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When we think of contamination in lubricated systems, we often focus on particle and water contamination. The fact of the matter is that there are many other
contaminants we should consider and attempt to control. Most contaminants, which include any material not contained in the lubricant's formulation, can potentially
damage the oil and the lubricated components. Although air is always present in lubricating oil, it is often justifiable to adopt measures to minimize its presence.
Air can exist in oil in three different states: dissolved, entrained and foam. Air dissolved in oil exists as individual molecules which are similar to CO2 dissolved in soda
water. This type of air is invisible and impractical to detect. Entrained air in oil is comprised of tiny air bubbles suspended in the oil. This type of air contamination is
arguably the most damaging, and can be identified by the oil having a cloudy appearance. Although there are several common causes for cloudy oil, this can be
identified by taking a sample of the oil and observing whether or not it clears up over time.
If the cloudiness was caused by water or another liquid contaminant, an aqueous layer should form as the sample clears. Foam is the other common type of air in oil.
Foam typically refers to the stable layer of relatively large bubbles that accumulate at the surface of a reservoir. In some systems, foam at the surface may not cause a
lot of damage, but the presence of a foam layer normally indicates extensive air entrainment.
Other causes include loss of antifoam additives, suction leaks, poor reservoir design, using the wrong viscosity or using too much antifoam additive. Under certain
circumstances, antifoam additives can be abnormally depleted. This often prompts users to add defoamant to a system and creates the opportunity to add too much.
Use caution and follow the proper guidelines when attempting to re-additize the oil.
In machine environments where dramatic pressure changes occur, such as a hydraulic pump, the dramatic and instantaneous volumetric change causes bubbles to
implode violently, which leads to erosion of machine surfaces. In hydraulics, entrained air can create other problems as well, such as spongy operations, loss of controls
and an increased likelihood of surface deposits in valves.
If a system has a history of foaming problems, it may be an ongoing problem of contamination or a system design issue. Some common reservoir problems that lead to
foam are using a sump that is too small, having oil return lines that terminate above the oil level causing mixing, or having suction and return lines in close proximity.
These problems can sometimes be addressed by using diffusers, installing baffles, or using plates or screens for gravity-return systems.
As I mentioned before, it may be impossible to completely eliminate air from lubricated systems, but steps should be taken to reduce it as much as can reasonably be
expected. Eliminating excessive air will likely give more life to your oil, improve system performance, and reduce wear and deposits. Remember, contamination control
is not just about filtering out dirt. It involves excluding and removing any foreign material from the system.