Filtration
Causes uses of brea breakdowns kdown s in hydraulic hydraulic and lub rication systems 70 - 80 % of all failures failures in hydraulic hydraulic systems and an d up to 45 % of all all bea b eari ring ng failur fail ures es are caus caused ed by solid and liquid c ontamination ontamination
2
of oil
Types ypes of cont c onta amina min ation tio n Effect
Types of cont amination
Gas eo u s Air Ai r
3
L iqui d
So l i d
Water Unknown Oil
Emery Metal Metal s cale Rust particles
extremely bad damage
Iron Steel Brass Bronze Alum Al um in ium iu m
bad damage
Laminated fabric Fibres Sealing Sealing abrasion Rubber particles from hoses Paint/varnish particles Oxidation Oxidation pr oducts of the hydraulic hydraulic fluid
minimal damage
Gaseous Contamination • Air Ai r
4
Consequences on sequences of Gaseous Contamination • Cavitation • Local oil oi l overhea overheating tin g • Leads Leads to t o unstable un stable regulation regulation behavior behavior • Reduces the dynamic dynamic lubri l ubri cation film thickness • Oil aging Cx Hy + O2
5
Ac A c i d s , H20, Sludg Sludge e
Catalysator: Catalysator: temperatur, temperatur, moist ure, copper, aluminiu m, paint and varnish Rapidly pidly age at high high tempe tempera rature tures s and and moisture moisture
Fluid Contamina ontamination tion • Water • Unknow nkno w n oil at at system refill
6
Conse ons equences of Fluid lui d Contamination • Corrosion • Decrease crease of dynamic viscosi visc osity ty
Decrease of lubrication film thickness
Contact of the surfaces
Reduction of oil durability
• Changes hanges of oil condit con dition ion
7
Generating sour oil aging products
Increase of oil aging speed
Generating mud
Origin rig in of t he Solid oli d Cont Conta amina min ation tio n •Exter nal n al contamination
•Wear (Cylinder)
•Initial con tamination tamination of the valve •External contamination •through system opening
•Repairs
•Initial •contamination (in the oil) •Wear (Pump)
8
Size Size Ra Ratio ti o of o f Partic rt icles les
m n i r e t e m a i D •
9
•Bear Bear lubric ating film •Fine/ coarse particle
•Human hair
Parts of o f Hydraulic Hydraulic Components omp onents Gear pump 0,5 up to 10µm
Vane pump 0,5 up to 5µm (J1)
Piston pump 0,5 up to 1µm (J2)
Valve 5 up t o 25µm (J1)
Servo valve
10
5 up to 8µm (J1) (J1)
Solid oli d Cont Conta amina min ation tio n
11
sand
metal particles
fibers
rust
weld pearls
abrasion abrasion of vulcanized rubber
oxidation products
color particles
Solid Contamination (>66-14 14µm) µm) •Fine c ontamin ation (> ns eq u en en c es es : •Co ns
- Wear - Inte Internal rnal leakage leakage - Ina Inaccurancy ccurancy of regulation regulation
•
- Valve blocking
•Coarse particles (>14µm) Consequence: Sudden n brea breakdown kdown of •Sudde components
12
(4-6µm) m) •Finest co ntaminati on (4-6µ Consequence Conse quences: s: - Siltation - Fast aster er oil aging aging
How is the Effect Effect of Contamination Evaluated Evaluated ? Condensation water Gearwheel Gearwheel abr asion Loose ridges Assem bl y co nta min atio n Lacquer rests Sand dust Machine manufacturer or operator
Other particles out of the environment Grinding swarf
Filter manufacturer
Form sand Production swarf Corrosive media Coal dust Rests of grinding tool Pressure water/splash water
13
Contamination of fresh oil Cooling lubricants
0
10
20
30
40
50
60%
Initial nit ial damage damages s to hydra hydr aulic uli c components Without commissioning flushing
With commissioning flushing
Commissioning
Lifetime
Conta ont amina min ation tio n as conse cons equential damage
Conta ont amina min ation tio n as conse cons equential damage
Embedded mbedded chip c hip
Surface damages damages of an internal in ternal gear gear pump p ump
Solid Partic rt icle le We Wear de d epends on • Size of soli d particles parti cles • Ratio betwee b etween n parti cle cl e size si ze// operation operatio n cycle • Form of solid particles • Operatio peration n over pr essur e • Flow veloci velocity ty • Material Material of the cont amination 19
Types of wear Ab r asi as i o n • Abr by particles betwee between adjacent adjacent moving surfaces surfaces
• Erosion by particles particles and high flu id velocity
Ad h esi es i o n • Adh from metalmetal-to-me to-metal tal friction (loss of fluid)
Fatig ue w ear ear • Fatig surf aces aces damage damaged d by particles are are subj ected ected to repeated repeated str ess
• Corrosion 20
by water water or chemicals chemicals (not covered covered below)
Abr Ab r asi as i o n by particles particles between adjacent moving surfaces
Effects Effects of abrasion :
21
•
Changes to tolerances
•
Leakages
•
Reduced Reduced efficiency
•
Particl Particl es produced in the system
•
cr eate eate more wear!
Erosion by particles and high fluid velocity The high velocity velocity of the fluid forces existing particles particles against the corners corners and edges edges of the system. system. Other coarse and fine particles therefore become become detached detached from the the surface surface and and there is is a gradual gradual attack attack on the surfaces surfaces in the system.
Erosion damage on the cog wheel
22
Adh Ad h esi es i o n from metal-to-met metal-to-metal al friction friction (loss of fluid) fluid) Low speed, excessive excessive load load and/or a reduction in fluid viscosity can reduce reduce the oil oil film thickness. This can result result in metal-to-metal contact, and and also possible possible shearing.
Adhesion on ball bearing
23
Surfa urf ace fatigue fatigu e surfaces damaged damaged by particles are are subjected to repeated stress The smallest cracks in the surface surface are surface surface fatigue fatigue hollowed out causing material material to break break off, therefore creating new particle particles. s. This action action causes causes an increase increase in wear. wear.
24 Surface fatigue on ball bearing
Contamination ontamination classifi classifica cation tions s NAS 1638 1638 (val (valid id unti un till 30.05.2 30.05.2001 001)) NA S-Co d e (nach NAS 1638)
25
00 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Nu m b er o f p ar t i c l es / 100m l 2 - 5 µm 5 - 15 µm µm 15 - 25 µm µm 25 - 50 µm µm 50 - 100 µm µm >100 µm µm 625
125
22
4
1
0
1250
250
44
8
2
0
2500
500
88
16
4
1
5000
1000
176
32
8
1
10000
2000
352
64
16
2
20000
4000
704
128
32
4
40000
8000
1408
256
64
8
80000
16000
2816
512
128
16
160000
32000
5632
1024
256
32
320000
64000
11264
2048
512
64
640000
128000
22528
4096
1024
128
1280000
256000
45056
8192
2048
256
2560000
512000
90112
16384
4096
512
5120000
1024000
180224
32768
8192
1024
-
2048000
360448
65536
16384
2048
-
4096000
720896
131072
32768
4096
Contamination ontamination classifi classifica cation tions s ISO 44 4406 – ISO Code Code ISO Code
26
(acc. to ISO 4406) 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Number of particles/100 particles/100ml ml from
up t o
16 32 64 130 250 500 1000 2000 4000 8000 16000 32000 64000 130000 260000 500000 1000000 2000000 4000000 8000000 16000000 32000000 6400 64 0000 0000 00 1300 13 0000 0000 000 0
32 64 130 250 500 1000 2000 4000 8000 16000 32000 64000 130000 260000 500000 1000000 2000000 4000000 8000000 16 00 000000 32 00 000000 64 00 000000 1300 13 0000 0000 000 0 250000 2500 0000 000 0
4406: 1999
21 / 18 / 15 >4µm (c) >6µm (c) >14µm (c) >2µm
>5µm
> 15µm
old 4406: 1987
Old and New New Proce Proc edures du res of Measurement Definition De finition of p article size (d) (d) ACFTD- def ini tio n o f particle sizes (ISO 4402: 1991) Fläche = 176,7 µm²
Fläche = 176,7 µm²
16,9 µm
16,9 µm
d = 16,9 µm
parti cle si ze = 16,9 16,9 µm
27
ISO ISO MTDMTD- definition of particle sizes (ISO 11171: 1999)
d = 15 µm Fläche = 176,7 µm²
particle size = 15 µm (c) Diameter Diameter of the coextensive circle
*ACFTD size (ISO 4402 : 1991) m < 1,0 1,0 2,0 2,7 3,0 4,3 5,0 5,9 7,0 7,4 10,0 10,2 14,0 15,0 16,9 20,0 23,4 25,0 30,0 37,3 40,0 50,0
ISOMTD NIST size (ISO 11171 : 1999) m (c) 4,0 4,2 4,6 5,0 5,1 6,0 6,4 7,0 7,7 8,0 9,8 10,0 13,0 13,6 15,0 17,5 20,0 21,2 24,9 30,0 31,7 38,2
Contamination ontamination classifi classifica cation tions s ISO 44 4406 – ISO Code Code
28
Contamination ontamination classifi classifica cation tions s SAE AS 4059 : 2001 Maximal number of parti cles (particl e per per 100 ml) Size (ACFTD), acc. to ISO 4402 calibrated or
> 1µm
> 6µm
> 15µm
> 25µm
> 50 µm
> 100 µm
70µm(c)
microsc. counting* Size (ISOMTD), acc. to 11171 calibrated or
> 4µm (c )
> 6µm (c )
> 14µm (c (c )
> 21µm (c (c )
> 38µm(c)
C
D
E
REM** Size code
A 000
C o d e -N o .
29
B 195
76
14
F
3
1
0
00
390
152
27
5
1
0
0
780
304
54
10
2
0
1
1560
609
109
20
4
1
2
3120
1220
217
39
7
1
3
6250
2430
432
76
13
2
4
12.500
4860
864
152
26
4
5
25.000
9730
1730
306
53
8
6
50.000
19.500
3460
612
106
16
7
100.000
38.900
6920
1220
212
32
8
200.000
77.900
13.900
2450
424
64
9
400.000
156.000
27.700
4900
848
128
10
800.000
311.000
55.400
9800
1700
256
11
1.600.000
623.000
111.000
19.600
3390
512
12
3 200 000
1 250 000
222 000
39 200
6780
1020
Which hic h Classifi Classification cation do d o we w e use in which whic h Applica Application tion ?
Correct Classification
30
Typical ypi cal clea c leali liness ness le l evel vel
31
SA E 12 ISO 22/21/18 Fresh Fre sh oil , delivered in barrels
SA E 9 Fresh Fre sh oi l,
SA E 7 ISO 17/16/13 Fresh Fre sh oi l, delivered by mi ni-container
SA E 5
ISO 19/18/15
delivered by tank tank tr uck
ISO 15/14/11
required for modern hydraulic systems
Cleanli leanliness ness requir requir ements for l ubricating ubr icating and hydrauli hydraulic c components comp onents
32
Cleanli leanliness ness requir requir ements for l ubricating ubr icating and hydrauli hydraulic c components comp onents
33
Industr ndu strial ial Standa Standards rds for Oil Contamination
1 mg/l
Contamination class ISO 18/16/14
How to Measure su re ?
35
Possibl oss ible e Extra xtr action cti on Metho Methods ds for fo r Measureme su rement nt dynamic
36
Possibl oss ible e Extra xtr action cti on Metho Methods ds for fo r Measureme su rement nt static Act uat or • Act
•Control
37
•ISO 22/20/17 •ISO 16/14/12 Time 9.30 Time 10.00
Measure sur ement Proce Proc edure dur es for Solid oli d Contamination Oerview
w ei g h i n g
gravimetric analysis
counting
microscopic analysis manual counting automatic counting
electronic analysis automatic particle counting devices (APC's) in field
in laboratory
38
Possibilit ossib ilitie ies s of Condi Condition tion Monitoring
FCU
Table compari son
39 Laboratory
Locally
Princip rin ciple le of Electr Electroni onic c Pa Particl rt icle e Counters
FCU
40
HYDAC Sensor Technology On-Line n-Lin e Partic Particle le Cou Count nter er •
patented HYDAC HYDAC sens or stable due to fiber-optic fiber-optic li ght guide technology for locally use
infrared diode only monochromatic light (of a wave wave length)
41
unlimited lifetime
light absorption
Working orki ng Method of Electro lectronic nic Particle rti cle Coun Countin ting g Cal i b r at i o n w i t h SRM 2806
] t l o V [ e g a t l o V
Meas u r em en t of of o i l c o n t am i n at i o n
] t l o V [ e g a t l o V
2µm
5µm
15µm
42
particl e size [µm] [µm]
time
25µm
Measuring surin g w ith Fluid Control ontr ol Unit (FCU) 10 1 2
14
16
18
2
20
0:01 0:02 0:03 0:04
4
6
8
10
12
[min]
[min]
SAE
0:01
0:03 0:04
0:05
0:05
0:06
0:06
0:07
0:07
0:08 0:09 0:10
•ISO
0:02
Documenting
0:08 0:09 0:10
0:11 0:11 0:12 0:12 0:13 0:13 0:14 0:14
PC
43 Navigating
SPS
Controlling
Measurement and Indicators
Why Monitoring Contamination 10%
10% 20%
35% 5% 20% So lid c o n t am in at io n Ag ein g of th e lu br ican ic antt Fau lt s in b earin g s elec t io n
L iq u id Co n t a m in at io n s elec tio n of th e lu b ric ant an t A s s e m b li n g f a u l t s
Source: FAG Wälzlagerschäden Publ.-Nr Publ.-Nr.: WL W L 82 102 / 2 DA
Why Monitoring Contamination Potential Reducing Cost Cleanliness Cl as s
Tar g et
Tar g et
Tar g et
Tar g et
22/19
19/16
18/15
17/14
16/13
21/18
18/15
17/14
16/13
15/12
20/17
17/14
16/13
15/12
14/11
19/16
16/13
15/12
14/11
13/10
NAS 5
18/15
15/12
14/11
13/10
12/9
NAS 4
17/14
14/11
13/10
12/9
12/8
NAS 9 NAS 6
NAS 3
Increase in reability 2x
3x
4x
5x
*Van Dorn-Demag
Filter il ter Functio unc tions ns
Before: pur ity level SAE 13
through filtration
46
Af t erw ard s: Aft pur it ity y level SAE SAE 4
Tasks of o f a Fil Filter ter
47
•
Preclud Preclud es distu rbances in regulation behavior
•
Reduces Reduces breakdown ti mes for the purpose of maintenance
•
Secures smoothly functions
•
Extends Extends th e durabili ty of the components
•
Supports the lubricating capability capability of t he fluid
•
Extends Extends th e durabili ty of the fluid
•
Removal of undesired undesired c orruptive components of t he medium and and system entry is prohib ited
•
Protection against d amagea amageable ble co mponents
Reduction of o peration peration costs
Tasks of o f a Fil Filter ter Component
Tasks
In the human body
In the hydraulic system
In the human body
Bronchial Tubes
Air Breather Filter
Cleaning Cleaning of the in- and outcoming outcoming air
Kidney
Return Line Filter
Separation of solid particles and water
Liver
Pressure Filter
Heart
Pump
Brain
Control Bloc
Dialysis
Bypass Filter
Blood
Working Fluid
Support of the organs and removal of contamination
Energy transport temperature, friction reduction
Nerve system
Control
Information system about
Information system about pressure, temperature and tank level
Protection of the organs or the components Generation of pressure and flow Responsible for the entire function of the body/ system Separation of solid particles and water
the organ condition
48
Blood sample
Oil sample
Sensor system
24 hours ECG
In the hydraulic system
Control of the fluid condition Control of the system condition
Filter il ter Element Materi Material al
Surface filter
49 Depth Depth filt er
Filter il ter Element Materi Material al Featu eatures res of o f Surface Sur face Fil Filters ters Mesh s ize determi determines nes filt ration r atio • Mesh area“ • Low ” free filter area (30(30-40 40% % of the th e total tot al filt fi lter er area) pressu re stabili ty • High differential pressure (especially (especially at lacing material) material) cleaning • Simple cleaning differential pressure • Low initial differential tection filter • Typical application: pro tection
50
Filter il ter Element Materi Material al Featu eatures res of o f Surface Sur face Fil Filters ters
suspension
cake
bridge
51
filter cloth filtrate
Filter Element Material Featu eatures res of o f Dept Depth h Filt ers b e experim experim entally entally • Filtration ratio mu st be determined
• Labyrinth effect Imposs ible e to c lean lean (exceptio (exceptio n: meta m etall mat) • Impossibl
• Extraordinary filtration performance • High di rt hold c apacity Typical al applic ation: damageable damageable components com ponents • Typic
52
Filter il ter Element Materi Material al Featu eatures res of o f Dept Depth h Filt ers
53
Filter Element Material Scaled up for fo r 15 times ti mes Surface filters
Wi r e m es h , 700 µm
Wi r e m es h , 100 µm
L ac es m es h , 50 µm
Depth Depth f ilters
54 Gl as s f i b er m es h , 20 µm
Pap er m es h
Met al m es h
Depth Filte ilt ers unde und er the t he Electron Electron Microscope
55
Effects of Free Filter il ter Surfa Surf ace Element Element A
Element B
thin f ibers, larger larger filter surf ace
very coarse fibers, smaller filt er surface
Filtered particles
56
1. Hardly pressure pressure drop in pure pure condition condition 2. Enormous particle particle holding capacity capacity,, NOT NOT at competition! competition!
Three hr ee Coat Coat Filter Fil ter Mat Mat Desi Design gn w ith Different Different Media
57
Coarse
Medium
Fine
(1. layer)
(2. layer)
(3. layer)
Filter il ter Element Materi Material al Characteristic Curves ] r a b [ e r u s s e r p l a i t n e r e f f i D
58
surface filter
Dirt hold capacity [g]
depth filter
Multipass-Test Determination of the ßx(c)-value ISO 16889 test filter element
•Nupstream 59
ßX(c)=
n upstream n downstream
x µm x µm
Featu eatures res of o f a High-Q ig h-Quali uality ty Element Element • High ßx(c)-values ISO 16889
• High ßx(c)-value-stability capacity • High dir t hold capacity
60
Multipass-Test
Multi ul tipa pass ss - Test ISO 16889
61
Multipass-Test Schematic chematic Demonstr mon stra ation tio n ISO 16889 test system
particle counter
test filter dirt injection system
62
ISO 16889
Featu eatures res of o f a High-Q ig h-Quali uality ty Element Element High ßx(c)-Values -Values / High ßx(c)-Value Stability ßx(c)- value and separation rate at the differential pressure
(single value demonstration)
1000 2 µm
3 µm
5 µm
6 µm
1000
8 µm
filter element : 10 Micron
10 µm
1000 99.9
99.8
absolute filtration
1000 99.9 99.8
200
99.5
100
100
100
t r e e u W l a v x ß ) c ( x
% n i 98.0 98.0 t e a r n o t 95.0 i a r a p 90.0 10 10 e S 90.0
nominal filtration
10
ß10
99.0 100
75.0
63
50.0 1 0
1
2
3
4
5
6
7
8
9
10
Element differential pressure in bar
11
12
13
14
15
0.0 1 16
Featu eatures res of o f a High-Q ig h-Quali uality ty Element Element High ig h Dirt Hold Capacity pacit y ISO 16889
compariso n of the dirt hold capacity ] r a 11 b [ e 10 r u s 9 s e 8 r p l 7 a i t 6 n e 5 r e f f 4 i d t 3 n e 2 m e 1 l e
64
of two filter elements elements identical in cons truction
Element A
Element B
0 0 1 2 3 4 5 6 7 8 9 10 11 11 12 12 13 14 15 16 16 17 18 19 20 20 21 22 23 24 24 25 26
dirt hold capacity [g ISOMT ISOMTD] D]
Featu eatures res of o f a High-Q ig h-Quali uality ty Element Element
ISO 16889
•
High ßx -value
•
High ßx -value-stability
•
High dirt hold capacity
Multipass-Test
Low long -term -term pressure drop cu rve
65
ISO 2941
High collapse cracking pressu re resist resist ance
ISO 3724
High flow t hrough fatigue strength
ISO 2943
Good media compatibil ity
High-Q igh-Quality uality Ele Eleme ment nt - Low Long Long Term Pressure Pressu re Dro Drop p Curve ur ve ] r a b [ e r u s s e r p l a i t n e r e f f i d t n e m e l e
66
Energy balance sh eet eet of 2 filter elements elements of identical cons truc tion 3.0 high energy costs with eleme element nt B
2.5 2.0 1.5 1.0
energy energy costs reversal point with eleme element nt A
Element B initial energy costs with elemen elementt A
0.5
Element A
initial p 0.0 operation operation time [ h ]
Featu eatures res of o f a High-Q ig h-Quali uality ty Element Element High ig h Colla Coll apse ps e Press Pressur ure e Resist si sta ance nc e ISO 2941
element eleme nt col lapsed at at 22 220 0 bar
67
ISO 3724
Featu eatures res of o f a High-Q ig h-Quali uality ty Element Element High Flow -Through hro ugh Fatigue tig ue Strength 5 4 r 3 a b
2 1
68
0 1 millio n load changes changes
Featu eatures res of o f a High-Q ig h-Quali uality ty Element Element Good Media Comp Compa atibili tib ility ty ISO 2943
69
Comparis om parison on Some om e Filter il ter Elements Elements
70
Develop velopment ment of Filtra Filtr ation tio n Technology Year
Dev el o p m en t
Fi l t r at i o n r at i o
1940
First air and oil filter for motors; screen filter
100 µm
1950
Big increase of hydraulics an and thus of filtration
1960
Application of star folded mats
50 up to 100 µ m
and supporting tubes 1970
71
Development of paper and
up to 3 µm
metal mesh elements
nominal
1980
Introduction of the Multi Pass Test, beginning of absolute filtration
up to 3 µm absolute
1990
Absolute filtration in all ranges
1 µm and 2 µm absolute
Insta nst allation location l ocation of o f Filt Filte ers Return line filter Pressure filter
Filter Filter uni t Suction filter
72
Off-line filter
Breather filter
Suction uct ion Filters CONTROLLING
M
73
Suction uct ion Filters Benefits • Protects the pump against co arse contamination • Cheap Peace of co nsc ience of th e design engin eer eer • Peace
74
Suction uct ion Filters Disadvantages Filtration is not pos sible • Finest Filtration cavitation especially specially during deep deep • Danger of cavitation temperatures temperatures (cold s tart) Guaranteeing ing protection prot ection agains agains t w ear, ear, the • Guarantee installation installation of further filters i s necessary necessary System must m ust be b e sw itched itc hed off for fo r element element • System changing
75
• Filter is badly accessibl e
Press Pressur ure e Filters il ters CONTROLLING
•
M
76
Press Pressur ure e Filters il ters Benefits • Filtration directly in fro nt of t he components wh ich are supp osed to be protected Desir ed purit y l evel evel i s guara g uarantee nteed d • Desir
• Finest filtration Change-over over filt f ilters ers are poss ible (24 (24 hours • Changeoperation)
77
Press Pressur ure e Filters il ters Disadvantages
78
•
More expensive expensive f ilter hou sing and element element
•
Complex eleme element nt cons truc tion d ue to necessary necessary d ifferential pressur e resistance
•
Pump is not directly pro tected
Return tur n Line Lin e Fil Filters ters CONTROLLING
M
79
Return tur n Line Lin e Fil Filters ters Benefits
80
•
Filtration Filtration of the whole back back flus hing flu id
•
The tank is not supplied with dirt of the system system
•
Cost-effectiv Cost-effectiv e filter hous ing and element element
•
Easy Easy element element ch ange upwards wit hout leakage leakage at at tank mounted filt ers
•
R-eleme R-elements nts have bypass
•
Finest filtration
•
Double filters are possi ble
•
Individual Individual pump protection in c omparison to pressure filters
Return tur n Line Lin e Fil Filters ters Disadvantages
81
•
Installation Installation of a bypass valve is recommended
•
In case case of single filters the system mus t be switc hed off in or der to change the eleme element nt
•
Big fi lters at high fl ow rates are are required (differential piston)
•
For easily damageable components an additional pressure filt er is recommended
Off-Line Filters CONTROLLING
•M
•
M
82
Off-Line Filters Benefits
83
•
Filtration ind ependent ependent of operating proc ess
•
High dirt hold through constant flow through
•
Cost-effi Cost-effi cient fi lter housi ng and element element
•
System System do es not have to be switch ed off durin g element change
•
Subsequent installation is possible
•
Good oil p urit y levels can be reached reached
Off-Line Filters Disadvantages
84
•
In case of h igh-value components a pressure fi lter must b e used as addit addit ional filt er
•
Increased Increased inv estment costs
•
Increased energy energy needs
•
No direct p rotectio n of easily easily damagea damageable ble components and of pump
•
Increased space needs
Bre Br eathe th er Filte Filt ers CONTROLLING
M
M
85
Bre Br eathe th er Filte Filt ers Benefits •
Relieves Relieves the system filt er by preventin preventin g cont amination from entering the tank during tank breathin breathin g
•
High air flow rate
•
Cost-effective
•
Environmentally friendly
Disadvantages •
86
If the filter is incorrectly sized, sized, dama damage ge may may occur to the tank and the pump
Filters
87
Filter il ter selecti selection on Prote rot ective cti ve and and Working ork ing Filte ilt er
88
Filter il ter selecti selection on Restricting stri cting the flow velocity
89
Filter sele selectio ction n - Determini termining ng the appropr ppr opriate iate filte filt er element lement
90
91
Filter Sizing
92
Filter Sizing
93
Effects of liq uid contamination contamination Free and emulsifies water causes most of the destruction to lubricants and machines
•o •H
•H
The water molecul is polar unlike the base oil.
94
• Below saturation saturation poi nt Water ater exists in a diss olved form, like humidi ty i n t he air. air. All water molecules are detached detached to polar compou nds in the oil (e.g.a (e.g.addi ddi tiv es, partic les).
• When When reachi reachi ong or exceedi exceeding ng the t he saturation point Water ater f orms either an emulsion, like fog , where microsc opic glob ules of water are are dispersed in stable suspension. This Causes Causes a visibl e cloud or h aze aze or Water exists as free water like rain that settles to tank/sump tank/sump bott om
• How much wate waterr can be solv solved ed in oil ? Saturation aturati on Level Level
Fluid X 5000
free water
2500
dissolved water = 82 % saturation
= 100 % saturation limit 0 •20
40
60
Temperature [°C]
80
limit
Saturation point s for f or differe d ifferent nt fl uids
HFD-fluid 5000
Synthetic -fluid Mineral Mineral o il A 2500
Mineral Mineral oi l B
Transfor mer oil 0
96
20
40
60
Temperatu re [°C]
80
Effects of liq uid contamination contamination 100ppm = 0,01%
How much water an oil can accept Depends epends highl y upon: • Type of base oil • Type and concentration concentration of additives
Saturation Saturation limit for water in a hy draulic oil 1200 1000 t n e t ] 800 n o m c p 600 r [ p 400 e t a W 200
• Existence of impu rities • Temperature
free and emulsified water
dissolved water
0 -20
-10
0
10
20
30
40
50
Temperature [°C] O il
Dis s o lv ed [ppm]
Emulsified [ppm]
Free [ppm]
New hydraulic fluid
0-40 0
40 0 -10 0 0
>1000
A g e d hydraulic fluid
0-80 0
80 0 -50 0 0
>5000
97 Examples with approx. values for a standard hydraulic fluid
How much m uch w ater ter should shoul d you tole tol erate? rate? „ A good rule of thumb is to control w ater ter to t he lowe low est levels levels you can reaso reasonably nably achi eve, eve, preferably w ell below below the oil’s oil’s saturation saturation po int at opera op eratin ting g temperature temperatur e.“ 98
•Source: Drew Troyer, Drew Troyer President Noria Global Services: "Establishing Moisture Contamination Targets Targets for Hydraulic Systems". Machinery Lubrication Magazine. January 2004
Water removing technologies
Source: Drew Troyer, Drew Troyer President Noria Global Services: "Establishing Moisture Contamination Targets Targets for Hydraulic Systems". Machinery Lubrication Magazine. January 2004
