Filtration

Innotek Training
Filtration Seminar
Training Seminar
Hydraulic Fluid Service Seminar
Contamination Fundamentals
Cost Savings through Fluid Service!
Effective filtration practices and in-depth monitoring
and evaluation of fluid attribute changes in hydraulic
and lubrication systems, provides alerts that lead to
corrective actions that will prevent breakdowns and
increase the life expectancy of important and
expensive hydraulic and lube system components.

The high costs of component repair and system

downtime can be kept to a minimum through a fluid
service program that includes using and maintaining
the proper system filtration and monitoring equipment.

WINDOW TO THE PROCESS!

Fluid Contamination is Expensive
for ALL Industries!
Contamination

THE ENEMY
TO
MODERN
HYDRAULIC
SYSTEMS
Fluid Analysis Terminology

Forms of Contamination
Particulates/water/gases
Sources of Contamination
Effects of Contamination
ISO/NAS Codes
Fluid analysis/measurement
Particle counter
Method & Location of sampling
Measurement error
Types of Contamination

SOLIDS

LIQUIDS

GASES
Particle Size Diameter Comparison
1 m = 0.001 mm = 0.000039

The human eye can only see

particles sized down to 40 microns.

Particle Particle
Human Hair = 80 micron 15 micron 5 micron
How do we measure fluid contamination?

ISO / NAS codes:

Are a measure of
particles/particulate per a
specific volume of fluid
Structure of ISO-Code max. amount of dirt particles
ISO Code: 22/18/13 in 100 ml > given size
ISO 4406: 1999 (E) - ISO Contamination Code Chart cont
Number of Particles per 100 ml Scale More Than Up To and Including
Number
Scale More Than Up To and Including
Number 14 8,000 16,000
28 130,000,000 250,000,000 13 4,000 8,000
27 64,000,000 130,000,000 12 2,000 4,000
26 32,000,000 64,000,000 11 1,000 2,000
25 16,000,000 32,000,000 10 500 1,000
24 8,000,000 16,000,000 9 250 500
23 4,000,000 8,000,000 8 130 250
22 2,000,000 4,000,000 7 64 130
21 1,000,000 2,000,000 6 32 64
20 500,000 1,000,000 5 16 32
19 250,000 500,000 4 8 16
18 130,000 250,000 3 4 8
17 64,000 130,000 2 2 4
16 32,000 64,000 1 1 2
15 16,000 32,000 0 0.5 1
How do we measure fluid contamination?

Structure of ISO-Code:
amount of dirt particles 22
in a 100 ml sample
larger than these specified sizes: 18
4m / 6m / 14m

Example: 13

larger than 4m = 2,234,000

larger than 6m = 195,000
larger than 14m = 4,250

4m / 6m / 14m
ISO Code = 22 / 18 / 13
How do we measure fluid contamination?

Structure of ISO-Code:
amount of dirt particles 22
in a 100 ml sample
larger than these specified sizes:
4m / 6m / 14m

Example:
larger than 4m = 2,234,000

ISO Code = 22 / /
How do we measure fluid contamination?

Structure of ISO-Code:
amount of dirt particles 22
in a 100 ml sample
larger than these specified sizes: 18
4m / 6m / 14m

Example:
larger than 4m = 2,234,000
larger than 6m = 195,000

ISO Code = 22 / 18 /
How do we measure fluid contamination?

Structure of ISO-Code:
amount of dirt particles 22
in a 100 ml sample
larger than these specified sizes: 18
4m / 6m / 14m

Example: 13

larger than 4m = 2,234,000

larger than 6m = 195,000
larger than 14m = 4,250

ISO Code = 22 / 18 / 13
How do we measure fluid contamination?

Structure of ISO-Code:
amount of dirt particles 22
in a 100 ml sample
larger than these specified sizes: 18
4m / 6m / 14m

Example: 13

larger than 4m = 2,234,000

larger than 6m = 195,000
larger than 14m = 4,250

ISO Code = 22 / 18 / 13
How do we measure fluid contamination?
Structure of SAE AS 4059 (previously
NAS Codes)
Class 4-6 m 6-14 m 14-21 m >21 m
00 125 22 4 1
0 250 44 8 2
1 500 89 16 3
2 1000 178 32 6
3 2000 356 63 11
4 4000 712 126 22
5 8000 1425 253 45
6 16000 2850 506 90
7 32000 5700 1012 180
8 64000 11400 2025 360
9 128000 22800 4050 720
10 256000 45600 8100 1440
11 51200 91200 16200 2880
12 1024000 182400 32400 5760

max. amount of dirt particles in 100ml at given size

Cleanliness Code Conversion: SAE AS 4059 Equivalent ISO 4406 Class Based on ISO 4406: 1999 and
SAE AS 4059 Revised 2005-05: Rev E 8/29/07
Cumulative Particles per 100 ml Differential Particles per 100 ml Code Code
Designatio Designation
n
> 1 um > 5 um > 15 um 5 to 15 um 15 to 25 um 25 to 50 um 50 to 100 um > 100 um
>4 >6 um(c) >14 6 to 14 14 to 21 um(c) 21 to 38 um(c) 38 to 70 > 70 um(c) Equivalent
SAE AS
um(c) um(c) um(c) um(c) ISO 4406
4059
Class
Size Size Size --- --- --- --- ---
Code A Code B Code C
195 76 14 --- --- --- --- --- 000 8/7/4
390 152 27 125 22 4 1 0 00 9/8/5
780 304 54 250 44 8 2 0 0 10/9/6
1,560 609 109 500 89 16 3 1 1 11/10/7
3,120 1,217 217 1,000 178 32 6 1 2 12/11/8
6,250 2,432 432 2,000 356 63 11 2 3 13/12/9
12,500 4,864 864 4,000 712 126 22 4 4 14/13/10
25,000 9,731 1,731 8,000 1,425 256 45 8 5 15/14/11
50,000 19,462 3,462 16,000 2,850 506 90 16 6 16/14/12
100,000 38,924 6,924 32,000 5,700 1,012 180 32 7 17/16/13
200,000 77,849 13,849 64,000 11,400 2,025 360 64 8 18/17/14
400,000 155,698 27,698 128,000 22,800 4,050 720 128 9 19/18/15
800,000 311,396 55,396 256,000 45,600 8,100 1,440 256 10 20/19/16
1,600,00 622,792 110,792 512,000 91,200 16,200 2,880 512 11 21/20/17
0
3,200,00 1,245,58 221,584 1,024,000 182,400 32,400 5,760 1,024 12 22/21/18
0 4
 Hydraulic Component Clearances Are Critical and
therefore require strategic filtration designs to remove the
sized particles that will attack the most critical components
of the hydraulic system

piston pump
gear pump
J1: 5 - 40m
J1: 0.5 - 5m
J2: 0.5 - 1m
J2: 0.5 - 5m
J3: 20 - 40m
vane pump J4: 1 - 25m
J1: 0.5 - 5m
J2: 5 - 20m
J3: 30 - 40m
servo valve
J1: 1 - 4m
J2: 100 - 450m valve
J3: 20 - 80m J1: 1 - 25m
 Guidelines Data Sheet

Provides ISO target cleanliness levels for various critical hydraulic/Lube

oil components and the filter selection that will achieve that
cleanliness level target.
 Hydraulic Component Clearances Are Critical and
therefore require strategic filtration designs to remove the
sized particles that will attack the most critical components
of the hydraulic system

8 5
Sources of Contamination
New Oil - Photomicrographs

ISO 16/14/11 ISO 17/15/13

Demanded by Modern Hydraulic Systems New Oil as Delivered in Mini-container

ISO 20/18/15 ISO 23/21/18

New Oil as Delivered in Tanker New Oil as Delivered in Barrels
Effects of Contamination

CAN EFFECTS OF CONTAMINATION BE STOPPED?

Basics of Fluid Contamination

Type of Contamination

Gaseous Liquid Solid Effects

Air Water Emery
Gases Metal Scale Extremely
Chemicals Rust Particles Damaging
Iron, Steel
Brass, Bronze Damaging
Aluminum

Laminated Fabric Minimal

Fibers Damage
Seal Abrasion
Rubber Hose Particles
Basics of Fluid Contamination

Measuring procedures for solid particle contamination

Weighing Counting

Gravimetric Microscopic Electronic

Analysis Analysis Analysis

Non-Homogeneous fluids Manual Automatic

Counting Particle Counters
(APCs)

Automatic
Counting In The Field

In The Lab
How do we measure fluid contamination?

Weighing: Gravimetric Concentration

20

18

16
ISOMTD mg/l

14

12

10

0
ISO 17/15/12 ISO 18/16/13 ISO 19/17/14 ISO 20/18/15 ISO 21/19/16 ISO 23/21/17 ISO 24/22/18
How do we measure fluid contamination?

Microscopic analysis

NAS 9 ISO 20/18/15

Photomicrograph
How do we measure fluid contamination?

Basic principle
light obscuration

Light source is an LED light

Durability
Holds calibration
Does not saturate quickly with
high contamination levels
 How do we measure fluid contamination?

14 micron
Size of Particles

6 micron

4 micron

Number of Particles = Number of Pulses

The number of pulses equals the number of particles.

How do we measure water content?

Karl-Fischer Analysis (chemical) Laboratory

Infrared Spectroscopy (optical) Laboratory
Turbidity Measurement (optical) Field
Crackle Test (acoustic) Field
Hydrogen Gas Method (chemical) Field
(WTK) Water test kit
Aqua Sensor - AS-2330 (electronic)
Field Installation
What errors can be made
during fluid sampling and analysis?

Fluid Analysis Kit

Sources of Error
Does the sample represent the system cleanliness?

Foreign media:

(air particulate, O2, water, oil or

chemicals on hands, etc.)

Type of extraction (static, dynamic)

Point of extraction
- Test Connection Penetration
type and type of test sample
fitting
- Best location to take sample
- Disadvantage of fluid samples
Sources of Error
Possible Sample Locations

VACUUM BOTTLE
SYRINGE

THROTTLE VALVE

RESERVOIRS

Taking a sample from Taking a sample

pressure header from stagnant fluid
Sources of Error-Reservoir sampling

Example:
Example:
Reservoir Extraction with auxiliary pump
Reservoir Extraction with Auxiliary Pump
Point at which suction hose
was lowered slowly to the
bottom of the tank.

suction hose
suction hose near bottom
near surface
ISO CLASS INCREASE FROM 15 TO 20
IS EQUIVALENT TO AN INCREASE IN
PARTICLE COUNT OF 32 TIMES!
Sources of Error
Point of Extraction - Test Connection Arrangement
Sources of Error
Point of Extraction - Where in the System is the best
representation of system fluid cleanliness?
Sources of Error
Disadvantages of Oil Sampling

A Snapshot in time - does it represent

the system cleanliness? Is it a peak or
minimum point?
Sources of Error
Advantages of Continuous real time on line
Measurement

Sample taken every

100 milliliter-real-time

This type measurement

tracks along with operating
changes going on in the
system.
Sources of Error

Major actuation
Point of maximum contamination

Filtration is removing particles

Filtration has reached equilibrium

Hydraulic Power Unit

Cylinder actuator

SERVO

Pressure filter

Return filter

Main Hydraulic Pump Kidney loop

filter

Reservoir
Sources of Error
Sampling Error
Leaving sample bottles open too long
Using previously contaminated bottles
Unaware of system operation immediately before
sampling resulting in inaccurate analysis and
conclusions.
Improper handling causing contamination from hands
Failure to flush sampling ports and lines before sampling

Note: Such errors are likely to result in higher contamination readings than
actual.
Element Technology
What Can Be Done?
To assure maximum component life, fluid life
and superior system and equipment operation?

CONTAMINANT LEVEL POPULATIONS

MUST BE REDUCED TO LEVELS
REQUIRED BY CRITICAL SYSTEM
COMPONENTS
HOW ?
Through Proper Filtering, Monitoring,
Analysis, and Control
 Contamination Control
Loss of component Cost of Equipment &
efficiency due to wear standard filtration component
(non-efficient operation)- repair and
System performance degradation Replacement labor
& component costs

System downtime Decrease in product

costs resulting from quality resulting
component failures- from poor control and
Can not produce operation higher
product rejection rates
Contamination Control
Cost of a superior
balanced filtration
Loss of component system up front
Efficiency due to wear Equipment &
(non-efficient operation) component repair and
replacement

System downtime Decrease in product

Costs resulting from Quality resulting from
Component failures Poor control and
Small investment for superior filtration results in operation
shrinking entire maintenance, quality, and manufacturing budget.
Required New Machine Cleanliness
Fluid Cleanliness / Service Life

Current
Target Target Target Target
Cleanliness

24/22/19 21/19/16 20/18/15 19/17/14 18/16/13

23/21/18 20/18/15 19/17/14 18/16/13 17/15/12

22/20/17 19/17/14 18/16/13 17/15/12 16/14/11

21/19/16 18/16/13 17/15/12 16/14/11 15/13/10

20/18/15 17/15/12 16/14/11 15/13/10 14/12/9

19/17/14 16/14/11 15/13/10 14/12/9 14/12/8

Life Ext. Factor 2X 3X 4X 5X

 Machinery Life Extension Factor

New Cleanliness Level (ISO Code)

Current Machine Cleanliness (ISO Code)

Hydraulics Roling
and Diesel Element
Engines Bearing
Journal Bearing
Gear Boxes
and Turbo
and Other
Machinery

Ref. Noria Corporation

Common Filter Terms

Micron => 1 m = 0.001 mm = 0.000039

Pressure Drop across the element
Beta Ratio
Beta Stability
DHC => Dirt holding capacity
Multi-Pass Testing
Filter Indicator
Element collapse Pressure
Filter By-Pass
Absolute vs. Nominal Rated Filtration
Surface vs. Depth Filtration Mechanisms
Features of a High Quality Element
High efficiency absolute element
Features optimization of all
element performance characteristics

High x-values (efficiency)

High x-value stability
High dirt holding capacity
Low long term pressure drop
High collapse stability
High flow fatigue stability
Wide fluid compatibility
Multi-Pass Testing
ISO 16889: 1999
What Data is Obtained?
Best performance comparison regarding
below parameters
Beta Ratios
Beta Stability
Dirt Holding Capacity

How is test completed?

ISO Medium Test Dust (ISO MTD)
Mil-5606 Hydraulic Fluid
Constant Viscosity
Constant Temperature at 40 degrees Centigrade
Constant Flow rate through filter
Constant rate of dirt injection
Continuous measurement of particle counts upstream vs. down stream.
Continuous measurement of pressures upstream & down.
What is Dynamic Filter Performance?
Filters that Perform in REAL LIFE!

The Test Lab Real Life

Steady Flow Continuous Variations

No Fatigue Cycles Millions of Fatigue Cycles
Constant Dirt Always Changing
Ingression Rate to Filter
Single Fluid Used Wide Variety
Temperature 100F -40F to 210F
ISO Medium Test Dust Debris, Water, Air
Accelerated Element Life Months
Multi-Pass Testing
ISO 16889: 1999 (ISO Standard for Performing Multi-Pass Test)

FOR EVERY 1000 PARTICLES

SIZED 5 micron OR GREATER
THAT ENTER THE FILTER,
ONE GOES THROUGH
WHEN THE BETA 5 IS = 1000
Beta Values Versus Efficiency
Beta Value Efficiency Particles Beta() Micron Upstream Particles Downstream
Beta X 2 50.0000% 100,000 50,000
Beta X 4 75.0000% 100,000 25,000
Beta X 10 90.0000% 100,000 10,000
Beta X 20 95.0000% 100,000 5,000
Beta X 40 97.5000% 100,000 2,500
Beta X 60 98.3333% 100,000 1,667
Beta X 75 98.6667% 100,000 1,333
Beta X 100 99.0000% 100,000 1,000
Beta X 125 99.2000% 100,000 800
Beta X 150 99.3333% 100,000 667
Beta X 200 99.5000% 100,000 500
Beta X 300 99.6667% 100,000 333
Beta X 500 99.8000% 100,000 200
Beta X 1,000 99.9000% 100,000 100
Beta X 2,000 99.9500% 100,000 50
Beta X 4,000 99.9750% 100,000 25
Beta X 5,000 99.9800% 100,000 20
Beta X 10,000 99.9900% 100,000 10
Beta X 20,000 99.9950% 100,000 5
Beta X 50,000 99.9980% 100,000 2
Beta Values Versus Efficiency
Beta Value Efficiency Particles Beta() Micron Upstream Particles Downstream
Beta X 2 50.0000% 100,000 50,000
Beta X 4 75.0000% 100,000 25,000
Beta X 10 90.0000% 100,000 10,000
Beta X 20 95.0000% 100,000 5,000
Beta X 40 97.5000% 100,000 2,500
Beta X 60 98.3333% 100,000 1,667
Beta X 75 98.6667% 100,000 1,333
Beta X 100 99.0000% 100,000 1,000
Beta X 125 99.2000% 100,000 800
Beta X 150 99.3333% 100,000 667
Beta X 200 99.5000% 100,000 500
Beta X 300 99.6667% 100,000 333
Beta X 500 99.8000% 100,000 200
Beta X 1,000 99.9000% 100,000 100
Beta X 2,000 99.9500% 100,000 50
Beta X 4,000 99.9750% 100,000 25
Beta X 5,000 99.9800% 100,000 20
Beta X 10,000 99.9900% 100,000 10
Beta X 20,000 99.9950% 100,000 5
Beta X 50,000 99.9980% 100,000 2
Beta Stability ISO 16889: 1999
High x-Values / High x-Value Stability
Beta Ratio remains at a relatively constant level at high pressure drops beyond
normal element operating ranges with high beta stability.

Point of element failure

Beta 100 Stability = 210 psi means that:

Beta Ratio at the rated micron will not drop below Beta Ratio = 100 until 210 PSID
 Poor Beta Stability Causes a loss of
adequate protection from the point that Beta drops
below manufacturers published beta specification
before the end of element life.

Significant loss of filter efficiency before the end of

element life
Loss of equipment through loss of protection
Increased wear and component failures
Increased downtime
Decrease in Customer Satisfaction
High Dirt Holding Capacity
ISO 16889: 1999

Decrease in downtime
when indicator is utilized for change-out indication
(Less Element Changes)

Decrease in replacement element costs

(longer lasting-utilizing full element capacity)

Decrease in maintenance/labor costs

DHC - Dirt Holding Capacity
DHC Measured at Terminal Pressure / Indicator Setting

INDICATOR TRIP POINT

Element Terminal Pressure

72
Superior Element Life
Pressure Drop Over Element Life Comparison

High efficiency element has higher D/P than a low efficiency element
HYDAC designs elements to increase D/P at a slower rate than others
Element technology
Compatibility with all modern fluids

ISO 2943 (ISO Standard for Fluid and Material of Construction Compatibility)
Features of a High Quality Element
with high flow fatigue stability
ISO 3724
Element Construction for High Efficiency & Performance
Element Recipe Layers

White Polyester Outerwrap

Superior elements are designed for max. Surface Area

Section Of Supported Element

Pleat spring movement

resilience

Upstream Support

Downstream Support
Media & Support Layers
Filter Element Support Core

HYDAC optimizes the number of pleats to maximize surface

area of the media.
HYDAC Elements Designed for Max. Surface Area
Section Of Unsupported Element

Lost
Effective
Area FLOW
Collapsed Pleat Caused by
Lack of Support in recipe structure

Typical Location of Fatigue Failures

Core support tube
FLOW

FORCE

Compressed Pleat Caused by

Lack of Adequate Support and high flow
velocity forces.
Filter Element Material Options
Caking occurs on surface of media under Particles enter fibers and become entrained
Non-violent non-turbulent flow conditions

Surface Filtration Depth Filtration

With depth media as shown above, the particles enter
With surface media (paper, metals, polyester) there is
the media and work their way down into the pores and
no mechanism to hold dirt in place when placing the
passages to become entrained. This provides the
element into a dynamic system with high velocity flow
mechanism that holds these particles in place when
changes and a reverse flow surging environment.
used in dynamic flow surging systems.
Filter Terms
Absolute vs. Nominal
ISO 16889: 1999 CONFORMANCE REQUIRED FOR ABSOLUTE FILTERS
Absolute Rated Filter x 75
Beta ratio, efficiency and Dirt holding capacity determined by conducting a
multipass test per ISO 16889: 1999 (filtration)
Most are in fact Fiberglass media.

NO INDUSTRY STANDARD EXISTS FOR NOMINAL FILTERS

Nominal Rated Filter
No industry standard exists to determine nominal element ratings.
Surface filtration (nominal) applied in actual systems can not achieve dirt
holding capacities derived through multipass testing.
Most are paper, cellulose, polyester, or metals
Beta efficiency and dirt holding are not valid data for nominal media per the
multipass test specification Depth media only is specified on the ISO
specification (ISO 16889: 1999)
Multi-Pass Test Report
ID: MPT990105 Test Date: 01/21/99
Test Component: FILPRO 160D010BN Tested By: HLM
TEST CONDITIONS
Fluid: MIL-H-5606 +ASA
Viscosity: 15.0 cSt
Test Dust: SAE 5-80
Test Flow: 60.0 L/min
Specific Test Flow: 12.8 mm/s
Base Upstream Gravimetric Level: 5.0 mg/L
Terminal Pressure: 72.0 psi
Filtration Area: 782.0 cm2
Bubble Point: N/A mmWC (5)

TEST RESULTS
Clean Element Pressure: 2.8 psi
Collapse Pressure: N/A psi
Bets 2/20/75: <2.0 / 8.5/12.3 m per ANSI / (NFPA)
TWA Beta 10: 32.7 T3.10.8.8 R1-1990
Efficiency: 96.94%
Dirt Holding Capacity: 7.9 grams
Specific Dirt Holding Capacity: 10.1 mg/cm2
Note: L/min - Liter per minute, mmWC - millimeter water column
Multi-Pass Test Report
ID: MPT981202 Test Date: 01/21/98
Test Component: 0160D010BN3HC Tested By: HLM
TEST CONDITIONS
Fluid: MIL-H-5606 +ASA
Viscosity: 15.0 cSt
Test Dust: SAE 5-80
Test Flow: 60.0 L/min
Specific Test Flow: 8.4 mm/s
Base Upstream Gravimetric Level: 5.0 mg/L
Terminal Pressure: 72.0 psi
Filtration Area: 1194.0 cm2
Bubble Point: N/A mmWC (5)

TEST RESULTS
Clean Element Pressure: 3.5 psi
Collapse Pressure: N/A psi
Bets 2/20/75: <2.0 / 2.6/4.8 m per ANSI / (NFPA)
TWA Beta 10: 2251 T3.10.8.8 R1-1990
Efficiency: 99.94%
Dirt Holding Capacity: 16.3 grams
Specific Dirt Holding Capacity: 13.6 mg/cm2
Note: L/min - Liter per minute, mmWC - millimeter water column
 Typical
Filter
Configurations
Pressure Line Filtration

Removes contaminants after hydraulic pump

Cost effective with high cost dirt sensitive, components
Filter before servo offers maximum protection from small particles
Lube System Filtration

Alternative A
In-Line Filtration

Alternative B
Off-Line
Filtration

Alternative A Alternative B
Provides maximum in-line protection Gives cost effective protection
Lowest contamination level No in-line system pressure drop
Continuous line filtration Can be single or duplex filter
Return Line Filtration

Cost effective for relatively dirt-tolerant systems

Provides limited pump protection
Not ideal with return flow surges
Comprehensive Filtration

Multiple Filters Provide Off-Line Filter Provides

Maximum protection High efficient filtration
Lowest contamination level Continuous filtration
Extended element & hydraulic system life Fill port for filtering new oil
 Absolute depth filters have an average pore size
of the element rating

Transfer cart-single filter

Initial ISO code results
from method of delivery

Fluid Storage Tank Hydraulic System

Single absolute Reservoir
depth filter

Filled from: Desired ISO = 16/14/11

Mini-totes 17/15/13 RATINGS UNDER
EQUILIBRIUM CONDITIONS
Tanker trucks 20/18/15
Micron
Metal drums 23/21/18 ISO Code
absolute
target
rating
20/18/15 20 micron
19/17/14 10 micron
18/16/13 5 micron
17/15/12 3 micron
 Filter Element 3 micron Beta=1000

# particles in # particles out

100,000 100

For every 1000 particles 3 micron or larger that

enter the element ---- one goes through when
the filter element is in equilibrium continuous
Re-circulating flow.
 Filter Element 3 micron Beta=1000

# particles in # particles out

100,000 100

For every 1000 particles 3 micron or larger that

enter the element ---- one goes through when
the filter element is in equilibrium continuous
Re-circulating flow.
 Effectively performing as a two pass process

Transfer cart dual filter

Initial ISO code results
from method of delivery

Hydraulic System
Fluid Storage Tank Reservoir
Dual series absolute
depth filter

Filled from: Desired ISO = 16/14/11

Mini-totes 17/15/12 RATINGS UNDER
Tanker trucks 20/18/15 EQUILIBRIUM CONDITIONS
Metal drums 23/21/18 ISO Code
Micron
absolute
target
rating
20/18/15 20 micron
19/17/14 10 micron
18/16/13 5 micron
17/15/12 3 micron
 The design and operation of a
Hydraulics System

Assess system requirements

Recommend optimum components
for performance and longevity
Monitor & Maintain fluid
characteristics, cleanliness and water
content
Assess
1. Determine TCL (target cleanliness level) Based on
system components
system pressure & environmental conditions
Use this guidelines document found on our website
In the Brochures section
Assess
2. Determine Current Conditions
particle contamination levels
water content
fluid health (ageing/effectiveness)
fluid sampling changes over time
Assess
2. Evaluate Current Protection in Place
to account for ALL sources of contamination
Assess
2. Evaluate Current Protection in Place
pressure filters
return line filters
offline filtration loops
breathers-high integrity and desiccant types
new oil protection treatment, transfer, polishing
monitoring (sampling)/change-out schedule
Recommend Filtration Upgrades

A = Offline Recirculating Loop

B = Pressure OR Return Filter
C = Pressure OR Return Filter AND Re-circulating Loop
D = Pressure AND Return Filter
E = Pressure AND Return Filter AND Re-circulating Loop
Recommend Filtration Upgrades
1. Betafit Elements

High x-values
High x-value stability
High dirt holding capacity
Low long term pressure drop
High collapse stability
High flow fatigue stability
Wide fluid compatibility
Recommend Filtration Upgrades
2. Addition of Offline Filtration Loops

Off line loop membrane Vacuum Dehydrator Filter coolers

Filtration when high water or when heat is a problem
Used for solid particulate in gas content is present
transfer and tank kidney loops
Recommend Filtration Upgrades
3. Addition and replacement of high
performance breathers

Breathers
Wide variety including:
- desiccant for water vapor removal
- spin-on
- with filler baskets
Monitor & Maintain
1. Contamination Monitoring Devices
Portable & Online
Water Content Sensors

FCU (Portable) CS (Permanent) AS (AquaSensor)

Perfect for plants with Perfect for larger, critical systems Water content sensor
many small machines where constant, monitoring is required
Monitor & Maintain
2. Supplemental Monitoring Techniques
Regular Fluid Sampling & Analysis

Fluid Sampling Kits

Provides information about more than contamination:
- additive depletion
- contamination
- water content
- viscosity
- wear metals
- trending from periodic sampling

Leads to predictive maintenance decisions

eliminating unplanned shutdowns.
Monitor & Maintain
3. Portable Offline and Fluid Handling Filtration Loops
Can be used on multiple machines if contamination
levels unexpectedly rise

Fluid transfer carts Hand-held Vacuum dehydrator

wheeled carts transfer cart - Water & aeration removal
- 2 stage (series) - Solid particle removal
- Water & solids
 The Science of Condition Monitoring
and Contamination Control
Condition Monitoring
Measure and determine the status of system components and fluid health to prevent
failure, optimize maintenance practices and fluid processing and/or replacement
intervals.

MAINTENANCE

failure oriented preventative

time

status
Condition Monitoring
predicted
Sensor Arrays for a Full Range
of fluid conditions monitoring

pressure
temperature
oil condition

acquisition
data
Remote Monitoring Capability:
Your Hand on the Pulse of the Systems

Driver Software
Level Intranet/Internet
sensor

Mobile telephone system

Pressure

Ethernet
sensor
Fixed network

Control room
GSM
Machines

Modem
Temperature
or sensor
Equipment

Contamination Sensor
sensor Monitoring
Unit
Aqua
sensor

Fluid condition
Monitor
Portable Online Particle Counter for Service Support

Features
Measuring of solid contamination in hydraulic and lube
oils
after market service and repair
Calibration to ISO 11943
field measurement equipment
Stores up to 3000 measured values
Inlet pressure range 15 - 5075 psi (1 - 350 bar)
Integrated pump for tank sampling
Easy to operate
Contamination Sensors on each machine
 Aqua Sensor for dissolved water on each machine

Main features:

Measurement of water content in oils

relative to the saturation level
Simultaneous measurement
of fluid temperature
High reliability due to compact
and rugged design
Calibration independent of different oil types
Unsusceptible to high pressure pulsation
Wide fluid temperature range
Aqua Sensor with readout

Features
Measurement of water content in hydraulic and
lubrication oils relative to the saturation concentration
Simultaneous measurement of the fluid temperature
Designed for stationary installation
Standard output options:
- 4-20mA analog outputs for percent
saturation and temperature
- switch/alarm outputs
- serial RS485 interface
- integrated display
Stationary Single Pass Filtration units

Features
Vane pump for
hydraulic oils
low cost
Gear pump 5 - 19 GPM (18 - 72 l/min)
Viscosity up to (1000 mm2/s)
for higher dirt quantity
Integrated pressure relief valve
Filter element type Dimicron membrane
high dirt holding capacity
reduced filtration costs
excellent single pass filtration
Stationary Single Pass Filtration units

Membrane type Dimicron filter elements

nominal flow rate per element 15 l/min
dirt holding capacity per element = 500 g (ISOMTD)
2 > 1000 @ dp = 2 bar
incinerable
Fluid Conditioning Water
Removing Systems
Functions:
Dewatering (vacuum
dehydration)
Filtering
Degassing (de-aeration)
Fluid Conditioning System

Applications in Power generation:

Lube system for steam turbines
Hydraulic steam control system
Mineral oil based
Phosphate ester only with rotary vane vacuum pump
Gear box cooling water pump
Lube system boiler feed pump
Oil storage
Applications in steel industry:
Hydraulic or Lube system for roller bearing (Morgoil system)
Applications in Pulp and Paper:
Main lube system or wet end hydraulic
Questions