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Hydraulic Fluid Service SeminarInnotek Filtration Training Seminar
Filtration Training Seminar
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Contamination Fundamentals
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Cost Savings through Fluid Service!• Effective filtration practices and in-depth monitoringand evaluation of fluid attribute changes in hydraulicand lubrication systems, provides alerts that lead tocorrective actions that will prevent breakdowns andincrease the life expectancy of important andexpensive hydraulic and lube system components .
• The high costs of component repair and systemdowntime can be kept to a minimum through a fluidservice program that includes using and maintainingthe proper system filtration and monitor ing equipment.
WINDOW TO THE PROCESS !
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Fluid Contamination is Expensive
for ALL Industries!
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Contamination
THE ENEMY
TOMODERNHYDRAULIC
SYSTEMS
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Fluid Analysis Terminology
• Forms of Contamination• Particulates/water/gases
• Sources of Contamination
• Effects of Contamination• ISO/NAS Codes• Fluid analysis/measurement• Particle counter• Method & Location of sampling• Measurement error
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Types of Contamination
SOLIDS
LIQUIDS
GASES
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Particle Size Diameter Comparison
Human Hair = 80 micron
1 m = 0.001 mm = 0.000039”
Particle5 micron
Particle15 micron
The human eye can only seeparticles sized down to 40 microns .
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ISO / NAS codes: Are a measure of
particles/particulate per aspecific volume of fluid
How do we measure fluid contamination?
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ISO 4406: 1999 (E) - ISO Contamination Code
Number of Particles per 100 ml
ScaleNumber
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 sizeChart cont…
ScaleNumber
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
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Structure of ISO-Code:amount of dirt particles
in a 100 ml samplelarger than these specified sizes:4µm / 6µm / 14µm
Example:
larger than 4µm = 2,234,000larger than 6µm = 195,000larger than 14µm = 4,250
ISO Code = / /
22
22
18
18
13
13
How do we measure fluid contamination?
4µm / 6µm / 14µm
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Structure of ISO-Code:amount of dirt particles
in a 100 ml samplelarger than these specified sizes:4µm / 6µm / 14µm
Example:
larger than 4µm = 2,234,000
ISO Code = / /
22
22
How do we measure fluid contamination?
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Structure of ISO-Code:amount of dirt particles
in a 100 ml samplelarger than these specified sizes:4µm / 6µm / 14µm
Example:
larger than 4µm = 2,234,000larger than 6µm = 195,000
ISO Code = / /
22
22
18
18
How do we measure fluid contamination?
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Structure of ISO-Code:amount of dirt particles
in a 100 ml samplelarger than these specified sizes:4µm / 6µm / 14µm
Example:
larger than 4µm = 2,234,000larger than 6µm = 195,000larger than 14µm = 4,250
ISO Code = / /
22
22
18
18
13
13
How do we measure fluid contamination?
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Structure of ISO-Code:amount of dirt particles
in a 100 ml samplelarger than these specified sizes:4µm / 6µm / 14µm
Example:
larger than 4µm = 2,234,000larger than 6µm = 195,000larger than 14µm = 4,250
ISO Code = / /
22
22
18
18
13
13
How do we measure fluid contamination?
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Class 4-6 µm 6-14 µm 14-21 µm >21 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 SAE AS 4059 (previouslyNAS Codes)
How do we measure fluid contamination?
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Cumulative Particles per 100 ml Differential Particles per 100 ml CodeDesignatio
n
CodeDesignation
> 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 AS4059
EquivalentISO 4406
Class
> 4um(c)
>6 um(c) >14um(c)
6 to 14um(c)
14 to 21 um(c) 21 to 38 um(c) 38 to 70um(c)
> 70 um(c)
SizeCode A
SizeCode B
SizeCode 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 Conversio n: SAE AS 4059 – Equivalent ISO 4406 Class Based on ISO 4406: 1999 andSAE AS 4059 Revised 2005-05: Rev E 8/29/07
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servo valve J1: 1 - 4µmJ2: 100 - 450µmJ3: 20 - 80µm
valveJ1: 1 - 25µm
piston pumpJ1: 5 - 40µmJ2: 0.5 - 1µmJ3: 20 - 40µmJ4: 1 - 25µmvane pump
J1: 0.5 - 5µmJ2: 5 - 20µmJ3: 30 - 40µm
gear pumpJ1: 0.5 - 5µmJ2: 0.5 - 5µm
Hydraulic Component Clearances Are Critical andtherefore require strategic f iltration designs to remove the
sized particles that will attack the most critical componentsof the hydraulic system
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Guidelines Data Sheet
Provides ISO target cleanliness levels for various crit ical hydraulic/Lubeoil components and the filter selection that will achieve that
cleanliness level target.
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Hydraulic Component Clearances Are Critical andtherefore require strategic f iltration designs to remove the
sized particles that will attack the most critical componentsof the hydraulic system
5µ8
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Sources of Contamination
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New Oil - Photomicrographs
ISO 16/14/11Demanded by Modern Hydraulic Systems
ISO 17/15/13New Oil as Delivered in Mini-container
ISO 20/18/15New Oil as Delivered in Tanker ISO 23/21/18New Oil as Delivered in Barrels
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Effects of Contamination
CAN EFFECTS OF CONTAMINATION BE STOPPED?
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Air
Gaseous
Water
Liquid
Laminated FabricFibers
Seal AbrasionRubber Hose Particles
Iron, SteelBrass, Bronze
Aluminum
EmeryMetal ScaleRust Particles
Solid
Type of Contamination
Basics of Fluid Contamination
MinimalDamage
Damaging
ExtremelyDamaging
Effects
ChemicalsGases
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Measuring procedures for solid particle contamination
ManualCounting
AutomaticCounting
Microscopic Analysis
In The Field
In The Lab
AutomaticParticle Counters
(APCs)
Electronic Analysis
Counting
Gravimetric Analysis
Weighing
Basics of Fluid Contamination
Non-Homogeneous fluids
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0
2
4
6
8
10
12
14
16
18
20
ISO 17/15/12 ISO 18/16/13 ISO 19/17/14 ISO 20/18/15 ISO 21/19/16 ISO 23/21/17 ISO 24/22/18
I S O M T D m g
/ l
Weighing: Gravimetric Concentration
How do we measure fluid contamination?
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Microscopic analysis
NAS 9 ISO 20/18/15Photomicrograph
How do we measure fluid contamination?
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Basic principle
light obscuration
Light source is an LED light• Durability• Holds calibration• Does not saturate quickly with
high contamination levels
How do we measure fluid contamination?
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The number of pulses equals the number of particles.
Size of Partic les
Number of Particles = Number of Pulses
4 micron
6 micron
14 micron
How do we measure fluid contamination?
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• Karl-Fischer Analysis (chemical) Laboratory• Infrared Spectroscopy (optical) Laboratory
• Turbidity Measurement (optical) Field • Crackle Test (acoustic) Field
• Hydrogen Gas Method (chemical) Field(WTK) Water test kit
• Aqua Sensor - AS-2330 (electronic) Field Installation
How do we measure water content?
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Fluid Analysis Kit
What errors can be madeduring fluid sampling and analysis?
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Foreign media:
(air particulate, O 2, water, oil or
chemicals on hands, etc.)
Type of extraction (static, dynamic)
Point of extraction
- Test Connection Penetrationtype and type of test samplefitting
- Best location to take sample- Disadvantage of fluid samples
Sources of ErrorDoes the sample represent the system cleanliness?
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Taking a sample frompressure header
Taking a samplefrom stagnant fluid
SYRINGEVACUUM BOTTLE
RESERVOIRS
THROTTLE VALVE
Sources of ErrorPossible Sample Locations
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Example:Reservoir Extraction with auxiliary pump
suction hosenear surface
suction hosenear bottom
Example: Reservoir Extraction with Auxiliary Pump
Point at which suction hosewas lowered slowly to thebottom of the tank.
ISO CLASS INCREASE FROM 15 TO 20IS EQUIVALENT TO AN INCREASE INPARTICLE COUNT OF 32 TIMES!
Sources of Error-Reservoir sampling
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Sources of ErrorPoint of Extraction - Test Connection Arrangement
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Sources of ErrorPoint of Extraction - Where in the System is the bestrepresentation of system fluid cleanliness?
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A Snapshot in time - does it representthe system cleanliness? Is it a peak orminimum point?
Sources of ErrorDisadvantages of Oil Sampling
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Sample taken every100 millil iter-real-time
Sources of Error Advantages of Continuous real time on lineMeasurement
This type measurementtracks along with operatingchanges going on in thesystem
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Sources of Error
Major actuationPoint of maximum contamination
Filtration is removing particles
Filtration has reached equilibrium
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Pressure f ilter
Reservoir
Return filter
Kidney loop
filter
Main Hydraulic Pump
SERVO
Cylinder actuator
Hydraulic Power Unit
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• Leaving sample bottles open too long
• Using previously contaminated bottles
• Unaware of system operation immediately beforesampling resulting in inaccurate analysis andconclusions.
• Improper handling causing contamination from hands
• Failure to flush sampling ports and lines before sampling
Note: Such errors are likely to result in higher contamination readings than
actual.
Sources of Error Sampling Error
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Element Technology
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To assure maximum component life, fluid lifeand superior system and equipment operation?
CONTAMINANT LEVEL POPULATIONS
MUST BE REDUCED TO LEVELSREQUIRED BY CRITICAL SYSTEM
COMPONENTS
HOW ? Through Proper Filtering, Monitoring,
Analysis, and Control
What Can Be Done?
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Cost ofstandard filtration
Loss of componentefficiency due to wear
(non-efficient operation)-System performance degradation
System downtimecosts resulting fromcomponent failures-
Can not produceproduct
Decrease in productquality resulting
from poor control andoperation – higher
rejection rates
Equipment &componentrepair and
Replacement – labor& component costs
Contamination Control
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Cost of a superiorbalanced filtration
system up front
System downtimeCosts resulting fromComponent failures
Decrease in productQuality resulting from
Poor control andoperation
Equipment &component repair and
replacement
Small investment for superior filt ration results inshrinking entire maintenance, quality, and manufacturing budget.
Loss of componentEfficiency due to wear
(non-efficient operation)
Contamination Control
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5X4X3X2XLife Ext. Factor
14/12/814/12/915/13/1016/14/1119/17/14
14/12/915/13/1016/14/1117/15/1220/18/15
15/13/1016/14/1117/15/1218/16/1321/19/16
16/14/1117/15/1218/16/1319/17/1422/20/17
17/15/1218/16/1319/17/1420/18/1523/21/18
18/16/1319/17/1420/18/1521/19/1624/22/19
TargetTargetTargetTargetCurrentCleanliness
Required New Machine CleanlinessFluid Cleanliness / Service Life
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Machinery Life Extension Factor
New Cleanliness Level (ISO Code)
C u r r e n
t M a c
h i n e
C l e a n
l i n e s s (
I S O
C o
d e
)
Hydraulicsand DieselEngines
RolingElementBearing
Journal Bearingand TurboMachinery
Gear Boxesand Other
Ref. Noria Corporation
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Common Filter Terms
Micron => 1 µ m = 0.001 mm = 0.000039”
Pressure Drop across the element
Beta Ratio
Beta StabilityDHC => Dirt holding capacity
Multi-Pass Testing
Filter Indicator
Element co llapse PressureFilter By-Pass
Absolute vs. Nominal Rated Filtrat ion
Surface vs. Depth Fil tration Mechanisms
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Features of a High Quality Element
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High efficiency absolute elementFeatures optimization of allelement performance characterist ics
• High ß x-values (efficiency)
• High ß x-value stability
• High dirt holding capacity
• Low long term pressure drop
• High collapse stability
• High flow fatigue stability• Wide fluid compatibility
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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 TestingISO 16889: 1999
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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!
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Multi-Pass TestingISO 16889: 1999 (ISO Standard for Performing Mult i-Pass Test)
FOR EVERY 1000 PARTICLESSIZED 5 micron OR GREATERTHAT ENTER THE FILTERONE GOES THROUGH
WHEN THE BETA 5 IS = 1000
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Beta Values Versus EfficiencyBeta Value Effic iency 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 1,333Beta 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 200Beta 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
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Beta Values Versus EfficiencyBeta Value Effic iency 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 1,333Beta 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 200Beta 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
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Beta Ratio remains at a relatively constant level at high pressure drops beyondnormal 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 ß x-Values / High ß x-Value Stabili ty
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Poor Beta Stability Causes a loss ofadequate protection from the point that Beta drops
below manufacturer’s published beta specification before the end of element life.
• Significant loss of fil ter efficiency before the end ofelement life
• Loss of equipment through loss of protection
• Increased wear and component failures• Increased downtime• Decrease in Customer Satisfaction
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• Decrease in downtime when indicator is uti lized for change-out indication(Less Element Changes)
• Decrease in replacement element costs (longer lasting-util izing full element capacity)
• Decrease in maintenance/labor costs
High Dirt Holding CapacityISO 16889: 1999
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DHC - Dir t Holding Capacity DHC Measured at Terminal Pressure / Indicator Setting
72
INDICATOR TRIP POINTElement Terminal Pressure
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Superior Element LifePressure Drop Over Element Life Comparison
High efficiency element has higher D/P than a low efficiency elementHYDAC designs elements to increase D/P at a slower rate than others
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ISO 2943 (ISO Standard for Fluid and Material of Construction Compatibility)
Element technologyCompatibil ity with all modern fluids
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Features of a High Quality Elementwith high flow fatigue stability
ISO 3724
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Element Recipe LayersElement Construction for High Efficiency & Performance
White Polyester Outerwrap
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Filter Element Support Core
Downstream SupportMedia & Support Layers
Upstream Support
Superior elements are designed for max. Surface Area
Section Of Supported Element Pleat spring movement
HYDAC optimizes the number of pleats to maximize surface area of the media.
resilience
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Core suppor t tube
Typical Location of Fatigue Failures
Collapsed Pleat Caused byLack of Support in recipe structure
Compressed Pleat Caused byLack of Adequate Support and high flowveloci ty forces.
LostEffective
Area
FLOW
FLOW
HYDAC Elements Designed for Max. Surface AreaSection Of Unsupported Element
FORCE
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Surface Filtration Depth FiltrationWith surface media (paper, metals, polyester) there isno mechanism to hold di rt in place when placing theelement into a dynamic system with high veloci ty flow
changes and a reverse flow surgin g environment.
With depth media as show n above, the particles enterthe media and work their way down into th e pores andpassages to become entrained. This provides themechanism that holds these particles in place whenused in dynamic flow s urging s ystems.
Caking occurs on surface of media underNon-violent non-turbulent flow condit ions
Parti cles enter fibers and become entrained
Filter Element Material Options
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Filter Terms Absolute vs. Nominal
ISO 16889: 1999 CONFORMANCE REQUIRED FOR ABSOLUTE FILTERS Absolute Rated Filter ß x 75 • Beta ratio, efficiency and Dirt holding capacity determined by conducting a
multipass test per ISO 16889: 1999 (filtration) • Most are in fact Fiberglass media.
NO INDUSTRY STANDARD EXISTS FOR NOMINAL FILTERS Nominal Rated Filter • No indust ry standard exists to determine nominal element ratings. • Surface filtration (nominal) applied in actual systems can not achieve dirt
holding capacities derived through multipass testing.• Most are paper, cellulose, polyester, or metals• Beta effic iency and dirt holding are not valid data for nominal media per the
multipass test specification – Depth media only is specified on the ISOspecif ication (ISO 16889: 1999)
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ID: MPT990105 Test Date: 01/21/99Test Component: FILPRO 160D010BN Tested By: HLM
TEST CONDITIONS Fluid: MIL-H-5606 +ASAViscosity: 15.0 cStTest Dust: SAE 5-80Test Flow : 60.0 L/minSpecific Test Flow: 12.8 mm/sBase Upstream Gravimetric Level: 5.0 mg/LTerminal Pressure: 72.0 psiFiltration Area: 782.0 cm2Bubble Point: N/A mmWC (5)
TEST RESULTS Clean Element Pressure: 2.8 psiCollapse Pressure: N/A psiBets 2/20/75: <2.0 / 8.5/12.3 µm per ANSI / (NFPA)TWA Beta 10: 32.7 T3.10.8.8 R1-1990Efficiency: 96.94%Dirt Holding Capacity: 7.9 grams
Specific Dirt Holding Capacity: 10.1 mg/cm2Note: L/min - Liter per minute, mmWC - millimeter water column
Multi-Pass Test Report
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ID: MPT981202 Test Date: 01/21/98Test Component: 0160D010BN3HC Tested By: HLM
TEST CONDITIONS Fluid: MIL-H-5606 +ASAViscosity: 15.0 cStTest Dust: SAE 5-80Test Flow : 60.0 L/minSpecific Test Flow: 8.4 mm/sBase Upstream Gravimetric Level: 5.0 mg/LTerminal Pressure: 72.0 psiFiltration Area: 1194.0 cm2Bubble Point: N/A mmWC (5)
TEST RESULTS Clean Element Pressure: 3.5 psiCollapse Pressure: N/A psiBets 2/20/75: <2.0 / 2.6/4.8 µm per ANSI / (NFPA)TWA Beta 10: 2251 T3.10.8.8 R1-1990Efficiency: 99.94%Dirt Holding Capacity: 16.3 grams
Specific Dirt Holding Capacity: 13.6 mg/cm2Note: L/min - Liter per minute, mmWC - millimeter water column
Multi-Pass Test Report
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TypicalFilter
Configurations
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• Removes contaminants after hydraulic pump• Cost effective with high cost dirt sensitive, components
• Filter before servo offers maximum protection from small particles
Pressure Line Filtration
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Alternative A • Provides maximum in-line protection• Lowest contamination level• Continuous line filtration
Lube System Filtration
Alternative B • Gives cost effective protection• No in-line system pressure drop• Can be single or duplex filter
Alternative AIn-Line Filtr ation
Alternative B
Off-LineFiltration
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Return Line Filtration
• Cost effective for relatively dirt-tolerant systems• Provides limited pump protection
• Not ideal with return flow surges
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Multiple Filters Provide • Maximum protection• Lowest contamination level• Extended element & hydraulic system life
Comprehensive Filtration
Off-Line Filter Provides • High efficient filtration• Continuous filtration• Fill port for filtering new oil
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Fluid Storage Tank Hydraulic SystemReservoirSingle absolute
depth filter
Transfer cart-single filter
Desir ed ISO = 16/14/11Filled from:Mini-totes – 17/15/13Tanker trucks – 20/18/15Metal drums – 23/21/18
Initial ISO code resultsfrom method of delivery
RATINGS UNDER
EQUILIBRIUM CONDITIONS
ISO Codetarget
Micronabsolute
rating
20/18/15 20 micron
19/17/14 10 micron
18/16/13 5 micron
17/15/12 3 micron
Absolute depth filters have an average pore size
of the element rating
Fil El 3 i B 1000
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Filter Element 3 micron Beta=1000
# particles in100,000
# particles out100
For every 1000 particles 3 micron or larger thatenter the element ---- one goes through whenthe filter element is in equilibrium – continuousRe-circulating flow.
Filt El t 3 i B t 1000
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Filter Element 3 micron Beta=1000
# particles in100,000
# particles out100
For every 1000 particles 3 micron or larger thatenter the element ---- one goes through whenthe filter element is in equilibrium – continuousRe-circulating flow.
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Fluid Storage TankHydraulic System
ReservoirDual series absolute
depth filter
Desir ed ISO = 16/14/11
Transfer cart – dual fi lter
Filled from:Mini-totes – 17/15/12Tanker trucks – 20/18/15Metal drums – 23/21/18
Initial ISO code resul tsfrom method of delivery
RATINGS UNDEREQUILIBRIUM CONDITIONS
ISO Codetarget
Micronabsolute
rating
20/18/15 20 micron
19/17/14 10 micron
18/16/13 5 micron
17/15/12 3 micron
Effectively performing as a two pass process
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The design and operation of a
Hydraulics System
• Assess system requirements • Recommend optimum components
for performance and longevity • Monitor & Maintain fluid
characteristics, cleanliness and watercontent
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Assess 1. Determine TCL (target cleanliness level) Based on
• system components• system pressure & environmental conditions
Use this guidelines document found on our websiteIn the Brochures section
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Assess 2. Determine Current Conditions
• particle contamination levels• water content• fluid health (ageing/effectiveness)• fluid sampling changes over time
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Assess 2. Evaluate Current Protection in Place
• to account for ALL sources of contamination
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Assess 2. Evaluate Current Protection in Place
• pressure filters• return line filters• offline filtration loops
• breathers-high integrity and desiccant types• new oil protection – treatment, transfer, polishing• monitoring (sampling)/change-out schedule
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A = Offline Recirculating LoopB = Pressure OR Return FilterC = Pressure OR Return Filter AND Re-circulating LoopD = Pressure AND Return Filter
E = Pressure AND Return Filter AND Re-circulating Loop
Recommend Filtration Upgrades
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Recommend Filtration Upgrades 1. Betafit Elements
• High ß x-values• High ß x-value stability
• High dirt holding capacity• Low long term pressure drop• High collapse stability• High flow fatigue stability• Wide fluid compatibility
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Recommend Filtration Upgrades 2. Addition of Offline Filtration Loops
Vacuum Dehydrator when high water orgas content is present
Off line loop membraneFiltration –Used for solid particulate intransfer and tank kidney loops
Filter coolers when heat is a problem
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Recommend Filtration Upgrades 3. Addition and replacement of high
performance breathers
Breathers Wide variety including:- desiccant for water vapor removal- spin-on- with filler baskets
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Monitor & Maintain1. Contamination Monitoring Devices• Portable & Online• Water Content Sensors
FCU (Portable)Perfect for plants withmany small machines
CS (Permanent)Perfect for larger, critical systemswhere constant, monitoring is required
AS (AquaSensor)Water content sensor
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2. Supplemental Monitoring Techniques• Regular Fluid Sampling & Analysis
Fluid Sampling Kits Provides information about more than contamination:- additive depletion- contamination- water content
- viscosity- wear metals- trending from periodic sampling
Monitor & Maintain
Leads to predictive maintenance decisions
eliminating unplanned shutdowns
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3. Portable Offl ine and Fluid Handling Filtration Loops• Can be used on multiple machines if contamination
levels unexpectedly rise
Monitor & Maintain
Fluid transfer cartswheeled carts
- 2 stage (series)
- Water & solids
Hand-heldtransfer cart
Vacuum dehydrator- Water & aeration removal- Solid particle removal
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The Science of Condition Monitoring
and Contamination ControlCondition Monitoring
Measure and determine the status of system components and fluid health to preventfailure, optimize maintenance practices and fluid processing and/or replacementintervals.
MAINTENANCE
failure oriented preventative
Condition Monitoring
time
status
predicted
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pr
e s
s ur
e
temperature
d a
t a
a c q u
i s i t i on
oil condition
Sensor Arrays for a Full Rangeof fluid conditions monitoring
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Remote Monitoring Capability :Your Hand on the Pulse of the Systems
Machinesor
Equipment
Intranet/Internet
C o n
t r o l r o o m
Levelsensor
Pressuresensor
Temperaturesensor
Contaminationsensor
Aquasensor
SensorMonitoring
Unit
Mobile telephone system
Fixed network E t h e r n e
t
G S M
M o
d e m
Fluid conditionMonitor
D r i v e r
S o
f t w a r e
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Features• Measuring of sol id contamination in hydraulic and lubeoils
after market service and repair• Calibration to ISO 11943
field measurement equipment• Stores up to 3000 measured values• Inlet pressure range 15 - 5075 psi (1 - 350 bar)• Integrated pump for tank sampling• Easy to operate
Portable Online Particle Counter for Service Support
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Contamination Sensors on each machine
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Aqua Sensor for dissolved water on each machine
Main features :
• Measurement of water content in o ilsrelative to the saturation level
• Simultaneous measurementof fluid temperature• High reliability due to compact
and rugged design• Calibration independent of different oil types• Unsusceptible to high pressure pulsation
• Wide fluid temperature r ange
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Features• Measurement of water content in hydraulic and
lubrication oi ls relative to the saturation concentration• Simultaneous measurement of the fluid temperature• Designed for stationary installation
• Standard output options:- 4-20mA analog outputs for percent
saturation and temperature
- switch/alarm outputs- serial RS485 interface- integrated display
Aqua Sensor with readout
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Features• Vane pump for
• hydraulic oils• low cost
• Gear pump 5 - 19 GPM (18 - 72 l/min)• Viscosity up to (1000 mm 2/s)• for higher dirt quantity
• Integrated pressure relief valve• Filter element type Dimicron ® membrane
• high dirt holding capacity• reduced filtration costs• excellent single pass filt ration
Stationary Single Pass Filtration units
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Membrane type Dimicron®
fil ter elements nominal flow rate per element 15 l/mindirt holding capacity per element = 500 g (ISOMTD)ß 2 > 1000 @ dp = 2 barincinerable
Stationary Single Pass Filtration units
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Fluid Conditioning – Water
Removing SystemsFunctions:
Dewatering (vacuum
dehydration)
Filtering
Degassing (de-aeration)
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Appl ications in Power generation :Lube system for steam turbinesHydraulic steam control system
• Mineral oi l based
• Phosphate ester only wi th rotary vane vacuum pumpGear box cooling water pumpLube system boiler feed pumpOil storage
Appl ications in s teel indus tr y:Hydraulic or Lube system for roller bearing (Morgoil system)
Appl ications in Pulp and Paper :Main lube system or wet end hydraulic
Fluid Conditioning System
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