You are on page 1of 5

Clean up your oil and keep it clean!

by Dave Whitefield life can you expect from cleaning either a 2-part code, or a 3-part code,
Principal Applications Engineer up your oil? as specified by the user. The 2-part
Bently Nevada Corporation • What about other types of code refers to particle counts in the 5
e-mail: dave.whitefield@bently.com
contamination? µm and 15 µm size ranges. A 3-part
• What steps can you take to clean code of 17/14/12 would indicate 640 to
up your oil? 1,300 particles/mL greater than or
equal to 2 µm, 80 to 160 particles/mL
ontaminated oil kills Let’s look at these issues one at a
greater than or equal to 5 µm, and 20 to
machines. Clean oil is one time.
40 particles/mL greater than or equal to
of the most important fac-
How is oil cleanliness quantified? 15 µm. See Table 1 and Figure 1.
tors affecting the service life of the
lubricated components of all ISO 4406 establishes the relationship ISO Code Minimum Maximum
machinery1. In hydraulic systems, clean between particle counts and cleanliness • • •

fluid is absolutely essential for success- in hydraulic fluids (common practice • • •

ful long-term operation. Although has extended the application of the • • •

machines equipped with rolling ele- standard to lubricants). This interna- 10 5 10


ment bearings are especially sensitive tional standard uses a code system to 11 10 20
to particulate contamination, machines quantify contaminant levels by particle 12 20 40
using fluid-film bearings are not im- size in micrometers (µm). Using ISO 13 40 80
mune to such damage. Many sources 4406, a machine owner/operator can set 14 80 160
cite dramatic improvements in expected simple limits for excessive contamina- 15 160 320
machine life resulting from even tion levels, based on quantifiable 16 320 640
modest improvements in lubricant cleanliness measurements. 17 640 1300
cleanliness. Table 1 illustrates the ISO 4406 18 1300 2500
This all sounds reasonable, and cleanliness codes2. This standard allows 19 2500 5000
smacks of common sense. Closer you to quantify current particulate 20 5000 10000
scrutiny reveals a few questions: cleanliness levels and set targets for 21 10000 20000
cleanup. The current standard provides 22 20000 40000
• How is oil cleanliness quantified?
a 3-part code to represent the number 23 40000 80000
• How clean is “new” oil?
of particles per milliliter (mL) of fluid • • •
• How clean does your oil need greater than 2 µm, 5 µm, and 15 µm, • • •
to be? respectively3. Many labs will report Table 1. ISO 4406 fluid cleanliness codes
• What improvements in machine (particles per mL).
1
For the purposes of this article, and in keeping with common industry practice, the terms “clean” and “cleanliness” refer to the amount and size of particulate
contamination in a lubricating or hydraulic fluid.
2
The ISO standard calls the codes “scale numbers.” You may also find them referred to as “range numbers” and represented as R5/R15 for 2-part codes and
R2/R5/R15 for 3-part codes.
3
The current standard is ISO 4406:1987(E). The ISO is now circulating a draft proposal, ISO/DFIS 4406:1999(E), for contamination levels measured with
automatic particle counters calibrated in accordance with ISO 11171. In the proposed standard, the three parts signify the number of particles/mL greater than
4 µm, 6 µm, and 14 µm, respectively (scale or range numbers R4/R6/R14).

ORBIT Fourth Quarter 1999 9


How clean does What improvements in machine life
17 / 14 / 12 your oil need to be? can you expect from cleaning up
Each machine your oil?
640 to 1300 20 to 40 class should be While it may feel good to know you
particles particles have clean oil in your machines, how
evaluated for clean-
≥ 2 µm ≥ 15 µm
liness levels appro- good can you afford to feel? The
80 to 160 priate to the answer to this question depends to
particles application. In gen- some degree on the specific machine
≥ 5 µm eral, machines with application. However, studies per-
tight clearances formed in many industries all show
Figure 1. ISO code example. and/or anti-friction dramatic extensions in expected
(rolling element) bearings benefit machinery life by improving lubricant
Notice each step in the ISO code greatly from very clean oil. Turbine cleanliness. In one example, a reduc-
represents either double or half the par- electro-hydraulic control (EHC) sys- tion of particles larger than 10 µm from
ticle count relative to an adjacent code. tems and many aeroderivative gas tur- 1000/mL to 100/mL resulted in a 5-
It is important to note the “/” character bines are examples of industrial fold increase in machine life… an
in the written form of the code is machines that require extremely clean attractive return on your cleanup invest-
merely a separator, and does not signify oil for proper performance and long ment. An additional benefit of cleaner
a ratio of the scale numbers. life. Filter systems rated to remove par- oil is a lower noise floor for wear parti-
ticles as small as 3 µm to 7 µm are cle detection measurements. It’s much
How clean is “new” oil?
commonly used in such applications. easier to detect subtle changes in the
Studies of “new” turbine oils,
Hydraulic systems’ targets should also amount of wear debris in a clean
crankcase oils, hydraulic fluids, and
be adjusted to cleaner levels for higher system than in a dirty one.
bearing oils delivered to customers
system operating pressures. (See Society of Automotive Engineers
indicate varying degrees of cleanliness,
related article, “Lubrication – A (SAE) studies have shown engine wear
with ISO codes from a low of 14/11, to
strategic part of asset management” reductions of 50% when filtering
as high as 23/20. Drum-delivered prod-
on page 6.) crankcase oil to 30 µm, and 70% when
ucts were generally found to be cleaner
Table 2 presents some typical base filtering to 15 µm, as compared with
than bulk-delivered products. Referring
lubricating oil cleanliness targets for filtering to 40 µm. By implementing
to Table 1, you might think twice
common machines and machine ele- some of the measures outlined in this
before putting “new” oil with an ISO
ments. Like most guidelines, these tar- article, you will soon be able to docu-
23/20 measurement in your machine.
gets are suggested as starting points. ment your own success stories.
Improper storage procedures can con-
You will probably make adjustments to
tribute additional contamination to new What about other types of
these levels as you learn how your
oil. Poor handling practices are another contamination?
machines respond to cleaner lubricants.
source of new oil contamination. (Do As destructive as particulate
you know what types of vessels are contamination can be, there are other
used in your plant for transporting and Machine / element ISO Target
contaminants that also contribute to oil
adding makeup oil? Are they as clean Roller bearing 16/14/12 degradation and premature machine
as you want your oil to be?) After Journal bearing 17/15/12 wear. A short list of “non-particulate”
implementing cleanup programs, many Industrial gearbox 17/15/12 contaminants includes water, coolants,
users find the dirtiest oil in their plant Mobile gearbox 17/16/13 fuels, and process fluids. The most
is incoming “new” oil. It is clear that Diesel engine 17/16/13 common of these is water. Water alone
proper filtering of new oil during or is a significant factor in lubricant
Steam turbine 18/15/12
before filling is a prudent and highly degradation. When combined with iron
Paper machine 19/16/13
desirable practice to extend machine or copper particles, water becomes
life. Table 2. Typical base cleanliness targets.
even more powerful in attacking

10 ORBIT Fourth Quarter 1999


• Measure and trend your progress.
(Don’t be afraid to adjust your
procedures as needed to meet your
targets.)
• Document the impact of your
investment on availability, mainte-
nance expense, and machine life.
With these elements delineated, some
of the practical aspects of improving
your filtration, storage, and handling
procedures can be addressed.

Improving filtration, storage, and


handling procedures
Many improvements to your filtra-
tion, storage, and handling procedures
can be made with minimal cost. A little
time spent simply reviewing your cur-
Figure 2. Effect of water on rolling element bearing life. rent storage and handling procedures
lubricant base-stocks and additives. The bearing lubricant sufficiently to cause can be revealing (and in some cases,
adverse effects of water in oil include: journal-to-bearing contact (wiping). even shocking). Figures 3, 4, and 5
• Lubricant breakdown, through oxi- The reduction in film thickness also illustrate a few problems commonly
dation and additive precipitation. increases the sensitivity of fluid-film seen in many operations. During the
• Changes in viscosity, affecting the bearings to particulate contaminants.
ability of a lubricant to maintain What steps can you take to clean up
the film thickness necessary to your oil?
protect the lubricated surfaces.
Let’s say you are now convinced that
• Corrosion. cleanup is the way to go, but you don’t
• Accelerated fatigue of lubricated know how to get there. Filtration, stor-
surfaces. age, and handling procedures are the
Even very small amounts of water can key areas to concentrate your energies.
be harmful in machines equipped with The important elements of a successful
rolling element bearings. Typical life campaign to clean up your oils are: Figure 3. Poor handling practices – filler
neck screen punched out.
reduction of rolling element bearings • Measure and evaluate current
caused by various concentrations of cleanliness levels to establish
water in oil is depicted in Figure 2. baselines for comparison.
Lubricant film thickness in fluid-film • Examine and evaluate your current
journal bearings is substantially larger storage and handling practices.
than that found in rolling element bear- • Set cleanliness targets based on
ings, and hydrodynamic pressures are your goals for longer machine life
typically lower. However, the babbitt in and/or reduced maintenance and
these bearings, being composed prima- downtime costs.
rily of lead and tin, is susceptible to
• Evaluate, select, and implement
oxidation damage from water and
the improvements in filtration,
oxygen. Water can also reduce the
storage, and handling procedures
load-carrying capacity of a fluid-film Figure 4. Poor storage practices – loose
required to achieve your goals. bung (drum cap).

ORBIT Fourth Quarter 1999 11


through machine components can scheduled intervals, or in response to
create a self-fulfilling prophecy of increasing contamination trends in your
machine destruction. Normal full- oil analysis data. Portable systems can
flow filtering removes some, but also be used for pre-filtering new oil
not all, wear particles. In fact, before or during system charging.
many full-flow filtration systems Cartridge-type filters are common on
are only effective in removing this type of equipment, so you can eas-
particles larger than 40 µm. ily change to the appropriate filter ele-
Concentrating on the hardest and ment for the specific cleanliness target
most abrasive particles is an effec- of each machine or machine class
tive strategy for this category of being serviced. Since cross-contamina-
contaminants. tion is a possibility with portable sys-
Once the contamination sources are tems, filter changes and adequate
identified, you can concentrate on the flushing are essential before use with a
areas most likely to generate your tar- different lubricant. Maintaining sepa-
Figure 5. Poor handling practices – dirty rate systems for each lubricant being
get cleanliness levels.
fill pump.
filtered is another solution to this
evaluation phase, it is important to Filtration potential problem.
identify contamination sources as well Offline recirculating (“kidney loop”)
as the levels. Contamination sources filtration systems can be very effective Storage and Handling
may include: in achieving and maintaining your Improvements to storage and handling
• Contaminated new oil. As previ- cleanliness targets. In some cases, a procedures can often be implemented
ously mentioned, new oil is often permanent installation is called for, at low cost, relative to the benefits.
not as clean as you might think, with continuous sidestream (“bypass”) Controlling temperature over a rela-
usually becoming contaminated filtering. In less critical applications, tively narrow range is important for
during transportation, storage, and where sump volumes are usually proper drum storage. Drums “breathe”
handling. smaller, the job can often be handled as the internal pressure increases and
with a cart-mounted portable filtration decreases with temperature variations.
• Built-in contamination. Machine
system (Figure 6). Portable cart- Moisture and other contaminants are
components can become contami-
mounted systems can be used at forced into the drum when the internal
nated from handling practices
pressure decreases. In most climates,
encountered during overhauls or
this problem must be addressed by stor-
rebuilding processes. It is impor-
ing drums in enclosed, temperature-
tant to review shop procedures
controlled storage facilities. Shielding
relating to cleanliness of internal
storage containers from dirt and mois-
wetted parts, hoses, and lubricant
ture are other obvious measures that
piping.
will keep your new oil in good condi-
• Ingested contamination.
tion. Be as careful with pumps and
Unfiltered sump vents and faulty
transfer containers as with your storage
seals are common problems which
containers. This will minimize the
can result in contaminants (includ-
chances of cross-contaminating with
ing water as well as particulates)
other lubricants and introducing con-
entering the lube system from the
taminants into machines when topping
outside environment. Minor modi-
or filling.
fications to vent systems can reap
rewards in this area. Water removal
• Internally-generated contamina- Since the sources for water contami-
tion. Recirculating wear particles nation are so numerous and ubiquitous,
Figure 6. Portable filter cart.

12 ORBIT Fourth Quarter 1999


eliminating all sources of moisture can • Filter/Dryers cleanup has proven to be one of the
be very difficult. Removing water from ▲ Cartridge-type filters that use simpler and more cost-effective meth-
oil can also be a challenging task, but super-absorbent materials to ods of achieving measurable improve-
there are several methods available. soak up water. ment. Don’t wait for contaminants to
Each method has advantages and disad- ▲ Dissolved water isn’t removed. destroy your machines. Clean up your
vantages, so each must be carefully oil and keep it clean!
• Vacuum Treating (Vacuum
evaluated for the particular application.
Dehydrating)
Some of the common methods for
▲ The wet lubricant is heated in a
removing water from oil, along with
vacuum to separate the water. References
their tradeoffs, include:
▲ Additives usually aren’t 1. Toms, Larry A., Machinery Oil Analysis,
• Settling/Evaporation
removed from the lubricant, 2nd Edition, Coastal Skills Training, Virginia
▲ Natural – gravity acts on the Beach, Virginia.
since it is a chemical separa- 2. Fitch, J. C., Oil Analysis Course Manual,
water to separate it from the oil,
tion. Noria Corporation, Tulsa, Oklahoma.
and water escapes from the
▲ Dissolved, emulsified, and free 3. A Guide to Standards for Contamination
fluid via natural evaporation. Specifications in Liquids, Pacific Scientific
water can be removed. Instruments, HIAC Royco Division.
▲ Inexpensive.
▲ When combined with effective 4. ISO/FDIS 4406:1999(E), International
▲ Least effective of known Standards Organization.
filtration media, capable of
methods. 5. Industrial Oils, Chevron USA, Incorporated.
being a highly-effective lubri- 6. The Handbook of Hydraulic Filtration,
▲ Properly-designed reservoir is cant purification system. Parker Hannifin Corporation, Parker
required. Filtration Division.
• Gas Sparging/Air Stripping
▲ Only free water is removed. 7. Machine Design, “How Dirt and Water
▲ The chemical separation princi- [Affect] Bearing Life,” Timken Bearing
• Centrifuging (Centrifugal ple of air stripping is used. Company.
Separation) ▲ Dissolved, emulsified, and free
▲ Only the free water form of water are removed.
water is removed to about 20 ▲ Additives are not removed.
ppm by weight, above the
▲ Nitrogen or air can be used.
saturation point.
▲ Entrained gases aren’t removed. Purchasing clean oil
▲ Emulsified water content tends An additional cleanup step, which is
to increase. often overlooked, is to specify the
▲ Dirt and other solids are removed. cleanliness levels of the lubricants you
▲ Additives can be removed by purchase. You may pay a little more up
this method. front, but the savings in machine avail-
• Coalescing Filters/Screens ability, filtration costs, and machine
life extension often more than offset
▲ Only free water is removed.
the additional cost. If you choose this
▲ A coalescing cartridge filter is
route, be sure to test the incoming oil
used to separate the water from
to verify you get what you paid for.
the oil.
▲ Additives can be removed by Conclusion
this method. It’s best not to take administration of
▲ Only effective for narrow your oils lightly. Attention to detail is
ranges of viscosity and specific paramount in achieving cleanliness lev-
gravity. els that produce large improvements in
▲ Some manufacturers claim “No machine life and availability. When it
removal of additives.” comes to machine life, lubricant

ORBIT Fourth Quarter 1999 13

You might also like