Step 4

LUBRICATION
- OIL CLEANLINESS

Compiled by: TOMOYA WATANABE

Translated by: SURAJIT DEB

 Minute particles in oil
and
Oil cleanliness management

In lubrication oil, numerous minute particles exist. These are known as contaminants. The lubrication oil that
is generally used in machineries, if examined closely, will reveal the presence of more than a million
particles in about 100 ml of oil.
These particles are not visible to the naked eye. But they are the cause of more than 70% of equipment
failures. The cleanliness of the oil being used in the machine should be checked correctly, the effectiveness
of the oil should be known, and oil cleanliness management is a necessity. Also this will be useful in
preventing equipment failures, and becomes a part of preventive maintenance.

Let us introduce the fundamental knowledge required for the oil cleanliness management.

(1) Method of appraisal of the minute particles present in the oil:

The cleanliness level of lubricating oil containing such particles, or in other words, the dirtiness
condition, should be expressed and appraised through standards : NAS 1638 and ISO 4406. The
example of how they are used will be introduced and explained here.

(2) Microscopic symbols for representative cleanliness

We shall present microscopic symbols for appraised cleanliness of sample lubricating oil filtered
through membrane. These can be referred to when actual evaluation of dirt in the oil will be done.
Each symbol is a representative example, and will differ with respect to various conditions related to
the type of equipment, type of oil, period of usage, environment etc. So, these representative symbol
should be referred as a standard of comparison, for the distribution of the microscopic particles of the
lubricating oil, and the extent of largeness of the particles.

(3) Types of microscopic particles and their reason

The representative symbols of the particles in a lubricating oil will be introduced. Also, how these
particles were generated, and how they came into the oil, are important things which should be
known, in order to maintain the clean condition of the oil.

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(4) The method of sample collection

In order to correctly evaluate the cleanliness of the lubricating oil, the sample collection method is
important.
By a wrong sample collecting method, the cleanliness level of the oil can not be judged and it may
end up in measuring the dirt of the sampling port, or dirt of the valves or dirt of the pump. Here,
what type of sampling method is good, and not good, will be discussed.

(5) Simple color comparison method

Compare with the ASTM color models and control the deterioration.

(6) Milli-pore filter based evaluation

The filter color and accumulated particles after filtration are examined to judge the contamination of
the oil under use.

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 1. Method of appraisal of the minute particles present in the oil:

(1A). NAS Grades ( NAS 1638 Standard )

The quantity of dirt in the oil ( foreign minute particles ) is divided into 5 gradations according to their
diameter range, and the NAS grades are accorded based on the quantity of particles in each size range.
In the chart below, the figures are no. of dirt particles in 100 ml of the sample oil, and the max quantity
against each size range is indicated for different grades.

NAS 1638 Gradation Table ( no. of particles / 100 ml. )

Grade 5 ~ 15 um* 15 ~ 25 um 25 ~ 50 um 50 ~ 100 um > 100 um

00 125 22 4 1 0
0 250 44 8 2 0
1 500 89 16 3 1
2 1000 178 32 6 1
3 2000 356 63 11 2
4 4000 712 126 22 4
5 8000 1425 253 45 8
6 16000 2850 506 90 16
7 32000 5700 1012 180 32
8 64000 11400 2025 360 64
9 128000 22800 4050 720 126
10 256000 45600 8100 1440 256
11 512000 91200 16200 2880 512
12 1024000 182400 32400 5760 1024

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 Example of NAS class level calculation
Result of dirt particle count in a 100 ml sample oil is as follows:
5 ~ 15 um = 35,730 nos.
15 ~ 25 um = 1,160 nos.
25 ~ 50 um = 305 nos.
50 ~100 um = 95 nos.
> 100 um = 15 nos.

The NAS Class level of this oil sample is :

As per NAS class norms in previous page, the NAS level for each size will be :
5 ~ 15 um = 8th level
15 ~ 25 um = 5th level
25 ~ 50 um = 6th level
50 ~100um = 7th level
> 100 um = 6th level

Based on above, the size which is present in maximum quantity will decide the
NAS Class level. Hence, the cleanliness level of this oil sample is:

NAS Class 8

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 (1B). ISO Grades ( ISO 44O6 Standard )

In ISO grades, the quantity of contamination ( no. of minute particles ) in 1 ml oil is measured and the total
of no. of particles of size >5 um and 15 um is expressed in codes.
Method of expression : ISO / ( is total count of > 5 um and is total count > 15 um.)

ISO 4406 Upper limit of ISO 4406 Upper limit of

Cleanliness particle count Cleanliness particle count
Code Nos. / ml Code Nos. / ml
1 0.02 13 80
2 0.04 14 160
3 0.08 15 320
4 0.16 16 640
5 0.32 17 1,300
6 0.64 18 2,500
7 1.30 19 5,000
8 2.50 20 10,000
9 5.00 21 20,000
10 10.00 22 40,000
11 20.00 23 80,000
12 40.00 24 160,000

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 Example of ISO class level calculation
Result of dirt particle count in a 100 ml sample oil is as follows:
5 ~ 15 um = 35,730 nos.
15 ~ 25 um = 1,160 nos.
25 ~ 50 um = 305 nos.
50 ~100 um = 95 nos.
> 100 um = 15 nos.

The ISO Class level of this oil sample is :

Particle count of > 5 um size is:

35730+1160+305+95+15 = 37305 nos. ( 100 ml)

Converting to 1 ml, this will become 374 nos. ( 1ml)

ISO cleanliness code for this will be : 16

Particle count of > 15 um size is:

1160+305+95+15 = 1575 nos. ( 100 ml)

Converting to 1 ml, this will become 16 nos. ( 1ml)

ISO cleanliness code for this will be : 11

Hence, the cleanliness level of this oil sample is: ISO 16 /11

2. Microscopic symbols for representative cleanliness

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(2a). 6Microscope photo sample of minute foreign particles
In various NAS Grades of cleanliness

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 (2b). Microscopic Photo Sample of

Representative Minute Foreign Particles

Microscope photo sample of representative minute foreign particle is shown here.

From such photo, we can know what type of foreign particles are there, wherefrom they can come,
their contribution to reasons of equipment failure, and this knowledge can help us in take in
appropriate preventive measures under maintenance.

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 3. Types of microscopic particles and their reason

Types of foreign particles and their reasons of entry

Contamination Rust Fibre Paint Dust

Metallic Particles

Csting Sand

Metalllic wear debris

Welding Sludge

worn out parts

Seal material and its

Grinding / Filing Dust

Grinding Dust
particles

Possible
sources of
contamination
Assembly work
done in a bad O O O O O O O O O O O
environment
Cleaning and
Flushing defect O O O O O O O O O O O

During storage
and - - - O - - - - - O O
transportation
Exposed portion
of cylinder rods - O - - - O - - - - O
etc.
During repair
work O - O O O O O O O O O

Generated inside
the circuit - - O O - O - - - O -

Enters with fresh

oil - - - - - - - - - - O

During oil
pouring O - O O - - - - - - O

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 4. The method of sample collection

Wrong Sampling Method

If oil sample is collected for cleanliness checking in the following methods, due to contamination at
the time of sample taking, correct cleanliness measurement can not be done.

Page

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Correct Sampling Method
Method of extraction from the line ( ISO4021)

Method of extraction from Oil Tank ( NFPA / T2.9.9 )

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 5. Simple color comparison method

Judgment by Color Comparison method w.r.t. ASTM – Colors

With deterioration of Oil, its color changes and becomes reddish. Judgement on oil deterioration
can be made by comparing with color of fresh oil ( ASTM No.). If it thickens to more than 2,
generally it reaches the limit of oxidation.

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 6. Milli-pore filter based evaluation

Judgment based on Milli-pore Filter

This is mainly used for contamination control of Hydraulic Oil. 100 ml of used oil is filtered through
0.8 micron Cellulose Filter, the contamination level is judged by the accumulation of foreign
particles on the filter. If this is closely observed by a loupe, the quality or type of contamination can
also be understood. This judgment method is also called Meiplan examination.

8. Example of check-sheet for Inspection of Oil & Oil Tank

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Click here for opening the Example Check Sheet.

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