Professional Documents
Culture Documents
Practical Contamination
Practical Contamination
Contamination
Management
From Processing
to Delivery
3
This results in the following
contamination management tasks:
Definitions:
Contamination monitoring analysis of processes with regard to the ingress of dirt caused
by them
Offline measurement measurement process in which the sample is taken from the
process system and analyzed elsewhere, e.g. taking an oil sample
and sending it in to a laboratory
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4
2 Contamination
Management
Basics
2.1
Definition of
Contamination Types
Various types of contamination
occur in power fluid systems:
gaseous (e.g. air), liquid (e.g. water)
and solid contaminants.
An overview of the various
contamination types is shown in
the following diagram:
5
Hard particles are frequently listed Fig. 2
separately in specifications.
Maximum values are specified
for the longest dimension these
hard particles may have, e.g.
largest abrasive particle:
max. 200 m or 200 x 90 m or
no particles > 200 m.
6
The following microscope images Fig. 3
show typical particle samples as
occur in power fluid systems.
Fig. 4
An average healthy human eye
can see items down to ca. 40 m
in size. Particle analyses are
conducted using a microscope or in
power fluid systems using particle
counters employing the light
extinction principle (cf. section
2.3.5).
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7
2.2
Consequences of
Particulate Contamination
in Power Fluid Systems
Particulate contaminants circulating Fig. 5
in power fluid systems cause Examples of Wear
surface degradation through to Movable Surfaces
general mechanical wear
(abrasion, erosion, and surface
fatigue).
component machining
system assembly
system filling
commissioning
system repair work
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8
A study conducted by the In practice ball bearings with their
University of Hanover describes punctiform contact are shown in
the factors impacting the fatigue life most cases to be less sensitive to
of roller bearings as follows: particulate contamination than
roller bearings with their linear
The quantity of contamination in contact. Friction bearings with
the lubricant is described by the their larger lubrication gaps are
particle quantity and size. the least sensitive to particulate
Combining this with particle contamination.
hardness and geometry results in
the type and extent of damage to
raceways, with the extent also
being affected by the elasto-plastic
behavior of the material. The
amount of damage is determined
by the quantity of particles in the
lubrication gap and the rollover
frequency. Continued rollover leads
to cracking, which in the form of
fatigue damage (pitting) leads to
roller bearing damage (bearing
failure).
Fig. 6
Factors Affecting
Roller Bearing Life (1)
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9
The following table provides an
overview of the most common gap
sizes:
Fig. 7
10
Fig. 8
Destroyed Raceway of
a Ball Bearing Caused by
Particulate Contamination
Fig. 9
Chip Embedded in the Surface
of a Friction Bearing
Contamination management
counters the situation as follows:
11
2.3
Classification of
Particulate Contamination
in Fluids
The objective of the procedures
described below is to enable a
reproducible classification of
particulate contaminants in fluids.
12
2.3.1 Fig. 10
ISO 4405 Hydraulic
Power Fluid
Fluid Contamination
Determining Particulate
Contamination Employing
Gravimetric Analysis
Methods
This international standard
describes the gravimetric method
for determining the particulate
contamination of hydraulic fluids.
Basic principle:
Gravimetric contamination is
calculated as follows:
13
2.3.2 Overview of the changes:
ISO 4406:1999
old ISO 4406:1987 new ISO 4406:1999
In ISO 4406, particle counts are
determined cumulatively, i.e. >
4 m (c), > 6 m (c) and > Size ranges > 5 m, > 4 m (c)
14 m (c) (manually by filtering > 15 m > 6 m (c)
the fluid through an analysis > 14 m (c)
membrane or automatically using
Dimension Longest dimension Diameter of the
particle counters) and allocated to
determined of a particle area-equivalent
measurement references.
circle
ISO 11171:1999
The goal of allocating particle
counts to references is to facilitate Test dust ACFTD dust 1-10 m ISO 12103-1A1
the assessment of fluid cleanliness Ultrafine fraction
ratings.
SAE Fine, ISO 12103-1A2
In 1999 the old ISO 4406 was AC Fine
revised and the size ranges of the SAE 5-80 m ISO 12103-1A3
particle sizes undergoing analysis ISO MTD
redefined. The counting method Calibration dust
and calibration were also changed. for particle counters
This is important for the user in his SAE Coarse ISO 12103-1A4
everyday work: Coarse fraction
Comparable Old ACFTD Comparable New NIST
Even though the measurement size ranges calibration ACFTD dusts calibration
references of the particles
undergoing analysis have changed, < 1 m 4 m (c)
the cleanliness code will change 4.3 m 6 m (c)
only in individual cases. When 15.5 m 14 m (c)
drafting the new ISO 4406 it was
ensured that not all the existing
cleanliness provisions for systems
had to be changed (Lit. HYDAC, Allocation of particle counts to If the number of particles counted in
Filters Power Fluid Technology, cleanliness classes: the sample is larger than 20, the
New Test Dust, New Calibration, result has to be reported with .
New Filter Testing Methods How No. of particles/ml Cleanliness
This Impacts Everyday Work). class Note: increasing the measurement
Over Up to reference by 1 causes the particle
count to double.
2,500,000 > 28
1,300,000 2,500,000 28 Example:
640,000 1,300,000 27 ISO class 18 / 15 / 11 says that the
320,000 640,000 26 following are found in 1 ml of
160,000 320,000 25 analyzed sample:
1,300 2,500 particles > 4 m (c) 80,000 160,000 24
160 320 particles > 6 m (c) 40,000 80,000 23 1,300 2,500 particles > 4 m (c)
10 20 particles > 14 m (c) 20,000 40,000 22 160 320 particles > 6 m (c)
10,000 20,000 21 10 20 particles > 14 m (c)
5,000 10,000 20
2,500 5,000 19
Fig. 11
1,300 2,500 18
Microscopic Examination of an
640 1,300 17 Oil Sample (100 ml)
320 640 16 Magnification 100x (ISO 18 / 15 / 11)
160 320 15
80 160 14
40 80 13
20 40 12
10 20 11
5 10 10
2.5 5 9
1.3 2.5 8
14
2.3.3
NAS 1638
Like ISO 4406, NAS 1638 describes
particle concentrations in liquids. The
analysis methods can be applied in
the same manner as ISO 4406:1987.
3 2,000 356 63 11 2
4 4,000 712 126 22 4
5 8,000 1,425 253 45 8
6 16,000 1,850 506 90 16
7 32,000 5,700 1,012 180 32
8 64,000 11,600 2,025 360 64
9 128,000 22,800 4,050 720 128
10 256,000 45,600 8,100 1,440 256
11 512,000 91,200 16,200 2,880 512
12 1,024, 000 182,400 32,400 5,760 1,024
Fig. 12
Microscopic Examination of an
Oil Sample (100 ml)
Magnification 100x (NAS 10)
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2.3.4 The SAE cleanliness classes can
SAE AS 4059 be represented as follows:
Like ISO 4406 and NAS 1638, SAE 1. Absolute particle count larger
AS 4059 describes particle than a defined particle size
concentrations in liquids. The
analysis methods can be applied Example:
in the same manner as ISO Cleanliness class according
4406:1999 and NAS 1638. to AS 4059:6
Size ISO 11171, > 4 m (c) > 6 m (c) > 14 m (c) > 21 m (c) > 38 m (c) > 70 m (c)
Calibration or
electron microscope**
Size coding A B C D E F
000 195 76 14 3 1 0
00 390 152 27 5 1 0
0 780 304 54 10 2 0
1 1,560 609 109 20 4 1
2 3,120 1,220 217 39 7 1
3 6,250 2,430 432 76 13 2
4 12,500 4,860 864 152 26 4
5 25,000 9,730 1,730 306 53 8
6 50,000 19,500 3,460 612 106 16
7 100,000 38,900 6,920 1,220 212 32
8 200,000 77,900 13,900 2,450 424 64
9 400,000 156,000 27,700 4,900 848 128
10 800,000 311,000 55,400 9,800 1,700 256
11 1,600,000 623,000 111,000 19,600 3,390 1,020
12 3,200,000 1,250,000 222,000 39,200 6,780
16
2.3.5 1. Manual procedure according 2. Automated particle counting
Procedure in Evaluating to ISO 4407 (Hydraulic fluid power
Fluid contamination Below follows a description of how
Fluid Samples According Determination of particulate common particle counters
to ISO 4406:1999, contamination by the counting employing the light extinction
NAS 1638 and method using a microscope). principle function.
SAE AS 4059
ISO 4407 contains a description of The figure below shows a
A representative sample is taken of a microscopic counting method for simplified rendering of the
the fluid and analyzed as follows: membranes. 100 ml of the sample measurement principle employed
undergoing analysis is filtered in the light extinction principle.
through an analysis membrane The light source transmits the
featuring an average pore size of monochromatic light through the oil
< 1-m and square markings. flow onto a photodetector, which
The standard also describes the generates a specific electrical
cleaning procedure and maximum signal. A shadow is created on the
particle count of the negative photodetector if a particle (black)
control. comes between the light source
and the photodetector.
After the analysis membranes are This shadow causes the electrical
dried, 10, 20 or 50 squares are signal generated by the sensor
counted depending on the size of to change. This change can be
the particles, followed by adding used to determine the size of the
the values and extrapolating to the shadow cast by this particle and
membrane diameter. thus the particle size to be
determined.
The manual count of the particles
is done in the old levels of > 5 m
and > 15 m since the longest Fig. 14
dimension of a particle is counted
in ISO 4407 yet the diameter of the
area-equivalent circle is counted in
the new ISO 4406:1999. As
described above, the reference
values obtained for this count
correspond to the reference values
of the new evaluation.
Fig. 13
17
The following types of automatic Fig. 15
particle counting are used:
18
3 Determining the 3.1
Residual Dirt Quantity Ultrasonic Method
of Components
The ultrasound method involves
Determining the residual dirt submitting the components to an
quantities present on components ultrasonic bath, exposing them for
can be done employing quantitative a defined period of time at a
and qualitative factors. defined ultrasonic setting and bath
temperature. The particulate
Quantitative: mg/component contamination is loosened by the
mg/surface unit exposure and then flushed off the
(oil-wetted surface) component using a suitable liquid.
mg/kg component
weight The particle dispersion in the
no. of particles > flushing liquid obtained in this
x m/component manner is analyzed according to
no. of particles > specified evaluation methods
x m/surface unit (cf. section 3.4).
(oil-wetted surface)
The ultrasonic energy setting and
Qualitative: length of the largest the duration of exposure have to be
particle (subdivision indicated in reporting the result.
into hard/soft) The ultrasonic procedure is
particularly suitable for small
Components with easily accessible components in which all surfaces
surfaces are components in which have to be examined. Cast
only the outer surface is of interest components and elastomers
for the most part when performing should not be subjected to
residual dirt analyses. There are ultrasonic washing if possible as a
exceptions here, e.g. transmission risk is posed here of the carbon
and pump housings, as the internal inclusions in the cast piece being
surface is of interest. These dissolved, thus skewing the results.
components belong to group 1 and These effects have to be
their surfaces are not easily ascertained prior to performing an
accessible in most cases. ultrasonic analysis.
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3.2 3.3
Flushing Method Shaking Method
Components with easily accessible This method is very rarely used, as
surfaces or components in which it is very difficult to reproduce
only surface parts have to be manually. However, results are
examined are analyzed using the reproducible when automatic
flushing method. This method shakers such as those used in
involves flushing the surface chemical laboratories are
undergoing analysis in a defined employed. The analyzed
clean environment using an components are components
analysis fluid, which also has a subject to wear whose inner
defined cleanliness. A negative surfaces are to be analyzed (e.g.
control or basic contamination pipes, tanks). The important thing
control is performed prior to is that the particles are flushed out
analysis in which all the surfaces of of the inside of the components
the environment, e.g. the collecting after being shaken.
basin, are flushed and the value
obtained reported as the basic
contamination of the analysis The following table shows a
equipment. The flushing fluid is comparison of the various methods
then analyzed using the specified for analyzing components and
evaluation methods. assemblies.
How performed
Components are Components are
flushed with the exposed to an
analysis fluid in a ultrasonic bath and
defined clean are then flushed with
environment. the analysis fluid.
Analysis can be
Reproducibility
performed quickly
20
3.4
Evaluation Methods
Evaluating particle-laden flushing
fluids can be done according to
various criteria. Gravimetric analysis
is useful for heavily contaminated
components, whereas particle
counts in various size ranges are
useful for very clean components.
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21
The following table provides an
overview of applications of the
analysis and evaluation methods:
U= usable
CU = conditionally usable
NU = not usable
*= section 4, Analysis of the Cleanliness of Systems on the Flushing/Test Stand.
** = It has to be ensured that the particles dislodged from the component can be flushed away.
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4 Analysis of the 4.1 The critical Reynolds number Re crit
Cleanliness of Turbulent Flow depends on kinematic velocity v,
flow rate Q of the fluid, and the
Systems on the geometry of the passage through the
Flushing/Test Stand Reynolds Number
flow is being conducted. If the
Reynolds number of a flow is smaller
The cleanliness of components and The Reynolds number a
than Re crit , the flow is said to be
systems that pass through a dimensionless reference
laminar. Turbulent flow is said to
flushing or test stand can be describes the flow properties of
be present for values above Re crit .
determined on the basis of the fluids. Below follows a brief
The critical Reynolds number for oil
cleanliness of the test fluid in some description of how the Reynolds
is given below.
cases. This indirect analysis number is derived using pipe flow
method is preceded by manual as an example.
Re crit oil = 1900 3000
analyses for validation purposes.
Weights are discounted in the
(Source: Kahrs, M.: Der Druckverlust in
For example, hoses are flushed by calculation of the Reynolds
Rohrleitungen lhydraulischer Antriebe;
hand and the results evaluated in number. Generally speaking, only
VDI Forschungsheft 537, Dsseldorf 1970)
accordance with the methods pressure, friction and inertial forces
discussed in section 3. At the same affect fluid elements and bodies
time, the cleanliness of the test subjected to flows. They have to be
fluid of the test stand is determined in balance at all points of the flow.
in the return flow, i.e. downstream If the relationship of friction and
of the component. inertial forces is the same in similar
points P1 and P2, then similar
If a correlation is detected between flows are said to be present.
the manual and the automatic
(indirect) value, this means that
indirect value analysis can be Fig. 18
selected as a measure of quality. Similar Flows
Around Different Cylinders
The flushing stand used for
analyzing the residual dirt content
of systems has to feature the
following:
Q
Re = 21220* applies to pipelines and hoses
di * v
23
The following diagrams show the 4.2
difference between laminar and Dispersion Effect
turbulent flow.
The oil used for flushing has to
have a dispersion effect so that
Fig. 19
particles are dislodged and
Laminar Flow Turbulent Flow transported off. Special thin-bodied
mineral-oil-type flushing oils can
All particles move without mixing. All particles are continuously mixed. contribute instrumentally to
improving the flushing effect. They
lower the adhesion force between
the dirt particles and the pipe wall.
By virtue of their excellent surface
wetting properties, they creep into
between the dirt particles and the
wall, thus causing the particles to
become dislodged. Experiments
have shown that by changing the
flushing fluid from an operating
fluid to a flushing oil,
The path of a particle is described by The path of a particle cannot be
component/system cleanliness can
a stream thread. predicted.
be increased by a factor of 4.
Flushing oils of this type have to
Parabola-shaped velocity distribution Relatively even time-averaged
then be closely matched to the
(applies to pipes). velocity distribution (flattened
hydraulic medium used as failure to
parabola).
properly match the two may lead to
the following:
marked foaming
filter blockage
clogging of the system
Reynolds number smaller than Re crit Reynolds number larger than Re crit
Source:
University of Wrzburg
Fluid Mechanics lecture
The above diagram shows a
parabolic, laminar flow in a pipe.
This shows that the flow velocity of a
laminar current in the middle of the
pipe (peak of the parabola) is larger
than along the pipe wall.
24
4.3 4.4 4.5
Flushing of All Ducts Pulsating Flow during Performing a Cleanliness
and Surfaces Flushing Check on a Flushing
Stand
When setting up the inspection and Pulsating flow or the reversal of
testing plan, it has to be ensured the flow direction also results in The cleanliness of components and
that all surfaces and ducts are improved removal of adhesive systems which undergo function
wetted during flushing. particles. In so doing, the main testing can be determined on a
effect is achieved by virtue of flushing or function test stand
alternating forces being applied (= flushing stand).
to the particles to be dislodged.
The same effect can be achieved This method is used for pumps,
via ultrasonic equipment or other cylinders, transmissions, control
vibration-generating equipment. units, power steering units, valve
blocks, etc.
Pressure testing
Flushing
Documentation of the flushing
results
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25
4.5.1 After 5 minutes of testing the pump A specification like this also
Determining Overall speed is increased to the maximum enables increased system
speed. This causes particulate contamination to be responded to
System Contamination contamination to be dislodged. The quickly. If these measurements are
system becomes increasingly only conducted once a day, a
The sampling site for an automatic cleaner. Particulate contamination whole days output might be
particle counter is defined as a site is still being released after 1 hour affected and have to be remedied.
upstream or downstream of the test of testing (standard test time: 10-15 The result is unnecessary costs
item, which is subjected to a direct min.), consequently the cleanliness that can be avoided by integrating
flow. The following is performed if of the return-line fluid (blue = a continuous measurement
the analysis result is to be downstream of the test item) never procedure.
additionally subjected to achieves the same cleanliness as
gravimetric analysis: upstream of the test item. When conducting a reference
measurement, the system is
the entire test fluid is collected and This method is suitable for disassembled after the test run, if
filtered through an analysis checking the cleanliness of items possible, and the individual
membrane being delivered quickly and simply components analyzed using the
in series testing, documenting it flushing method.
or an inline membrane retainer and then concluding the flushing
featuring the analysis membrane is procedure when the target value is
integrated in the return-flow line. achieved. By integrating the
measurement circuit in the
Now the test item is tested in manufacturing instrumentation and
accordance with the inspection and control system it is also possible to
testing plan, during which the quickly detect any deviations and
cleanliness classes are recorded. initiate suitable measures. The goal
of continuous cleanliness
Example 1: monitoring is to monitor process
reliability with regard to system
The schematic below shows the cleanliness upon delivery.
analysis performed on a pump test
stand.
Fig.21
Example:
26
5 Contamination Contamination monitoring extends
Monitoring to checking the cleanliness status
of all manufacturing and assembly
processes considered relevant in
The reliability of hydraulic systems
this connection. (cf. analysis
can be impacted heavily by
methods, described in section 4)
particulate contamination during
Proper preparation and informing
the running-in phase. The risk of
all those involved are key in
outages during the first minutes or
contamination monitoring.
hours of operation is particularly
high as the foreign particles
introduced or created during the
assembly process are still relatively
large and can thus cause sudden
outages. During continued
operation, these large particles are
ground into smaller ones, the result
being that damage can be caused
to the surfaces of system
components during this crushing
process. The consequences are
leakage, degraded output and
efficiency, or a shortening of the
components service life.
27
5.1 5.2 5.3
Planning and Design How Sampling is Done Inspection
of the Manufacturing
First, the objective of contamination A representative sampling is taken and Assembly Line
monitoring is specified, e.g. of the fluids and components; the
samples are stored so as to Properly trained or experienced
Determining the current situation prevent any further contamination. individuals while inspecting the
Special sampling bottles are used manufacturing and assembly line
Checking fluctuations between
for the fluid samples; the can detect some sources of
batches
components are stored in defined contamination. That is why such an
Checking washing processes clean packaging. inspection is conducted during the
Comparing the target with the actual audit. The findings made during
situation The analysis is performed in inspection are then compared with
accordance with the methods the results in hand.
Determining the sampling point specified in sections 3 and 4 and
the findings recorded.
During the planning and design
phase, the sampling points for
components and taking liquid
samples are determined using a
production plan or operation sheet.
The employees to be involved in
contamination monitoring are
informed of the objectives and
procedures.
NOTE:
Manufacturing has to continue in
the same manner, meaning that no
additional cleanliness levels, etc.
are to be integrated. The purpose of
contamination monitoring is not to
check the quality produced by the
employees but rather determining
the causes and sources of
contamination.
Fig. 22
28
5.4
Results
The contamination monitoring
results describe the condition at
the time at when sampling is done.
The findings might look like this:
Fig. 23
Fig. 24 Fig. 25
Micro-photograph Micro-photograph
Analysis membrane Analysis membrane
29
6 Drafting a Cleanliness These individual components or
Specification system areas should be subdivided
into sensitivity areas.
By applying a cleanliness
specification to components and Category Designation Description
the system it can be ensured that A low particle-sensitivity For the most part low-
as-supplied quality is constant. pressure systems with
large gap tolerances
The following should be borne in
mind when drafting a cleanliness B particle-sensitive Low-pressure systems with
specification: small gap tolerances
C high particle sensitivity High-pressure systems
State of the art with small gap tolerances
Benchmarking and with exacting demands
what do others do? made of safety and security
systems
Inclusion of previous experience
if available
Defining and implementing
A maximum particulate
contamination management as an
contamination value is specified for
official project
each of these cleanliness
Inclusion of all hierarchy levels categories.
Accurate documentation of how the
specification was developed A car motor illustrates this
subdivision below:
Developing clear-cut definitions
Category Motor area
Next, it has to be determined which
components in the system are the A Air
most sensitive. Frequently it is not Coolant water circuit
possible to achieve the same level B Low-pressure oil circuit
of cleanliness throughout the
system during assembly. C Diesel direct injection
High-pressure oil circuit
If suitable filtration takes place
upstream of the sensitive In addition, the fluid cleanliness
components, an area of low- ratings of the individual system and
contamination-sensitive process fluids are defined.
components can be defined
upstream of this filtration and an
area of highly contamination-
sensitive components downstream
of the filter.
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6.1
Establishing
Cleanliness Specifications
The following parameters are
defined in the cleanliness
specifications for the components:
32
Example of a Cleanliness Representative samples are taken
Specification of the system fluids at the specified
sampling points. All testing
parameters are specified, i.e. the
1. Goal of the duration of testing, what is tested,
cleanliness specification the pressures, speeds. When
The goal in implementing this conducting static inspection and
cleanliness specification is to testing, e.g. pressure testing in
achieve a constant level of pipeline and hoses, make sure that
cleanliness for system X. a flushing effect is present so that
the cleanliness of these
2. Applicability components can be determined,
(system designation) i.e. the static pressure test has to
This specification applies to system be followed by a dynamic flushing
X including its series A, B, and C. It process in order to analyze the
extends to all components whether actual quantity of particles which is
sourced or manufactured in house. flushed out of the component.
It also specifies the system fluids of
system X with regard to their 6. Evaluation method
cleanliness. In the component analyses the
analysis membrane is dried until it
3. Extent of inspection and achieves a constant weight, and
testing; inspection and testing then cooled in a defined dry
cycles environment and weighed. This
5 samples/month of each procedure is repeated subsequent
component are to be taken and to filtration. The weight differential
analyzed. If the supplier parts indicates the gravimetric
achieve a constant cleanliness contamination of the component.
value after 6 months, the sampling This is followed by visually
cycle can be extended to sampling examining the analysis membranes
every 2 or 3 months. An analysis of through a microscope and
the entire (assembled) system is to measuring the longest particles.
be done at least once a week prior
to delivery. Checking of the fluid Evaluation of the fluid samples is
cleanliness should optimally be done in accordance with ISO 4405,
done on a continuous basis. ISO 4407, ISO 4406:1999 or
NAS 1638.
4. Sampling
Sampling of components is to be 7. Accuracy
done at goods receiving. Sampling The analysis equipment has to be
of components is to be brought to a residual dirt content of
representative; samples are to be 0.2 mg prior to conducting the
packed in a dust-tight manner and analysis so that the measurements
sent in to the laboratory. The fluid taken of the component samples
samples are to be taken at the are sufficiently accurate. This is
sampling points indicated in the determined by performing a
inspection and testing plan, or an negative control, i.e. flushing the
instrument to be connected equipment without testing. When
directly. the result of the analysis drops
below 0.5 mg, the batch size is to
5. Analysis method be increased and thus a mean
The flushing method is to be used value of the results computed.
for component analysis. The
surfaces of the component are 8. Analysis fluids to be used
flushed in a defined clean The following analysis fluid should
environment using x ml of the test be used for the component
fluid (XY) which possesses a analyses: ABC-XX, with a
cleanliness of xx under a cleanliness class of 14 / 12 / 9
pressure of z bars as specified by and no particles > 40 m.
the inspection and testing plan.
The flushed-off particulate
contamination is collected on an
analysis membrane and subjected
to gravimetric analysis.
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33
9. Documentation 11. Procedure to be followed in
The documentation of the results the event that the specification
is to done using a result sheet is not adhered to
(cf. sample). The supplier components are to be
returned to the supplier in the event
10. Limit values that the specification is not adhered
The components are subdivided to. If this procedure results in
into 3 cleanliness classes: production delays, the components
will be cleaned and analyzed by us
Category at the suppliers expense.
Designation Description
A low particle- For the most part low-pressure
sensitivity systems with large gap tolerances
B particle-sensitive Low-pressure systems with small gap
tolerances
C high particle High-pressure systems with small gap
sensitivity tolerances and exacting demands
Fluid samples:
34
7 Sources of wear special, lint-free clothing.
Contamination in The assembly equipment has to be
properly cleaned so as to prevent
the Manufacturing the ingress of dirt here, too.
and Assembly of
Hydraulic Systems Raising the Awareness of
Employees
Particulate contamination can enter
In order to achieve the objective of
a power fluid system in various
defined cleanliness of components
ways. The main sources of
and systems it is important that
ingression are shown in the
employees at all levels be involved
following diagram:
in this process. Frequently, a
considerable savings potential is
contained in the employees wealth
Fig. 26
of ideas and experience
particularly those working at
assembly lines and in fabrication.
Experience has shown that when
employees are able to identify with
the objective being striven for, they
are more able to help in
implementing it quickly and
effectively.
36
Example: Pipeline flushing When purchasing washing
after bending systems, make sure to specify the
component cleanliness to be
achieved and the maximum
Fig. 28 contamination load of the washing
Micro-photograph fluid in terms of mg/l or a
Analysis membrane cleanliness class.
Advantage:
temporary cost savings
37
The following methods are used in
standard maintenance:
Filtration
Belt-type filter X
Bag/backflush filter X
Micronic filter X
(tube/disk filters)
Ultrafiltration X X
Distillation X X (for high boiling X
point differences)
Separator X X (density difference)
Oil separator X
Coalescer X
The type and composition of the That is why it is advisable to A typical example is described
cleaning medium is to be taken into additionally define minimum below.
account in selecting the fluid change intervals and to regularly
maintenance options indicated monitor the cleanliness of the At a leading automotive supplier,
above. When using ultrafiltration, washing fluid in addition to the the camshafts were to be cleaned
it has to be borne in mind that standard parameters like pH value to a defined cleanliness of
separating out the cleaning or microbial count. 9 mg/component. Point of departure:
substances cannot be avoided in
certain cases. In addition, Residual dirt values of cleaned
components are increasingly being Technical specifications of the washing
ultrafiltration can only be used for
precleaned washing media since defined and specified as an machine present on site:
the performance of the separating acceptance criterion for the Tank volume: 80 l
membranes is degraded when they cleaning system. It is of paramount
are loaded with particulate importance that constant Pump delivery rate: 250 l/min (centrifugal pump)
contamination. adherence be maintained to these Washing agent: Ardox 6478 chemetall
values. It is also imperative that the
quality of the cleaning fluid be Concentration: 2.3 3 %
Using Filtration as Fluid maintained at a constant, high Bath temperature: ca. 50 C
Maintenance for Separating out level.
Filtration: Backflush filter downstream
Particulate Contamination
This can be achieved by the of pump, 50 m filter rating
Bag and backflush filters in various targeted use of microfilters
microfilter ratings are the standard featuring a constant, absolute
equipment used in the separation rate. For the most part,
maintenance of the fluid of washing tube filters or disk filters are used. Process data:
systems. Although these filters are The advantage offered by these
Bath change frequency: 1 time/week
suitable for removing large filter types as compared to
quantities of contamination from a standard hydraulic filter elements is Throughput: 3,000 4,000
system, they are not suitable in their high contaminant retention components/day
most cases for maintaining defined rate owing to their depth effect.
Wash cycle: 15 s/component
cleanliness classes. Owing to their
design, they do not offer much Thanks to the high contaminant
resistance; i.e. the counterpressure separation rate offered by these Challenge:
built up across the filter is very low, filter types, they remove a high
below 1 bar for the most part. That amount of contamination from the Clogging of the tank
is why this filter type is frequently washing fluid; this causing the
used in the main (full) flow when filters to become quickly exhausted Quality no longer sufficient
feeding cleaning fluid into the and blocked. after 2-3 days
washing or flushing chamber. The A sufficiently long service life
Fluctuation in the contamination
filter housings are equipped with coupled with high washing fluid
content of the components
pressure gauges for monitoring the cleanliness can be achieved by
upstream of the line: 30 50 mg
proper functioning of the filter. combining filters for removing the
main portion of contaminants from Cleaning costs per component not
Bag filters pose the risk that the system with absolute to be any higher than 0.008
overloading can cause the bag to microfilters.
Cleaning costs could not be
be destroyed and large allowed to increase, although
E 7.604.1/05.09
38
Goal of optimizing the cleaning
line:
39
7.2.2 On a function test stand not only
Function Testing function testing is performed but
the components and systems are
run in as well. A frequent side
Most systems come into contact
effect of this is the flushing effect of
with the hydraulic fluid during initial
the system undergoing testing.
system filling or function testing.
By employing targeted fluid
This process affords the
maintenance and cleanliness
manufacturer a substantial
monitoring, this flushing effect can
opportunity to decisively impact the
be used to ensure that systems
final cleanliness of the entire
possess a defined, constant
system. By employing suitable
cleanliness status upon delivery.
filtration of the filling and test fluids,
system cleanliness can be quickly
Cleanliness monitoring provides
optimized upon delivery or
information on the process stability
commissioning.
of the upstream fabrication and
cleaning steps. Frequently,
The cleanliness of the final product
continuous monitoring of test fluid
can be controlled via function
cleanliness results in the
testing in the same way as by a
cleanliness of the entire system as
washing machine.
supplied being documented.
This approach is used in mobile
Some companies have the
hydraulics, turbines or paper
following motto:
machinery upon delivery or during
commissioning in order to
The test stand is our last washing
demonstrate to the final customer
machine.
that his system is being supplied
with the specified cleanliness.
This statement might be true,
however it is an expensive
approach in practice. Yet when
performing process reliability
measures for supplying systems
with a defined cleanliness, this is
the first approach.
Fig. 31
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40
1. Example: Fig. 32
Fig. 34
Cleanliness class achieved by the
test fluid: NAS 3
E 7.604.1/05.09
41
7.3 7.4
Storage, Logistics Supplier Parts
and Ambient Conditions and Components
Manufactured In-house
Unfortunately, improper component
storage is not uncommon. Seals Suitable cleanliness specifications
and gaskets which arrive at the for internally produced and sourced
assembly line clean and packed in parts enable the ingress of
bags are unpacked and filled into contamination into systems to be
containers which are dirty for the minimized right from the beginning.
most part as this involves less work
and effort.
In most cases, these factors are
not taken into consideration and
substantial savings potential that
could be easily utilized through
improved packaging and storage is
overlooked.
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42
8 Commissioning Flushing
This method is most frequently
chosen for large systems in order
to minimize wear during
commissioning.
Fig. 35
43
9 Economic Efficiency The next step involved forwarding This economic efficiency analysis
Analysis the cleanliness specifications to the also includes the expenses
suppliers, who received orientation associated with contamination
training and are periodically management (seminars, consulting
The core aspects of contamination
monitored. fees, analysis costs).
management are a cost analysis
and efficiency review. The following
The results of optimization:
costs are considered in the cost
analysis:
Less tool wear in surface
machining
Warranty and non-warranty
courtesy work Longer service life of the machining
fluid
Energy costs (e.g. cooling and
reheating of washing machines Enhanced effectiveness of the
during fluid changes) downstream washing processes as
less dirt had to be removed thanks
Test stand costs (test item time)
to optimized storage and
Costs of the tools and dies of machining
machine tools (increased wear due
Longer intervals between changing
to high particle concentrations)
the washing and flushing fluids,
Fluid costs (washing machines, consequently Saturday shifts
test stations, machine tools) could be dispensed with
Labor costs (reworking, cleaning of Fewer outages at the test stand,
washing machines, machine tools, i.e. the system is checked up to
etc.) 3 times when performance
deviations occur. These idle
Filter costs
cycles were reduced by 90 %,
thus resulting in increased
The following economic efficiency
productivity.
analysis describes the success of
contamination management as Drop in warranty and non-warranty
illustrated by a manufacturing line courtesy work by 50 %
in the automotive industry with an as the main reason for the outages
output of 3,000 systems/day. turned out to be particulate
Manufacturing is done 260 contamination, which resulted in
days/year. A contamination review leakage and imprecise control in
showed that the cleanliness of the the system.
function test stand fluid, the
Shortening of the test stand time.
intermediate storage conditions
and a machining process had to be
Unfortunately we were not
optimized. The optimization costs
permitted to publish the detailed
are shown below:
data behind these savings.
Following from an economic
efficiency analysis conducted by
the customer in-house, savings of
0.60 per system were achieved.
468,000
45
10 Contamination The goal of contamination can be done immediately if this
Management in Practice management is now to improve the value is exceeded, thus ensuring
degree of cleanliness so that this that no contaminated systems
undesirable behavior no longer leave the factory.
In the sections above we discussed
occurs on the test stand and the
the impacts of particulate
associated costs of warranty and Random sampling is done to check
contamination on the service life
non-warranty courtesy work are the supplier quality and non-
and reliability of hydraulic systems,
reduced. conformant components returned
how the cleanliness of fluids on
to suppliers or washed in-house at
components can be specified, and
Step 1: Analysis of the Test Fluid the suppliers expense.
how contamination monitoring is
performed. The cleanliness of the test fluid is
Step 5: Economic Efficiency
determined. The analyses show
Analysis
Deploying contamination that the test fluid cleanliness
management results in the upstream of the test item amounts
Contamination management
following tasks for all participants in to a cleanliness rating of 22 / 20 /
started off with analyzing the costs
the production process: 18 according to ISO 4406, the
associated with warranty and non-
largest metallic particles are 400
warranty courtesy work as the
Suppliers: m in size, and the largest fibers
result of increased malfunction at
measure 3,000 m.
Ensuring the defined as-supplied the test stands.
condition of products.
Step 2: Optimizing the Function
These costs are reanalyzed after
Test Stand
Selecting the packaging of products optimization and compared.
to be supplied so that no additional By additionally integrating bypass
contamination occurs during microfiltration, which maintains test The savings achieved through
transportation and storage. fluid cleanliness at 15 / 13 / 10, optimization are briefly described in
95 % of the performance deviations Economic Efficiency Analysis.
System vendors can be prevented.
and manufacturers: The cost savings in that case
This also results in a drop in amounted to ca. 468,000/year.
Careful transportation, handling,
warranty and non-warranty This optimization process lasted
storage and unpacking of products.
courtesy work. ca. 2 years.
Keep products clean after they are
Step 3: Lowering the Filter Costs Step 6: Documentation
unpacked or after seals/plugs have
at the Test Stands and New Projects
been removed.
By performing a contamination The contamination management
Assemble/install the components in
monitoring audit, it might be findings are collected in a database
a suitably clean environment.
determined a large amount of and used in the development of
particulate contamination is being new systems.
transported into the system by the
The following example shows how
manufacturing processes and The defined maximum residual dirt
these individual parts can be
sourced components. This content becomes standard in new
combined in contamination
particulate contamination has to be systems in the same way that
management.
removed from the system at the dimensions, surface grades and
function test stand, which functions tolerances have been. This
Description of
here as the last washing operation. residual dirt content is primarily in
the Point of Departure:
This results in costs that could reference to the specification that
System X has been successfully otherwise be avoided. applies to System Y.
manufactured and marketed for
years. During the past few years, A concept is developed in which The specification is adapted in
System X has been developed the washing and machining keeping with the experience gained
further and a new generation, processes and intermediate with the prototypes. Cleanliness
System Y, created. Y features storage are optimized. and cleaning costs are primarily
improved performance properties, A cleanliness specification along determined by the design of new
is more compact than X, and with a test plan for system fluids is systems.
operates at higher system drafted. This specification is
pressures than X. The result is that forwarded to external as well as
System Y is somewhat more internal suppliers and the
sensitive to particulate contamination. components supplied with a
defined, constant cleanliness.
This is reflected in increased
performance deviations during Step 4: Integrating Particle
function testing. This deviation no Counting in Quality Assurance
longer occurs when Y is passed
through the test stand a second or A particle sensor is integrated in
third time. the function test stand for the
purpose of continuous quality
An investigation of the matter has control of the as-supplied quality of
shown that this unwanted behavior System Y. A limit is defined for the
E 7.604.1/05.09
47
Reference List (14) University of Wrzburg, Authors
Fluid Mechanics lecture
(1) H. Werries, Einfluss von HYDAC Filtertechnik,
Fremdpartikeln in Wlzlagern und (15) Nancy Carosso, NASA USA, Andreas Busch, Dipl.-Ing. (FH)
Manahmen zu ihrer Vermeidung, Contamination Engineering Design,
University of Hanover, 1992 www.de.ksc.nasa.gov/dedev/labs/ Elke Fischer, Dipl.-Ing.
cml_lab/CONTMON_DESIGN.html eficon, Bensheim
(2) R.W. Park, Moog Australia Pty #1.1
Ltd., Contamination Control a
Hydraulic OEM Perspective,
Monash University, Australia, 1997
(7) CETOP RP 94 H
Determination of solid particulates
in hydraulic fluids using an
automatic particle counter
employing the light extinction
principle.
49