Other Current Standards for Particle Contamination
How Tough are Your Particles?
How Silt is Formed
How Silt Affects Bearings
Silt Degrades Hydraulic Valve Performance
How Particles Influence Engine Wear
Proactive Maintenance in Three Easy Steps
Conspicuous Charting is Key to Proactive Maintenance Success
Case Study: Nippon Steel
Case Study: Kawasaki Steel
Port of Tacoma Slashes Engine Rebuild Costs by 66% on 21 Straddle Carriers
BHP Decreases Failure Rate and Turns Up The Speed with Effective Lubrication Management
Case Study: General Motors
Step No. 1 - Set Target Cleanliness Levels
Typical Hydraulic Fluid Cleanliness Targets
Field Particle Counts – Averages of 25,000 Samples
Reliability Penalty Factor (RPF)
RPF (continued) Reliability Penalty Factor (RPF)
Machine I.D.: Date:
Safety Risks Upon Failure
Score
None
Low
Medium
High
0
1
4
8
Cost of Downtime Low
0
Hourly or Daily Downtime Costs (A) Medium High Extremely High
1
2
3 A x B
Typical Length of Downtime (B) Short
0
Long
1
2
3
4
RPF (continued)
Material and Labor Costs to Repair
Score
Low
Extremely High
0
1
2
3
4
5
Effectiveness of Early Warning Systems
Score
Highly Effective
0
Not Effective
1
2
3 Composite RPF Score
Reliability Penalty Factor = 10 Max
Contaminant Severity Factor (CSF) - Hydraulics
CSF - Hydraulics (continued)
Contaminant Severity Factor (CSF) - Hydraulics
Machine I.D.: Date:
Operating Pressure (psi)
Score
0 - 1,000
1001 - 2000
2001 - 3500
3501 - 5000
>5000
0
1
1.5
2
3
Valves
Score
Manual and Solenoid
0
Cartridge
Proportional
Servo
1
1.5
2
Pumps and Motors
Score
Gear
Vane
Fixed Piston
Variable Volume
0
1
1.5
2
CSF - Hydraulics (continued) Cyclic Loading
Score Frequency and Severity of Pressure Cycles Low Medium High
Constant Pressure
0.5
0
1
1.5
Varnish Potential
Score
Low
Medium
High
Extremely High
0
0.5
1
1.5
Water In Oil Contamination
Score
<100 PPM
<500 PPM
<1000 PPM
>1000 PPM
0
0.5
1
1.5
Particle Hardness/Abrasivity
Score
Low
Medium
High
0
0.5
2
Composite CSF Score
Contamination Severity Factor = 10 Max
Target Cleanliness Grid (TCG)
Contaminant Severity Factor (CSF) - Gearboxes
Contaminant Severity Factor (CSF) - Gearboxes
Contaminant Severity Factor (CSF) - Gearboxes
Life Extension Table New Cleanliness Level (ISO Code) 20/17 26/23 25/22
)
e d o C O SI (
s s e ni l n a el C e ni h c a M t r
n er u C
24/21 23/20 22/19 21/18 20/17
19/16
18/15
13/10
14/11
13/10
12/9
11/8
10/7
3.5
9
4
>10
5
>10
6
>10
7.5
>10
9
>10
>10
>10
>10
>10
>10
>10
>10
4
2.5
4.5
3
6
3.5
6.5
4
7.5
5
8.5
6.5
10
7
>10
9
>10
10
>10
>10
>10
>10
4
2.5
5
3
7
3.5
9
4
>10
5
>10
6
>10
7
>10
9
>10
>10
>10
>10
>10
>10
3
2
3.5
2.5
4.5
3
5
3.5
6.5
4
8
5
9
6
10
7.5
>10
9
>10
>10
>10
>10
3
2
4
2.5
6
3
7
4
9
5
>10
6
>10
7
>10
8
>10
10
>10
>10
>10
>10
2.5
1.5
3
2
4
2.5
5
3
6.5
4
7.5
5
8.5
6
9.5
7
>10
8
>10
10
>10
>10
2
1.5
3
2
4
2.5
5
3
7
3.5
9
4
>10
5
>10
6
>10
8
>10
9
>10
>10
1.7
1.3
2.3
1.5
3
2
3.7
2.5
5
3
6
3.5
7
4
8
5
10
6.5
>10
8.5
>10
10
1.6
1.3
2
1.6
3
2
4
2.5
5
3
7
3.5
8
4
>10
5
>10
6
>10
7
>10
>10
1.4
1.1
1.8
1.3
2.3
1.7
3
2
3.5
2.5
4.5
3
5.5
3.5
7
4
8
5
10
5.5
>10
8.5
1.3
1.2
1.5
1.5
2
1.7
3
2
4
2.5
5
3
7
3.5
9
4
>10
5
>10
7
>10
10
1.2
1.1
1.5
1.3
1.8
1.4
2.2
1.6
3
2
3.5
2.5
4.5
3
5
3.5
7
4
9
5.5
10
8
1.3
1.2
1.6
1.5
2
1.7
3
2
4
2.5
5
3
7
4
9
5
>10
7
>10
9
1.2
1.05
1.5
1.3
1.8
1.4
2.3
1.7
3
2
3.5
2.5
5
3
6
4
8
5.5
10
7
1.3
1.2
1.6
1.5
2
1.7
3
2
4
2.5
5
3
7
4
9
6
>10
8
1.2
1.1
1.5
1.3
1.8
1.5
2.2
1.7
3
2
3.5
2.5
5
3.5
7
4.5
9
6
1.3
1.2
1.6
1.5
2
1.7
3
2
4
2.5
5
3
7
4.5
>10
6
1.2
1.1
1.5
1.3
1.8
1.5
2.3
1.7
3
2
3.5
2.5
5.5
3.7
8
5
1.3
1.2
1.6
1.5
2
1.7
3
2
4
2.5
6
3
8
5
1.2
1.1
1.5
1.3
1.8
1.5
2.3
1.7
3
2
4
2.5
6
3.5
1.3
1.2
1.6
1.5
2
1.7
3
2
4
3.5
6
4
1.2
1.1
1.5
1.3
1.8
1.5
2.3
1.8
3.7
3
4.5
3.5
1.3
1.2
1.6
1.5
2
1.7
3
2
4
2.5
1.2
1.1
1.5
1.4
1.8
1.5
2.3
1.8
3
2.2
1.3
1.3
1.6
1.6
2
1.8
3
2
1.3
1.2
1.6
1.4
1.9
1.5
2.3
1.8
1.4
1.2
1.8
1.5
2.5
1.8
1.2
1.1
1.6
1.3
2
1.6
17/14
14/11
15/12
7
18/15
15/12
16/13
3
19/16
16/13
17/14
5
Hydraulics and Diesel Engines
Rolling Element Bearings
Journal Bearings and Turbo Machinery
Gear Boxes and Other
Clean Oil Helps You Detect Faults Earlier
Oil Pump or Dirt Pump?
Step No. 2 – Take Specific Actions to Achieve Targets
Where Does Particle Contamination Come From?
Case Study: How Clean Are New Oils?
Clean New Oil Management
Rack-Mount Lube Dispensing Station – Contamination Control
Lube Storage – Things to Avoid
Oil Cans and Top-up Containers – Things to Avoid
Take the Sump Management Self Exam
Tank and Sump Ventilation
Modernization of Vents and Breathers
New Tank Filter/Breather Hardware
Hatch Covers Need to be Sealed Tight
Shaft Seals…Oil Retention or Dirt Exclusion?
Controlling Hydraulic Cylinder Ingression
Filter Media Determines Filter Integrity
Make Sure Your Filters are Beta Rated
Filter Location Options
Portable Filtration
Offline Filters
Other Full Flow Filters
Crankcase Oil Contamination
Case Study – How Filtration Influences Oil Oxidation (AN) in Automatic Transmission Fluids
Step No. 3 – Monitoring and Controlling Particle Concentrations
Three Ways to Count and Size Particles
Automatic Optical Particle Counters (OPC)
How Optical Particle Counters Work
How Contaminants Appear to Optical Particle Counters
Procedure for Reducing Water Interferences with Optical Particle Counters
Onsite Optical Particle Counters
Pore Blockage Particle Counters – How They Work
Pore Blockage Particle Counting
Comparison of Optical to Pore Blockage
Particle Settling Can Alter Oil Analysis Results
Proper Particle Resuspension is Required Prior to:
How to Use Particle Counting in Oil Analysis
Water Contamination – The Scourge of Lubricating Oils
Water Contaminated Oil – States of Co-Existence
Controlling Water Ingression
Outdoor Drum Storage – Red Drum is Tilted for Water Drainage but What is Wrong?
Cleanout Hatch Shows Machine is a Rainmaker
Water Contamination – Contamination – Base Base Oil Effects
Water Contamination – Contamination – Additive Additive Effects
Water Contamination – Contamination – Machine Machine Effects
Effects of Water on Journal Bearings and Hydraulic Pumps
Water-Related Damage to Rolling Element Bearings
Water Contamination – Generator of Other Contaminants
Do Regular Walk-Around Visual Inspections for Water
How Low Should Moisture Limits (Targets) be Set?
Life Extension Table - Moisture New Moisture Level (ppm) 10,000
5,000
2,500
1,000
500
250
100
50
Rolling Rolling Rolling Rolling Rolling Rolling Rolling Rolling Element Journal Element Journal Element Journal Element Journal Element Journal Element Journal Element Journal Element Journal
)
m p p( l
e v e L er ut si o M t r
n er u C
50,000
2.3
1.6
3.3
1.9
4.8
2.3
7.8
2.9
11.2
3.5
16.2
4.3
26.2
5.5
37.8
6.7
25,000
1.6
1.3
2.3
1.6
3.3
1.9
5.4
2.4
7.8
2.9
11.2
3.5
18.2
4.6
26.2
5.5
1.4
1.2
2.0
1.5
3.3
1.9
4.8
2.3
6.9
2.8
11.2
3.5
16.2
4.3
1.4
1.2
2.3
1.6
3.3
1.9
4.8
2.3
7.8
2.9
11.2
3.5
1.6
1.3
2.3
1.6
3.3
1.9
5.4
2.4
7.8
2.9
1.4
1.2
2.0
1.5
3.3
1.9
4.8
2.3
1.4
1.2
2.3
1.6
3.3
1.9
1.5
1.3
2.3
1.6
1.4
1.2
10,000 5,000 2,500 1,000 500 250 100
Published Limits on Moisture
Be Aware of the Effects of Changing Oil Temperature
Measuring Water Concentrations
Crackle Test – A Sight and Sound Procedure
FTIR – Detection of Water in Oil
Measuring Water in Oil By Karl Fischer
Measuring Water in Oil Using Calcium Hydride Test Kits
Summary of Lab Test Method for Quantifying Water Content
How to Monitor Moisture
Water Removal Methods
Air Contamination: States of Co-Existence
Air Entrainment Problems Relate to Tank or Sump Design
Is There a Foam Problem Here? How About Air Entrainment?
Foam in Reservoir
When is Foam a Problem?
Air is the Primary Source of Oxygen in the Oxidative Degradation of an Oil
Glycol/Antifreeze Contamination in Engine Oil
Mechanism of “Oil Ball” Formation from Glycol (antifreeze) Contamination of Crankcase Oil
How to Detect Glycol in Crankcase Oil
Notes on Glycol
How to Use Elemental Analysis to Detect Glycol Contamination
High Soot Contamination in Engine Oil
Influence of Soot on Viscosity
Tests for High Soot Load
FTIR – Detection of Soot in Crankcase Oil
How to Monitor Soot Using FTIR
Fuel Contamination in Engine Oil (Fuel Dilution)
Tests for Fuel Contamination (Fuel Dilution)
Flash Point Test
How to Monitor Fuel Dilution Using Flash Point
Understanding and Analyzing Machine Wear
What Causes Changes in Wear Debris Concentrations
Dirt Causes Increased Wear and Oil Consumption
The Secret to Fault Detection and Analysis
Technologies Used to Analyze Wear Debris
Spectrometric Analysis of Wear Metals
Know Your Elements
How Spectrometric Elemental Analysis Works
Emission Spectrometer Anatomy
How Wear Particle Size Influences Spectrometric Analysis
The Progression of Mechanical Wear
Particle Size Sensitivities of Wear Particle Technologies
Rotrode Filter Improves Large Particle Measurement
RDE Spectroscopy Can Help Determine the Severity of a Wear Problem
Elemental Analysis by X-Ray Fluorescence Spectroscopy (XRF)
XRF is More Sensitive to Large Particles
XRF Applications and Benefits
Using SEM to Characterize Active Wear
Combining SEM with EDX (Energy Dispersive Xray) to Look at Component Metallurgy
Three Ferrous Density Testers
Direct Reading Ferrography
Using the Hall Effect to Determine Ferrous Particle Concentrations
Using Ferrous Particle Retardation
Using Exception Testing to Determine the Root Cause of an Active Wear Problem
Analytical Ferrography
Analytical Ferrography
Ferrographic Analysis – What it is Trying to Tell You?
*or ferrous particle count
1. Is There a Fault or Abnormal Wear?
2. If Yes to 1. Prepare Particles for Microscopic Examination (Analytical Ferrography)
Preparation of a Ferrogram
Procedure for Preparing a Filtergram
Field Filtergram (Patch) Makers
Ferrogram vs. Filtergram?
Microscopic Examination of Ferrogram
3. Where is the Abnormal Wear Coming From?
Localizing Problems with Oil Analysis
Heat Treated Ferrograms Helps Identify Metals
Characterizing Particle Composition by Visual Inspection
Look at Particle Metallurgy to Identify Source of Wear
Chemical Microscopy
4. What is Causing the Wear to Occur?
Shapes of Common Wear Particles
Examine Appearance of Particle to Identify Cause
Tips for Recognizing Common Problems
Abrasive Wear
Abrasive Wear Particles
Adhesive Wear
Adhesive Wear Particles
Surface Fatigue
Surface Fatigue Particles
Corrosive Wear
Corrosive Wear Particles
Spheres
Non-Ferrous Wear Particles
Friction Polymer Formation
Iron Oxide
5. How Severe or Threatening is it?
6. Can the Abnormal Wear be Arrested?
Ferrogram Particle Identification Guide
LaserNetTM Fines - Automated Wear Particle Morphology
Aspect Ratio Characterizes Wear Type
LaserNetTM Fines - Operational Principal
LaserNetTM Fines - Wear Particle Image Map
LNF Case Study - Gearbox Test Stand
LNF vs. Ferrography
Wear Particle Atlas on CD-ROM
Field Tests and Inspections
Simplify Oil Analysis…Use Easy Field Tests
Visual External Machinery Inspections
Routine Inspection of Sight Glasses is Oil Analysis
Visual Internal Machinery Inspections
Visual Inspection of Oil in a Sample Bottle
Using Oil Color as a Field Test
Using Oil Odor as a Field Test
Other Sensory Inspections
Field Test for Solid Contaminants
Simple Field Method for Preparing Patch
Field Test for Ferrous Particles
Field Test for Water Contamination – The Crackle Test
