PPM Distribution, Is it Better than ISO Code for Interpreting Particle

Count Data?
by Ray Garvey
Emerson Process Management
Originally published in Lubrication & Fluid Power Magazine
ABSTRACT:
A brilliant new method called PPM distribution calculates precisely how much particulate debris is in
the lubrication system. The systems debris values are calculated by multiplying the parts per million of
debris by the lubricant volume to determine milliliters (ml or cc) of particulate debris in three adjacent
size ranges: 4- to 6-microns, 6- to 14-microns, and >14-microns. Peaks in the distribution plot
indicate the nominal size for each different source of contamination or wear. The proportional area
under each peak reveals how much contamination or how much wear debris is in the lubrication
system. This quantitative new method presents particle count information in an intuitive format. The
result is easy interpretation of system contamination and realistic insight about the size of wearing
defects. Examples are given showing how the PPM distribution can provide insights that might be
missed by using the ISO 11171 code values for contamination control and wear indications.

PPM Article Details:

Wouldnt you really like to know how much debris is in your lubrication systems and how much of it is
larger and smaller than the filter cutoff size? Wouldnt you like to know the size of the damage you
expect to find on bearings and gears simply as a result of non-intrusive oil analysis? Both of these
volume and size measurements can now be done using the data from a good laser particle counter[1].
The new patent pending method is called, PPM distribution.
The article, Is Your Particle Counter Giving you Particle Count and Size Distribution, gave an example
of how PPM distribution can be used to reveal two different problems that are taking place at one
time. In that case dust contamination came into a roots blower and caused abrasive wear. The
distribution showed a peak at 24 microns corresponding to the dust contamination and a second peak
at 40 microns corresponding to the metallic wear debris.
This article provides additional examples and explanations of how the PPM distribution works and how
it adds real value to traditional ISO code representation of particle count information.
Figure 1 below shows four examples that have all been normalized so that each has exactly one PPM
of total particulate debris. It is interesting how the four examples have significantly different ISO
codes although all four have exactly the same volume of debris. This is easy to comprehend
considering the fact that ISO codes represent the cumulative numbers of particles greater than 4-, 6-,
and 14-microns, without allowing for how much greater in size the particles actually are.

Just to report that particles are larger than 6-microns is not sufficient. It makes a BIG difference
depending on much greater than 6-six microns the particle s actually are. For example in the 6- to 14micron category, a single 13-micron particle is ten times more massive than a 6-micron particle.
You will see on Figure 1 that the target cleanliness level of 18/16/13 is achieved in example A and
close to being achieved in example B while the other two examples (B and C) appear to be worse.
Figure 2, on the other hand shows that samples A and D are actually the ones with problems
evidenced by the peaks in the > 14-micron size ranges. Sample A has 700 particles greater than 4microns with 15 of these particles in the vicinity of 40 micron size. You can see that these larger
particles occupy approximately 90% of the volume of debris in the system! Example D has a similar
circumstance with double peaks in the larger size ranges.

Figure 1. Four examples with particle count reported in ISO format, each with precisely 1PPM

Figure 2. Same four examples with PPM distribution graphs.

What is PPM by weight?

Normally when someone says, PPM, they mean parts per million by weight. PPM w/w means that the
weight of one part divided by weight of whole (x10^6).
Chemists use w/w because it works well with single-phase solutions. However, nobody really knows
the density of particles specific gravity varies from 1 to 5 depends on material & morphology; while oil
specific gravity is about 0.9. Spectrometers report PPM w/w.
Spectrometers are calibrated with single-phase solutions, not with particulate mixtures. The reasons
for this are obvious. A spectrometer only measures the ultra-fine particulate debris. Most everything
bigger than 5 microns is missed altogether. These are serious limitations regarding Fe, Cu, Pb, Sn,
and Si. With all of these we care most about particles > 5 microns.

What is PPM by volume?

PPM v/v means that the volume of one part (e.g. particles) Is divided by volume of whole (e.g. oil)
(x10^6). This is meaningful for mixtures of solids with solids or solids with liquids. You dont need to
know the density of the constituents.
Optical particle counters directly measure the shadow area of individual particles. The size reported is
the diameter of a circle with same area. It is reasonable to use this size to estimate the volume of the
particles in ranges measured by the particle counter.
To get PPM v/v, determine the volume of debris (micro-liter) in a liter of oil. You can use PPM v/v for
wear and contamination analysis.

For wear analysis, if you know how much metal is in the lube system, you know how much material
has been removed from the machine.
For contamination analysis, if you know how much particulate is in the oil, you know how much
filtration will be needed to remove it.
PPM Distribution is more than just ISO Code
This measurement provides valuable new information. The ISO cleanliness code is a convenient way to
report the number of particles per milliliter in these size ranges:
> 4 microns
> 6 microns
>14 microns
The PPM distribution includes additional insights because it provides the total amount of wear and
contamination 2 ways. First it reports PPM v/v, and second it determines the system debris in ml.
Peaks and inflections in the PPM distribution plot correspond to specific sources of contamination and
wear.

What is System Debris?

The system debris is the total amount of particulate debris in the lubrication system. Multiply PPM v/v
by lubrication system volume (liters x 1000) to get system debris (milliliters). You can easily visualize
how much debris or wear metal this represents using small syringe (or maybe a big one!). Use this
information to calculate the dirt holding capacity for filters to estimate how much it costs to remove
system debris. Keep in mind that filter companies report filter capacity in grams assuming a value for
specific gravity of dust.

How to test wet/dirty oils?

Yes, you can test wet oils. Immiscible water droplets in oil will produce counts which are falsely
interpreted as solid particles. This is done using methods for water masking (US Patent 6,064,480). In
this case the cloudiness disappears oil and water emulsion becomes transparent. This works with
extremely high water contamination, and with water-glycols. Yes, you can test very dirty oils to get
size PPM distribution.
Also, you will occasionally want to test extremely high particle concentrations. Recall that above
20,000 particles/ ml the particle counter may be saturated. Dilution with clean solvent allows testing
of all industrial lubricants, even 1,000,000 particles/ml. Software accounts for dilution ratio and counts
contributed by dilution.

How to keep from loosing big particles?

It is very important that the larger particles not be allowed to be lost. Proper mixing entrains air in the
sample. Degassing takes valuable time while larger particles fall to bottom. It is a good idea to degas
upside down, then dispense the sample from top-to-bottom through laser sensor as shown in Figure 3.

Figure 3. US Patent 6,418,799 method for degassing samples for laser particle counting.

Key points about PPM Distribution

It is important to measure PPM distribution on all types of machinery. This includes very low to very
high viscosity grades (e.g., VG 32 to VG 680). It also includes very clean to very dirty samples (ISO
10 to ISO 26. You will want to trend and alarm on PPM measured in all three ranges. And you want be
sure to sample from the active zone where the oil is hot and circulating.
Be sure to mask water when needed and validate the results using Wear Debris Analysis. WDA is able
to find root cause and severity. It is perfect for determining what the root causes are that produced
the peaks in the PPM distribution plot. See Figure 4.

Figure 4. Wear debris analysis

A single sample will often have more than one contaminant. In this case you characterize each group
of particles in the distribution using the WDA template.
Finally, you will want to take advantage of the Systems Debris computation. Once you know the total
systems debris and you have identified which particle group is associated with each peak in the
distribution using WDA, then you can proportion the total systems debris into categories
corresponding to the area under each peak. For instance in Example D shown in Figure 2 you can
estimate that 40% of the debris volume is associated whit the 13-micron nominal size distribution
while the remaining 60% is associated with the 26-micron nominal size distribution.

CONCLUSION

The new PPM distribution method adds valuable new insight to industrial oil analysis. By quantifying
the total systems debris, combining this with wear debris analysis to identify which source is
responsible for each characteristic peak in the distribution, the user can determine how much filtration
is needed or how much wear has taken place recently. Keep in mind that this measure is only the
freshly generated debris that is actively circulating in the oil. As such the PPM distribution method
provides critical insight needed to screen for contamination and wear problems.

REFERENCES:

R. E. Garvey, Is Your Particle Counter Giving You PPM and Size Distribution? Practicing Oil Analysis
Magazine
[1] The CSI Model 5200 or CSI Model 52PC are recommended for use with OilView software to achieve
best results.

Ray Garvey is the Tribology Solutions Manager for Emerson Process Management CSI. His certifications
include PE, CLS, and OMA1. He is an inventor named on eight patents, six of which pertain to
industrial oil analysis.