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It is fairly common to see this contamination level in new oils taken directly from bulk storage. In this case,
the oil sample includes 4.2 ppm v/v of contaminants with peak size at 5 mm.
Figure 1. Typical New Oil Sample
CSI has recently developed an improved method for analyzing particle count data and particle size
distributions. The CSI 5200 Trivector particle counter determines data in up to eight size ranges. These
data are then used to estimate the concentration in parts-per-million (ppm by volume - see
Understanding PPM by Volume and PPM by Weight on page 34) and the size corresponding to the
maximum number of particles in the sample. Examples of some particle size distribution plots obtained by
this method are shown in Figures 1, 2 and 3.
The premise behind calculating the ppm by volume is to use the particle count data in the different size
ranges to interpolate between data points. In this way, the number of particles in each one-micron window
can be estimated. Based on these estimates, the total volume of particulate material can be determined,
either as a total or in different size categories, by assuming the equivalent spherical diameter of the
particle measured by the particle counter.
The principal value of calculating particle size distributions is to provide additional information on the
types of particles and possible wear mechanism present. For example, Figure 1 shows the typical particle
size distribution of new oil taken from bulk storage. The ISO code for this sample was 21/20/15, fairly high
for new oil. However, by reviewing the particle size distribution, which shows a particle size maximum
around five microns, this high particle count can simply be assigned to generally unclean new oil allowing
the correct maintenance action - in this case, filtering the oil prior to use.
This oil sample has 8.7 ppm v/v solids greater than 4 mm . In this instance, atomic emission spectroscopy
would do a good job quantifying contaminants and wear debris. The peak concentration corresponds to
particles around 4 mm.
Figure 2. In-service Oil from an Automatic Transmission
Contrast the plot in Figure 1, with the plot shown in Figure 2, which illustrates particle size distribution for
fluid from an automatic transmission. The particle count distribution reflects what is expected to be normal
wear from this type of equipment. The high concentration of particles in the sub-five micron range
indicates normal rubbing wear, and therefore, there is no immediate need for maintenance activity.
This sample contains almost no particles in the detectable range for spectrometric analysis (less than five
to eight microns). Based on SEM-EDX data, the large particles were found to be silicon (dirt) particles
around 24 mm in size and large ferrous particles around 40 mm in size. The total dust and wear in this
case is 116 ppm v/v. Without particle count and particle size distribution data, this problem may have
been missed completely if spectrometric wear metal data was relied upon as the sole means of detecting
the problem.
Figure 3. In-service Oil from a Roots Blower
The third example, illustrated in Figure 3, most clearly demonstrates the value of evaluating the particle
count distribution. In this example taken from a roots blower, a high overall particle count was observed,
just like in Figures 1 and 2. However, based on the particle count distribution,
in conjunction with complementary tests such as scanning electron microscopy - energy dispersive X-ray
(SEM-EDX), it can be determined that this component is in need of immediate attention. Large dirt
particles, and more significantly, large ferrous material, indicate a serious mechanical problem exists.
Particle counting has proven to be an effective tool in detecting active machine wear. Used in conjunction
with particle size distribution and parts per million by volume, it can also be an excellent tool in
differentiating between possible root causes.
Note: Ray Garvey is the tribology solutions manager for Emerson Process Management CSI. His
certifications include PE, CLS, and OMA1. He is an inventor named on seven patents, five of which
pertain to industrial oil analysis.
But what is the particle size distribution and ISO code for the cube of silicon in
the oil? Assuming the oil is totally clean, we now have one 60 x 60 x 60 g
cube in 1 ml of oil, so the number of particles in the oil is one. Obviously,
having only one particle in an oil sample is unrealistic. So lets take the 60 x
60 x 60 cube and break it up into 1,000 equal pieces. Now we have 1,000 6 x
6 x 6 micron cubes, so what is the ppm w/w? Obviously nothing has changed;
we still have a total weight of 0.5 g, or 0.56 ppm w/w. But what is the particle
count? One-thousand particles of six microns distributed in 1 ml of oil results
in a greater than six micron ISO range code of 17, significantly higher than
when one 60-micron cube is dropped into the oil.
As a rule of thumb, if you take one ppm w/w of a material such as silicon and
disperse it according to a normal particle size distribution, such as that shown
in Figure 1, the average ISO cleanliness rating will be close to ISO 18/16/13.
This example serves to illustrate not only the difference between ISO particle
count data and ppm w/w, but also why particle counting is significantly more
sensitive to contamination ingress than spectrometric data, particularly when
base fluid cleanliness levels are kept very low (ISO 16/14/11 and cleaner).