Manual of Analysis and Comparison Photographs: System Conditions
Manual of Analysis and Comparison Photographs: System Conditions
Handbook
SYSTEM CONDITIONS
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Index Introduction
Pg’s
Introduction 2 In hydraulic fluid power systems, power is
General Information 3-6 transmitted and controlled through a liquid
Sampling Procedures 7-9 under pressure within an enclosed circuit.
Cleanliness Reporting
The liquid is both a lubricant and a power-
Formats 10-15 transmitting medium.
Micron Rating Size The presence of solid contaminant particles
Comparisons 16-17
in the liquid interferes with the ability of the
Comparison Photographs
hydraulic fluid to lubricate and causes wear to
for Contamination Classes 18-29
the components. The extent of contamination
Hydraulic Component
Manufacturer’s
in the fluid has a direct bearing on the
Recommendations 30-31 performance and reliability of the system and
Hydraulic System Target it is necessary to control solid contaminant
Cleanliness Levels 32 particles to levels that are considered
Filter Element Beta appropriate for the system concerned.
Ratio Information 33
A quantitative determination of particulate
Information on
Reynolds Numbers 34
contamination requires precision in obtaining
the sample and in determining the extent
Information on
Pressure Changes 35 of contamination. Liquid Automatic Particle
Viscosity Conversion Chart 36 Counters (APC) (MP Filtri Products), work on the
Cleanliness Code Comparison 37
light-extinction principle. This has become an
accepted means of determining the extent of
Measuring Water in Hydraulic
and Lubricating fluids 38-39 contamination. The accuracy of particle count
Contamination Monitoring
data can be affected by the techniques used to
Products 40-41 obtain such data.
IMPORTANT. For definitive and comprehensive guidance on condition monitoring and the content held within this
document, always refer to the relevant standard.
MP Filtri UK Ltd has created this document based on related current standards dated as such. The document
is intended as a guide only and MP Filtri UK Ltd reserves the right to alter content, specifications, artwork and
related information without prior written notice.
To ensure that you always have the latest revision of this document, please go to www.mpfiltri.co.uk
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General Information
The NAS 1638 reporting format was developed for use where the principle
means of counting particles was the optical microscope, with particles
sized by the longest dimension per ARP598. When APC’s came in to
use this provided a method of analysing a sample much faster than the
ARP598 method. A method of calibrating APC’s was developed, although
they measured area and not length, such that comparable results to that
of ARP598 could be obtained from the same sample. Now, APC’s are the
primary method used to count particles and the projected area of a particle
determines size. Because of the way particles are sized with the two
methods, APC’s and optical microscopes do not always provide the same
results. NAS 1638 has now been made inactive for new design and has
been revised to indicate it does not apply to use of APC’s.
Prior to ISO 11171, the previous APC calibration method most widely
utilised was ISO 4402, which used Air Cleaner Fine Test Dust (ACFTD) as the
reference calibration material. ACFTD is no longer manufactured and the
ISO 4402 method using this dust has been made obsolete. The industry
developed the method ISO 11171, which supersedes ISO 4402, with a
calibration standard based on NIST-certified samples of ISO 12103-1 A3
medium test dust suspended in hydraulic oil. There is a difference between
the particle measurements by ISO 4402 and ISO 11171. To retain the same
cleanliness measure, calibrations using ISO 11171 are conducted to a
corrected particle count scale. For example, particles reported as 5 um with
the ISO 4402 method are reported as 6 um (c) by the ISO 11171 method. In
fact 5 um corresponds to 6.4 um (c), and some round off was conducted for
simplification.
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Particle size analysis
Several methods and instruments based on different physical principles
are used to determine the size distribution of the particles suspended in
aeronautical fluids. The numbers of particles found in the different size
ranges characterize this distribution. A single particle therefore has as
many equivalent diameters as the number of counting methods used.
Figure 1 shows the size given to the particle being analysed (shading) by a
microscope as its longest chord and an APC calibrated in accordance with
ISO 11171 using the Standard Reference Material NIST SRM 2806 sized
by the equivalent projected area.
Particle to be analyzed
Equivalent size
Equivalent size
d = 10 μm
d = 13 μm
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Differences between NAS 1638 and AS4059E.
AS4059E was developed as a replacement/equivalent to the obsolete NAS
1638 format, where table 2 relates to the old AS4059D standard and table
1 is the equivalent NAS1638 standard. However, there are differences.
Particularly in Table 2, (Cumulative Particle Counts).
Counting of Smaller Particles.
AS4059E allows the analysis and reporting of smaller particle sizes than
NAS 1638.
Counting Large Particles and Fibres.
In some samples, it has been observed that many of the particles larger
than 100 micrometers are fibres. However, APC’s size particles based
on projected area rather than longest dimension and do not differentiate
between fibres and particles. Therefore, fibres will be reported as particles
with dimensions considerably less than the length of the fibres. A problem
with fibres is that they may not be present in fluid in the system but rather
have been introduced as the result of poor sampling techniques or poor
handling during analysis.
Determining AS4059E Class Using Differential Particle Counts:
This method is applicable to those currently using NAS 1638 classes and
desiring to maintain the methods/format, and results equivalent to those
specified in NAS 1638.
Table 1 applies to acceptance criteria based on differential particle counts,
and provides a definition of particulate limits for Classes 00 through 12. A
class shall be determined for each particle size range. The reported class
of the sample is the highest class in any given particle range size.
NOTE: The classes and particle count limits in Table 1 are identical to NAS 1638.
Measurements of particle counts are allowed by use of an automatic particle
counter (calibrated per ISO 11171 or ISO 4402:1991), or an optical or electron
microscope. The size ranges measured and reported should be determined
from Table 1 based on the measurement method.
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Determing AS4059E Class Using Cumulative Particle Counts:
This method is applicable to those using the methods of previous revisions
of ÅS4059 and/or cumulative particle counts. The cleanliness levels for
this method shall be specified by the appropriate class from Table 2. To
provide versatility, the applicable cleanliness class can be identified in the
following ways:
a. Basing the class on the highest class of multiple size ranges .
b. Total number of particles larger than a specific size.
c. Designating a class for each size range.
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Sampling Procedures
Methods of
taking samples
from hydraulic
applications
using appropriate
receptacles
ENSURE THAT ALL DANGERS ARE
ASSESSED AND THE NECESSARY
PRECAUTIONS ARE TAKEN DURING
THE SAMPLING PROCESS.
DISPOSAL OF FLUID SAMPLES
MUST FOLLOW PROCEDURES
RELATING TO COSHH.
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Methods of taking sample from hydraulic
applications, using appropriate recepticles
Operate system for at least 30 minutes Operate system for at least 30 minutes
before taking a sample before taking a sample
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Methods of taking sample from hydraulic
applications, using appropriate recepticles
Operate system for at least one hour Operate system for at least one hour
before taking a sample before taking a sample
Thoroughly clean area around the point Thoroughly clean area around the point
of entry to the reservoir of entry to the reservoir where sample
bottle is to be inserted
Attach sample bottle to the sampling
device Clean outside of ultra clean sample
bottle using filtered solvent, allow to
Carefully insert sampling hose into evaporate dry
the midway point of the reservoir. Try
not to touch sides or baffles within the Dip sample bottle into reservoir, cap
reservoir and wipe
Release vacuum, disconnect bottle and Label the bottle with the necessary
discard fluid information for analysis e.g. Oil type, running
hours, system description etc.
Repeat the above three steps three times
to ensure flushing of the equipment
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Cleanliness Reporting Formats
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Cleanliness Reporting Formats
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Classes of Contamination
According to NAS 1638
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Cleanliness Reporting Formats
This SAE Aerospace Standard (AS) defines cleanliness levels for particulate
contamination of hydraulic fluids and includes methods of reporting data
relating to the contamination levels.
Tables 1 and 2 below provide differential and cumulative particle counts
respectively for counts obtained by an automatic particle counter, e.g.
LPA2.
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Cleanliness Reporting Formats
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How BIG are the particles
we have to control
Micron Rating Size Comparisons
1 Micron* = 0,001mm
25,4 Micron* = 0,001inch
(* correct designation = Micrometre)
Substance Microns
from to
For all practical purposes particles of 1 micron size and smaller are
permanently suspended in air.
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How BIG are the particles
we have to control
Micron Rating Size Comparisons
4 -14µm
Typical particles
in a hydraulic system
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Comparison Photographs
1 graduation= 10 µm
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for Contamination Classes
1 graduation= 10 µm
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Comparison Photograph’s
1 graduation= 10 µm
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for Contamination Classes
1 graduation= 10 µm
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Comparison Photograph’s
1 graduation= 10 µm
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for Contamination Classes
1 graduation= 10 µm
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Comparison Photograph’s
1 graduation= 10 µm
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for Contamination Classes
1 graduation= 10 µm
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Comparison Photograph’s
1 graduation= 10 µm
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for Contamination Classes
1 graduation= 10 µm
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Contamination Classes
NAS 12
ISO 23/21/18
NAS 9
ISO 21/18/15
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Contamination Classes
NAS 7
ISO 18/15/13
NAS 6
ISO 17/15/12
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Hydraulic Component Manufacturer***
Recommendations
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Hydraulic Component Manufacturer***
Recommendations
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Hydraulic System
Target Cleanliness Levels****
Where a hydraulic system user has been able to check cleanliness levels
over a considerable period, the acceptability, or otherwise, of those
levels can be verified. Thus if no failures have occurred, the average level
measured may well be one which could be made a bench mark. However,
such a level may have to be modified if the conditions change, or if specific
contaminant-sensitive components are added to the system. The demand
for greater reliability may also necessitate an improved cleanliness level.
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Filter Element Beta Ratio
Information
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Technical Information on
Reynolds Numbers
Where:
Q = Volumetric Flow Rate (litres/min)
di = Inside diameter or equivalent diameter of largest flow gallery (mm)
v = Viscosity of the flushing fluid at normal flushing temperature (Cst)
Flushing Information for Various Pipe Diameters
Component cleaning/flushing systems can only be effective if Turbulent
Flow is achieved.
The following guideline is with a fluid having a 86 - kg/m 3 fluid density
(typical mineral oils) and 30 cst viscosity.
Pipe size nom Core inches Core mm Flow for Re = 4000
1/4” 0.451 11.5 65 1/min
1/2” 0.734 18.6 105 1/min
1” 1.193 30.3 171 1/min
1 1/4” 1.534 39.0 220 1/min
1 1/2” 1.766 44.9 254 1/min
2” 2.231 56.7 320 1/min
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Pressure Changes
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36
-20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
100000 100000
50000 50000
10000 Lines shown indicate oils ISO grade Viscosity Index of 100. 10000
Lower V.I. oils will have a steeper slope.
5000 Higher V.I. oils will have a flatter slope. 5000
3000 3000
2000 2000
1000 1000
500 500
400 400
300 300
200 200
150 150
100 100
50 50
40 40
30 30
20 20
IS
15 O 15
1
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6.0 IS IS IS IS IS IS IS 0 6.0
IS O O
O O O O O O 10
7 10 15 22 32 46 68 0
5.0 5.0
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4.0 4.0
-20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
TEMPERATURE, DEGREES CELSIUS
Viscosity Conversion Chart
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Measuring WATER in hydraulic
and lubricating fluids
Saturation Levels
Since the effects of free
(also emulsified) water is
more harmful than those of
dissolved water, water levels
should remain well below the
saturation point. However,
even water in solution can
cause damage and therefore
every reasonable effort should
be made to keep saturation
levels as low as possible.
There is no such thing as too
little water. As a guideline,
we recommend maintaining
saturation levels below 50% in
all equipment.
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Typical Water Saturation Levels
- For new oils
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Contamination Monitoring Products
VPAF – 100
A simple way to check
the fluid used in hydraulic
applications is to verify
the contamination of solid
particles ; the KIT “VPAF –
100” is suitable for checking
these contaminants.
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Contamination Monitoring Products
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The complete range of
Contamination
Monitoring Products
When contamination is
the problem,
we have
the solution.
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Don’t let Contamination
Create a Crisis!
70–80% of all failures on hydraulic systems + up
to 45% of all bearing failures are due to
contaminants in the hydraulic fluid.
Ltd.
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