The approach of detecting and analyzing sludge and varnish problems in machinery is not the same as used oil analysis. In many instances this is because the evidence is not always in the oil. The sludge and varnish should be analyzed directly, using a completely different set of tests and evaluation parameters. Still, used oil analysis plays an important diagnostic role to help reveal candidate causes as well as to rule-out others.

The conditions that commonly lead to sludge and varnish problems vary, which complicates the process of identifying the root cause analytically. There are at least 25 unique lubricant degradation mechanisms leading to sludge or varnish formation.

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Optical particle counters (OPC’s) have a long history of use in industrial hydraulic applications. Traditionally, their success has been limited to scientific laboratories and other highly controlled environments. However, in recent years, attempts have been made to apply the use of OPC’s to the particle counting of used hydraulic fluids and industrial lubricants. As a result, serious concerns have been raised regarding the accuracy and reliability of OPC’s in such applications. The objective of this bulletin is to present important facts from reliable and documented sources for the general benefit of existing or prospective users of OPC’s. As particle counting moves into the mainstream of machine condition monitoring, users must have reliable information to identify and select appropriate technologies.

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