Solutions for clean oil

Fluid Management Technical Handbook

The ARGO-HYTOS guide to fluid management and oil condition monitoring

Index

Damaging Factors.................................................................4-5 Contamination Ingress..........................................................6-7 Visualizing Contamination. ....................................................8-9 Water Content................................................................. 10-11 Solutions for Clean Oil. ..................................................... 12-13 Products ......................................................................... 14-15 Cleanliness Standards........................................................16-17 Target Cleanliness Levels. ........................................................18 Return on Investment Calculation. ..........................................19 Viscosity/Temperature Diagrams....................................... 20-23 ARGO-HYTOS worldwide.......................................................24

Damaging Factors

Contamination Ingress
Dirt and water ingress from environment through worn seals

Spray water ingress Condensation

Wear particles generated

Damaged seals allow air ingress

Contaminant/Problem

Cause
Start up contamination, oil contamination from environment, dirt ingress during maintenance/repair, component breakdown, wear Leaking cooler, damaged seals, no/insufficient filler cap, condensation Product design, leaks, damaged seals, low oil level Blocked valve, damaged cooler Wrong fluid added to system Overstressed fluid

Dirt Water Air Heat Mixture Shear


Blocked valve caused by contamination Contamination from unfiltered new oil, or oil mixtures

Insufficient filtration Dirt and water ingress

Water ingress from leaking cooler

Sludge build up

Effect on Systems
Early breakdown, increased wear, reduced system performance/lifetime Loss of oil performance, oil life shortened, corrosion Cavitation, oxidation, oil life shortened Loss of oil performance, oil life shortened, component damage Damaged fluid, loss of system performance Oil life shortened, damaged fluid

Detected by
Particle counter Water sensor Dielectricity/conductivity/ viscosity sensor Temperature sensor Dielectricity/conductivity/ viscosity sensor Viscosity sensor

Solution
Filter oil to correct target cleanliness level (TCL) Water removal element, vacuum unit, oil change Seal system, add/change oil Check/repair system, change oil Drain system, flush, refill with filtered oil Check system, change oil

Visualizing Contamination

75 m Human hair (40120 m)

Visible 40 m Not Visible

14 m 4 m Critical solid particles responsible for wear

Fine particles are not visible to the human eye.

mv

Particles passing through the laser beam block light from shining onto the detector, generating a signal proportional to the particle size. Electronics interpret the signal.

Light blocking sensor

Visually the oil in these bottles looks the same. One is considerably dirtier than the other.

Automatic particle counters give a fast, accurate and repeatable contamination picture of your oil.

Verschlei der Laufflchen

Bearing damaged by pitting

lalterungsprodukte

Shaft damaged by erosion

Damage caused by oil aging

Clutch case damaged by oil aging

Oil mixture damage causing floculation

Bearing seal damaged by microdiesel effect Source: KraussMaffei

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Water Content

Water absorbing capacities of different fluid types

Mineral oil containing 500 ppm H2O

Synthetic ester containing 500 ppm H2O

ppm = parts per million, 500 ppm = 0,5l water in 1000l oil

10,000 ppm 1,000 ppm 100 ppm

1% 0.1% 0.01%

2500 2000 ppm H2O 1500 1000 500 0 Mineral oil Synthetic ester

The water absorbing capacity varies from oil to oil. At saturation point (>100% Relative humidity) free water will cause the fluid to have a cloudy appearance.

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Consequences of water contamination

Accelerated oil oxidation

Negative influence on: Capacity of air separation Antifoams Lubrication performance

Degeneration of additives

Accelerates: Corrosion Wear

Shortened oil lifetime System failure

An installed moisture sensor gives early warning, permitting fast action to extend the oil lifetime and machine availability.

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Solutions for Clean Oil

Process Oil Transfer with/without particle monitoring Single pass filtration with or without particle monitoring during filling of new hydraulic equipment/systems Multipass filtration with or without particle monitoring during oil flushing Permanent multipass filtration with or without particle monitoring

Mobile off-line filtration with/without particle monitoring Permanent off-line filtration with/without particle monitoring Periodic Oil Condition Monitoring

Periodic oil condition monitoring, either online, on-machine or in laboratory

Permanent Oil Condition Monitoring

Permanent on-line oil condition monitoring

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Reason Remove contamination from new oil reduces start up failures, reduces warranty claims

Product Mobile filter systems

Remove wear debris, contamination and/or water to extend oil life, reduce breakdowns

Mobile filter systems

Remove wear debris, contamination and/or water to extend oil life, reduce breakdowns. Roll-off cleanliness certification.

Stationary off-line filter systems Particle monitors

Regular monitoring to understand how the fluid and system work together. Reduce external lab costs by up to 90%. Troubleshooting tool. Roll off cleanliness certification. Start up wear debris analysis. Follow proactive/predictive maintenance regimes. Reduce breakdowns. Reduce lab costs. Roll-off cleanliness verification/ certification. System control.

Portable particle counters

Particle monitors Oil condition sensors Stationary off-line filter systems

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Products

1. Stationary off-line filter systems Simply and rapidly fit to your existing systems. Get maximum fluid performance and lifetime with permanent off-line cleaning. Flow rates from 4 to 370 l/min, filter finenesses from 3 m upwards. Water removal elements available.

FN series

FNA series

2. Mobile filter systems Easy to use systems for through filter filling and cyclic cleaning with or without particle monitoring. Flow rates from 3 to 45 l/min, filter finesses from 3 m upwards. Water removal elements available.

FA series

UM series

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3. Online oil condition monitors Prevent damage with early stage diagnosis by using OPCom for continuous real time online particle monitoring, OPCom AS for particle counting in aerated fluids, and LubCos H20+ for moisture content and oil ageing measurement.

OPCom

LubCos H2O+

OPCom AS

4. Portable particle counters Our wide range of particle counter and monitors meet all your requirements. Use PODS Pro for bottle and online particle counting with viscosity and temperature measurement, in your lab or in field. Use OPCom Portable for plug and play online sampling, with built-in battery and memory, for day to day monitoring and as a troubleshooting tool.

OPCom portable

PODS Pro

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Cleanliness Standards
ISO 4406:1999
Counts/ml, Cumulative ISO Class Particles/ml 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 x28 0 0.01 0.01 0.02 0.02 0.04 0.04 0.08 0.08 0.16 0.16 0.32 0.32 0.64 0.64 1.3 1.3 2.5 2.5 5 5 10 10 20 20 40 40 80 80 160 160 320 320 640 640 1,300 1,300 2,500 2,500 5,000 5,000 10,000 10,000 20,000 20,000 40,000 40,000 80,000 80,000 160,000 160,000 320,000 320,000 640,000 640,000 1,300,000 1,300,000 2,500,000 2,500,000 Although there is no direct relationship between ISO 4406:1999 and NAS 1638 a rough guide can be found below. NAS 3 4 5 6 7 8 9 10 11 ISO -/12/9 -/13/10 -/14/11 -/15/12 -/16/13 -/17/14 -/18/15 -/19/16 -/20/17

Note: NAS 1638 has been replaced by SAE AS 4059 in 2001.

counts at each size are compared with the table to find the contamination code. The code is written as 3 numbers separated by a '/'. For example: 19/17/14. The first number represents the count at 4 m(c ), the second at 6 m(c ) and the third at 14 m(c ). More details can be found in ISO Standard 4406:1999.

ISO 4406:1999 is a 3 digit code, representing the cumulative counts per ml at 4, 6 and 14 m(c). The

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SAE AS 4059 E Counts/100 ml, cumulative NAS 1638 has been replaced by SAE AS 4059 in 2001.

SAE AS 4059 Max contamination limits. Particles/100ml Size, ISO 4402 calibration > 1 m > 5 m > 15 m > 25 m > 50 m > 100 m or optical microscope Size, ISO 11171 calibration > 4 m(c) > 6 m(c) > 14 m(c) > 21 m(c) > 38 m(c) > 70 m(c) or electron microscope A B C D E F Size Code 195 76 14 3 1 0 000 390 152 27 5 1 0 00 780 304 54 10 2 0 0 1,560 609 109 20 4 1 1 2 3,120 1,217 217 39 7 1 3 6,250 2,432 432 76 13 2 4 12,500 4,864 864 152 26 4 5 25,000 9,731 1,731 306 53 8 6 50,000 19,462 3,462 612 106 16 7 100,000 38,924 6,924 1,224 212 32 200,000 77,849 13,849 2,449 424 64 8 400,000 155,698 27,698 4,898 848 128 9 800,000 311,396 55,396 9,796 1,696 256 10 1,600,000 622,792 110,792 19,592 3,392 512 11 3,200,000 1,245,584 221,584 39,184 6,784 1,024 12
Data is sorted into cumulative particle counts per 100 ml, and is expressed either as the total number of particles for a given size (for example AS 4059 Class 6) or by designating a class for each size range (for example 6B/5C/4D/3E/3F).

Counts/100 ml, differential* Classes 00 0 1 2 3 4 5 6 7 8 9 10 11 12 5 to 15 m 125 250 500 1,000 2,000 4,000 8,000 16,000 32,000 64,000 128,000 256,000 512,000 1,024,000 15 to 25 m 22 44 89 178 356 712 1,425 2,850 5,700 11,400 22,800 45,600 91,200 182,400 25 to 50 m 4 8 16 32 63 126 253 506 1,012 2,025 4,050 8,100 16,200 32,400 50 to 100 m over 100 m 1 2 3 6 11 22 45 90 180 360 720 1,440 2,880 5,760 0 0 1 1 2 4 8 16 32 64 128 256 512 1,024

Differential particle counts per 100 ml at various size ranges. For example, for a classification of NAS 6, the particle counts in each particle size range must be below the counts/100 ml shown in the table for NAS class 6. *Classes and contamination limits identical to NAS 1638.

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Ta r g e t C l e a n l i n e s s L e v e l s

Recommended Target Cleanliness Levels (TCL) according to ISO 4406:1999 for different system components. Pumps Axial piston pumps Radial piston pumps Gear pumps Vane pumps Motors Axial piston motors Radial piston motors Gear motors Vane motors Valves Directional control valves (solenoid valves) Pressure valves Flow control valves Check valves Proportional valves Servo valves Cylinders 21/18/15 21/18/15 21/18/15 21/18/15 20/17/14 17/14/11 21/18/15 21/18/15 21/18/15 21/18/15 20/17/14 21/18/15 21/18/15 21/18/15 20/17/14 If the operating pressure is increased in a system, it is necessary to improve the oil cleanliness in order to achieve the same wear lifetime for the components. Operating pressure 0 - 100 bar 100 - 160 bar 160 - 210 bar 210 - 250 bar 250 - 315 bar 315 - 420 bar 420 - 500 bar 500 - 630 bar Change in oil cleanliness 3 classes worse 1 class worse none 1 class better 2 classes better 3 classes better 4 classes better 5 classes better

By improving system cleanliness the lifetime of the hydraulic or lubrication system can be extended: Type of System Hydraulic Lube Initial ISO Code -/19/17 -/21/19 Target ISO Code -/14/11 -/15/12 Lifetime extended by: x4 x3

Return on Investment Calculation

19

Calculate your return on investment No of machines Annual operating hours Hourly machine costs Hourly labour cost Current machine uptime % Current machine downtime % Downtime hours total: (a) (b) (c) (d) (e) (f) (g)

Example 3 4000 45 45 95 5

your Formula figures

4000 x 3 x 0,05=600 (b x a)/100 x f 500 100 80 3600 j x 0,8 k x c k x d l + m

Mechanical/electrical failure (h) Hydraulic failure Caused by the fluid Fluid related downtime costs Labour costs for repair Total maintenance cost (j) (k) (l)

(m) 3600 (n) 7200

Fluid service will prevent up to 80 % of fluid related failures leaving 20 % Remaining downtime hours Reduction in downtime costs Reduced labour costs Total new maintenance cost Total savings for your facility, simply by caring for your oil: 16 720 720 k x 0,2 l x 0,2 m x 0,2 n x 0,2

(o) 1440

5760

n - o

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V i s k o s i t y - / Te m p e r a t u r e D i a g r a m

100,000 50,000 20,000 10,000 5,000 3,000 2,000 1,000 500 400 300 200 kinematic viscosity [mm2/s] 150 100 75 50 40 30 20 15
ISO

10 9 8 7 6 5 4

VG 7

-20

-10

10

20

30

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ISO

ISO

VG 1

ISO ISO

50 VG 0 100 0
VG 6 VG 4 80 60

ISO
ISO

VG 3

20
20

ISO
ISO

VG 2

VG 1
VG 1

VG 1

ISO
0

VG 1

ISO

VG

ISO
22

VG 3

ISO

VG 4

ISO

VG 6

ISO
8

50
00

40

50

60

70

80

90

100

110

120

temperature [C]

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V i s k o s i t y - / Te m p e r a t u r e D i a g r a m

Hydraulic oils, motor vehicle transmission oils, automatic transmission fluid oils and oils according to MIL - PRF - 5606
200,000 100,000 50,000 20,000 10,000 5,000
H

2,000 1,000 500 400 300 200 150 100 50 40 30 20 16 12 10 9 8 7 6

-L

AT

/H
SA

-L P6 8x SA

E9 0

E8 0

F
H -L /H -L P4 6

kinematic viscosity [mm2/s]

ac

co

rdi

ng

to

MI

L-

PR

F-

56

06
H -L /H -L P3 2

5 -25 -20 -15 -10 -5 0 5 10

20

30

40

50

60 70 80 90 100 110 120

temperature [C]

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Motor oils

200,000 100,000 50,000 20,000 10,000 5,000 2,000 1,000 500 400 300 200 150 100 50 40 kinematic viscosity [mm2/s] 30 20 16 12 10 9 8 7 6 5 -25 -20 -15 -10 -5 0 5 10 20 30 40 50 60 70 80 90 100 110 120
SA

E1

SA 0 0W E 3 AE 2 S
0W -3 0

-2 0

temperature [C]

SA E1 0W

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