Filtration

Causes of breakdowns in
hydraulic and lubrication systems
70 - 80 % of all failures in hydraulic systems
and
up to 45 % of all bearing failures
are caused by

solid and liquid contamination

of oil

Types of contamination
Effect

Types of contamination

Gaseous

Liquid

Solid

Air

Water
Unknown Oil

Emery
Metal scale
Rust particles

extremely
bad damage

Iron
Steel
Brass
Bronze
Aluminium

bad
damage

Laminated fabric
Fibres
Sealing abrasion
Rubber particles
from hoses
Paint/varnish particles
Oxidation products
of the hydraulic fluid

minimal
damage

Gaseous Contamination
Air

Consequences of Gaseous
Contamination

Cavitation
Local oil overheating
Leads to unstable regulation behavior
Reduces the dynamic lubrication film
thickness
Oil aging
CxHy + O2 Acids, H20, Sludge
Catalysator: temperatur, moisture, copper,
5

aluminium, paint and varnish

Rapidly age at high temperatures and moisture

Fluid Contamination
Water
Unknown oil at system refill

Consequences of Fluid
Contamination
Corrosion
Decrease of dynamic viscosity

Decrease of lubrication film thickness

Contact of the surfaces
Reduction of oil durability

Changes of oil condition

Generating sour oil aging products

Increase of oil aging speed
Generating mud

Origin of the Solid Contamination

External contamination

Wear (Cylinder)

Initial contamination
of the valve
External contamination
through system opening

Repairs

Initial
contamination
(in the oil)
Wear (Pump)

Diameter in mm

Size Ratio of Particles

Bear lubricating film Fine/ coarse particle

Human hair

Parts of Hydraulic Components

Gear pump
0,5 up to 10m

Vane pump
0,5 up to 5m (J1)

Piston pump
0,5 up to 1m (J2)

Valve
5 up to 25m (J1)

Servo valve

10

5 up to 8m (J1)

Solid Contamination

11

sand

metal particles

fibers

rust

weld pearls

abrasion of
vulcanized rubber

oxidation
products

color
particles

Solid Contamination
Fine contamination (>6-14m)
Consequences:

- Wear
- Internal leakage
- Inaccurancy of regulation
- Valve blocking
Coarse particles (>14m)
Consequence:
Sudden breakdown of
components

12

Finest contamination (4-6m)

Consequences: - Siltation
- Faster oil aging

How is the Effect of Contamination Evaluated ?

Condensation water
Gearwheel abrasion
Loose ridges
Assembly contamination
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

10

20

30

40

50

60%

Initial damages to hydraulic

components
Without commissioning flushing

With commissioning flushing

Commissioning

Lifetime

Contamination as consequential
damage

Contamination as consequential
damage

Embedded chip

Surface damages of an internal

gear pump

Solid Particle Wear depends on

Size of solid particles
Ratio between particle size/ operation
cycle
Form of solid particles
Operation over pressure
Flow velocity
Material of the contamination
19

Types of wear
Abrasion
by particles between adjacent moving surfaces

Erosion
by particles and high fluid velocity

Adhesion
from metal-to-metal friction (loss of fluid)

Fatigue wear
surfaces damaged by particles are subjected to
repeated stress

Corrosion
20

by water or chemicals (not covered below)

Abrasion
by particles between adjacent moving surfaces

Effects of abrasion:

21

Changes to tolerances
Leakages
Reduced efficiency
Particles produced in the system
create more wear!

Erosion
by particles and high fluid velocity
The high velocity of the fluid forces existing particles against
the corners and edges of the system.
Other coarse and fine particles therefore become detached
from the surface and there is a gradual attack on the surfaces
in the system.

Erosion damage on the cog wheel

22

Adhesion
from metal-to-metal friction (loss of fluid)
Low speed, excessive load and/or a reduction in fluid
viscosity can reduce the oil film thickness.
This can result in metal-to-metal contact, and also possible
shearing.

Adhesion on ball bearing

23

Surface fatigue
surfaces damaged by particles are subjected to
repeated stress
The smallest cracks in the
surface are surface fatigue
hollowed out causing
material to break off,
therefore creating new
particles. This action causes
an increase in wear.

24
Surface fatigue on ball bearing

Contamination classifications
NAS 1638 (valid until 30.05.2001)
NAS-Code
(nach NAS 1638)

25

00
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14

Number of particles/ 100ml

2 - 5 m 5 - 15 m 15 - 25 m 25 - 50 m 50 - 100 m >100 m
625

125

22

1250

250

44

2500

500

88

16

5000

1000

176

32

10000

2000

352

64

16

20000

4000

704

128

32

40000

8000

1408

256

64

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 classifications
ISO 4406 ISO Code

26

ISO Code
(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/100ml
from
up to
16
32
32
64
64
130
130
250
250
500
500
1000
1000
2000
2000
4000
4000
8000
8000
16000
16000
32000
32000
64000
64000
130000
130000
260000
260000
500000
500000
1000000
1000000
2000000
2000000
4000000
4000000
8000000
8000000
16000000
16000000
32000000
32000000
64000000
64000000
130000000
130000000
250000000

4406: 1999

21 / 18 / 15
>4m(c) >6m(c) >14m(c)
>2m
>5m >15m

old
4406: 1987

Old and New Procedures of

Measurement
Definition of particle size (d)
ACFTD- definition of
particle sizes (ISO 4402: 1991)
Flche =
176,7 m

Flche =
176,7 m

16,9 m

16,9 m

d = 16,9 m

particle size = 16,9 m

27

ISO MTD- definition of

particle sizes (ISO 11171: 1999)

d = 15 m
Flche =
176,7 m

particle size = 15 m (c)

Diameter of the
coextensive circle

*ACFTD size
(ISO 4402 :
1991) mm
< 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) mm (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 classifications
ISO 4406 ISO Code

28

Contamination classifications
SAE AS 4059 : 2001
Maximal number of particles (particle per 100 ml)
Size (ACFTD),
acc. to ISO 4402
calibrated or
microsc. counting*
Size (ISOMTD),
acc. to 11171
calibrated or
REM**
Size code

Code-No.

29

> 1m

> 4m(c)

> 6m

> 15m

> 6m(c)

> 14m(c)

> 25m

> 21m(c)

> 50 m

> 100 m

> 38m(c)

70m(c)

000

195

76

14

00
0
1
2
3

390
780
1560
3120
6250

152
304
609
1220
2430

27
54
109
217
432

5
10
20
39
76

1
2
4
7
13

0
0
1
1
2

4
5
6
7
8
9
10
11

12.500
25.000
50.000
100.000
200.000
400.000
800.000
1.600.000

4860
9730
19.500
38.900
77.900
156.000
311.000
623.000

864
1730
3460
6920
13.900
27.700
55.400
111.000

152
306
612
1220
2450
4900
9800
19.600

26
53
106
212
424
848
1700
3390

4
8
16
32
64
128
256
512

12

3.200.000

222.000

39.200

6780

1.250.000

1020

Which Classification do we use in

which Application ?

Correct
Classification

30

Typical clealiness level

31

SAE 12
ISO 22/21/18
Fresh oil ,
delivered in barrels

SAE 9
ISO 19/18/15
Fresh oil,
delivered by tank truck

SAE 7
ISO 17/16/13
Fresh oil,
delivered by mini-container

SAE 5
ISO 15/14/11
required for modern
hydraulic systems

Cleanliness requirements for lubricating

and hydraulic components

32

Cleanliness requirements for lubricating

and hydraulic components

33

Industrial Standards for Oil

Contamination

1 mg/l

Contamination class ISO 18/16/14

How to Measure ?

35

Possible Extraction Methods

for Measurement
dynamic

36

Possible Extraction Methods

for Measurement
static
Actuator

Control

37

ISO 22/20/17 ISO 16/14/12

Time 9.30
Time 10.00

Measurement Procedures for Solid

Contamination
Oerview

weighing

gravimetric
analysis

counting

microscopic
analysis
manual
counting
automatic
counting

electronic
analysis
automatic
particle counting
devices (APC's)
in field

in laboratory

38

Possibilities of Condition
Monitoring

FCU

Table comparison

39
Laboratory

Locally

Principle of Electronic Particle

Counters

FCU

40

HYDAC Sensor Technology

On-Line Particle Counter

41

patented HYDAC sensor

stable due to fiber-optic light guide technology for
locally use

infrared diode
only monochromatic
light (of a wave length)
unlimited lifetime

light absorption

Working Method of Electronic

Particle Counting
Measurement of oil contamination

Voltage [Volt]

Voltage [Volt]

Calibration with SRM 2806

2m

5m

15m

42

particle size [m]

time

25m

Measuring with Fluid Control Unit

(FCU)
10

12

14

16

18

20

[min]

[min]

0:01

0:01

0:02
0:03
0:04

SAE

0:06

0:07

0:07

10

12

ISO

0:04

0:06

0:10

0:03

0:05

0:09

0:02

0:05

0:08

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%
Solid contamination
Ageing of the lubricant
Faults in bearing selection

Liquid Contamination
selection of the lubricant
Assembling faults

Source: FAG Wlzlagerschden Publ.-Nr.: WL 82 102 / 2 DA

Why Monitoring Contamination

Potential Reducing Cost
Cleanliness
Class

Target Target Target Target

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

18/15

15/12

14/11

13/10

12/9

17/14

14/11

13/10

12/9

12/8

NAS 9
NAS 6
NAS 5
NAS 4
NAS 3

Increase in reability
2x

3x

4x

5x

*Van Dorn-Demag

Filter Functions

Before:
purity level SAE 13

through filtration
46

Afterwards:
purity level SAE 4

Tasks of a Filter

47

Precludes disturbances in regulation behavior

Reduces breakdown times for the purpose of
maintenance
Secures smoothly functions
Extends the durability of the components
Supports the lubricating capability of the fluid
Extends the durability of the fluid
Removal of undesired corruptive components of the
medium and system entry is prohibited
Protection against damageable components

Reduction of operation costs

Tasks of a Filter
Component

48

Tasks

In the human body

In the hydraulic
system

In the human body

In the hydraulic
system

Bronchial Tubes

Air Breather Filter

Cleaning of the in- and outcoming air

Kidney

Return Line Filter

Separation of solid particles and water

Liver

Pressure Filter

Heart

Pump

Brain

Control Bloc

Responsible for the entire function

of the body/ system

Dialysis

Bypass Filter

Separation of solid particles and water

Blood

Working Fluid

Support of the organs

and removal of
contamination

Nerve system

Control

Information system about Information system about

pressure, temperature
the organ condition
and tank level

Blood sample

Oil sample

Sensor system

24 hours ECG

Protection of the organs or the components

Generation of pressure and flow

Energy transport
temperature, friction
reduction

Control of the fluid condition

Control of the system condition

Filter Element Material

Surface filter

49
Depth filter

Filter Element Material

Features of Surface Filters
Mesh size determines filtration ratio
Low free filter area
(30-40% of the total filter area)
High differential pressure stability
(especially at lacing material)
Simple cleaning
Low initial differential pressure
Typical application: protection filter
50

Filter Element Material

Features of Surface Filters
suspension

cake

bridge

51

filter cloth
filtrate

Filter Element Material

Features of Depth Filters
Filtration ratio must be experimentally
determined
Labyrinth effect
Impossible to clean (exception: metal mat)
Extraordinary filtration performance
High dirt hold capacity
Typical application: damageable components

52

Filter Element Material

Features of Depth Filters

53

Filter Element Material Scaled up

for 15 times
Surface filters

Wire mesh, 700 m

Wire mesh, 100 m

Laces mesh, 50 m

Paper mesh

Metal mesh

Depth filters

54
Glass fiber mesh, 20 m

Depth Filters under the Electron

Microscope

55

Effects of Free Filter Surface

Element A

Element B

thin fibers, larger filter surface

very coarse fibers, smaller filter surface

Filtered particles

56

1. Hardly pressure drop in pure condition

2. Enormous particle holding capacity, NOT at competition!

Three Coat Filter Mat Design

with Different Media

57

Coarse

Medium

Fine

(1. layer)

(2. layer)

(3. layer)

Differential pressure [bar]

Filter Element Material

Characteristic Curves

58

surface filter

Dirt hold capacity [g]

depth filter

Multipass-Test
Determination of the x(c)-value
ISO 16889
test
filter element

Nupstream
59

nupstream x m
X(c)=
ndownstream x m

Features of a High-Quality Element

High x(c)-values
ISO 16889

High x(c)-value-stability
High dirt hold capacity

60

Multipass-Test

Multipass - Test
ISO 16889

61

Multipass-Test
Schematic Demonstration
ISO 16889
test system

particle
counter

test filter
dirt
injection
system

62

ISO 16889

Features of a High-Quality Element

High x(c)-Values / High x(c)-Value
Stability
x(c)- value and separation rate at the differential pressure
(single value demonstration)

1000
2 m

3 m

5 m

6 m

8 m

filter element : 10 Micron

10 m

1000
99.9

1000

99.8

absolute filtration

1000
99.9
99.8

200

99.5

100

99.0
100

x - Wert

x(c)- value

98.0 98.0

nominal filtration

95.0

10

10

10

90.0

90.0
10
75.0

63

50.0
1
0

10

Element differential pressure in bar

11

12

13

14

15

0.0
1
16

Separation rate in %

100

100

Features of a High-Quality Element

High Dirt Hold Capacity
element differential pressure [bar]

ISO 16889

64

comparison of the dirt hold capacity

of two filter elements identical in construction
11
10
9

Element A

8
7
6
5

Element B

4
3
2
1
0
0 1 2 3 4 5 6 7 8 9 10 11 12131415 16171819 20212223 242526

dirt hold capacity [g ISOMTD]

Features of a High-Quality Element

ISO 16889

High x-value

High x-value-stability

High dirt hold capacity

Multipass-Test

Low long-term pressure drop curve

65

ISO 2941

High collapse cracking pressure resistance

ISO 3724

High flow through fatigue strength

ISO 2943

Good media compatibility

element differential pressure [bar]

High-Quality Element - Low Long

Term Pressure Drop Curve
Energy balance sheet
of 2 filter elements of identical construction
3.0
high energy costs
with element B

2.5
2.0
1.5
1.0

energy costs reversal point

with element A

Element B
initial energy costs
with element A

0.5

66

Element A

initial
Dp 0.0
operation time [ h ]

Features of a High-Quality Element

High Collapse Pressure Resistance
ISO 2941

element collapsed at 220 bar

67

ISO 3724

Features of a High-Quality Element

High Flow-Through Fatigue
Strength
5

bar

4
3
2
1

68

0
1 million load changes

Features of a High-Quality Element

Good Media Compatibility
ISO 2943

69

Comparison Some Filter Elements

70

Development of Filtration
Technology

71

Year

Development

Filtration ratio

1940

First air and oil filter for

motors; screen filter

100 m

1950

Big increase of hydraulics and

thus of filtration

1960

Application of star folded mats

and supporting tubes

50 up to 100 m

1970

Development of paper and

metal mesh elements

up to 3 m
nominal

1980

Introduction of the Multi Pass Test,

beginning of absolute filtration

up to 3 m
absolute

1990

Absolute filtration in all ranges

1 m and 2 m
absolute

Installation location of Filters

Return line filter
Pressure filter

Filter unit
Suction filter

72

Off-line filter

Breather filter

Suction Filters
CONTROLLING

73

Suction Filters
Benefits
Protects the pump against coarse
contamination
Cheap
Peace of conscience of the design engineer

74

Suction Filters
Disadvantages
Finest Filtration is not possible
Danger of cavitation especially during deep
temperatures (cold start)
Guaranteeing protection against wear, the
installation of further filters is necessary
System must be switched off for element
changing
75

Filter is badly accessible

Pressure Filters
CONTROLLING

76

Pressure Filters
Benefits
Filtration directly in front of the components
which are supposed to be protected
Desired purity level is guaranteed
Finest filtration
Change-over filters are possible (24 hours
operation)
77

Pressure Filters
Disadvantages

78

More expensive filter housing and element

Complex element construction due to

necessary differential pressure resistance

Pump is not directly protected

Return Line Filters

CONTROLLING

79

Return Line Filters

Benefits

80

Filtration of the whole back flushing fluid

The tank is not supplied with dirt of the system

Cost-effective filter housing and element

Easy element change upwards without leakage at

tank mounted filters

R-elements have bypass

Finest filtration

Double filters are possible

Individual pump protection in comparison to

pressure filters

Return Line Filters

Disadvantages

81

Installation of a bypass valve is recommended

In case of single filters the system must be switched

off in order to change the element

Big filters at high flow rates are required

(differential piston)

For easily damageable components an additional

pressure filter is recommended

Off-Line Filters
CONTROLLING

82

Off-Line Filters
Benefits

83

Filtration independent of operating process

High dirt hold through constant flow through

Cost-efficient filter housing and element

System does not have to be switched off during

element change

Subsequent installation is possible

Good oil purity levels can be reached

Off-Line Filters
Disadvantages

84

In case of high-value components a pressure filter

must be used as additional filter

Increased investment costs

Increased energy needs

No direct protection of easily damageable

components and of pump

Increased space needs

Breather Filters
CONTROLLING

85

Breather Filters
Benefits

Relieves the system filter by preventing contamination

from entering the tank during tank breathing
High air flow rate
Cost-effective
Environmentally friendly

Disadvantages

86

If the filter is incorrectly sized, damage may occur to

the tank and the pump

Filters

87

Filter selection
Protective and Working Filter

88

Filter selection
Restricting the flow velocity

89

Filter selection - Determining the

appropriate filter element

90

91

Filter Sizing

92

Filter Sizing

93

Effects of liquid contamination

Free and
emulsifies
water causes
most of the
destruction to
lubricants and
machines

o
H

The water
molecul is
polar unlike the
base oil.

94

Below saturation point

Water exists in a dissolved form, like
humidity in the air. All water molecules are
detached to polar compounds in the oil
(e.g.additives, particles).

When reachiong or exceeding the

saturation point
Water forms either an emulsion, like fog,
where microscopic globules of water are
dispersed in stable suspension. This Causes a
visible cloud or haze or

Water exists as free water like rain that

settles to tank/sump bottom

 How much water can be solved in oil ?

Saturation Level

Fluid X
5000

free water

2500

dissolved water
= 100 % saturation
limit

= 82 % saturation limit

0
20

40

60

Temperature [C]

80

Saturation points for different fluids

HFD-fluid
5000

Synthetic -fluid
Mineral oil A
Mineral oil B

2500

Transformer oil
0

96

20

40

60

Temperature [C]

80

Effects of liquid contamination

How much water an oil can accept

Depends highly
upon:
Type of base oil
Type and
concentration of
additives

Saturation limit for water in a hydraulic oil

1200

Water content
[ppm]

100ppm
=
0,01%

Existence of impurities
Temperature

1000
800

free and emulsified

water

600
400
200

dissolved w ater

0
-20

-10

10

20

30

40

Temperature [C]
O il

D is s olve d
[pp m ]

E m u lsifie d
[p pm ]

Fre e
[pp m ]

New
h yd ra u lic
flu id

0-4 0 0

4 0 0 -10 0 0

>1000

Aged
h yd ra u lic
flu id

0-8 0 0

8 0 0 -50 0 0

>5000

97
Examples with approx. values for a standard
hydraulic fluid

50

How much water should you tolerate?

A good rule of thumb is to control
water to the lowest levels you can
reasonably achieve, preferably well
below the oils saturation point at
operating temperature.
98

Source: Drew Troyer, Drew Troyer President Noria Global Services: "Establishing Moisture
Contamination 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 for Hydraulic Systems". Machinery Lubrication Magazine. January 2004