Contamination Control - Essential to a Condition Based Maintenance Program

Holly Jo Borden

Entek

Abstract:

Oil analysis provides contamination analysis, physical and chemical properties analysis, and wear

debris diagnosis. These three elements of oil analysis help with on-site screening and laboratory

testing, but they cannot prevent contamination ingression or maintain specific cleanliness codes.

Oil analysis is analogous to receiving an “A” on a school report card and contamination control is

the process of maintaining that “A”. The primary function of contamination control is to stop the

ingression or ingestion of contamination at the source. This involves proper sampling technique

and location, adequate filtration, good lubricant transfer methods and basic ‘good housekeeping’ of

lubricants and related equipment. This paper will discuss the need for good contamination control

and the various techniques for achieving it.

Key Words:

Additives

Bearings

Circulating system

Cleanliness

Contaminant

Degradation of Lubricant

Filtration

Fluids

Hoses, Piping

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Gears

Maintenance

Lubricant Storage

Lubricants

Oils

Particles

Seals

Proper Sampling:

The main source for achieving and maintaining that “A” is controlling contamination at the various

sources of ingression. Contaminant ingression can happen in something as basic as lubricant

sampling. Representative sampling starts with proper sample port location. Initially, critical

machines must be identified for primary and secondary sampling ports. Since user-friendly

techniques and consistency are the prime objectives; clearly labeled, permanent, live-zone sample

port installation is the best practice. The best location is in a circulating system down stream of the

“work-end” environment, upstream of filtration and at a turbulent zone, like an elbow where fluid is

mixed and changes direction during normal equipment operation. The “work-end” environment

can consist of bearings, gears, pumps, cylinders or actuators. The return line, before filtration is a

primary location that allows maximum information, while minimizing data disturbance. If filters are

working correctly, they will remove information or data from fluid; therefore it is not beneficial to

sample after a filter unless the filter life itself is in question. Also, try to avoid dead pipe or hose

ends and do not sample if a machine is cold or not operating.

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 & LUF X LW
$
& LUF X LW
%
& LUF X LW
&
Pump

R e tu rn P rim a ry
L in e S a m p lin g
F ilte r P o rt

R e s e rv o ir

Actual test port installation is important because it provides a sealed source for obtaining an oil

sample. For pressurized systems, there are the following options: minimess, portable minimess,

quick disconnects and only as a last option ball/needle valves. The minimess sample ports offer

dust caps to seal the opening from external elements and offer the option of probe-on style bottles

for on-line sampling. The quick disconnect can be capped and provides the ability of connecting

with portable filter carts for off-line filtration or to create a circulating system.

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 Bottle cap is
never removed
Turbulent
fluid line
(return line)

Flush
Minimize Data
valve
first
Disturbance

Minimize
environmental
ingression

A critical component in contamination control when sampling is the flushing of the test port before

actual sampling begins. A minimum of five times the capacity of the test port, tubing or piping must

be flushed out and disposed of before a valid sample can be obtained. The bottle sample should

only be filled approximately 70% full to allow for proper agitation. Since this process is critical to

contamination control and can vary between individuals, it is best to have written guidelines for

flushing and obtaining the bottle sample.

The actual bottle that is used for sampling can be a contamination source. Bottles should always

be shipped with the caps attached and not opened until a sample is to be taken. Sample bottles

should be at least 100-120 milliliters (4-5 ounces) in size, a clear/transparent plastic, not hand

crushable with at least a “clean” cleanliness rating. Bottle cleanliness ratings are: Clean, Super

Clean and Ultra Clean. A clean bottle is classified as having less than 100 particles greater than

10 microns per milliliter of fluid. ISO 3722 is an old bottle cleanliness guideline that ignores the

bottle cleaning technique, but does specify a Required Cleanliness Level (RCL). One option for

obtaining contamination control during sampling is to use ‘Samplyzer’ style bottles that do not

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require the cap to be removed. The plastic bag technique is another option. This involves placing

a capped sample bottle into a zip-close bag, then place all zip-sealed sample bottles and sampling

device (vampire pump) into a larger zipped bag before going out into a plant environment. To

obtain a lubricant sample, flush the sample port, remove the sample bottle cap without opening the

zipped bag, pull the plastic bag tight around the bottle opening and thread onto the vacuum

sampling device. The plastic bag must be thin enough to puncture with the vacuum pump tubing.

When the bottle is 70% full remove the vacuum pump and re-attach the cap from inside the bag.

Once the lid is attached the bag can be disposed of along with the plastic tubing used with the

vacuum pump. Remember the plastic tubing is much like the plastic sample bottles, in that it

cannot be reused for lubricant sampling. These techniques provide contamination control and

contaminant exclusion in a usually dirty fluid sampling procedure.

Lubricant Storage and Supply:

Lubricant supply companies can offer assistance in a contamination control program. Suppliers

can advise on proper lubricant selection and reducing the number of different lubricants used

within one plant. This lubricant consolidation will help to eliminate contamination during handling

and transferring of lubricants, but only if it is done correctly. Caution is advised when selecting

lubricants as to not void any equipment warranties. Some lubricant suppliers offer this service free

of charge to keep current lubricant business. Other services suppliers may offer are improved oil

transfer equipment designed to maintain higher levels of cleanliness. Suppliers may charge for

these services, but the cost savings in streamlining the lubricants and controlling contamination will

offset the charges. New oil cleanliness level is another area that lubricant suppliers need to be

involved with. Since lubricant manufacturers are not required to provide a specific cleanliness, it is

each plant's responsibility to provide ISO cleanliness code requirements in the written purchase

specification. A study done by Duhva mining in South Africa found that the oil from the refinery

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was meeting ISO specification (ISO 16/13), but the bulk oil tankers transporting the oil were

contaminating the lubricant. These tankers were not being properly cleaned between fluid loads.

Duhva found that the hoses used for filling the mine’s bulk tanks were not sealed between usage,

the air breathers on the tanks were inefficient and incorrectly installed and measuring the oil level

in the tank was performed by a common dipstick exposed to the environment. This study points

out a few items that can be easily overlooked, but need to be standardized. Contamination control

was necessary for the transfer process once the lubricant supplier meets the ISO specifications;

the tanker truck contractor was the source of the contamination. Contaminant exclusion is a lot

less expensive than cleaning the fluid once it is in service.

Storage methods and environment can effect lubricant shelf life. As a rule of thumb, first-in/first-out

(FIFO) inventory and usage is recommended. FIFO ensures better contamination control through

less handling of fluids. Lubricants are packaged in different forms, such as: pails (20 liters),

drums (200 liters), totes (1600 liters) and bulk tanks. Select the packaging that suits each

individual plant's consumption rate and storage capability. Extreme hot and cold temperatures can

cause chemical degradation of a lubricant, depending upon the fluid type and additive package.

Airborne moisture can also begin to degrade hygroscopic oils. Indoor storage becomes

necessary for pails, drums and totes. This provides a clean and dry environment away from

industrial contamination, dirt and humidity. Drums should be kept in a horizontal position on

proper racks with the bungs at the three and nine o’clock positions. This storage rack allows for

proper rotation and keeps the bungs tight at all times. A rack-mount lubricant dispensing station

should have a central desiccant breather that is attached to each of the horizontal drums. The

drums need (clean, visible) level gages, individual spin-on filters and a capped quick disconnect (or

male fitting) to dispense the lubricant. Oil transfer or dispensing should be done using a portable

filter cart or small, single-use disposable containers.

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Once a container seal is broken contamination ingression becomes a problem. If lubricants must

be stored outside, try to minimize exposure to adverse environmental conditions. Lay drums on

their side so that the bung is positioned below the lubricant level. Use drum covers or tilt the drum

if it must be stored upright. Adequate labeling of stored lubricants, transfer equipment, and

transport containers helps to eliminate cross contamination of fluids. When using a stored

lubricant it is best to agitate them on a drum tumbler and confirm the condition of the oil before

putting it into service. A general guideline for storage is a clean, dry indoor room with a constant,

moderate temperature utilizing proper storage racking. These elements will help to minimize

contamination and maximize lubricant shelf life.

Contaminant Exclusion – Filtration:

The most common sources of contaminant ingression are built in, ingested and internally

generated. Built-in contamination can come from new or rebuilt equipment; the best control

mechanism is to flush the “new” equipment and hoses with clean fluids. These fluids and test

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stand lubricants will need to be periodically checked to ensure cleanliness levels. Ingested

contamination can come from a process, new oil, atmosphere or combustion. Some techniques to

restrict or exclude this ingression is to seal off systems with cylinder boots, low ingression wiper-

seals, restrictive ventilation (accumulators, spin-on filters and desiccating breathers) and tightly

sealed hatch covers and equipment plugs. Replace pipe-thread fittings with o-ring type fitting to

cut leakage and contamination ingestion. Gearbox vents and reservoirs can also be fitted with

breathers that restrict the ingestion of airborne particle and moisture contamination. The best way

to control contamination during new oil transfer is by using a portable filter cart. Filter carts can

control dirt and moisture within a fluid and are usually portable. Fluid compatibility must be

addressed when using the filter cart for different equipment. The hoses must be kept clean and

sealed when not in use and the filters must be monitored and changed when necessary. Portable

filter carts can also be used to circulate and clean in-service fluids within a gearbox or reservoir.

This process can be achieved through installing quick disconnects for the inlet and outlet hoses of

the filter cart.

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Good general filtration provides a good defense against generated contamination. Proper filter

selection is very critical. Make sure that the filters have a good Beta rating, are absolute, fiberglass

filters that can resist surge and cold-start failures. Off-line continuous filtration may be cost justified

for some systems. Again, some filter suppliers my offer on-site audits to determine filtration and

contamination control needs.

Conclusion:

An effective contamination control program must be guided by the basic principles of material

balance (new oil/contaminant ingression – filter/breather/seal removal = target cleanliness level).

The implementation of a contamination control program should be within the domain of the user;

therefore it must be simple and straightforward. Do not forget to perform regular visual

inspections. Sensory inspection and checking sight glasses are inexpensive and easy ways to

control contamination. Planning and writing procedures are an absolute necessity.

Contamination control should be plant wide and not subjective to each maintenance person.

There are many successful contamination control programs in existence, learn from others and

replicate what is already a proven technique.

References:

Borden, Holly Jo, “Proper Lubricant Sampling – The First Step in Successful Oil Analysis” Enteract

Proceedings, May 1999.

Entek, Oil Analysis Course Workbook, 1998.

Fitch, James C., “Three-Step Implementation to Fluid Contamination Control”, Technical

Application Article, Entek.

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Godin, Frank, “Best Practices for Lubricant Storage and Handling”, Practicing Oil Analysis ’99

Conference Proceedings, October 1999.

Golomb, Frank and Robin, Lana, “Synthetic Lubricants, Contamination Control and Oil Analysis

Team Up” Practicing Oil Analysis, May/June 1999.

Mizell, Scott, “Proactive Maintenance at Weyerhaeuser”, Practicing Oil Analysis, July/August 1999.

Rotondi, Roger H., “Oil Analysis, A Valuable Tool In Predictive Maintenance”, Enteract 1995.

Schnuir, Alan, “Operation Clean-up”, Practicing Oil Analysis, September/October 1998.

Troyer, Drew D., “Lubricant Condition Monitoring A Proactive, Reliability Driven Approach”, Entek.

Troyer, Drew, “Secondary Sampling Pinpoints Wear Problems”, Practicing Oil Analysis,

September/October 1999.

Troyer, Drew D., “ Sampling Procedures Build a Solid Foundation for Oil Analysis Success”,

Practicing Oil Analysis, March/April 1999.

Williamson, M.K., “A Low Cost On-Site Oil Analysis Strategy”, Enteract, May 1999.

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