Measurement Expertise for Moisture in Oil Condition Monitoring
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Measurement Expertise for Moisture in Oil Condition Monitoring

By 19/07/2022July 21st, 2022No Comments

Protecting Your Machinery & Equipment From Moisture

Industrial oils play an important role in many industries. They are applied to improve the performance of industrial machinery and equipment and protect them against damage during operation. There are different types of industrial oils and their classification is based on their origin and composition. Moreover, these points also determine some of the most important properties of the oil. Together with the system of additives used in their formulation, they further impact their application.

Water contamination in industrial oils can cause severe issues with machinery components. The presence of water can alter the viscosity of a lubricant as well as cause chemical changes resulting in additive depletion and the formation of acids, sludge, and varnish. Water testing is always a part of any lubricant condition monitoring program. Water contamination in industrial oils with strong water separation properties has been historically difficult to measure with any technique. Many things can go wrong in an industrial facility – bearing failure, wear of moving mechanical parts, heat damage caused by friction, foaming, sludge creation, metallic corrosion, and additive depletion. Each of these particular consequences can be traced back to the presence of water in lubrication. Root cause analysis is imperative to steady operation at any facility, but preventative measures are also crucial. Understanding the causes of failure and the steps to avoid them is at the heart of efficient processing.

Dpstar’s unique moisture in oil measurement monitors the water activity of the oil continuously and online, which directly indicates the margin to free water formation in the oil. Unlike traditional sampling methods, which can take days or weeks to produce test results, Dpstar’s continuous measurement ensures reliable equipment performance at all times.  With over 30 years in providing capacitive moisture sensors for gas and oil, Dpstar has become the veritable industry standard and the market leader in protecting critical equipment, from heavy machinery to hydraulic systems to power transformers. Dpstar supplies the latest technology and instrumentation, designed to gauge compliance with each customer’s defined goals. A full range of measurement approaches fulfills the quality assurance needs of manufacturers.

Causes & Problems Of Moisture In Oil

Moisture is a known contaminant in a wide variety of applications and processes, but the presence of moisture in industrial use oil can be particularly detrimental. Affecting the quality and performance of the oil, water is known to increase viscosity and cavitation. It also degrades additives and film strength and presents the opportunity for biological contamination and corrosion. No matter the engine, gearbox, turbine, or bearing type, in-service lubricant oils are designed to accommodate heavy compressibility while remaining chemically inert and unreactive. It is essential that the oil’s viscosity remains unchanged and free of contaminants to prevent costly wear on the engine. We have all heard the saying, “oil and water don’t mix.” Unfortunately, that doesn’t necessarily apply to lubrication oils. Water can exist in several states in lubrication oils and can cause damage to valuable assets if left unchecked. Among the most common oils found in industry, lubrication oil is the largest segment. Its importance is derived from its essential role in machine functionality and reliability.

Some of the applications most susceptible to water contamination include:

Pulp & Paper
Transmission fluid
Maritime
Turbine Operation
Lubrication oil
Hydroelectric Generation 

Water Contamination

Water accounts for a major part of mechanical failures. In some heavily water-contaminated oil systems e.g. in the paper industry, water is the predominant cause of failing components. Water reduces the lubricity of the oil, due to the lower viscosity and poor load capacity of water. When water is exposed to the high pressures found in load zones e.g. bearings and gears, the water droplets collapse (implode). The resulting micro-jets create micro-pitting in metal surfaces and can even result in metal-to-metal contact when water vapor pushes the oil away momentarily. Free hydrogen ions in the water can further worsen the situation since they migrate into machine components making steel brittle and prone to crack. Water also results in corrosion and erosion leading to pitting damage. Furthermore, water acts as a catalyst for oil degradation, speeding up the oil’s tendency to oxidize and form resins, sludge, and varnish.

Water contamination in oil can be categorized into three forms of water; Dissolved, Emulsified and Free water each of which causes its own direct and indirect problems to the engine.

  • Dissolved water: water molecules dispersed one by one throughout the oil; like humidity in air.
  • Emulsified water: microscopic globules of water dispersed in stable suspension in the oil; like fog in the air.
  • Free water: water that readily settles to tank/sump bottom; like rain.

Cavitation & pitting: Occurs in areas where water is present and oil is compressed; the water implodes, causing the metal surfaces to crack and release more particles.

Causes & Problems Of Moisture In Oil

Moisture is a known contaminant in a wide variety of applications and processes, but the presence of moisture in industrial use oil can be particularly detrimental. Affecting the quality and performance of the oil, water is known to increase viscosity and cavitation. It also degrades additives and film strength and presents the opportunity for biological contamination and corrosion. No matter the engine, gearbox, turbine, or bearing type, in-service lubricant oils are designed to accommodate heavy compressibility while remaining chemically inert and unreactive. It is essential that the oil’s viscosity remains unchanged and free of contaminants to prevent costly wear on the engine. We have all heard the saying, “oil and water don’t mix.” Unfortunately, that doesn’t necessarily apply to lubrication oils. Water can exist in several states in lubrication oils and can cause damage to valuable assets if left unchecked. Among the most common oils found in industry, lubrication oil is the largest segment. Its importance is derived from its essential role in machine functionality and reliability.

Some of the applications most susceptible to water contamination include:

Pulp & Paper
Transmission fluid
Maritime
Turbine Operation
Hydroelectric Generation 
Lubrication oil

Water Contamination

Water accounts for a major part of mechanical failures. In some heavily water-contaminated oil systems e.g. in the paper industry, water is the predominant cause of failing components. Water reduces the lubricity of the oil, due to the lower viscosity and poor load capacity of water. When water is exposed to the high pressures found in load zones e.g. bearings and gears, the water droplets collapse (implode). The resulting micro-jets create micro-pitting in metal surfaces and can even result in metal-to-metal contact when water vapor pushes the oil away momentarily. Free hydrogen ions in the water can further worsen the situation since they migrate into machine components making steel brittle and prone to crack. Water also results in corrosion and erosion leading to pitting damage. Furthermore, water acts as a catalyst for oil degradation, speeding up the oil’s tendency to oxidize and form resins, sludge, and varnish.

Water contamination in oil can be categorized into three forms of water; Dissolved, Emulsified and Free water each of which causes its own direct and indirect problems to the engine.

  • Dissolved water: water molecules dispersed one by one throughout the oil; like humidity in air.
  • Emulsified water: microscopic globules of water dispersed in stable suspension in the oil; like fog in the air.
  • Free water: water that readily settles to tank/sump bottom; like rain.

Cavitation & pitting: Occurs in areas where water is present and oil is compressed; the water implodes, causing the metal surfaces to crack and release more particles.

Free Water Formation – The Critical Point

Water can dissolve in oil. When the water content of the oil increases, it eventually reaches the saturation point of the oil. Once the fluid has reached its saturation point, any additional water introduced will separate out as free water by forming a distinct layer. Alternatively, the oil can form dispersion with water, which turns the oil cloudy. Since most oils are less dense than water, the water layer will usually settle below the oil with time.

Free water formation is critical in terms of problems related to water in oil. When water is no longer dissolved in the oil, corrosion and wearing of equipment increase rapidly. Therefore, it is important to keep the moisture content safely below the saturation point. The ability of oil to hold dissolved water depends on the type and age of the oil as well as its additives. Two major factors have an effect on the saturation point as the oil ages:  temperature fluctuations and changes in the chemical make-up due to the formation of new substances as by-products of the chemical reactions.

Almost every fluid has the ability to hold a certain amount of dissolved water – and acceptable amounts of water for a process depend on the application and oil type. The maximum it can hold is called the saturation point. Once the fluid reaches its saturation point, additional water separates out as free water. Because most oils are less dense than water, the free water will settle below the oil. Oil’s saturation point is a function of the composition of its base stock (mineral or synthetic) as well as the type of additives, emulsifiers, and antioxidants present. The saturation point is also dependent on the age of the oil and its reaction to fluctuations in temperature and changes in chemical composition caused from by-products.

Benefits of Regular Oil Analysis

Lubrication plays such a vital role in keeping your plant running its best, taking proper care of your lube system means you are caring for your entire plant’s operations. Performing regular oil analyses on your lubrication system provides valuable insights into the operating levels of your machines and the lubricant running through them. Without proper and consistent analysis, you are leaving the efficiency of your equipment to chance.

Benefits of Regular Oil Analysis

Lubrication plays such a vital role in keeping your plant running its best, taking proper care of your lube system means you are caring for your entire plant’s operations. Performing regular oil analyses on your lubrication system provides valuable insights into the operating levels of your machines and the lubricant running through them. Without proper and consistent analysis, you are leaving the efficiency of your equipment to chance.

Detailed Breakdown of Lubricant Performance

This overview can pinpoint problem areas based on contaminant type and indicate what problems may arise from the contamination. Certain metals, such as aluminum and iron, may indicate piston or cylinder damage. Water or antifreeze leaks cause major issues down the line, specifically putting strain on the whole machine as it tries to push the thickened oil through. Detection of water can also be indicative of broken seals or that the equipment is not running at the optimal temperature.

Find Problems Before They Occur

With consistent oil testing, small issues can be identified and dealt with before they become big problems. Improper filtration causes multiple issues for your machines that can lead to extensive and expensive repairs. Pin-pointing potential problem areas can save time and money when you can stop problems in their tracks.

Fewer Repairs & Less Down Time

Most big problems with machinery start small and grow increasingly worse over time. Through regular oil analyses, high levels of wear metal that signal internal parts breaking down can be detected early. By regularly analyzing the lubricants in your machines, you will catch issues earlier and be able to fix problem areas quickly and efficiently before extensive repairs and unplanned downtime are needed.

Longer Lasting Equipment & Cost Savings 

Early detection through oil analysis is not only useful for preventing large repair bills or loss of production, but it can also improve the overall operating status of your equipment and help your machinery last longer. Better running, longer-lasting equipment means fewer repairs over the life of the equipment and less frequent replacement of component parts in your equipment.

Sampling Versus Continuous Measurement

Detecting water is key to preventing oil from exceeding design limitations, especially when continuous lubrication is a must. Component wear and jamming become critical issues and can cause damage, capital loss, and jeopardize the safety of personnel.

Manual sampling is time-consuming, costly, and inefficient, particularly when real-time monitoring provides better insight into changing conditions. Continuous monitoring offers several improvements over manual monitoring for lubrication, fuel and hydraulic oils, diesel, and any oil-based fluid.

Monitoring Methods

Sample-based (off-line) monitoring in a laboratory (the traditional way) Continuous (real-time) measurement
• Measurement data cannot be used for control
• Hard to predict failures
• Human error
• Temperature changes can affect results
• Suitable for long-term trend observations		 • Can be in the mainstream (in-line) or side stream
• Can be connected to automation systems or dryers
• Representative of temperature conditions that affect solubility
• No user dependence

Sampling Versus Continuous Measurement

Detecting water is key to preventing oil from exceeding design limitations, especially when continuous lubrication is a must. Component wear and jamming become critical issues and can cause damage, capital loss, and jeopardize the safety of personnel.

Manual sampling is time-consuming, costly, and inefficient, particularly when real-time monitoring provides better insight into changing conditions. Continuous monitoring offers several improvements over manual monitoring for lubrication, fuel and hydraulic oils, diesel, and any oil-based fluid.

Monitoring Methods

Sample-based (off-line) monitoring in a laboratory (the traditional way) Continuous (real-time) measurement
• Measurement data cannot be used for control
• Hard to predict failures
• Human error
• Temperature changes can affect results
• Suitable for long-term trend observations		 • Can be in the mainstream (in-line) or side stream
• Can be connected to automation systems or dryers
• Representative of temperature conditions that affect solubility
• No user dependence

Advantages of Vaisala’s Thin-Film Polymer Technology

Knowing the concentration of dissolved water relative to the oil’s saturation point is the best indicator to predict when the oil and water will begin to separate. This information can be used to detect water ingress problems, trigger maintenance events and oil replacement intervals. Detecting the dangerous accumulation of water in oil begins with reliable and accurate measurement. Only direct inline measurement with a capacitive polymer sensor offers real-time information. These inline measurements provide continuous data that can be acted upon quickly to prevent harmful conditions. Access to this information provides a measurable return on investment with energy savings, preventative maintenance scheduling and fault indication.

Vaisala moisture in oil transmitters feature the HUMICAP® sensor, a capacitive thin-film polymer sensor developed for demanding moisture measurements in liquid hydrocarbons.  The HUMICAP® sensor consists of four functional layers: glass substrate, lower electrode, water-active polymer layer, and porous upper electrode. The thin film polymer both absorbs and releases water as the surrounding moisture level changes. Water molecules move into and out of the polymer layer until a moisture equilibrium between the polymer and the oil is reached. Variations in moisture level prompt the dielectric properties of the polymer film to change, causing the capacitance of the sensor to also change. The instrument’s electronics measure the capacitance of the sensor and convert it into a water activity measurement. The upper electrode prevents any oil, additives or particulates from penetrating through to the polymer, allowing it to only measure the water molecules ensures that measurement is independent of the oil type.

The water activity (0…1) or Relative Saturation (0…100%RS) measurement is independent of oil type, additives, age, and temperature. With this measurement, there is no need for oil specific correction tables.  Vaisala’s moisture in oil transmitters utilize the HUMICAP® sensor specifically designed for oil, and use the same principle as other Vaisala humidity products. There is no need for special reference oil or calibration as the sensor can be calibrated against widely used relative humidity standards. References such as saturated salt solutions, handheld humidity meters, or humidity generators can be used. Just like the measurement, calibration is independent of oil type.  Vaisala’s moisture in oil transmitters provide continuous measurement so there is no need to send samples to a testing laboratory, where the risk of contamination is much higher.

Unique Benefits of Vaisala HUMICAP

Advantages of Vaisala’s Thin-Film Polymer Technology

Knowing the concentration of dissolved water relative to the oil’s saturation point is the best indicator to predict when the oil and water will begin to separate. This information can be used to detect water ingress problems, trigger maintenance events and oil replacement intervals. Detecting the dangerous accumulation of water in oil begins with reliable and accurate measurement. Only direct inline measurement with a capacitive polymer sensor offers real-time information. These inline measurements provide continuous data that can be acted upon quickly to prevent harmful conditions. Access to this information provides a measurable return on investment with energy savings, preventative maintenance scheduling and fault indication.

Vaisala moisture in oil transmitters feature the HUMICAP® sensor, a capacitive thin-film polymer sensor developed for demanding moisture measurements in liquid hydrocarbons.  The HUMICAP® sensor consists of four functional layers: glass substrate, lower electrode, water-active polymer layer, and porous upper electrode. The thin film polymer both absorbs and releases water as the surrounding moisture level changes. Water molecules move into and out of the polymer layer until a moisture equilibrium between the polymer and the oil is reached. Variations in moisture level prompt the dielectric properties of the polymer film to change, causing the capacitance of the sensor to also change. The instrument’s electronics measure the capacitance of the sensor and convert it into a water activity measurement. The upper electrode prevents any oil, additives or particulates from penetrating through to the polymer, allowing it to only measure the water molecules ensures that measurement is independent of the oil type.

The water activity (0…1) or Relative Saturation (0…100%RS) measurement is independent of oil type, additives, age, and temperature. With this measurement, there is no need for oil specific correction tables.  Vaisala’s moisture in oil transmitters utilize the HUMICAP® sensor specifically designed for oil, and use the same principle as other Vaisala humidity products. There is no need for special reference oil or calibration as the sensor can be calibrated against widely used relative humidity standards. References such as saturated salt solutions, handheld humidity meters, or humidity generators can be used. Just like the measurement, calibration is independent of oil type.  Vaisala’s moisture in oil transmitters provide continuous measurement so there is no need to send samples to a testing laboratory, where the risk of contamination is much higher.

Unique Benefits of HUMICAP

Robust Reliability

  • Accurate water saturation and PPM measurements in rapidly changing conditions.
  • All equipment comes with NIST or Accredited calibration and is field calibratable.
  • No moving parts in transmitters.

Long-term stability

  • Thin film polymer sensor designs protect from contamination and are highly selective to water only.
  • Capacitive technology provides long term stable measurement.
  • Insensitive to additives or contaminants in oil.
  • Auto-recovery from full saturation.

Rapid Response

  • In situ, real time measurement of moisture in oil as true relative saturation (%RS).
  • Eliminates need for sampling and lab analysis for moisture.
  • Easy installation via ball valve.
  • Installable even in energized transformers.

Why Choose Dpstar?

Dpstar is Vaisala official distributor in Malaysia specializing in humidity, temperature, dew point, carbon dioxide (CO2), biogas quality, moisture in oil, continuous data logging, continuous monitoring, dissolved gas analysis, hydrogen peroxide, pressure, and etc. Our goal is to provide you with products and services that best fulfill your needs – we do this through a holistic mix of performance, reliability, and convenience. Dpstar has become the market leader with over 30 years of experience providing Capacitive Moisture Sensors for the direct measurement in oil across multiple industries. Dpstar brings best-in-class value based on scientific innovation and industry leadership to our customers every day. Our unique approach to moisture in oil measurement allows users to monitor the water activity of the oil in real-time, which directly indicates the margin to free water formation in the oil. Unlike traditional sampling methods, which can take days or weeks to produce test results, Dpstar’s continuous measurement ensures reliable equipment performance at all times. Time-consuming sampling and laboratory analysis are no longer needed. This not only reduces the risk of human-induced error but also provides cost savings in equipment and chemicals.

Online measurement enables you to schedule service intervals and prevent unscheduled downtime supporting your preventive maintenance programs. It also reduces the risk of failures to critical and expensive machine parts, while requiring the activation of oil drying systems only when necessary. This is especially important in applications where the consequences of water contamination are high, such as turbines, marine engines, and paper mills.

Why Choose Dpstar?

Our goal is to provide you with products and services that best fulfill your needs – we do this through a holistic mix of performance, reliability, and convenience. Dpstar has become the market leader with over 30 years of experience providing Capacitive Moisture Sensors for the direct measurement in oil across multiple industries. Dpstar brings best-in-class value based on scientific innovation and industry leadership to our customers every day. Our unique approach to moisture in oil measurement allows users to monitor the water activity of the oil in real-time, which directly indicates the margin to free water formation in the oil. Unlike traditional sampling methods, which can take days or weeks to produce test results, Dpstar’s continuous measurement ensures reliable equipment performance at all times. Time-consuming sampling and laboratory analysis are no longer needed. This not only reduces the risk of human-induced error but also provides cost savings in equipment and chemicals.

Online measurement enables you to schedule service intervals and prevent unscheduled downtime supporting your preventive maintenance programs. It also reduces the risk of failures to critical and expensive machine parts, while requiring the activation of oil drying systems only when necessary. This is especially important in applications where the consequences of water contamination are high, such as turbines, marine engines, and paper mills.

Products Solutions

Relative Humidity (RH), Temperature (T) Measurement

Browse our selection of measuring and monitoring instruments designed and manufactured for optimum reliability, accuracy, and durability.

Vaisala Indigo200 Series Transmitters 

Vaisala Indigo500 Series Transmitters 

Vaisala Moisture In Oil Probe MMP8

Vaisala Handheld Moisture & Temperature Meter for spot-checking in oil MM70

Moisture & Temperature in Oil Transmitter Series MMT330

Vaisala Moisture & Temperature Transmitter for Oil MMT162

Achieving Maximum Productivity Of Your Industrial & Manufacturing Operations

Industrial oils provide lubrication to industrial machinery and equipment and in that way support heavy-duty operations. Industrial oils are designed to withstand tough operating conditions which include high temperatures and pressure and heavy loads. In addition, they possess long-term stability, efficiency, and extended service life which also matches the requirements of demanding industrial settings. Thanks to HUMICAP® sensor technology that offers long-term stable and precise measurements that you can trust, no matter how robust the application, these sensors are able to protect machines and machine parts against wear and tear, oxidation, rust, corrosion, deposit formation, sludge, and surface damage or degradation.

Get In Touch With Our Experts Today!

Dpstar Group
No 35, Jalan OP ½, Pusat Perdagangan One Puchong,
Off Jalan Puchong, 47160 Puchong,
Selangor Darul Ehsan, Malaysia.
Email: [email protected]

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