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What is Varnish?
Varnish is a thin, insoluble film deposit that is usually found on bearings, reservoirs, and internal components. It is a high molecular weight substance that is insoluble in oil. Varnish insoluble's are more than 80 percent soft contaminants, which are less than 1 micron in size and are not measured by traditional oil analysis. Insoluble compounds have polar affinities and, over time, begin to migrate from the body of the base oil to machine surfaces, based on system and oil conditions. Initially, the surfaces start to show a gold/tan color building to darker gum layers that develop into lacquer. Just like a "cloud", oil has the natural ability to hold oxidation-by-products in suspension. Once the "cloud" is full it rains, this "rain" is the point where varnish deposits start forming on internal metal surfaces of the lubrication system.
How is Varnish Formed?
Varnish formation is a severe reliability issue. All lubricating oils will create insoluble materials given severe and/or unusual operating conditions. These insoluble's create lubricant imbalance due to factors such as heat, oxidation, cross- and chemical-contamination, micro-dieseling, and water contamination. The tendency and speed at which turbine oils produce these products is greatly influenced by the formulation of the product, the stress on the oil, and system contamination levels. These system stresses are heat, water, and contamination, which all accelerate the oxidation process of the oil.
How can I test my oil for Varnish?
Varnish can occur in oils that visually appear healthy and clean, with no visible signs for concern through normal oil analysis. It cannot be identified by the typical in-service turbine oil tests or routine oil analysis. Low total acid number (TAN), a low ISO particle count and a high RPVOT does not guarantee that the lubricant is immune from varnish.
OILKLEEN uses the V-PAK or Varnish Prevention Analysis Kit, which is a series of tests that will determine the level of varnish, soluble varnish, water, particles, and sub-micron contamination in your oil. This test will also measure and monitor the amount of anti-oxidation additives in your oil thus helping you to determine the rate of depletion and the ability for your oil to protect itself against oxidation.
There are many labs out there claiming to have a varnish test kit but only OILKLEEN offers a low cost test kit specifically designed for varnish and then a solution to remove the contamination if present in your oil.
How can I remove Varnish from my system?
OILKLEEN is the developer and manufacture for electrostatic oil cleaners and various other filtration and varnish removal technologies. OILKLEEN electrostatic filtration technology can clean oil to the molecule level and can remove the insoluble sub micron contamination known to cause varnish. Once the varnish is removed from the oil, the clean oil will absorb varnish build up from internal components and metal surfaces, and then the electrostatic filter can remove it. Once the varnish has been stripped from the system and the oil is varnish free an electrostatic oil cleaner should be used as a permanent kidney loop filter, to remove oxidation by products causes by normal operation and thus protecting the oil anti-oxidation additives and extending the life of the oil.
What is Soluble Varnish and how can I remove it?
During the oxidation process there are acidic molecules known as free radicals or "Soluble Varnish". These acidic molecules are soluble at higher temperatures (like during operation) and will precipitate out of the oil during cooler times (like shut downs, or cool spots in the piping that are not circulating oil). The OILKLEEN Electrostatic oil cleaner can remove all varnish build up in system and all the insoluble varnish and particulate in the oil. However, the soluble varnish will precipitate out when the oil is cooled and will show up in the oil. This can be seen in higher numbers on the colorimetric patch test, or cloudiness in the oil when cooled down.
OILKLEEN has developed a patent pending process and a unique blend of acid absorbing resin matrix media in our soluble varnish removal filter that fits in all OILKLEEN electrostatic filter housings. This cartridge has proven acid absorption media that will absorb the soluble varnish and completely remove it from the system in a short period of time. The OILKLEEN computer has a built in soluble varnish removal program that allows you to operate in soluble varnish mode and once completed, then switch back to the OILKLEEN electrostatic filter element for normal filtration and varnish removal. The OILKLEEN system is the only electrostatic system that removes both insoluble varnish, particles to a molecule level, water, and soluble varnish in one single system.
Why are the Anti-oxidation additives important in my oil?
Most OEM oil companies use a mixture of Phenol and Amine type anti-oxidation additives or just a single Phenol type in the formulation of the oil's. During the oxidation process of the oil these will deplete as they do their intended job of fighting the precursors to varnish and oxidation. This is a natural process in the life of a lubricant but can be increased by the addition of heat, oxygen, wear, and water contamination in the oil. This will dramatically increase the rate at with varnish is formed and the life of the lubricant and the effects can be catastrophic on the internal components of you lube system. Once these deplete you cannot replace them!
OILKLEEN uses FTIR to identify these additives in your and compare them to your new oil to determine the current condition of your oil. The OILKLEEN system can protect your anti-oxidation additives by removing the harmful oxidation before it depletes these important additives and dramatically extending the life of your oil and productivity of your equipment.
How can I remove Water from my oil?
OILKLEEN has developed a patent-pending process to remove emulsified and free water from your oil. The OILKLEEN water removal filter is a large stainless steel canister that fits into the housing of any OILKLEEN system giving it the ability to remove water. Most water contamination is the occasional egress of water and can require very expensive machines to remove it. The OILKLEEN water removal filter element has a mixed blend media that actually will actually use coalesce while absorbing water molecules from the oil. This blend of media has the ability to absorb 1000 times its weight and thus remove many gallons of water in a single element. Once the water is removed from the oil then you simply install the electrostatic filter element and go back to normal filtration and varnish removal. OILKLEEN also offers a twin tank design system that will allow continuous water removal and electrostatic filtration at the same time.
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