Contamination Fundamentals - …Abrasion Wear 8 µ 5µ This 4 micron wide particle is able to float...

$Page 1: Contamination Fundamentals - …Abrasion Wear 8 µ 5µ This 4 micron wide particle is able to float into a 5 micron clearance area as it passes through a control valve or similar un\൩t.$
Contamination Fundamentals

Types of Contamination

SOLIDS

LIQUIDS

GASES

Particle Size Diameter Comparison

Human Hair = 80 micron

1 µm = 0.001 mm = 0.000039”

Particle 5 micron

Particle 15 micron

The human eye can only see particles sized down to 40 microns.

Presenter

Presentation Notes

When we look at particulate contamination I want to impress upon you, the understanding that the size particles that will attack critical components in a hydraulic or lube system are those between 2 to 20 micron in size. The human hair cross-section is about 70 to 80 micron in diameter. The human eye can only see particles from 40 micron and larger. The particulate contamination that we are concerned about in these systems are those particles that are invisible to the human eye. YOU ARE MANAGING THE PARTICULATES THAT YOU CAN NOT SEE!

ISO 4406: 1999 (E) - ISO Contamination Code

Number of Particles per 100 ml

Scale Number

More Than Up To and Including

28 130,000,000 250,000,000

27 64,000,000 130,000,000

26 32,000,000 64,000,000

25 16,000,000 32,000,000

24 8,000,000 16,000,000

23 4,000,000 8,000,000

22 2,000,000 4,000,000

21 1,000,000 2,000,000

20 500,000 1,000,000

19 250,000 500,000

18 130,000 250,000

17 64,000 130,000

16 32,000 64,000

15 16,000 32,000

Structure of ISO-Code max. amount of dirt particles ISO Code: 22/18/13 in 100 ml > given size

Chart cont…

Scale Number

More Than Up To and Including

14 8,000 16,000

13 4,000 8,000

12 2,000 4,000

11 1,000 2,000

10 500 1,000

9 250 500

8 130 250

7 64 130

6 32 64

5 16 32

4 8 16

3 4 8

2 2 4

1 1 2

0 0.5 1

Presenter

Presentation Notes

The structure of an ISO Code is three distinct numbers separated by forward slashes. (22/18/13). These numbers are scale numbers that reflect a range number of particles in 100 milliliters of sample fluid. If you go from a 22 scale to a 23 scale number you double the quantity. If you go to 23 from 24 you double again, and so on.

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

Example: larger than 4µmc = 2,234,000 larger than 6µmc = 195,000 larger than 14µmc = 4,250

ISO Code = / /

22

22

18

18

13

13

How do we measure fluid contamination?

4µmc / 6µmc / 14µmc


Example: larger than 4µmc = 2,234,000

ISO Code = / /

22

22



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

ISO Code = / /

22

22

18

18



Example: larger than 4µmc = 2,234,000 larger than 6µmc = 195,000 larger than 14µmc = 4,250

ISO Code = / /

22

22

18

18

13

13


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

Class 2-5 µm 5-15 µm 15-25 µm >25 µm

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

Structure of NAS Codes


Presenter

Presentation Notes

NAS codes and the SAE codes have class numbers which represent the particle counts for the different size particles as shown above. There is distinction between the 2-5 micron, 5-15 micron, 15-25 micron and >25 micron. There is correlation between the different methods see next sheet.

Cumulative Particles per 100 ml Differential Particles per 100 ml Code Designation

Code Designation

> 1 um > 5 um > 15 um 5 to 15 um 15 to 25 um 25 to 50 um 50 to 100 um > 100 um

SAE AS 4059

Equivalent ISO 4406

Class

> 4 um(c) >6 um(c) >14 um(c)

6 to 14 um(c)

14 to 21 um(c) 21 to 38 um(c) 38 to 70 um(c)

> 70 um(c)

Size Code A

Size Code B

Size 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

1,600,000 622,792 110,792 512,000 91,200 16,200 2,880 512 11 21/20/17

3,200,000 1,245,584 221,584 1,024,000 182,400 32,400 5,760 1,024 12 22/21/18

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

SAE AS 4059

Presenter

Presentation Notes

SAE AS 4059 to ISO 4406: 1999 correlation chart.

servo valve J1: 1 - 4µm J2: 100 - 450µm J3: 20 - 80µm

valve J1: 1 - 25µm

piston pump J1: 5 - 40µm J2: 0.5 - 1µm J3: 20 - 40µm J4: 1 - 25µm vane pump

J1: 0.5 - 5µm J2: 5 - 20µm J3: 30 - 40µm

gear pump J1: 0.5 - 5µm J2: 0.5 - 5µm

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

Presenter

Presentation Notes

What determines the micron rating of the filter element you apply to any particular system? The most critical component with the finest filtration requirement targeting the smallest particulate in the system. If filtration is designed to remove and maintain a small population of these particles, the larger particles of concern to the larger tolerance components will also efficiently be removed with this same element.

Abrasion Wear

5µ 8 µ

Presenter

Presentation Notes

This 4 micron wide particle is able to float into a 5 micron clearance area as it passes through a control valve or similar unit. If the valve starts to control and the surface below starts moving, the particle which can not clear the surfaces will bind up as the surface starts to move and it will lock into place and cut and gouge the surface as it moves and tries to control. This happens many times in the life of the system. It is the primary mode of failure 70 to 90% of the time.

Surface fatigue Wear - Bearings 1. Initiation particle

trapped and crushed 2. Surface dented – fault Created – crack initiated

3. After “X” fatigue cycles further micro cracks

propagate.

4. Surface fails, spall created & Particles release and enter flow

Presenter

Presentation Notes

In Fatigue wear, when you have load bearing bearing surfaces rolling on each other, they can come into contact with a foreign contamination particle and crush it under load, After crushing, the action causes a fault to be developed in the surface of the metal bearing, This fault begins to propagate under load like the branches of a tree. Eventually creating a spall which breaks into many contaminate particles which flow through and attack the system and components.

Sources of Contamination

Presenter

Presentation Notes

Where does particulate contamination come from external to the system? In fabrication and when the system is opened to do maintenance. best way to clean reservoir – Flushing rig if possible Tank leakage – access covers and flanged connections to tank, use precision clampload tightening methods – compress seals/O-rings uniformly. Choice of breather critical – no air allowed to bypass element Dirty new oil – Dependent on method of delivery Pump wear – moving/rubbing rotors – introduce wear debris. Piping Scale - Like Rust - Oxidation reaction with water and oxygen. Must monitor water content levels in hydrocarbon based fluids. Dirt on cylinder rods – largest point of dirt ingression in well designed unit. 8. It is important to consider filtration in the return line as the cylinder is the largest point of ingression in the system and the return filter has the first shot at the contamination before entering the reservoir.

New Oil - Photomicrographs

ISO 16/14/11 Demanded by Modern Hydraulic Systems

ISO 17/15/13 New Oil as Delivered in Mini-container

ISO 20/18/15 New Oil as Delivered in Tanker

ISO 23/21/18 New Oil as Delivered in Barrels

1 class => 21=2X

4 classes => 24=16X 7 classes => 27=128X

Presenter

Presentation Notes

Most modern Hydraulic and lubrication systems require ISO target levels of around 16/14/11 when utilizing proportional valves and some of the more sophisticated variable displacement pumps. Fluid delivered in mini totes up to 350 Gallons, typically are delivered at 17/15/13 (one code dirtier) How much dirtier is this fluid than the system requires? Two times as dirty. Fluid delivered in tanker truck is delivered at about 20/18/16 (4 codes dirtier) – how much dirtier? (16 times as dirty) Now we really need to determine how this will be cleaned up before putting into the system that requires 16/14/11. Fluid delivered in 55 gallon drums is delivered at about 23/21/18 (7 codes dirtier) How much dirtier is this? 128 times as dirty.

CAN EFFECTS OF CONTAMINATION BE STOPPED? Effects of Contamination

Presenter

Presentation Notes

With Heat Water and Dirt and metal particles, wear and failure is 70% to 90% contamination related! I am HYDAC – we make leading technology filtration in many industries. Can I stop this from happening? NO – I CAN ONLY SLOW IT DOWN SIGNIFICANTLY - AT THE END OF THE DAY, WHEN THE COMPONENT FAILS IN THE SYSTEM THE ROOT CAUSE WILL STILL BE 70% TO 90% CONTAMINATION RELATED!

Air

Gaseous

Water

Liquid

Laminated FabricFibers

Seal AbrasionRubber Hose Particles

Iron, SteelBrass, Bronze

Aluminum

EmeryMetal Scale

Rust Particles

Solid

Type of Contamination

Basics of Fluid Contamination

MinimalDamage

Damaging

ExtremelyDamaging

Effects

Chemicals Gases

Basic principle light obscuration

Light source is an LED light • Durability • Holds calibration for 2 years • Does not saturate when

reading high contamination levels


The number of pulses equals the number of particles.

Size of Particles

Number of Particles = Number of Pulses

4 micron

6 micron

14 micron


Classification of oil / water mixtures

H H O

Dissolved Water: Homogenous mixture of oil and water. The water molecules are discrete and thoroughly mixed with the oil molecules. Free Water Bulk Water: Above the saturation point, water molecules are aggregated into separate drops (clumps of water). The mixture is no longer homogenous. Emulsified Water: Is a special form of free water. Tiny droplets (1-10 micron size) of water stay suspended in oil and form a hazy or cloudy mixture in the oil.

Presenter

Presentation Notes

Water is also a very significant contaminate: Water comes in the dissolved state - read definition Water comes in the Free State as Bulk water or Emulsified water. Bulk water – Read definition - This water does not combine or mix Emulsified water – Read definition - This water causes problems with operating components in systems - especially pumps, cavitation and piping scale. Also causes problems with particle counters.

Contamination Issues caused by available water: FREE WATER ISSUES: • Corrosion caused by free water contamination – corrosion pits, rough surfaces, and release of abrasive flakes into the fluid – rust and aluminum oxide. • Microbial colonization caused by free water – odors, acids, slime, and health problems. • Loss of lubricity caused by free water entering contact loading zones, allowing opposing surfaces to crash together – results in high friction, wear and seizure. • Additive depletion caused by free water retaining polar additives DISSOLVED WATER ISSUES: • Faster oil oxidation caused by dissolved water accelerating this form of oil degradation – leads to oil acidity, thickening, varnishes, sludge & resins • Reduced Fatigue life caused by dissolved water promoting propagation of fatigue cracks in metals • Demolition of Ester-based fluids and additives caused by dissolved water reacting with esters – hydrolysis - results in formation of acids, gels, and loss of additives

Presenter

Presentation Notes

Read each as they come up by mouse click. Free water can cause the following failure modes: Dissolved water can cause the following failure modes.

Taking a sample from pressure header

Taking a sample from stagnant fluid

SYRINGE VACUUM BOTTLE

RESERVOIRS

THROTTLE VALVE

Sources of Error Possible Sample Locations

PRESSURE HEADER

Presenter

Presentation Notes

Where are samples taken? First method – throttle high pressure fluid from the pressure header downstream of hydraulic or lube pump. Second method – Taking samples from the reservoir via vacuum removal methods.

Definitions:

Saturation Point: • max. amount of water that can be dissolved in the

fluid at a specific temperature • measured in ppm – max level is fluid dependent

Saturation Level: • the percentage of water dissolved in the fluid

relative to the saturation point • measured in % - max level should be less than or

equal to 50%.

Example: Reservoir Extraction with auxiliary pump

suction hose near surface

suction hose near bottom

Example: Reservoir Extraction with Auxiliary Pump

Point at which suction hose was lowered slowly to the bottom of the tank.

ISO CLASS INCREASE FROM 15 TO 20 IS EQUIVALENT TO AN INCREASE IN PARTICLE COUNT OF 32 TIMES!

Sources of Error-Reservoir sampling

Sources of Error Point of Extraction - Test Connection Arrangement

Point of Extraction - Where in the System is the best representation of system fluid cleanliness?

TEST POINT SHOULD BE LOCATED IMMEDIATELY DOWN STREAM OF

HYDRAULIC OR LUBE PUMP, BEFORE FILTRATION, BEFORE

CONTROL AND BEFORE ACTUATION.

HPU

Presenter

Presentation Notes

The best point to take fluid samples would be immediately down stream of the hydraulic pump before filtration, control, or actuation as shown above

IDEAL SAMPLE POINT-GEAR LUBE SYSTEM

IDEAL SAMPLE POINT LOCATION

Presenter

Presentation Notes

The best point to take fluid samples would be immediately down stream of the lube oil pump before filtration, or control devices.

• Leaving sample bottles open too long

• Using previously contaminated bottles

• Being unaware of system operation immediately before sampling – possibly resulting in inaccurate analysis and conclusions from sample report data.

• Improper handling of sample causing contamination from hands, atmosphere, chemicals and water.

• Failure to flush sampling ports and lines before sampling results in readings that include built up deposits of dirt and sludge in lines.

Note: Such errors are likely to result in higher contamination readings than actual.

Sources of Error Sampling Errors caused by:

Presenter

Presentation Notes

In taking fluid samples, be aware of the following: Read each bullet.

Element Technology

Hydraulic Power Unit Cylinder actuator

Control Valve

Pressure filter

Main Hydraulic Pump

Reservior

Single Pressure filtration strategy

• COST OF FACILITY PREP • COST OF DESIGN AND ACQUISITION • COST OF MACHINE • COST OF UTILITIES • COST OF INSTALLATION & STARTUP • COST OF RUNNING MACHINE • COST OF MAINTAINANCE • COST OF DECOMMISSIONING • COST OF REMOVAL/DISPOSAL

$$$$

Cost of single standard filtration

Strategy

Loss of component efficiency due to wear

(non-efficient operation)- System performance degradation

System downtime costs resulting from component failures-

Can not produce product

Decrease in product quality resulting

from poor control and operation – higher

rejection rates

Equipment & component repair and

Replacement – labor & component costs

Contamination Control

Pressure filter

Reservoir

Return filter

Kidney loop filter

Main Hydraulic Pump

SERVO

Cylinder actuator

Hydraulic Power Unit Comprehensive and/or Balanced Filtration Strategy

Cost of a comprehensive balanced filtration system

System downtime Costs resulting from Component failures

Decrease in product Quality resulting from

Poor control and operation

Equipment & component repair and

replacement

Small investment for comprehensive filtration results in shrinking entire maintenance, quality, and manufacturing budget.

Loss of component Efficiency due to wear

(non-efficient operation)

Hydraulic Power Unit Investment:

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

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

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

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

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

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

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

Target Target Target Target Current

Cleanliness

Required New Machine Cleanliness Fluid Cleanliness vs. Service Life

Cleanup 5 ISO Codes (32 times cleaner) yields a life extension factor of 4 times

5 ISO CLASS IMPROVEMENT

Machinery Life Extension Factor

Curre

nt M

achi

ne C

leanl

ines

s (IS

O Co

de)

Hydraulics and Diesel Engines

Rolling Element Bearing

Journal Bearing and Turbo Machinery

Gear Boxes and Other

Ref. Noria Corporation

Features of a High Quality Element

BETAMICRON 4 Features optimization of all element performance characteristics

• High ßx-values (efficiency)

• High ßx-value stability

• High dirt holding capacity

• Low long term pressure drop

• High collapse stability

• High flow fatigue stability

• Wide fluid compatibility

• Structrual pleat support with resilience and

memory

BETAMICRON 4 ABSOLUTE NON-WOVEN SYNTHETIC

Nickel or (Tin) Coated End Caps and Support Tubes

- Nickel (Tin) Coating Allows the Use of One Standard Element for ALL Application Needs.

High BETA Efficiency

High BETA Stability in severe dynamic fluid conditions over element life

High Dirt holding capacity

High degree of pleat stability & support due to high quality structrual design

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.

Multi-Pass Testing ISO 16889: 1999

The Test Lab Real Life

• Steady Flow • No Fatigue Cycles • Constant Dirt • “Ingression Rate” to Filter • Single Fluid Used • Temperature 100°F • ISO Medium Test Dust • Accelerated Element Life

• Continuous Variations • Millions of Fatigue Cycles • Always Changing • Wide Variety • -40°F to 210°F • Debris, Water, Air • Months

What is Dynamic Filter Performance? Filters that Perform in REAL LIFE!

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 Ratio remains at a relatively constant level at high pressure drops beyond normal element operating ranges with high beta stability.

Beta 100 Stability = 210 psi means that: Beta Ratio at the rated micron will not drop below Beta Ratio = 100 until 210 PSID

Beta Stability ISO 16889: 1999

Point of element failure

High ßx-Values / High ßx-Value Stability

Element 1

Element 2

10000

1000

100

Poor Beta Stability Causes a loss of adequate protection from the point that Beta drops below manufacturer’s 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

• 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

High Dirt Holding Capacity ISO 16889: 1999

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

72

INDICATOR TRIP POINT Element Terminal Pressure

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


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Contamination Fundamentals - …Abrasion Wear 8 µ 5µ This 4 micron wide particle is able to float...

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