Wm Canning Marston Bentley Div

Fluid Cleanliness Awareness Training

GE Australia, November 2010

Presented byMohammed Ali Ken McKenzie Regional Technical Services Country ManagerMacDermid Offshore SolutionsIntroductionParticle Analysis & Contamination Control

Why Particle Counting is Carried Out?What are Particles?Automatic Particle Counters vs Optical MicroscopesFluid Cleanliness Testing Review & ConclusionIntroductionParticle Analysis & Contamination Control

Why Particle Counting is Carried Out?What are Particles?Automatic Particle Counters vs Optical MicroscopyFluid Cleanliness Testing Review & ConclusionWhy Particle Counting is Carried Out?Particles are Contamination 50% of Components replaced due to Wear 55% Hydraulic System problems attributed to Dirt

Time is Money !

Why Particle Counting is Carried Out?Preventive MaintenanceExamination & Identification of dirt Prediction of Component (Seals, Pumps, Valves...) Failure & Filter Blockage What are Particles?An Individual Unit of Particulate MatterSize & Shape Vary Greatly

Group ExerciseWhat are Particles Made From?How Do Particles Form?What Impact do Particles have on Equipment? Damage Caused By ParticlesSoft Particles (Grease, Paste, Fibres, Filter Media, Seals...) Block FiltersHard Particles (Sand, Silica, Rust, Swarf...) Cause Abrasion & Wear Increase Contamination Level. Block Filters (to a Lesser Extent).Soft Particles - Polymers and Fibres

Hard Particles - Silica

Hard Particles - Rust

Hard Particles - Bright Metal

Hard Particles - Black Metal

IntroductionParticle Analysis & Contamination Control

Why Particle Counting is Carried Out?What are Particles?Automatic Particle Counters vs Optical MicroscopesFluid Cleanliness Testing Review & Conclusion

Automatic Particle Counters vs Optical MicroscopyAutomatic Particle Counters (APCs)Two Types:Laser Light Scattering or ObstructionUse Light Reactive Electronics to Size the Shadow of Particles (e.g. PAMAS) Pressure DifferentialUse Set Size Mesh Filters andPressure Differential recorded acrossthem (e.g. PALL)Automatic Particle Counters vs Optical MicroscopyAPCs require little Training to UseLight Scattering APCs See Gas Bubbles and Insoluble Liquids as ParticlesAPCs Round Irregular Particles to an Average SizeAPCs See Long Fibres as a String of Small ParticlesAPCs have Problems with Oceanic HW500 Fluids Automatic Particle Counters vs Optical MicroscopyOptical Microscopy requires Training to UseOptical Microscopy Allows Qualitative and Quantitative Analysis of ParticlesOptical Microscopy Seeing is Believing

ConclusionMacDermid Favour Optical MicroscopyIntroductionParticle Analysis & Contamination Control

Why Particle Counting is Carried Out?What are Particles?Automatic Particle Counters vs Optical MicroscopesFluid Cleanliness Testing Review & ConclusionFluid Cleanliness TestingFluid Sampling & HandlingSlide PreparationParticle CountingCleanliness ClassesFluid Sampling & HandlingTaking a Clean Fluid SampleOpen Sample Valve to Obtain Steady FlowAllow ~ litre Fluid to Flush Valve and LineFlush Sample Bottle & Lid Twice in the Fluid StreamDo Not Touch Valve until Sample has been TakenFluid Sampling & HandlingFluid Sampling & Handling Always Increases Contamination LevelsContamination Level in the System is Always Lower than the CountError Should be Kept to a Minimum

ARP598B Particle Count BasicsFilter 100 ml Fluid Sample through Gridded MembranePrepare Microscope SlideExamine Slide Under Microscope.Particle are counted according to size:5, 15, 25, 50 & >100 m Slide PreparationSlides Prepared in a Clean RoomEnsure that all Equipment making contact with the Fluid Sample is Flushed CleanDo Not Breath on or Lean Over Fluid Sample or test Equipment

Optical MicroscopeUpright Binocular, Transmitted light 10x Eyepiece, Min 4x/5x & 10x ObjectivesGraticule in Eyepiece for Particle SizeGraticule must be Calibrated (using Stage Micrometer)Calibration Not Always Possible in Reality !

Sizing Particles with a GraticuleTotal Area on Standard Filter Membrane is 960mm2Width of One Grid Square is 3.08mm or 3080m.

Sizing Particles with a Graticule50x Magnification 1 Division = 20 m100x Magnification 1 Division = 10 m

Photos Courtesy of PALLSizing Particles with a Graticule500x Magnification 1 Division = 2 m

Particle Size = 40 mPhotos Courtesy of PALLParticle CountingCount is Performed to ARP 598 with Class reported by as either AS or NAS LevelExamine Areas Over Whole Membrane Do Not Concentrate on the Middle Few Squares

Particle SizeCount ParticlesMagnification>100 mWhole Membranex50>50 m 20 Grid Squaresx50>25 m20 Grid Squaresx100>15 m10 Grid Squaresx100 > 5 m 10 Unit Areas x200Particle CountingParticle Distribution should be Uniform, Uneven Distribution Will Invalidate the CountParticle Size guided by its Largest Dimensioni.e. Fibre Length can be more than 10x its Width Error in Counting Should not be Greater than 10% between Operators or Laboratories

Particle CountingCount for 100ml Fluid & Whole membrane Factor needed to convert Count from Area Examined to Whole membrane

Area ExaminedArea mm2FactorWhole Membrane960x11 Grid Square~9.5x10010 Grid Squares~95x1020 Grid Squares~190x51 Unit AreaMicroscope dependentParticle CountingCount for 100ml Fluid & Whole membrane.Factor needed to convert Count from Volume tested to 100ml.

Fluid VolumeFactor100x150x225x4Cleanliness ClassesNAS1638 (Old Industry Standard)Particles Counted according to Size Ranges: 5-15, 15-25, 25-50, 50-100 & >100 mCleanliness Class generally dictated by larger particlesAS4059Cumulative Count based on Particle Size:>1, >5, >15, >25, >50 & >100 mNumeric Class qualified by Letter Code based on Particle Sizes counted

NAS 1638SizeMaximum Contamination LimitsOptical Count5-15 m15-25m25-50m50-100m> 100mClass0012522410025044820150089163121000178326132000356631124400071212622458000142525345861600028505069016732000570010121803286400011400202536064912800022800405072012810256000456508100144025611512000912001620028805121210240001824003240057601024AS4059SizeMaximum Contamination LimitsOptical Count> 1m> 5m> 15m> 25m> 50m> 100mSize CodeABCDEF000195761431000390152275100780304541020115606091092041231201220217397136520243043276132412,5004860864152264525,00097301730306538650,00019,5003460612106167100,00038,90069201220212328200,00077,90013,9002,450424649400,000156,00027,7004,90084812810800,000311,00055,4009,8001,700256111,600,000623,000111,00019,6003,390512123,200,0001,250,000222,00039,2006,7801,020TroubleshootingPoor or Erratic Cleanliness Results?Is Your Room Clean?Is Your Technique Good Enough?Has a Background/Blank Contamination Count been made?Fluid Transport Issues?

Blank AnalysisPrepare a Blank Membrane Slide Using 100 5ml Filtered Water Total Count should be