LUBRICATION

A Technical Publication Devoted to the Selection and Use of Lubricants Published By Texaco Inc. 2000 Westchester Avenue White Plains, NY 10650
Volume 87 Number 1 January, 2001
To request a new subscription or to report a change of address (enclose mailing label), please write to: Robert J. Taylor, Texaco Inc., 1111 Bagby Street, Houston, TX 77002; or by e-mail: lubricationmagazine@texaco.com Copyright 2001 by Texaco Inc. All Rights Reserved. Materials may not be reproduced or reprinted without written permission of Texaco Inc.

TECHNICAL EDITOR: LYNNE L. MEGNIN MANAGING EDITOR: JAMES B. COLEY PRODUCED BY: BAKER PRINTING, BAKER, LA

HYDRAULIC FLUID CLEANLINESS

INTRODUCTION
Anyone who has dealt with hydraulic systems for any length of time will admit that hydraulic systems have evolved from a simplistic, crude state into extremely complex systems in a relatively short time. Some essential reference points in the development of hydraulic systems include the building of the pyramids and the scientific research of Blaise Pascal and Albert Einstein. The first documented use of hydraulic technology applied as a labor saving technology occurred during the construction of the Egyptian pyramids. Over a thousand years later in the 1600s, Pascal discovered hydraulics as a science. Through that discovery came Pascals Law which states, Pressure exerted on a confined fluid is transmitted throughout the fluid, undiminished, in all directions and acts with equal force on all equal areas. Three hundred years later in the early 1900s, Albert Einstein said this about hydraulics, Why is it that this magnificent applied science, which makes life easier and reduces work, bring us little happiness? The simple answer runs because we have not yet learned to make sensible use of it. One look at the hydraulics equipment associated with the PLC (programmable logic controller) controlled robotics in use today is all it takes to know that todays hydraulic systems are very sophisticated and that we are now taking advantage of this magnificent applied science. Unfortunately, hydraulic fluid handling practices have not advanced at the same rate as the equipment. For that reason, much of todays sophisticated hydraulic equipment fails prematurely and does not live up to its projected performance potential. Close examination of failed components has revealed that more than four times as

LUBRICATION many hydraulic system failures are caused by improper fluid condition than all other causes combined. This fact makes it imperative that the message concerning the importance of hydraulic fluid cleanliness and how to achieve a state of cleanliness be conveyed to hydraulic fluid users. This article will examine the meaning of cleanliness, discuss contamination sources, and offer solutions to promote fluid and system cleanliness. equipment warranty on the continuous maintenance of specified cleanliness levels. If a system reaches unacceptable cleanliness levels and the condition is not quickly corrected, the warranty will be voided.

TYPES OF CONTAMINATION
Contamination can take several forms, including, but not limited to: 1. Metallic Particulate is normally the by-product of metallic component wear. Environmental dust, dirt from construction or maintenance, or anything that can breakdown into small pieces can also be classified as particulate. Circulation of a slurry of fluid and particulate will generate even more particulate from abrasion. The particles generated internally will be harder than the surfaces from which they came, thus becoming even more damaging to machine surfaces. 2. Foreign Materials such as pieces of gasket material, gasket sealers such as silicone sealant, damaged O-rings, debris from the construction or assembly process, welding buckshot, and material introduced during start-up and normal operation all contribute to contamination of hydraulic systems. 3. Other Hydraulic Fluids or Formulas are normally introduced during the filling process. This contamination can come from the equipment used to transfer hydraulic fluid from storage containers to the system. Hand pumps, hoses, storage drums, and vessels are all typical sources of fluid contamination. 4. Water can form through the simple process of atmospheric condensation in a vented-to-atmosphere system. Maintenance personnel washing down an area can introduce water into a hydraulic system by

HOW CLEAN IS CLEAN?

Cleanliness is a relative term, which prompts us to ask, How clean is clean? The degree or level of cleanliness in one application may not be sufficient in another. For example, the required cleanliness for the fluid in a hydraulic floor jack is substantially different than for the fluids used in manufacturing machine robotics; yet, they are both hydraulic systems. For this reason we must define clean. The term clean, as referred to in this article, describes the cleanliness of the hydraulic fluid and the hydraulic system. Clean hydraulic systems are defined by a quantifiable, measurable level of particulate, foreign matter, other hydraulic fluids or formulas, and water or moisture. The concentration of these contaminants determines the degree of cleanliness of the hydraulic fluid. The importance of maintaining a clean hydraulic system cannot be ignored. Because of the large number of contamination related system failures, the NFPA (National Fluid Power Association) and ANSI (American National Standards Institute) have established minimum system cleanliness standards. From the use of these standards, target cleanliness levels can be established for each application. The basis of the individual targets must be set to the most sensitive component in the system. The most common cause cited for denial of warranty claims in hydraulic systems is contamination. Many original equipment manufacturers are now predicating the

LUBRICATION inadvertently directing the water hose at a vent on a reservoir, or washing a reservoir that is not completely sealed. 5. Gases caused by aeration, cavitation, or poor design can contaminate a hydraulic system. Sources for gases can be leaking pump seals, pump suction side leaks, or the oil being returned to the bulk fluid above, rather than below, oil level. There is a common belief among hydraulic fluid users that if the hydraulic fluid supplier would just deliver clean fluid, there would not be a problem. Unfortunately, excessive particulate contamination can occur from many sources. Every time a hydraulic fluid is handled the particulate contamination increases. For example, particulate can be introduced when new hydraulic oil is blended, pumped, packaged, transferred, pumped into a new system, or added to an active system. These are not the only sources for particulate. Each source contributes a little and eventually the level of contamination can become excessive if measures are not taken to control it. It is true that new hydraulic fluid should be clean. However, a target cleanliness level must be determined first. The fluid supplier is trying to supply a fluid that is cost competitive and will perform the desired task for many, many applications. Supplying fluids that are totally particulate-free would drive the cost of the fluid excessively high. In reality, the only point at which the particulate level is truly critical is in the hydraulic system itself. For that reason it is recommended that the required hydraulic fluid cleanliness level be determined and that target be met as the fluid is pumped into the application. Even if the new hydraulic fluid is clean when it is delivered, if it is pumped into a storage tank that is grossly contaminated, any efforts to deliver clean fluid will be wasted. Many end users tend to overlook the cleanliness of their own storage tanks. They also fail to realize that their storage tanks can be a major source for contamination if they are not vented properly. Also, if the storage tanks are equipped with steam coils, as many of them are, they occasionally leak steam condensate into the hydraulic fluid. The following is a generic, logical path to insure the best opportunity for favorable fluid performance: 1. Insure that the proper fluid and viscosity are being used. 2. Insure that the storage container is clean and dry.

SOURCES OF CONTAMINATION
NEW HYDRAULIC OIL New hydraulic oil is formulated to optimize system performance by: Being non-compressible Reducing friction Reducing component wear Transferring heat easily Separating water easily Releasing entrained air quickly Providing a viscous seal Each oil formulation is tested for all of these attributes and several performance characteristics. It is also tested for compatibility with other hydraulic fluids. All of these tests are performed with clean, dry fluids, and there is not a test that includes contamination with particulate and/or water. Therefore, for the fluid to perform in a hydraulic system the same way it performed in the tests, it must be kept clean and dry. For those who might think there should be a test that includes particulate and water, there are simply too many different types, amounts, and combinations of particulate and fluids that occur in hydraulic systems for this to be feasible. The thin fluid film is what the moving parts are supposed to be riding on. However, if the particulate is larger in diameter than the thickness of the fluid film, it is easy to see that the moving parts will be riding on the particulate rather than the fluid film. Any test that might be developed which includes particulate would not be reflecting fluid performance.

LUBRICATION 3. Insure that the storage container is vented properly by using the appropriate vent filter. 4. Insure clean fluid is delivered by establishing a reasonable target cleanliness level and have the fluid filtered to the target level, or cleaner, when it is pumped into the storage tank, tote, or other storage container. 5. Read the certificate of analysis (C of A) to determine the moisture content of the new fluid. 6. Establish the appropriate target cleanliness level and circulate the fluid in the storage container through a kidney loop filtration system until the target is met and can be maintained. 7. Filter the fluid any time it is transferred from the storage container. 8. Filter the fluid as it is transferred into the active system. 9. Determine and maintain the system target cleanliness level with either the filtration designed into the system or by using a kidney loop filtration system attached to the hydraulic system. 10. Set-up a monitoring schedule and submit representative samples of the fluid for testing. 11. Insure that everyone that can affect the test results sees and understands the test results, including the clean-up people and the person that enters the results in the computer or other data monitoring form. If this path is taken, the particulate level of the new fluid will be reduced because the checks and balances will be in place to capture any contamination before it gets to the active system. HYDRAULIC SYSTEM CONSTRUCTION When a hydraulic system is constructed, contaminants are produced by the construction process. Cutting, grinding, welding, excess gasket sealers, excess bolt thread dressing, and general construction atmospheric dust all contribute to an unclean system. A newly constructed system must be thoroughly cleaned and flushed to insure maximum cleanliness. Introducing new, clean hydraulic fluid to a dirty system will do little, if anything, to slow component wear or prevent system failure. INGRESSED MATERIALS Contamination of a hydraulic system also occurs from ingression of materials. An example of ingressed material is a reservoir which has a 3 diameter oil return line, entering a 10 diameter hole in the top of the reservoir. The 10 hole exists to allow for return line movement during operation. This opening offers an excellent point for contamination ingression. Particulate in the atmosphere, water from area wash downs, and manufacturing debris will find their way into the opening and contaminate the fluid reservoir. A simple rubber or leather boot attached to the surface of the reservoir and the return pipe to fill the gap will solve the problem and reduce fluid contamination. In order to prevent ingress of particulate through the system vent, the proper system vent must be installed. As hydraulic system fluid demands change, the fluid level rises and falls causing air to enter and exit the space above the fluid level in the reservoir. This action is commonly referred to as breathing. If the vent is not properly filtered, particulate from the atmosphere will enter the vent hole and contaminate the fluid. Another example of particulate ingress is on the rod end of a hydraulic cylinder. As the rod is extended, it is wiped off by a wiper and the oil seal. However, a very thin oil film will still be present and air borne particulate will deposit on the extended, wet rod. When the rod is retracted, some of the particulate will get past the seal and wiper and be washed off the rod by the fluid inside the cylinder. The better the condition of the seal, the less likely this will be a problem.

LUBRICATION INTERNAL GENERATION Internal generation of contaminants is unavoidable in an operating system. Normal wear of moving parts causes particulate that will serve to reduce the efficiency of the system. If not dealt with, the normal wear will degrade the system and its components. Particle concentrations in hydraulic fluid are abrasive. Abrasive wear to components increases the particle concentrations in the fluid. Correct filtering and properly located filters can dramatically reduce their damaging effects. MAINTENANCE ACTIVITIES Many times maintenance activities performed on hydraulic systems produce contamination. Opening a reservoir in an extremely dusty environment will cause a dramatic increase in particle count. Disassembly and re-assembly of components often introduces foreign material into the system. Excess gasket dressing, pipe thread sealant, thread cutting oils from replacement piping, and old gasket material often find their way into the hydraulic system. The paper-like qualities of gasket material serve to block the surface of filter media and reduce the efficiency of the filter. Even small quantities of thread cutting fluid or any foreign fluids can negatively impact the hydraulic fluid formulation. Any change to the hydraulic fluid that alters the compressibility, lubrication qualities, or particulate concentrations will degrade the efficiency and life of the system. HEAT Heat is another form of fluid contamination. Most hydraulic fluids are not designed to operate at excessively high temperatures. In fact, if the hydraulic fluid is allowed to exceed critical temperature, the chemical structure changes, viscosity varies, and usable life is drastically reduced. This critical temperature is typically 140F (60C). It has been said that for every 18F (10C) of fluid temperature increase above the critical temperature, the fluid oxidation rate doubles and the fluid life is cut in half. This number can change both for the better or worse, depending on the fluid in question, with the extremes being synthetics and biodegradables. Heat sources include: Improper system design Pump cavitation or aeration Wrong fluid Wrong fluid viscosity Ingression of air and compression of the entrained air Wrong application of equipment Failure of or absence of heat exchanger Inadequate temperature differential between ambient and heat exchanger Lack of shrouding of exchanger to force direction of cooling air Forcing too much oil through the relief valve (poor system design) MOISTURE Moisture is a very common form of contamination in hydraulic systems. Quite often, the moisture comes from the atmosphere around the reservoir. The moisture condenses in the vapor space above the oil level in the reservoir on the cooler interior metal walls and roof of the reservoir. If the interior walls of the reservoir are not protected adequately by an appropriate coating, the moisture will cause rust to form. The rust will flake off into the hydraulic fluid where it will be carried into the inlet of the pump and distributed throughout the entire system. Reservoir vent filters can aid in reducing or eliminating the introduction of moisture from the atmosphere by incorporating water barrier technology in their filter matrix. Water can also enter the system through inspection holes and through other service openings, if the opening covers are not replaced and resealed after each maintenance event. Rain and area wash downs can introduce

LUBRICATION water into hydraulic systems through these unsecured openings. Water and oil heat exchangers, which should be pressure tested before placed in service, are sometimes used to control the hydraulic fluid temperature. If the tube bundle in the exchanger leaks, water will enter the hydraulic fluid and be distributed throughout the system. Poor fluid storage practices can often introduce water into a hydraulic system. Many times, drums of hydraulic fluid are stored near a hydraulic system for convenience. The drum is usually unprotected from the environment, rain, dust, dirt, and area wash downs. The top of the drum becomes contaminated with all these materials, and when opened to add fluid to the system, the contamination flows directly into the open drum. When drums are left upright the head (top) of the drum is often filled with rainwater. If the drum opening is not sealed properly, the naturally occurring heating and cooling effects of the drum can cause water on the head of the drum to be pulled through the threads and into the fluid. If free water is allowed to remain in the hydraulic system, bacterial growth can occur. Once excess moisture is present, all the conditions required to create such a reaction inside a normal hydraulic system are present. Moisture, air, oil, and heat can create some very undesirable reaction byproducts such as odor, rust, chemical changes to additives, and increased oxidation rate. Every effort should be made to reduce the amount of moisture in a hydraulic system. The corrosion damage caused by moisture contamination contributes to system failure, increased maintenance costs, and more frequently occurring downtime. cost analysis must be administered to determine if a redesign of the system is the correct solution. Consider the following example: The problem is excess contamination, overheated fluid, and poor maintenance practices. The system reservoir is located under the electrically heated equipment where the ambient temperature is approximately 135F. The area is washed down frequently with water. The high ambient air temperature condition was created when several units were configured to reduce heat losses and reduce electrical power requirements. The original design called for the reservoirs to be positioned so that adequate heat dissipation could be accomplished by ventilating the space. It is important at this point to remember that one of the functions of the reservoir is heat dissipation through the walls. The improved heat loss reducing configuration of the machines has caused the majority of the hydraulic system failures. Because the area is so hot, it is difficult to get maintenance personnel to enter the area to work. Those who enter the area cannot remain very long. Hydraulic fluid leaks persist and the oxidation rate increases because the high ambient temperatures reduce heat radiation capability. The return line to the reservoir also introduces fluid into the reservoir above the fluid level. This causes air to become mixed into the fluid. These air bubbles enter the pump and are compressed. This results in adiabatic compression, the results of which can be seen in the following examples: Air bubble at 70F and 14.7 psi: -Compressed bubble to 1,000 psi = over 1,300F; a 985 psi increase causes a 1,230F temperature increase. -Compressed bubble to 10,000 psi = 3,000F; a 9,930 psi increase causes a 2,930F temperature increase. The heat generated by adiabatic compression occurs at the surface of the bubble and dissipates quickly in the fluid. However, if it is allowed to continue, the effects are mani-

COMMON FAILURE CONDITIONS

INADEQUATE DESIGN Existing hydraulic systems with contamination problems are frequently caused by inadequate design. System design failures are often the most difficult to resolve. A real

LUBRICATION fest as a steady increase in overall system temperature. Once this starts occurring, heat exchange capabilities of the system must be adequate to handle the extra heat. Handling of excess heat translates into money spent unnecessarily. One of the functions of the reservoir is to radiate heat. It is often thought that if the reservoir is large, then heat exchangers are not necessary. Here is an example of why that thinking is flawed. If a 200 gallon reservoir in location with a 30F temperature differential (ambient cooling air is approximately 30F cooler than the oil during stable operating conditions), the reservoir can only shed approximately one-half horsepower (Hp) of heat. As fluid temperatures increase, the lubricating qualities, viscosity, and film thickness of the fluid diminish resulting in component wear, particulate generation, and system failure. The combination of high ambient temperatures, inadequate maintenance, and adiabatic compression produce frequent component failures, increased maintenance cost, and excessive downtime resulting in reduced profits. In this example, it is clear that a comparison of the savings realized by the new heat loss reducing design and the increased cost associate with hydraulic system expense and down time is needed. At least superficially, it appears that this system is doomed to fail completely. One of the best solution to an inadequate design problem, such as the one shown in Figure 1, is to relocate the machines so adequate reservoir heat radiation and oil cooling can occur. However, the production requirements and budget of the facility cannot tolerate shutdown, redesign, and relocation. Situations like this demonstrate the need for serious consideration of target cleanliness levels and system maintenance during the design phase of any hydraulic system. The system in Figure 1 could be significantly improved by the addition of a heat exchanger on the hydraulic fluid reservoir.

Control Panel
Hydraulic Reservoir (below press)

Control Panel
Hydraulic Reservoir (below press)

Control Panel
Hydraulic Reservoir (below press)

ELECTRICALLY HEATED HYDRAULIC PRESS

ELECTRICALLY HEATED HYDRAULIC PRESS

ELECTRICALLY HEATED HYDRAULIC PRESS

PLASTIC CURTAIN

Ambient Temperature in this area (Hydraulic System Cooling Air) ~ 135F

PLASTIC CURTAIN

ELECTRICALLY HEATED HYDRAULIC PRESS

ELECTRICALLY HEATED HYDRAULIC PRESS

ELECTRICALLY HEATED HYDRAULIC PRESS

Hydraulic Reservoir (below press)

Hydraulic Reservoir (below press)

Hydraulic Reservoir (below press)

Control Panel

Control Panel

Control Panel

Figure 1 - Inadequate Design

LUBRICATION OTHER FLUIDS Ashless (Zinc-free) Fluids In some cases, different hydraulic fluid formulations can contaminate the system by creating reaction by-products. If a user is currently using a zinc-containing hydraulic fluid and decides to replace it with an ashless (non-zinc containing) fluid, the entire system must be drained and flushed thoroughly. A mixture of a zinccontaining fluid and an ashless fluid can cause a reaction, which can form salts that will eventually plug system filters. This is primarily a function of the difference in pH between the two products, caused by different additive chemistries. The fluid and equipment suppliers should be consulted concerning proper flushing procedures and cleaning methods when the user switches from one fluid to another. Mineral Oil and Synthetic Fluids Another problem can occur when a hydraulic system is switched from a mineral oil based hydraulic fluid to a synthetic fluid. If the entire system is not drained and flushed thoroughly, the expected advantages of the synthetic fluid may be compromised by the presence of the mineral oil. Changing hydraulic fluid types can only be done properly if the system is thoroughly drained and cleaned of all the other fluid prior to introducing a new fluid. There can also be adverse effects from introducing a synthetic fluid to a system that has seals that are not compatible with synthetics. The effects of the fluid on elastomers should be readily available from the system designer, seal manufacturer, or the fluid supplier. Biodegradables Another cause for concern is when mineral oils are replaced with biodegradable fluids. There is an old proverb that states, Be careful what you ask for, because you just might get it. The same holds true here for biodegradable fluids. The primary focus during biodegradable oil formulation is making a product that can degrade easily. It is feasible that some of these fluids could degrade while in storage, before even being introduced to the hydraulic system. It is important to understand that all hydraulic fluids are biodegradable. In fact, everything is biodegradable. It is just a matter of what conditions are necessary and how much time it takes something to biodegrade. With respect to hydraulic fluids, biodegradability is simply a matter of how quickly it changes from its original form into a chemical form that is environmentally innocuous (water, carbon dioxide, mineral salts, and biomass). For something to be classified as readily biodegradable it must meet accepted standard test criteria, which specifically state how quickly it becomes environmentally innocuous. Unfortunately, all the components needed to promote biodegradability such as heat, entrained air, and water are commonly present in hydraulic systems. This presence directly affects the rate at which biodegradable fluids break down. Great care must be taken to remove air and water from a system containing biodegradable fluids. Heat buildup must also be kept to a minimum. If the system is not properly controlled, biological growth and extremely noxious odor will result. At this point, the system must be shutdown and thoroughly cleaned in order to meet biological cleanliness levels. Above average temperature control of biodegradable fluids should also be used. Biodegradable fluids should operate at temperatures at or below 140F. If the fluid is allowed to exceed 140F, oxidation of the fluid increases rapidly and the fluid life is shortened dramatically. Changing to biodegradable fluids requires a thorough

LUBRICATION cleaning of the system. Failure to properly clean the system can increase biodegradability and increase toxicity of the fluid in the system, especially if a mixture of other fluids, air, and water can change the biodegradability of the fluid to an undesirable level. OXIDATION Oxidation is another source of hydraulic fluid failure. Oxidation occurs when oxygen reacts with the oil to form a multitude of compounds. The first reactions form unstable hydroperoxides. The hydroperoxides react to form alcohols, aldehydes, ketones, acids, and oxy-acids that are soluble in oil. These acidic products increase the viscosity of the oil and can be corrosive to metal in the system. Polymerization and condensation reactions produce insoluble gum, sludge, and varnish. These products serve to plug openings, increase wear, cause the system to become sluggish in operation, and reduce clearances making the system ultimately inoperable. Temperature is a primary accelerator of oil oxidation, as well as moisture, dirt, metal particles, paint, joint compounds, and insoluble oxidation products. The rate of oxidation will approximately double for every 18F (10C) rise above 140F (60C) in fluid temperature. The life of the hydraulic fluid is cut in half with just 1% sludge concentration because contamination makes the oxidation rate double. Metal particulate, such as copper, iron, nickel, brass, and steel, are known to promote catalytic reactions and accelerate oil oxidation. This catalytic reaction is further enhanced by the presence of water. In the first stages of oxidation, both the viscosity and the neutralization number of the oil will increase. The neutralization number is commonly used to determine when oil oxidation has progressed to the point where the oil becomes aggressive and should be replaced. The varnishes that are formed during oxidation will deposit on shiny metal surfaces, such as directional valve spools and the internals of servo valves. This will result in sticky operation and/or sluggish performance. The sticking of directional valve spools causes more electrical solenoid failures than all other causes combined.

SETTING TARGET CLEANLINESS LEVELS

Target cleanliness levels, in this context, represent the maximum contamination levels at which hydraulic fluids can be expected to function as designed and achieve optimum equipment performance and reliability. The cleanliness target must meet the requirements of the most sensitive component in the system combined with system pressure and safety considerations. The consequences of failing to set target cleanliness levels for every hydraulic system, and not exceeding those targets, is reduced system life, decreased fluid life, and greater safety risks. Down time and overall system operation and maintenance costs will also be higher. Particle contamination is typically made up of sand, silica, loam, tiny metal particles, wood fibers, rags, oil absorbent materials, or any other solid material that can be broken down into small particles. Particulate can cause problems, such as blocking small openings, if the particles are too large. This can be especially harmful if the opening is a control orifice. If the particle is about the same size as the clearances in pumps or motors, it may enter the opening and then become trapped between the moving surfaces. This can cause abrasive wear, which produces more particulate that further contaminates the system. It is also important to recognize that very few particles are round. They are usually irregular in shape and have many sharp edges that create more system wear as

LUBRICATION they are circulated. The particulates lodge themselves in valves, which can result in burned out electrical solenoids. Very small particles referred to as silt flow through the system without much restriction. Due to high velocity streams and directional changes in flow, impingement of these particles on surfaces causes erosion that increases the clearance between moving parts and in control orifices. This promotes internal leakage and generates additional wear particles that
PUMPS Pressure Fixed Gear Fixed Vane Fixed Piston Variable Vane Variable Piston VALVES Pressure Directional (solenoid) Pressure Control (modulating) Flow Controls (standard) Check Valves Cartridge Valves Screw-in Valves Prefill Load-sensing Directional Valves Hydraulic Remote Controls Proportional Directional (throttle valves) Proportional Pressure Controls Proportional Cartridge Valves Proportional Screw-In Valves Servo Valves ACTUATORS Pressure Cylinders Vane Motors Axial Piston Motors Gear Motors Radial Piston Motors Swash Plate Design Motors HYDROSTATIC TRANSMISSIONS Pressure

further degrade the system. This has a negative impact on system control performance and repeatability. The velocity through temporary or permanent orifices changes with plugging or erosion as the size of the hole changes. As the hole changes in size, the velocity of the fluid and particulate passing through it also changes. Velocity change results in a change in the erosion dynamics. The size of particulate contamination varies from visible materials to the unaided
140 - 210 bar 2,000 - 3,000 psi 19/17/15 19/17/14 18/16/14 18/16/14 17/15/13 <210 bar <3,000 psi 20/18/15 19/17/14 19/17/14 20/18/15 20/18/15 18/16/13 20/18/15 18/16/14 18/16/13 18/16/13 18/16/13 18/16/13 18/16/13 16/14/11* 210+ bar 3,000+ bar 18/16/13 18/16/13 17/15/13 17/15/13 16/14/12 210+ bar 3,000+ psi 19/17/14 19/17/14 19/17/14 20/18/15 19/17/14 17/15/12 19/17/14 17/15/13 17/15/12 17/15/12* 17/15/12* 17/15/12* 17/15/12 15/13/10* 210+ bar 3,000+ psi 20/18/15 18/16/13 17/15/12 19/17/14 18/16/13 16/14/12* 280+ bar 4,000+ psi 16/14/11*

<140 bar <2,000 psi 20/18/15 20/18/15 19/17/15 19/17/15 18/16/14

<140 bar 140 - 210 bar <2,000 bar 2,000 - 3,000 psi 20/18/15 20/18/15 19/17/14 21/19/17 20/18/14 18/16/14 <210 bar <3,000 psi 20/18/15 19/17/14 18/16/13 20/18/15 19/17/13 17/15/13 210 - 280 bar 3,000 - 4,000 psi 16/14/12*

Hydrostatic Transmissions (in-loop fluids) 17/15/13 BEARINGS Ball Bearing Systems Roller Bearing Systems Journal Bearings (high speed) Journal Bearings (low speed) General Industrial Gearboxes
*Requires precise sampling practices to verify cleanliness levels.

15/13/11* 16/14/12* 17/15/13 18/16/14 17/15/13

Table 1 - Cleanliness Code Chart, courtesy of Vickers, Corp.

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LUBRICATION eye (approximately 40 micron or larger) to microscopic sizes of less than 1 micron. Particles visible to the unaided eye are normally larger than the clearances of most hydraulic system components. Because those particles that will gradually degrade the system are not visible, a visual inspection of the fluid is a very poor test of cleanliness. TARGET CLEANLINESS Typically, cleanliness targets are expressed as a range. First, it must be understood that cleanliness is not a general term used to describe the state of a hydraulic system. Cleanliness is a quantitative value based on the design and components used in a particular hydraulic system. The current international cleanliness standard for lubricating or hydraulic fluid is defined by (International Standards Organization) ISO 4406. Work is being done on the ISO Cleanliness Standard, but supporting data for the new standard does not presently exist. Therefore, for this article the information reflects the existing ISO 4406 Standard. As the new standard is developed and better supported, it should supercede ISO 4406. The number of a particular sized particle in a stated amount of fluid (1 ml) determines the cleanliness of the fluid. The number of particles must be determined using an approved laboratory particle counting procedure. This number of particles per milliliter of fluid is then plotted on a cleanliness chart. The chart has a range code that starts at 0 and goes to 25. However, anything beyond 17 is unsuitable for use in nationally published standards. DETERMINING TARGET CLEANLINESS CODES There are simply too many extenuating circumstances for any governing body to make definitive, absolute statements concerning target cleanliness codes. There is no official method for determining the target; however, the following cleanliness target worksheet, shown in Figure 2, is a good starting point.
FACTOR SAFETY & ECONOMIC CONCERNS (Mandatory) PRESSURE: Over 5,000 psi 3,001 - 5,000 psi 1,000 - 3,000 psi Under 1,000 psi 6 A: ______ 6

4 3 2 1 Pressure Factor: 4 3 2 1

B: ______

COMPONENTS: Servo Valves Variable Piston Pump, Proportional Valve PC Flow Control, Fixed Piston Pump, Vane Pump All Others

Components Factor: FLUIDS: 1 Water Bearing Fluids or Phosphate Ester 0 All Others Fluids Factor: TOTAL OF A-D:

C: ______

D: ______ E: ______

Conversion of Fluid Cleanliness Factor to ISO 4406 Code: 5 = 19/17/15 7 = 18/16/14 9 = 17/15/13 11 = 15/14/11 6 = 19/17/14 8 = 18/16/13 10 = 16/14/12 12 = 15/13/10

13 = 14/12/10 14 = 14/11/09

Figure 2 - Cleanliness Target Worksheet

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LUBRICATION METHOD FOR READING CLEANLINESS CODE CHART Locate the particle size across the bottom of the chart; move up the right side of the chart to the number of particles in the sample for that size, then move straight across to the left side of the chart to the corresponding range code number. For the example sample fluid shown in Table 2, the 2 micron (m) size is located at the bottom of the chart. Move up the right side of the chart to the point representing 5,120 particles. Move directly left of that point to the range code of 20. Following this same method for 5 and 15 micron particle sizes, the range codes are 14 and 12 respectively. The cleanliness code for this sample then becomes 20/14/12. The previous ISO cleanliness code only referenced the 5 and 15 micron particle sizes, so when only two numbers are given, they will represent only the 5 and 15 micron particles. However, the current ISO 4406 code, shown in Table 2, consists of three numbers that represent the 2, 5, and 15 micron particle sizes. equipment for maintaining fluid cleanliness is not included in the design phase, it may be very difficult and expensive to achieve the fluid cleanliness necessary for optimal performance. A system that includes servo valves demands methods of filtration and filter locations that insure fluid cleanliness. Typical cleanliness levels for servo valves are ISO 15/13/10. It is usually more economical to install the equipment necessary to achieve this cleanliness level during the design phase of the equipment. If a reservoir is located in a dusty environment and the vent is unfiltered, fluid contamination will increase with every rise and fall of the fluid level in the reservoir. In some cases, this one seemingly small design flaw can eventually cause total system failure. Inadequate temperature control can cause chemical breakdown of the hydraulic fluid and alter the viscosity. The changes caused by excess heat in the fluid will cause reduced oil film thickness and permit moving parts to wear more rapidly. This will increase the concentration of particles in the system causing a component or the entire system to fail. The particle size distribution is such that the population of smaller particles is greater than the larger particles. Consequently, the thinner oil film means more damaging particles are present in fluid of the same cleanliness level.

FAILURE CAUSING CONDITIONS

In order to achieve maximum performance from a hydraulic system, the target cleanliness level must be established during the design phase of the system. If the
TYPICALLY WRITTEN 24/22/20 19/18/14 17/16/13 15/13/10

RATING Very Dirty Typical "new" oil cleanliness Suitable for turbines Servo valves in high pressure applications

2 MICRON 24 19 17 15

5 MICRON 22 18 16 13

15 MICRON 20 14 13 10

Table 2 - Typical Particle Counting Data

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LUBRICATION IMPROPER FILTRATION Improper filtration includes, but is not limited to, incorrect filter placement, inadequate filter flow, incorrect filter media, and incorrect filter matrix design or construction. There is a seemingly logical tendency for hydraulic system users to want to protect the system by placing a filter on the suction side of the pump. The thought is that this should effectively keep the particulate that has settled out in the reservoir from being pulled into the pump and circulated throughout the system. Current published standards discourage this practice. Although placing a filter on the suction side of the pump is seemingly logical, it is not the thing to do. If the filter is even remotely efficient, it will eventually plug. It does not even have to plug entirely to damage the system. If it restricts the flow to the pump at all, cavitation will occur and the pump will be damaged. This will create metal particulate that will circulate through the system doing damage as it goes along and creating more metal particulate. A large portion of it will eventually return to the reservoir where it will settle and then be drawn back to the pump suction filter. This will continue to escalate into a very serious problem. Filtration is necessary to achieve target cleanliness levels within a hydraulic fluid system. For maximum efficiency, there are specific locations where filters should be located such as pressure lines, return lines, or re-circulating lines. If the filters are not placed properly in the system, removal of contaminants will not be effective. Filter placement is categorized by the three major functions they perform: ingression prevention, system cleanliness maintenance, and component isolation. Any component that has the ability upon failure to cause a safety hazard, or is a critical function component, should have an isolation filter placed upstream of that component. PROPER FILTRATION Pumps naturally produce particulate during normal operation. Pumps also operate with the potential of producing large amounts of contamination if an internal failure occurs. The pressure line filter should be located just downstream of the pump discharge as illustrated in Figure 3(B). (Figure 3(A) demonstrates the improper location of a filter.) A return line filter is necessary to capture particles generated by internal wear and collected on cylinder rods while extended.

HYDRAULIC RESERVOIR

HYDRAULIC RESERVOIR

HYDRAULIC PUMP

PRESSURE RELIEF VALVE

HYDRAULIC PUMP

PRESSURE RELIEF VALVE PRESSURE FILTER

(A)

(B)

Figure 3 - Improper vs. Proper Filter Location

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LUBRICATION

HYDRAULIC RESERVOIR

HYD. PUMP

RETURN LINE FILTER

PRESSURE RELIEF VALVE PRESSURE FILTER

Figure 4 - Demonstration of Valves Recirculating filters are included with recirculating pumps in specific applications where the achievement of the target cleanliness cannot be accomplished without a circulation loop or additional confidence is required. Shown in Figure 4, the recirculation loop can also be used when filling or topping off the reservoir and it can be used to clean up the oil while the system is inactive. It is also the best location for heat exchangers and filters on systems using variable displacement pumps. Proportional valves and servo valves are constructed with very close tolerances between their metering and moving parts. Because they have to react to very small changes in pilot flows or electrical signal changes, small particles, called silt, can restrict movement of the parts or even cause valves to completely fail. In this case, a failure could be defined as any change in performance that results in a reduction in productivity. This is demonstrated in Figure 5. High collapse elements (>2,000 psi) should be used in all non-bypass housings. Non-bypass filters should be used upstream of individual valves or banks of valves to protect the valves against pump failure. The filter, shown in Figure 6(A), is blocked off resulting in a differential pressure increase and/or flow stop until the filter is changed. Figure 6(B) shows a bypass filter arrangement. When the filter plugs, the pressure overrides the spring pressure, unseats the ball check, and allows fluid to bypass the plugged filter. A very common mistake made in selecting isolation filters is to designate a filter with finer filtration media than the systems main filter. This causes shorter isolation filter life and service that is more frequent. Each time systems are opened for maintenance or service the potential for contamination increases. To properly maintain efficient filtration of a hydraulic fluid system the target cleanliness levels must be established and followed for the entire system.

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LUBRICATION

SECONDARY RECIRCULATING FILTER PRIMARY RECIRCULATING FILTER RECIRCULATION PUMP (KIDNEY LOOP)

HYD. PUMP

RETURN LINE FILTER

PRESSURE RELIEF VALVE PRESSURE FILTER

Figure 5 - Demonstration of Recirculating Loop

IN-LINE FILTER

IN-LINE FILTER

SPRING-LOADED BYPASS

(A)

(B)

Figure 6 - Non-bypass and Bypass Filtration PREDICTIVE OR PREVENTIVE MAINTENANCE Hydraulic fluid system failures occur in large part due to inadequate predictive or preventive maintenance and from a lack of education about cleanliness. The success of any hydraulic fluid cleanliness program is dependent on the knowledge level of each participant. It is vital that the introduction of new oil into a system be done in accordance with system cleanliness standards: Opening to the system must be clean. Transfer device for the fluid must be clean. Surface of the new oil container must be clean.

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LUBRICATION Oil must be filtered to the target cleanliness standards set for the system before it is introduced. The employee responsible for collecting samples must be aware of the potential for contamination during the sampling procedure. The use of sampling ports and hoses will help minimize the introduction of external contamination. Maintenance employees involved in housekeeping activities need to be aware of the potential for system contamination during area wash downs and clean-up. Maintenance personnel must realize that if a component experiences catastrophic failure during use, it has probably introduced metal particulate to the system. The process of changing that component will also introduce even more contamination. As a crude first line of defense, hydraulic systems are often equipped with magnets, usually in the reservoir. These magnets are simply to help keep the chunks of ferrous metal out of the pump inlet and from being deposited throughout the system. Magnets are a good indicator of the amount of magnetic metallic particulate that is in the fluid. Too often these magnets are forgotten and are never even examined. They should be examined periodically and used as a good indicator of system wear. If proper fluid cleanliness has been maintained, the magnets should remain clean and free of metal particulate. must take into account the required cleanliness of the individual components and proper filtration to insure appropriate cleanliness. However, if the design is adequate and the installation acceptable for proper operation and system cleanliness, but the system is not monitored for actual condition of the hydraulic fluid, the entire effort is wasted. Hydraulic pumps and components generate particulate naturally during operation. Wear occurs as the system performs the intended tasks. If the results of this wear are not monitored and the contamination levels controlled, system failure is inevitable. There are several different methods of monitoring fluid cleanliness. Where, when, and how the fluid is monitored determines the method. Where the fluid sample is collected, or where the monitoring is done is determined by the information desired. For proper system operation, bulk storage sampling must be a part of maintaining hydraulic fluid cleanliness in a system. Although hydraulic fluid manufacturers make serious efforts to produce clean fluids, they will become contaminated through handling, transfer, and storage. Pipes or hoses, tank cars, drums, and transfer pumps all provide sources of fluid contamination. Typical cleanliness levels of new hydraulic fluids from reputable suppliers statistically run about ISO Cleanliness Levels of 17/16/14 or worse. These numbers virtually eliminate 3 levels of system sensitivity classifications from use with this fluid as delivered to the customer site. Adding to the problem of delivered hydraulic fluid cleanliness is the casual approach many users take to bulk storage contamination control. Open drums of hydraulic fluid with hand pumps inserted can be found in process areas, in maintenance shops, and near operating equipment. Sampling of the fluid in the drum should be accomplished by using a vacuum pump to draw a sample up out of the drum or

MONITORING FLUID CONDITIONS

Once the hydraulic fluid system has been properly designed, installed, flushed, and filled with clean hydraulic fluid, it becomes necessary to determine if the system is working properly. This process is referred to as condition monitoring. Table 3 shows some guidelines for condition monitoring of a hydraulic fluid system. Proper equipment design and installation are necessary to most economically maintained fluid cleanliness. The design

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LUBRICATION sampling from the pump outlet. Proper handling of bulk hydraulic fluid requires the filtration of the fluid as it is being introduced into the system. Fluid additions or introducing fluid into a new system should be done within the target cleanliness levels determined for the operating system. Portable filtration systems are available that meet national or international standards for cleanliness. Figure 7 is an example of such a portable filtration device.

CONDITION Water in Fluid Neutral Number (Total Acid Number)

STANDARD ASTM D95 or D1744 ASTM D974

ALLOWABLE VARIATION AND SUGGESTED CORRECTIVE ACTION Reclaim or remove water if over 0.05% (500 ppm). Locate and eliminate source of water. Change of 0.2 above original, then be alert. Change out if increase is above 0.5. Increase of 10% could indicate onset of oxidation or mixing of fluids of higher viscosity. Determine which and take action as required. Two or more ISO ranges above target, check photomicrograph or microscopically check for the presence of bright metals. Hazy or cloudy appearance indicates the presence of water or fine particles. Perform quantitative analysis. Oils exhibiting separation times greater than 30 minutes should be refortified or replaced. Fluid is probably oxidized. Perform quantitative analysis such as RBOT (ASTM D2272) or infrared analysis. Do not use Specto for any wear metal trending or analysis. Spectro analysis is particle size limited and will not see any meaningful particles relative to wear. Benchmark additive levels in new fluid. When any element of the additive package loses 25% or more of the original value, contact refiner.

Viscosity

ASTM D445

Particles

ISO 4406, ANSI T2.24.1-1991

Visual

None

Poor Demulsibility

ASTM D1401

Burnt Odor

None

Wear Metals

Spectro

Additive Package

Spectro or Infrared

Table 3 - Condition Monitoring Guidelines

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Figure 7 - Portable Filtration Device

SAMPLING POINTS AND METHODS

In an operating system, the point at which a sample is extracted is determined by the desired information. Often the sample must be drawn from a pressure line. This is done when specific information about the condition of the pump, effectiveness of filters, and levels of contamination

entering components is desired. The sample should be representative of the fluid flowing through the system during normal operation. The sample must also be taken with the system operating and the fluid flowing at normal operating temperature and flow rate. The most beneficial point is where the fluid flow is turbulent. Turbulent flow insures even distribution of the contaminants throughout the fluid sample.

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LUBRICATION Samples taken from return lines must follow the same requirements as pressure lines. This method of fluid sampling allows for monitoring of contamination generation by specific components. Fluid sampling of the return line provides the overall indication of system contamination. The sample must be taken upstream of the return line filter to insure there is a representative sample of the entire system. If the hydraulic system does not have provisions for extracting fluid samples from pressure or return lines, then the sample must be taken from the system reservoir. Reservoir samples will provide information on fluid viscosity, acid levels, water content, and depletion. The samples will not provide accurate indications of particle contamination. Particulate in the fluid reservoir will naturally settle to the bottom. Residence time will determine how many particles settle. The reservoir will contain a particle distribution that will vary in size and concentration at different depths in the reservoir. Any time a system is opened to the atmosphere the potential for additional contamination exists. Very few reservoirs are equipped with sample points or valves. This means the reservoir is typically opened to extract the sample. This permits outside contamination to enter the system. The sample bottle or container is then submerged into the fluid providing a path for contaminant to travel into the system. Additionally, the reservoir typically contains particulate from the operating system and any particulate that may have been present from construction and assembly. This means a true representation of the operating system will not be present in the fluid sample. It will hold contaminants that may have originated during construction, were stirred up during the sampling process, and not contain particles that were filtered out by the return line filter. Therefore, sampling from the reservoir is the least reliable point at which to sample the fluid. Another type of sampling is online sampling. Online monitoring of hydraulic fluid cleanliness has certain benefits over sampling methods discussed earlier. The major advantage of online sampling is the greater accuracy of the report since there is no opportunity for external contaminates to be introduced to the count. Using this method, frequently it is not necessary to even remove the fluid from the system. Another major advantage of online sampling is that the results are delivered within seconds of actual sampling. Using a sampling process requires the sample to be transported to a remote laboratory either on- or off-site to a vendor laboratory. Extracting a sample, transportation, handling at the laboratory, and actual testing all increase the potential for particulate contamination.

FLUID ANALYSIS SERVICES

Unless the hydraulic system user has an analysis laboratory on-site, hydraulic fluid samples will normally be sent to off-site labs for analysis. The lab report should provide the following information: Performance against target cleanliness results for all three particle sizes-2m, 5m, and 15m Particle count summary Plotted cleanliness code chart of target levels and actual levels Particle count summary of previous samples and current sample Water concentrations Viscosity ratings Photo analysis (color) and description Historical information comparisons of present sample to previous sample Spectro analysis for additives trending SEM/EDX analysis (Scanning Electron Microscope/Energy Dispersive X-ray) including written explanation of analysis

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LUBRICATION Written recommendations and summary of the analysis The actual data from a lab report should provide information showing actual fluid condition as compared to target levels. The format of the data should be readable, clear, and usable by all parties involved in the management, operation, and maintenance of the hydraulic fluid system. The frequency and depth of a report is determined by the application. If the results of the analysis indicate the system is operating within the target cleanliness levels, then the next sample analysis may not need to be as in-depth or detailed. If the analysis indicates target values have been exceeded, then corrective action should be taken to control those limits. It would be helpful to have a detailed analysis following corrective action to determine if the desired results have been achieved. The information from the analysis can provide additional service if it is used as part of a statistical process control (SPC) program. The advantage of SPC is the indications shown from historical data as plotted on trending charts. Taking advantage of this information can improve the operating efficiency and productivity of the hydraulic system. To take full advantage of the fluid analy sis, everybody that can impact the test results should see the results. This includes, but is not limited to, the following personnel: purchasing agent, project engineer, process engineer, operator, sample collector, housekeeping or clean-up personnel, and maintenance mechanics. Anyone that can have a direct impact on the cleanliness of the hydraulic fluid or system should be trained and knowledgeable in the methods and procedures for maintaining hydraulic fluid cleanliness.

SUMMARY
Over 80% of all hydraulic failures are preventable if you do not use contaminated fluid. The argument can be made that maintaining proper hydraulic fluid cleanliness has the potential to reduce downtime by approximately 80%; thus, having a major impact on profitability. Hydraulic fluid cleanliness is the weak link in the progressive chain of application and technology that has raised the science of hydraulic fluid power. Albert Einstein once expressed a concern that the applied science of hydraulics offered us little happiness. Today, that situation could no longer exist if we learn to apply a systematic and comprehensive method to maintaining fluid cleanliness.

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