify the general oil type based upon the nominaldielectric value and upon the change in dielectric as a function of temperature Words: Additive, dielectric, emulsified, moisture, oil, proactive, synthetic, waterBackground: The measurement of moisture in lubricants, hydraulics, and transformer fluidsusing an automatic in-shop device is a valuable capability for industrial plant maintenancedepartments. Following is a list of some advantages for doing analysis on site:* ownership and control;* immediate results with immediate retest when needed;* testing by people who know most about machinery; data is electronically stored with no transfer between lab and user; and test incoming fluids, with ability to fix problems, and verify adage that "oil and water don't mix" is not entirely true.

4 They do mix, to a greater or lesserextent, depending on oil base stock and additives. This paper addresses a method for evaluatingwater content, considering that water can either be in solution with the lubricant, emulsified withthe lubricant, or carrying ftee water droplets in the lubricant. Before introducing themeasurement methods, one should understand the answers to these questions.* What are the functions of a lubricant? a hydraulic? a transformer oil?* What are the effects of moisture in these fluids?, In what forms does water exist in the oil?* What are the effects of water on lubricant additives?tIThe answers to these important questions establishes the need to not only measure total watercontent, but to identify what amount is in solution, emulsion, or free of a Lubricant, Hydraulic, or Transformer: Lubricating oils serve multiplefunctions in mechanical systems.

5 They reduce friction in each of the threp lubrication regimesdepending on application type: hydrodynamic, elestohydrodynamic (EHD), and applications with conformal bearings, such as Babbitt bearings, the lubricant transfersdistributed loads, in the form of radial pressure, from shaft to sleeve. This regime is referred to ashydrodynamic lubrication and is similar to hydroplaning of an automobile on wet pavementFor highly loaded anti-friction bearings and gears, the viscosity of the lubricant must increaseexponentially under the pressure due to lubricant being forced bl /een the rolling element andthe raceway. The lubricant viscosity increases until the oil has the bulk elastic modulus of a solid,and is able to transmit highly concentrated loads.

6 Elastohydrodynamic lubrication practicallyeliminates metal to metal contact with extremely low frictional energy traction type applications such as slides and wheels, the lubricant serves to reduce wear dueto sliding contact and abrasion. In this case the physical loads are transmitted through-metal-tometal contact. The traction or friction in this type of system can be very high, with coefficient ofsliding friction as high a 1/3 of the normal force that presses the two components together. Thefriction, wear, and traction can be greatly reduced by lubricating the surface(s) so that only alimited amount of shear can be transmitted between components. This can be done with eithersolid lubricants (molybdenum disulfide or graphite) or with liquid lubricants including extremepressure and anti-wear addition to these requirements for transferring loads, reducing friction, and minimizing wear,lubricants fulfill several other functions critical to machine life.

7 These include sealing surfacesfrom corrosion, nd other forms of chemical attack, transmitting hydraulic power, leaning awaycontaminants and wear debris, cooling hot surfaces, and isolating (electrically) dissimilar metalsfrom gal v,,aic interaction. In the special case of transformer applications, oil provides cooling andelectrical isolation ( , a low dielectric medium).Effects of Water on Lubricants, Hydraulics, and Transformer Oils: Moisture is deleteriousto most mechanical systems, hydraulic systems, and transformers. It causes problems byrendering the oil additives ineffective, by corroding metal surfaces, and by incapacitatingelastohydrodynamic (EHD) chemically reacts with many oil additives thereby disabling their ability to provideantiwear, anti-oxidation, extreme pressure (EP), anti-foaming, and detergency also consumes all or part of the dispersant and emulsifier additives intended to preventcontaminants from coalescing or is well known that moisture promotes corrosion of metal surfaces.

8 Water is a reactive speciesat room temperature, especially towards metals. Typically metals under ambient conditions and contain an oxide coating. However, metals that are under stress or wear mayproduce a "fresh" surface that is highly reactive. For example, a scratch or crack exposes metalresulting in the following reaction:M+ 1120 ->MO+ H2In this reaction the electron rich oxygen atom reacts with the electron deficient metal to form anew compound. The metal forms a new oxide coating and produces hydrogen gas. Dependingori the metal (or alloy) present, the hydrogen may diffuse along grain boundaries, causing an effectknown as hydrogen embrittlement, which accelerates wear polar nature of the water molecule supports ionic mobility and encourages chemical attack tocopper, lead, and other reactive metal surfaces, particularly in the presence of air and water.

9 Italso supports electrochemical interaction between galvanically dissimilar oil wetted metal partsleading to rL. * mentioned earliL,, EHD lubrication depends on the unique pressure-viscosity property ofmineral oils and synthetic lubricants. Free water droplets are unable to maintain physicalseparation between rollingelements or between gear teethurnder these extremely high WATER & BEARING LIFE pressures. The resulting impacts BASED ON 100% LIFE AT % WATERcan cause surface damage andshortened component life. w 250uL_ 200 ..-Water contamination of the lube 0 150or hydraulic oils shortenscomponent and machine life. 100 Timken Bearing Company report m 50 ---orn the effect of water on bearing.

10 _-----------life as shown on the attached 0 0 Notice that reducing PERCENT WATER water contamination from Figure 1.(100 ppm) to or (25 __1ppm) increases bearing life by afactor of times!The Form(s) of Water in Oil: There are three forms or states in which water is found whencombined with oil. The water can be dissolved in the oil in the sense that it is hydrated, dissolvedor reacted with additives tlhat are mixed with the oil. In another state, oil can be dispersed oremulsified with the oil. Finally, it can be independently stratified or mixed as free water dropletswhich are separate from the oil. Each of these damages the oil and the mechanical system in adifferent dissolved in the oil consumes performance enhancing additives and promotes corrosion.