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    Head Office (Darwin)

    Perth

    Brisbane / PNG

    Oil Cleanliness

    AUSTRALIAN

    OWNED AND OPERATED

    Introduction

    Oil cleanliness play’s a huge role across a wide range of industries around the world every day. From the garbage trucks that collect your rubbish, to the power station that generates your electricity oil cleanliness is vital in ensuring the reliable operation of this equipment. Our team has compiled some information to provide some education around how oil is measured, why oil is measured and what can be done to mitigate and clean dirty oil to ensure down time and costly repairs are minimised wherever possible.

    Power Generation

    Mining

    Marine

    General Industry

    New Oil is Typically Dirty Oil…

    New oil can be one of the worst sources of particulate and water contamination.

    25/22/19 is a common ISO code for new oil which is not suitable for hydraulic or lubrication systems. A good target for new oil cleanliness is 16/14/11.

    Understanding ISO Codes

    The ISO cleanliness code (per ISO4406-1999) is used to quantify particulate contamination levels per millilitre of fluid at 3 sizes 4m[c], 6m[c] and 14m[c]. The ISO code is expressed in 3 numbers (example: 19/17/14). Each number represents a contaminant level code for the correlating particle size. The code includes all particles of the specified size and larger. It is important to note that each time a code increases the quantity range of particles is doubling and inversely as a code decreases by one the contaminant level is cut in half.

    ISO 4406:1999 Code Chart
    Range
    Code
    Particles per Millilitre
    More Than Up To/Including
    24 80000 160000
    23 40000 80000
    22 20000 40000
    21 10000 20000
    20 5000 10000
    19 2500 5000
    18 1300 2500
    17 640 1300
    16 320 640
    15 160 320
    14 80 160
    13 40 80
    12 20 40
    11 10 20
    10 5 10
    9 2.5 5
    8 1.3 2.5
    7 0.64 1.3
    6 0.32 0.64
    Particle Size Particles
    per
    Millilitre
    ISO 4406 Code
    Range
    ISO
    Code
    4μm[c] 151773 80000~16000 24
    4.6μm[c] 87210
    6μm[c] 38363 20000~40000 22
    10μm[c] 8229
    14μm[c] 3339 2500~5000 19
    21μm[c] 1048
    38μm[c] 112
    68μm[c] 2
    Particle
    Size
    Particles
    per
    Millilitre
    ISO 4406 Code
    Range
    ISO
    Code
    4μm[c] 69 40~80 13
    4.6μm[c] 35
    6μm[c] 7 5~10 10
    10μm[c] 5
    14μm[c] 0.4 0.32~0.64 6
    21μm[c] 0.1
    38μm[c] 0.0
    68μm[c] 0.0

    TARGET ISO CODES

    When setting target ISO fluid cleanliness codes for hydraulic and lubrication systems it is important to keep in mind the objectives to be achieved. Maximizing equipment reliability and safety, minimizing repair and replacement costs, extending useful fluid life, satisfying warranty requirements, and minimizing production down-time are attainable goals. Once a target ISO cleanliness code is set following a progression of steps to achieve that target, monitor it, and maintain it will yield justifiable rewards for your efforts. Make an impact on reliability by controlling contamination.

    Recommended* Target ISO Cleanliness Codes and media selection for systems us petroleum based fluids per ISO4406:1999 for particle sizes 4µ[c] / 6µ[c] / 14µ[c]

    Set the Target.

    The first step in identifying a target ISO code for a system is to identify the most sensitive component on an individual system, or the most sensitive component supplied by a central reservoir. If a central reservoir supplies several systems the overall cleanliness must be maintained, or the most sensitive component must be protected by filtration that cleans the fluid to the target before reaching that component.

    Other Considerations.

    Table 1 recommends conservative target ISO cleanliness codes based on several component manufacturers guidelines and extensive field studies for standard industrial operating conditions in systems using petroleum based fluids. If a non-petroleum based fluid is used (i.e. water glycol) the target ISO code should be set one value lower for each size (4μ[c] / 6μ[c] / 14μ[c]). If a combination of the following conditions exists in the system the target ISO code should also be set one value lower:

    • Component is critical to safety or overall system reliability.
    • Frequent cold start.
    • Excessive shock or vibration.
    • Other severe operation conditions.

    Pumps Pressure
    < 138 bar
    < 2000 psi
    Media
    βPx[c] = 1000
    (βpx = 200)
    Pressure
    138-207 bar
    2000 – 3000
    psi
    Media
    βx[c]=1000
    (βx = 200)
    Pressure
    > 207 bar
    > 3000 psi
    Media
    βx[c]=1000
    (βx = 200)
    Fixed Gear 20/18/15 22μ[c] (25μ) 19/17/15 12μ[c] (12μ)
    Fixed Piston 19/17/14 12μ[c] (12μ) 18/16/13 12μ[c] (12μ) 17/15/12 [c] (6μ)
    Fixed Vane 20/18/15 22μ[c] (25μ) 19/17/14 12μ[c] (12μ) 18/16/13 12μ[c] (12μ)
    Variable Piston 18/16/13 [c] (6μ) 17/15/13 [c] (6μ) 16/14/12 [c] (3μ)
    Variable Vane 18/16/13 [c] (6μ) 17/15/12 [c] (3μ)
    Valves
    Cartridge 18/16/13 12μ[c] (12μ) 17/15/12 [c] (6μ) 17/15/12 [c] (6μ)
    Check Valve 20/18/15 22μ[c] (25μ) 20/18/15 22μ[c] (25μ) 19/17/14 12μ[c] (12μ)
    Directional
    (solenoid)
    20/18/15 22μ[c] (25μ) 19/17/14 12μ[c] (12μ) 18/16/13 12μ[c] (12μ)
    Flow Control 19/17/14 12μ[c] (12μ) 18/16/13 12μ[c] (12μ) 18/16/13 12μ[c] (12μ)
    Pressure Control
    (modulating)
    19/17/14 12μ[c] (12μ) 18/16/13 12μ[c] (12μ) 17/15/12 [c] (6μ)
    Proportional
    Cartridge Valve
    17/15/12 [c] (6μ) 17/15/12 [c] (6μ) 16/14/11 [c] (3μ)
    Proportional
    Directional
    17/15/12 [c] (6μ) 17/15/12 [c] (6μ) 16/14/11 [c] (3μ)
    Proportional
    Flow Control
    17/15/12 [c] (6μ) 17/15/12 [c] (3μ) 16/14/11 [c] (3μ)
    Proportional
    Pressure Control
    17/15/12 [c] (6μ) 17/15/12 [c] (6μ) 16/14/11 [c] (3μ)
    Servo Valve 16/14/11 [c] (6μ) 16/14/11 [c] (3μ) 15/13/10 [c] (3μ)
    Bearings
    Ball Bearing 15/13/10 [c] (3μ)
    Gearbox (industrial) 17/15/13 12μ[c] (12μ)
    Journal Bearing
    (high speed)
    17/15/12 [c] (6μ)
    Journal Bearing
    (low speed)
    17/15/12 [c] (6μ)
    Roller Bearing 16/14/11 [c] (6μ)
    Actuators
    Cylinders 17/15/12 [c] (6μ) 16/14/11 [c] (3μ) 15/13/10 [c] (3μ)
    Vane Motors 20/18/15 22μ[c] (25μ) 19/17/14 12μ[c] (12μ) 18/16/13 12μ[c] (12μ)
    Axial Piston Motors 19/17/14 12μ[c] (12μ) 18/16/13 12μ[c] (12μ) 17/15/12 [c] (6μ)
    Gear Motors 20/18/14 22μ[c] (25μ) 19/17/13 12μ[c] (12μ) 18/16/13 12μ[c] (12μ)
    Radial Piston Motors 20/18/15 22μ[c] (25μ) 19/17/14 12μ[c] (12μ) 18/16/13 12μ[c] (12μ)
    Test Stands, Hydrostatic
    Test Stands 15/13/10 [c] (3μ) 15/13/10 [c] (3μ) 15/13/10 [c] (3μ)
    Vane Motors 20/18/15 [c] (6μ) 16/14/11 [c] (3μ) 16/14/11 [c] (3μ)

    ‘Depending upon system volume and severity of operating conditions a combination of filters with varying degrees of filtration efficiency might be required (I.e. pressure, return, and off-line filters) to achieve and maintain the desired fluid cleanliness.

    Example ISO Code
    Operating Pressure 156 bar, 2200 psi
    Most Sensitive Component Directional Solenoid 19/17/14 Recommended Baseline ISO Code
    Fluid Type Water Glycol 18/16/13 Adjust Down One Class
    Operating Conditions Remote Location, Repair
    Difficult, High Ingression Rate
    17/15/12 Adjust Down One Class,Combination of
    Critical Nature, Severe Conditions

    Dual Glass Verse Cellulose Media

    Glass media has superior fluid compatibility versus cellulose with hydraulic fluids, synthetics, solvents, and high water based fluids. Glass media also has a significant filtration efficiency advantage over cellulose, and is classified as “absolute” where cellulose media efficiency is classified as “nominal”.

    Elements of different media with the same “micron rating” can have substantially different filtration efficiency. Figure 1 provides a visual representation of the difference between absolute and nominal filter efficiency.

    The illustrated glass element would typically deliver an ISO Fluid Cleanliness Code of 18/15/8 to 15/13/9 or better depending upon the system conditions and ingression rate. The cellulose element would typically achieve a code no better than 22/20/17.

    Runaway contamination levels at 4μ[c] and 6μ[c] are very common when cellulose media is applied where a high population of fine particles exponentially generate more particles in a chain reaction of internally generated contaminate.

    Inorganic glass fibers are much more uniform in diameter and are smaller than cellulose fibers. Organic cellulose fibers can be unpredictable in size and effective useful life. Smaller fiber size means more fibers and more void volume space to capture and retain contaminate.

    Glass media has much better dirt holding capacity than cellulose. When upgrading to an absolute efficiency glass media element the system cleanliness must be stabilized. During this clean-up period the glass element halts the runaway contamination as the ISO cleanliness codes are brought into the target cleanliness range. As the glass element removes years of accumulated fine particles the element life might be temporarily short.

    Once the system is clean the glass element can last up to 4-5 times longer than the cellulose element that was upgraded as shown in figure 2.

    IMPROVE CLEANLINESS

    Cleaner Fluid, Longer Component & Fluid Life, More Uptime!

    When setting target ISO fluid cleanliness codes for hydraulic and lubrication systems it is important to keep in mind the objectives to be achieved. Maximizing equipment reliability and safety, minimizing repair and replacement costs, extending useful fluid life, satisfying warranty requirements, and minimizing production down-time are attainable goals. Once a target ISO cleanliness code is set following a progression of steps to achieve that target, monitor it, and maintain it will yield justifiable rewards for your efforts. Make an impact on reliability by controlling contamination.

    Hydraulic Component
    Develop a Fluid Cleanliness Target

    Waltan Tools and Equipment can help you develop a plan to achieve and maintain target fluid cleanliness. Arm yourself with the support, training, tools and practices to operate more efficiently, maximize uptime and save money.

    Current ISO
    Code
    Target ISO
    Code
    Target ISO
    Code
    Target ISO
    Code
    Target ISO
    Code
    2 x Life 3 x Life 4 x Life 5 x Life
    28/26/23 25/23/21 25/22/19 23/21/18 22/20/17
    27/25/22 25/23/19 23/21/18 22/20/17 21/19/16
    26/24/21 23/21/18 22/20/17 21/19/16 21/19/15
    25/23/20 22/20/17 21/19/16 20/18/15 19/17/14
    25/22/19 21/19/16 20/18/15 19/17/14 18/16/13
    23/21/18 20/18/15 19/17/14 18/16/13 17/1512
    22/20/17 19/17/14 18/16/13 17/15/12 16/14/11
    21/19/16 18/16/13 17/15/12 16/14/11 15/13/10
    20/18/15 17/15/12 16/14/11 15/13/10 14/12/9
    19/17/14 16/14/11 15/13/10 14/12/9 14/12/8
    18/16/13 15/13/10 14/12/9 13/11/8
    17/15/12 14/12/9 13/11/8
    16/14/11 13/11/8
    15/13/10 13/11/8
    14/12/9 13/11/8

    Succeed with a Total Systems Cleanliness Approach

    Developing a Total System Cleanliness approach to control contamination and care for fluids from arrival to disposal will ultimately result in more reliable plant operation and save money. Several steps to achieve Total Systems Cleanliness include: evaluate and survey all hydraulic and lubrication systems, establish an oil analysis program and schedule, insist on specific fluid cleanliness levels for all new fluids, establish a baseline and target fluid cleanliness for each system, filter all new fluids upon arrival and during transfer, seal all reservoirs and bulk tanks, install high quality particulate and desiccant breathers, enhance air and liquid filtration on existing systems wherever suitable, use portable or permanent off-line filtration to enhance existing filtration, improve bulk oil storage and handling during transfer, remove water and make a commitment to fluid cleanliness.

    The visible cost of proper contamination control and total systems cleanliness is less than 3% of the total cost of contamination when not kept under control. Keep your head above the surface and avoid the resource draining costs associated with fluid contamination issues including:

    • Downtime and lost production
    • Component repair/replacement
    • Reduced useful fluid life
    • Wasted materials and supplies ($)
    • Root cause analysis meetings
    • Maintenance labour costs
    • Unreliable machine performance
    • Wasted time and energy ($)

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    We have done business with Winnellie Hydraulics on numerous occasions and find them to always be nothing but professional, honest and reliable.Their customer service is excellent and they are always a pleasure to work with. We would highly recommend Winnellie Hydraulics and we look forward to continuing business with Max and the team in the up and coming future.
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    Winnellie Hydraulics are up most professional and I am always impressed with the service offered and provided. The team at Winnellie Hydraulics are highly skilled, innovative and ever reliable. They continue to be the Territory’s leading service specialists within the fields of the hydraulic and pneumatic services and solutions. The team have a broad range of knowledge in hydraulic, pneumatic, hose management and products across a extensive range of divisions. The team at Winnellie Hydraulics are easy to work with and really appreciate their customers and strive for continuous business improvement.
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    Rob North
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    Efficient, professional and dedicated. The team at Winnellie Hydraulics are a pleasure to work with and are customer service specialists.Max and the team have taken on many challenges to assist with emergent scopes at our onshore facility in Darwin. They go above and beyond to meet the timeline required without missing a beat on quality.I highly recommend dealing with them and look forward to future business.Thanks guys
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    The team at Winnellie Hydraulics are customer service specialists! They certainly go above and beyond to meet the needs of customers and are a great local service and supply business. I highly recommend dealing with them.
    Darren Steele
    Darren Steele
    02:59 07 Feb 21
    For all your Hydraulic & Pneumatic needs, Winnellie Hydraulics has you covered.Max and the team run a great operation that supports the Oil & Gas and Mining industries.With great brands supporting them, they are truly the one stop shop for all your engineering needs.
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    The team at Winnellie hydraulics, is great to work with, they understand our priority and service delivery to our Defence clients, No job too small or big and delivering of high quality products and service. Also really easy to deal with in regards to faults/ warranty and SME service . Highly recommended to use.
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    Winnellie Hydraulics are a Parker PPD for the NT which means they have full access to all Parkers Hannifin products & our local Engineering team in Australia who can work with Winnellie on any projects where clients needs are meet using Parkers products & their insulation experience
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    Ben Tilbrook
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