Copyright Brendan Casey www.HydraulicSupermarket.

com 2004
Are Your Filters Destroying Your Hydraulic Components?
Two Types Of Filters That Can Damage Hydraulic Components
And What to Do About It
Brendan Casey, www.HydraulicSupermarket.com
Introduction
While it is widely known that particles reduce the service life of hydraulic components,
the notion that a hydraulic system can have too many filters is rarely considered. Some
filters do more harm than good and their installation in a hydraulic system can cause
failures. In this report, the advantages and disadvantages of different filter locations are
discussed and the negative effects that some filters have on hydraulic component life are
examined.
Selecting Filter Locations
The function of the filters in a hydraulic system is to maintain fluid cleanliness at a level
that maximizes component life. The appropriate cleanliness level is based on factors such
as operating pressure and the internal clearances of the components within a system. The
process of selecting, achieving and maintaining an appropriate fluid cleanliness level has
been well documented
1
.

Given that the objective of this process is to gain maximum
service life from the components in a system, it is imperative to understand which filter
locations have the opposite effect.
Suction Filtration
From a filtration perspective, the pump intake is an ideal location for filtering media. The
absence of both high fluid velocity, which disturbs trapped particles, and high pressure-
drop across the element, which forces migration of particles through the media, increases
filter efficiency. These advantages are outweighed by the restriction the element creates
in the intake line and the negative effect this has on pump life.
Pressure Filtration
Locating filtering media in the pressure line provides maximum protection for
components located immediately downstream. Filtration rates of two microns or less are
possible, due to the pressure available to force fluid through the media. Filter efficiency is
reduced by the presence of high flow velocities, and pressure and flow transients, which
disturb trapped particles. The major disadvantage of pressure filtration is economic.
Because the housings and elements must be designed to withstand peak system pressure,
pressure filtration has the highest initial and ongoing cost.
Return Filtration
The rationale for locating filtering media in the return line is this: if the reservoir and the
fluid it contains starts out clean and all air entering the reservoir and returning fluid is
adequately filtered, then fluid cleanliness will be maintained. The other advantage of the
return line as a filter location is that sufficient pressure is available to force fluid through
Copyright Brendan Casey www.HydraulicSupermarket.com 2004
fine media (typically 10 microns), but pressure is not high enough to complicate filter or
housing design. This combined with relatively low flow velocity, means that a high
degree of filtering efficiency can be achieved at an economical cost. For these reasons,
return filtration is a feature of most hydraulic systems. The main disadvantage of return
line filtration is that the back pressure created by the element can damage some
components.
Off-line Filtration
Off-line filtration enables continuous, multi-pass filtration at a controlled flow velocity
and pressure drop, which results in high filtering efficiency. Filtration rates of two
microns or less are possible, and water absorbent filters and heat exchangers can be
included in the circuit for total fluid conditioning. The main disadvantage of off-line
filtration is its high initial cost, although this can usually be justified on a life-of-machine
cost basis.
Filters That Do More Harm Than Good
Some filters can actually do more harm than good in a hydraulic system and therefore
their installation is misguided. Suction and drain line filters fall into this category.
Suction Line Filters
Pump inlet or suction filters usually take the form of a 150-micron (100-mesh) strainer,
which is screwed onto the pump intake penetration inside the reservoir. The restriction
caused by a suction strainer, which increases at low fluid temperatures (high viscosity)
and as the element clogs, increases the chances of a partial vacuum developing at the
pump inlet. Excessive vacuum at the pump inlet causes cavitation erosion and mechanical
damage.
Cavitation Erosion. When a partial vacuum develops in the pump intake line, the decrease
in absolute pressure results in the formation of gas and/or vapor bubbles within the fluid.
When these bubbles are exposed to elevated pressures at the pump outlet they implode
violently. Collapse pressures greater than 145,000 PSI have been recorded
2
and if micro-
dieseling occurs (combustion of air/oil mixture) temperatures as high as 2012F are
possible
3
. When bubbles collapse in proximity to a metal surface, erosion occurs.
Cavitation erosion contaminates the hydraulic fluid and damages critical surfaces.
Chronic cavitation can cause extreme metal loss and lead to pump failure.
Mechanical Damage. When a partial vacuum develops at the pump inlet, the mechanical
forces induced by the vacuum itself can cause catastrophic failure. The creation of a
vacuum in the pumping chambers of an axial pump puts the piston-ball and slipper-pad
socket in tension. This joint is not designed to withstand excessive tensile force and as a
consequence, the slipper becomes detached from the piston (Figure 1). This can occur
either instantaneously, if the vacuum-induced tensile force is significant enough, or over
many hours of service as the ball joint is repetitively put in tension during inlet.
Copyright Brendan Casey www.HydraulicSupermarket.com 2004
Figure 1. Slipper separated from its piston as a
result of excessive vacuum at the pump inlet.
The piston retaining plate, the primary function of which is to keep the piston slippers in
contact with the swash plate, must resist the forces that act to separate the piston from its
slipper. This vacuum-induced load accelerates wear between the slipper and retaining
plate and can cause the retaining plate to buckle. This allows the slipper to lose contact
with the swash plate during inlet, and it is then hammered back onto the swash plate
when pressurized fluid acts on the end of the piston during outlet. The impact damages
the piston slippers and swash plate, leading rapidly to catastrophic failure.
In bent axis pump designs, the piston is better able to withstand vacuum-induced tensile
forces. Piston construction is generally more rugged and the piston ball is usually held in
its shaft socket by a bolted retaining plate. However, tensile failure of the piston stem
and/or buckling of the retaining plate can still occur under high vacuum conditions.
Tensile failure of the piston stem is more likely to occur in bent axis designs which use a
device other than the pistons to synchronize cylinder speed, due to the smaller diameter
of the piston stem (Figure 2).
Figure 2. Bent axis piston design prone to failure
as a result of excessive vacuum at the pump inlet.
In vane pump designs, the vanes must extend from their retracted position in the rotor
during inlet. As this happens, fluid from the pump inlet fills the void in the rotor created
by the extending vane. If excessive vacuum exists at the pump inlet it will act at the
base of the vane. This causes the vanes to lose contact with the cam ring during inlet, and
they are then hammered back onto the cam ring as pressurized fluid acts on the base of
the vane during outlet. The impact damages the vane tips and cam ring, leading rapidly to
catastrophic failure.
Gear pumps are mechanically the least susceptible to vacuum-induced forces. Despite
this fact, research has shown that suction strainer clogging caused by resinous, oil
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oxidation by-products can reduce the service life of an external gear pump by at least 50
percent
4
.
Given the potential for suction strainers to damage the pump, why use them at all? This
question becomes more curious when you consider that if the reservoir and the fluid it
contains starts out clean and all air and fluid entering the reservoir is adequately filtered,
the fluid in the reservoir will not contain hard particles large enough to be captured by a
coarse mesh strainer. Clearly, examination of the arguments for installing suction
strainers is required.
Trash Exclusion. The argument that suction strainers should be fitted to protect the pump
from debris that enter the reservoir as a result of careless maintenance practices, is a
popular one. Nuts, bolts, tools and similar debris pose minimal threat to the pump in a
properly designed reservoir, where the pump intake is located a minimum of four inches
off the bottom. When anecdotal evidence is presented that debris, which entered the tank
through careless maintenance did cause a pump failure, its weight is diminished on the
basis that, had a suction strainer been fitted, the same neglect of its maintenance would
have eventually resulted in the same outcome premature pump failure. Notwithstanding
the above, the preferred solution to this problem is to take action to prevent contaminants
from entering the reservoir in the first place.
Warranty. Another popular misconception surrounding suction strainers is that their
absence voids pump manufacturers warranty. If a nut or bolt enters the pump through its
intake causing it to fail, it is reasonable to expect that the manufacturer will deny
warranty. It is also reasonable to expect the manufacturer to deny warranty if a pump
failure is caused by particles smaller than the mesh of a strainer or by cavitation as a
result of a clogged strainer. So if a pump fails through either contamination or cavitation,
the manufacturer is unlikely to accept warranty - suction strainer or no suction strainer.
Drain Line Filters
In the earlier discussion of return filtration, it was pointed out that the variable back
pressure created by the element can damage some components. This applies to pumps
and motors. Connecting case drain lines to return filters can result in excessive case
pressure, which causes seal failure and mechanical damage.
Seal Failure. High case pressure results in excessive load on the lip of the shaft seal. This
causes the seal lip to wear a groove in the shaft, which eventually results in leakage past
the seal. If case pressure exceeds the shaft seals design limits, instantaneous failure can
occur. The subsequent loss of oil from the case can result in damage through inadequate
lubrication.
Mechanical Damage. The effect of high case pressure on axial piston pumps is the same
as excessive vacuum at the pump inlet. Both conditions put the piston-ball and slipper-
pad socket in tension during inlet (Figure 3). This can cause buckling of the piston
Copyright Brendan Casey www.HydraulicSupermarket.com 2004
retaining plate and/or separation of the slipper from the piston, resulting in catastrophic
failure.
Figure 3. Effect of excessive case drain
pressure on axial piston design.
High case pressure can cause the pistons of radial piston motors to be lifted off the cam.
This can occur in operation during the outlet cycle. The pistons are then hammered back
onto the cam during inlet, destroying the motor. If residual case pressure remains high
when the motor is stopped, loss of contact between the pistons and cam can allow the
motor to freewheel, resulting in uncontrolled machine movement.
To avoid these problems, pump and motor case drain lines must not be connected to the
return filter. Case drains should be returned to the reservoir through dedicated
penetrations. These penetrations must be higher than the units case port and be
connected to a drop-pipe inside the reservoir that extends below minimum fluid level. For
the reasons outlined above, filters are not recommended on case drain lines. While this
does allow a small percentage of fluid to return to the reservoir unfiltered, in most
applications the contamination risk is low and can be effectively managed using oil
analysis and other condition-based maintenance practices.
Throw Away The Filters
Where suction and case drain filters are fitted, the case for removing and discarding them
is compelling. In most applications, the contamination control benefits these filters offer
are strongly outweighed by the negative impact they have on component service life. In
applications that demand their installation or where human barriers prevent their removal,
precautions must be taken to prevent component damage.
Suction Filters
If suction filtration is installed, a filter located outside of the reservoir is preferable to a
suction strainer. The inconvenience of servicing a filter located inside the reservoir is a
common reason why suction strainers go unserviced - until the pump fails. If a suction
strainer is used, opt for 60 mesh (240 microns) rather than the more common 100 mesh
(150 microns). The strainer should be grossly oversized for the pumps flow rate to
ensure that pressure drop is minimized, even under the most adverse conditions.
Copyright Brendan Casey www.HydraulicSupermarket.com 2004
Regardless of the type of filter employed, it must incorporate a bypass valve to prevent
the element from creating a pressure drop that exceeds the safe vacuum limit of the
pump. A gauge or transducer should also be installed downstream of the filter to enable
continuous monitoring of absolute pressure at the pump inlet.
Case Drain Filters
If a filter is fitted to a pump or motor drain line it should be no finer than 25 microns and
be grossly oversized for the expected flow rate. The filter housing must incorporate a
bypass valve with an opening pressure lower than the maximum, allowable case pressure
for the particular component (typically 5-15 PSIG). Installing a gauge or transducer
upstream of the filter for monitoring case pressure is also advisable.
Conclusion
The main objective of contamination control is to extend the service life of hydraulic
components. Suction and case drain filters can reduce the service life of pumps and
motors and therefore their installation in pursuit of this objective is paradoxical. Effective
contamination control is achievable using alternative filter locations that do not
compromise component service life. However, if suction or case drain filters are included
in a system, precautions must be taken to ensure that they do not cause damage to the
components they are installed to protect.
References
1
Casey, B. (2002). Insider Secrets to Hydraulics, pp. 3-12.
Available: http://www.InsiderSecretsToHydraulics.com
4
Ingvast, H. (1993). Diagnosing Tyrone Gear Pump Failures, The Third Scandinavian
International Conference On Fluid Power, vol. 2, pp. 535-546.
2
Okada, T., Iwai, Y. and Awazu, K. (1989). Study of Cavitation Collapse Pressure and
Erosion Part 1: A method for Measurement of Collapse Pressure, Wear, vol. 133, pp.
219-232.
3
Suzuki, R., Tanaka, Y., Totten, G. and Bishop, R. (2002, July). Removing Entrained
Air in Hydraulic Fluids and Lubrication Oils", Machinery Lubrication, pp. 56-62.
Further Reading
Preventing Hydraulic Failures, by Casey, B.
Available: http://www.InsiderSecretsToHydraulics.com/hydraulic-failures.html