Fluid Analysis Field Guide · Fluid Analysis Field Guide Sampling Methods There are four main sampling methods you can use: • Method 1 (Preferred): Ball valve with PTFE (or similar

Fluid Analysis Field Guide

For Measuring, Analyzing & Improving Lubricant Condition

Introduction to Contaminates

Understanding ISO Codes

Setting Cleanliness Targets

Sampling Methods

Fluid Analysis

Flushing Best Practices

Fluid Power Diagram Symbols Cheat Sheet

Helpful Conversion Charts

RIG Services & Contact Information

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4-6

7-8

9-10

11-13

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15-19

20-21


Introduction to Fluid Contaminates

Contaminates find their way into fluid systems through many sources. Even brand new systems that have been “pre-flushed” can accumulate contaminates during the installation and start-up process. Common sources of contaminates include:

System components:• Cylinders• Filters• Flow meters• Hydraulic motors• Hoses & pipes• Pumps• Tanks & reservoirs• Valves

Externally Introduced:• Reservoir breathing• Cylinder rod seals• Bearing seals• Component seals

Operations & Maintenance Introduced:• Assembly of systems• Installation of systems• Operation of system• Break-in of system• Fluid degradation over time• System or parts disassembly & repair• Make-up oil

Accidents, 15%

Outdated, 15%

Mechanical Wear, 50%

Corrosion, 20%

Common Contaminates:

Silica – Sand, dust

and other environmentalcontaminates

Bright Metal - Shiny

metal pieces often productsof component wear

Black Metal - Oxidized

ferrous metal inherent in hydraulic & lubricating systems

Cake of Fines – Silt

particles build up and block filters

Water –Can enter the

system through leaks, condensation, inadequate reservoir covers, and temperature changes.

Sources of Contaminates:

Factors The Decrease Equipment Life

A study by MIT found 70% of component replacements and loss of machine life is due to surface degradation. Study by Dr. E Robinowicz, M.I.T.

Fibers – Sourced from

paper and fabrics such as shop rags, gloves, etc.

Rust – Presence indicates

water in the system, oftenfrom oil storage tanks and similar vessels

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How to Read ISO Cleanliness Codes

ISO CodesISO cleanliness codes help us understand the amounts and sizes of contaminating particles in fluids and set target goals when cleaning fluids.

ISO codes quantify contamination levels per milliliter of fluid at three distinct particle sizes: 4μ[c], 6μ[c], and 14μ[c].

When you are looking at an ISO code, you are looking at three measurements;

1. The volume of particles in the fluid that are 4μ[c] in size and greater

2. The volume of particles 6μ[c] and greater3. And the volume of particles 14μ[c] and greater.

What is often the most confusing about ISO codes is that the ISO number is a code that corresponds to a range, and is not a volume measurement itself. The chart below shows how ISO codes correspond to volume measurements.

The important thing to remember is that for every 1 point increase in ISO code, there is a DOUBLING of the contaminate volume range. So, if you go from a code 19 to a code 20, you jump from a contaminate range of 2,500-5,000 particles per milliliter (p/ml) to a range of 5,000-10,000 p/ml.

Let’s take an ISO cleanliness code example and break down it’s meaning. Let’s say your fluid test comes back with an ISO code number that reads 23/21/20. That would mean:• You have particles 4μ[c] (and larger) present in your

fluids in the range of 40,000-80,000 p/ml• 6μ[c] particles or larger present in volumes between

10,000-20,000 p/ml• And particles 14μ[c] or larger present in volumes of

5,000 -10,000p/ml.

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Setting Target ISO Cleanliness Codes

Setting TargetsWhile every situation is different, we are often aiming for ISO code ranges that land somewhere between 12-17 for the first number, 10-14 on the second, and 8-13 for the third AFTER fluid reconditioning.

When we set goals for fluid reconditioning programs, we take several factors into consideration. Above is an example of a chart we might use to reference the following key factors and determine acceptable ISO codes and particle ranges. When using this chart, we are taking into account:

• Your main objectives for the cleaning program (minimizing repairs, extending equipment life, meeting regulations, satisfying warranties, etc)

• The most sensitive component coming into contact with the fluid, This component is the one we want to based the entire standard off of to make sure our fluid is optimized for that critical piece of equipment.

• The type of fluid used (petroleum or non-petroleum based fluids).• The presence of additional factors, including:

• How critical the most sensitive component is to safety or overall system reliability• Frequent cold starts• Excessive shock or vibration• Severe operating conditions

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Target Fluid Cleanliness Worksheet

Setting Targets

Use the list of parameters below to carefully consider operational and environmental conditions. Once complete, find your Recommended Cleanliness Level (RCL) by plotting weighted criteria on the chart on the next page.

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Target ISO Worksheet Chart

Setting Targets

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Sampling Methods

There are four main sampling methods you can use:• Method 1 (Preferred): Ball valve with PTFE (or similar seats), or a test point• Method 2 (Second Best): Valve of unknown contamination shedding capabilities• Method 3 (Only if Line Sample Unavailable): Reservoir or bulk containers sampling• Method 4 (Last Resort): Bottle dripping

Method 1: Small ball valve with PTFE or similar seats, or a test point

1. Operate the system for at least 30 minutes prior to taking a sample (for even particle distribution)

2. Open the sampling valve and flush 1 liter of fluid through the valve. Do not close valve after flushing

3. When opening the sample bottle, take extreme care not to contaminate it

4. Half fill the bottle with system fluid. Use this to rinse the inner surfaces and then discard

5. Repeat step four a second time without closing the valve6. Collect sufficient fluid to fill ¾ a bottle (to allow contents to be

redistributed) 7. Cap the sample immediately and close the sample valve. DO NOT

TOUCH THE VALVE WHILE RETRIVING SAMPLE8. Label the sample bottle with system details and package for

transport to lab

Method 2: Valve of unknown contamination shedding capabilities

1. Operate the system for at least 30 minutes prior to taking sample (for even particle distribution)

2. Open the sampling valve and flush 3-4 liters of fluid through the valve. Do not close the valve.

• Recommended: connect the outlet valve back to the reservoir using flexible tubing

3. After flush, remove the flexible tubing from the valve with the valve still open and fluid flowing. Remove the cap of the sample bottle and collect sample using steps 4-6 of Method 1.

4. Cap the sample immediately and then close the sample valve. DO NOT TOUCH THE VALVE WHILE TAKING THE SAMPLE

5. Label the sample bottle with system details and package for transport to lab

Method 3: Sampling from reservoirs and bulk containers

1. Operate the system for at least 30 minutes prior to taking sample (for even particle distribution)

2. Clean the area of entry to the reservoir where sample will be obtained

3. Flush the hose of the vacuum sampling device with filtered (0.8μ[c] solvent to remove possible contamination

4. Attach a suitable sample bottle to the sampling device, carefully insert the hose into the reservoir, mid-way into the fluid. Take care not to scrape the hose against the sides of the tank or baffles to avoid contamination getting sucked into the hose

5. Pull the plunger on the body of the sampling device to produce vacuum and half fill the bottle

6. Unscrew bottle slightly to release vacuum, allow hose to drain7. Flush the bottle by repeating steps 4-6 two or three times8. Collect sufficient fluid to ¾ fill the sample bottle, release the

vacuum and unscrew the sample bottle. Immediately recap and label the sample bottle.

Method 4: Bottle Dripping

1. Operate the system for at least 30 minutes prior to taking sample in order to even distribute particles

2. Clean the area of entry to the reservoir where sample will be obtained

3. Ensure the outside of the bottle is clean by flushing with filtered solvent

4. Remove the cap from the sample bottle. Carefully fil the sample bottle by dipping it into the reservoir and then discard the fluid after rinsing the inside of the sample bottle

5. Repeat Step Four. Carefully fill the sample bottle, cap immediately and wipe the outside

6. Secure any openings in the reservoir

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Short Element Life Troubleshooting Guide

Application(Old or New)

Check Filter Sizing

Check SystemCleanliness

Check Indicator

Fit ΔP Gauge And Verify Clean ΔP

Has Anything Altered in the System?

• Recent maintenance• New oil added• Change in oil type• Change in temperature• Change in flow rate

Check System Cleanliness Level

Increase Surface Area• Longer Bowl• Larger Assembly

System Clean-Up Occurring

Verify System Specifications

Particularly Flow Rate

Check Fluid Chemistry

Spectrographic Check Indicator

Water Content

Filterability Test On New & System

Oil

Check for Gels & Precipitates

Inspect System Filter Element

Very Possible System or Component Problems

• Other analysis tests• Wear debris• SEM/EDX• Check by-pass valve

Change Indicator

New Old

OkayAbove required level

No

Okay

Faulty

Faulty

Above required level

Clean ΔP too high

Okay

Okay

Okay

Okay

Higher than expected

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Analysis Methods Guide

Method Units Benefits Limitations

Optical Particle Count Number/mL

• Provides size distribution• Unaffected by fluid

opacity• Unaffected by water and

air in fluid sample

Sample preparation time

Automatic Particle CountNumber/mL

Fast and repeatableSensitive to silt, water, air

and gels

Patch test and fluid contamination

comparator

Visual comparison/cleanliness

code

• Rapid field analysis of system fluid cleanliness levels

• Helps identify types of contamination

Provides approximate contamination levels

FerrographyScaled number of

large/small particles

Provides basic information on ferrous and magnetic

particles

Low detection efficiency on non-magnetic particles e.g.

brass, silica

Spectrometry PPMIdentifies and quantifies

contaminant material

• Cannot size contaminants

• Limited above 5 μ[c]

Gravimetric mg/LIndicates total mass of

contaminant

• Cannot distinguish particle size

• Not suitable for moderate to clean fluids

• Ex. ISO 18/16/13

Particulate Fluid Analysis Methods

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Water Contamination Analysis

Analysis

Water Content Analysis Methods

Method Units Benefits Limitations

Crackle Test NoneQuick indicator of presence of free water

Does not permit detection below saturation

Chemical (calcium hydride)

Percentage or PPMA simple measurement of water content

Not accurate on dissolved water

Distillation PercentageRelatively unaffected by oil additives

Limited accuracy on dry oils

FTIR Percentage or PPM Quick and inexpensiveAccuracy does not permit detection below 0.1% or 1,000 PPM

Karl Fischer Percentage or PPMAccurate at detecting low levels of water (10-1,000PPM)

Not suitable for high levels of water. Can be affected by additives

Capacitive Sensors (Water sensors)

Percentage of saturation or PPM

Very accurate at detecting dissolved water, 0-100% of saturation

Cannot measure water levels above saturation (100%)

Water contamination causes:• Oil breakdown, additive precipitation

and oil oxidation• Reduced lubricating film thickness• Accelerated metal surface fatigue• Corrosion

Sources of water contamination:• Heat exchanger leaks• Seal leaks• Condensation of humid air• Inadequate reservoir covers• Temperature reduction causing

dissolved water to turn into free water

10,000 PPM 1%

1,000 PPM 0.1%

100 PPM 0.01%

Water concentration in oil should be kept as far below the oil saturation point as possible

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Flushing Overview

Removing Contaminates with FlushingWe use flushing to remove contamination that has gotten into fluid systems through system assembly, installation, maintenance and operation. To flush a system, fluids are passed through the system at a high velocity (usually hot oil).

Flushing is a critical part of maintaining a systems operating integrity. Without regular flushing and monitoring of ISO cleanliness levels, equipment life will be shortened and the risk of breakdowns increases.

The first step in flushing a system, is to determine a Reynolds number for the system. Reynolds

No (Re) is a non-dimensional number that provides the degree of turbulence within a pipe or a hose.

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Ideal Flushing Equipment Set Up

Once you’ve established the flushing formula, a flushing plan and equipment need to be established. Ideal flushing equipment setup includes:

Flushing Filter used to:• Remove particles that have built up in the system• Remove large particles that could cause catastrophic failure• Extend “in-service’ filter element life

Pressure Line to:• Stop pump wear debris from traveling through the system• Catch debris from a catastrophic pump failure and prevent secondary system damage• Act as a Last Change Filter (LCF) and protect downstream components

Return Line:• Captures debris from component wear or ingression traveling to the reservoir• Promote general system cleanliness

Air Breather• Prevents ingression of airborne particulate contamination • Extends filter element service life• Maintains system cleanliness

Kidney Loop/Off-line• Controls system cleanliness when pressure

line flow reduces• Used for systems where pressure or return

filtration is impractical• Acts as a supplement to the in-line filters,

improving cleanliness control and filter service life (especially in high dirt ingression systems)

Additional Filters:• Place ahead of critical/sensitive equipment• Protect against catastrophic machine failure

(non-bypass filters most common)• Reduce wear and stabilize valve operation

(prevents stiction)

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Relevant Filtration & Contamination Standards

ISO Code Details

ISO 2941 Filter elements – verification of collapse/burst pressure rating

ISO 2942 Filter elements – verification of fabrication integrity and determination of the first bubble point

ISO 2943 Filter elements – verification of material compatibility with fluids

ISO 3722 Fluid sample containers – qualifying and controlling cleaning methods

ISO 3724 Filter elements – determination of resistance to flow fatigue using particulate contaminant

ISO 3968 Filters – evaluation of differential pressure vs. flow characteristics

ISO 4021 Extraction of fluid sample from lines of an operating system

ISO 4405 Determination of particulate contamination level by the gravimetric method

ISO 4406 Method for coding the levels of contamination by solid particles

ISO 4407 Determination of particulate contamination by the counting method using an optical microscope

ISO 10949 Guidelines for achieving and controlling cleanliness of components from manufacture to installation

ISO 11170 Filter elements – sequence of test for verifying performance characteristics

ISO 11171 Calibration of automatic particle counters for liquids

ISO 11500 Determination of particulate contamination by automatic particle counting using the light extinction principle

ISO 11943 Methods for calibration and validation of on-line automatic particle-counting systems

ISO 16889 Filter elements – multi-pass method for evaluating filtration performance of a filter element

ISO 18413 Component cleanliness – inspection document and principles related to contaminant collection, analysis, and data reporting

ISO 23181 Filter elements – determination of resistance to flow fatigue using high viscosity fluids

SAE ARP4205 Filter elements – method for evaluating dynamic efficiency with cyclic flow

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Symbol Cheat Sheet

ISO1219-1: Fluid power systems and components- Graphic symbols and circuit diagrams. Part 1 – Graphic symbols for conventional use and data processing applications

Common Fluid Power Circuit Diagram Symbols

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Viscosity Conversions

Kinematic cSt (mm2/s)

Saybolt UniversalSeconds (SUS)

40°C (104°F) 100°C (212°F)

5 42 43

10 59 59

15 77 78

20 98 99

25 119 120

30 142 143

35 164 165

40 187 188

45 210 211

50 233 234

55 256 257

60 279 280

65 302 303

70 325 326

75 348 350

100 463 466

200 926 933

400 1853 1866

600 2779 2798

To Convert to At Multiply cSt at same temperature by

SUS 40°C (104)°F 4.63

SUS 100°C (212°F) 4.66

Redwood N°1 60°C (140°F) 4.1

Engler All temperatures

0.13

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Viscosity/Temperature Chart

Temperature, Degrees Fahrenheit

1. Plot oil viscosity in centistokes at 40 °C (104 °F) and 100 °C (212 °F)2. Draw a straight line through the points3. Read off centistokes at any temperatures of interest4. Lines shown indicate ISO preferred grades of 100 Viscosity Index.5. Lower V.I. oils will have steeper slopes; higher V.I. oils will have flatter slopes

How to Use the Chart

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• 1 gpm (US) = 0.832 gpm (UK)• Note: Values to three significant figures

Pressure – psi and bar | 1 psi = 0.067 bar | 1 bar = 14.5 psi

Psi Bar Bar Psi

20 1.38 1 14.5

30 2.07 2 29.0

40 2.77 3 43.5

50 3.45 4 58.0

60 4.14 5 72.5

70 4.83 6 87.0

80 5.52 7 102

90 6.21 8 116

100 6.90 9 131

200 13.8 10 145

300 20.7 15 218

400 27.6 20 290

500 34.5 25 363

600 41.4 30 435

700 48.3 35 508

800 55.2 40 580

900 62.1 45 653

1,000 69 50 725

1,100 75.9 55 798

1,200 82.8 60 870

1,300 89.7 65 943

1,400 96.6 70 1,015

1,500 104 75 1,088

1,600 110 80 1,160

Pressure – psi and bar | 1 psi = 0.067 bar | 1 bar = 14.5 p

1,700 117 85 1,233

1,800 124 90 1,305

1,900 131 95 1,378

2,000 138 100 1,450

2,250 155 150 2,175

2,500 172 200 2,900

2,750 190 250 3,630

3,000 207 300 4,350

3,500 241 350 5,080

4,000 258 400 5,800

4,500 310 450 6,530

5,000 345 500 7,250

Pressure – PSI and bar

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• 1 gpm (US) = 0.832 gpm (UK)• Note: Values to three significant figures

1 US gpm = 3.79 liters/min | 1 liter/min = 0.264 US gpm

US gpm L/min L/min US gpm

5 18.9 5 1.3

10 37..9 10 2.6

15 56.8 20 5.3

20 75.7 30 7.9

25 94.6 40 10.6

30 114 50 13.2

35 133 60 15.9

40 151 70 18.5

45 170 80 21.1

50 189 90 23.8

55 208 100 26.4

60 227 125 33.0

65 246 150 39.6

70 265 200 52.8

75 284 250 66.1

80 303 300 79.3

85 322 350 92.5

90 341 400 105.7

95 360 450 118.9

100 379 500 132.1

125 473 550 145.3

150 568 600 158.5

175 662 650 171.7

200 757 700 184.9

1 US gpm = 3.79 liters/min | 1 liter/min = 0.264 US gpm

225 852 750 198.2

250 946 800 211.4

275 1,040 900 237.8

300 1,140 1,000 264.2

Hydraulic Flow – US gpm and liters/minute

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Measurement Conversion Factors

To Convert Into Multiply By

Into To Convert Divide By

Liter Cubic Meter 0.001

Liter Gallon (US) 0.2642

Micrometer (Micron) Inch 0.000039

Foot Inch 12

Inch Millimeter 25.4

Meter Foot 3.28

Meter Yard 1.09

Mile Kilometer 1.609

Liter/sec Cubic meter/min 0.06

Meter/sec Kilometer/hour 3.6

Kilogram Pound 2.205

Pound Ounce 16

Kilowatt Horsepower 1.341

Kilowatt BTU//hour 3412

Atmosphere PSI 14.7

Bar PSI 14.5

KiloPascal PSI 0.145

Bar KiloPascal 100

Bar Inches of mercury (Hg) 29.53

Inches of Water Pascal (Pa) 249

Celsius (Centigrade) Farhenheit °C X 1.8 + 32

Degree (Angle) Radian 0.01745

To Use Conversion Table:

1. Convert units appearing in column 1 into equivalent values in column 2 , multiply by column 3• Ex. To convert 10 Liters into Gallons, multiple 10 x 0.2642 = 2.642 Gallons

2. To convert units in column 2 to units in column 1, divide by the factor in column 3• To convert 40 ounces in pounds, take 40/16 = 2.5 pounds

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RIG ISO Cleanliness Shutdown Program

Quality. Service. Experience 20

Engineering ServicesSenior Field Engineer Meets

Project Team to Review Scope

Data ReviewedEngineer, MLA or MLT manager

reviews data for corrective action

Project Plant PreparedTo meet safety, budget, timeline and

OEM specs

Engineered Sales SolutionsExperienced sales engineers work with the project team

for the best solution

Experienced Engineers / Project ManagersSafely perform services, right sized

equipment to meet operation milestones

Safe Successful ProjectEnsures smooth start-ups for Owners, EPC and Mechanicals

On-Time Project CompletionProject timeline and OEM specs

ae safely met for successful start to plant operations

Example ProgramYour specific program will vary to meet the needs of your equipment and systems. Typical program steps include:

Fluid Change Out

Change Filters & Breathers

Reservoir CleaningFilter out > Clean >

Filter in

Add BSF™(Breather Sample

Filter)

Varnish Mitigation

VacuumDehydration

Side Stream Filtration(HVOF)

Surge Flushing

Chemical Cleaning / Degrease

Steam / Air Blow

Hydrolazing Hydrostatic / Pneumatic Testing

Equipment Rental


Contact Reliable Industrial Group

Power Plants – Startup & keep turbines, compressors, generators, boilers and all other critical equipment at peak performance

Refining & Petrochemicals –Meet critical startup dates & specifications with piping and rotating equipment pre-commissioningOffshore – Commissioning

services conveniently provided through our modular equipment that can be on-site in under 48 hours worldwide

Chemicals & Manufacturing – Achieve smooth startup of new systems with pre-commissioning of lube oil piping, process piping & critical equipment.

Paper & Pulp Mills –Effective fluid movement

plant-wide is only possible with contaminant free

equipment.

LNG Loading/Unloading – Work closely with EPC and owners to ensure safe and successful pre-commission services

Rubber / Manufacturing Plants – Rugged manufacturing environments require constant vigilance from initial startup to on-going maintenance.

Fluid Analysis Field Guide · Fluid Analysis Field Guide Sampling Methods There are four main sampling methods you can use: • Method 1 (Preferred): Ball valve with PTFE (or similar

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