Contamination Control

Contamination Control
Equipment Management Series
 Overview
 Why Contamination Control?
 Contamination Sources
 Effects
 Measuring
 Prevention
 Why Contamination Control?

 Contaminated fluid systems:

• Shorten component and fluid life
• Reduce productivity
• Can lead to catastrophic failure and costly
downtime and repairs
 Why Contamination Control?

 Tests prove clean oil improves life

• Increased bearing life
• No contamination-related failures
from 6,000 to 11,000 hours
 Overview
 Why Contamination Control?
 Contamination Sources
 Effects
 Measuring
 Prevention
 Contamination Sources

Particles
Dirt

Metals
THE SYSTEM

Heat Air

Chemical
 Contamination Sources

 Built-in
 New fluids
 Ingressed contamination
• Cylinder wiper seals
• Reservoir vent ports
• Poor maintenance
 Generated internally
Two Types of Contamination

40 Microns & Larger Under 40 Microns

 Overview
 Why Contamination Control?
 Contamination Sources
 Effects
 Measuring
 Prevention
 Effects
 Erratic steering
 Cylinder drift
 Slower performance
 Unreliable operation
 Lower productivity
 Machine downtime
 Higher operating costs
 Timken Bearing Study
 Reason for study:
• Reduced bearing life
• 8,000 hours vs. 12,000 hours
 Method:
• Introduced 20 – 30 micron particles into new
bearings
Timken Bearing Study
Timken Bearing Study
 Overview
 Why Contamination Control?
 Contamination Sources
 Effects
 Measuring
 Prevention
 REC'D
181296 N 19850 324
Date
Taken
15-11-96
Measuring Contamination ELEMENT ELEVATED - POSSIBLY DUE TO DIRTY ENTRY. PRATICLE COUNT IS HIGH
CHECK SEALS AND BREATHER FOR DIRT ENTRY POINTS.
PREVIOUS POSSIBLE BEARING OR GEAR TRAIN WEAR. CHECK MAGNETIC PLUG FOR
REC'D #1 EXCESSIVE FERROUS METAL. OIL CHANGED AT THIS SERVICE EQUIP. # WL701

 Spectrographic Analysis
JOBSITE * BIG SUMP
201196 N 19526 244 MAKE CAT
Henry Walker Contracting P/L MODEL 994
Date Att: Mr Alan Carson SERIAL No. 9YF00040
PO Box 294 COMPARTMENT PUMP DRIVE
Taken IRON IS SLIGHTLY HIGH. ALL OTHER ELEMENTS TEST RESULTS APPER NORMAL.
Clov erdale OIL BRAND & TYPE BELRAY TL4

• IdentifiesPREVIOUS
elements in oil
WA 6105 OIL CHGD? Y
19-10-96 ORDER No. YANDI

POSSIBLE BEARING OR GEAR TRAIN WEAR. CHECK MAGNETIC PLUG FOR FOR LABEL #
LAB.I.D. #
13-45
96X52691

REC'D #2 EXCESSIVE FERROUS METAL. OIL CHANGED AT THIS SERVICE. EVALUATION CODE B

• Only up to 10-15 microns

251096
Date
N 19282 261 Date
Taken
12/12/96 OIL TOTAL HOURS
ADDED HOURS ON OIL
IRON ELEVATED - POSSIBLY DUE TO DIRTY ENTRY.PARTICLE COUNT RESULTS
TO BE ADDED WHEN AVAILABLE.
CHECK SEALS AND BREATHERS FOR DIRT ENTRY POINTS. CHECK MAGNETIC

in size
CURRENT
Taken FOR HOURS ON OIL IS SLIGHTLY HIGH. ALL OTHER ELEMENTS TEST RESULTS PLUG FOR EXCESSIVE FERROUS METAL. OIL CHANGED AT THIS SERVICE.
REC'D
06/10/1996 APPEAR NORMAL 181296 N 19850 324
Date
PREVIOUS CHECK MAGNETIC PLUG FOR EXCESSIVE FERROUS METAL. OIL CHANGED
Taken
15-11-96
AT DUE TO DIRTY ENTRY.PARTICLE COUNT RESULTS
IRON ELEVATED - POSSIBLY
CHECK SEALS AND BREATHER FOR DIRT ENTRY POINTS.
REC'D #3 THIS SERVICE. PREVIOUS
#1
POSSIBLE BEARING OR GEAR TRAIN WEAR. CHECK MAGNETIC PLUG FOR
REC'D EXCESSIVE FERROUS METAL. OIL CHANGED AT THIS SERVICE
141096 N 19021 279 201196 N 19526 244
Date
Taken IRON IS SLIGHTLY HIGH. ALL OTHER ELEMENTS TEST RESULTS APPER NORMAL.
19-10-96
ELEMENT OIL CONDITION/CONTAMINANTS
PREVIOUS POSSIBLE BEARING OR GEAR TRAIN WEAR. CHECK MAGNETIC PLUG FOR FOR
REC'D #2 EXCESSIVE FERROUS METAL. OIL CHANGED AT THIS SERVICE.
CONCENTRATIONS IN PPM 251096 N % OF
19282261 ALLOWABLE
Date
DATE CU FE CR PB AL SI MO NA MG SN ZN W F A ST OXI NIT SULFORTBN
Taken PCT
HOURS ON TANHIGH.
OIL IS SLIGHTLY PQ *** ELEMENTS TEST RESULTS
ALL OTHER
6/10/96 APPEAR NORMAL
181296 8 389 1 2 32 51 - 13 - CUR 1 - N - - - - -
PREVIOUS - - - - - -
CHECK MAGNETIC PLUG FOR EXCESSIVE FERROUS METAL. OIL CHANGED AT
REC'D #3 THIS SERVICE.
201196 15 301 2 5 32 75 - 42 - #1 2 - N -
141096 - N -19021 - 279 - - - 314 - - -
251096 4 304 1 1 8 18 - 10 - #2 1 - N - - -ELEMENT- - - - 2 - - OIL CONDITION/CONTAMINANTS
-
141096 8 211 1 1 7 13 - 11 - #3 1 - N -
DATE
- - - IN PPM-
CONCENTRATIONS
CU FE CR
-
PB AL SI MO NA MG
-
SN
14
ZN
-
W F
- -% OF ALLOWABLE
A ST OXI NIT SUL TBN PCT TAN PQ ***
181296 8 389 1 2 32 51 - 13 - CUR 1 - N - - - - - - - - - - -
201196 15 301 2 5 32 75 - 42 - #1 2 - N - - - - - - - 314 - - -
251096 4 304 1 1 8 18 - 10 - #2 1 - N - - - - - - - 2 - - -
141096 8 211 1 1 7 13 - 11 - #3 1 - N - - - - - - - 14 - - -
 Measuring Contamination
 Particle Count Par ticle Count
• Quantifies particles 1-200 Size Categor ies
microns > 2 M icr ons
> 5 M icr ons
> 10 M icr ons
> 15 M icr ons
> 25 M icr ons
> 50 M icr ons
> 75 M icr ons
> 100 M icr ons
 Understanding Particle Counting
 ISO codes
 28 code ranges
 ISO Codes
 Expressed in X/Y form
 X = number of particles larger than 5
microns (>5)
 Y = number of particles larger than 15
microns (>15)
 Example: 16/13
 ISO Code Chart
28 ISO Codes Number of Particles / mL
23 40,000 - 80,000
22 20,000 - 40,000
21 10,000 - 20,000
20 5000 - 10,000
19 2500 - 5000
18 1300 - 2500
17 640 - 1300
16 320 - 640
15 160 - 320
14 80 - 160
13 40 - 80
12 20 - 40
11
NOTE: Particle count
10 - 20
10 doubles at each level 5 - 10
9 2-5
8 1-2
 Recommended Cleanliness Targets

Hydraulic Systems (Implement & Steering).....…ISO 18/15

Vehicles With Electronic Transmissions..……….ISO 18/15
Vehicles With Mechanical Transmissions……….ISO 21/17
Fill oils........................................................…..….ISO 16/13
Non-Pressurized, Non-Filtered Compartments..…Not Established
 Compare the Difference

Very Hydraulic/
Dirty Minimum Steering Fill
Oil Target Targets Oils

24 21 18 16
5 Microns
& Greater 160,000 20,000 2,500 640

19 17 15 13
15 Microns
& Greater
5,000 1,300 320 80
 Contamination Control Example

How much of a difference will cleaning your oil

from ISO 19/16 to 16/13 really make?

Example: 32 GPM pump working 8

hours/day for 200 days
 Contamination Control Example
Amount of “Dirt” Flowing
Amount of “Dirt” in Oil Through Pump in One Year

ISO 19/16 464,47 kg/yr

ISO 18/15 22,4 kg/yr
ISO 16/13 8,9 kg/yr
 Overview
 Why Contamination Control?
 Sources
 Effects
 Measuring
 Prevention
 Prevention
 Housekeeping
 Oil storage and transfer
 Change filters carefully
 Parts handling and storage
 Hose assembly and storage
 Care in maintenance and repair
 Particle counting
 Housekeeping
 Sweep floors daily
 Clean up spills immediately
 Keep work benches
uncluttered and free of debris
 Limit use of floor storage
Housekeeping
 Oil Storage and Transfer
 Use a transfer filter cart
 Change when warm and agitated
 Use barrel covers
 Kidney-Loop Filtration System

Shown to increase oil and component life and reduce costs

 Change Filters Carefully
 Change on schedule
 Remove used filter carefully
 Do not pre-fill new filter
 Use high efficiency filters on serviced
machines
 Examine used filters
 Parts Handling and Storage
 Keep components packaged until ready to
install
 Return parts to storage in packaging
 Protect in-process components
 Wash components before assembly
 Hose Assembly and Storage
 Keep hoses plugged and capped
 Use Cat hose cleaner
 Care in Operation and Maintenance

 Perform daily inspections

 Keep hydraulic tank filled
 Maintain valves
 Use rod protectors
 Watch temperature
gauges
Questions?