What are the benefits and challenges of using synthetic lubricants for your applications?

1 What are synthetic lubricants?

Synthetic lubricants are man-made fluids that are designed to have specific properties and characteristics for different purposes. They are usually made from synthetic base oils, such as polyalphaolefins (PAOs), esters, polyglycols, or silicones, and blended with additives, such as antioxidants, anti-wear agents, detergents, or friction modifiers. Synthetic lubricants can offer many advantages over conventional mineral oils, such as higher viscosity index, lower pour point, better thermal stability, longer service life, and improved fuel economy.

2 How do synthetic lubricants degrade?

Like any other lubricant, synthetic lubricants can degrade over time due to various factors, such as oxidation, thermal breakdown, shear stress, water ingress, or additive depletion. Oxidation is the chemical reaction of the lubricant with oxygen, which can produce sludge, varnish, acids, or peroxides. Thermal breakdown is the loss of lubricant properties due to high temperatures, which can cause evaporation, polymerization, or cracking. Shear stress is the mechanical force that reduces the molecular weight and viscosity of the lubricant. Water ingress is the contamination of the lubricant by water, which can cause corrosion, emulsification, or hydrolysis. Additive depletion is the consumption or degradation of the additives that enhance the lubricant performance.

3 How do synthetic lubricants get contaminated?

Synthetic lubricants can also get contaminated by external sources, such as dirt, dust, metal particles, wear debris, fuel, coolant, or other fluids. Contamination can affect the lubricant quality and function, as well as cause damage to the equipment and components. Contamination can be classified into three types: solid, liquid, or gaseous. Solid contamination can be abrasive, cutting, or non-cutting, depending on the shape and size of the particles. Liquid contamination can be soluble, insoluble, or emulsified, depending on the solubility and compatibility of the fluids. Gaseous contamination can be air, nitrogen, or other gases, which can cause foaming, cavitation, or oxidation.

4 How can condition monitoring help?

Condition monitoring is the process of measuring and analyzing the physical and chemical parameters of the lubricant and the equipment to assess their condition and performance. Condition monitoring can help you detect and prevent lubricant degradation and contamination, as well as identify and diagnose any problems or failures. Condition monitoring can also help you optimize your lubricant selection, application, and maintenance, as well as extend your lubricant and equipment life span and reduce your operating costs and environmental impact. Condition monitoring can be done by various methods, such as sampling, testing, analysis, or online sensors.

5 What are the best practices for condition monitoring?

To get the most out of your condition monitoring program, it is important to establish your goals and objectives, such as improving reliability, efficiency, safety, or compliance. You should also choose the right lubricant and equipment for your application and operating conditions. Additionally, you should implement a regular and consistent sampling and testing schedule based on the lubricant and equipment type, age, and condition. Utilizing appropriate testing methods and equipment, such as viscosity, acid number, particle count, water content, or infrared spectroscopy is essential. Furthermore, you should interpret and compare the test results with the baseline and trend data as well as industry standards and guidelines. Taking corrective and preventive actions based on the test results and recommendations is also important. Finally, it is essential to document and communicate your condition monitoring results and actions in addition to evaluating and improving your condition monitoring program.

6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?