Contamination Handbook For use with the Schroeder EasyTest Patch Test Kit (EPK) and TWG Fluid Analysis
Table of Contents How to use this handbook.... page 4 Contamination Classification in accordance with ISO 4406: 1987/1999.... page 5-6 Contamination Comparison Photos.......... page 9-18 Types of Contamination....page 19-35 Contamination Classification in accordance with SAE AS4059:D.... page 7 Contamination Classification in accordance with NAS 1638-01/1964... page 8 3 CONTAMINATION HANDBOOK
How to use this handbook This Contamination Handbook is supplied as part of the EasyTest TM Patch Test Kit (EPK-K) from Schroeder Industries and can also be used as reference tool for other fluid analysis projects, including estimating the ISO Cleanliness Code for water glycol fluid samples (Schroeder part number TWG). The photos found on pages 8 through 17 were taken through a 100X microscope after 100 ml of fluid was pulled through a 0.8µm patch 47 mm in diameter. These photos are also applicable for 28 ml of fluid pulled through a 0.8µm 25 mm patch and viewed under a 100x microscope. As noted on each page, the space between two neighboring scale marks is 10µm. These photos represent the various cleanliness levels identified for each respective photograph. To determine the general contamination class level of fluid sample in question, the residue on the resulting patch is compared to that seen in the photos on pages 8 through 17. The closest match will reveal the estimated contamination level of the subject fluid sample. Particle count information provided in the classifications on pages 4 through 7 are included for reference only. Exact particle counts cannot be determined with the patch method of analysis. CONTAMINATION HANDBOOK 4
Contamination classification in accordance with ISO 4406:1987/1999 ISO- Class Number of Particles more than up to & including 0 0,5 1 1 1 2 2 2 4 3 4 8 4 8 6 5 16 32 6 32 64 7 64 130 8 130 250 9 250 500 10 500 1,000 11 1,000 2,000 12 2,000 4,000 13 4,000 8,000 14 8,000 16,000 ISO- Class more than Number of Particles up to & including 15 16,000 32,000 16 32,000 64,000 17 64,000 130,000 18 130,000 250,000 19 250,000 500,000 20 500,000 1,000,000 21 1,000,000 2,000,000 22 2,000,000 4,000,000 23 4,000,000 8,000,000 24 8,000,000 16,000,000 25 16,000,000 32,000,000 26 32,000,000 64,000,000 27 64,000,000 130,000,000 28 130,000,000 250,000,000 5 CONTAMINATION HANDBOOK
Contamination classification in accordance with ISO 4406-1987/1999 determination of ISO code Particle Count Per 100ml Larger Than Indicated Size 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 2.5 1.3 6.4 3.2 1.6 8 4 2 10 6 10 5 10 4 22/18/13 ISO Class 5 2.5 1.3 6.4 3.2 1.6 8 4 2 10 3 10 2 10 1 5 2.5 1.3 6.4 3.2 1.6 8 4 2 1 10-1 2 5 10 15 20 ISO 4406:1987 4 6 10 14 20 ISO 4406:1999 10-2 CONTAMINATION HANDBOOK particles size in μm 6
Contamination classification in accordance to SAE AS4059: D ISO 4402 >1 µm >5 µm >15 µm >25 µm >50 µm >100 µm ISO 11171 >4 µm >6 µm >14 µm >21 µm >38 µm >70 µm SAE Code A B C D E F Contamination classes 000 00 0 1 2 3 4 5 6 7 8 9 10 11 12 195 390 780 1,560 3,120 6,250 12,500 25,000 50,000 100,000 200,000 400,000 800,000 1,600,000 3,200,000 76 152 304 609 1,220 2,430 4,860 9,730 19,500 38,900 77,900 156,000 311,000 623,000 1,250,000 14 27 54 109 217 432 864 1,730 3,460 6,920 13,900 27,700 55,400 111,000 222,000 3 5 10 20 39 76 152 306 612 1,220 2,450 4,900 9,800 19,600 39,200 1 1 2 4 7 13 26 53 106 212 424 848 1,700 3,390 6,780 0 0 0 1 1 2 4 8 16 32 64 128 256 512 1,020 7 CONTAMINATION HANDBOOK
Contamination classification in accordnce to NAS 1638-01/1964 Extended to particle range 2-5 μm NAS- Class Number of Particles Amount of Contamination (ACFTD) 2-5 μm 5-15 μm 15-25 μm 25-50 μm 50-100 μm >100 μm [mg/l] 00 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 625 1,250 2,500 5,000 10,000 20,000 40,000 80,000 160,000 320,000 640,000 1,280,000 2,560,000 5,120,000 125 250 500 1,000 2,000 4,000 8,000 16,000 32,000 64,000 128,000 256,000 512,000 1,024,000 2,048,000 4,096,000 22 44 88 178 356 712 1,425 2,850 5,700 11,400 22,800 45,600 91,200 182,400 364,800 729,000 4 8 16 32 63 126 253 506 1,012 2,025 4,050 8,100 16,200 32,400 64,800 129,600 1 2 3 6 11 22 45 90 180 360 720 1,440 2,880 5,760 11,520 23,040 0 0 1 1 2 4 8 16 32 64 128 256 512 1,024 2,048 4,096 0. 01 0. 1 0. 2 0. 5 1 3 5 7-10 20 40 80 CONTAMINATION HANDBOOK 8
Contamination Comparison Photos ISO 4406: 1999 Class 14/12/9 SAE AS 4059: D Class 4 NAS 1638 Class 3 1 scale mark= 10µm 9 CONTAMINATION HANDBOOK
Contamination Comparison Photos ISO 4406: 1999 Class 15/13/10 SAE AS 4059: D Class 5 NAS 1638 Class 4 1 scale mark= 10µm CONTAMINATION HANDBOOK 10
Contamination Comparison Photos ISO 4406: 1999 Class 16/14/11 SAE AS 4059: D Class 6 NAS 1638 Class 5 1 scale mark= 10µm 11 CONTAMINATION HANDBOOK
Contamination Comparison Photos ISO 4406: 1999 Class 17/15/12 SAE AS 4059: D Class 7 NAS 1638 Class 6 1 scale mark= 10µm CONTAMINATION HANDBOOK 12
Contamination Comparison Photos ISO 4406: 1999 Class 18/16/13 SAE AS 4059: D Class 8 NAS 1638 Class 7 1 scale mark= 10µm 13 CONTAMINATION HANDBOOK
Contamination Comparison Photos ISO 4406: 1999 Class 19/17/14 SAE AS 4059: D Class 9 NAS 1638 Class 8 1 scale mark= 10µm CONTAMINATION HANDBOOK 14
Contamination Comparison Photos ISO 4406: 1999 Class 20/18/15 SAE AS 4059: D Class 10 NAS 1638 Class 9 1 scale mark= 10µm 15 CONTAMINATION HANDBOOK
Contamination Comparison Photos ISO 4406: 1999 Class 21/19/16 SAE AS 4059: D Class 11 NAS 1638 Class 10 1 scale mark= 10µm CONTAMINATION HANDBOOK 16
Contamination Comparison Photos ISO 4406: 1999 Class 22/20/17 SAE AS 4059: D Class 12 NAS 1638 Class 11 1 scale mark= 10µm 17 CONTAMINATION HANDBOOK
Contamination Comparison Photos ISO 4406: 1999 Class 23/21/18 SAE AS 4059: D Class 13 NAS 1638 Class 12 1 scale mark= 10µm CONTAMINATION HANDBOOK 18
Types of Contamination Particle Type: Mainly Rust; white particles are additives Effect: - Rapid oil aging - Breakdowns in pumps, valves - Wear and tear 4 5 1 scale mark = 45 µm 6 19 CONTAMINATION HANDBOOK
Types of Contamination Particle Type: Oil ageing products Effect: - Blocking of filters - Silting 4 5 1 scale mark = 45 µm 6 CONTAMINATION HANDBOOK 20
Types of Contamination Particle Type: Metal fragment Effect: - Breakdowns in pumps, valves - Wearing of seals - Leakage - Oil ageing 1 scale mark = 45 µm 21 CONTAMINATION HANDBOOK
Types of Contamination Particle Type: Particles and fragments in bronze, brass and copper Effect: -Breakdowns in pumps, valves - Oil ageing - Leakage - Wearing of seals 1 scale mark = 45 µm CONTAMINATION HANDBOOK 22
Types of Contamination Particle Type: Gel-type residue from filter element Effect: - Blocking of filter - Silting 1 scale mark = 45 µm 23 CONTAMINATION HANDBOOK
Types of Contamination Particle Type: Silicates due to lack of, or inadequate, air breather-filter Effect: -Heavy wear on components -Breakdowns in pumps, valves - Wearing of seals 1 scale mark = 45 µm CONTAMINATION HANDBOOK 24
Types of Contamination Particle Type: Colored particles (red/brown), synthetic particles (blue) Effect: -Breakdowns in pumps, valves -Wearing of seals 1 scale mark = 45 µm 25 CONTAMINATION HANDBOOK
Types of Contamination Particle Type: Fibers due to initial contamination, open tank, cleaning cloths, etc. Effect: - Blocking of nozzles - Leaking from seat valves 1 scale mark = 45 µm CONTAMINATION HANDBOOK 26
Types of Contamination Contaminant: Coal dust Machine: Gearbox Industry: Coal Mining Patch Test filter: 5 Magnification: 100x Probable Indications: unfiltered vent/breather 27 CONTAMINATION HANDBOOK
Types of Contamination Contaminant: Dirt / silicon / organic Machine: Gearbox Industry: Cement Patch Test filter: 10 Magnification: 100x Probable Indications: Ingress most likely through unfiltered vent/ breather CONTAMINATION HANDBOOK 28
Types of Contamination Contaminant: Silicates/organic dirt Machine: Pump gearbox Industry: Mining Patch Test filter: 10 Magnification: 100x Probable Indications: Dirt ingress through unfiltered/ Unscreened breather (verified). 29 CONTAMINATION HANDBOOK
Types of Contamination Contaminant: Fiber, synthetic Machine: Gearbox Industry: Food processing Patch Test filter: 5 Magnification: 100x Probable Indications: Most likely source of fiber is degrading filter or fibrous gasket material. CONTAMINATION HANDBOOK 30
Types of Contamination Contaminant: Wear metals: oxidized ferrous (blackened) and brass/bronze (gear facing) Machine: Gearbox Industry: Mining Patch Test filter: 10 Magnification: Probable Indications: 100x Oxidized ferrous material indicates excessive temperature possible cutting or grinding at metal to metal interface. Bronze residue is sacrificial gear face material. 31 CONTAMINATION HANDBOOK
Types of Contamination Contaminant: Oxidized ferrous wear metal, brass/bronze; some silicate and emulsified oil. Machine: Gearbox Industry: Mining Patch Test filter: 10 Magnification: 100x Probable Indications: Water content in oil confirmed with positive crackle test; high temperature cutting wear. Silicate and coal dust in combination with lubricant acting as abrasive. CONTAMINATION HANDBOOK 32
Types of Contamination Contaminant: Oxidized ferrous cutting wear metal possibly from failing seal; dirt Machine: Pump gearbox oil. Industry: Mining Patch Test filter: 10 Magnification: Probable Indications: 100x Cutting wear most likely from seal; contaminated with dirt, most likely from unfiltered breather vent. 33 CONTAMINATION HANDBOOK
Types of Contamination Contaminant: Oxidized ferrous material Machine: Vacuum pump Industry: Chemical Patch Test filter: 5 Magnification: 100x Probable Indications: Cutting wear from seal failure; extremely high temperature in evidence CONTAMINATION HANDBOOK 34
Types of Contamination Contaminant: Water emulsified in oil captured by organic dirt Machine: Gearbox Industry: Mining Patch Test filter: 10 Magnification: 100x Probable Indications: Dirt has entered open breather vent, along with water ingress. 35 CONTAMINATION HANDBOOK
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