Oil Flushing Tips to Address the Fish Bowl Effect

Jim Fitch, Noria Corporation
Tags: oil flushing

Oil Flushing Tips to Address the Fish Bowl Effect

I've learned that many people are skittish about flushing practices and even periodic oil changes. This fear seems to be driven, in some cases, by an unsavory past experience or alarming anecdotes passed on by others. The story usually begins with a seemingly healthy machine. As a preventive maintenance measure, the machine is scheduled for an oil change or flush. Immediately afterward, the machine fails. The quick conclusion reached is flushes and oil changes cause sudden-death mechanical failure.

Sound familiar? Is this a case of false perception or sobering reality? Perhaps this old aphorism applies: "If it ain't broke, don't fix it"? Does human intervention shorten or extend the service life of machinery? You may recall a column I wrote a while back about the hot stove effect. I recounted that Mark Twain observed that if a cat happens to jump on a hot stove, he will never jump on a hot stove again. This, of course, is a good thing. However, not so good is the fact that he will not jump on a cold stove, either, or perhaps anything that bears the slightest resemblance to a stove.

For the cat, all stoves are hot. As intelligent people, we should not fall prey to the same twisted logic. But, just as stoves are occasionally hot (and caution is advised), so too there is a modicum of reality that flushing and oil changes can induce failure. Let's take a look at some of the reasons why they might indeed be related to failure.

Stirring the Fish Bowl (BS&W Monitor)

Those of us who have had tropical fish know that the slightest agitation of an unchanged fish bowl causes the water to murk-up with sediment, uneaten food and excrement. In short order, most of these solids will resettle but not exactly in the same way as before; they move to new resting sites. The water will look clearer but will still suspend fine particles for a considerable time. Disturbing the sediment in oil lubrication systems can produce similar "fish bowl" effects.


Illustrated image of a BS&W monitoring system

Figure 1. Use a BS&W bowl to monitor and periodically time the purge.

Sumps and reservoirs serve as settling tanks to aid in the removal of sludge, dead additives, dirt, wear debris, water and other heavier-than-oil contaminants. These low-lying impurities are collectively referred to as bottom sediment and water (BS&W). In the same sense that we wouldn't want a loaded oil filter to burst, sending a dense debris field downstream, we also wouldn't want to agitate the BS&W in our sumps and reservoirs. Imagine this sequence of events relating to an oil change:

  1. The drain port of a reservoir is removed, and the aged oil flows out by gravity into a waste oil container.

  2. Some of the BS&W is purged with the oil, but much of it stays clinging to the reservoir floor.

  3. During the drain, oil flowed toward the tank by gravity through piping, valves, pumps and filter housings, carrying suspended particles that were previously trapped in nooks and crannies. Some of these backwashed particles resettle in various locations, presenting the risk that they will be re-entrained into the oil on machine restart.

  4. When fresh new oil comes plunging into the reservoir, the BS&W is stirred up into a murky mass.

  5. On machine restart, the suspended reservoir muck and the displaced particles in the lines and machine components become mobilized by the flowing fluid and travel throughout the system.

  6. Some of these suspended particles induce accelerated wear in frictional load zones (bearings, gears, pumps, etc.), while others get trapped in narrow glands, oilways and orifices, causing restricted oil flow (starvation conditions).

  7. The dense concentration of particles and impaired oil flow start a chain of events that ends in machine failure.

How to Prevent This from Happening

In the ideal world, we wouldn't allow BS&W to accumulate, and oil changes wouldn't be necessary. Nobody lives in the ideal world. While the real world can't eradicate BS&W, we can control its accumulation and later resuspension. Here are some suggestions:

Suggestions for Skilled, Precision-based Flushing

Flushes offer numerous benefits with few side effects when done with skill and precision. Conversely, poorly planned and executed flushes can spell trouble for even the most reliable machines. Without question, a flush is an intrusive intervention of an operating machine and should never be performed unless a pressing need exists. Its purpose is to dislodge the machine's internal surfaces from varnish, sludge and other harmful deposits.

illustrated images of wand flushing a transfer cart and cleaning stored lubricants

Figure 2. Proper utilization of a filter cart plays an important role in the process.

The risks of not performing a needed flush include oil starvation from line restrictions and motion impediment of critical machine parts. And, postponing a needed flush can make matters substantially worse.

Therefore, before planning and performing a flush, know the pitfalls and countermeasures. Here are some suggestions related specifically to flushing and the fish bowl effect:

Remember the law of unintended consequences. At a minimum, do your homework and be proactive. And, when it comes to flushes of larger oil circulating systems, give serious consideration to hiring a professional contract flushing service.

Remember, BS&W and the fish bowl effect is a serious lurking danger. Don't let your guard down.