1. Fluid Care (Contamination Control)
Kris Mikulan

2. Agenda
Types of Contamination
Sources of Contamination
Influence of Contamination
Real-World Approach to Contamination Control
Fluid Treatment in Plant Settings

3. Types of Contamination

4. Types of Contamination
Gases
Chemicals
+ Heat

5. Particle/Solid Size Comparison
Human Hair = micron
The human eye can only see particles sized down to 40 microns.
1 m = mm = ”
Particle
15 micron
Particle
5 micron

6. How to Measure Solid Particle Contamination
Structure of ISO-Code (ISO 4406:1999):
amount of dirt particles in a 100 ml sample larger than these specified sizes:
4µm / 6µm / 14µm 22 18
Example:
larger than 4µm = 2,234,000 13
larger than 6µm = 172,000
larger than 14µm = 4,250
ISO Code = / 18 / 13

7. Sources of Contamination

8. Sources of Particle Contamination

9. Sources of Water Contamination
Contaminated new oil
Moisture from ambient air
Leakage of cooling systems
Process water
Leakage of seals
Chemical processes
Combustion
Oxidation
Neutralization H O

10. Sources of Air Contamination
Unprimed Pump
Suction line too small
Incorrect Motor Speed
Returned
Line Above
Fluid Level
Reservoir
Vent
Blocked
Suction
Lift Too High
Incorrect
Fluid
Viscosity
Incorrect
Fluid
Temp-erature
Partly Blocked Inlet
Reservoir too small; insufficient fluid rest time between use

11. Influence of Contamination

12. Effects of Contamination
CAN EFFECTS OF CONTAMINATION BE STOPPED?
N O !!!!
GAS
SLOW IT DOWN!!

13. Influence of Contamination on Hydraulic Systems
Cylinder Drift
Jerky Steering
Erratic Operation
Slower Performance
Shorter Service Intervals
Higher Operating Costs
Lost Productivity
System efficiency can drop by up to 20% before an operator even detects a problem!

14. Over-sized Particles will Attack the Most Critical Components of your Hydraulic System5µ
8 µ

15. Contamination Issues Caused by Water
Free Water
Corrosion: Corrosion pits, rough surfaces, and release of abrasive flakes into the fluid – rust and aluminum oxide
Microbial colonization / Bacteria: Odors, acids, slime, and health problems
Loss of lubricity: Free water enters contact loading zones, allowing opposing surfaces to crash together – results in high friction, wear and seizure
Additive depletion: Free water retains polar additives
Dissolved Water
Faster oil oxidation: Accelerates this form of oil degradation – leads to oil acidity, thickening, varnishes, sludge & resins
Reduced Fatigue life: Propagation of fatigue cracks in metals
Demolition of Ester-based fluids and additives: Reacting with esters – hydrolysis - results in formation of acids, gels, and loss of additives

16. Effects of Gaseous Contamination
Accelerated oil aging (Oxidation)
Noise
Increase of temperature
Dynamic operating problems, stiffness reduction
Decrease of pump efficiency
Damage of components (e.g. Cavitation)
Varnish formation
Change of viscosity
t = 5 Min.
t = 15 Min.
t = 90 Min.

17. Real-World Approach to Contamination Control

18. Real-World Approach to Contamination Control

19. Hydraulic & Lube System Maintenance
Condition Monitoring (Diagnostics):
Measure and determine the status of system components and fluid health to prevent failure, optimize maintenance practices and fluid processing and/or replacement intervals.
MAINTENANCE
failure oriented
PREVENTIVE
REACTIVE
time
status
Condition Monitoring
PREDICTIVE

20. Maintenance Methods and their Associated Costs
Investment in Condition Monitoring (Predictive Maintenance) results in cost effective maintenance

21. Monitoring Contamination Levels over Time
influenced by
heavy contamination of the fluid
during operation
caused by
long term wear
Breakdown rate
Usage
phase
Fatigue
Service time:
Optimum
Predictive
Too early
Preventive
Too late
Reactive
Start up
Reduced unscheduled downtimes
Reduced loss of production
Reduced consequential damages
Benefits of Condition Monitoring
initial contamination
Operating time
Roll-off Cleanliness
Program at Factory

22. Monitoring Contamination Levels
Aqua Sensor AS
(Temp & Water Saturation in %)
and
Contamination Sensor CS
(ISO code)
Contamination Sensor Module CSM

23. Monitoring Contamination Levels
9/20/2018
Monitoring Contamination Levels
Sample taken every
100 milliliter-real-time
This type measurement
tracks along with operating
changes going on in the
system.

24. Design and Operation of Hydraulic & Lube Systems
Assess system requirements
Determine TCL & Current Conditions
Evaluate all Sources of Contamination & Current Protection in Place
Recommend optimum components for performance and longevity
High Efficiency Depth Elements (Filters)
Addition of on/off-line filtration loops & high performance breathers
Monitor & Maintain fluid characteristics, cleanliness and water content
Contamination Monitoring Devices & Supplement Monitoring Techniques
Portable Off-Line and Fluid Handling Filtration Loops

25. Assess System Requirements
Determine TCL
(Target Cleanliness Level) based on
System components
System pressure & environmental conditions
Use manufacturer’s recommended guidelines for system cleanliness
when available.

26. Assess System Requirements
2. Determine Current Conditions
Particle contamination levels (ISO Code)
Fluid water content
Fluid health (ageing, remaining life)
Fluid sampling changes over time (lab)

27. Assess System Requirements
3. Evaluate ALL Sources of Contamination
Account for ALL source of contamination!
GAS

28. Assess System Requirements
4. Evaluate Current Protection in Place
Pressure and return line filters
Off-line filtration loops
Breathers – High integrity and desiccant types
New oil protection – Treatment, transfer, polishing
Monitoring (sampling) and change-out schedule

29. Recommended Filtration Upgrades
1. High Efficiency Depth Elements
Look for :
High ßx-values
High ßx-value stability
High dirt holding capacity
Low long term pressure drop
High collapse stability
Bottom Line:
Use high quality filters in Filter Carts, Kidney Loop Systems, Pressure/Return Filters, Dehydrators, etc. , for best results!

30. Recommended Filtration Upgrades
A = Pressure OR Return Filter
B = Pressure AND Return Filter
C = Pressure OR Return Filter AND continuous re-circulating Loop
D = Pressure AND Return Filter AND continuous re-circulating Loop

31. Recommended Filtration Upgrades
2. Addition of Off-Line Filtration Loops
OLF
OLF Compact
FAMH
OF5HD
MAFH
LSA / LSW
Off-line Filtration – Kidney Loop Systems
Used for solid particulate in
transfer and tank kidney loops
Dehydration Units
Water & aeration removal
- Solid particle removal
Filter coolers
when heat is a problem

32. Particulate Removal Systems
OF5H Series of Stationary Kidney Loop Filtration System for standard hydraulic fluids available in 7gpm or 14gpm models
High efficiency, high capacity elements for dirt and/or water removal
Viscosity Range: 1,000 SUS as standard (options for oils up to 15,000 SUS)
OLF Compact Kidney Loop Filtration System for standard hydraulic oils
Flow rate: up to 4.9gpm
Viscosity range: max 10,000SUS
OLF Series with Flow Rate options: 5-20gpm
Stainless steel housings with gear pump as standard option for fluids up to 5000SUS
Stackable high efficiency Dimicron® elements
3 ISO Class improvement in a single pass
Extremely high dirt holding capacity (over 1lb of dirt per element)

33. Water Removal Systems MAFH-E Dehydration Station
Newer, Positive Pressure Technology to remove water from hydraulic systems
Designed for mineral oil fluids - 75 to 2500 SUS
Flow rate: 15gpm
Simple operation and low maintenance (no vacuum pump to service)
Two gear pumps run continuously, outputs are balanced (no cycle)
High dewatering efficiency, AS1000 Standard and low energy consumption
High Efficiency Filtration
FAMH Vacuum Dehydrator
System that uses vacuum operation to remove water and gases from oil
Designed for mineral oil fluids - 75 to 2500 SUS
Flow rates: gpm
High dewatering efficiency, AS1000 Standard
High Efficiency Filtration

34. Recommended Filtration Upgrades
3. Addition of High Performance Breathers
Breathers – Wide variety including:
Desiccant for water vapor removal
Spin-on
With filler baskets

35. Monitor & Maintain Fluid Characteristics, Cleanliness and Water Content
1. Contamination Monitoring Devices
Portable & In-Line Contamination Sensor
Water Content Sensor
Particle Counter FCU
(Portable)
Perfect for plants with many small machines
Contamination Sensor CS
(Permanent installation)
Perfect for larger, critical systems where constant monitoring is required
Water Sensor AS
(Permanent installation)
Determine Relative Humidity of water in Oil

36. Leads to predictive maintenance decisions reducing unplanned shutdowns
Monitor & Maintain Fluid Characteristics, Cleanliness and Water Content
2. Supplement Monitoring Techniques
Regular Fluid Sampling & Analysis (Lab)
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
reducing unplanned shutdowns

37. Fluid Treatment in Plant Settings

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

39. Recommended New Oil Treatment at Plant
Fluid Storage Tank
Hydraulic System Reservoir
Transfer from delivery
container
Process fluid-clean to target
ISO level minus two
Staged filtration of fluid from storage to system
System receives fluid
At cleanliness level required
Or better.
Filter cart
Filter Cart
Cycle time of off-line loop determined as
result of received
cleanliness level.
ISO 20/18/15
ISO 14/12/9
ISO 16/14/11
Water
element
3 micron
depth
Potential Water
ingression via
condensation
5 micron & 3 micron
Two stage filters
Insure a high integrity
breather and tight tank
penetrations and couplings
are implemented.
CS1000/AS1000
Dehydrator as needed
Insure access covers
Tightened with uniform
Bolt clamp loads
Contamination & Aqua Sensor

40. Balanced Pressure & Kidney Loop Filtration Strategy
Continuous full flow circulation 24/7
Significantly higher performance efficiency than a return filter
25% work
Pressure Filter
75% work
Kidney Loop
System OF5HD
Reservoir
Portable Contamination Monitoring FCU

41. Ideal Fluid Handling Configuration
When receiving fluids, insure positive, sealed, reliable connections
Insure tanks and piping/tubing connections are tight
Do not allow system to be open to atmosphere any longer than necessary to make connections and disconnections
Bag and cap connection ports after each fill or transfer operation on cart and on system supply and receiving containers
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 impact of ingression along the path from storage to critical system)
Set up filtration (off loop) to achieve the target ISO code minus two code required by the hydraulic/lube system
Hydraulic System
Reservoir
Fluid Storage Tank
Off-line filter
loop

42. The End Thank you for your time and attention!