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Hydac Filter Training
Hydac Filter Training
Causes of breakdowns in
hydraulic and lubrication systems
70 - 80 % of all failures in hydraulic systems
and
up to 45 % of all bearing failures
are caused by
Types of contamination
Effect
Types of contamination
Gaseous
Liquid
Solid
Air
Water
Unknown Oil
Emery
Metal scale
Rust particles
extremely
bad damage
Iron
Steel
Brass
Bronze
Aluminium
bad
damage
Laminated fabric
Fibres
Sealing abrasion
Rubber particles
from hoses
Paint/varnish particles
Oxidation products
of the hydraulic fluid
minimal
damage
Gaseous Contamination
Air
Consequences of Gaseous
Contamination
Cavitation
Local oil overheating
Leads to unstable regulation behavior
Reduces the dynamic lubrication film
thickness
Oil aging
CxHy + O2 Acids, H20, Sludge
Catalysator: temperatur, moisture, copper,
5
Fluid Contamination
Water
Unknown oil at system refill
Consequences of Fluid
Contamination
Corrosion
Decrease of dynamic viscosity
Wear (Cylinder)
Initial contamination
of the valve
External contamination
through system opening
Repairs
Initial
contamination
(in the oil)
Wear (Pump)
Diameter in mm
Human hair
Vane pump
0,5 up to 5m (J1)
Piston pump
0,5 up to 1m (J2)
Valve
5 up to 25m (J1)
Servo valve
10
5 up to 8m (J1)
Solid Contamination
11
sand
metal particles
fibers
rust
weld pearls
abrasion of
vulcanized rubber
oxidation
products
color
particles
Solid Contamination
Fine contamination (>6-14m)
Consequences:
- Wear
- Internal leakage
- Inaccurancy of regulation
- Valve blocking
Coarse particles (>14m)
Consequence:
Sudden breakdown of
components
12
Filter manufacturer
Form sand
Production swarf
Corrosive media
Coal dust
Rests of grinding tool
Pressure water/splash water
13
10
20
30
40
50
60%
Commissioning
Lifetime
Contamination as consequential
damage
Contamination as consequential
damage
Embedded chip
Types of wear
Abrasion
by particles between adjacent moving surfaces
Erosion
by particles and high fluid velocity
Adhesion
from metal-to-metal friction (loss of fluid)
Fatigue wear
surfaces damaged by particles are subjected to
repeated stress
Corrosion
20
Abrasion
by particles between adjacent moving surfaces
Effects of abrasion:
21
Changes to tolerances
Leakages
Reduced efficiency
Particles produced in the system
create more wear!
Erosion
by particles and high fluid velocity
The high velocity of the fluid forces existing particles against
the corners and edges of the system.
Other coarse and fine particles therefore become detached
from the surface and there is a gradual attack on the surfaces
in the system.
22
Adhesion
from metal-to-metal friction (loss of fluid)
Low speed, excessive load and/or a reduction in fluid
viscosity can reduce the oil film thickness.
This can result in metal-to-metal contact, and also possible
shearing.
23
Surface fatigue
surfaces damaged by particles are subjected to
repeated stress
The smallest cracks in the
surface are surface fatigue
hollowed out causing
material to break off,
therefore creating new
particles. This action causes
an increase in wear.
24
Surface fatigue on ball bearing
Contamination classifications
NAS 1638 (valid until 30.05.2001)
NAS-Code
(nach NAS 1638)
25
00
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
125
22
1250
250
44
2500
500
88
16
5000
1000
176
32
10000
2000
352
64
16
20000
4000
704
128
32
40000
8000
1408
256
64
80000
16000
2816
512
128
16
160000
32000
5632
1024
256
32
320000
64000
11264
2048
512
64
640000
128000
22528
4096
1024
128
1280000
256000
45056
8192
2048
256
2560000
512000
90112
16384
4096
512
5120000
1024000
180224
32768
8192
1024
2048000
360448
65536
16384
2048
4096000
720896
131072
32768
4096
Contamination classifications
ISO 4406 ISO Code
26
ISO Code
(acc. to ISO 4406)
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Number of particles/100ml
from
up to
16
32
32
64
64
130
130
250
250
500
500
1000
1000
2000
2000
4000
4000
8000
8000
16000
16000
32000
32000
64000
64000
130000
130000
260000
260000
500000
500000
1000000
1000000
2000000
2000000
4000000
4000000
8000000
8000000
16000000
16000000
32000000
32000000
64000000
64000000
130000000
130000000
250000000
4406: 1999
21 / 18 / 15
>4m(c) >6m(c) >14m(c)
>2m
>5m >15m
old
4406: 1987
Flche =
176,7 m
16,9 m
16,9 m
d = 16,9 m
27
d = 15 m
Flche =
176,7 m
*ACFTD size
(ISO 4402 :
1991) mm
< 1,0
1,0
2,0
2,7
3,0
4,3
5,0
5,9
7,0
7,4
10,0
10,2
14,0
15,0
16,9
20,0
23,4
25,0
30,0
37,3
40,0
50,0
ISOMTD
NIST size
(ISO 11171 :
1999) mm (c)
4,0
4,2
4,6
5,0
5,1
6,0
6,4
7,0
7,7
8,0
9,8
10,0
13,0
13,6
15,0
17,5
20,0
21,2
24,9
30,0
31,7
38,2
Contamination classifications
ISO 4406 ISO Code
28
Contamination classifications
SAE AS 4059 : 2001
Maximal number of particles (particle per 100 ml)
Size (ACFTD),
acc. to ISO 4402
calibrated or
microsc. counting*
Size (ISOMTD),
acc. to 11171
calibrated or
REM**
Size code
Code-No.
29
> 1m
> 4m(c)
> 6m
> 15m
> 6m(c)
> 14m(c)
> 25m
> 21m(c)
> 50 m
> 100 m
> 38m(c)
70m(c)
000
195
76
14
00
0
1
2
3
390
780
1560
3120
6250
152
304
609
1220
2430
27
54
109
217
432
5
10
20
39
76
1
2
4
7
13
0
0
1
1
2
4
5
6
7
8
9
10
11
12.500
25.000
50.000
100.000
200.000
400.000
800.000
1.600.000
4860
9730
19.500
38.900
77.900
156.000
311.000
623.000
864
1730
3460
6920
13.900
27.700
55.400
111.000
152
306
612
1220
2450
4900
9800
19.600
26
53
106
212
424
848
1700
3390
4
8
16
32
64
128
256
512
12
3.200.000
222.000
39.200
6780
1.250.000
1020
Correct
Classification
30
31
SAE 12
ISO 22/21/18
Fresh oil ,
delivered in barrels
SAE 9
ISO 19/18/15
Fresh oil,
delivered by tank truck
SAE 7
ISO 17/16/13
Fresh oil,
delivered by mini-container
SAE 5
ISO 15/14/11
required for modern
hydraulic systems
32
33
1 mg/l
How to Measure ?
35
36
Control
37
weighing
gravimetric
analysis
counting
microscopic
analysis
manual
counting
automatic
counting
electronic
analysis
automatic
particle counting
devices (APC's)
in field
in laboratory
38
Possibilities of Condition
Monitoring
FCU
Table comparison
39
Laboratory
Locally
FCU
40
41
infrared diode
only monochromatic
light (of a wave length)
unlimited lifetime
light absorption
Voltage [Volt]
Voltage [Volt]
2m
5m
15m
42
time
25m
12
14
16
18
20
[min]
[min]
0:01
0:01
0:02
0:03
0:04
SAE
0:06
0:07
0:07
10
12
ISO
0:04
0:06
0:10
0:03
0:05
0:09
0:02
0:05
0:08
Documenting
0:08
0:09
0:10
0:11
0:11
0:12
0:12
0:13
0:13
0:14
0:14
PC
43
Navigating
SPS
Controlling
Measurement
and
Indicators
10%
20%
35%
5%
20%
Solid contamination
Ageing of the lubricant
Faults in bearing selection
Liquid Contamination
selection of the lubricant
Assembling faults
22/19
19/16
18/15
17/14
16/13
21/18
18/15
17/14
16/13
15/12
20/17
17/14
16/13
15/12
14/11
19/16
16/13
15/12
14/11
13/10
18/15
15/12
14/11
13/10
12/9
17/14
14/11
13/10
12/9
12/8
NAS 9
NAS 6
NAS 5
NAS 4
NAS 3
Increase in reability
2x
3x
4x
5x
*Van Dorn-Demag
Filter Functions
Before:
purity level SAE 13
through filtration
46
Afterwards:
purity level SAE 4
Tasks of a Filter
47
Tasks of a Filter
Component
48
Tasks
In the hydraulic
system
In the hydraulic
system
Bronchial Tubes
Kidney
Liver
Pressure Filter
Heart
Pump
Brain
Control Bloc
Dialysis
Bypass Filter
Blood
Working Fluid
Nerve system
Control
Blood sample
Oil sample
Sensor system
24 hours ECG
Energy transport
temperature, friction
reduction
Surface filter
49
Depth filter
cake
bridge
51
filter cloth
filtrate
52
53
Laces mesh, 50 m
Paper mesh
Metal mesh
Depth filters
54
Glass fiber mesh, 20 m
55
Element B
Filtered particles
56
57
Coarse
Medium
Fine
(1. layer)
(2. layer)
(3. layer)
58
surface filter
depth filter
Multipass-Test
Determination of the x(c)-value
ISO 16889
test
filter element
Nupstream
59
nupstream x m
X(c)=
ndownstream x m
High x(c)-value-stability
High dirt hold capacity
60
Multipass-Test
Multipass - Test
ISO 16889
61
Multipass-Test
Schematic Demonstration
ISO 16889
test system
particle
counter
test filter
dirt
injection
system
62
ISO 16889
1000
2 m
3 m
5 m
6 m
8 m
10 m
1000
99.9
1000
99.8
absolute filtration
1000
99.9
99.8
200
99.5
100
99.0
100
x - Wert
x(c)- value
98.0 98.0
nominal filtration
95.0
10
10
10
90.0
90.0
10
75.0
63
50.0
1
0
10
11
12
13
14
15
0.0
1
16
Separation rate in %
100
100
ISO 16889
64
Element A
8
7
6
5
Element B
4
3
2
1
0
0 1 2 3 4 5 6 7 8 9 10 11 12131415 16171819 20212223 242526
ISO 16889
High x-value
High x-value-stability
Multipass-Test
65
ISO 2941
ISO 3724
ISO 2943
2.5
2.0
1.5
1.0
Element B
initial energy costs
with element A
0.5
66
Element A
initial
Dp 0.0
operation time [ h ]
67
ISO 3724
bar
4
3
2
1
68
0
1 million load changes
69
70
Development of Filtration
Technology
71
Year
Development
Filtration ratio
1940
100 m
1950
1960
50 up to 100 m
1970
up to 3 m
nominal
1980
up to 3 m
absolute
1990
1 m and 2 m
absolute
Filter unit
Suction filter
72
Off-line filter
Breather filter
Suction Filters
CONTROLLING
73
Suction Filters
Benefits
Protects the pump against coarse
contamination
Cheap
Peace of conscience of the design engineer
74
Suction Filters
Disadvantages
Finest Filtration is not possible
Danger of cavitation especially during deep
temperatures (cold start)
Guaranteeing protection against wear, the
installation of further filters is necessary
System must be switched off for element
changing
75
Pressure Filters
CONTROLLING
76
Pressure Filters
Benefits
Filtration directly in front of the components
which are supposed to be protected
Desired purity level is guaranteed
Finest filtration
Change-over filters are possible (24 hours
operation)
77
Pressure Filters
Disadvantages
78
79
80
Finest filtration
81
Off-Line Filters
CONTROLLING
82
Off-Line Filters
Benefits
83
Off-Line Filters
Disadvantages
84
Breather Filters
CONTROLLING
85
Breather Filters
Benefits
Disadvantages
86
Filters
87
Filter selection
Protective and Working Filter
88
Filter selection
Restricting the flow velocity
89
90
91
Filter Sizing
92
Filter Sizing
93
o
H
The water
molecul is
polar unlike the
base oil.
94
Fluid X
5000
free water
2500
dissolved water
= 100 % saturation
limit
= 82 % saturation limit
0
20
40
60
Temperature [C]
80
HFD-fluid
5000
Synthetic -fluid
Mineral oil A
Mineral oil B
2500
Transformer oil
0
96
20
40
60
Temperature [C]
80
Water content
[ppm]
100ppm
=
0,01%
Existence of impurities
Temperature
1000
800
600
400
200
dissolved w ater
0
-20
-10
10
20
30
40
Temperature [C]
O il
D is s olve d
[pp m ]
E m u lsifie d
[p pm ]
Fre e
[pp m ]
New
h yd ra u lic
flu id
0-4 0 0
4 0 0 -10 0 0
>1000
Aged
h yd ra u lic
flu id
0-8 0 0
8 0 0 -50 0 0
>5000
97
Examples with approx. values for a standard
hydraulic fluid
50
Source: Drew Troyer, Drew Troyer President Noria Global Services: "Establishing Moisture
Contamination Targets for Hydraulic Systems". Machinery Lubrication Magazine. January 2004
Source: Drew Troyer, Drew Troyer President Noria Global Services: "Establishing Moisture
Contamination Targets for Hydraulic Systems". Machinery Lubrication Magazine. January 2004