Contamination Fundamentals

Types of Contamination

SOLIDS

LIQUIDS

GASES
Particle Size Diameter Comparison
1 µm = 0.001 mm = 0.000039”

The human eye can only see

particles sized down to 40 microns.

Particle Particle
Human Hair = 80 micron 15 micron 5 micron
Structure of ISO-Code max. amount of dirt particles
ISO Code: 22/18/13 in 100 ml > given size
ISO 4406: 1999 (E) - ISO Contamination Code Chart cont…
Number of Particles per 100 ml Scale More Than Up To and Including
Number
Scale More Than Up To and Including
Number 14 8,000 16,000
28 130,000,000 250,000,000 13 4,000 8,000
27 64,000,000 130,000,000 12 2,000 4,000
26 32,000,000 64,000,000 11 1,000 2,000
25 16,000,000 32,000,000 10 500 1,000
24 8,000,000 16,000,000 9 250 500
23 4,000,000 8,000,000 8 130 250
22 2,000,000 4,000,000 7 64 130
21 1,000,000 2,000,000 6 32 64
20 500,000 1,000,000 5 16 32
19 250,000 500,000 4 8 16
18 130,000 250,000 3 4 8
17 64,000 130,000 2 2 4
16 32,000 64,000 1 1 2
15 16,000 32,000 0 0.5 1
How do we measure fluid contamination?

Structure of ISO-Code:
amount of dirt particles 22
in a 100 ml sample
larger than these specified sizes: 18
4µmc / 6µmc / 14µmc

Example: 13

larger than 4µmc = 2,234,000

larger than 6µmc = 195,000
larger than 14µmc = 4,250

4µmc / 6µmc / 14µmc

ISO Code = 22 / 18 / 13
How do we measure fluid contamination?

Structure of ISO-Code:
amount of dirt particles 22
in a 100 ml sample
larger than these specified sizes:
4µmc / 6µmc / 14µmc

Example:
larger than 4µmc = 2,234,000

ISO Code = 22 / /
How do we measure fluid contamination?

Structure of ISO-Code:
amount of dirt particles 22
in a 100 ml sample
larger than these specified sizes: 18
4µmc / 6µmc / 14µmc

Example:
larger than 4µmc = 2,234,000
larger than 6µmc = 195,000

ISO Code = 22 / 18 /
How do we measure fluid contamination?

Structure of ISO-Code:
amount of dirt particles 22
in a 100 ml sample
larger than these specified sizes: 18
4µmc / 6µmc / 14µmc

Example: 13

larger than 4µmc = 2,234,000

larger than 6µmc = 195,000
larger than 14µmc = 4,250

ISO Code = 22 / 18 / 13
How do we measure fluid contamination?
Structure of NAS Codes

Class 2-5 µm 5-15 µm 15-25 µm >25 µm

00 125 22 4 1
0 250 44 8 2
1 500 89 16 3
2 1000 178 32 6
3 2000 356 63 11
4 4000 712 126 22
5 8000 1425 253 45
6 16000 2850 506 90
7 32000 5700 1012 180
8 64000 11400 2025 360
9 128000 22800 4050 720
10 256000 45600 8100 1440
11 51200 91200 16200 2880
12 1024000 182400 32400 5760

max. amount of dirt particles in 100ml at given size

 Cleanliness Code Conversion: SAE AS 4059 – Equivalent ISO 4406 Class Based on ISO 4406: 1999 and
SAE AS 4059 Revised 2005-05: Rev E 8/29/07
Cumulative Particles per 100 ml Differential Particles per 100 ml Code Code
SAE AS 4059 Designation Designation
> 1 um > 5 um > 15 um 5 to 15 um 15 to 25 um 25 to 50 um 50 to 100 um > 100 um
> 4 um(c) >6 um(c) >14 6 to 14 14 to 21 um(c) 21 to 38 um(c) 38 to 70 > 70 um(c) Equivalent
SAE AS
um(c) um(c) um(c) ISO 4406
4059
Class
Size Code Size Size --- --- --- --- ---
A Code B Code C
195 76 14 --- --- --- --- --- 000 8/7/4
390 152 27 125 22 4 1 0 00 9/8/5
780 304 54 250 44 8 2 0 0 10/9/6
1,560 609 109 500 89 16 3 1 1 11/10/7
3,120 1,217 217 1,000 178 32 6 1 2 12/11/8
6,250 2,432 432 2,000 356 63 11 2 3 13/12/9
12,500 4,864 864 4,000 712 126 22 4 4 14/13/10
25,000 9,731 1,731 8,000 1,425 256 45 8 5 15/14/11
50,000 19,462 3,462 16,000 2,850 506 90 16 6 16/14/12
100,000 38,924 6,924 32,000 5,700 1,012 180 32 7 17/16/13
200,000 77,849 13,849 64,000 11,400 2,025 360 64 8 18/17/14
400,000 155,698 27,698 128,000 22,800 4,050 720 128 9 19/18/15
800,000 311,396 55,396 256,000 45,600 8,100 1,440 256 10 20/19/16
1,600,000 622,792 110,792 512,000 91,200 16,200 2,880 512 11 21/20/17
3,200,000 1,245,584 221,584 1,024,000 182,400 32,400 5,760 1,024 12 22/21/18
 Hydraulic Component Clearances Are Critical and
therefore require strategic filtration designs to remove the
sized particles that will attack the most critical components
of the hydraulic system

piston pump
gear pump
J1: 5 - 40µm
J1: 0.5 - 5µm
J2: 0.5 - 1µm
J2: 0.5 - 5µm
J3: 20 - 40µm
vane pump J4: 1 - 25µm
J1: 0.5 - 5µm
J2: 5 - 20µm
J3: 30 - 40µm
servo valve
J1: 1 - 4µm
J2: 100 - 450µm valve
J3: 20 - 80µm J1: 1 - 25µm
Abrasion Wear

8µ 5µ
Surface fatigue Wear - Bearings
1. Initiation particle 2. Surface dented – fault
trapped and crushed Created – crack initiated

3. After “X” fatigue cycles 4. Surface fails, spall created &

further micro cracks Particles release and enter flow
propagate.
Sources of Contamination
New Oil - Photomicrographs

ISO 16/14/11 ISO 17/15/13

Demanded by Modern Hydraulic Systems New Oil as Delivered in Mini-container

1 class => 21=2X

ISO 20/18/15 ISO 23/21/18

New Oil as Delivered in Tanker New Oil as Delivered in Barrels

4 classes => 24=16X 7 classes => 27=128X

Effects of Contamination
CAN EFFECTS OF CONTAMINATION BE STOPPED?
Basics of Fluid Contamination

Type of Contamination

Gaseous Liquid Solid Effects

Air Water Emery
Gases Chemicals Metal Scale Extremely
Rust Particles
Damaging
Iron, Steel
Brass, Bronze
Aluminum
Damaging

Laminated Fabric
Fibers
Minimal
Seal Abrasion Damage
Rubber Hose Particles
How do we measure fluid contamination?

Basic principle
light obscuration

Light source is an LED light

• Durability
• Holds calibration for 2 years
• Does not saturate when
reading high contamination
levels
 How do we measure fluid contamination?

14 micron
Size of Particles

6 micron

4 micron

Number of Particles = Number of Pulses

The number of pulses equals the number of particles.

Classification of oil / water mixtures

Dissolved Water:
Homogenous mixture of oil and water. The O
water molecules are discrete and thoroughly
mixed with the oil molecules. H H
Free Water
Bulk Water:
Above the saturation point, water molecules
are aggregated into separate drops (clumps of
water). The mixture is no longer homogenous.
Emulsified Water:
Is a special form of free water. Tiny droplets (1-
10 micron size) of water stay suspended in oil
and form a hazy or cloudy mixture in the oil.
Contamination Issues caused by available water:
FREE WATER ISSUES:
• Corrosion caused by free water contamination – corrosion
pits, rough surfaces, and release of abrasive flakes into the
fluid – rust and aluminum oxide.
• Microbial colonization caused by free water – odors, acids, slime, and
health problems.
• Loss of lubricity caused by free water entering contact loading zones,
allowing opposing surfaces to crash together – results in high friction,
wear and seizure.
• Additive depletion caused by free water retaining polar additives
DISSOLVED WATER ISSUES:
• Faster oil oxidation caused by dissolved water accelerating this form of
oil degradation – leads to oil acidity, thickening, varnishes, sludge & resins
• Reduced Fatigue life caused by dissolved water promoting propagation
of fatigue cracks in metals
• Demolition of Ester-based fluids and additives caused by dissolved water
reacting with esters – hydrolysis - results in formation of acids, gels, and
loss of additives
Sources of Error
Possible Sample Locations
PRESSURE HEADER
VACUUM BOTTLE
SYRINGE

THROTTLE VALVE

RESERVOIRS

Taking a sample from Taking a sample from

pressure header stagnant fluid
Definitions:

Saturation Point:
• max. amount of water that can be dissolved in the
fluid at a specific temperature
• measured in ppm – max level is fluid dependent

Saturation Level:
• the percentage of water dissolved in the fluid
relative to the saturation point
• measured in % - max level should be less than or
equal to 50%.
Sources of Error-Reservoir sampling

Example:
Example:
Reservoir Extraction with auxiliary pump
Reservoir Extraction with Auxiliary Pump
Point at which suction hose
was lowered slowly to the
bottom of the tank.

suction hose
suction hose near bottom
near surface
ISO CLASS INCREASE FROM 15 TO 20
IS EQUIVALENT TO AN INCREASE IN
PARTICLE COUNT OF 32 TIMES!
Sources of Error
Point of Extraction - Test Connection Arrangement
Point of Extraction - Where in the System is the best
representation of system fluid cleanliness?
HPU

TEST POINT SHOULD BE LOCATED

IMMEDIATELY DOWN STREAM OF
HYDRAULIC OR LUBE PUMP,
BEFORE FILTRATION, BEFORE
CONTROL AND BEFORE
ACTUATION.
IDEAL SAMPLE POINT-GEAR LUBE SYSTEM

IDEAL SAMPLE POINT

LOCATION
Sources of Error
Sampling Errors caused by:
• Leaving sample bottles open too long
• Using previously contaminated bottles
• Being unaware of system operation immediately before sampling –
possibly resulting in inaccurate analysis and conclusions from
sample report data.
• Improper handling of sample causing contamination from hands,
atmosphere, chemicals and water.
• Failure to flush sampling ports and lines before sampling results in
readings that include built up deposits of dirt and sludge in lines.
Note: Such errors are likely to result in higher contamination readings
than actual.
Element Technology
Hydraulic Power Unit Cylinder actuator
Single Pressure
• COST OF FACILITY PREP filtration
• COST OF DESIGN AND ACQUISITION
• COST OF MACHINE strategy
• COST OF UTILITIES
• COST OF INSTALLATION & STARTUP
• COST OF RUNNING MACHINE
• COST OF MAINTAINANCE
Control Valve
• COST OF DECOMMISSIONING
• COST OF REMOVAL/DISPOSAL

Pressure filter
$$$$
Main Hydraulic
Pump

Reservior
 Contamination Control
Loss of component Cost of single
Equipment &
efficiency due to wear standard filtration
component
(non-efficient operation)- Strategy
repair and
System performance degradation Replacement – labor
& component costs

System downtime Decrease in product

costs resulting from quality resulting
component failures- from poor control and
Can not produce operation – higher
product rejection rates
Hydraulic Power Unit Comprehensive and/or Balanced
Filtration Strategy

Cylinder actuator

SERVO

Pressure filter

Return filter

Main Hydraulic Pump

Kidney loop
filter

Reservoir
Hydraulic Power Unit Investment:

Cost of a comprehensive
Loss of component balanced filtration system
Efficiency due to wear Equipment &
(non-efficient operation) component repair and
replacement

Decrease in product
System downtime
Quality resulting from
Costs resulting from
Poor control and
Component failures
operation
Small investment for comprehensive filtration results in
shrinking entire maintenance, quality, and manufacturing budget.
Required New Machine Cleanliness
Fluid Cleanliness vs. Service Life
Cleanup 5 ISO Codes (32 times cleaner) yields a life extension factor of 4 times

Current
Cleanline Target Target Target Target
ss
24/22/19 21/19/16 20/18/15 19/17/14 18/16/13

23/21/18 20/18/15 19/17/14 18/16/13 17/15/12

22/20/17 19/17/14 18/16/13 17/15/12 16/14/11

5 ISO18/16/13
21/19/16
CLASS17/15/12
IMPROVEMENT
16/14/11 15/13/10

20/18/15 17/15/12 16/14/11 15/13/10 14/12/9

19/17/14 16/14/11 15/13/10 14/12/9 14/12/8

Life Ext. Factor 2X 3X 4X 5X

 Machinery Life Extension Factor
Current Machine Cleanliness (ISO Code)

Hydraulics Rolling
and Diesel Element
Engines Bearing

Journal Bearing
Gear Boxes
and Turbo
and Other
Machinery

Ref. Noria Corporation

Features of a High Quality Element
BETAMICRON 4
Features optimization of all
element performance characteristics

• High ßx-values (efficiency)

• High ßx-value stability
• High dirt holding capacity
• Low long term pressure drop
• High collapse stability
• High flow fatigue stability
• Wide fluid compatibility
• Structrual pleat support with resilience and
memory
BETAMICRON 4 ABSOLUTE
NON-WOVEN SYNTHETIC
Nickel or (Tin) Coated End Caps and
Support Tubes
- Nickel (Tin) Coating Allows the Use
of One Standard Element for ALL
Application Needs.
High BETA Efficiency
High BETA Stability in severe dynamic
fluid conditions over element life
High Dirt holding capacity
High degree of pleat stability & support
due to high quality structrual design
Multi-Pass Testing
ISO 16889: 1999
What Data is Obtained?
Best performance comparison regarding
below parameters
• Beta Ratios
• Beta Stability
• Dirt Holding Capacity

How is test completed?

• ISO Medium Test Dust (ISO MTD)
• Mil-5606 Hydraulic Fluid
• Constant Viscosity
• Constant Temperature at 40 degrees Centigrade
• Constant Flow rate through filter
• Constant rate of dirt injection
• Continuous measurement of particle counts upstream vs. down stream.
• Continuous measurement of pressures upstream & down.
What is Dynamic Filter Performance?
Filters that Perform in REAL LIFE!
The Test Lab
• Steady Flow
• No Fatigue Cycles
• Constant Dirt
• “Ingression Rate” to Filter
• Single Fluid Used
• Temperature 100°F
• ISO Medium Test Dust
• Accelerated Element Life
Real Life
• Continuous Variations
• Millions of Fatigue Cycles
• Always Changing
• Wide Variety
• -40°F to 210°F
• Debris, Water, Air
• Months
Multi-Pass Testing
ISO 16889: 1999 (ISO Standard for Performing Multi-Pass Test)

FOR EVERY 1000 PARTICLES

SIZED 5 micron OR GREATER
THAT ENTER THE FILTER,
ONE GOES THROUGH
WHEN THE BETA 5 IS = 1000
Beta Values Versus Efficiency
Beta Value Efficiency Particles ≥ Beta() Micron Upstream Particles Downstream
Beta X 2 50.0000% 100,000 50,000
Beta X 4 75.0000% 100,000 25,000
Beta X 10 90.0000% 100,000 10,000
Beta X 20 95.0000% 100,000 5,000
Beta X 40 97.5000% 100,000 2,500
Beta X 60 98.3333% 100,000 1,667
Beta X 75 98.6667% 100,000 1,333
Beta X 100 99.0000% 100,000 1,000
Beta X 125 99.2000% 100,000 800
Beta X 150 99.3333% 100,000 667
Beta X 200 99.5000% 100,000 500
Beta X 300 99.6667% 100,000 333
Beta X 500 99.8000% 100,000 200
Beta X 1,000 99.9000% 100,000 100
Beta X 2,000 99.9500% 100,000 50
Beta X 4,000 99.9750% 100,000 25
Beta X 5,000 99.9800% 100,000 20
Beta X 10,000 99.9900% 100,000 10
Beta X 20,000 99.9950% 100,000 5
Beta X 50,000 99.9980% 100,000 2
Beta Values Versus Efficiency
Beta Value Efficiency Particles ≥ Beta() Micron Upstream Particles Downstream
Beta X 2 50.0000% 100,000 50,000
Beta X 4 75.0000% 100,000 25,000
Beta X 10 90.0000% 100,000 10,000
Beta X 20 95.0000% 100,000 5,000
Beta X 40 97.5000% 100,000 2,500
Beta X 60 98.3333% 100,000 1,667
Beta X 75 98.6667% 100,000 1,333
Beta X 100 99.0000% 100,000 1,000
Beta X 125 99.2000% 100,000 800
Beta X 150 99.3333% 100,000 667
Beta X 200 99.5000% 100,000 500
Beta X 300 99.6667% 100,000 333
Beta X 500 99.8000% 100,000 200
Beta X 1,000 99.9000% 100,000 100
Beta X 2,000 99.9500% 100,000 50
Beta X 4,000 99.9750% 100,000 25
Beta X 5,000 99.9800% 100,000 20
Beta X 10,000 99.9900% 100,000 10
Beta X 20,000 99.9950% 100,000 5
Beta X 50,000 99.9980% 100,000 2
Beta Stability ISO 16889: 1999
High ßx-Values / High ßx-Value Stability
Beta Ratio remains at a relatively constant level at high pressure drops beyond
normal element operating ranges with high beta stability.

10000

Element 1
1000
Element 2

100 Point of element failure

Beta 100 Stability = 210 psi means that:

Beta Ratio at the rated micron will not drop below Beta Ratio = 100 until 210 PSID
 Poor Beta Stability Causes a loss of
adequate protection from the point that Beta drops
below manufacturer’s published beta specification
before the end of element life.

• Significant loss of filter efficiency before the end of

element life
• Loss of equipment through loss of protection
• Increased wear and component failures
• Increased downtime
• Decrease in Customer Satisfaction
High Dirt Holding Capacity
ISO 16889: 1999

• Decrease in downtime
when indicator is utilized for change-out indication
(Less Element Changes)

• Decrease in replacement element costs

(longer lasting-utilizing full element capacity)

• Decrease in maintenance/labor costs

DHC - Dirt Holding Capacity
DHC Measured at Terminal Pressure / Indicator Setting

INDICATOR TRIP POINT

Element Terminal Pressure

72
Superior Element Life
Pressure Drop Over Element Life Comparison

High efficiency element has higher D/P than a low efficiency element
HYDAC designs elements to increase D/P at a slower rate than others