In our biomedical research application, we rely on Busch R5-400 vacuum pumps. Initially, our mechanics used Castol Tection 15W-40, a diesel engine oil, in the pumps which proved to be unsuitable due to its high-detergent multi-viscosity properties. Following our recommendation, they switched to the suggested oil, Busch R-590. Despite claims that the oil had turned to sludge in the past, Busch assured us this was not possible. However, upon reverting to Busch R-590, the oil thickened and eventually solidified, leading to pump failure. Suspecting a reaction between a solvent in the labs and the oil, we transitioned to CPI Engineering CP-9016-100 oil, a hydrotreated parrafin without additives. While initially performing better than the Busch oil, it too is now exhibiting signs of solidification after just 2 months of use. Has anyone encountered this issue before or have insights on which solvent may be causing it? Any recommendations for an alternative oil? Regular oil analysis has revealed peaks in both the Busch and CPI oils before solidification. These pumps operate continuously for approximately 12 hours daily before being shut down until the following day. - Rich Wurzbach, Maintenance Reliability Group
If the Castrol Tection is providing positive results, why not stick with it? Is there a way to conduct laboratory analysis on the sticky black substance to determine the solvent used?
The Castrol Tection Extra 15W-40 oil is experiencing issues due to its high-detergent multi-viscosity properties. The detergents in the oil are causing clogs in the oil coalescing filters, leading to oil passing through the filters and potentially carrying over lighter base oil fractions. This results in an increase in oil viscosity over time, leading to higher operating temperatures and wear levels. To address this issue, considering switching to a non-detergent, single viscosity motor oil may be beneficial. However, it is important to understand the root cause of the solidification of the oil and choose a product specifically formulated for optimal performance in these conditions. Analyzing the sludge in the oil is proving to be a complex task as it involves a mixture of various organic compounds that have oxidized or reacted chemically. Switching to a full synthetic oil, such as a polyalphaolefin (PAO), may improve performance by reducing the presence of residual refining byproducts that could be contributing to the solidifying effect. Overall, seeking input from others who have experienced similar issues and their solutions, as well as conducting further analysis in the lab, will help in making an informed decision on selecting the right oil for optimal performance. Your thoughts and suggestions are welcome. - Rich Wurzbach Maintenance Reliability Group.
When using Busch R5-400 vacuum pumps with Busch R-590 oil, it is likely that the manufacturer would recommend their own 15W-40 oil in a Busch container. However, it appears that there is contamination in the circulating oil of the pump. If the vacuum pump is a rotary vane type, it is important to consider the following factors: increase the frequency of oil changes (ideally less than every 2 months), minimize topping up to prevent dirt from entering the system and avoid over-lubrication which can lead to increased heat and quicker oil breakdown. Installing an external oil filtration system may be beneficial for larger quantities. In a recent article, gearbox issues were identified due to ash entering the system, causing oil thickening. It may be necessary to improve the oil cooling system or check for a faulty oil return valve. Considering the oil consumption of the pump as per its operating principle, transitioning to a synthetic oil could be a costly investment. For more information on Busch vacuum pumps, visit: http://www.buschpump.com/busch2004/pump-r5/operating-principals.htm.
While I haven't personally used the R5 models, I have had experience with other Busch products. Upon reviewing the maintenance manual, I was surprised to find that the oil in these machines needs to be changed every 1000 hours, which is quite frequent for a running machine. In comparison to my other machines running at 3600 rpm, this stands out as an outlier. Following Steven's advice, I opted to install an external lubrication system with a filter and cooler after facing repeated seal and bearing issues. This has not only increased reliability but also allows me to conduct oil sampling, level checks, and changes online. Some considerations to keep in mind are the operating temperature (R-590 being high temp >100C) and the potential impact on oil separation. I have encountered issues with the 5-gallon pails that Busch delivers oil in, as they can easily introduce water or other contaminants. If in doubt, it's best to order new oil. Additionally, for a Welch vacuum pump used in a glove box, I found it necessary to add a chemical filter (ACID NEUTRALIZATION TRAP) to prevent the catalyst from reacting with the oil. It's possible that the lab solvents could also be affecting the oil quality. I have attached the viscosity curve for Busch oil for comparison with other oils.
Dear Steven and Bayway, Thank you for sharing valuable information about the rotary vane pump and its 14-quart oil capacity. High temperatures pose a challenge, especially with the pump running continuously during the day shift and remaining idle overnight. To address this issue, we are exploring the possibility of implementing a logic system to alternate between the four pumps in the skid. This will help in reducing vacuum levels in the tank, allowing the pumps to cool off and facilitate the flow of oil back to the lower chamber. We are currently conducting tests on new oil containers to check for contaminants, following your recommendation. While integrating a separate drop-out container or external filter may not be feasible due to safety concerns, we are looking into ways to minimize oil carryover and reduce the need for frequent top-offs. Utilizing synthetic oil may offer a solution to extend maintenance intervals in case of missed or delayed oil changes. It is worth noting that similar Busch vacuum pumps in other parts of the facility do not encounter the same issues, possibly due to differences in operating patterns. Cycling the pumps is essential to prevent heat buildup and oil carryover in the discharge. Thank you for your insights and suggestions. Kind regards, Rich Wurzbach
Quite an intriguing issue you're dealing with, Rich! It does indeed sound like there may be a reaction happening between a solvent in the lab and the oil. One possibility might be that the pumps are getting exposed to a solvent with a high level of solubility, causing the oil to degrade faster. You might want to conduct a solvent compatibility test with your oil to deduce which solvent could be causing this issue. As for alternative oil options, I've had success with multiple pumps using Mobil DTE Oil Heavy Medium. It has an excellent thermal/oxidative resistance which could solve your issue with solidification. You might also want to check the oil feed rate. Sometimes, a higher operating temperature leads to oil degradation. But before any changes in oil or rate, I would highly recommend reaching out to the manufacturer for official recommendations. They might have insights specific to your model!
Hi Rich, it could indeed be suspect solvents reacting with your vacuum pump oils, but it might also be down to how your pump system is set up. If there is a high amount of solvent vapor coming in direct contact with your oil, that might be bringing about these problems. Ideally, there should be separation methods like a cold trap or a molecular sieve upstream from the pump to minimize solvent-Oil interactions. As for alternative oils, I've had success with Inland 19 ultra. It's a hydrocarbon oil similar to the Busch oil but less prone to solidification, particularly coupled with the abovementioned separation techniques. Regular oil changes and system maintenance are crucial too. Hope this provides some new insight.
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Answer: Answer: Common issues with vacuum pump oils include thickening, solidification, and sludge formation, which can lead to pump failure.
Answer: Answer: Vacuum pump oil solidification can be caused by reactions with solvents present in the environment or by incompatible oil properties for the specific application.
Answer: Answer: To prevent vacuum pump oil solidification, it is essential to use oils specifically designed for vacuum pump applications and to conduct regular oil analysis to detect any issues early on.
Answer: Answer: Depending on the specific application and compatibility with solvents present, alternative oils such as hydrotreated paraffin oils without additives may be considered as potential replacements for vacuum pump oils prone to solidification.
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