Particle Counting: Getting

Started and Best Practices

Presented by Noria Corporation

Sponsored by:

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Considered to be one of the most crucial tests in oil analysis,
the importance of particle counting can’t be overstated. Particle
counting helps identify potential problems in fluids and lubricants
by monitoring and detecting the number and size of different
particles in the oil sample. From spotting high contamination or
wear conditions to checking turbine oil cleanliness, particle
counting is an invaluable part of any oil analysis or condition
monitoring program.

Although pioneers like Dr. E.C. Fitch showed the value and utility
of counting particles in lubricant systems by the 1970s, it took
over a decade before it was widely used by industrial plants. This
guide is designed to help those who want to get more value and
actionable insights from particle counting or start a new program.
We will also cover advances in digital particle counting, such as
the ability to identify wear particles or distinguish particles from
bubbles to improve root cause analysis and PdM activities.

Determining the Absolute Number of Particles

There are a few methods currently in common use for particle counting; each has its own strengths.
Which you choose for a given application depends on your needs and goals. Consider the criticality of
your equipment and select a particle counting tool that will give you the insights needed to improve
reliability and reduce total cost of ownership.

Four types of wear debris particles

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Optical Microscopy
Also known as ISO 4407, optical microscopy is the original method for determining the cleanliness level
of a fluid by taking a portion of the oil sample and examining it under an optical microscope. During this
procedure, a sample of the oil is taken, and the particles are counted manually. This number can then be
used to determine the cleanliness of the entire fluid amount. While this method requires manual power
and can be slow at times, it is still considered one of the most reliable and accurate methods available
for particle counting.

Basic Optical Particle Counting

Automatic optical particle counting, or ISO 11500, is one of the most widely used methods for
determining fluid cleanliness. Unlike optical microscopy, this method uses a commercial instrument
to help determine the particle count. Machines can range from more cost-effective portable units to
large, full-scale lab-based instruments. No matter which machine option you choose, all will use either
a white light source or a laser to count the particles.

With laser-based instruments, the light is focused into an unimpeded beam and focused on a specific
point. As particles pass through the instrument, they come into contact with the laser and light scatters
onto the photocell. The change in voltage across the photocell directly relates to the size of the particle
that passed through.

A laser detecting particles in a sample

With white light instruments, particles pass through a specific detection zone and create a shadow
on a photocell detector. The photocell detector has a continual stream of voltage running through it,
and when a particle comes into contact with it, the voltage drops and creates a shadow. This shadow
directly correlates to the size of the particle passing through it.

There are several factors that should be considered when looking into automatic optical particle
counters. The first aspect to consider is that most particles from used oil samples are not a perfect

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sphere. To counteract this, the equivalent spherical diameter method was developed. With this method,
the particle is counted in the size range under which its shadow would have appeared if the particle had
been a perfect sphere. This means the average fluid cleanliness is estimated which allows for the ISO
code, which will be discussed later, to be monitored and trended over consecutive samples.

Projected Area (µm2)

Particle size based on

equivalent spherical
40 diameter
microns2

Diameter
Larger Particle 7.2 microns

Small Particle

Voltage Drop Particle Diameter (microns)

Four types of wear debris particles
The next factor to consider is false positives. Using the optical particle counting method, air bubbles,
free water, and emulsified water all appear like they are particles. While most of the air and water can
be nullified using ultrasonic baths, vacuum degassing, and solvent extractions, there is still a potential
for false positives to show in the report. This can happen through multiple particle coincidences and
additive floc. Because of this, special care and attention must be given to procedural details when
using many optical particle counters, however there are newer technologies helping to solve these
issues through the use of “true optical” technology.

“True Optical” Particle Counters

Most optical particle counters provide basic count results, but newer technologies that employ high-
definition lenses and cameras (known as “true optical” systems) are able to identify particles in addition
to counting them, even reporting what type of wear is taking place.

With these deeper insights, an IoT system like the Atten2 S120 OilWear can help identify wear and
failure conditions earlier, allowing you to take corrective action as needed. This can both extend the
interval between certain service activities and help ensure that necessary actions are taken at the
earliest signs of problems.

Standard automatic optical particle counters have problems differentiating bubbles from particles

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as described above, but a true optical system that is able to ignore bubbles and other interference
can improve the accuracy of data trending and avoid inaccurate readings. Using basic optical particle
counters may mean you are spending time and resources on misguided maintenance activities if air
bubbles are being counted as particles, causing false high contamination readings.

In highly critical applications, getting accurate insights about machine health and wear conditions can be
invaluable in preventing expensive downtime without performing maintenance activities unnecessarily.

Pore Blockage Particle Counting

The pore blockage particle counting method, or BS3406, is the method by which a volume of fluid
is passed through a mesh screen with a well-defined pore size. The pore size is typically around 10
microns, and there are two instruments that take advantage of this method.

The first measures how the flow decreases across the membrane when it gets plugged, first by larger
particles, and then by smaller ones as the larger ones begin to fully plug up the screen. The second
measures the increase in differential pressure across the screen as it becomes plugged with particles.
Both instruments rely on a continual, constant flow of oil and are tied to software algorithms that turn
the results into an ISO cleanliness rating based off of ISO 4406:99, which will be discussed later.

While pore blockage particle counting doesn’t have to deal with false positives caused by air, water, and
dark fluids, they don’t currently have the same range as an optical particle counter. This is because the
particle size distribution is only a rough estimate and is dependent on the accuracy of the algorithm to
correctly report ISO fluid cleanliness codes. Despite this, pore blockage particle counting does report
the accumulated concentration of particles in the oil and in some instances, it does offer advantages,
such as with heavily contaminated oils and dark fluids.

No matter what method (or combination of methods) you choose, keep your end goals in mind. Once
you have the tools you need, gaining an understanding certain sampling best-practices and lubrication
concepts will help you to get more value from your equipment.

Understanding Particle Count Data

Before Sampling
There are several variables that can affect an oil analysis’s results during a particle count. To make sure
you are getting an accurate picture of your lubricant’s health and the state of your machines, samples
should only be collected before the filters. By taking samples after the filter, it would only be testing the
efficiency of the filter and not the cleanliness of the oil itself. For solid, reliable data, the process used
for collecting samples must be consistent. This includes making sure to sample from the same point
and using the same sample method each time. This ensures you are trending accurate data for the
oil. The sampling equipment and collection bottles should also be devoid of any dirt or moisture, and
should only be removed from their storage when necessary to avoid extra contaminants.

Before taking a sample, it is extremely important to clean the machine’s sample port with a lint-free
cloth to avoid adding to the particle count. You should also consider using a new zip-lock bag to open
and close the sample bottle to help keep as much environmental dust and moisture out of the sample
as possible.

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 A machine modified with sample ports and sight glasses for easier and more accurate data collection.

Not only do your sampling methods need to be proactive and protective, but if you send your samples off
for testing, you need to make sure it’s a reliable laboratory. If the lab is not handling samples correctly,
the test results will be distorted, and could potentially lead to a false positive. If the facility is near you,
taking a surprise visit is a great way to see how samples are processed and how clean the facility is.

Sampling Results
Once you have conducted your particle counting tests, it’s time to decode the information so that the
results may be used to understand the current contamination level of the machine. To ensure that results
could be understood across any industry and testing method, the ISO developed a set of regulations
for decoding the data. This made it easier for technicians to transcribe the information in a universally
agreed-upon method. Over the decades, a number of methods have been used as the standard, and
each new standard evolves and effectively solves an issue that came up in the previous method.

Who is ISO?
The International Organization for Standardization, or the ISO, is
a global organization made up of international representatives
and experts that help establish different standards for a
variety of industries including commercial and industrial.
The ISO operates in more than 160 countries and helps set
guidelines and standards for a variety of products that make
international trade and business transactions more accessible
and straightforward.

NAS 1638
To help industry professionals better disseminate particle count information in a consistent and
formatted context, ISO 4406 was developed. ISO 4406 helped create a standardized method for
reporting particle count data. Despite its name, this standard was first developed by the National
Aerospace Standards (NAS) organization as a response to the chaotic world of aircraft hydraulic fluids
by establishing set standards for particle counting and was originally titled NAS 1638.

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In the first version of this standard developed in the 1970s, professionals would use an optical
microscope to measure the size of solid particles in one milliliter of oil and then place them in one of
five size categories:

- 5-15 microns - 15-25 microns

- 25-50 microns - 50-100 microns
- >100 microns
These numbers were then imputed into a chart that
helped classify the oil’s cleanliness by ranking it from
00 to 12 based on the total number of particles in
each of the size ranges. The lower the number, the
cleaner the oil. But as particle filters became more
efficient and advanced at removing large particles
from oil, it made the upper size ranges of NAS 1638
less accurate at depicting the particle distribution in
the oil.

As filters continued to advance, ISO decided it wasn’t

necessary to continue to report on the concentration
of these larger particles. By recognizing that hydraulic
oil cleanliness is a top priority and that the current
system of measuring particles wasn’t keeping up
with the industry, ISO set out to create a new particle
counting standard that more accurately reflected the
concentration of particles they were seeing. What Particles being captured by filter media
they created became known as ISO 4406.

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The Creation of ISO 4406
NUMBER OF PARTICLES PER mL
Not only did ISO set out to create a classification tool
that more accurately reflected the particle counts, but
they wanted the system to be easier to understand. Up to and Range
More than
Including Number
This also included expanding the classification
standards to include all lubricating fluids so there was 5,000,000 10,000,000 30
one core standard accepted across all industries.
2,500,000 5,000,000 29
With their first round of edits, the ISO cut down 1,300,000 2,500,000 28
the number of categories from five to two, with a 640,000 1,300,000 27
potential third category for special circumstances. 320,000 640,000 26
For the representative particle sizes, they chose 2, 5,
80,000 160,000 25
and 15 microns, with 2-microns being the optional
category. The next significant alteration that was 80,000 160,000 24
made involved changing the entire scale. Also known 40,000 80,000 23
as the Renard table, ISO created a scale that ranged 20,000 40,000 22
from 0.9 to 30, which allowed for a simplified method
10,000 20,000 21
of expressing small and large particles using a single
value. 5,000 10,000 20
2,500 5,000 19
This system stayed in place until the 1990s when 1,300 2,500 18
it became apparent that the current method of
640 1,300 17
calibrating the automatic particle counters wasn’t
meeting the requirements set out by the ISO 9000 320 640 16
standard. Not only was there a lack of control over 160 320 15
the calibration material, but it was also discovered 80 160 14
that the particles sizes were not being reported
40 80 13
the same. This led to their final edit of the particle
20 40 12
measuring system – ISO 4406:99.
10 20 11
ISO 4406:99 5 10 10
2.5 5 9
With the increased efficiency and accuracy of
microscopic telescopes, it became easier and 1.3 2.5 8
more reliable to report on particle sizes smaller 0.64 1.3 7
than 5 microns. Combine this with the knowledge 0.32 0.64 6
that smaller particles were becoming an increasing
0.16 0.32 5
concern over larger particles, and it is easily
understood why ISO decided to officially create a 0.08 0.16 4
third cleanliness code. 0.04 0.08 3
0.02 0.04 2
ISO set the new cleanliness codes at 4, 6, and 14
microns as this provided the best representation 0.01 0.02 1
of the particles that were the closest to the oil’s
ISO 4406 Chart
thickness, which cause the most damage to surfaces.

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SAE AS4059
Although ISO’s newer standards have been widely adopted, it is important to note that some industries
and countries still use the SAE AS4059 system to measure the particles in their oils. This reporting
method may already be somewhat familiar to some in the industry because it utilizes the same reporting
table as the previously mentioned NAS 1638 method. While they might take advantage of the same
reporting table, the SAE method has an optional reporting method where instead of a single code that
represents the oil’s cleanliness, it can report on the specified cumulative particle size count. This can be
identified by a suffix letter after the class number that will tell you what cumulative particle size count
category the code represents.

While there isn’t an incorrect cleanliness standard, it is important to be aware of other standards as you
conduct business with other industries and countries.

Reasons for High Particle Counts

4 Common Possibilities
After testing the oil and receiving the results back, if the
particle count is high, there are generally four possible
explanations.

The first is that the machine is not in any immediate danger,

but either a filter has failed, or a new source has developed
for particles to enter through. This can be solved by fixing the
filter or correcting the source of the particle ingression.

The second is that there is a new ingression source, or a filter

failure and the machine is in immediate danger because of
the resulting high particle count. This is corrected by swiftly
cleaning up the oil and by fixing the failed filter or ingression
source.
Undetected contamination can
cause severe damage The third is that the high particle count is due to abnormal
wear particles that will threaten the machine’s overall
reliability. This is resolved by performing a root cause failure analysis and following up with the
appropriate remediations and clean-up procedures.

The final is that the high reading is due to either a sampling error, an analytical error such as with the
particle counter’s calibration, or soft particles such as dead additives.

Setting up an Onsite Oil Analysis Program

There are many reasons for wanting to set up an onsite oil analysis program, but no matter the reason,
one of the first questions that usually comes to mind is “What particle counter should I use?”

While there are a number of high-quality particle counters to choose from, consider your end goal—if

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you are taking particle counts to help identify wear and failure conditions earlier, a “true” optical system
like the Atten2 S120 OilWear may be a good choice. With this system, you not only get the ISO code
and mass number, but the system is also able to differentiate between air or water bubbles and actual
debris particles, giving you more accurate readings and trend lines even when bubbles are present.

A true optical particle counter can distinguish different particles in the oil, even classifying them based
on a library of samples built into the system. This library will help the system identify exactly what type
of wear is taking place, such as cutting, sliding, and/or fatigue wear.

No matter what system you choose, there are many uses for particle counting:

- Contamination - Mechanical wring out

- Verifying filter performance - Allowing for on-demand lab oil analysis

- Confirming corrective maintenance - Verifying pump conditions

- Verifying stored lubricant cleanliness - Identifying changing atmospheric contamination

- Identifying botches machine repairs - Troubleshooting and isolating problems

- Identifying new filter defects - Detecting high corrosive wear

- Identifying abrasive wear conditions - Determining new oil cleanliness

Standard optical particle counters can give you basic details like ISO codes. In low-criticality applications
you may not require much more information than that, but for high-criticality assets, such as turbine oil
systems, a more advanced solution will help you get a better picture of lubricant and machine health.

How to Conduct More Accurate Particle Counting

Once the appropriate particle counter has been selected, there are several steps you can take to ensure
you are producing an accurate particle count.

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 The Atten2 can detect and identify different types of wear particles while also
distinguishing them from bubbles for more accurate readings.

1. Make sure the sample is taken from the correct location using proper sampling procedures. Take
special care to minimize contamination during sample collection and leave headspace in the bottle.

2. Make sure the sample bottle is at least 2 ISO range codes cleaner than the desired lowest levels of
ISO fluid cleanliness.

3. Remember to dilute viscous fluids and contaminated samples using a reagent-grade kerosine that
has been prefiltered before counting particles. The substance used to dilute the viscous fluid can
also be prefiltered if its cleanliness is in question.

4. Test for free and emulsified water using a moisture screening method, such as the crackle test.
If there is water present, it can be vacuum dehydrated or treated with a 50:50 mix of the oil and a
mixture of three parts toluene and one part isopropyl alcohol.

5. If a few minutes pass between sampling and testing, make sure to reagitate the sample for five
minutes using a paint shaker.

6. Ensure the effects of the air bubbles are negated by using a vacuum ultrasonic bath and/or a vacuum
degreaser.

7. Don’t leave the onsite particle counter idle on the shelf; make the most of the invaluable asset each
day.

How to Get the Most from Your Particle Counter

Particle counting machines are one of the best tools for measuring and understanding the root cause a
machine’s failure due to particle contamination. By understanding what the particle counter is revealing,
you effectively use the information collected from your oil samples.

Although it is good practice to set goals and targets based upon the numbers you receive from the ISO
4406:99, you cannot overlook the results from the particle counter itself. A general rule is that for every
increase in the ISO code that you experience, the amount of particles in your oil sample effectively
doubles. Therefore, you cannot solely rely on the ISO code to dictate your follow-up actions. When you

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receive your report back from the onsite lab, examine the individual counts and then begin to gauge
whether the actions you are taking to achieve your cleanliness targets are effective.

For example, if your target goal is to have an ISO code of 18/16/13 but your code numbers are coming
back as 19/17/14, your natural reaction may be to think that your oil is dirty. But, if you check the individual
particle counts, you can see how far off you actually are for achieving your goal, down to a singular
particle. From here, a quick round of filtering may be all you need to reach your target cleanliness goal.

8 Proactive Uses for Your Particle Counter

Routinely check that oils that are in service are within targeted
cleanliness levels.
Check the cleanliness level of new oils.
Identify failed or defective filters.
Check that seals and breathers are working effectively.
Confirm that systems are properly cleaned and flushed after repair
work.
Confirm that new hydraulic systems are cleaned and flushed
before use.
Identify poor maintenance practices.
Identify the need and timing for portable filtration systems.

Other Uses for Particle Counters

Monitoring individual particles sizes can provide other important information. Take filter performance,
for example. By using a particle counter and taking samples before and after the filter, you can look at
the individual particle counters to determine if the filter efficiency and micron values are similar to what
they were advertised to be.

Particle counting also helps you select filters for specific machines and understand a filter’s life
expectancy. For example, if you analyze particle counts both before and after the filter, you can evaluate
whether the filter is deteriorating. The father apart the particle count numbers are, the better the filter
is performing.

A particle counter is a great tool for any lube technician and plant. As long as you are conscious of how
you handle the machine and evaluate the results, the benefits of a particle counter are truly limitless.

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Atten2 OilWear On-Line Particle Counter 2.0

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Using high-definition lenses, cameras & lighting, this system takes the guesswork out of what’s in your
fluid by actually identifying particles in addition to counting them, then going even further by recognizing
the exact type of wear taking place.

Reliability 360, a Delta Fuel Program, is the premier provider of reliability services to critical plants
& equipment across the USA.

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• Power • Pulp & Paper

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