Chapter 4

Chapter 4 Hydraulic Filtration Principles
LEARNING OBJECTIVES
Upon completing this chapter, you should be able to:
Understand the need for effective filters in hydraulic systems.
Describe the function of strainers and filters in hydraulic systems.
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Classify the hydraulic filters according to various parameters.

Explain the operation of the hydraulic filter with a bypass valve.
Understand the function of duplex filters in hydraulic systems.
Distinguish the full-flow filtration and the proportional flow filtration.
Describe the location-specific filters in hydraulic circuits.
Describe the off-line filtration used in hydraulic systems.
Explain the multipass test to specify various performance parameters of hydraulic filters.
Define the Beta ratio and the efficiency of hydraulic filters.
Introduction
Modern hydraulic systems are susceptible to many types of contamination, as explained in the
previous chapter. If unfiltered, the contaminants in a hydraulic system can cause the premature
wear of the internal system surfaces and promote fluid leakage in the system. They also clog the
flow paths in the system. Moreover, the presence of water in the system fluid can lead to corrosion
and the accelerated wear of the system components. Studies have revealed that most of the
component replacements in hydraulic systems are necessary because of the damaging effects of
fluid contamination. Therefore, an efficient filtration system should be an integral part of every
hydraulic system to separate the insoluble particulate matter as well as the water from the system
fluid.
Filters/strainers with filter media are the necessary devices for removing particulate
contamination from hydraulic systems. A piece of filter media can be regarded as the heart of any
hydraulic filter/strainer. It is that part of the filter used to separate particles out of the fluid stream
that passes through it. Filters are fitted at appropriate locations in a hydraulic circuit for the
effective control of the contamination present in the circuit. This chapter describes the
classification of hydraulic filters and filter elements according to various parameters.
Copyright @ 2016. Universal Publishers.
Filters in hydraulic systems must perform predictably and efficiently throughout their service
life. A filter is, therefore, rated for the smallest size of particles it removes and the efficiency with
which it removes these particles. Filter performance is measured based on some standard laboratory
tests. This chapter further explains various aspects of filtration in hydraulic systems, in a systematic
manner.
Strainers and Filters

A strainer/filter consists of a filter element, which is essentially a piece of filter media containing
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millions of tiny pores. A strainer is a coarse filter consisting of a wire screen with openings usually
greater than 149 microns (< 100 mesh number). A filter usually consists of a filter element with a
section of finer filter media than that of the strainer, in a ported enclosure. The piece of the filter
media is often pleated and enclosed in a canister. A bypass valve can be included in the filter for
the protection against the filter burst. The filter can also be provided with a visual indicator or
electrical indicator or both to indicate the extent of the pressure differential across the filter, as a
result of its clogging. Sometimes a magnet is incorporated into the filter structure to attract and
hold the ferromagnetic particles in the system. Figure 4.1 shows the simplified cross-sectional view
of a hydraulic filter. The rest of the chapter describes various aspects of hydraulic filters.
Figure 4.1 | A simplified representation showing the cross-sectional view of a hydraulic filter.
Types and Classifications of Hydraulic Fluid Filters

Hydraulic filters are designed and constructed to handle petroleum-based fluids, water-based fluids
or synthetic fluids. They may be classified according to various criteria, such as (1) the filtration
phenomena, (2) the nature of filter media, (3) the materials of their construction, (4) installation
locations, (5) assembly options, and (6) technology types. Options for the filter element material
include stainless steel (for wire mesh), cellulose, paper, fiberglass, or synthetic fiber. Filters based
on their installation locations include suction filters, pressure filters, return-line filters, and off-line
filters. An in-line filter is a simple filter, in which the axes of the inlet, the filter element, and the
outlet are aligned in a straight line. Other types of assembly options include cartridge, spin-on,
and/or duplex filters. The options for the filter technology types include full-flow, full-flow with
bypass, and proportional flow arrangements. The following sections explain the important types of
hydraulic filters and filter media.
Filter Media According to the Filtration Phenomena: Hydraulic filter media can be classified
according to the filtration phenomena as (1) mechanical, (2) absorbent, and (3) adsorbent.
Mechanical type media contain closely woven metal screens and/or metal disks separated by thin
spacers. A piece of mechanical type media is capable of removing relatively coarse particles only.
Absorbent type Media consist of a wide range of inactive, porous, and permeable materials, such as
paper, cellulose, cotton, and wood pulp. Paper filters are impregnated with resins for added
strength. In a filter with the absorbent media, very fine particles in the fluid are absorbed, as the
fluid permeates the media.
Adsorbent type Media include charcoal and fuller’s earth. This type of media element should not be
employed in a hydraulic system since they are likely to remove the essential additives from the
system. Remember, adsorption is a surface phenomenon. It refers to the tendency of particles to
adhere to the exterior of the filter material.
Filter Media According to the Nature of Filtration: Filters can be classified based on the nature of
filtration media as (1) surface media and (2) depth media. The following paragraphs explain these
classifications:
Surface Media are made from the woven wire. Figure 4.2(a) shows the sketch of the surface media
of a filter. The filter captures contaminants in the fluid stream on one side of the wire screen, which
faces the fluid flow. That is; the fluid passes through one layer of the filter media. Since the process
used in the manufacturing of wire screens can be very accurately controlled, the surface type media
have a consistent pore size.
Figure 4.2 | Graphic representations of the types of filters according to the nature of filtration.
Depth Media are thick-walled filter media that are constructed out of absorbent materials. Figure
4.2(b) shows the sketch of the depth media of a filter. When the hydraulic fluid is passed through
the filter, the fluid takes a torturous path through the porous materials that make up the filter media.
The filter absorbs the contaminants throughout the depth of the filter material as the fluid flows
through the media. This type of media can have a very high contaminant capture rate even for tiny
particle sizes, depending on the distribution of pore sizes. Therefore, the contaminant capturing
capacity of the filter with the depth media is much higher than that of a filter with the surface
media. Filters with the depth media should be considered for hydraulic applications involving high
levels of contamination, as in steel and paper mills.
Filter Media According to the Materials of Construction: There are four basic types of filter media
according to the materials of construction. They are (1) Wire-mesh media, (2) Cellulose media, (3)
Synthetic media, and (4) Water removal media. The following paragraphs explain these
classifications:
Wire-mesh Media are made of epoxy-coated stainless steel. They can be used to catch the large
particles that might rip up a regular filter. Therefore, a wire mesh filter is useful as a coarse filter
for hydraulic applications. They are typically available in the following three mesh sizes: (1) 100
mesh yielding 149-micron filtration, (2) 200 mesh yielding 74-micron filtration, and (3) 325 mesh
yielding 44-micron filtration. The definition of the term ‘mesh’ is given in a latter section under the
sub-heading ‘Performance Ratings of Filters’.
Cellulose Media are made from plant fibres. They are microscopic in size and are held together by
resins. A piece of the media is then pleated and assembled as disposable elements. Cellulose fibers
are rough in texture and irregular in size and shape. The cellulose media offer more resistance to
the flow as they contain fine pores. Their useful service life is limited.
Synthetic Media are man-made, consistent, and rounded off to provide the least resistance to the
flow. They are made of inorganic microfine glass fibers that are randomly laid into a multi-layered
web with tapered pore geometry, having larger pores on the upstream surface and finer and finer
pores along the depth of the media, as shown in the schematic diagram of Figure 4.3. The media are
impregnated with resins and then thermally cured for strength and stability. The multi-layered
design of the filter element results in the formation of media with predictable filtration efficiency,
and provides a superior contaminant catching surface area, and thus results in its maximum dirt
holding capacity.
Figure 4.3 | A schematic diagram with a piece of depth filter media with the multi-layered design.
Water Removal Media: Water is undesirable in mineral oils and synthetic hydraulic fluids. The free
water in hydraulic fluids can be removed by using water removal media. The media part is a highly
adsorbent copolymer laminate with an affinity for the water. The water can be bonded to the filter
media and removed from the system. Some of the methods to remove water from the fluid media
are given in the section at the end of the chapter.
Filters According to Assembly Choices: Filters according to the assembly choices can be of the
following two types. They are (1) Cartridge type and (2) Spin-on type. Early fluid filters each
consisted of a permanent housing with the replaceable filter element or ‘cartridge’. Later, the
‘spin-on’ filter design was introduced. This design is a self-contained housing and filter element
assembly. The ineffective one can be unscrewed from its mount and discarded. A new one can be
carefully screwed onto the mount. This design made the filter replacements more convenient.
However, in recent times, manufacturers are shifting back in favour of the cartridge type filter
construction as it generated less wastage with each filter replacement.
Filters with Sub-assemblies: Filters with sub-assemblies are of the following two types. They are
(1) Bypass filters and (2) Duplex filters. The following paragraphs present the details of these two
types of filters:
Filter with Bypass Valve: When a filter element is fully loaded with contaminants, it may burst or
collapse while in operation. A filter integrated with a bypass valve can be used to prevent such an
eventuality. Figure 4.4 shows the schematic diagram of the filter with a bypass valve. Assume that
this type of filter is connected to a hydraulic system. This filter assembly is a type of relief valve
that diverts all or part of the fluid flow back to the system reservoir, once the permissible maximum
pressure differential across the filter is reached. However, the fluid remains unfiltered while it
passes through the bypass valve. The preset maximum pressure differential across the filter
typically ranges from 1. 8 bar [25 psi] to 7 bar [102 psi], and must be well below the collapse
pressure of the filter.
Figure 4.4 | A schematic diagram showing the cross-sectional view of a bypass filter.
Duplex Type Filter: In many hydraulic applications, it is not convenient to shut down the process
lines for the purpose of maintaining/replacing filters. For such applications, duplex filters can be
used. The schematic diagram of Figure 4.5 shows a typical duplex type filter. It is an assembly of
two (or more) filter chambers with a selector valve to select one filter at a time for active filtration.
Assume that the duplex filter is connected to a hydraulic system. When the filter element in the
selected chamber becomes dirty and needs servicing, the duplex valve is shifted without shutting
down the system, thus blocking the flow through the ineffective filter and allowing the flow
through the second filter. The clogged filter element can then be cleaned or replaced while the flow
continues to pass through the currently active filter.
Figure 4.5 | A schematic diagram of a duplex type hydraulic filter.

Courtesy: MAHLE Filtersysteme, GmbH, Germany
Filters According to Technology Types: There are two basic designs of fluid filtration systems
according to the volume of circulating fluid subjected to filtration during each cycle. They are (1)
Full-flow filtration and (2) Proportional-flow filtration.
Full-flow filtration: In a filter with the arrangement for full-flow filtration, the entire volume of the
fluid in the fluid circulating system passes through the filter element during each cycle, thus
eliminating the possibility of the contaminated fluid bypassing the filter element and entering the
system again. In the full-flow filter, the filter element must be sized to permit the entire fluid flow
through the filter without causing an appreciable pressure drop across the filter. The full-flow filter
can also be provided with a bypass relief valve.
Proportional-flow filtration: At times, the entire volume of the fluid in a hydraulic system need not
be filtered, and only a portion of the fluid needs to be passed through the filter element during a
given cycle of fluid circulation. This requirement can be met through the use of proportional or
partial flow filters. Figure 4.6 shows the schematic diagram of a proportional flow filter. It mainly
consists of a filter with a venturi and a passage that connects the hollow part of the filter to the
venturi. A portion of the high-pressure fluid entering the filter passes through the venturi without
filtration, and the remaining portion of the fluid is subjected to filtration as it passes through the
filter element. However, it may be noted that a constant recirculation of the fluid through the
system, filters the entire fluid.
Figure 4.6 | A schematic diagram showing the cross-section of a proportional flow filter.
Filters According to Installation Locations: Another significant aspect of filters used in hydraulic
systems is their mounting locations. The fluid medium of a hydraulic system must be filtered at
appropriate locations for ensuring dependable operation of the system. Much depends on the
cleanliness requirements of the system components, equipment duty cycle, the nature of working
environment, and other system variables. Care must be taken to position the filters at locations,
where the fluid flow is uniform and where the technicians can service these filters quickly.
Typically, the fluid filtration can be carried out before the pumping, after the pumping, and in the
fluid return lines. Apart from these mounting locations, it can be a separate subsystem independent
of the main hydraulic system.
According to their locations in hydraulic systems, filters are categorized into four types. They
are (1) Suction strainers and suction filters, (2) Pressure filters, (3) Return-line filters, and (4)
Off-line filters. The constructional features, advantages, and disadvantages, of all these
location-specific filters, are briefly explained in the following sections with the help of the partial
hydraulic circuit in Figure 4.7, showing a reservoir, pumps, and all types of the location-specific
filters.
Figure 4.7 |A partial hydraulic system schematic with various location-specific filters.
Suction Strainer: The suction strainer is installed at the pump suction side, as shown in the circuit
of Figure 4.7. It is a coarse filter, usually made of a piece of wire mesh, having a mesh width
greater than or equal to 149 microns. It provides protection to the pump from the coarse particles,
most economically. When the strainer is in continuous use, it gets clogged with contaminants. A
blocked strainer can starve the pump, which, in turn, can cause cavitation. The major problem with
the suction strainer is that it is difficult to clean the submerged strainer. Due to such drawbacks, as
explained, suction strainers offer only least benefit to hydraulic systems. A clean and properly
sealed reservoir, an efficient air breather, and an arrangement for the excellent return-line filtration
can eliminate the need for a suction strainer in a hydraulic system.
Suction Filter: The suction filter is always connected to the pump suction side, as shown in the
circuit of Figure 4.7. It is a coarse filter having a mesh width in the range from 5 to 149 microns. It
is usually mounted outside of the reservoir in a service-friendly manner. It essentially provides
protection to the pump from the coarse particles, economically. As suction filters are capable of
removing only coarse particles, they offer only medium benefit to hydraulic systems. They,
therefore, cannot be used for the primary protection against the contamination in hydraulic systems.
Pressure Filter: The pressure filter is always installed downstream of the pump, as shown in the
circuit of Figure 4.7. It is constructed with a rugged casing, to handle the high operating pressures.
It can also be smaller and finer with a mesh width of the range from 10 – 20 microns. It must be
sized for the specific flow rate in the line. It may be designed for use as a full-flow filter or a
partial-flow filter. It can also be arranged for the duplex mode of operation. The main function of
the pressure line filter is to keep the fluid that comes directly from the pump clean. It serves to
protect the expensive and dirt-sensitive downstream components, such as the valves and actuators,
from the pump-generated contamination. Hence, the pressure filters offer high benefit to hydraulic
systems. However, the pressure filters are more expensive since their housings are pressurized.
Moreover, the servicing of the pressure filters is difficult because of their heavy-duty construction.
Return-line Filter: A return-line filter is installed in the return line, as shown in the circuit of Figure
4.7. It is usually a low-pressure housing that can be mounted on the top of or within the reservoir. It
can also be designed for the duplex mode of operation. The purpose of the return-line filter is to
trap the dirt from the system working components, as well as the particles entering the system
through the worn piston-rod seals in the system, if any. It prevents the contaminants arising in the
system parts from getting into the reservoir. Return-line filters are used to remove particles of size
25 microns (or better) in the mineral-based fluids and 10 microns (or better) in the synthetic fluids.
A return-line filter can tolerate a higher pressure differential across its filter element than that of a
comparable suction filter. Because of these advantages, the return-line filters offer high benefit to
hydraulic systems. However, they may be subjected to flow surges while in operation.
Off-line Filtration:
It is essentially a subsystem independent of the main hydraulic system and consisting primarily of a
separate pump and filter unit fitted on a mobile cart, as shown in the circuit of Figure 4.7. The
graphic of the off-line filtration unit is additionally shown in Figure 4.8. This unit is also known as
re-circulating or kidney-loop or auxiliary filter. An off-line filtration system is relatively easy to
retrofit on an existing hydraulic system. It can also serve many hydraulic systems. This unit is used
to achieve the best possible filtration results in hydraulic systems.
Figure 4.8 | A graphic showing an off-line filtration unit installed on a cart.

Courtesy: Engineered Filtration, Inc., USA
In the offline filtration system, fluid is pumped out of the reservoir, passed through the filter,
and then allowed to return to the reservoir in a continuous fashion, independent of the operation of
the main hydraulic circuit. It is possible to maintain a reduced level of contamination in the system
by maintaining a steady fluid flow in the off-line sub-circuit. Therefore, it is easy to get an
excellent filtration performance in the off-line filtration system. Further, it utilizes low-pressure
housings that can easily be accessed and serviced without shutting down the main hydraulic
system. Off-line filters, therefore, offer high benefit to hydraulic systems. However, an additional
pump-motor unit is required if an off-line filtration system is to be employed. The recommended
flow rate per minute for the off-line filtration is 10% of the reservoir capacity for standard
applications and 20% for the associated systems with servo valves and proportional valves. For
example, a standard hydraulic system with a 200-litre reservoir can employ an off-line filtration
unit with a 20 lpm filtration pump.
Test Your Knowledge #4.1

1. _________ filter media is made of plant fibres.
2. ________ filter media are made of glass fibres laid into a multi-layered web.
3. A ________ valve can be incorporated into a hydraulic filter to prevent the collapse of its
filter element.
4. The maintenance of a ___________ type filter can be carried out during the system
operation.
5. In a _______ filter, only a portion of the hydraulic fluid is passed through the filter
element during a given cycle of fluid circulation.
[Choose from: By-pass, Cellulose, Depth, Duplex, Proportional flow, Synthetic, Wire-mesh]
Comparison of Filter Types and Locations

Most of the hydraulic systems would benefit greatly from having a combination of suction,
pressure, return-line, and off-line filters. Consultation to the comparison chart of the filters, as
given in Table 4.1, may be helpful in making a decision on the selection of filters for the hydraulic
systems.
Table 4.1| Comparison of location-specific hydraulic filters

Type Advantages Disadvantages
Strainer Protects suction filter and pump from coarse Use coarse filter media
particles Servicing difficult
Offer only moderate benefit
Suction Protects pump from coarse particles Use coarse filter media
filter Service-friendly Large-size housing
Economical Offer only moderate benefit
Pressure Protects valves and actuators from pump Must handle full system
filter generated contaminants pressure
Adaptable for finer filtration Housing must be sturdy
Offers high benefit Expensive
Return-line Removes wear debris from hydraulic actuators Must handle flow surges
filter & valves Provides no direct component
Lower pressure ratings protection
Easier to install, Lower costs
Offers high benefit
Off-line Easy to retrofit on an existing system Initial cost is relatively high
filter Adaptable for finer filtration Requires additional space
Continuous and steady filtration
Unaffected by flow surges

Easy servicing without main system shutdown
Offers high benefit
Contamination Indicators
The contamination indicator in a hydraulic filter is usually provided with a visual or electrical
indicator to signal the need for the replacement of its filter element. It is also capable of sensing the
pressure differential directly across the filter element. The signal can be a visual, pop-up indicator
with a red button to indicate that the filter element is clogged and the set differential pressure across
the filter has been exceeded. Engineers use electrical/electronic sensors when connections to
remote sensing devices, such as alarms, horns, or lights, are desired. This arrangement allows for
the replacement of the filter element only when its full dirt holding capacity has been reached,
rather than periodically replacing the filter elements on a time-scale basis. The contamination
indicator is especially important with a suction filter to assist in the detection of excess pressure
drop in the system line.
Performance Ratings of Filters

The degree of cleanness achieved by a hydraulic system fluid can be linked to the performance of
the filter elements used in the system. These filter elements are rated on the basis of their ability to
separate the contaminants of particular sizes from the system fluid, under the specific test
conditions. Filter manufacturers publish various filter performance data. Amongst others, two basic
parameters specified by the manufacturers are the mesh number (sieve number) and the micron
ratings. The following sections describe these two parameters. In addition, there exists an industry
standard called the ‘multi-pass test’ to measure the performance ratings of filters such as the Beta
(ß) Ratio and the filter efficiency. Subsequent sections describe the details of the multi-pass test.
Mesh Number/Sieve Number:

The mesh size or fineness of a wire-mesh filter can be expressed in terms of its mesh number or
sieve number. It is the number of openings from the center of any one wire of the wire mesh to the
center of the parallel wire one inch away. A 2-mesh screen has two openings across one linear inch
of the screen, and a 100-mesh screen has 100 openings. Figure 4.9 illustrates the method of
determining the mesh number. A higher mesh number points to a finer filter. Table A8.1 of
Appendix 8 gives a table for the mesh to the micron conversion.
Figure 4.9 | A schematic diagram illustrating the determination of mesh number.
Micron (m) Rating: The micron rating of a filter indicates its ability to remove a specified
percentage of particles of a certain size. Accordingly, there are two most popular micron ratings for
the hydraulic filters. They are (1) absolute micron rating and (2) nominal micron rating. It is to be
noted that the micron ratings can be misleading if one does not fully understand how to use them.
The following sub-sections elaborate these two ratings.
Absolute Micron Rating of a filter is the smallest size of particles it can capture in excess of 98.6%
on the first pass through it. It indicates the size of the largest opening in the filter.
Nominal Micron Rating of a filter is the smallest micron size of particles it can capture in a
specified quantity, in the range from 50% to 95% on the first pass through it. For example, a filter
might be defined as having a nominal rating of 80% for particles of the size greater than or equal to
20 microns. As the filter manufacturers rate the wire mesh and the cellulose media elements
nominally, they might be only 50% efficient at the rated micron size.
Beta Ratio
The Beta (ß) ratio of the filter is also known as the filtration ratio. It signifies the effectiveness of
the filter element in removing the contaminants from the associated hydraulic system. Figure 4.10
shows the schematic diagram of the partial test setup for measuring the Beta ratio of the filter. In
this test, it is necessary to pump a calibrated fluid with a homogeneous amount of contaminants,
through the test filter. Then, count the numbers of particles equal to or larger than the specified
size, upstream and downstream of the test filter, using the automatic particle counters (APCs). The
Beta ratio can then be determined by using the formula given below:
Betaratiox(c)=ParticlecountintheupstreamfluidParticlecountinthedownstreamfluid
Figure 4.10 | A schematic diagram showing the partial test setup for measuring the Beta ratio of the
test filter.
Where the subscript ‘x’ stands for the specified particle size and subscript ‘(c)’ refers to the
‘certified’ calibration. That is, the subscript, (c), indicates the test adherence to the new ISO 16889
standard.
For example, ß5(c) = 1000 for the test filter indicates the presence of 1000 times more particles of
size 5 microns upstream than that at the downstream of the filter. Table 4.2 gives the ß ratio for
some sets of upstream and downstream particles.
Table 4.2 | Beta ratios and the corresponding filter efficiencies of a hydraulic filter
Upstream particles ( x m) Downstream particles ( x m) Beta (ßx) ratio Efficiency(x)
1,00,000 50,000 2 50.0%
1,00,000 5,000 20 95.0%
1,00,000 1,333 75 98.7%
1,00,000 1,000 100 99.0%
1,00,000 500 200 99.5%
1,00,000 100 1000 99.9%
Filter Efficiency
The Beta ratio of the filter alone means very little. Its calculation is a preliminary step in finding the
filtration efficiency of the filter. The filter efficiency represents the ability of the filter to remove
contaminants of a specified size under the specified test conditions. This efficiency, in terms of
percentage, can be found by the following equation:
Efficiency(x)=(11ß)x100
For example, an Efficiency (10) = 80% for the test filter indicates that the filter is 80% efficient in
removing 10 microns size particles.
Example 4.1: In a Multi-pass test for finding the performance of hydraulic test filter, 50000
particles of size 4 m are counted upstream, and 10000 particles of the same size range are
counted downstream of the filter. Calculate the Beta ratio and efficiency of the filter.
Solution:
Given:
Upstream particle count = 50000
Downstream Particle count = 10000
Beta ratio, ß(x) = (Upstream particle count / Downstream particle count)
Beta ratio, ß(4) = (50000 / 10000) = 5
Efficiency (4) = [1 – (1/5)] x 100% = 80%
Beta Ratio and Filter Efficiency

Table 4.2 gives the values of the Beta ratio and the corresponding efficiency of a hydraulic filter for
various combinations of upstream and downstream particles. Simply put a higher Beta ratio of the
filter points to higher filter efficiency.
Example 4.2: Explain the meaning of Beta ratio, ß4(c) =100 of a hydraulic filter, in precise
terms.
Answer:
ß4(c) = 100 signifies that there are 100 times as many 4m particles upstream of the filter as
compared to that at its downstream in a standard test as per the ISO 16889 standard. In other words,
this filter is 99% efficient at removing 4m particles.
Example 4.3: What is the inference you can draw from the Beta ratio, (5/10/20) = 2/20/75, in
respect of a filter media?
Answer:
In this example, the media tested can remove:

50% of 5-micron size particles
95% of 10-micron size particles
98.7% of 20-micron size particles
Differential Pressure (P)

The differential pressure (P) across the filter, while in operation in a hydraulic system, indicates the
difference between its inlet and outlet pressures. It points to an irrevocable loss of pressure in the
system. The major factors that contribute to a higher pressure differential are (1) finer filter media,
(2) the amount of contamination, (3) flow rate, and (4) fluid viscosity. The following paragraph
gives a brief explanation of these factors.
The differential pressure across the filter increases as its Beta ratio or efficiency gets better. The
differential pressure across the filter increases due to the clogging of the filter media with the
contaminants while in service. Another reason for the increased differential pressure is due to the
friction as a result of the fast-moving fluid in the system. A higher viscosity fluid also contributes
to the increased pressure differential.
Particle Capture Efficiency

The particle capture efficiency (dirt holding capacity) of a filter indicates the quantity of the solid
dirt that its filter element can hold before it has to be replaced. It is the weight of the specified
artificial contaminant (ISO medium test dust) that must be added to the fluid upstream of the filter
to produce a given pressure differential across the filter under the specified conditions. This
efficiency indicates the service life of the filter and hence is an important parameter of the filter.
Burst Pressure
The burst pressure of a filter is also known as the ‘collapse pressure’. It can be determined as per
the standard ISO 2941/ANSI B93.25. It is the minimum inside-out pressure differential that a
spin-on hydraulic filter can withstand without the outward structural or media failure. The
minimum burst pressure of a filter designed with a bypass valve should typically be at least two
times greater than the full-flow pressure drop across the bypass valve. The burst pressure of the
filter with no bypass valve should be higher than the setting of the associated relief valve
downstream of the filter.
The Multipass Test
The multi-pass test gives reproducible test data for assessing the performance of the filter elements.
This test provides an accurate and universally accepted test method to describe the efficiency of the
filter element in removing the particles of the standard test dust from the test fluid over a wide
range of particle sizes, under the controlled laboratory conditions. This test has been standardized
by ISO (ISO 16889:2008), SAE (SAE J1858), ANSI and NFPA. This standardization allows every
filter manufacturer to test a given filter at the range of flow rates and terminal pressure drop ratings
that match the requirements of the application. The standardization also allows the designer to
compare the published filter ratings among the different brands of filters reliably so that a
cost-effective filter system can be selected for the application. The following paragraphs give the
details of the multi-pass test.
The multi-pass test can be used to determine the following filter element performance ratings (1)
Filtration efficiency [Beta ratio], (2) Particle capture efficiency or Dirt holding capacity, and (3)
Pressure differential across the test filter.
The set up for the multi-pass test is shown in Figure 4.11. The test bench for the multi-pass test
primarily consists of a pump and automatic particle counters (APCs) installed at the upstream and
the downstream of the test filter. The APCs are calibrated as per the ISO-certified calibration fluid.
The test unit also consists of a contaminant injection system for adding a concentrated stream of
artificial contaminants (Medium test dust conforming to ISO 11703-1) of known particle size
distribution in measured quantities to the fluid upstream of the filter element. The contaminated
fluid is pumped continuously through the test filter at a constant flow rate under the steady-state
condition to load the filter element progressively. The upstream and the downstream particle counts
are taken every minute using the APCs. From these measurements, the particle capture efficiency
(Beta ratio) of the test filter can be determined. Further, the differential pressure across the test
filter is recorded. In most instances, the testing specialist concludes the multi-pass test once the
differential pressure across the filter reaches the specified limit, or the Beta ratio falls below the
specified level.
Figure 4.11 | A schematic diagram showing the test set up for the multi-pass test.
The ISO 16889 standard for the multi-pass test has made great progress in providing a method
with a repeatable performance and ratings under the laboratory conditions. It may, however, be
noted that this standard method often does not translate into a repeatable performance on actual
hydraulic systems operating with pressure surges and temperature variations. The multi-pass test
can be modified to include a range of duty cycles, to test filters in a dynamic environment. For
example, the flow rate can be changed quickly to simulate various duty cycles.
Filter Characteristics
Figure 4.12 gives the typical particle size Vs efficiency characteristics of a filter rated for a mesh
width of 5 . It shows the efficiencies of the 5 filter element in filtering particles of different sizes.
Figure 4.12 | Particle size Vs. Efficiency characteristic of a filter.

Filter Selection
Filters are important devices for maintaining the cleanness of hydraulic systems to a satisfactory
level. Therefore, their proper selection is an important aspect of the hydraulic system design. For
this purpose, it is necessary to know the system characteristics, such as the flow rate, the working
pressure, the viscosity of the system fluid, and the amount of expected system contamination. It is
also important to consider the cleanness level requirements of the system. Next, the performance
specifications of each filter/filter element, such as its micron rating, Beta-ratio/filter efficiency,
dirt-holding capacity, and the maximum permissible pressure differential across the filter, must be
considered. Other important factors, such as the pressure rating, reliability, service life, and the cost
of the filters, are no less important. The compatibility of the materials of filter construction with the
fluid used in the system must also be considered. The filters should match their performance
specifications to the system requirements to obtain the desired cleanness level.
Application Notes, Hydraulic Filters

The most popular application for suction filters is with the variable speed hydrostatic pumps
commonly found in the harsh off-road mobile applications and the industrial variable-speed drives.
The pressure filters are used in hydraulic systems in paper and steel mills, aircraft industry, and
plastic injection moulding and die-casting machines. The return-line filter is the best in systems
consisting of pumps designed for high performances and/or components with close tolerances. It
can also be used in systems, which do not have large contaminant-settling reservoirs.
Test Your Knowledge #4.2

1. ________filters in hydraulic systems provide protection to valves and actuators from
pump generated contaminants.
2. In ________ filtration, continuous filtration of the fluid in a hydraulic system can be done
independently of the operation of the system.
3. The number of openings in a wire-mesh filter from one wire to a parallel wire one inch
away is called its ____________ number.
4. ________ is the filter specification that measures the ratio of the upstream number of a
given size of particles to the downstream number of the same size of particles, of the filter.
5. The ________pressure is the minimum pressure a hydraulic filter element can withstand
without outward structural or media failure.
[Choose from: Beta ratio, Burst, Cellulose, Dash, Differential, Mesh, Multi-pass, Off-line,
Pressure, Return-line, Suction, Synthetic, Wire-mesh]
Water Removal from Hydraulic Systems

The life of the critical wear components in a hydraulic system can be significantly extended by
keeping the fluid in the system in a clean and dry state. Water can be removed from the hydraulic
system by using water removal media or vacuum dehydration or other methods. The water removal
media can be prepared with desiccants or a coalescer. Vacuum dehydrator units can be used when
the water concentration level in hydraulic fluids is greater than 100 ppm (0.01%). The following
paragraphs explain some of the methods to remove water from hydraulic systems:
Absorption: A filter with a water absorbing element can be used to absorb and retain the free
water and the dissolved water in the fluid medium of a hydraulic system.
Gravity Precipitation Unit: This method holds the hydraulic fluid in the chambers of a gravity
precipitation unit for settling out the contamination, free water, and particles.
Centrifuge: This method separates the free water from the hydraulic fluid chamber by the
centrifugal force generated by the rapidly rotating cone-shaped disks inside the chamber.
Coalescer: A coalescer is designed to remove the free water from the fluid by passing it through
the unique coalescing elements.
Vacuum Dehydration purifier: In this method, the free water and the dissolved water can be
removed by the vacuum dehydration unit with a vacuum pump, a circulation heater, and
dispersion media. The vacuum pump draws the fluid into the unit through the heater, where the
fluid temperature is raised approximately to 65 0C [150 0F]. The fluid is then exposed to vacuum
while it flows through the pores of the dispersion media. The water is boiled off from the unit,
and the fluid is effectively dehydrated.
Objective Type Questions

1. Which type of hydraulic filter can be used to prevent the collapse of a filter due to clogging of
its filter element?
a) Filter with bypass valve
b) Duplex filter
c) Proportional filter
d) Full flow filter
2. Which type of hydraulic filter do you use for its easy maintenance without shutting down the
process line?
a) Filter with bypass valve
b) Duplex type of filter
c) Proportional filter
d) Full flow filter
3. Which type of hydraulic filter do you use for the immediate protection of valves and cylinders
in a hydraulic system?
a) Suction filter
b) Pressure filter
c) Return-line filter
d) Off-line filter
4. Which type of hydraulic filter do you use for filtering fluid independent of the main hydraulic
system?
a) Suction filter
b) Pressure filter
d) Off-line filter
5. Which type of hydraulic filter can be used to trap dirt from the working components of a
hydraulic system?
a) Suction filter
b) Pressure filter
d) Off-line filter
6. Which of the following types of filters offers high benefit in hydraulic systems?
a) Strainer
b) Suction filter
d) None
7. What is the efficiency of the hydraulic filter with a beta ratio of 20 for 4 particles?
a) 50%
b) 80%
c) 95%
d) 99%
8. When a hydraulic filter performance is expressed as ß4 = 75, what does it mean?

a) Beta ratio of 4, 75% efficient at removing 75-micron particles
b) Beta ratio of 75, 98% efficient at removing 4-micron particles
c) Beta ratio of 4, 75% efficient at removing 4-micron particles
d) Beta ratio of 75, 75% efficient at removing 4-micron particles
9. Which of the Beta Ratios given below provides the better wear protection at 10 microns?
a) ß5 = 75
b) ß10 = 200
c) ß25 = 200
d) ß200 = 10
10. The pressure differential across a hydraulic filter unit increases due to:
a) The use of higher viscosity fluid
b) The clogging of the filter media
c) The friction of fast-moving fluid
d) All of the above
Questions
1. Why is it necessary to install an efficient filtration system in a hydraulic system?
2. Explain the functional and constructional aspects of strainers used in hydraulic systems.
3. What are the differences between a strainer and a filter in respect of a hydraulic system?
4. Differentiate between the absorbent type and the adsorbent type of hydraulic filters.
5. Classify hydraulic filters according to their nature of filtration.
6. Differentiate the surface filter media and the depth filter media, as used in hydraulic systems.
7. What are the materials used to make the filter media for hydraulic filters? Briefly, explain.
8. What are the advantages of the synthetic filter media?
9. Differentiate the cellulose filter media and the synthetic filter media.
10. What is a bypass filter, as used in hydraulic systems?
11. Explain the working principle of a hydraulic filter with a bypass valve, with the help of its
schematic diagram.
12. Explain the function of a duplex type hydraulic filter, with the help of its schematic diagram.
13. What is a full-flow hydraulic filter?
14. What is a proportional flow hydraulic filter?
15. How do you differentiate between the full-flow filtration and the proportional flow filtration?
16. Explain how the bypass valve compliments the full-flow filter when used in a hydraulic
system.
17. Explain the significance of the location-based hydraulic filtration.
18. Which are the typical locations where filters can be installed in hydraulic systems?
19. Explain the essential function and installation features for suction filters in hydraulic systems.
20. Explain the essential function and requirements of pressure filters in hydraulic systems.
21. What are the disadvantages of suction filters?
22. Explain the primary function of the return-line filters used in hydraulic systems.
23. Enumerate the advantages and disadvantages of the pressure filters in hydraulic systems.
24. What are the advantages of return-line filters?
25. Explain the hydraulic off-line filtration technique with a neat sketch.
26. What are the advantages of the off-line filters used in hydraulic systems?
27. Are the pressure and return-line filters enough to protect a complex hydraulic system
adequately? Justify you answer.
28. What are the performance specifications of hydraulic filters?
29.
29. Define the two types of micron ratings in respect of hydraulic filters?
30. What is the difference between the absolute micron ratings and the nominal micron ratings?
31. What is the burst rating of a hydraulic filter?
32. Explain the multi-pass test for a hydraulic filter with the schematic diagram of the test setup.
33. What are the parameters that can be determined through the multi-pass test for a hydraulic
filter?
34. How is the efficiency of hydraulic filter evaluated?

35. What is Beta ratio of a hydraulic filter? Explain with a numerical example.
36. What is filter efficiency and what is its significance in hydraulic systems?
37. How is the Beta ratio of a hydraulic filter related to its efficiency?
38. Explain the meaning of Beta ratio, ß4(c) = 2, pertaining to a hydraulic filter.
39. Write short notes on the following terms related to hydraulic filters: (1) Synthetic filter media,
(2) Proportional flow filtration, (3) Multi-pass test, and (4) Dirt holding capacity.
40. Write short notes on the following terms pertaining to hydraulic filters: (1) Depth filter, (2)
Duplex filter, (3) Off-line filtration, and (4) Beta ratio.
41. What system characteristics do you consider when specifying a hydraulic filter?
42. What factors do you consider while selecting hydraulic filters?
43. What are the different ways to remove water from hydraulic systems?
Numerical Problems
1. Find out the Beta ratio of the filter when 10000 particles of >= 20 m enter the filter, and 9950
of these particles are trapped by the filter? Also, calculate the efficiency of filtration for the
given particulate size. {Ans: ß(20) = 200, (20) = 99.5%}
2. What is the meaning of ß4(c) =1000, pertaining to a hydraulic filter? Also, calculate the
corresponding filter efficiency.
3. In a multi-pass test, 30000 and 1000 particles of size 4 microns or greater were recorded in
automatic particle counter upstream and downstream of the test filter respectively. Determine
the efficiency of the filter for a given particulate size? {Ans: (4) = 96.67%}
References
1. Article on: ‘Condition Monitoring for Hydraulic and Lubricating Fluids’ HYDAC
International GmbH, Hauptstrasse, Saarbrücken, www.hydac.com
2. Article on: ‘Element Technical Data Fundamentals’, SCHROEDER INDUSTRIES LLC.
3. Article on: ‘Filtration’ Stauff Corporation, Inc., 7 Wm. Demarest Place, Waldwick, New
Jersey, USA.
4. Article on: ‘Hydraulic & Lubrication Filters, Part I: Filter Types and Locations and Part II:
Proper Filter Sizing, HY-PRO Filtration’, www.filterelement.com
5. Article on: ‘Hydraulic filtration - part 1, 2, 3, 4’, Penton Media, Inc. & Hydraulics &
5.
Pneumatics magazine.
6. Article on: ‘Hydraulic Filtration and Contamination’, Filter Manufacturers Council, NC, USA,
www.filtercouncil.org
7. Article on: ‘Hydraulic System Filters New ISO Fluid and Cleanliness Rating Standards’, Moog
Inc., NY USA, www.moog.com
8. Articles on (1) ‘The Micron Rating for Media in Fluid Filters’, Revised October 2005, and (2)
‘Hydraulic Filter Performance Criteria’, Filter Manufacturers Council, Research Triangle Park,
NC, USA.
9. Cartridge Filtration, Schroeder Industries, Leetsdale, PA, USA.
10. Catalog: MAHLE Industrial Filters, MAHLE Filtersysteme GmbH, Industriefilter
Schleifbachweg 45 D-74613 Öhringen.
11. Document on ‘MAHLE Industrial Filters, Filtration processes for the metal working industry’,
MAHLE Filtersysteme GmbH, Industriefilter, Schleifbachweg, Öhringen, www.mahle.com
12. Document on: ‘Filter Element Beta Ratio Information’, Swift Filters, Inc., Ohio, USA.
13. Document on: ‘Filters & contamination controls’, Fluidea
14. Document on: ‘Hydraulic & Lubrication Filters, Part I: Filter Types and Locations’, HY-PRO
FILTRATION, U. S. A., www.filterelement.com
15. Document on: ‘The Handbook of Hydraulic Filtration’, Parker Hannifin Corporation,
Metamora, OH, USA.
16. Documents on: ‘Hydraulic Filtration Technical Reference’ (Doc. No. F115354 rev.1), and
‘Hydraulic Filtration Product Guide’, Donaldson Company, Inc., Minneapolis, MN, USA.

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Chapter 4 Hydraulic Filtration Principles

Classify the hydraulic filters according to various parameters.

Strainers and Filters

Types and Classifications of Hydraulic Fluid Filters

Figure 4.5 | A schematic diagram of a duplex type hydraulic filter.

Figure 4.8 | A graphic showing an off-line filtration unit installed on a cart.

Test Your Knowledge #4.1

Comparison of Filter Types and Locations

Table 4.1| Comparison of location-specific hydraulic filters

Unaffected by flow surges

drop in the system line.

Performance Ratings of Filters

Mesh Number/Sieve Number:

Figure 4.9 | A schematic diagram illustrating the determination of mesh number.

1,00,000 50,000 2 50.0%

Beta ratio, ß(x) = (Upstream particle count / Downstream particle count)

Beta ratio, ß(4) = (50000 / 10000) = 5

Efficiency (4) = [1 – (1/5)] x 100% = 80%

Beta Ratio and Filter Efficiency

In this example, the media tested can remove:

Differential Pressure (P)

Particle Capture Efficiency

The Multipass Test

Figure 4.12 | Particle size Vs. Efficiency characteristic of a filter.

Application Notes, Hydraulic Filters

Test Your Knowledge #4.2

Water Removal from Hydraulic Systems

Objective Type Questions

8. When a hydraulic filter performance is expressed as ß4 = 75, what does it mean?

d) Beta ratio of 75, 75% efficient at removing 4-micron particles

34. How is the efficiency of hydraulic filter evaluated?

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