Contamination

• List the different types of contaminants

and the damage they cause.
• Determine what size particles are coded
in the ISO 4406:99.
• Differentiate the types of wear/fatigue.
• Describe the three states and
progression of water contamination.
• Explain how water affects base oils,
additives and machine surfaces.
• List the four states of air contamination.
• Describe the three steps of proactive
maintenance.

© Noria Corporation
Contamination

Contamination Control – Building Reliability

OTHER
LUBRICANTS

SOLIDS MOISTURE AIR

(PARTICLES)
SOOT

RADIATION HEAT

Fluid contamination control targets the

primary cause of wear and lubricant
failure, forming the central strategy of a

Ref: JCF
ANTIFREEZE
proactive maintenance program.

00839 MLI
FUEL

© Noria Corporation
Contamination

Damage Caused by Oil Contamination

Changes Oil Changes Physical Chemically Attacks Mechanically Destructs
Contaminant
Chemistry Properties of Oil Machine Surfaces Machine Surfaces

Solids (dirt, metal • Oxidation • Viscosity effects • Adherent varnish • Abrasion

particles, soft • Additive depletion (especially from soot) • Surface fatigue
insolubles, soot)
Water • Oxidation • Viscosity effects • Acidity destruction • Cavitation
• Additive depletion (emulsions increase • Rust • Scuffing (loss of film
viscosity) strength)
Fuel • Additive depletion • Lowers flash point • Sulfuric acid • Film strength loss
(diesel, gasoline, • Aromatics • Lowers viscosity (corrosion)
natural gas) • Sulfur • Increases vapor
pressure
Glycol (antifreeze) • Oxidation • Viscosity increase • Acidity increase • Film strength loss

Ref: JCF
• Sludge • Deposits • Abrasion from oil balls
Air • Oxidation • Oxidation, viscosity • Rust and corrosion • Cavitation
• Microdieseling increase • Varnish from
• Foam microdieseling

00196 MLI
Heat • Thermal degradation • Viscosity increase or • Varnish • Film strength loss
• Oxidation decrease (cracking) • Acidity

© Noria Corporation
• Volatility
 Contamination | Particle

Case Study: Nippon Steel

100
Action Plan:
90 • Cleanliness targets
PERCENT OF NEW INSTALLATIONS AND FRACTIONAL DEFECTIVE

• Sampling ports
80 Pump replacement
frequency (% of total) • Improved filters and
70 breathers
• Onsite particle counts
60

50 Achievements:

40
• 75% reduction in oil
consumption

Ref: Nippon Steel

30 • 80% reduction in
hydraulic repairs
20
• 50% reduction in bearing
Program purchases
10
implementation

00173 MLI
0
1 2 3 4 5 6 7

© Noria Corporation
YEARS
Contamination | Particle

Case Study: Kawasaki Steel

120%
Action Plan:
Pre-contamination control levels
1. Set cleanliness targets
100%
2. Installed off-line filters

80% 3. Onsite particle counter

60% 100%

Ref: Kawasaki Steel

100%

40%

20% 43%
38%

00172 MLI
25% Fluid Consumption
20% 20%
4%
8% 8% Breakdown Frequency
0%
1 2 3 4 5

© Noria Corporation
YEARS
Contamination | Particle

National Research Council of Canada Study

Particle-induced Non-particle-induced

Sector Abrasion Erosion Fatigue Adhesion Fretting Other Total

Pulp and Paper 217 93 13 36 4 19 382

Forestry 101 - 14 25 12 6 158

Mining 551 117 25 15 1 17 726

Agriculture 735 54 45 104 2 - 940

Transportation 799 - 202 240 17 68 1,326

Ref: STL
Power Generation 69 30 - 31 26 34 190

Total 2,472 294 299 451 62 144 3,722

00162 MLI
Percentage by
Category 82% 18%

© Noria Corporation
Particles Cause Wear!
 Contamination | Particle

Particle Contamination: Both Cause and Effect of Wear

The vigilant practice of monitoring particles in oil effectively tracks the No. 1 cause of wear
(particles) and the No. 1 effect of wear (wear particles) using a single technology.

Failure Inducing Particle Producing

Proactive maintenance approach
focuses on controlling the rate failure inducing Abrasion
Abrasion particles occurrences
Cavitation
Erosion Adhesion
Caused by Not caused
Silting particles Corrosion by particles

Ref: Noria, JCF

Surface Fatigue Misalignment
Denting Predictive maintenance focuses on addressing the
particles which are a consequence of wear as well Wrong Oil
as induced failure particles

00196 MLI
“Reliability and maintainability are a function of “Contamination is the greatest single cause of
contamination control and contamination control lubricant malfunction and subsequent excessive

© Noria Corporation
leads to long life.” — wear of parts.” — Mobil Oil
General Electric
 Contamination | Particle

Bearing Manufacturers Speak Out on Contamination

Causes of Bearing Failures* (SKF) Contamination vs. Bearing Life (NSK)
Inadequate lubrication 60

Contamination very clean

RELATIVE BEARING FATIGUE LIFE

Overloading 50

Poor design
Wear 40
Environmental conditions
Miscellaneous
30
0 10 20 30 40 50 60 70 80 90 100
*Note: A single bearing failure can be due to multiple causes. moderately dirty
20
Causes of Bearing Failures (NSK)

Ref: SKF, NSK

50
Lubrication Issues
45 10
50 Refer to:
40 dirty
35 • Lack of lubricant
30 • Excessive 0
25 1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0
30 lubrication

00154 MLI
20 CONTAMINATION FACTOR
• Incorrect
15 Long Service Life Short Service Life
10 17 lubrication
5 3 selection

© Noria Corporation
0 • Chemical "Bearings can have an infinite life when particles larger than the
Fatigue Lubrication Contamination Installation
Issues Issues
degradation lubricant film are removed." – SKF
Contamination | Particle

Three-body Abrasive Wear

Wear particle produced
A particulate wear process by which particles are pressed
between two sliding surfaces.

Other names
Plowing, cutting, gouging, broaching

Surface damage Third Body (particle)

scratch marking, scoring, furrows, grooves and polishing, sanding

Influencing factors
• Surface hardness
• Particle size/hardness

Ref: ECF, McCrone

• Misalignment (reduces working clearance)
• Film thickness (load, viscosity, speed)
• Particle concentration
Imbedded Particle
Wear particles
cutting debris, machining swarf, cork screw, pig tail, needles

03761 MLI
Machines/components affected
pistons/cylinders, swash plates, journal bearings, gears, cams,
rolling-element bearings

© Noria Corporation
Contamination | Particle

Surface - Fatigue Wear

Often begins by denting due to hard or soft 1
particles. This creates a stress riser (berm). Pits and dents
disrupt EHD
Repeated high loading (stress reversals) on berm or film thickness
particles causes surface fatigue and eventually pits
form. This leads to larger pits from flaking followed Particle over-rolling
by spalls. 2
Other names
contact fatigue, spalling, pitting, brinnelling, cratering
Denting by soft particles

Ref: SKF, Tallian, Dowson

Controlling surface fatigue
Berm Dent
• Increase film thickness
• Reduce surface roughness 3 Pit
• Maximize hardness
• High pressure-viscosity coefficient Flaking enlarges pits Denting by hard particles

• Avoid particle contamination

• Keep oil dry

00791 MLI
High risk contacts Pitchline
rolling element bearings, gear teeth at pitchline, Pitch Arc

© Noria Corporation
cams and rollers Fatigue Wear Zone on Gears
Contamination | Particle

Erosion - Impact Wear

Erosion Wear is the loss of material that results Particle
Impingement
from repeated impact of small, solid particles, Erosion by
entrained gas or liquid medium, impinging on a Silica
(SEM image)
surface at any significant velocity.
Influencing Factors:
• Particle shape • Particle velocity
• Particle size • Temperature
• Particle hardness

Erosive wear is most prominent in hydraulic systems

Ref” Herguth
05306 MLI
© Noria Corporation
Contamination | Particle

Understanding Particle Size

Red Blood Cell Bacteria

(3 µ) Size Typical Number of
(5 µ)
Particles in 1 ml
Talcum Powder
Microns (µ) Inches
White Blood Cells
Particle size
(20 µ) (10 µ) 3 0.00012 1,036 range
causing the
5 0.0002 584 vast majority
10 0.0004 183 of machine
wear
Fine Floor
20 0.0008 36
Dust (40 µ)
40 0.0016 5
80 0.0032 1

As size gets ... number

Ref: Noria
larger ... becomes smaller
Human Hair
(80 µ)

02975 MLI
Microns(µ) = micrometers (µm)
1,000,000 microns = 1 meter
µ = micron
25,400 microns = 1 inch

© Noria Corporation
25.4 microns = 0.001 inch
Contamination | Particle

How Tough are Your Particles?

Ref Timken
25 mg 120 mg 170 mg >1000 mg

00036 MLI
Wear Debris Wear Debris Wear Debris Wear Debris

Particles of high compressive strength (hardness) and angularity

© Noria Corporation
(sharp edges) cause the greatest damage.
Contamination | Particle

Proactive Maintenance in Three Easy Steps

1 • Set ORS cleanliness targets. Make “cleanliness”
• Target cleanliness level should reflect a focal point
reliability goals. in lubrication.

2 • Take specific actions to achieve targets Next, focus on reducing the

(modifications). cost of cleanliness.
1. Reduce ingression
2. Improve filtration

Ref: JCF
3 Measure contaminant levels frequently. • Keep numbers conspicuous.

03601 MLI
1. What gets measured gets done (Step 2). • Deploy the invisible filter.
2. Post control charts of measured results. • Investigate non-conforming

© Noria Corporation
particle counts. – Ask why?
Contamination | Particle

ISO 4406:2017 Solid Contaminant Code

Example Particle Count Renard Series Table Number of particles per mL
R4 /R6 /R14 Range
Count
More than Up to and including number (R)
Size in Larger Than ISO 18/16/13

If only two range numbers are used: ISO */16/13 or ISO 16/13
Microns (c) Size per ml 5,000,000 10,000,000 30
2,500,000 5,000,000 29
4 1,752 1,300,000 2,500,000 28
640,000 1,300,000 27
6 517 320,000 640,000 26
160,000 320,000 25
10 144
80,000 160,000 24
14 55 40,000 80,000 23
20,000 40,000 22
20 25 10,000 20,000 21
5,000 10,000 20
50 1.3 1,752 particles > 4µm/ml 2,500 5,000 19

Ref: JCF, ISO 4406:2017

1,300 2,500 18
75 0.27
517 particles > 6µm/ml 640 1,300 17
100 0.08 320 640 16
160 320 15
80 160 14
55 particles > 14µm/ml 40 80 13
20 40 12
4µm 6µm 14µm ISO Code 10 20 11
5 10 10
1,301 321 41 18/16/13
2.5 5 9
1.3 2.5 8

00550 MLI
2,500 640 80 18/16/13 one 4X 0.64 1.3 7
more as many 0.32 0.64 6
2,501 641 81 19/17/14 particle particles 0.16 0.32 5
0.08 0.16 4

© Noria Corporation
0.04 0.08 3
5,000 1,300 160 19/17/14
0.02 0.04 2
0.01 0.02 1
Contamination | Particle

Typical ISO Cleanliness Levels

System with Typical Hydraulic Filtration 20/18/16 New Oil from Barrel 22/20/18

Ref: Pall, LubeWorks

01845 MLI
© Noria Corporation
System with β3 >200 Filtration 14/13/11 New System with Built-in Contaminants 23/22/20
Contamination | Particle

How much does it take to make a lubricant dirty?

1 One aspirin

2 Dropped into a 55 gallon

drum of lubricant

Ref JCF
1 ppm (approximately ISO 18/15/12)

00064 MLI
ISO 4406:2017

© Noria Corporation
Too dirty for many hydraulic and turbine oil systems!
Contamination | Particle

Oil Pump or Dirt Pump?

At ISO 21/18, this hydraulic system passes 136
50-pound bags of dirt through the teeth of the
pump in one year.
Filter ISO Code Dirt 50-lb. Relative Pounds of Dirt Filter Performance
(lbs.) Bags Pump Life Passing Through Absolute - Beta > 75
Pump/Year Nominal - Beta > 5
25 micron
21/18 6,784 136 1
nominal
10 micron
19/16 1,809 36 1.9
nominal
Pump
10 micron 50 gpm
16/13 211 4.2 4.4
absolute
6 micron
14/11 53 1 8.8
absolute

Ref: JCF, BHRA

3 micron
12/9 14 0.28 15
absolute

All figures are approximations Approximate Tank

Cleanliness

00167 MLI
At ISO 14/11, only one 50-pound bag

© Noria Corporation
of dirt passes through the pump.
Contamination | Particle

Machine Life-extension Table

NEW CLEANLINESS LEVEL (ISO CODE)
20/17 19/16 18/15 17/14 16/13 15/12 14/11 13/10 12/9 11/8 10/7

CURRENT CLEANLINESS (ISO CODE)

5 3 7 3.5 9 4 >10 5 >10 6 >10 7.5 >10 9 >10 >10 >10 >10 >10 >10 >10 >10
26/23
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
25/22
3 2 5.3 2.5 4.5 3 5 3.5 6.5 4 8 5 9 6 10 7.5 >10 >10 >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
24/21
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 9 >10 >10
2 1.5 3 2 4 2.5 5 3 7 3.5 9 4 >10 5 >10 6 >10 >10 >10 >10 >10 >10
23/20
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
22/19
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
21/18
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
300% Increase in 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
20/17
Life Extension 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
19/16
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
35% Increase in 18/15
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

Ref: Noria
Life Extension
1.3 1.2 1.6 1.5 2 1.7 3 2 4 2.5 6 3 8 5
17/14
1.2 1.1 1.5 1.3 1.8 1.5 2.3 1.7 3 2 4 2.5 6 3.5
Table Legend 1.3 1.2 1.6 1.5 2 1.7 3 2 4 3.5 6 4
16/13
1.2 1.1 1.5 1.3 1.8 1.5 2.3 1.8 3.7 3 4.5 3.5
Hydraulics Rolling
1.2 1.2 1.6 1.5 2 1.7 3 2 4 2.5
and Diesel Element 15/12

03617 MLI
Engines Bearings 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
Journal 14/11
1.3 1.2 1.6 1.4 1.9 1.5 2.3 1.8
Bearings Gear Boxes
and Turbo and Other 1.4 1.2 1.8 1.5 2.5 1.8
13/10

© Noria Corporation
Machinery 1.2 1.1 1.6 1.3 2 1.6

Based on ISO 4406:99 - 4 micron range number has been omitted.

Contamination | Water

Water Contamination – The Scourge of Lubricating Oils

Use ORS Practices
• Restrict its ingression
• Recognize its presence
• Analyze its state and concentration
• Remove it quickly

Ref: JCF
Too often ignored as a primary
failure root cause.

00239 MLI
Water is the second most
destructive contaminant.

© Noria Corporation
Contamination | Water

Water Contaminated Oil - States of Co-existence

Dissolved Water The water saturation point is the maximum
Water molecules dispersed one-by-one throughout the
oil like humidity
amount of dissolved water an oil will hold.

Emulsified Water
Microscopic globules of water dispersed in stable
suspension in the oil; like fog

Free Water
Water that readily settles to tank/sump bottom like rain

Oil
Dissolved* Emulsified* Free* cloudy oil
(ppm) (ppm) (ppm) clear/bright
(water-in-oil
oil – dissolved
emulsion)
New Hydraulic Fluid 0-200 200-1,000 >1,000 water only

Ref: JCF
Aged Hydraulic Fluid 0-600 600-5,000 >5,000 lacey cuff
(oil-in- water
New R&O Oil 0-150 150-500 >500 emulsion)

00241 MLI
Aged R&O Oil 0-500 500-1,000 >1,000
free water
New Crankcase Oil 0-2,000 >2,000 N/A

© Noria Corporation
*Beware, these are approximate values assuming water had
contaminated these different oil types
Contamination | Water

Water-related Damage to Rolling-element Bearings

Water puts bearings at high risk when the machine
is at rest. Once static etching/corrosion gets started, Water-related
bearing failure is imminent. Bearing Deposits
• Impaired pressure-viscosity coefficient
(poor film strength)
• Hydrogen embrittlement
• Rust particles lead to three-body abrasion
• Pitted/etched rusted surfaces lead to
*Depends on oil chemistry and temperature

PERCENT BEARING LIFE REMAINING

two-body abrasion 110
100
• Static etching/corrosion Might Appear

Ref: SKF, Mobil

Often Appears
90 Normal Cloudy
80
While all states of water in oil can cause damage to 70
60
the oil and machine, emulsified water is considered
50 Bearings can lose 75%
the most destructive. of life due to water

04043 MLI
40
30 before oil is cloudy*
“The presence of water in lubricating oils can 20
shorten bearing life down to 1 percent or less, 10

© Noria Corporation
0
depending on the quantity present.” – SKF 0 0.05 0.1 0.15 0.2 0.25
PERCENT WATER IN OIL
Contamination | Water

Oil/Water Demulsibility
Typical Results Related tests:
Test Objective/ Summary Applications
Good Bad • ASTM D2711
(for oil viscosities above 200
Demulsibility This test method provides a guide for determining the water 40/40/0(5) 0/0/80 cSt @ 40˚C)
ASTM D1401 separation characteristics for oils. This test was originally developed Turbine oils,
• DIN 51589-1-1991 X
specifically for steam turbine oils having viscosities of 32 to 150 cSt hydraulic fluid, Introduces water in the form
oil/water/emulsion
at 40˚C. The three measurements for oil/water/emulsion (cuff) are compressor oils, (time in minutes of steam
presented in that order and are separated by forward slashes. Test gear oils to separate)
minutes are shown in parentheses.
Paddle revolves
at 1,500 RPM
Significance Ineffective oil/water separation can for five minutes

lead to corrosion, poor lubrication, rapid oil Emulsifying

40 ML Distilled water
plus 40 ML oil sample Thermometer
agent
oxidation and hydrolysis. Freely
100 ML

Ref: Lubrizol, GT, JCF

Graduated cylinder
separated
Causes of Poor Demulsification Emulsified
water
• Oil mixed with detergents and dispersants (crankcase oil) water droplet
• Depletion of demulsifying additives (water washing) (Micelle)
• Oil oxidation (oxide insolubles)
• Oil heavily contaminated (polar impurities)
• Water heavily contaminated
• Distilled water 40/40/0 EP Gear Oil
• Seawater 0/0/80 Oil

01489 MLI
• Oil contaminated with surfactants 3 ML cuff
allowed Emulsion
(parts coating and process chemicals)
• Oil contaminated with washdown soaps/detergents Water

© Noria Corporation
• Cold oil temperatures
• High oil turbulence Water or oil bath
40/40/0 25/25/30 0/0/80 130˚F or 54˚C
Contamination | Water

Water Contamination – Base Oil Effects

Water-related Problem What’s Happening

Water promotes changes in chemical and physical

Oxidation and hydrolysis properties in mineral oils and some synthetics.
• Acid formation
• Viscosity change
• Varnish
• Sludge

Water encourages aeration problems.

Aeration
• Foaming

Ref: JCF
• Air entrainment

00245 MLI
Viscosity effects Water leads to stable emulsions, higher viscosity
and non-Newtonian properties (higher viscosity and

© Noria Corporation
impaired load carrying capacity).
Contamination | Water

Water Contamination – Additive Effects

Additive Attacked Mode of Attack Result

Antioxidant (phenols)
Hydrolysis (chemical • Sediment (floc)
ZDDP reactions with water) • Acids
• Additive mortality
• Hydrogen sulfide
Rust inhibitor
• Sludge
• Sediment
De-emulsifying agents Water washing • Additive mortality
• Bacteria
• Poor oil/water

Ref: JCF
Detergents and separation
dispersants

00240 MLI
Dielectric constant
Borate EP increase (oil becomes an • Loss of additive
electric conductor) performance

© Noria Corporation
Contamination | Water

Water Contamination – Machine Effects

Water-related Problem What’s Happening

Corrosion • Water in oil gives acid its greatest destructive potential.

• Water is the central promoter of rust.

Film strength loss • Water in elastohydrodynamic contacts (rolling element bearings)

cause film strength failure and hydrogen embrittlement.
• Water flash-vaporization in hydrodynamic contacts (journal
bearings) causes bearing failure.

Ref: JCF
Steam damage • Water is the leading cause of hydraulic pump cavitation
(vaporous cavitation). Water passing between loading
frictional surfaces can explode, causing metal fracture (7oz of
H2O turns into 55 gallons of steam).

00246 MLI
Silting and filter plugging

© Noria Corporation
• Water causes poor filterability and valve stiction.
Contamination | Corrosion

Chemical – Corrosion Wear

Corrosion wear is surface damage resulting Controlling Corrosion
from exposure to a reactive environment • Corrosion-resistant
metallurgy
Other names:
• Fluid contamination control
corrosion fatigue, fretting corrosion, cavitation (heat, moisture, water,
corrosion, erosive corrosion, stress corrosion, acids, bacteria)
galvanic corrosion, etching, crevice crack • Protective barrier
(coatings, surface
corrosion, static corrosion
treatments, etc.)
• Corrosion-controlling
additives (rust inhibitors,
Fluid metal deactivators, over-
Causes
• Free or emulsified water
contamination
• Acids
• Heat: Rust rate doubles for
every 10˚C (18˚F) increase
in temperature – starts at
about 60˚C (140˚F)
• Electrolytes, salt
• Bacteria
• Hydrogen sulfide
• Combustion by-products,

Ref: ECF, GT, JCF

base additives, etc.) high-sulfur fuels
Fluid
• Oil analysis (early • High humidity
Intergranular attack
detection of water, acids • Depleted rust/corrosion
Uniform attack and depleted corrosion inhibitors
inhibitors)
Fluid

03031 MLI
• Properly timed oil changes
Fluid
• Corrosion preservative
treatments/practices for

© Noria Corporation
stored or standby
Pitting attack Subsurface attack equipment
Contamination | Water

Water Contamination – Generator of Other Contaminants

Bacteria (microbes) Wax curd
(cold start temperature induced in
some motor oils)

Rust particles Sludge

(water mops up polar impurities,
leading to sludge)

Ref: JCF
Soot agglomeration Acids

00257 MLI
(H2SO4, organic acids, etc.)

© Noria Corporation
Contamination | Water

Life Extension Table for Setting ORS Dryness Targets

NEW MOISTURE LEVEL (PPM)

10,000 5,000 2,500 1,000 500 250 100 50

Rolling- Rolling- Rolling- Rolling- Rolling- Rolling- Rolling- Rolling-
Journal Journal Journal Journal Journal Journal Journal Journal
element element element element element element element element

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
CURRENT MOISTURE LEVEL (PPM)

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

10,000 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

5,000 1.4 1.2 2.3 1.6 3.3 1.9 4.8 2.3 7.8 2.9 11.2 3.5

Ref: SKF, OSU, DT

2,500 1.6 1.3 2.3 1.6 3.3 1.9 5.4 2.4 7.8 2.9

1,000 1.4 1.2 2.0 1.5 3.3 1.9 4.8 2.3

500 1.4 1.2 2.3 1.6 3.3 1.9

01081 MLI
250 1.5 1.3 2.3 1.6

100 1.4 1.2

© Noria Corporation
Contamination | Air

Air Contamination: States of Co-existence

Co-mingling State Risks to Oil/Machine
DISSOLVED High levels of dissolved air from pressurized oil accelerates
Normal levels 10 percent by volume for mineral oils (undissolved). additive depletion and oxidation
No clouding

ENTRAINED Oil compressibility, poor heat transfer, film strength failure, oxidation,
Unstable suspended microscopic air bubbles in oil - clouding cavitation, varnishing (microdieseling)

FREE Hydraulic compressibility, corrosion, vapor lock, loss of

Trapped pockets of air in dead zones, high regions, stand pipes system controls

FOAM Hydraulic compressibility, corrosion, vapor lock (retarded oil

Highly aerated tank and sump fluid surfaces (>30 percent air) supply), loss of system controls

Ref: JCF, ECF

Entrained Air Control…
• Reduces foam Mineral oil is 10%
(PERCENT BY VOLUME)

air at atmospheric
pressure
• Reduces oxidation
AIR SOLUBILITY

• Reduces pump cavitation

00237 MLI
Phosphate ester
• Reduces varnishing Water-glycol Foam
• Reduces spongy hydraulics
Free air

© Noria Corporation
• Reduces erratic fluid flow
Entrained air
• Reduces overheating PRESSURE (ATMOSPHERES)
Dissolved air
Contamination | Air

Causes of Poor Air Detrainment and Foaming

Air-release Problems
• Low surface tension Good foam
Stable foam suppression
• Oxidation
return line return line
• Polar contaminants
• Water contamination
• Solvents Contribute to

• Certain additives Foam Tendency Problems

• Small (crushed)

Ref: JCF, Duncanson

air bubbles
(a 2mm air bubble will rise [detrain]
twice as fast as a 1mm air bubble)
Contribute to
• High oil viscosity
Foam Stability Problems

00576 MLI
• Too much defoamant Poor air release Good air release
Low surface tension High surface tension
• Solid suspensions that

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enables bubble to break air bubbles stay large and
apart and hang in oil rise rapidly
seed air bubbles
Contamination | Air

Aeration Affects
How Aeration Affects Oil Flow, Cavitation Erosion and Oil Thermal Damage (varnish potential)

Suction-line Restriction Aerated Tank

Pump Imploding air bubbles Pump

(adiabatic heat,
localized thermal oil
Formation of damage, Imploding air bubbles
vapor and microdieseling) (oil damage)
entrained air

To machine

Ref: Mecoil, JCF

Suction-line
restriction (too Actual oil flow
narrow, too long, Cavitation (5 LPM)
partially closed damage from
valve, improper vapor
filter, etc.)
Expected oil flow: 20
From tank LPM

05411 MLI
Entrained air from
foamy, aerated tank

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Contamination| Cavitation Wear

Cavitation Wear
Cavitation Wear Mechanism Pump valve plate damaged by cavitation wear Cavitation damage to journal bearing

Initial
Bubble Collapsing
Bubble

Microjet
Source
Air/Vapor Bubbles
are Compressed

Ref: ECF, ASM, GT

Vaporous Cavitation
The process begins by the entrainment of oil
or water vapor bubbles (e.g., suction lines).
Later, a sudden pressure increase causes the
Gaseous Cavitation
As gas bubbles (typically air) travel into
high-pressure regions, they collapse,
producing intense pressure and potential
Machine/surface potential
affected by cavitation wear
• Control valves/valve seats
• Pumps

02957 MLI
bubbles to collapse and produce a microjet surface damage. This commonly occurs
from suction to the pressure sides of • Actuators
that impinges upon a nearby surface.
Note, a 7-ounce glass of water turns into 55 high-pressure pumps. • Spool lands

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gallons of steam. Vaporous cavitation is the • Journal bearings
most destructive.
• Hydraulic cylinders
Contamination | Air

Foam Examples

Ref: Noria 02051

00449 MLI
Foam in reservoir

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Foam caused by mixing two incompatible oils
Summary

Contamination
• Describe and list contaminants.
• What size particles are coded in the
ISO 4406:99?
• What are some types of wear and fatigue
due to solid contamination?
• List the three states of water
contamination.
• Explain how water affects base oils,
additives and machine surfaces.
• List the four states of air contamination.
• What are the three steps of a proactive
maintenance strategy?

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Contamination Control
• List contaminant exclusion and
removal approaches.
• Describe the particle population
growth life cycle if no contamination
control is in place.
• Describe the function and purpose of
desiccant breathers.
• Describe the different types of filter
media and use the beta ratio to
identify filter efficiency.
• Identify methods to stop ingression
and remove water, air and varnish
contamination.

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• Identify the filtration options to
remove varnish.