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Oil Contamination 1679643628
Oil Contamination 1679643628
Oil Contamination 1679643628
Hydraulic Filtration
The Handbook of Hydraulic
Filtration is intended to
technology.
It is dedicated as a reference
of filtration devices is an
Contamination Basics 2
Fluid Analysis 32
Appendix 34
1
Contamination Basics
Filtration Fact Contamination Causes
Most Hydraulic Failures
If any one of these functions is
impaired, the hydraulic system will not
perform as designed. The resulting
Properly sized, installed, and The experience of designers and users
downtime can easily cost a large manu-
maintained hydraulic of hydraulic and lube oil systems has
facturing plant thousands of dollars
verified the following fact: over 75% of
filtration plays a key role per hour. Hydraulic fluid maintenance
all system failures are a direct result
helps prevent or reduce unplanned
in machine preventative of contamination!
downtime. This is accomplished
maintenance planning. through a continuous improvement
The cost due to contamination is
program that minimizes and removes
staggering, resulting from: contaminants.
Micrometer Scale
Relative Sizes of Particles Particle sizes are generally measured
on the micrometer scale. One microm-
Substance Microns Inches eter (or “micron”) is one-millionth of
Grain of table salt 100 .0039 one meter, or 39 millionths of an inch.
Human hair 70 .0027 The limit of human visibility is approx-
Lower limit of visibility 40 .0016 imately 40 micrometers. Keep in mind
Milled flour 25 .0010 that most damage-causing particles in
hydraulic or lubrication systems are
Red blood cells 8 .0003
smaller than 40 micrometers.
Bacteria 2 .0001 Therefore, they are microscopic and
cannot be seen by the unaided eye.
3
Contamination Types and Sources
▼ Carbon ▼ Fibers
4
Contamination Types and Sources
Damage
Generated Contamination
Abrasive Wear—Hard particles Erosive Wear—Fine particles in
bridging two moving surfaces, a high speed stream of fluid eat
scraping one or both. away a metering edge or critical
surface.
Cavitation Wear—Restricted
inlet flow to pump causes fluid Adhesive Wear—Loss of oil film
voids that implode causing allows metal to metal contact
shocks that break away critical between moving surfaces.
surface material.
Corrosive Wear—Water or
Fatigue Wear—Particles chemical contamination in the
bridging a clearance cause fluid causes rust or a chemical
a surface stress riser that reaction that degrades a
expands into a spall due to surface.
repeated stressing of the
damaged area.
5
Contamination Types and Sources
Filtration Fact
Most system ingression
Prevention
▼ Use spin-on or dessicant style filters for reservoir air breathers.
▼ Flush all systems before initial start-up.
▼ Specify rod wipers and replace worn actuator seals.
▼ Cap off hoses and manifolds during handling and maintenance.
▼ Filter all new fluid before it enters the reservoir.
6
Contamination Types and Sources
Water
Contamination
Types
There is more to proper fluid
maintenance than just removing Typical Saturation Points
particulate matter. Water is virtually a
universal contaminant, and just like Fluid Type PPM %
solid particle contaminants, must be
removed from operating fluids. Water Hydraulic Fluid 300 .03%
can be either in a dissolved state or in
a “free” state. Free, or emulsified, Lubrication Fluid 400 .04%
water is defined as the water above the
saturation point of a specific fluid. At Transformer Fluid 50 .005%
this point, the fluid cannot dissolve or
hold any more water. Free water is
generally noticeable as a “milky”
discoloration of the fluid.
7
Contamination Types and Sources
Damage
Filtration Fact ▼ Corrosion of metal surfaces is reached, ice crystals form, adversely
affecting total system function. Operating
A simple ‘crackle test’ will ▼ Accelerated abrasive wear
functions may also become slowed or
tell you if there is free ▼ Bearing fatigue
erratic.
▼ Fluid additive breakdown
water in your fluid. Apply a
▼ Viscosity variance Electrical conductivity becomes a pro-
flame under the container.
▼ Increase in electrical conductivity blem when water contamination weakens
If bubbles rise and ‘crackle’
the insulating properties of a fluid, thus
from the point of applied Anti-wear additives break down in the decreasing its dielectric kV strength.
heat, free water is present presence of water and form acids. The
combination of water, heat and dissimilar
in the fluid.
metals encourages galvanic action. Pitted
and corroded metal surfaces and finishes
8
Contamination Types and Sources
50
% Water In Oil
Effect of water in oil on bearing life (based on 100% life at .01% water in oil.)
Reference: ”Machine Design” July 86, ”How Dirt And Water Effect Bearing Life” by Timken Bearing Co.
Sources Fluids are constantly exposed to water Water can enter a system through worn
▼ Worn actuator seals and water vapor while being handled cylinder or actuator seals or through
▼ Reservoir opening leakage and stored. For instance, outdoor stor- reservoir openings. Condensation is
age of tanks and drums is common. also a prime water source. As the fluids
▼ Condensation
Water may settle on top of fluid con- cool in a reservoir or tank, water vapor
▼ Heat exchanger leakage tainers and be drawn into the contain- will condense on the inside surfaces,
er during temperature changes. Water causing rust or other corrosion
may also be introduced when opening problems.
or filling these containers.
9
Contamination Types and Sources
Filtration Fact Prevention
Excessive water can usually be into standard filter housings and are
Free water is heavier than removed from a system. The same pre- generally used when small volumes of
oil, thus it will settle to the
ventative measures taken to minimize water are involved.
particulate contamination ingression
bottom of the reservoir in a system can be applied to water Centrifugation
where much of it can be contamination. However, once exces- Separates water from oil by a spinning
sive water is detected, it can usually motion. This method is also only
easily removed by opening
be eliminated by one of the following effective with free water, but for larger
the drain valve. methods: volumes.
flow and low viscosity within the element. These elements fit
applications.
10
Contamination Types and Sources
Air Contamination
Types Damage Sources
Air in a liquid system can exist in ▼ Loss of transmitted power ▼ System leaks
either a dissolved or entrained (undis- ▼ Reduced pump output ▼ Pump aeration
solved, or free) state. Dissolved air may
▼ Loss of lubrication ▼ Reservoir fluid turbulence
not pose a problem, providing it stays
▼ Increased operating temperature
in solution. When a liquid contains
Prevention
undissolved air, problems can occur as ▼ Reservoir fluid foaming
▼ System air bleeds
it passes through system components. ▼ Chemical reactions
There can be pressure changes that ▼ Flooded suction pump
compress the air and produce a large Air in any form is a potential source of ▼ Proper reservoir design
amount of heat in small air bubbles. oxidation in liquids. This accelerates ▼ Return line diffusers
This heat can destroy additives, and corrosion of metal parts, particularly
the base fluid itself. when water is also present. Oxidation
of additives also may occur. Both
If the amount of dissolved air becomes processes produce oxides which pro-
high enough, it will have a negative mote the formation of particulates, or
effect on the amount of work form a sludge in the liquid. Wear and
performed by the system. The work interference increases if oxidation
performed in a hydraulic system relies debris is not prevented or removed.
on the fluid being relatively incom-
pressible, but air reduces the bulk
modulus of the fluid. This is due to the
fact that air is up to 20,000 times more
compressible than a liquid in which it
is dissolved. When air is present, a
pump ends up doing more work to
compress the air, and less useful work
on the system. In this situation, the
system is said to be ‘spongy’.
11
Fluid Cleanliness Standards
Filtration Fact In order to detect or correct problems,
a contamination reference scale is
The ISO 4406:1999 (International
Standards Organization) cleanliness
Knowing the cleanliness used. Particle counting is the most level standard has gained wide accep-
common method to derive cleanliness tance in most industries today. This
level of a fluid is the basis
level standards. Very sensitive optical standard references the number of par-
for contamination control instruments are used to count the ticles greater than 4, 6, and 14 microm-
measures. number of particles in various size eters in a known volume, usually 1 mil-
ranges. These counts are reported as liliter or 100 milliliters. The number of
the number of particles greater than a 4+ and 6+ micrometer particles is
Filtration Fact certain size found in a specified
volume of fluid.
used as a reference point for “silt” par-
ticles. The 14+ size range indicates the
The ISO code index quantity of larger particles present
numbers can never which contribute greatly to possible
catastrophic component failure.
increase as the particle
sizes increase
(Example: 18/20/22).
All particle distributions
have more smaller than ISO CODE 19 / 16 / 13
larger particles.
Particles
> 4 microns (c)
Particles
> 14 microns (c)
Particles
> 6 microns (c)
Range Number Micron (c) Actual Particle Count Range (per ml)
19 4+ 2,500 - 5,000
16 6+ 320 - 640
13 14+ 40 - 80
12
Fluid Cleanliness Standards
ISO 22/19/17 fluid (magnification 100x) ISO 17/14/11 fluid (magnification 100x)
13
Fluid Cleanliness Standards
Component Cleanliness
Filtration Fact Level Requirements
Most machine and hydraulic Many manufacturers of hydraulic and
load bearing equipment specify the
component
optimum cleanliness level required for
manufacturers specify a their components. Subjecting compo-
target ISO cleanliness nents to fluid with higher contamina-
tion levels may result in much shorter
level to equipment in
component life.
order to achieve optimal
performance standards. In the table below, a few components
and their recommended cleanliness
levels are shown. It is always best to
14
Fluid Cleanliness Standards
(1) Size Range, Optical Microscope, based on longest dimension as measured per ARP598, APC Calibrated per ISO 4402:1991.
(2) Size Range, APC Calibrated Per ISO 11171 or Electron Microscope, based on projected area equivalent diameter.
(3) Classes and contamination limits identical to NAS 1638.
15
Filter Media Types and Ratings
The filter media is that part of Depth Media
Filtration Fact the element which removes the
contaminant.
For depth type filter media, fluid must
Surface media can be take indirect paths through the materi-
Media usually starts out in sheet form,
al which makes up the filter media.
cleaned and re-used. An and is then pleated to expose more sur-
Particles are trapped in the maze of
ultrasonic cleaner is face area to the fluid flow. This reduces
openings throughout the media.
pressure differential while increasing
usually the best method. Because of its construction, a depth
dirt holding capacity. In some cases,
type filter media has many pores of
Depth media typically the filter media may have multiple
various sizes. Depending on the distrib-
layers and mesh backing to achieve
cannot be cleaned and ution of pore sizes, this media can have
certain performance criteria. After
it is not re-usable. being pleated and cut to the proper a very high captive rate at very small
length, the two ends are fastened particle sizes.
together using a special clip, adhesive,
or other seaming mechanism. The most The nature of filtration media and the
common media include wire mesh, contaminant loading process in a filter
cellulose, fiberglass composites, or element explains why some elements
other synthetic materials. Filter media last much longer than others. In gener-
is generally classified as either surface al, filter media contain millions of tiny
or depth. pores formed by the media fibers. The
pores have a range of different sizes
and are interconnected throughout the
Surface Media
layer of the media to form a tortuous
For surface type filter media, the fluid path for fluid flow.
stream basically has a straight through
flow path. Contaminant is captured on
the surface of the element which faces
the fluid flow. Surface type elements
are generally made from woven wire.
Since the process used in manufactur- 74 m
ing the wire cloth can be very accurate-
ly controlled, surface type media have a
consistent pore size. This consistent
pore size is the diameter of the largest
hard spherical particle that will pass
through the media under specified test
conditions. However, the build-up of
contaminant on the element surface
Surface Media
will allow the media to capture parti-
cles smaller than the pore size rating.
Likewise, particles that have a smaller
diameter, but may be longer in length
(such as a fiber strand), may pass
downstream of a surface media.
16
Filter Media Types and Ratings
Flow Direction
17
Filter Media Types and Ratings
Filtration Fact The Multipass
Test Multipass Test
Filter media ratings The filtration industry Contaminant
uses the ISO 4572 Downstream
expressed as a Beta Ratio
“Multipass Test Sample
Flow Meter
indicate a media’s particle Procedure” to evaluate
removal efficiency. filter element perfor-
mance. This procedure Test
⌬P Gauge
is also recognized by Filter
Beta Ratio
The Beta Ratio (also known as the 50,000
B10 = =5
filtration ratio) is a measure of the 10,000
particle capture efficiency of a filter
element. It is therefore a performance
rating.
Beta Ratio
Downstream
Particles Beta Ratio (x) Efficiency (x)
Upstream 100,000
Particles 50,000 = 2 50.0%
50,000
100,000 =
5,000 20 95.0%
5,000
100,000 =
1,333 75 98.7%
1,333
100,000 > (x) microns
100,000 =
1,000 100 99.0%
1,000
100,000
500 = 200 99.5%
500
100,000 =
100 1000 99.9%
100
19
Filter Media Selection
Filtration Fact A number of interrelated system
factors combine to determine proper
cleanliness level as a more efficient
element. Secondly, the charts indicate
There is no direct media and filter combinations. To accu- the effect of system pressure on the
correlation between rately determine which combination is required ISO code. As system pressure
ideal for your system all these factors increases, the oil film thickness
using a specific media and need to be accounted for. With the between component parts decreases.
attaining a specific ISO development of filtration sizing soft- This reduction in clearance allows
cleanliness classification. ware such as inPHorm, this information smaller micron particles to have
can be used to compute the optimal harmful effects.The charts attempt to
Numerous other variables selection.However, in many instances provide flexibility by providing several
should be considered, such the information available may be possible solutions for each compo-
as particulate ingression, limited. In these cases “rules of nent/system pressure combination.
thumb”, based on empirical data and
actual flow through filters, Selection software such as inPHorm
proven examples, are applied to try
(shown left) can be an extremely useful
and filter locations. and get an initial starting point.
tool in the selection and specification
The charts on the following pages of the proper filtration product. With
are designed for just those instances. computer aided selection, the user can
Be aware that rules of thumb utilize quickly determine the pressure loss
“standard” values when looking at com- across a given element, and/or housing
ponents, ingressions, and other system combination, within specific operating
parameters. Your specific system may parameters. The tedious process of
or may not fit into this “standard” plotting viscosity at various points
classification. and calculating a pressure drop is
eliminated. Additionally, selection
One of the more important points of
software can predict system perfor-
the charts is to emphasize element
mance and element life – ideal for
efficiency. Note that as less efficient
predictive maintenance programs.
elements are utilized, more passes are
required to obtain the same ISO
20
Filter Media Selection
P = Full flow pressure filter (equals
one filtration placement) Lubrication Systems
R = Full flow return filter (equals one Component Type Suggested Media Efficiency Number of Minimum Filter
filtration placement) Cleanliness Code Betax >200 Filter Placements* Placements
O = Off-line (flow rate 10% of reser- Ball Bearings 2 1.5 P or R, & O
voir volume equals .5 of a filtra- 16/13/11
tion placement) 2 1 P or R
* Number of filtration placements in Roller Bearings 5 2 P&R
system, more placements are the 17/14/12
option of the specifier. 2 0.5 0
Journal Bearings 5 1.5 P or R, & O
Gear Boxes 18/15/13
10 2.5 P, R & O
Hydraulic Systems
Component Type System Pressure Suggested Media Efficiency Number of Minimum Filter
Cleanliness Code Betax >200 Filter Placements Placements
2 1 P
<1000 17/14/12
5 2 P&R
Servo Valves
1000-3000 16/13/11 2 1.5 P&O
>3000 16/12/10 2 2 P&R
2 1 P
<1000 18/15/13 5 1.5 P&O
10 2.5 P, R & O
Proportional
2 1 P
Valves 1000-3000 18/14/12
5 2 P&R
2 1.5 P&O
>3000 17/14/11
5 2.5 P, R & O
5 1 P or R
<1000 19/16/14
10 2 P&R
2 0.5 O
Variable Volume
1000-3000 18/16/14 5 1.5 P or R, & O
Pumps
10 2.5 P, R & O
2 1 P or R
>3000 18/15/13
5 2 P&R
5 0.5 O
<1000 20/17/15
10 1.5 P or R, & O
Vane Pumps
5 1 P or R
Fixed Piston Pumps 1000-3000 19/17/14
10 2 P&R
Cartridge Valves
5 1.5 P or R, & O
>3000 19/16/13
10 2.5 P, R & O
10 1 P or R
<1000 21/18/16
Gear Pumps 20 2.5 P, R & O
Flow Controls 1000-3000 20/17/15 10 1.5 P or R, & O
Cylinders 5 0.5 O
>3000 20/17/14
10 1.5 P or R, & O
21
Filter Element Life
Filtration Fact Contaminant Loading
Contaminant loading in a filter ele- element accounts for why some
As an element loads with ment is simply the process of blocking elements last longer than others.
the pores throughout the element. As
contamination, the For a given filter media thickness and
the filter element becomes blocked
differential pressure will filtration rating, there are fewer pores
with contaminant particles, there are
with cellulose media than fiberglass
increase over time; slowly fewer pores for fluid flow, and the pres-
media. Accordingly, the contaminant
sure required to maintain flow through
at first, then very quickly loading process would block the pores
the media increases. Initially, the dif-
as the element nears it’s of the cellulose media element quicker
ferential pressure across the element
then the identical fiberglass media
maximum life. increases very slowly because there is
element.
an abundance of media pores for the
fluid to pass through, and the pore The multilayer fiberglass media
blocking process has little effect on the element is relatively unaffected by
overall pressure loss. However, a point contaminant loading for a longer time.
is reached at which successive block- The element selectively captures the
ing of media pores significantly various size particles, as the fluid pass-
reduces the number of available pores es through the element. The very small
for flow through the element. pores in the media are not blocked by
At this point the differential pressure large particles. These downstream
across the element rises exponentially. small pores remain available for the
The quantity, size, shape and arrange- large quantity of very small particles
ment of the pores throughout the present in the fluid.
Incremental
Life
Time
22
Filter Element Life
Filter Element Life Profile
Every filter element has a characteris- instrumentation for recording the Then, the quantity, size, shape, and
tic pressure differential versus contam- change in the pressure loss across the arrangement of the pores in the filter
inant loading relationship. This rela- filter element is seldom available. Most element determine the characteristic
tionship can be defined as the “filter machinery users and designers simply life profile. Filter elements that are
element life profile.” The actual life specify filter housings with differential manufactured from cellulose media,
profile is obviously affected by the sys- pressure indicators to signal when the single layer fiberglass media and multi-
tem operating conditions. Variations in filter element should be changed. layer fiberglass media all have a very
the system flow rate and fluid viscosity different life profile. The graphic
affect the clean pressure differential The Multipass Test data can be used comparison of the three most common
across the filter element and have a to develop the pressure differential media configurations clearly shows
well-defined effect upon the actual versus contaminant loading relation- the life advantage of the multilayer
element life profile. ship, defined as the filter element life fiberglass media element.
profile. As previously mentioned, such
The filter element life profile is very operating conditions as flow rate and
difficult to evaluate in actual operating fluid viscosity affect the life profile for
systems. The system operating versus a filter element. Life profile compar-
idle time, the duty cycle and the isons can only be made when these
changing ambient contaminant condi- operating conditions are identical and
tions all affect the life profile of the the filter elements are the same size.
filter element. In addition, precise
100
Cellulose Single Layer Multilayer
90 Fiberglass Fiberglass 6
DIFFERENTIAL PRESSURE (PSI)
23
Filter Housing Selection
Filtration Fact Filter Housings
The filter housing is the pressure vessel
Pressure Ratings
Location of the filter in the circuit is the
Always use an element which contains the filter element. It primary determinant of pressure rating.
condition indicator with any
usually consists of two or more sub- Filter housings are generically
assemblies, such as a head (or cover) designed for three locations in a cir-
filter, especially those that and a bowl to allow access to the filter cuit: suction, pressure, or return lines.
do not have a bypass valve. element. The housing has inlet and out- One characteristic of these locations is
let ports allowing it to be installed into a their maximum operating pressures.
fluid system. Additional housing features Suction and return line filters are
Filtration Fact may include mounting holes, bypass
valves and element condition indicators.
generally designed for lower pressures
up to 500 psi (34 bar). Pressure filter
An element loading with
contaminant will continue Visual/electrical element
condition indicator
to increase in pressure
differential until either: Bypass valve Assembly
Pressure housing
Filter element
Drain port
The primary concerns in the housing locations may require ratings from 1500
selection process include mounting psi to 6000 psi (103 bar to 414 bar).
methods, porting options, indicator It is essential to analyze the circuit for
options, and pressure rating. All, except frequent pressure spikes as well as
the pressure rating, depend on the phys- steady state conditions. Some housings
ical system design and the preferences have restrictive or lower fatigue
of the designer. Pressure rating of the pressure ratings. In circuits with fre-
housing is far less arbitrary. This should quent high pressure spikes, another
be determined before the housing style type housing may be required to
is selected. prevent fatigue related failures.
24
Filter Housing Selection
The Bypass Valve
The bypass valve is used to prevent the with a “no bypass” or “blocked”
collapse or burst of the filter element bypass option. This prevents 12
when it becomes highly loaded with any unfiltered flow from going
“bypass to-tank” option. This allows the ferential pressure rating close
unfiltered bypass flow to return to tank to maximum operating pressure of the element to withstand the bypass valve
through a third port, preventing unfil- system. When specifying a bypass type differential pressure when the bypass
tered bypass flow from entering the filter, it can generally be assumed that valve opens.
system. Other filters may be supplied the manufacturer has designed the
After a housing style and pressure
rating are selected, the bypass valve
setting needs to be chosen. The bypass
valve setting must be selected before
sizing a filter housing. Everything else
being equal, the highest bypass
Bypass Filter Blocked cracking pressure available from the
Bypass Filter manufacturer should be selected. This
will provide the longest element life for
a given filter size. Occasionally, a lower
950 psi setting may be selected to help
Bypass (66 bar) 0 psi
(0 bar) minimize energy loss in a system, or to
valve
50 psi reduce back-pressure on another com-
setting ponent. In suction filters, either a 2 or
(3.4 bar) 3 psi (0.14 bar or 0.2 bar) bypass valve
Filter is used to minimize the chance of
(Elements potential pump cavitation.
Blocked)
1000 psi
1000 psi (69 bar)
(69 bar)
Flow
25
Filter Housing Selection
Filtration Fact Element Condition
Indicators
Housing And
Element Sizing
Always consider low tem- The element condition indicator The filter housing size should be large
signals when the element should be enough to achieve at least a 2:1 ratio
perature conditions when
cleaned or replaced. The indicator usu- between the bypass valve setting and
sizing filters. Viscosity ally has calibration marks which also the pressure differential of the filter
increases in the fluid may indicates if the filter bypass valve has with a clean element installed. It is
opened. The indicator may be mechan- preferable that this ratio be 3:1 or
cause a considerable
ically linked to the bypass valve, or it even higher for longer element life.
increase in pressure differ- may be an entirely independent differ-
ential through the filter ential pressure sensing device. For example, the graph on the next
Indicators may give visual, electrical or page illustrates the type of catalog
assembly.
both types of signals. Generally, indica- flow/pressure differential curves which
tors are set to trip anywhere from are used to size the filter housing. As
Filtration Fact 5%-25% before the bypass valve opens. can be seen, the specifier needs to
know the operating viscosity of the
Pressure differential fluid, and the maximum flow rate
(instead of an average) to make sure
in a filter assembly
that the filter does not spend a high
depends on: portion of time in bypass due to flow
1. Housing and surges. This is particularly important
in return line filters, where flow multi-
element size
plication from cylinders may increase
2. Media grade the return flow compared to the pump
3. Fluid viscosity flow rate.
4. Flow rate
It is recommended to use
an element condition
indicator with any filter, Filter
Bypass
Differential Pressure
Pressure
do not incorporate a 3:1 Optimum
Ratio
bypass valve.
Clean
Element
P
26
Filter Housing Selection
1.5
20
1.25
200 SUS 100 SUS
15
1.
0.75 10
0.5
5
0.25
0 0
0 10 20 30 40 50 60 70 80 90 100
(GPM) Flow (LPM)
0 25 50 75 100 125 150 200 225 250 275 300 325 350 375
If the filter described in the graph was Most standard filter assemblies utilize filter element and the bypass valve
fitted with a 50 psi (3.4 bar) bypass a bypass valve to limit the maximum pressure setting must be considered.
valve the initial (clean) pressure dif- pressure drop across the filter A cellulose element has a narrow
ferential should be no greater than 25 element. As the filter element becomes region of exponential pressure rise.
psi (1.7 bar) and preferably 16 2¼3 psi blocked with contaminant, the pres- For this reason, the relationship
(1.1 bar)or less. This is calculated from sure differential increases until the between the starting clean pressure
the 3:1 and 2:1 ratio of bypass setting bypass valve cracking pressure is differential and the bypass valve
and initial pressure differential. reached. At this point, the flow pressure setting is very important. This
through the filter assembly begins relationship in effect determines the
bypassing the filter element and passes useful life of the filter element.
3:1 RATIO through the bypass valve. This action
▼ 50/3 = 16 2/3 psid (1.1 bar)
limits the maximum pressure differen- In contrast, the useful element life of
tial across the filter element. The the single layer and multilayer fiber-
important issue is that some of the glass elements is established by the
2:1 RATIO system contaminant particles also nearly horizontal, linear region of rela-
▼ 50/2 = 25 psid (1.7 bar) bypass the filter element. When this tively low pressure drop increase, not
happens, the effectiveness of the filter the region of exponential pressure rise.
▼ At 200 sus fluid, the maximum flow
element is compromised and the Accordingly, the filter assembly bypass
range would be between 42 gpm attainable system fluid cleanliness valve cracking pressure, whether 25 or
and 54 gpm (159 lpm and 204 lpm) degrades. Standard filter assemblies 75 PSI (1.7 or 5.2 bar), has relatively
normally have a bypass valve cracking little impact on the useful life of the
pressure between 25 and 100 PSI (1.7 filter element. Thus, the initial
and 6.9 bar). pressure differential and bypass valve
setting is less a sizing factor when
The relationship between the starting fiberglass media is being considered.
clean pressure differential across the
27
Types & Locations of Filters
Filtration Fact Filter Types and Locations
▼ Suction ▼ Return
Suction strainers are often ▼ Pressure ▼ Off-line
Pressure Filters
Pressure filters are To System
located downstream
Pressure
from the system pump.
Filter
They are designed to
handle the system
pressure and sized for
the specific flow rate
in the pressure line
where they are
located.
29
Types & Locations of Filters
Filtration Fact Off-Line
Filtration Off-Line Filter
Rule of thumb:
Also referred to as recir-
size the pump flow of an culating, kidney loop, or Existing
Air breather Hydraulic
off-line package at a auxiliary filtration, this or Lube
System
filtration system is totally
minimum of 10% of the
independent of a
Pump
main reservoir volume. machine’s main hydraulic
system. Off-line filtration
consists of a pump, filter,
Filtration Fact electrical motor, and the
appropriate hardware Off-Line
Filter
The cleanliness level of a
connections. These com-
system is directly propor- ponents are installed off-
Optional Cooler
tional to the flow rate line as a small sub-
system separate from
over the system filters.
the working lines, or included in a fluid ness, but does not provide specific com-
cooling loop. Fluid is pumped out of the ponent protection. An off-line filtration
reservoir, through the filter, and back to loop has the added advantage that it is
the reservoir in a continuous fashion. relatively easy to retrofit on an existing
With this “polishing” effect, off-line fil- system that has inadequate filtration.
tration is able to maintain a fluid at a Also, the filter can be serviced without
constant contamination level. As with a shutting down the main system. Most
return line filter, this type of system is systems would benefit greatly from
best suited to maintain overall cleanli- having a combination of suction, pres-
sure, return, and off-line filters.
Flow Rate Effect on Off-Line Filtration The table to the right may be
Performance helpful in making a filtration
10 6
Number of particles upstream per millilitre greater than reference size
location decision.
10 5
10 4 23/21/18
10 3
m)
20/18/15
ISO Correlation
(38 lpm)
100 GPM .8 lp
19/17/14
m)
(3
0 lp
(38
10 2
PM
18/16/13
1G
16/14/12
M
GP
10
10 15/13/10
.1
For beta rated filters with
a minimum rating of beta (10) = 75
.01
10 3 10 4 10 5 10 6 10 7 10 8 10 9 10 10 10 11 10 12
Ingression rate
(Number of particles > 10 micron ingressing per minute)
Source based on Fitch, E.C., Fluid Contamination Control, FES, Inc.,
Stillwater, Oklahoma, 1988.
30
Types & Locations of Filters
31
Fluid Analysis
Filtration Fact ▼ Patch
▼ Portable
Test
Particle Counter content, and compared to known ISO
The only way to know the standards. By using this comparison,
▼ Laboratory Analysis
the user can get a “go, no-go” estimate
condition of a fluid is
of a system’s cleanliness level.
Fluid analysis is an essential part of
through fluid analysis.
any maintenance program. Fluid analy-
Visual examination is not Another lesser-used deviation of the
sis ensures that the fluid conforms to
patch test would be the actual count-
an accurate method. manufacturer specifications, verifies
ing of the particles seen under the
the composition of the fluid, and deter-
microscope. These numbers would
mines its overall contamination level.
32
Fluid Analysis
There is a National Fluid Power
Association (NFPA) standard for
extracting fluid samples from a
reservoir of an operating hydraulic
fluid power system.(NFPA T2.9.1-1972).
There is also the American National
Standard method (ANSI B93.13-1972)
for extracting fluid samples from the
lines of an operating hydraulic fluid
power system for particulate contami-
nation analysis. Either extraction
method is recommended.
micron range. Strengths of this recent XYZ Corporation Parker Hannifin Corporation
16810 Fulton County Road #2
reported in parts per million, 12345 Middleton Rd.
Anywhere USA 41114 Metamora, OH 43540
Tele:(419)644-4311
technology include accuracy, repeata- Attn: Fax:(419)644-6205
> 2 µm 353242.0
2.0 28
1.5
p
5.0
4.0
3.0
2.0
20
19
18
1.5
a
p
5.0
4.0
3.0
13
12
2.0
e 1.5 11
r 101
Laboratory Analysis
2.0 8
1.5
> 100
before taking the sample and 2. Dotted graph line indicates recommended ISO Code level.
2 5 10 15 20 25 30
SIZE (microns)
40 50 60 80 100
33
Appendix
SAMPLING
PROCEDURE
Obtaining a fluid sample for particle A. In the Tank Sampling
counts and/or analysis involves impor- l. Operate the system for
tant steps to make sure you are getting at least 1/2 hour.
a representative sample. Often 2. Use a small hand-held vacuum
erroneous sampling procedures will pump bottle thief or “basting
disguise the true nature of system syringe” to extract sample. Insert
cleanliness levels. Use one of the sampling device into the tank to one
following methods to obtain a half of the fluid height. You will prob-
representative system sample. ably have to weight the end of the
sampling tube. Your objective is to
I. For systems with a obtain a sample in the middle por-
sampling valve tion of the tank. Avoid the top or bot-
A. Operate system for a least 1/2 hour. tom of the tank. Do not let the
B. With the system operating, open the syringe or tubing came in contact
sample valve allowing 200 ml to 500 ml with the side of the tank.
(7 to 16 ounces) of fluid to flush the 3. Put extracted fluid into an
sampling port. (The sample valve approved, pre-cleaned sample bottle
design should provide turbulent flow as described in the sampling valve
through the sampling port.)
method above.
C. Using a wide mouth, pre-cleaned
4. Cap immediately.
sampling bottle, remove the bottle
5. Tag with information as described
cap and place in the stream of flow
in sampling valve method.
from the sampling valve. Do NOT
“rinse” out the bottle with initial
B. In-Line Sampling
sample. Do not fill the bottle more
1. Operate the system for at
than one inch from the top.
D. Close the sample bottle immediate- least 1/2 hour.
ly. Next, close the sampling valve. 2. Locate a suitable valve in the
(Make prior provision to “catch” the system where turbulent flow can be
fluid while removing the bottle from obtained (ball valve is preferred). If
the stream.) no such valve exists, locate a fitting
E. Tag the sample bottle with perti- which can be easily opened to pro-
nent data: include date, machine vide turbulent flow (tee or elbow).
number, fluid supplier, fluid number 3. Flush the valve or fitting sample
code, fluid type, and time elapsed point with a filtered solvent. Open
since last sample (if any). valve or fitting and allow adequate
flushing. (Take care to allow for this
II. Systems without a step. Direct sample back to tank or
sampling valve into a large container. It is not
There are two locations to obtain a necessary to discard this fluid.)
sample in a system without a sampling
valve: in-tank and in the line. The
procedure for both follows:
34
Appendix
Sample Multipass Lab Report
4. Place in an approved
and pre-cleaned sam- Model xxxx Lab Report xxxx
Element xx Date xx
ple bottle under the Flow 30 Gpm Tested By xxx
Anti-static
stream of flow per Additive In Fab.Int. 10 In Water Acftd Batch xxx
Test Fluid Fluid Mil-H-5606/Shell Asa-3 Counts On-Line
sampling valve 98/102F;14.77-15.3 C
methods above. Element Pressure
5. Cap sample bottle Drop At Test Diff. Press. (PSID) INJECTION FLUID
Termination Terminal 235.0 Grav (MG/L) Flow (L/Min)
immediately. Clean Ass’y 5.0 Initial 1226.8 7 Point
6. Tag with important Housing 3.2 Final 1279.4 Average
Element 1.8 Average 1253.1 0.453
information per the NET 233.2
sampling valve method. System Gravimetrics (MG/L): Base: 5.0 Final: 11.8
Note: Select a valve or
% Net Time Delta P. Grams Inject. Particle Distribution Analysis-Part./H Size
fitting where the Ass’y Added Flow (Up/Down/Beta) Particle Size
pressure is limited to Elem’t 2 3 5 7 10 12
Test Point Clean 4.89 2.22 1.11 0.89 0.22 0.00
200 PSIG (14 bar) or Information
Fluid 8.32 1.75 0.44 0.00 0.00 0.00
less.
% of Net ⌬Psi 2.5 25.4 10.8 14.4 0.451 13,178.00 6,682.00 2,678.00 1,382.00 643.30 436.10
7.6 10,168.00 2,863.00 340.30 39.55 3.18 0.23
Regardless of the method Duration of Test 1.30 2.33 7.85 34.9 200 1,900
being used, observe com- (Minutes) 5 31.1 16.7 17.7 0.455 14,060.00 7,214.00 2,822.00 1,427.00 673.00 463.20
13.5 11,056.03 3,391.00 406.48 35.91 1.59 0.23
mon sense rules. Any
1.27 2.13 6.94 39.7 420 2,000
equipment which is used Assembly ⌬Psi 10 35.8 28.3 20.3 0.455 13,900.00 7,207.00 2,817.00 Upstream Particle Count
in the fluid sampling 25.1 10,590.00 3,274.00 395.30
procedure must be 1.31 2.20 7.13
20 39.0 51.6 22.1 0.453 14,950.00 7,833.00 3,201.00 Downstream Particle Count
washed and rinsed with a Element ⌬Psi 48.4 9,496.00 2,869.00 375.00
filtered solvent. This Cumulative 1.57 2.73 8.54 Test Point Beta Ratio
includes vacuum pumps, Capacity 40 42.6 98.3 24.2 0.455 12,410.00 6,696.00 2,857.00 1,495.00 700.70 474.68
(Grams) 95.1 7,843.00 2,277.83 380.58 38.83 1.82 0.46
syringes and tubing. Your
1.58 2.94 9.51 49.8 390 1,000
goal is to count only the Injection Flow 80 45.1 191.6 25.6 0.453 11,420.00 6,299.00 2,768.00 1,456.00 681.10 469.30
particles already in the (Liters/Min) 188.4 6,152.00 1,709.00 234.30 32.28 5.46 2.50
system fluid. Dirty 1.86 3.69 11.8 45.1 120 190
100 45.9 238.2 26.1 0.451 11,130.00 6,136.00 2,717.00 1,427.00 669.40 460.90
sampling devices and
235.0 6,013.00 1,690.00 262.50 41.14 8.87 5.23
non-representative 1.85 3.63 10.4 34.7 75.5 88.1
samples will lead to Minimum Beta: Ratio’s 1.27 2.13 6.94 32.6 75.5 88.1
erroneous conclusions Time Avg. Beta Ratio’s 1.36 2.42 7.97 37.2 220 800
and cost more in the Final Capacity (Grams): Apparent: 26.1 Retained: 25.8
long run.
Minimum Beta Ratio For
Particle Size During Test
Weighted Avg Beta Ratio For Cumulative Dirt Added Calculated Amount
Particle Size Over Test Duration During Test Of Grams Retained
35
Appendix
36
Temperature ⬚C
Appendix
20 AN M H 100
No -0- IL- ydra
Di . 2 F 9 G L-7 u
es u No rad 80 lic Flu
10 el el
Fu No . 4 e1 8 id M
8 J el . 3 Fue 01
0
IL-O
-56
Ke P-5 Fu l 06 50
6 ros
en
el
e
4 40
JP
3 -4
Av
era
ge 35
Av
2 iat
ion
Ga
so
1.5 lin
e—
Kinematic Viscosity—Centistokes
Av
era
Viscosity—Saybolt Universal Seconds
ge
1
.9
.8
.7
.6
-60 -40 -20 0 20 40 60 80 100 150 200 250 300 350 400 500
Temperature ⬚F
37
Parker Worldwide Filtration Group Technical
Sales Offices Sales & Service Locations
Contact Parker’s worldwide service Finite Filter Division Filter Division U.K.
and distribution network by calling: 500 Glaspie Street Churwell Vale
Oxford, MI 48371 Shaw Cross Business Park
Argentina • +54 (1) 752 4129 Phone: (248) 628-6400 Dewsbury, England WF12 7RD
Australia • +61 (2) 634 7777 Fax: (248) 628-1850 Phone: +44 1924 487000
Austria • +43 (2622) 23501 3 Fax: +44 1924 487060
Belgium • +32 (2) 762 1800 Hydraulic Filter Division
Brazil • +55 (11) 3917 1407 16810 Fulton County Road #2 Filter Division U.K.
Canada • 1-800-272-7537 Metamora, OH 43540 UCC Products
China • +86 (21) 6249 9755 Phone: (419) 644-4311 P.O. Box 3
Czech Republic • +42 (2) 752544 Fax: (419) 644-6205 Thetford, Norfolk
Denmark • +45 (43) 541133 IP24 3RT England
Finland • +358 (0) 8784211 Process Filter Division Phone: (44) 1842-754251
France • +33 (50) 258025 1515 W. South Street Fax: +44 1842-753702
Germany • +49 (69) 311096 P.O. Box 1300
Hong Kong • +852 2428 8008 Lebanon, IN 46052 Finn Filter Division
Hungary • +36 (1) 25 22 539 Phone: (765) 482-3900 Fin-31700
India • +91 (22) 577 1671 Fax: (765) 482-8410 Urjala As., Finland
Italy • +39 (2) 451921 Phone: (358) 3 54 100
Japan • +81 (45) 861-3811 Racor Division Fax: (358) 3 54 10100
Korea • +82 (2) 561 0414 3400 Finch Road
Mexico • 1-800-272-7537 P.O. Box 3208 Parker Hannifin Ind. e Com.
Netherlands • +31 (5410) 85000 Modesto, CA 95353 Ltda. Filter Division
New Zealand • +64 (9) 573 1523 Phone: (800) 344-3286 Via Anhanguera, Km. 25,3
Norway • +55 (99) 867760 Phone: (209) 521-7860 05276-977 – São Paulo
Poland • +48 (22) 461455 Fax: (209) 529-3278 – SP, Brazil
Singapore • +65 261 5233 Phone: +55 (11) 847 1222
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Spain • +34 (1) 6757300 Hydrocarbon Products
Sweden • +46 (8) 760 2960 Route #3 Box 9 Parker Hannifin Asia Pacific
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United Kingdom • +44 1924 487000 Fax: (918) 652-8882 648-23 Yeoksam-dong
United States of America • 1-800-272-7537 Kangnam-ku, Seoul,
Venezuela • +58 (2) 238 5422 Korea 135-080
Phone: 82 2 561 0414
Fax: 82 2 556 8187