2005,Badal,L.,The Importance of ISO Cleanliness Codes

The Importance of ISO Cleanliness Codes

Leonard Badal, Chevron Global Lubricants; John Whigham, Petrolink USA Inc.; Trigg Minnick, Des-CaseCorporation

The International Organization forStandardization (ISO) has developeda code system called ISO Cleanlinesscodes, a universal standard formeasuring and reporting particulatecontamination levels in fluids. ISO4406:99 is the newest and mostcommonly used cleanliness code. It isassigned on the basis of the numberof particles per unit volume greaterthan 4, 6 and 14 microns. Thenumbers are given in this specificorder for consistency in comparison.Each code represents a range of solidparticles present in a lubricant.

What are ISO Cleanliness Codes?First, particle count analysis is conducted on a representative sample of the fluid ina system. The particle count test provides the quantity and micron size of thevarious solid contaminants in the fluid. The actual particle count and subsequentISO Cleanliness Code are compared to the target code for the system. If the actualcleanliness level of a system is worse than the desired target, corrective action isrecommended.

Different mechanical systems have distinct levels of cleanliness that are requiredfor optimum life and minimum component wear. Contaminants in a systemaccelerate wear, reduce efficiency, increase operating costs and can causesignificant downtime.

Typically, new fluids are not clean fluids. Bulk lubricants from blending plants canrange from 19/17/15 to 17/14/13, while sealed drum lubricants can havecleanliness codes as high as 22/21/19. In contrast, highly filtered fluids may have acode of 16/14/11 or lower.

Importance of Code ComplianceHigh ISO Cleanliness codes indicate high levels of particulate contamination in theoil, which increase wear and shorten the lives of both machinery and lubricants.However, if a company maintains a sophisticated and effective contaminationcontrol program, the codes can be used to achieve increased efficiency and reduceddowntime.

The codes are also used as a basis for comparison, to understand how equipmentperforms under specific cleanliness levels. Maintenance personnel typically use thecodes to evaluate the need for various levels of contamination protection.

ISO Cleanliness codes themselves do not differ for various components. There areno set standards outside a handful of original equipment manufacturerrecommendations, but Table 1 provides a fluid cleanliness guide for hydraulicsystems.

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The Importance of ISO Cleanliness Codes http://www.machinerylubrication.com/article_detail.asp?articlei...

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Table 1. Typical Cleanliness Recommendations

Generally, the tighter the tolerance on the component’s metal-to-metal surfaces,the tighter the cleanliness code. For instance, servo valves on hydraulic systemsare more susceptible to contamination-related failures than low-speed gearboxes.Therefore, the hydraulic reservoir fluid will require a lower ISO code (cleaner fluid)than the gearbox. This knowledge allows maintenance departments to focus onpreventing failures instead of treating them, and prompts them to employenhanced tactics to keep contamination out of the hydraulic reservoir.

Click Here to see Figure 1

Contamination Prevention and RemovalThere are numerous methods available to meet the appropriate cleanliness codes,which vary according to equipment and environment. The main objective is to stopcontamination from initial entry, because studies show that it is approximately tentimes more cost-efficient to prevent contamination than it is to remove it once it ispresent in a system. Specific solutions include quality breathers, hydraulic sleevesand improved storage and handling of fluids.

Several technologies exist for the removal of solid contaminants from a lubricationsystem. The most widely used method is filtration, followed by centrifuge andelectrostatic technologies.

It is also important to institute a contamination control program for theestablishment and monitoring of appropriate target cleanliness codes formachinery, storage and dispensing of lubricants, periodic cleaning of reservoirtanks and storage vessels, and installation of breathers to reduce ingression ofcontaminants. Oil analysis can be used for tracking trends to determine the valueof various preventive maintenance efforts.

Some of the major lubricant manufacturers offer programs to help control fluidcontamination and maximize lubricant investment values. For instance,ChevronTexaco’s IsoClean™ Solutions offers fluid conditioning services to removedamaging particulates from system fluids and IsoClean™ storage containers toprovide fluid contaminant protection and improve facility and system cleanliness.Desiccant breathers created by Des-Case® Corporation reduce airborne particulateand water contamination, which are leading causes of lubricant-related equipmentfailure. Petrolink USA, Inc., offers on-site lubricant reconditioning and preventivemaintenance services to manufacturing facilities in the Midwest, Northeast andSoutheastern areas of the United States.

Industry Utilization of ISO Cleanliness CodesIndustry as a whole is beginning to implement solutions to achieve compliance withISO Cleanliness codes. Manufacturers of machinery are establishing targetcleanliness codes for systems and are also providing extended warrantyconsiderations for end-users who maintain long-term system hygiene as part oftheir reliability programs.

In addition, end-use customers are becoming more educated about contaminationcontrol and as a result, are creating buy-in from upper management to employsolutions that optimize reliability. Companies are implementing programs tomeasure their system cleanliness and provide tools for removing contaminants.They can also utilize life extension tables to illustrate potential benefits in reducingsystem contamination from high to low levels, along with capturing the economicvalue of these solutions.

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Click Here to see Table 2. New Cleanliness Level (ISO Cosde)

Moving to Proactive MaintenanceIt can be difficult to convince maintenance staff of the importance of complyingwith and relying on the value of ISO Cleanliness codes. Due to the recent economy,maintenance departments are usually squeezed for time and money. Also, becausecontaminants are microscopic and invisible to the eye, most planners are unawareof the harm these unseen contaminants can cause to system reliability. Therefore,new tactics can often be seen as burdensome and inconvenient.

However, with recent emphasis on education and training, more maintenancepersonnel are learning about the problems associated with contamination. Onceappreciative of the benefits that improved cleanliness offers, most maintenancedepartments are eager to travel the road to less downtime and improved reliabilityand profitability. Nevertheless, the transition can sometimes be tough, becausewhile the maintenance department must deal with typical issues such as rebuilds,outages and frequent oil changes, it must simultaneously execute new measuresthat require extra time. Plus, depending on the equipment and environment, it ispossible that benefits may not be seen for an extended period of time.Consequently, this paradigm shift requires a great deal of discipline andcommitment from the maintenance staff.

Cases from the FieldThere are many cases where compliance with a higher standard of cleanliness hassignificantly improved operations at industrial facilities. For instance, the authorsassisted a leading national independent petroleum refiner to institute all-inclusivecontamination control programs. The petroleum refiner has significantly reducedlubricant spending along with upgrading its products to Group II and synthetics.They have experienced fewer maintenance failures over the last three years, alongwith significantly reducing lubricant purchases.

A major Midwest power plant realized a lubricants cost savings of 53 percent over afive-year period through better housekeeping measures and improved filtration,which included the use of desiccant breathers. After several months of practicingthese improved processes, oil analysis reports showed a substantial decrease insilicon levels. The ISO level set for new oil supplied was 18/17/14. When the firstin-service sample was taken, readings were 15/14/12, indicating that the oil wascleaner than when it came in the door. By consistently maintaining levels belowcode, the plant has achieved a four-fold extension of lubricant life. The same oil hasbeen in service since October 2002 and based on sampling trends and sustainablecleanliness codes, plant technicians are expecting to extend its life to as much asfive to seven years.

Several years ago, Petrolink worked with a major wheel hub manufacturing facilityin the Midwest who was experiencing large numbers of pump, valve and cylinderfailures. The contamination levels in most of the systems were significantly higherthan established targets and the maintenance department was primarily focused onrepairing failed equipment.

The company implemented its preventive maintenance service program at thecustomer plant, which involved analysis, reservoir cleaning, fluid reclamation,filtration upgrades and system flushing. The results were staggering: In the firstyear, the plant reduced component usage and failures and unscheduled downtimeby 60 percent, allowing maintenance staff to concentrate on proactive maintenanceactivities versus reactive. This resulted in bottom-line savings of $450,000.

These case studies help underline the huge savings and increased efficiency thatindustrial facilities can achieve through reliability-based maintenance programsthat effectively monitor system cleanliness and remove contaminants. Byimplementing these programs, combined with the effective utilization of ISOCleanliness codes as part of an efficient contamination control plan, increasedefficiency and reduced downtime can be achieved. This means significant benefitsfor a company’s bottom line and enduring success in today’s highly competitiveglobal economy.

Please reference this article as:Leonard Badal, Chevron Global Lubricants; John Whigham, Petrolink USA Inc.; Trigg Minnick, Des-CaseCorporation, "The Importance of ISO Cleanliness Codes". Machinery Lubrication Magazine. September 2005

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2005,Badal,L.,The Importance of ISO Cleanliness Codes