Contamination Fundamentals

Transcription

1 Contamination Fundamentals

2 Contamination THE ENEMY TO MODERN HYDRAULIC SYSTEMS

3 Types of Contamination SOLIDS LIQUIDS GASES

4 Particle Size Diameter Comparison 1 µm = mm = The human eye can only see particles sized down to 40 microns. Human Hair = 80 micron Particle 15 micron Particle 5 micron

5 Structure of ISO-Code ISO Code: 22/18/13 max. amount of dirt particles in 100 ml > given size ISO 4406: 1999 (E) - ISO Contamination Code Chart cont Number of Particles per 100 ml Scale Number More Than Up To and Including Scale Number 14 More Than 8,000 Up To and Including 16, ,000, ,000, ,000 8, ,000, ,000, ,000 4, ,000,000 64,000, ,000 2, ,000,000 32,000, , ,000,000 16,000, ,000,000 8,000, ,000,000 4,000, ,000,000 2,000, ,000 1,000, , , , , , , ,000 64, ,000 32,

6 How do we measure fluid contamination? Structure of ISO-Code: amount of dirt particles in a 100 ml sample larger than these specified sizes: 4µm / 6µm / 14µm Example: larger than 4µm = 2,234,000 larger than 6µm = 195,000 larger than 14µm = 4, µm / 6µm / 14µm ISO Code = 22 / 18 / 13

7 How do we measure fluid contamination? Structure of SAE AS 4059 (previously NAS Codes) Class µm µm µm max. amount of dirt particles in 100ml at given size >21 µm

8 Cleanliness Code Conversion: SAE AS 4059 Equivalent ISO 4406 Class Based on ISO 4406: 1999 and SAE AS 4059 Revised : Rev E 8/29/07 Cumulative Particles per 100 ml Differential Particles per 100 ml Code Designation Code Designation > 1 um > 5 um > 15 um 5 to 15 um 15 to 25 um 25 to 50 um 50 to 100 um > 100 um > 4 um(c) Size Code A >6 um(c) Size Code B >14 um(c) Size Code C 6 to 14 um(c) to 21 um(c) to 38 um(c) to 70 um(c) --- > 70 um(c) --- SAE AS 4059 Equivalent ISO 4406 Class /7/ /8/ /9/6 1, /10/7 3,120 1, , /11/8 6,250 2, , /12/9 12,500 4, , /13/10 25,000 9,731 1,731 8,000 1, /14/11 50,000 19,462 3,462 16,000 2, /14/12 100,000 38,924 6,924 32,000 5,700 1, /16/13 200,000 77,849 13,849 64,000 11,400 2, /17/14 400, ,698 27, ,000 22,800 4, /18/15 800, ,396 55, ,000 45,600 8,100 1, /19/16 1,600, , , ,000 91,200 16,200 2, /20/17 3,200,00 0 1,245, ,584 1,024, ,400 32,400 5,760 1, /21/18

9 Guidelines Data Sheet Provides ISO target cleanliness levels for various critical hydraulic/lube oil components and the filter selection that will achieve that cleanliness level target.

10 Sources of Contamination

11 New Oil - Photomicrographs ISO 16/14/11 Demanded by Modern Hydraulic Systems ISO 20/18/15 New Oil as Delivered in Tanker ISO 17/15/13 New Oil as Delivered in Mini-container ISO 23/21/18 New Oil as Delivered in Barrels

12 Effects of Contamination CAN EFFECTS OF CONTAMINATION BE STOPPED?

13 Basics of Fluid Contamination Type of Contamination Gaseous Liquid Solid Effects Air Gases Water Chemicals Emery Metal Scale Rust Particles Extremely Damaging Iron, Steel Brass, Bronze Aluminum Damaging Laminated Fabric Fibers Seal Abrasion Rubber Hose Particles Minimal Damage

14 Basics of Fluid Contamination Measuring procedures for solid particle contamination Weighing Counting Gravimetric Analysis Microscopic Analysis Electronic Analysis Non-Homogeneous fluids Manual Counting Automatic Counting Automatic Particle Counters (APCs) In The Field In The Lab

15 How do we measure fluid contamination? 20 Weighing: Gravimetric Concentration ISOMTD mg/l ISO 17/15/12 ISO 18/16/13 ISO 19/17/14 ISO 20/18/15 ISO 21/19/16 ISO 23/21/17 ISO 24/22/18

16 How do we measure fluid contamination? Microscopic analysis NAS 9 ISO 20/18/15 Photomicrograph

17 How do we measure fluid contamination? Basic principle light obscuration Light source is an LED light Durability Holds calibration Does not saturate quickly with high contamination levels

18 How do we measure fluid contamination? 14 micron Size of Particles 6 micron 4 micron The number of pulses equals the number of particles. The height of the pulses equals the size of the particles.

19 How do we measure water content? Karl-Fischer Analysis (chemical) Laboratory Infrared Spectroscopy (optical) Laboratory Turbidity Measurement (optical) Field Crackle Test (acoustic) Field Hydrogen Gas Method (chemical) Field (WTK) Water test kit Aqua Sensor - AS-2330 (electronic) Field Installation

20 Sources of Error Does the sample represent the system cleanliness? Foreign media: (air particulate, O 2, water, oil or chemicals on hands, etc.) Type of extraction (static, dynamic) Point of extraction - Test Connection Penetration type and type of test sample fitting - Best location to take sample - Disadvantage of fluid samples

21 Sources of Error Possible Sample Locations SYRINGE VACUUM BOTTLE THROTTLE VALVE RESERVOIRS Taking a sample from pressure header Taking a sample from stagnant fluid

22 Sources of Error-Reservoir sampling Example: Example: Reservoir Extraction with auxiliary pump Reservoir Extraction with Auxiliary Pump Point at which suction hose was lowered slowly to the bottom of the tank. suction hose near surface suction hose near bottom ISO CLASS INCREASE FROM 15 TO 20 IS EQUIVALENT TO AN INCREASE IN PARTICLE COUNT OF 32 TIMES!

23 Sources of Error Point of Extraction - Test Connection Arrangement

24 Sources of Error Point of Extraction - Where in the System is the best representation of system fluid cleanliness?

25 Sources of Error Disadvantages of Oil Sampling A Snapshot in time - does it represent the system cleanliness? Is it a peak or minimum point?

26 Sources of Error Advantages of Continuous real time on line Measurement Sample taken every 100 milliliter-real-time This type measurement tracks along with operating changes going on in the system.

27 Sources of Error Major actuation Point of maximum contamination Filtration is removing particles Filtration has reached equilibrium

28 Sources of Error Sampling Error Leaving sample bottles open too long Using previously contaminated bottles Unaware of system operation immediately before sampling resulting in inaccurate analysis and conclusions. Improper handling causing contamination from hands Failure to flush sampling ports and lines before sampling Note: Such errors are likely to result in higher contamination readings than actual.

29 Element Technology

30 What Can Be Done? To assure maximum component life, fluid life and superior system and equipment operation? CONTAMINANT LEVEL POPULATIONS MUST BE REDUCED TO LEVELS REQUIRED BY CRITICAL SYSTEM COMPONENTS HOW? Through Proper Filtering, Monitoring, Analysis, and Control

31 Hydraulic Power Unit Cylinder actuator Single Pressure filtration strategy Control Valve Pressure filter Main Hydraulic Pump Reservior

32 Contamination Control Loss of component Cost of efficiency due to wear standard filtration (non-efficient operation)- System performance degradation Equipment & component repair and Replacement labor & component costs System downtime costs resulting from component failures- Can not produce product Decrease in product quality resulting from poor control and operation higher rejection rates

33 Hydraulic Power Unit Comprehensive or Balanced Filtration Strategy Cylinder actuator SERVO Pressure filter Return filter Main Hydraulic Pump Kidney loop filter Reservoir

34 Contamination Control Loss of component Efficiency due to wear (non-efficient operation) Cost of a superior balanced filtration system up front Equipment & component repair and replacement System downtime Costs resulting from Component failures Decrease in product Quality resulting from Poor control and operation Small investment for superior filtration results in shrinking entire maintenance, quality, and manufacturing budget.

35 Required New Machine Cleanliness Fluid Cleanliness vs. Service Life Cleanup 5 ISO Codes (32 times cleaner) yields a life extension factor of 4 times Current Cleanliness Target Target Target Target 24/22/19 21/19/16 20/18/15 19/17/14 18/16/13 23/21/18 20/18/15 19/17/14 18/16/13 17/15/12 22/20/17 21/19/16 19/17/14 18/16/13 18/16/13 17/15/12 17/15/12 5 ISO CLASS IMPROVEMENT 16/14/11 16/14/11 15/13/10 20/18/15 17/15/12 16/14/11 15/13/10 14/12/9 19/17/14 16/14/11 15/13/10 14/12/9 14/12/8 Life Ext. Factor 2X 3X 4X 5X

36 Machinery Life Extension Factor Current Machine Cleanliness (ISO Code) Hydraulics and Diesel Engines Journal Bearing and Turbo Machinery Rolling Element Bearing Gear Boxes and Other Ref. Noria Corporation

37 Common Filter Terms Micron => 1 µm = mm = Pressure Drop across the element Beta Ratio Beta Stability DHC => Dirt holding capacity Multi-Pass Testing Filter Indicator Element collapse Pressure Filter By-Pass Absolute Rated Filtration Nominal Rated Filtration Surface Filtration Mechanism Depth Filtration Mechanism

38 High efficiency absolute element Features optimization of all element performance characteristics High ß x -values (efficiency) High ß x -value stability High dirt holding capacity Low long term pressure drop High collapse stability High flow fatigue stability Wide fluid compatibility

39 Multi-Pass Testing ISO 16889: 1999 What Data is Obtained? Best performance comparison regarding below parameters Beta Ratios Beta Stability Dirt Holding Capacity How is test completed? ISO Medium Test Dust (ISO MTD) Mil-5606 Hydraulic Fluid Constant Viscosity Constant Temperature at 40 degrees Centigrade Constant Flow rate through filter Constant rate of dirt injection Continuous measurement of particle counts upstream vs. down stream. Continuous measurement of pressures upstream & down.

40 What is Dynamic Filter Performance? Filters that Perform in REAL LIFE! The Test Lab Steady Flow No Fatigue Cycles Constant Dirt Ingression Rate to Filter Single Fluid Used Temperature 100 F ISO Medium Test Dust Accelerated Element Life Real Life Continuous Variations Millions of Fatigue Cycles Always Changing Wide Variety -40 F to 210 F Debris, Water, Air Months

41 Multi-Pass Testing ISO 16889: 1999 (ISO Standard for Performing Multi-Pass Test) FOR EVERY 1000 PARTICLES SIZED 5 micron OR GREATER THAT ENTER THE FILTER, ONE GOES THROUGH WHEN THE BETA 5 IS = 1000

42 Beta Values Versus Efficiency Beta Value Efficiency Particles Beta() Micron Upstream Particles Downstream Beta X % 100,000 50,000 Beta X % 100,000 25,000 Beta X % 100,000 10,000 Beta X % 100,000 5,000 Beta X % 100,000 2,500 Beta X % 100,000 1,667 Beta X % 100,000 1,333 Beta X % 100,000 1,000 Beta X % 100, Beta X % 100, Beta X % 100, Beta X % 100, Beta X % 100, Beta X 1, % 100, Beta X 2, % 100, Beta X 4, % 100, Beta X 5, % 100, Beta X 10, % 100, Beta X 20, % 100,000 5 Beta X 50, % 100,000 2

43 Beta Stability ISO 16889: 1999 High ß x -Values / High ß x -Value Stability Beta Ratio remains at a relatively constant level at high pressure drops beyond normal element operating ranges with high beta stability Element Element Point of element failure Beta 100 Stability = 210 psi means that: Beta Ratio at the rated micron will not drop below Beta Ratio = 100 until 210 PSID

44 Poor Beta Stability Causes a loss of adequate protection from the point that Beta drops below manufacturer s s published beta specification before the end of element life. Significant loss of filter efficiency before the end of element life Loss of equipment through loss of protection Increased wear and component failures Increased downtime Decrease in Customer Satisfaction

45 High Dirt Holding Capacity ISO 16889: 1999 Decrease in downtime when indicator is utilized for change-out indication (Less Element Changes) Decrease in replacement element costs (longer lasting-utilizing full element capacity) Decrease in maintenance/labor costs

46 DHC - Dirt Holding Capacity DHC Measured at Terminal Pressure / Indicator Setting INDICATOR TRIP POINT Element Terminal Pressure 72

47 Superior Element Life Pressure Drop Over Element Life Comparison High efficiency element has higher D/P than a low efficiency element design high efficiency elements to increase D/P at a slower rate than others with high efficiency elements crossover point with high efficiency elements High efficiency element Low efficiency element

48 Element technology Compatibility with all modern fluids ISO 2943 (ISO Standard for Fluid and Material of Construction Compatibility)

49 Features of a High Quality Element with high flow fatigue stability ISO 3724

50 ABSOLUTE RATED MULTI-LAYER SPIN-ON FILTERS high performance absolute rated durable synthetic media spin-on filters.

51 Typical Paper element from Low cost supplier Single layer of media Cellulose; No support layers or transition layers for resisting surge flows

52 Element Construction for High Efficiency & Performance Element Recipe Layers

53 Superior elements are designed for max. Surface Area Section Of Supported Element Pleat spring movement resilience Upstream Support Downstream Support Media & Support Layers Filter Element Support Core Optimization of the number of pleats to maximize surface area of the media is required for maximum performance

54 Superior Elements Designed for Max. Surface Area Section Of Unsupported Element Lost Effective Area FLOW FLOW Collapsed Pleat Caused by Lack of Support in recipe structure Typical Location of Fatigue Failures Core support tube FORCE Compressed Pleat Caused by Lack of Adequate Support and high flow velocity forces.

55 Filter Element Material Options Caking occurs on surface of media under Non-violent non-turbulent flow conditions Particles enter fibers and become entrained Surface Filtration With surface media (paper, metals, polyester) there is no mechanism to hold dirt in place when placing the element into a dynamic system with high velocity flow changes and a reverse flow surging environment. Depth Filtration With depth media as shown above, the particles enter the media and work their way down into the pores and passages to become entrained. This provides the mechanism that holds these particles in place when used in dynamic flow surging systems.

56 Filter Terms Absolute vs. Nominal ISO 16889: 1999 CONFORMANCE REQUIRED FOR ABSOLUTE FILTERS Absolute Rated Filter ß x 75 Beta ratio, efficiency and Dirt holding capacity determined by conducting a multipass test per ISO 16889: 1999 (filtration) Most are in fact Fiberglass media. NO INDUSTRY STANDARD EXISTS FOR NOMINAL FILTERS Nominal Rated Filter No industry standard exists to determine nominal element ratings. Surface filtration (nominal) applied in actual systems can not achieve dirt holding capacities derived through multipass testing. Most are paper, cellulose, polyester, or metals Beta efficiency and dirt holding are not valid data for nominal media per the multipass test specification Depth media only is specified on the ISO specification (ISO 16889: 1999)

57 Pressure Line Filtration Hydraulic pump Reservior Removes contaminants after hydraulic pump Cost effective with high cost dirt sensitive, components Filter before servo offers maximum protection from small particles

58 Return line filtration Actuator/cylinder Actuator/cylinder Control valve Control valve Hydraulic pump Reservior Cost effective for relatively dirt-tolerant systems Provides limited pump protection Not ideal with return flow surges

59 Balanced pressure & return line filtration strategy Cylinder actuator Control valve Pressure filter Return filter Main Hydraulic Pump Reservoir

60 Balanced pressure & kidney loop Filtration Strategy Cylinder actuator Pressure filter SERVO Main Hydraulic Pump Kidney loop filter Reservoir

61 Comprehensive Filtration Reservior Multiple Filters Provide Maximum protection Lowest contamination level Extended element & hydraulic system life Off-Line Filter Provides High efficient filtration Continuous filtration Fill port for filtering new oil

62 Lube System Filtration In-line lubrication filtration strategy Provides maximum in-line protection Lowest contamination level with single filtration strategy Continuous In-line filtration

63 Lube System Filtration Off-line lubrication filtration strategy: Gives cost effective protection No in-line system pressure drop Can be single or duplex filter

64 Lube System Filtration In-line & off-line balanced lubrication filtration strategy: Provides maximum protection & performance Lowest contamination level Balanced Filtration continuous line & off line filtration Best element life and system protection

65 FLUID HANDLING CONCEPTS AND CONSIDERATIONS

66 TARGET ISO 16/14/11 VIA MINI TOTES ISO 17/15/13 ISO 20/18/15 ISO 23/21/18 VIA TANKER VIA BARRELS FLUID HANDLING CONSIDERATIONS Method of delivery Contamination ISO cleanliness target level Storage method Fluid handling while in storage Transfer method Maintenance practices System integrity (tightness and handling) METHOD OF DELIVERY PLANT ENTRY METHOD Target ISO level = 16/14/11 Fluid Storage target level = 15/13/10 = 1 ISO code cleaner TRANSFER PUMP AND FILTER STORAGE TANK MAKEUP FLUID TO HYDRAULIC SYSTEM Hydraulic System Reservoir 16/14/11

67 Fluid transfer and loop filtration carts in single or in series double Pressure to 87 psi Flows to 14 gpm Features Single or Two Stage Filtration (In Series) Water Removal Capability

68 Filter Element 3 micron Beta=1000 System operating in equilibrium (constant loop recirculation) # particles in 3µ 1,000,000 # particles out 3µ 1000 Single pass 62,500 Depth Filter Membrane Filter Single Pass For every 1000 particles 3 micron or larger that enter the element ---- one goes through when the filter element is in system equilibrium continuous re-circulating flow, however significantly less efficiency on a single pass.

69 Effectively performing as a two pass process Initial ISO code results from method of delivery Transfer cart dual filter Fluid Storage Tank Dual series absolute depth filter Hydraulic System Reservoir Filled from: Mini-totes 17/15/12 good transfer filtration required & simple recirculation loop to drop 2 codes Tanker trucks 20/18/15 good transfer filtration required & simple recirculation loop to drop 5 codes Metal drums 23/21/18 good transfer filtration required & simple recirculation loop to drop 8 codes Set up to achieve 1 ISO level cleaner than target to account for Un-anticipated ingression in tank and during transfers. Desired ISO = 16/14/11 RATINGS UNDER EQUILIBRIUM CONDITIONS ISO Code target 20/18/15 19/17/14 18/16/13 17/15/12 Micron absolute rating 20 micron 10 micron 5 micron 3 micron

70 Two filter elements series configuration 3 micron Beta=1,000,000 System operating in equilibrium (constant loop recirculation) # particles in 3µ # particles out 3µ # particles out 2 nd 3µ 1,000,000 first = 1000 Second = 1 Single pass 62,500 Efficiency level for two Beta 1000 filters in series In equilibrium = 1,000,000. Single pass 3,906 For every 1,000,000 particles 3 micron or larger that enter the element set, one goes through when the filter element is in equilibrium continuous re-circulating flow, however again significantly less efficiency than equilibrium condition but same level of improvement jump that you would see in equilibrium.

71 Ideal fluid handling configuration: In receiving fluids, insure positive, sealed, reliable connections Insure tanks and piping/tubing connections are tight Sample fluids in storage tank periodically anticipate ingression Replace filter elements regularly when indicator trips Have transfer filters located close to system fill point (minimize ingression) Set up filtration (off loop) to achieve the target ISO code minus one code required by the hydraulic/lube system Fluid Storage Tank Fluid Storage Hydraulic System Gear Reservoir Box or Reservoir

72 Assess 2. Determine Current Conditions particle contamination levels water content fluid health (ageing/effectiveness) fluid sampling changes over time

73 Assess 2. Evaluate Current Protection in Place to account for ALL sources of contamination

74 Assess 2. Evaluate Current Protection in Place pressure filters return line filters offline filtration loops breathers-high integrity and desiccant types new oil protection treatment, transfer, polishing monitoring (sampling)/change-out schedule

75 Recommend Filtration Upgrades 1. Betafit Elements High ß x -values High ß x -value stability High dirt holding capacity Low long term pressure drop High collapse stability High flow fatigue stability Wide fluid compatibility

76 Recommend Filtration Upgrades 2. Addition of Offline Filtration Loops Off line loop membrane Filtration Used for solid particulate in transfer and tank kidney loops Vacuum Dehydrator when high water or gas content is present Filter coolers when heat is a problem

77 Recommend Filtration Upgrades 3. Addition and replacement of high performance breathers Breathers Wide variety including: - desiccant for water vapor removal - spin-on - with filler baskets

78 Monitor & Maintain 1. Contamination Monitoring Devices Portable & Online Water Content Sensors Particle counter (Portable) Perfect for plants with many small machines Contamination Sensor (Permanent installation) Perfect for larger, critical systems where constant, monitoring is required Water content sensor

79 Monitor & Maintain 2. Supplemental Monitoring Techniques Regular Fluid Sampling & Analysis Fluid Sampling Kits Provides information about more than contamination: - additive depletion - contamination - water content - viscosity - wear metals - trending from periodic sampling Leads to predictive maintenance decisions eliminating unplanned shutdowns.

80 Monitor & Maintain 3. Portable Offline and Fluid Handling Filtration Loops Can be used on multiple machines if contamination levels unexpectedly rise Fluid transfer carts wheeled carts - 2 stage (series) - Water & solids Hand-held transfer cart Vacuum dehydrator - Water & aeration removal - Solid particle removal

81 Sensor Arrays for a Full Range of fluid conditions monitoring flow pressure particles temperature oil condition humidity level data acquisition

82 Remote Monitoring Capability: Your Hand on the Pulse of the Systems Machines or Equipment Level sensor Pressure sensor Temperature sensor Contamination sensor Aqua sensor Ethernet Intranet/Internet Mobile telephone system GSM Modem Sensor Monitoring Unit Fixed network Driver Software Control room Fluid condition Monitor

83 Portable Online Particle Counter for Service Support Features Measuring of solid contamination in hydraulic and lube oils after market service and repair Calibration to ISO field measurement equipment Stores up to 3000 measured values Inlet pressure range psi (1-350 bar) Integrated pump for tank sampling Easy to operate

84 Contamination Sensors on each machine

85 Fluid water content sensor with readout Features Measurement of water content in hydraulic and lubrication oils relative to the saturation concentration Simultaneous measurement of the fluid temperature Designed for stationary installation Standard output options: mA analog outputs for percent saturation and temperature - switch/alarm outputs - serial RS485 interface - integrated display

86 Fluid water sensor transducer Desired features : Measurement of water % content in oils relative to the saturation level Simultaneous measurement of fluid temperature

87 Stationary Single Pass Filtration units Features Vane pump for hydraulic oils low-gram-dirt removal cost Gear pump 5-19 GPM (18-72 l/min) Viscosity up to (1000 mm 2 /s) Integrated pressure relief valve Filter element type = membrane filter high dirt holding capacity reduced filtration costs-lowest cost per gram dirt removed single pass filtration rating not required for system to be in equilibrium (constant fluid recirculation.)

88 Stationary Single Pass Filtration units Membrane type filter elements nominal flow rate per element 15 l/min dirt holding capacity per element = 500 g (ISOMTD) ß 2 > dp = 2 bar incinerable