HYDRAULIC

FILTRATION
DESIGN GUIDE

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HYDRAULIC FILTRATION DESIGN GUIDE

TABLE OF CONTENTS
Hydraulic filters: Size, location, and quality..................................... 3

Hydraulic Symbology 304 – conditioning and monitoring.............. 6

Where are hydraulic filters used?..................................................... 8

▼
What are the most important hydraulic filtration terms MARY GANNON
Editor
you must understand?...................................................................... 9

What is the difference between cellulose and glass filter media?..... 12

Beta ratio: Identifying the quality of a hydraulic filter element....... 13

What is surface media vs. depth media?......................................... 14

Where should I locate my hydraulic filter?....................................... 15 ▼

PAUL HENEY
What are hydraulic filtration systems?.............................................. 16
VP, Editorial Director

Where are filtration systems used?.................................................. 17

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How do you remove water from your hydraulic system?................. 18

Maintaining reliability with hydraulic filters..................................... 21

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 Hydraulic filters:
Size, location, and quality
F
iltration quality is the single most important measure of
hydraulic machine health. More hydraulic failures are a result
of particle contamination than any other cause. Some inside
information is required to effectively apply filtration, but it mostly
boils down to size, location and quality.
Hydraulic filters are sized based on the flow passing through
them at an acceptable pressure drop. It is important to consider
pressure drop, which is the pressure developed by the friction of
the fluid against and through the material of the filter assembly
itself, because the majority of filters are installed with a bypass
valve designed to open by the backpressure created by the
clogged element. By sizing a filter intelligently, pressure drop
is created only as the element becomes clogged with particles,
preventing premature bypass, a condition when fluid passes
through unfiltered.
To prevent excessive pressure drop, filter assemblies are often
sized larger than required. An oversized assembly ensures little
energy is lost to pressure drop, and as a corollary, larger filter
elements are capable of holding more dirt before they become
clogged. Because an adequately sized filter assembly provides
both higher dirt-holding capacity and higher flow capacity, the
choice to oversize a filter is limited only by real estate and price.
With this in mind, choose filters as big as is reasonable. Never
install a filter with borderline flow capacity, as it can go into
bypass quickly and often, especially as it becomes clogged.
Additional considerations for sizing a filter are the fluid type and
viscosity, as well as the quality and efficiency of the filter media.
Highly viscous oil creates more backpressure than does thin
oil, and you should also consider how oil viscosity will vary with
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Image:
Ohio
Fabricators
extreme changes in ambient temperature, such as with mobile
equipment. Obviously, cold oil is thicker, and a marginally sized
filter will bypass until the fluid reaches operating temperature.
Filter media quality plays a part in sizing assemblies for two
reasons: Finer filtration (i.e., lower micron rating), is more restrictive
to flow because of the smaller gaps in the media, which are
required to trap smaller particles. Also, the quality of the filter
media plays a part because premium synthetic depth-media has
a higher dirt holding capacity and will take longer to clog than
cheap paper or cellulose media. If you are unsure of the variables
when you are applying or purchasing a new filter assembly, it is
advised to oversize the element and to use a high-quality medium.
LOCATION DETERMINES TYPE
By and large, hydraulic filters are used in three primary functional
locations: return lines, pressure lines and off-lines. The venerable
return-line filter is the most commonly used on a hydraulic
machine, especially on mobile equipment. It is installed
somewhere between the last valve or actuator of a hydraulic
circuit and the reservoir so the oil is filtered as it enters the
tank. This mounting location ensures oil in the reservoir is clean
and limits the re-introduction of wear-related contamination
generated in the hydraulic system itself. Oil should then be clean
and once again ready for recirculation by the pump.
The spin-on filter is still the most popular choice for mobile
machinery, but traditionally the quality of paper and cellulose
media left much to be desired. However, the major players in the
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(continued)
Hydraulic filters: Size, location, and quality
filtration game make higher quality synthetic fiber media for their
spin-on elements, and other than the newer series of medium
pressure filters of some manufacturers, the synthetic canisters can
be installed onto existing low-pressure heads.
The low- to medium-pressure cartridge style filter assemblies are
also popular for use in return lines. These units have removable
bowls with which filter cartridges are inserted. When a filter
element becomes clogged, the bowl is screwed off, the cartridge
removed and replaced, and then the bowl is screwed back on
again. This design is more ecologically friendly, as it requires no
bulky steel outer shell, is simpler to manufacture, and once used,
cartridge elements are easier to drain of residual waste oil.
Cartridge filter assemblies are often more expensive than their
spin-on counterparts, but they’re available in a wider range of
filter media, which is usually higher quality. In addition to synthetic
elements, filter cartridges are also available in various media
such as wire mesh, water-absorbing, paper, polyester, etc. It is
important to consider the media, because so many are available,
and not all are created equally. For example, some paper filter
media absorb water, but others made from polyester do not.
The synthetic media typically have higher dirt holding, which
should be factored into price considerations of your replacement
elements; a synthetic element might cost twice as much as a
paper element, but could hold four times the dirt.
The pressure filter assembly is also relatively common, and is
useful for protecting the hydraulic system downstream of the
pump. Sometimes contamination makes its way into the reservoir
and is fed into the circuit via the pump. By placing a filter after
the pump, anything introduced into the oil and not caught by
the return filter will be trapped by the pressure filter, keeping the
downstream components safe. Pumps sometimes wear rapidly
or break apart internally, and pressure filters will catch the pieces
before they damage anything else in the system. When used in
this capacity, pressure filters often have no bypass valve, providing
ultimate protection.
Pressure filters must be rated for the nominal pressure of the
circuit, which can be 3,000 or 5,000 psi or higher. This higher-
pressure capability dictates that the filter be manufactured from
steel, which means they are quite heavy. Pressure filters use
cartridge style elements, and in most circumstances, the elements
have a high collapse rating to withstand the possibility of higher-
pressure differential, especially when there is no bypass valve.
The third most common location for a filter is in what’s called a
kidney loop, which is also referred to as an offline filter circuit. A
kidney loop gets its term from the methods of blood cleaning
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HYDRAULIC FILTRATION DESIGN GUIDE
outside the body, such as with a dialysis machine, and how it
bypasses the online filters, the kidneys. A hydraulic kidney
loop is a circuit with a dedicated pump whose only job is to
circulate tank fluid to clean it (and usually cool it). Most high-end
hydraulic machines use a combination of pressure, return and
offline filtration, and typically the offline filter has the finest filter
quality. Because the kidney loop isn’t exposed to the flow and
pressure spikes of the system, it provides a reliable method of
ultra-fine filtration quality that introduces no backpressure into
the working circuit.
Although any filter can be used in a kidney loop, filter media
quality is available much finer than even the best synthetic media
found in pressure and return filters. Additionally, some offline filter
media has extremely high dirt holding capacity, allowing them to
remain running on the machine, in some cases, for years.
EXAMINE FILTER RATINGS
Hydraulic filter quality varies as much as the construction and
application of the units themselves. Filters are qualified by both
the average size of particles they trap and the efficiency in which
they’re trapped. Filter quality is expressed in the micron, which
is a thousandth of a millimeter, and micron rating describes the
theoretical maximum sized particle the medium will allow to pass.
For example, a 10-μm filter should trap any 10-μm particle passing
through it. In reality, this is not the case. Filter ratings are either
nominal or absolute, and each describes the general capacity for
the filter to remove particles of the specified size at a specified
efficiency. A filter with a nominal rating is low efficiency, and a filter
with an absolute rating is high efficiency. The problem is that any
manufacturer can describe their filter with any micron rating as
long as they publish the efficiency of the media, so you must be
careful when selecting them.
Filter efficiency is often expressed by beta ratio, which is a ratio
derived from a test measuring the number of particles upstream
of the filter to downstream of the filter. Test dust is added to the
oil of a sophisticated test rig that counts the number of particles
before the subject and then counts the particles again after the
fluid has passed through. Particle micron size must be specified
when describing beta ratio, and conversely, no filter micron rating
is worthwhile without knowing the beta ratio at which it was
tested. Once filter beta ratio is calculated, we can further deduce
the filter efficiency to decide if a filter is absolute or nominal.
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(continued) HYDRAULIC FILTRATION DESIGN GUIDE
Hydraulic filters: Size, location, and quality

If 100,000 5-μm particles are measured upstream of the filter and

100 particles are measured downstream of the filter, the filter has a
Beta Ratio of 1,000, and is expressed as β5 1,000.

• To now calculate efficiency, we subtract one from the beta

ratio and then divide by the beta ratio.

For example: (1000-1)/1000 = 0.999 or 99.9%.

• Our theoretical test filter is 99.9% efficient at removing

5-micron particles.

Absolute filters must have βx ≥ 75 (x = specified micron size),

according to ISO 16889: 1999, which is 98.7% efficiency. Anything
below these numbers is considered a nominally rated filter, and
such filters can drop as low as a beta ratio of 2, or 50% efficiency.
Avoid nominally rated filters, if possible. When filter competence
is low, the excess of particles turns the fluid into a liquid lapping
compound, of which its abrasiveness further wears components,
subsequently increasing the abrasiveness of the fluid itself. To be
safe, use only absolute filters with >75 beta ratios.

A filter should be of minimum quality for the most sensitive

hydraulic component in the system. Checking the datasheets
of all components will help, as they will specify their required
oil cleanliness level, and often the minimum micron filter rating.
However, there’s no evidence it’s possible to have “too clean” of
oil, and filter quality should be as fine as space, cost and pressure
drop will allow.

High-pressure filter kits such as these are designed to protect

against wear and malfunction, and are usually placed near control
valves or other critical components.

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HYDRAULIC SYMBOLOGY
304 – CONDITIONING AND
MONITORING
T
he use of hydraulic symbols must be comprehensive in
your efforts to detail the workings of a complete hydraulic
system. Hydraulic machines consist of more than pumps,
valves and actuators, of course, even though they are
often the stars of the show. Those stars would quickly fall into the
other side of fame without components to condition and monitor
your machine.
Conditioning symbols are those representing components used
to filter, heat, cool or otherwise treat the hydraulic fluid of your
machine. If you recall from way back in Hydraulic Symbology 101,
we draw fluid conditioning symbols most often with a diamond-
shaped basic shape. From this basic diamond, fluid moves
through the component symbol in many ways. I’ve detailed the
basic filter symbol, shown in Figure 1.
Figure 1. Filters
Imagine hydraulic fluid flowing in from the top of the diamond,
where it’s able to fill the chamber. The dashed line is neither
a pilot or drain line, as is described in previous articles, but
perforations. Fluid must pass through the perforations leaving
particles trapped atop the layer. Actual perforations are
microscopic, but it represents the real-world filter quite well.
Clean fluid exits the bottom, most often directly into the reservoir,
once again ready to be pumped out.
Hydraulic systems need protection from atmospherically
suspended particles such as dust, welding fallout and machining
particles. Differential cylinders require an extra fluid volume to
extend, and that fluid must draw from the reservoir. As the fluid
volume decreases in the reservoir, air draws in to replace it,
6 www.fluidpowerworld.com
and without some form of contamination removal, atmospheric
contamination may enter the system. The breather filter allows air
to pass while trapping particles. The second symbol in Figure 1,
with the arc above the filter element, is such a device.
The complete filter assembly in Figure 1 is a compilation of
components for filtering and monitoring filter condition. Fluid
passes straight through the middle, where particles get trapped
inside the media. The symbol for a pressure gauge sits to the left.
This pressure gauge differs in that two opposed lines terminate
on either side of the gauge. Known as the differential pressure
gauge, it compares pressure upstream to downstream of the
filter to show the pressure drop through the filter element.
Showing pressure drop rather than absolute pressure offers an
accurate method to trigger filter replacement when the filter
begins to clog. An upstream pressure gauge would provide just
a backpressure reading at the filter, instead of pressure drop
through the element.
To the right of the filter is a spring offset check valve denoted
with a 25 psi spring value. This check valve provides a bypass flow
path should pressure drop increase due to an excessively clogged
filter. Return lines are generally poor locations for backpressure,
so this check valve provides an alternate flow path when the filter
becomes too clogged to flow well enough. At 25 psi, the check
valve starts to open to reduce backpressure through the element.
Take note that flow through the check valve is not filtered,
allowing contamination to pass right through.
In Figure 2, I show the compound symbol for a duplex filter
assembly. A duplex filter allows on-demand filter change while
the hydraulic system still runs. The fluid first enters from the top
of a 3-way ball valve. The three cones show the top inlet and
two horizontal outlets possible depending on the location of the
handle shown sprouting from the bottom. Some 3-way valves are
simply a circle with an L-shaped line connecting two of the three
ports, but I find this version more succinct.
Juxtaposed to the 3-way ball valve are two objects appearing to be
spring return cylinders. These are, in fact, pop-up indicators. The
spring value would be equivalent to about two-thirds the setting of
the bypass check valves. If the bypass valves begin to open at 45
psi, the pop-up indicator overcomes its spring at 30 psi to warn the
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(continued)
Hydraulic Symbology 304 –
conditioning and monitoring
maintenance team that the filter should be changed soon. Often
turning from green to red at the time of pop-up, they automatically
reset when pressure drop returns to normal after the filter change.
Figure 2. Duplex filter assembly and anti-cavitation assembly.
You can see each filter has its bypass valve (which is sometimes
in the filter element itself), although I’ve omitted the spring valve
to reduce clutter. After fluid passes the filter through the bottom,
both elements join to a single outlet where clean oil exits the
assembly. Most duplex filters are inline mounted rather than in-
tank and may be pressure filters as well as return line filters.
The anti-cavitation filter assembly in Figure 2 provides a couple
more symbology options for a filter assembly. Much of it is the
same as the filter assembly in Figure 1 but includes two more
options. The second check valve is to allow an anti-cavitation
function to the system. There are circumstances where a hydraulic
system might want to “float,” meaning that it could be pulled,
lifted or pushed under gravity or load forces. For example, if a
cylinder is pushed upon while stationary, fluid may need to be
pulled in from the reservoir to take up the volume differential.
Without the check valve, the cylinder could cavitate and create air
bubbles to potentially damage the cylinder when re-pressurized.
The component to the right of the diamond filter is a differential
pressure switch. By comparing pressure upstream to downstream
as in the pressure gauge of Figure 1, this switch triggers some
light, PLC or another warning that the filter should be changed
soon. The symbol itself is a square box with a fixed spring symbol
atop. The three dots are electrical contacts, while the line shows
the default electrical path in this case “closed” to connect the
bottom to the left side contact. When pressure matches the
switch’s spring value, the contact shifts to the right, closing the
electrical circuit and signalling the warning.
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HYDRAULIC FILTRATION DESIGN GUIDE
No fluid conditioning package is complete without control
over the temperature of the hydraulic fluid. Heaters, coolers
or heat exchangers benefit most hydraulic systems, especially
those located variable climates or working conditions. Figure
3 shows the diamond symbol as heaters and coolers. The first
symbol on the left depicts the vertical hydraulic fluid flow path,
bisecting two inward-facing arrows. These arrows do not denote
a fluid flow path, as is typical for the symbol, but the direction of
thermal transfer, and showing the symbol for a heater, such as an
electric in-tank coil type.
Figure 3. Heat-exchangers and coolers
The cooler symbol second left is very similar to the heater
save the two outward-facing arrows, which represent heat
evacuating from the fluid. This symbol is basic and does not
tell us if the cooler is liquid-to-liquid or liquid-to-air, although
I would assume liquid-to-air if compared to the symbol on its
right. The heat exchanger symbol combines the internals of the
heater and cooler, showing the capacity to direct heat inward
or outward (but never simultaneously). However, poking out
from the right is an extra pair of fluid lines first entering from
the top and then exiting from the bottom. The extra lines stand
for a coolant fluid, which may be city water or water-glycol,
either cooled or heated. Tube and shell or brazed plate cooler
are examples of a liquid-to-liquid cooler.
The final compound symbol surrounded by an enclosure line is the
liquid-to-air cooler. This unit would be either a tube and fin or bar
and plate style cooler common to forced air coolers. The compound
shape to the right shows two conjoined triangles forming the fins
of a cooling fan attached to the circular prime mover symbol for an
electric motor. The letter “M” stands for motor, and if its enclosure
were square would signal an internal combustion engine.
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 Image courtesy of Adobe Stock.
Where are hydraulic
filters used?
H
ydraulic filters are used anywhere in a hydraulic system
particle contamination is to be removed. Particle
contamination can be ingested through the reservoir,
created during the manufacture of system components, or
generated internally from the hydraulic components themselves
(especially pumps and motors). Particle contamination is the
primary cause of hydraulic component failure.
Hydraulic filters are used in three key locations of a hydraulic
system, depending on the required degree of fluid cleanliness.
Nearly every hydraulic system has a return line filter, which traps
particles ingested or generated out in the hydraulic circuit.
The return line filter traps particles as they enter the reservoir,
providing clean fluid for reintroduction into the system.
8 www.fluidpowerworld.com
Although less common, hydraulic filters are used in the pressure
line, after the pump. These pressure filters are more robust, as
they are submitted to full system pressure. If your hydraulic system
has sensitive components, such as servo or proportional valves,
pressure filters add a buffer of protection should contamination
be introduced into the reservoir, or if the pump fails.
The third place hydraulic filters are used is in a kidney loop circuit.
An offline pump/motor group circulates fluid from the reservoir
through a high-efficiency filter (and usually through a cooler as
well). The advantage to offline filtration is it can be very fine, while
creating no backpressure in the primary hydraulic circuit. Also, the
filter can be changed while the machine is operational.
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WHAT ARE THE MOST IMPORTANT
HYDRAULIC FILTRATION TERMS
YOU MUST UNDERSTAND?
BETA RATIO

Beta Ratio describes the ratio between contamination particles

measured upstream of the test filter to downstream of the test
filter. For example, using the ISO 16889 multi-pass test standard,
labs artificially contaminate a given volume of hydraulic fluid with
a given volume of certified test dust until the fluid is saturated.

The lab runs the contaminated hydraulic fluid through the tested
filter assembly. Then, using sophisticated particle counting
equipment, they measure the number of particles before and
then again after the filter. The lab calculates the Beta Ratio by
dividing the number of particles before the filter by the number
Image: Ohio Fabricators of particles after. For example, if the manufacturer presents
their 5 micron (5µ) filter for testing and the lab measures 200,000

I
particles before the filter and then only 1,000 particles after the
t’s not enough for you to learn how to design or install hydraulic
filter, the Beta Ratio is 200.
systems. Any fluid power professional worth their weight in
hydraulic oil approaches their education holistically, even if this I should mention that the Beta Ratio must be expressed
education occurs after your last exam in college. Engineers and alongside the micron rating of the filter. Our 5µ example only
designers absolutely must consider how to make it easier for becomes valid should the manufacturer express it alongside the
the mechanic who will eventually maintain the machine, offering Beta Ratio. Filter ratings are sometimes arbitrarily based upon
various access points for test gauges, ball valves to isolate sub- the manufacturer’s whim, and any filter could be given any rating
circuits and filters located where the technician has easy access. without expressing how efficiently it removes those particles. A
t-shirt could remove some number of 5-micron particles, albeit
Moreover, technicians and mechanics perform their jobs well
not very efficiently. This concept brings us to our next term.
when familiar with fluid power best practices, especially from
a maintenance perspective. At the same time, nobody is
EFFICIENCY
expecting your construction equipment mechanic to learn about
the frequency response of servovalves, but other subjects are
universal to the industry. Really just an expansion of the Beta Ratio, filter efficiency is
another way of expressing how well a filter removes particles of a
The subset of filtration is arguably the most universally required, given size. To calculate filter efficiency, simply subtract one from
applied by everyone between the engineer and mechanic the Beta Ratio and then divide that by the Beta Ratio. I’ll use the
to ensure pumps, valves, and actuators operate reliably and example using a Beta Ratio of 1000:
efficiently. Filtration, of course, protects equipment spanning
dozens of other industries, but much of the conversation
regarding hydraulic oil filtration is unique. To master hydraulics,
you need to master the following terms.

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(continued)
What are the most important hydraulic
filtration terms you must understand?
Using this formula, we can see that a Beta Ratio of 1000 equates to
99.9% efficiency, which is very efficient. For example, a decent filter
is anything above 98% efficiency. Anything less is not worth putting
on your machine. Although it seems like the 99.9% filter is only 1.9%
better than the 98% efficient filter, let me put it another way.
The 98% efficient filter is trapping particles at a 50:1 clip (Beta
Ratio of 50). So if we have 100,000 particles upstream of the filter,
2,000 particles are passing straight through. However, with the
99.9% efficient element (1000 Beta Ratio), only 10 of those 100,000
particles can make it through. The finer filter actually removes two
hundred times more particles and is exponentially more efficient.
It should be clear that it’s often misleading when you play around
with efficiency numbers. When manufacturers express nominal
efficiency, it often describes the percentage of particles the filter
may trap. You can expect this from paper or cellulose filter media.
Filters with absolute ratings will generally trap all or most of the
particles of the expressed size. Look for synthetic filter media for
the most efficient filtration.
DIRT HOLDING CAPACITY
Let’s face it, a filter’s primary role is to hold onto dirt. Next to the
proficiency in which a filter traps particles, the quantity of particles
trapped takes a close second place. It’s not enough to trap a few
particles and call it a day. As a filter traps particles, those particles
block the flow path through the fibers of the element, which in
turn increases backpressure. Backpressure in hydraulic lines —
especially return lines — can be detrimental. To ward off excessive
backpressure, hydraulic filters use bypass check valves that open
when pressure rises above their spring value.
What’s worse than trapping only a few particles is letting all
particles pass right through. When a filter goes into bypass
because its media is clogged, you have precisely zero filtration
occurring. I’m not pointing this out as a public service
announcement to change your filter as required (which is
essential), but as a segue into the importance of a filter with high
dirt holding capacity.
Three factors play into the number of particles a filter will hold —
media type, construction style and physical size. The media refers
to the fiber or mesh cloth or textile from which the manufacturer
makes. A depth media is one where many layers of fiber create a
volume where particles become trapped. A surface media is one
where essentially one layer stops particles from passing.
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HYDRAULIC FILTRATION DESIGN GUIDE
Depth media offers a higher dirt retention capacity, with many
possible layers of fiber to trap particles. A surface media can easily
clog its pores, although some such as wire mesh may be cleaned
and re-used. The construction and spacing of the pleats also play
into dirt holding capacity. A filter with many deep pleats will trap
much more than an inexpensive model using fewer shallow pleats.
Finally, it will make sense that a physically larger filter assembly
has more volume to trap contamination, holding more while
offering reduced pressure drop.
PARTICLE COUNT
It’s critical for you to understand the number of particles
contaminating your hydraulic fluid. By elucidating just how “dirty”
your oil is, you can make adjustments in filtration quality and
element changeover based on real-world results of your filtration
program. A simple bin tipper hydraulic circuit, for example, gets
by with less stringent filter quality. In contrast, your CNC tube
bending machine operates with high precision proportional valves
and requires finer filtration.
But how fine is fine? Most hydraulic component manufacturers
will specify the required fluid cleanliness required for the best
performance of their pump, valve or actuator. If you can’t find that
information, the below chart offers a guideline.
The numbers atop the three righthand columns represent the
three sizes of particles deemed most damaging to a hydraulic
system – 4, 6 and 14 microns. Listed in those columns is a digit
standing for a range of particles found in 100 ml of fluid as
measured by an electronic particle counter. That digit signified an
ISO code offering a range of particles, as listed below. Together,
the three digits represent the ISO 4406 contamination code.
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(continued)
What are the most important hydraulic
filtration terms you must understand?
If we use the vane pump as an example, which requires at least
19/17/14 or better for protection, we simply pick each range of
the below chart to represent the maximum range of particles you
should measure in the 100 ml of sample fluid. ISO Code 19 tells
us there are between 260,000 and 500,000 particles larger than 4
microns, including both 6- and 14-micron particles. Then the 17
equates to between 64,000 and 130,000 6 micron particles. Finally,
the 14 tell us between 8,000 and 16,000 particles of the 14-micron
and larger size may be in the fluid sample.
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HYDRAULIC FILTRATION DESIGN GUIDE
You’ll have noticed that every code doubles the number of
particles in each range. As you move up in the ISO Code, particles
increase exponentially, so just a few digits difference (say 11 to 14)
stands for eight times the number of particles.
There is no downside to having fluid cleaner than the
recommended ISO Code. Because of their precise internals and
high-pressure drop, servovalves like to see very few damaging
particles circulating, so you must achieve at least 15/13/10 for
reliable operation. However, your gear pumps and directional
valves will not complain should you offer up the same level of
cleanliness. In fact, I consider dirty oil to act much like a lapping
compound, which wears away the metal of pumps, valves and
motors. In turn, this wearing of metal adds to the circulating
contamination, further exacerbating the lapping effect. There is
no such thing as “too clean” hydraulic fluid.
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What is the difference between
cellulose and glass filter media?
M
anufacturers make cellulose fibers from long chains of
plant material processed into a pulp and then drawn
out into strands. Glass media comes from a more
complicated process of first drawing molten silica
fibers and then combining them into a strand using a resin binder.
The product of either process looks surprisingly similar, but their
performance resembles each other very little.

Both cellulose and glass media has a place in filtering hydraulic

fluid from damaging particles. However, their effectiveness may
best be compared to how both an electric scooter and luxury
sedan both serve their purpose — the context is essential.

Cellulose filter media offers a thick layer of fiber cloth, pleated

and then wrapped around a perforated core. Cellulose may
sometimes go by “paper” fiber, which correctly implies a sheet-
like fiber pattern across the cloth. Defined as surface media,
particles get trapped closer to the paper media’s leading-edge,
where particles accumulate and create a resistance to flow. Image: Ohio Fabricators

Some cellulose media also inherently absorb water. This

property may be a benefit or disadvantage, depending on your
filter’s purpose. Some hydraulic systems are exposed to water
contamination, and a cellulose element is excellent at absorbing
free water (just not dissolved water). Please note that as water
content increases, so does pressure drop as the fibers swell in size.
As far as raw filtering ability goes, the cellulose media merely
passes the exam with a minimum grade. Even the best cellulose
filter elements are likely less than 75% efficient, which describes
a filter that may or may not filter passing particles of a given
size. Such a low efficiency gives the media a “nominal” rating,
meaning the media’s given micron rating should be taken with a
grain of salt.
So if cellulose medium’s benefit list is shorter than its downside
list, why use it? It is inexpensive to manufacture, which makes
it the scooter in the previous vehicle analogy. A replacement
spin-on filter element may often cost little more than your venti
blonde americano. With that in mind, you must also consider
what a cellulose element is protecting. A log splitter employs
commodity-level hydraulic pumps, valves, and cylinders, where
economy takes priority over quality. A paper filter media protects
essential hydraulic components just fine, and every 20-year-old
log splitter is proof of this.
The filter manufacturer uses glass media yarn to create rolls of
cloth — the foundation for synthetic glass filter elements. The
consistent nature of the fiber layers combined with multiple
layers provides glass media superior dirt holding capacity. This
“depth media” traps particles through their entire thickness and
not just on the surface.
Glass media offers exceptional filter quality, capable in some
cases of filtering 3-micron particles with 99.95% efficiency. This
effectiveness qualifies the glass media as an “absolute” filtration
rating, where lab tests confirm their rating. Immune from water
absorption, any free water within your hydraulic oil will not
increase pressure drop. However, if you require such absorption,
you’ll have to install supplemental cellulose filter assemblies.
Indeed, the glass media filter offers superior dirt holding
capacity, finer and more efficient filtration and immunity from
water. In many ways, it is superior to cellulose paper filters,
so what’s the downside? Cost is easily the downside. A high-
quality filter comes at the relative price of a luxury sedan, and
such quality filtration is a must to protect expensive hydraulic
machinery. Which should you choose? The best you can afford.
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 BETA RATIO: IDENTIFYING
THE QUALITY OF A HYDRAULIC
FILTER ELEMENT
I
wrote about the ISO 4406 cleanliness code in my last two blogs
and here I’d like to take it a bit further and discuss beta ratios.
Beta ratios are important to help us identify the quality of a
hydraulic filter element. If using the ISO Code to help identify
and specify a target oil cleanliness, then filter efficiency ratings
help you achieve that target by knowing how well a given filter
media can trap particle contamination.
The beta ratio of a filter element is essentially its efficiency
at a specified particle size, and this is important to note. If a
filter product sheet simply provides an efficiency number, it’s
completely arbitrary because even the worst quality media can
filter out 100% of the marbles that pass into it, for example.
However, how that filter media performs with 3-µm particles is a
completely different story.
Image: Adobestock
13 www.fluidpowerworld.com
A beta ratio is arrived at by testing a filter with the ISO 16889:2008
multi-pass method for evaluating filtration performance. A special
ISO certified test dust is added to a closed system including a
calibrated electronic particle counter both before and after the
test filter. The test is run under specific conditions spelled out in
the evaluation procedure, and the particles before the filter are
counted and then compared to the particles counted after the filter.
The number of particles counted upstream is divided by the
number of particles downstream, which provides the beta
ratio for the filter element being tested. There is a bit of math
involved, but it’s quite simple. When a beta ratio is expressed, it
is always expressed with the particle size the media is designed
for. For example, β5 200 means the filter element trapped 200
5-µm particles for every one it let through.
Once you know the beta ratio of a filter, you can calculate
how efficient it is at removing that specified particle size. The
calculation for efficiency is simply:
(Beta Ratio – 1) ÷ Beta Ratio = Efficiency x 100
Using our above example, we can do the math:
(200 – 1) ÷ 200 = 99.5%
This means that our imaginary filter will remove 99.5% of the
5-µm particles that pass through it. This efficiency, or beta ratio,
signifies this is a pretty high quality filter media, meaning it
would most likely be synthetic to achieve that result.
When any filter can achieve a beta ratio of around 70 (just above
98% efficiency), we consider it to be an absolute rating. Anything
below 98% is considered “nominal,” meaning it will trap an
average size of particles of a particular size, but no guarantees. I
would consider any nominally rated filter element to be only for
the most budget applications. If you care about the longevity of
your hydraulic machine, ensure you use only absolute-rated filters.
If β5 200 is a good filter, I consider a β3 2000 to be excellent,
with the range of filtration the cleanest hydraulic systems in the
world rely on. There is added expense to a higher beta ratio,
but I can guarantee the expense isn’t nearly as high as machine
failures and hours of downtime on a critical machine.
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What is surface media
vs. depth media?
I
nside of any filter assembly resides the material intended to
trap undesirable particle contamination as hydraulic fluid passes
through the filter element. Although filter elements often look
similar at first glance, the construction and quality of each can
vary widely. The two types of filter media construction, surface
media and depth media, offer advantages and disadvantages,
and which option is used depends on the application.
Surface media is created by weaving or layering metal, paper or
synthetic fibres to create a porous surface where the openings are
an engineered, relatively consistent size. The woven steel mesh
of a suction strainer is a typical example of a surface type filter
media. The construction of the mesh leaves precise gaps between
the layers of wire, and in this case, is described by the number
of layers per square inch. A finer mesh is reflected in a higher
number, and also results in finer filtration, meaning the micron size
of the openings is smaller. Table 1, at right, shows the comparison
between microns and mesh number.
The initial advantage of surface media filtration is they offer low
pressure drop due to their relatively large nominal hole sizes.
Fluid passes freely through surface media, allowing all particles
to pass except those larger than the hole size, which get
14 www.fluidpowerworld.com
trapped. As the surface media becomes clogged with particles
over time, surface media quickly loses its advantage of low
pressure drop. As fewer and fewer open pores allow fluid and
particles to pass, pressure drop increases exponentially, and the
element needs cleaning or replacing.
Therein lies the second advantage of surface media, especially
with strainers; they can be cleaned and replaced. During regular
servicing, a suction strainer can be cleaned with a solvent bath
and then replaced before enough particles are trapped to cause
excessive backpressure.
A depth media uses multiple layers of fiber or foam so that particles
can be trapped within the depth of the filter, rather than just on the
surface. Because a depth type filter element can be created with
multiple layers of increasingly small pore sizes, they provide a dual
benefit of trapping many particles of various sizes, and are capable
of very high dirt holding capacity before pressure drop increases.
The disadvantage is they experience higher pressure drop right out
of the gate, especially through a lower micron rating.
Depth media is more costly, and is typically given an “absolute”
rating, meaning they trap nearly every single particle larger than
the filter size its rated for. This is important to consider, since
pump, valve and component manufacturers provide minimum
requirements of filtration, which must be met using filters with
absolute ratings.
A depth media filter element is used most often as the primary
filter for contamination removal and offers finer filtration —
much finer — than any surface media can offer. A 350 mesh
strainer offers an average pore size of 40 microns, and it’s nearly
impossible to get much finer than this with surface media. A
depth media element using a quality synthetic material can
provide absolute filtration down to 3 microns or finer.
Surface media elements for hydraulic machinery are used
nearly exclusively with suction strainers, and depth media
elements are the standard choice for return-line, pressure and
kidney-loop filtration. Although some manufacturers make
crossover product — depth media for suction strainers, for
example — these products are rare.
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WHERE SHOULD I LOCATE MY
HYDRAULIC FILTER?
A
re filters a one-size fits all type of product? Certainly not.
When selecting a filter, you must understand where the
ideal location for that filter will be. You also need to do an
overall assessment to determine if one filter is enough or if you
should install multiple filters throughout your system.
Most hydraulic systems use a single return line filter, most often
either an in-tank unit or an inline spin-on filter assembly. Return
filters are typically the most economical and practical, if only one
filter must be used. They clean all fluid returning from the system,
which removes any internally generated particles. You should be
careful when selecting return line filters, however, because spikes
in both pressure and flow can occur in return lines.
Pressure filters are common for use after the pump, effectively
safeguarding downstream components from particles either
ingested into the reservoir or generated by the pump itself. You
can even purchase pressure filters without a bypass valve, which
normally allows flow to circumvent the filter when it begins to clog.
15 www.fluidpowerworld.com
Image: Adobestock
When ultimate filtration is required, an offline system is most
efficient. Offline filtration requires a dedicated pump and motor
to circulate tank flow through an often very fine filter with high
dirt holding capacity. Often called a “kidney loop” filter, these
systems run even with the machine does not, and are not
exposed to unstable operating conditions related to the primary
circuit. The downside is the added expense of an additional
pump, motor and filter assembly.
Regardless of which location you install your filter (which is, of
course, all three), ensure it operates using a bypass indicator.
The bypass indicator comes in either a pop-up device, a pressure
gauge or lighted switch. When backpressure measured in the
filter reaches a preset point — typically between 60-80% of
bypass valve cracking pressure — the indicator warns you the
element must be soon changed.
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What are
hydraulic
filtration
systems?
F
iltration systems, commonly referred to as filter carts, are
used for the external filtration of hydraulic fluids. These
components are helpful for systems that may not need
constant filtration, but only require it on occasion. They
may also be used prior to the introduction of new hydraulic fluid
into a system. The function of these components in the overall
fluid power system is no different than their internal counterparts.
They clean the hydraulic fluid and prevent the system from
malfunctioning due to contamination (which leads to wear). As Image: Adobestock
filtration carts are external, they come with the required pieces
to connect the fluid power system to the cart. When looking The next criteria that should be inquired about is the operating
to purchase a filtration system, many companies only provide conditions of the system, such as the viscosity range. The
flow rate and price. But other criteria such as type, operation temperature extremes of the system should also be noted, since
conditions, and construction should be taken into consideration. the viscosity of a fluid is dependent on its temperature. The flow
rate of the system should also be taken into account — these most
One of the more important criteria that can be considered is the
commonly come in 5, 10 and 15 gpm ratings.
filter type. These filter types are the same as discussed in the
hydraulic filter section: Bag, wire mesh, and magnetic. However, The final area to inquire about is the construction of the system.
when purchasing a filtration system, it is also important to ensure This includes the size, weight, hose length, hose connection type,
that the replacement filter elements are easy to obtain. It would and power cord length. Size and weight of the machine may not
also be a good idea to check if the filters compatible with your seem that important, as they often come on carts, but if the filter
filtration system offer a range of beta ratings, as well as media system can not easily reach the desired location (or at all) then it
types. These specifications would allow continued use of the won’t be of much help. One way around that is to ensure that the
filtration system across a change of process operations, or in a hose length is long enough to reach the desired location.
variety of applications.
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WHERE ARE
FILTRATION
SYSTEMS
USED?

F
iltration systems are used anywhere upgraded or auxiliary
filtration is required in a hydraulic system. A filtration system
is available in either permanent kidney loop circuits or
portable filter cart assemblies. Either system is used to
improve the cleanliness of the hydraulic fluid in a hydraulic machine.
Often, filtration systems are used to augment existing filtration,
such as the return line filter.

The kidney loop filtration systems, also known as off-line filtration,

include a pump/motor group circulating fluid out from the
hydraulic reservoir, through a filter, and then back into the tank.
The filters in these systems are often very low micron and very
high efficiency. The steady flow of fluid from a dedicated pump
prevents issues related to high efficiency filters in the pressure or
return lines of the circuit, such as backpressure or pressure spikes.
Often times, a kidney loop system will include an oil-cooler,
providing complete fluid conditioning for the machine.
Filtration systems can also be portable, and no hydraulic shop is
complete without a filter cart. A filter cart is a dedicated pump/
motor group, just as with a kidney loop system, but is mounted to
what is essentially a hand cart. Built onto the cart is one or more
hydraulic filters, with lengths of suction and discharge hose. The
cart can be wheeled to the hydraulic machine requiring servicing,
where the suction pipe is inserted into the filler port of the reservoir.
The discharge port is placed onto or into a return port on the tank,
the cart powered on, and then fluid filters as it circulates.
Illustration by Bill Simon
The advantage of a filter cart is that it can improve the fluid
cleanliness on a machine after only a couple days of operation.
Using a low micron filter with high efficiency and dirt holding
capacity will allow you to use one cart for all of your plant’s
machines, avoiding expensive kidney loop systems on every
system. Also, hydraulic fluid should only be added to a reservoir
via a filter cart. Fresh hydraulic fluid from a drum or bucket is not
clean by fluid power standards. To prevent adding contamination
from enter the system you’re trying to protect, all oil should be
filtered as it enters the tank.

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How do you
remove water from
your hydraulic system?
I
t’s common knowledge that particulate contamination is
unwanted in hydraulic systems. Contamination in hydraulic
oil can damage mobile and industrial machinery. Of as
much concern should be water in oil, as it too can lead to
component failure.

Water in hydraulic fluid can be seen as free, dissolved or

emulsified and can reduce hydraulic fluid lubricity, cause pitting
against metal surfaces, degrade additives and accelerate oil
aging. As a result, it is necessary to mitigate the presence of
water in hydraulic systems. But before you can do that, first you
must understand what types of water exist in a hydraulic system.

Free water is easily identifiable, as it can be visually seen if you

pull oil from a system. This water separates clearly from the oil
and can easily be decanted out of the reservoir because the
specific gravity of most oils is less than 1.00.

Emulsified water is that which has blended with the oil so it can’t
be decanted. Think of a bottle of salad dressing, in which the oil
and vinegar/water are mixed upon shaking.

Dissolved water is the most difficult to identify and remove. This

usually forms as the oil temperature increases — just as it is
easier to dissolve salt in boiling water, so it is easier for hydraulic
fluid to absorb water in hotter temperatures.

For emulsified or dissolved water, vacuum dehydration is the best

option. These online or offline machines use heat (within a critical
range as too high a heat will break down the oil) and vacuum
technologies to remove water from oil. These systems will also
Image: Adobestock
remove particulates in the final stage. But other options exist.

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 HYDRAULIC FILTRATION DESIGN GUIDE

(continued)
How do you remove water from hydraulic fluid?

GRAVITY SEPARATION
Because water generally has a higher specific gravity than
hydraulic fluid (exceptions do exist e.g. HFD-R), it tends to settle
at the bottom of the reservoir
when given sufficient resident
time in a still environment. Here,
opening the drain valve and
allowing the water to drain off
may be sufficient. Increasing the
fluid’s temperature and employing
a cone-shaped separating tank
improve the effectiveness of
gravity separation. This is a simple,
low-cost water removal option
but it only removes free water.
High fluid viscosity /oxidation
Example of gravity
by-products and polar additives
separation setup.
and impurities inhibit the effective
separation of oil and water, some oils are designed to hold water
in suspension rather than to allow it to separate out, takes time,
need of usually two tanks and therefore double the space and oil,
no gas removal (degassing).
fluid flow. Smaller drops unite to form larger ones at the fiber
nodes during this process. Large water droplets are separated
by gravity or with a special separation element/layer. Water is
collected on the bottom of the housing (for phosphate esters
on top) and it can be discharged by opening a valve. Coalescing
elements offer high dewatering rates for high water contents
(free water), and are suitable for hydraulic- and lubricating oils
and diesel fuels.
CENTRIFUGE
Centrifugal separators remove free
water faster than gravity separators.
They also remove some emulsified
water depending upon the relative
strength of the emulsion versus the
centrifugal force of the separator.
They are a good option for continuous
decontamination of fluids with good
demulsibility (water separating Example of a
centrifuge
characteristics).
system.

FILTER ELEMENTS POSITIVE PRESSURE DEHYDRATORS

Water absorbing elements can be used in standard filter housings, Positive pressure systems blow air through the operating fluid in
monitoring via differential pressure, water is not released even if a reaction chamber. Drying the air is achieved by increasing the
pressure increases. However, only free and some of the emulsified temperature of the ambient air in a side channel blower and by
water is removed. They also getting it into contact with warmer oil. The air is introduced into
feature high element costs in the reaction chamber by a blower. The dry air takes up the water
applications with continuous water from the oil and is pushed out of the reaction chamber by the
ingression and don’t provide gas incoming air. The operating fluid is cycled through the reaction
removal (degassing). chamber by a system of two pumps.
Cellulose filters remove some
dissolved water and are simple to
install. However, they release water
when pressure or temperature
increases and increase stress on
the oil if continuous cooling and
heating is applied.

Free water settles on the fibers of

Example of super absorbent the coalescing element. Droplets
polymer (SAP).
are transported deeper into
the coalescing element by the

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 HYDRAULIC FILTRATION DESIGN GUIDE

(continued)
How do you remove water from hydraulic fluid?

VACUUM DEHYDRATORS

In vacuum based systems, a vacuum is created in a vacuum COMPARISON OF WATER REMOVAL METHODS:
chamber by means of a vacuum pump. With the vacuum,
ambient air is sucked into the vacuum chamber. The vacuum
expands the ambient air and proportionately reduces the
relative humidity of the air. The oil is distributing within the
vacuum chamber over a large surface area, resulting in a large
and thin fluid film.

Due to the temperature increase when coming into contact

with the warmer oil, the air is further dried and takes up the
water from the oil. The humid air is evacuated via the vacuum
pump. Depending on the applied vacuum and oil temperature,
the water is evaporated (mass transfer) or boiled out (flash
distillation) from the oil.

They remove water to very low levels even under high ambient
humidity, and are suitable even for systems requiring lowest
target levels of moisture.
Notes:
1. Absorbing Elements do have a micron rating as well that is
relatively high for certain manufacturers (e.g. 40 microns),
but the main purpose is for water removal. Ideally, absorbing
elements should be used in conjunction with particulate
elements (staged filtration)
2. Some Coalescing Elements include a particulate filter
portion (plea) for protection of the hydrophilic material.
In order to prolong the coalescing element life time, a
particulate filter can be added upstream.
3. The Centrifuge can remove some of the larger particulates
as well

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 Image courtesy of Adobe Stock.
Maintaining reliability
with hydraulic filters
F
luid conditioning is the top priority for those intending
to keep their hydraulic machines happy and reliable.
Control of the various forms of fluid contamination ensures
components will run within their design criteria efficiently
and dependably. Major forms of fluid contamination include water,
air, heat and particle.
Particle contamination is often highest during machine startup,
where the remains of cutting, grinding and welding have found
homes in the nooks and crannies of reservoirs, manifolds, hoses
and actuators. Contamination can spike once again during
careless maintenance or catastrophic component failure. Luckily,
particle contamination is extremely easy to control, which makes it
all the more shocking when people don’t take filtration seriously.
Every hydraulic machine requires fluid filtration, and there are
three major types; suction filters, pressure filters and return filters.
Suction filters are mounted inside the hydraulic reservoir on the
suction tube as a primary defense against larger chunks, but are
made of steel mesh and limited in their capacity to reduce the
21 www.fluidpowerworld.com
finer wear-causing particles. The use of suction filters is also a bone
of contention, as some feel they cause more problems than they
solve, such as becoming clogged and creating pump cavitation.
However, suction strainers work with pressure and return line filters
to maintain the integrity of hydraulic oil. They prevent the ingestion
of solid contaminants into the fluid reservoir by capturing and
collecting larger particulates in the fluid flowing to the pump. This
can prevent serious damage to the pump.
Pressure filters are installed downstream of pumps or in sub-
circuits of the system requiring different, and often finer, levels
of filtration than the rest of the circuit. Installed after the pump,
a pressure filter can protect all the components downstream
from anything ingested by the pump. Depending on how they
are rated from their manufacturer, pressure filters can range from
500 to 10,000 psi and higher, adding insurance in even the most
demanding hydraulic application.
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(continued) HYDRAULIC FILTRATION DESIGN GUIDE
Maintaining reliability with hydraulic filters

Return filters are the most common form of fluid protection in a

hydraulic system, and are normally either spin-on filter assemblies
or in-tank drop-in assemblies. The venerable spin-on filter resides
on the vast majority of mobile machinery, and is available in low-
to mid-range quality filter media. They are sometimes outfitted
with water absorbing filter media, which can remove freestanding
water from oil, if such a problem is a concern.

In-tank return filters, previously the realm of industrial hydraulics

only, have infiltrated the mobile market as well. They offer
medium- to high-quality filter media in a convenient and space-
saving mounting configuration. Their location in the fluid stream,
as with spin-on return filters, allows them to remove many of the
particles created or ingested by the rest of the system, leaving a
reservoir full of sparkly-clean oil.

Filters are classified by the smallest size of particles they

reasonably remove from the oil in one pass through the element,
such as “10 µm.” It is important when discussing filtration quality
that the efficiency is stated for which the rating was classified.
For example, a 10-µm filter requires we know how efficient it
was at removing 10-µm particles in a single pass, such as 99%.
Efficiency is often expressed as a beta ratio, which is the ratio of
particles upstream of the filter to downstream of the filter during
standardized testing; for example, “10 µm at Beta 200,” which
means 99.5% efficient at removing 10-µm particles in one pass.
Obviously, lower micron filtration and higher efficiency is ideal,
although price can be a consideration as filtration quality rises.
Finer filtration is more restrictive, so attention to pressure drop
detail should be paid, just as sizing any filter to be appropriate for
the flow of the circuit should be considered.

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 WHERE ARE
YOUR FILTERS?
If you bought from OFCO,
you’d be using them now.

Strainers • Filters • Breathers • Diffusers

Proudly Made in the USA • ISO 9001:2015 Compliant
Stock and Custom Filtration Solutions
Ohio Fabricators Company designs and manufactures your
hydraulic solutions right here in our Central Ohio factory.
Our quick-ship program for standard products means you
receive your shipment within days, not months. Even custom-
filtration solutions get our unparalleled delivery times.
Call or email our sales team today to check our info@ohfab.com • 888.354.0291
stock and discuss your specifications. www.ohfab.com

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