Hydraulic Fluids 11-21

Maximum number of particles per 100 ml in the Number of particles per 1 ml Scale number
more than up to
specified particle size range Class 2,500,000 > 28
5–15 mm 15–25 mm 25–50 mm 50–100 mm >100 mm 1,300,000 2,500,000 28
640,000 1,300,000 27
125 22 4 1 0 0 320,000 640,000 26
250 44 8 2 0 0 160,000 320,000 25
80,000 160,000 24
500 89 16 3 1 1 40,000 80,000 23
1,000 178 32 6 1 2 20,000 40,000 22
10,000 20,000 21
2,000 356 63 11 2 3
5,000 10,000 20
4,000 712 126 22 4 4 2,500 5,000 19
8,000 1,425 253 45 8 5 1,300 2,500 18
640 1,300 17
1,6000 2,850 506 90 16 6 320 640 16
32,000 5,700 1,012 180 32 7 160 320 15
80 160 14
64,000 11,400 2,025 360 64 8 40 80 13
128,000 22,800 4,050 720 128 9 20 40 12
10 20 11
256,000 45,600 8,100 1,440 256 10 5 10 10
512,000 91,200 16,200 2,880 512 11 2.5 5 9
1,024,000 182,400 32,400 5,760 1,024 12 1.3 2.5 8
0.64 1.3 7
Purity classes in accordance with NAS 1638 0.32 0.64 6
0.16 0.32 5
0.08 0.16 4
0.04 0.08 3
0.02 0.04 2
0.01 0.02 1
0.00 0.01 <1

Degree of contamination as per ISO 4406

Count result
Particle Number Scale
Particle Number size per 1 ml number
size per 1 ml
>4 mm 1452.53 18
>4 mm 1452.53 ISO 4406:1999 18/15/11
>6 mm 274.4 15
>6 mm 274.4 >14 mm 18.51 11
>14 mm 18.51

Count result
Particle Number Class
Particle Number range per 100 ml
size per 1 ml
5–15 mm 17,175 7
>5 mm 186.2
15–25 mm 955 5
>15 mm 14.45 NAS 1638 Class 7
25–50 mm 418 6
>25 mm 4.9
50–100 mm 64 6
>50 mm 0.72
>100 mm 8 5
>100 mm 0.08

Example for classification of a count result

Recommendations for degrees of purity

Type of hydraulic system Degree of purity

Sensitive control systems, laboratory, aerospace systems 11/8
High-performance servo systems, high-pressure systems with long life 14/11
Reliable, high-quality systems, general machines 16/13
Medium pressure range, general machines + automotive 18/14
Low pressure range, general/heavy-duty machines, automotive 19/15
Low-pressure systems with large tolerances 21/17

FIGURE 11.11 Degrees of purity for hydraulic fluids as per ISO 4406 and NAS 1638.

© 2006 by Taylor & Francis Group, LLC

Lubricant Properties and Test Methods 30-31

30.3.3 Particle Counting — ISO 4406, ISO 11171

Fluid cleanliness is also a key factor for machinery system reliability, especially for hydraulic and precision
bearing systems. Insoluble particulates due to dirt ingress and oil degradation will increase with equipment
use. These materials will cause silting, gumming and abrasion of machinery parts. In practice, there is
a direct relationship between oil cleanliness and component usable life — the cleaner the system, the
longer the life of the oil and oil wetted parts. With supplementary filtering and clean oil makeup, the
particle count can be expected to maintain a nominal value or “dynamic equilibrium.” This “baseline”
represents the normal condition of the system. Any increase in particulate counts above the baseline
indicates an increase in contamination, regardless of whether the particles are wear metals, ingress dirt or
oil degradation by-products. Electronic particle counting is the preferred method of monitoring system
cleanliness. Since the number of particles per milliliter increases dramatically as particle size diminishes,
both the size and count data must be interpreted to determine to potential effect on a given machinery/fluid
system. The interpretation is further complicated by the fact that even small changes in the count bin sizes
have dramatic effect on counts recorded. To overcome this problem, the ISO community established the
ISO 4406 and ISO 11171 standards for fluid cleanliness monitoring.
The 4406 standard characterizes fluid cleanliness in increments from 0.01 to 2,500,000 particles per
milliliter of sample. The 4406 standard specifies three bin ranges and a series of numerical codes to indicate
the count in each bin, where:

• The first code indicates the particle count above 4 µm

• The second code indicates the particle count above 6 µm
• The third code indicates the particle count above 14 µm

The system is open-ended and can expand in either direction, above or below the current codes. In practice,
particle count data from a counter is compared to the ISO 4406 table (Table 30.3) for determination of the
ISO cleanliness rating for each size range. For example, a sample containing 80–160 particles per milliliter
greater than 4 µm; 20–40 particles per milliliter greater than 6 µm; and, 5–10 particles per milliliter
greater than 14 µm, would generate a cleanliness code of 14/12/10.
The ISO 11171 standard defines the requirements for particle counter measurement calibration and
data reproducibility. The standard cover flow rates, coincidence error, resolution, and sensor and volume
accuracy. It also ensures that all instruments are calibrated to the same National Institute of Standards
and Technology (NIST) traceable standards.

30.3.3.1 Comments
For simple hydraulic systems, the particle count will directly correlate with system reliability. However,
for machinery systems containing bearings and gears, particle counting does not indicate the nature of
the debris and other analysis techniques should be used when high particle counts are observed.
There are a number of particle counters available in bench top and portable versions. In addition,
there are a number of on-line particle-count sensors available for real-time monitoring of equipment
fluid systems. The sensors are extensions of the benchtop light-extinction particle counter technology,
packaged in a rugged casing to withstand the rigors and high pressures of on-line machinery fluid systems.
The sensors evaluate count data with preset limits and generate automatic alarms for immediate operator
attention such as green-light/red-light.
It should be noted that while most instruments have good measurement repeatability, different man-
ufacturers’ instruments and sensors will not give the same results for the same sample if the instrument
does not meet ISO 11171. In addition, entrained water and air bubbles affect all particle counters. Some
models handle air bubbles. However, water bubbles are counted as particles by all models. These problems
can result in unreliable counts especially for the smaller particle sizes.

© 2006 by Taylor & Francis Group, LLC

30-32 Handbook of Lubrication and Tribology

30.3.4 X-Ray Fluorescence Spectroscopy

XRF Spectroscopy is similar to AES except that x-ray energy rather than heat is used to stimulate the
metal atoms in the sample. The x-ray source raises the energy level of the atoms in the sample, resulting
in a corresponding release of x-ray energy from the excited atoms. The ASTM D4927, ASTM D6443, and
ASTM D6481 are specifically for determining additive metals in unused oils.

30.3.4.1 Comments
XRF can monitor solids, fluids, or dissolved metals in oil (whether naturally occurring, introduced as
additives, or resulting from normal wear processes in machinery) and can measure particles of all sizes. In
addition to benchtop XRF spectrometers, there are a number of XRF sensors for off- and on-line elemental
analysis. These sensors utilize both flow-through and filter patch technologies.

30.3.5 Water Determination by Karl Fischer Titration — ASTM D6304

The ASTM D6304 test determines water level by titrating a measured amount of the sample and the
Karl Fischer reagent. The reagent reacts with the OH molecules present in water and depolarizes an
electrode. The corresponding current change is used to determine the titration endpoint and calculate the
concentration value for water present.

30.3.5.1 Comments
Note many other compounds including some oil additives contain OH molecules. These will be counted
as water, skewing the results. Note the most common interfering materials are mercaptans and sulfides.

TABLE 30.3 Determination of the ISO Cleanliness Rating

ISO Min. Max. ISO Min. Max.

code count count code count count

1 0.01 0.02 15 160 320

2 0.02 0.04 16 320 640

3 0.04 0.08 17 640 1,300

4 0.08 0.16 18 1,300 2,500

5 0.16 0.32 19 2,500 5,000

6 0.32 0.64 20 5,000 10,000

7 0.64 1.3 21 10,000 20,000

8 1.3 2.5 22 20,000 40,000

9 2.5 5 23 40,000 80,000

10 5 10 24 80,000 160,000

11 10 20 25 160,000 320,000

12 20 40 26 320,000 640,000

13 40 80 27 640,000 1,300,000

14 80 160 28 1,300,000 2,500,000

© 2006 by Taylor & Francis Group, LLC

Lubricant Properties and Test Methods 30-33

Also, high-additive package lubricants such as motor oils will generate erroneous results due to addit-
ive interference. Consequently, the Karl Fischer test should not be used to evaluate water in crankcase
lubricants.

References
[1] National Lubricating Grease Institute (NLGI), www.nlgi.org.
[2] American Petroleum Institute (API), www.api.org.
[3] Society of Automotive Engineers (SAE), www.sae.org.
[4] Coordinating Research Council, Inc. (CRC), www.crcao.com.
[5] Caterpillar Machine Fluids Recommendations, Document SEBU6250-11, Caterpillar Inc.
October 1999.
[6] General Motors Maintenance Lubricant Standard LS2 for Industrial Equipment and Machine
Tools, Edited by General Motors Corporation, LS2 committee on maintenance lubricant standards,
revised 1997.
[7] Special Manual Lubricants Purchase Specifications Approved Products, Document 10-SP-95046
Cincinnati Milacron (Cincinnati Machine) Company, July 1995.
[8] Lubricating Oil, Fuel and Filters Engine Requirements, Detroit Diesel Corporation, 1999,
www.detroitdiesel.com.
[9] International ASTM “Standards on Petroleum Products and Lubricants” Volumes 05.01, 0.02, 0.03,
and 0.04. www.astm.org.
[10] Rand, Salvatore J., “Significance of Test for Petroleum Products,” 7th ed., International ASTM, 2003.
[11] Institute of Petroleum (IP). www.energyinst.org.uk.
[12] Deutsches Institut fur Normung e.V. (DIN), www.normung.din.de.
[13] American National Standards Institute (ANSI), www.ansi.org.
[14] International Standards Organization (ISO), www.iso.org.
[15] Toms, Larry A., Machinery Oil Analysis — Methods, Automation & Benefits, 2nd ed., Coastal Skills
Training Inc., Virginia Beach, VA, 1998.

© 2006 by Taylor & Francis Group, LLC