L-4532 Contamination Guide for Hydraulic Fluids, Oils and ......L-4532 L-4532 | Created 10.2016...

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Contamination Guide for Hydraulic Fluids, Oils and Diesel Fuels

L-4532

L-4532 | Created 10.2016

Contamination Guide for Hydraulic Fluids, Oils and Diesel Fuels L-4532

Schroeder Industries En TOC

- TABLE OF CONTENTS -

Contamination ........................................................................................................................................................................ 4 Types of Contamination ................................................................................................................................................. 4 Sources of Contamination ............................................................................................................................................. 5 InfluenceofContamination ............................................................................................................................................ 6Environments ......................................................................................................................................................................... 8 Cleanliness in Hydraulic Systems and Diesel Fuel Supply ........................................................................................... 8 Controlling Contamination ............................................................................................................................................. 9Detection of Contamination ................................................................................................................................................ 10 Particle Counter ........................................................................................................................................................... 10 Water Sensor ................................................................................................................................................................11 Lab Report ................................................................................................................................................................... 12Application of Contamination Sensors .............................................................................................................................. 12 Using Particle Counters ............................................................................................................................................... 12 Installation Guide ......................................................................................................................................................... 14Hardware and Accessories ................................................................................................................................................. 17 TCM ............................................................................................................................................................................. 17 HY-TRAX® .................................................................................................................................................................... 17 TIM .............................................................................................................................................................................. 18 TSU ............................................................................................................................................................................. 18 TMU ............................................................................................................................................................................. 18 TPM ............................................................................................................................................................................. 19 TMS ............................................................................................................................................................................. 19 TWS ............................................................................................................................................................................. 19 HMG ............................................................................................................................................................................ 20 EPK ............................................................................................................................................................................. 20 SMU ............................................................................................................................................................................. 20 Bottle Samples ............................................................................................................................................................ 21Data Integration .................................................................................................................................................................... 23 Facility / Equipment Monitoring Systems ........................................................................................................................... 23 Individual Sensor Interfacing ....................................................................................................................................... 23 HY-TRAX® .................................................................................................................................................................... 24 CM-Expert ................................................................................................................................................................... 24 Equipment Management and Validation ............................................................................................................................. 26 Roll-off Cleanliness ...................................................................................................................................................... 26 QualityControlandVerification ................................................................................................................................... 29 Contamination Monitoring for Preventive Maintenance ...................................................................................................... 29Glossary ................................................................................................................................................................................ 30

L-4532 Contamination Guide for Hydraulic Fluids, Oils and Diesel Fuels

4 En Schroeder Industries

Contamination

Types of Contamination

Varioustypesofcontaminationoccurinfluidpowersystems:gaseous(e.g.air),liquid(e.g.water)andsolidcontaminants.Solidcontaminationissubdividedintothreegroups:extremelyhard,hardandsoftparticles.Extremelyhardparticlescancausesubstantialdamageinfluidpowersystemsiftheyarenot removed as quickly as possible. Preventive measures can reduce the ingress of contaminants in systems.

Anoftenoverlookedsourceforprematurefluiddegradationandconsequentsystemdamageisheat.Thisisespeciallyimportantifthetanksizeissmallandthefluiddoesnothaveenoughtimeto properlycooldown.Anelevatedheatlevelinthefluidcanspeed-uptheoilagingeffectsofthefluidandshortentheoveralltimethefluidcanbeusedinahydraulicsystem.

Theaveragehealthyhumaneyecanseeitemsdowntoapproximately40μm(Microns)insize.Incomparison,ahumanhairis70to80μmindiameter.Particlesthatcauseproblemsinhigh performing,highpressurehydraulicsystemsareintherangeofapproximately5to15μm(1μmisequalto0.001mmor0.000039inches).



TheobjectiveoftheISO4406:1999istoclassifyparticulatecontaminantsinhydraulicfluids. Particlecountsaredeterminedcumulatively(i.e.>4μm,>6μmand>14μm)andcodedfor easy comparison.

ThefollowingtableexplainshowtheISOcodeisdeterminedforaparticularfluidsample:

Amicronratinginafilter,orelement,identifiesthesizeofparticlesthataparticularfiltrationmediawillremove.Forinstance,SchroederZ10filtermediaisratedatß10≥1000,meaningthatitcanremoveparticlesof10μmandgreaterat99.9%efficiency.

Sources of Contamination

The source for Particulate Contamination is often found related to the tank itself; un-cleaned tanks putinuse(filledwithfluidwithoutcleaningtank),dirtaddedduringmaintenancecycles,tankopentotheenvironmentandmissingorlowqualityairbreathersontank.Newfluidisgenerallydirtierthanwhatasystem,andspecificcomponentsinthesystem,wouldrequireforproperperformanceand/oradequatelifeexpectancy.Overtime,pipescale(rust),pumpwearanddirtonrods/cylindersaddcontaminationtothefluid.

Waterinthehydraulicsystemscanbecausedbymoisturefromambientair,leakageofcoolingsystemsorprocesswater,leakageofsealsandchemicalprocessessuchascombustion,oxidationand neutralization.



Design issues in the hydraulic system can contribute to Air/Gasesinhydraulicfluids.Ifthereturnlineisabovethefluidlevelinthetank,aircanbemixedintothefluid.Incorrectmotorspeeds,unprimedpumps,suctionlinestoosmall,suctionliftstoohighandblockedinletsareamongotherreasonsforair contamination over time.

Influence of Contamination

Inhydraulicsystems,70to90%ofwearandfailureiscontaminationrelated.Only10to30%canbetracedbacktomisuse,defectsorage.Contamination cannot be stopped, only slowed down!

Systemefficiencycandropbyupto20%beforeanoperatorevendetectsaproblem,suchascylinderdrift,jerkysteering,erraticoperationorslowerperformance.Overall,contaminationresultsinshorterserviceintervals,higheroperatingcostsandlostproductivity.

Hydrauliccomponentclearancesarecriticalandrequirestrategicfiltrationtoremovedamagingparticles.Criticalclearancesforindividualhydrauliccomponentsareshowninthetablebelow:

Particulatecontaminantscirculatinginfluidpowersystemscausesurfacedegradationthroughgeneralmechanicalwear(abrasion,erosion,andsurfacefatigue).Thiswearcausesincreasingnumbersofparticlestobeformed,theresultbeingthatwearincreasesifthe“chainreactionofwear”isnotproperlycontained(byreducingcontamination).Gapsgrowlarger,leakageoilflowsincreaseinsizeandoperatingefficiency(e.g.ofpumps,cylinders)decreases.

FreeWatercauses:

• Corrosion:Corrosionpits,roughsurfacesandreleaseofabrasiveflakesintothefluid• Microbialcolonization/Bacteria:Odors,acids,slime,andhealthproblems• Lossoflubricity:Freewaterenterscontactloadingzones,allowingopposingsurfacesto

crashtogether,resultsinhighfriction,wearandseizure• Additivedepletion:Freewaterretainspolaradditives

Component TypicalCriticalClearance(µ)

1.GearPump(J1,J2) 0.5-5

2.Vane-cellPump(J1) 0.5-5

3.PistonPump(J2) 0.5-1

4.ControlValve(J1) 1-25

5.ServoValve(J1) 1-4



DissolvedWaterisresponsiblefor:

• Fasteroiloxidation:Acceleratesthisformofoildegradation,leadstooilacidity,thickening, varnishes,sludge&resins• ReducedFatiguelife:Propagationoffatiguecracksinmetals• DemolitionofEster-basedfluidsandadditives:Reactingwithesters(hydrolysis)resultsin

formationofacids,gels,andlossofadditives

Aireffects:

• Oiloxidation:Mostlyoxygenreactswithoilresultinginprematuredegradation(oilaging)• Varnishformation(oilaging)• Cavitation:Formationandcollapseofgaseousoilcavitiescausesdecreaseinpumpefficiency

and damage to pumps • Noiseandincreaseoftemperatureresultindynamicoperatingproblemsandsystem

stiffness reduction• Micro-Diesel-Effect• Change of viscosity



Environments

Cleanliness in Hydraulic Systems and Diesel Fuel Supply

Hydraulic Systems

DetermineTCL(TargetCleanlinessLevels)basedonmostsensitivesystemcomponents,systempressureandenvironmentalconditions.Refertothetablebelowforguidance.Keepinmindthat theMicronratingsofthefilter(s)inthesystemhaveagreatinfluenceonwhatISOTargetLevels canbereached:

Remark: Use manufacturer’s recommended guidelines for system cleanliness when available.

Diesel Fuel

TheTier4enginesarebuilttomorestringentspecificationsthaneverbefore.Highoperatingpressureinexcessof30,000psiand2-5microninjectornozzletolerancesmakeengineinjectorsystemsandfuelpumpsvulnerabletocontaminationlevelsthatwerenotanissueinthepast.WhiletheCommonRailSystemdoesprovideimprovedpower,betterfuelefficiencyandlowerexhaustemissions,atthesametimerequiresanewleveloffuelcleanlinessandcare.Thiscleanlinessrequirementforthefuelisnowmissioncriticaltosystemoperation.OEMengineandinjectionmakersarerequiringthatfuelusedintheenginemeettightguidelinesbeforewarrantyclaimsareaccepted.Today’srequirementscallfordieselfuelcleanlinessattheenginesinjectionsofISO11/8/6,orbetter,andawaterlevelof<200ppmwater,bothofwhicharehardertoobtainwiththesurfactantsforlubricityfoundin today’sULSD.



Controlling Contamination

Determinecurrentfluidconditionsbasedonparticlecontaminationlevels(ISOCode),fluidwaterconcentrationandfluidhealth(aging,remaininglifeandsamplingchangesovertime).Particlecontaminationandwaterconcentrationcanbedeterminedbyimplementingon-lineorportablemonitoringdevices(sensors).Fluidtestinginlabsettingsisrecommendedforoilagingparameters,fluidschemicalcomposition,toseechangesovertimeandascontrolmeasurements(inaddition tosensors).

AfterevaluatingallsourcesofcontaminationsuchasDirt,MetalParticles,Water,Gases/AirandHeat,evaluatethecurrentprotectioninplace:

• Pressureandreturnlinefilters• Off-linefiltrationloops(Kidneyloopsystems)• Breathers – High integrity and desiccant types• Newoilprotection–Treatment,transfer,polishing• Monitoring(sampling)andchange-outschedule

Recommendoptimumcomponentsforperformanceandlongevity.Usehighefficiencydepthfilterelementsforoptimizedandefficientfiltrationofhydraulicfluids.Whenchoosingafilter,andspecificallyanelement,lookfor:

• Highßx-values• Highßx-valuestability• High dirt holding capacity• Lowlongtermpressuredrop• High collapse stability

BottomLine:UsehighqualityfiltersinFilterCarts,KidneyLoopSystems,Pressure/ReturnLineFilters,Dehydrators,etc.,forbestresults!

Allopeningsonthehydraulicfluidtankmustbecoveredandhighperformance breathers should be added. Air Breatherscomeinawidevariety,suchasspin-ontypesforeasyreplacement,withfillerbasketandmostimportantly,desiccanttypesforwatervaporremovaloftheoutside airbeingdrawn-in.

Formonitoringandmaintainingfluidcharacteristics,cleanlinessandwatercontentusecontaminationmonitoringdevices:

• Portable & In-Line Contamination Sensors: Portable Particle counters are ideal for plants withmanysmallmachinesorforfieldserviceofmobileequipment.ContaminationSensorspermanentlyinstalledareperfectforlarger,criticalsystemswhereconstantmonitoring is required.

• Water Content Sensor:Measureswatersaturationin%.Areadingof100%indicatesthepresenceoffreewaterinthefluid/systemandmustbeavoided.Forfluidsinhydraulictankswithnormaltemperatureranges(fluidcooleddown),awatersaturationbelow40%should be maintained.



Supplementmonitoringtechniques,likeregularfluidsamplingandlabanalysisprovideadditionalinformationbeyondcontamination:

• Additive depletion• Contamination>Checkin-plantreadings• Watercontent(ppm)>Checkin-plantreadings• Viscosity• Wear metals• Trending from periodic sampling

Detection of Contamination

Particle Counter

Themostaccuratewaytomeasurefluidcontamination(ISOCode)isbyapplyingtheuseoftheLightObscurationPrinciple(opticalsensorwithlightbarrier):

On-line or portable particle counters apply the same light obscuration principle for measuring solid particlesinhydraulicfluidsandfordeterminingtheISOcode.

Thefluidpassesthroughalightbarrier.ThelightsourceiseitheranInfraredLEDoralaser(mostlyusedforlaboratoryequipment).Ashadowiscreatedonthephotodiodeifaparticlecomesbetweenthelightsourceandthephotodetector.Thisshadowcausestheelectricsignalemittedbythesensortochange.Thischangecanbeusedtodeterminethesizeoftheshadowcastbythisparticleandthus the particle size to be determined. This procedure enables the cleanliness classes accordingtoISO4406:1987,ISO4406:1999,andNAS1638orSAEAS4059ifrequired,tobe accurately determined.

The“noise”involvedinthismeasurementprinciple is extraneous liquids and gases whichcausethelightbeamtobeinterruptedandthusbecountedasparticles.Properfluidconditioning before particle counting is very important(e.g.useofamanifoldblockwithflowcontroloranindependentpump-drivenTestMate®SensorUnit|TSU).Theparticlecounter should be calibrated according to ISO11943(forISO4406:1999).



Water Sensor

A specially designed capacitance sensor is used in the TestMate®WaterSensor(TWS)series. Watermoleculesaremovedintoandoutofthesensorbychangesinthesaturationlevelofthefluid.Thecapacityvalueofthesensorchangeswiththepopulationofwatermoleculesinthesensorandis directly related to the saturation level. The change in capacity value is electronically converted and displayed as the saturation level in percent.

Thedrivingforceisthewatervaporpressure.Thewatervaporpressureofthewaterinthefluidisconfrontedbythewatervaporpressureofthewaterinthesensor.Waterismovedintoandout of the sensor until a pressure equilibrium is reached. If the equilibrium is disturbed by adding water(increasingthewatervaporpressureoftheoil)ordryingtheoil(decreasingthewatervaporpressure),wateragainstartstomoveintooroutofthesensor.

Whenaddingwatertodryoil,thewatervaporpressureincreasesuntiltheoilissaturatedwithwater.Thispointiscalledthesaturationpoint.Thecorrespondingpressureisthesaturatedwatervaporpressureandisthepointwheretheoilcannotdissolveanymorewater.Whenthispointisexceeded,freeoremulsifiedwateristheresult.Althoughdifferentoilscandissolvedifferentamountsofwater(inppm)atthesaturationpoint,thesaturatedwatervaporpressurehasthesamevalueforalloiltypesatagiventemperature.Thesaturationlevelis100%atthispoint.

Technicallyspeaking,theWaterSensormeasuresthesaturationlevelofoilbylookingatthewatervaporpressure.Thesimplerelationbetweenwatervaporpressureandsaturationlevelis:

Saturation level[%]= *100

Usingreadingsinppmtoascertainaharmfullevelofwaterisdifficultduetodifferencesinfluidpropertieswhichincludeoilage,fluidtypeandadditivelevels.Forexample,awatercontentof300ppminasyntheticesterwouldbeideal,butthesamewatercontentinamineralbasedoilcouldhavedisastrousconsequences.Furthermore,thisonlygivesaquantitativemeasureanddoesnotanswerthequestionwhetherornotthewatercontentisstillacceptable.

The saturation level does provide a clear indication of the fluid’scondition as it is directly relates to the oilssaturationconcentration(SaturationPoint).

Example: Oil A Oil BTemperature 20°C 20°C

Saturation Level 100% 100%

Saturatedwatervaporpressure 2,3kPa 2,3kPa

Water concentration at saturation 78 ppm 358 ppm

measured water vapor pressuresaturated water vapor pressure



Lab Report

Schroederofferstwotypesofsamplekits:oneforhydraulicfluid(P/NTHF)andoneforwaterglycol(P/NTWG).Refertothenextsection for tests performed for each of these kits. Upon receipt of orderforanyofthesepartnumbers,asamplekitcontainingacleansamplebottle,blankform,andmailingcontainerisshippedtothecustomer.Afterthesamplehasbeentaken,thecustomersimplycompletestheformandenclosesitalongwiththesampleinthemailing container provided. Kits are packaged and sold in lots of 10.

Foreachsamplesubmitted,alabreportwillbegeneratedandforwardeddirectlytotheuserviae-mailorpostalmail(pertheuser’srequest).ItisstronglyrecommendedthataMSDS(MaterialSafetyDataSheet)andabaseline(unused)fluidsamplebesubmittedwiththeinitialsampletobeanalyzed.Inadditiontoservingasabaselineforcomparisontosubsequentresults,thesampleofnewoilwillbeusedtodeterminewarninglimitsforviscosityandTAN(TotalAcidNumber).

Customerscancreatetheirownpersonalloginandpasswordtoviewalloftheirreportsinoneeasytouseinterfaceat:http://eoilreports.com/

Information gained by using this service can help identify potential problems in a hydraulic system at minimalcosttotheuser.Fluidanalysiscanprovideanswerstoimportantquestionssuchas:

- DoIhavetherightfiltrationsysteminplaceforefficientcontaminationcontrol? - Isthefluidinmysystemexperiencingchangesthatcouldnegativelyimpactcomponent lifeorsystemperformance?

Application of Contamination Sensors

Using Particle Counters

Newfluid,deliveredbythesupplier,isgenerallynotcleanenoughforimmediateusewithoutpriorfiltrationandtreatment.Ingeneral,modernhydraulicsystemsdemandfluidcleanlinessofISO16/14/11.NewfluiddeliveredinbarrelscouldbeasdirtyasISO23/21/18.Ifthefluidisdeliveredinatankertruck,thecleanlinessmightbeISO20/18/15.Thebestcleanlinesslevelscanbeexpectedifthefluidisdeliveredinamini-containerwithanISO17/15/13.EventhisfluidisoneISOclassabovethe target cleanliness level required.

Handlingofnewfluidinaplantinvolvesseveralpointsofcontactbetweenreceivingandhydraulicreservoir(pointofuse).Ateachstepintheprocess,thefluidshouldbefilteredeitherbypermanentlyinstalledfiltersorbyfiltercartsusinghighefficiencyfilterelements.IfthesystemrequiresISO16/14/11cleanlinesslevels,thenthefluidshouldbefilteredtoISO14/12/9inthefluid storage tank.

THF Sample Report Form



Asageneralrule,thefluidshouldbeprocessedtotargetlevelminustwoISOlevels.ThiscanbeachievedbyaddingaKidneyLoopSystemonthefluidstoragetankthatwillpolishthefluidtorequiredISOlevels:

Filtersystemswithdualfilters,socalledStagedFiltration,arepreferred.Itallowsremovaloflargerparticlesinthefirstfilterandsmallerparticlesinthesecondfilter.E.g.a10Micronelementinthefirstfilteranda5Micronelementinthesecondfilterpreventsthefirstfilterfromfilling-upprematurelyandallowelementchangeintervalstobealignedmorecloselyonbothfilters.Inaddition,thefirstfiltercanbeequippedwithawaterabsorbingelementifthefluidhasfreewatercontent.

Finally,thehydraulicsystemreservoir(orhydraulicsystemitself)shouldbemonitoredwithparticulateandwatercontaminationsensors,anddehydratorsshouldbeusedtomaintainalowwatersaturationlevel at all times.

Inmanycases,onlyasinglepressurefilterisusedinahydrauliccircuittoprotecttheequipmentandtocleanthefluid.Thisonefilterisresponsiblefor100%oftheworkandthereisnoback-upofanykind. If the filter is filled-up, and consequently goes into by-pass, the fluid is not filtered and the system is no longer protected.AbalancedapproachwouldbeaddingaKidneyLoopSystemonthefluidreservoirand,inthebestcase,asystemreturnfilteraswell.

AKidneyLoopSystemiscontinuouslyworking24/7withconstantflowandisnotinfluencedbypressureandflowvariationsthatarepresentinatypicallyhydraulicsystem.Therefore,thefilterworksveryefficientlyinremovingparticlesandendsupprovidingabout75%ofthework(removingofparticles),whilethepressure/systemfilternowhandlesabout25%.



Onhydraulicsystems,ContaminationMonitoringinvolvesaContaminationSensorthatmeasuresthecleanlinessofthefluidanddeterminesthecorrespondingISOCodealongwithaWaterSensorthatmeasuresthewaterconcentrationofthefluidin%saturation(relativehumidity). Thediagrambelowshowstheplacementoftwosensorcombinationsplacedinahydraulicsystem.Theonetotheleftmonitorsthefluidconditioncomingfromthepumpanddetectsimproperfluidfiltration(returnfilter)orproblemswiththepump(wearandtear).Thesystempumpprovidestheflowforthesensorswhilethesystemisinuse.

Ontheright,thesamesensorcombinationisshown,butthistimeincombinationwithanindependentpump.Thissystem(TestMate®SensorUnit|TSU)doesnotdependonthehydraulicsystemtosupplyfluidformonitoring,butworksconsistentlyandindependently.Itmonitorsthefluidinthetankdirectly.

Installation Guide

The TestMate®ContaminationMonitor(TCM)measurestheparticularcontaminationoffluidsbytakingasampleoutofthemainstreamandmeasuringtheparticulatesize,theparticulatecountintheindividualsizeclassandthefluidflow(ml/min)todeterminethecorrespondingISOcode(andSAECode,optionalNAScodeavailableaswell).Therefore,itisimportanttoconnectthelinesonthesystem and to place the sensor correctly for accurate readings. A few rules should be followed:

• It is highly recommended to use the optional manifoldblockwith the TCM(showninpicture).Thisallowsforflowcontrolandassuresbackpressurethroughthemeasuringcell.Inaddition,themanifoldblockallowsplacementofanoptionalTestMate® Water Sensor (TWS)thatmeasuresthefluidtemperatureandwatersaturation.

Flui

d Fl

ow D

irect

ion



• A pressure differential(pressuredifferencebetweeninletandoutlet)of 70-100 psi is recommendedtogeneratesufficientfluidflowthroughthesensor.

• Install the sensor in a vertical position,sothatthefluidflowsfrombottomtotop(southto north,asshowninpicture)throughthesensor.Never install the TCM (or TIM) as a high point in a system!

• Keepclosedistances,shortlinelengths,byinstallingtheTCM close to the measuring point. ThefaceoftheTCM,withthedisplay,canberotatedby270°degrees.Ifthedisplaywouldendupinaninconvenientplace,ordifficulttoread,useaSensorMonitoringUnit(SMU)or remote display.

• Whenusingflexhoses,avoidkinkingofthehoses.UseMinimess(2mmID)hoses,max.25incheslong,orMinimess(4mmID)hosesatinletwhen2mmIDproducesanoverlylargepressure drop. The hose should be kept as short as possible (nottoexceed25inches).Theuseofelbowspreventsthekinking of hoses.

• Assure that you have turbulentflowatthepointofextraction in thesystem.AvoidplacingTee’sinlonghydrauliclinesthathavelaminarflow,inordertogettheparticulatesintothesensorandnotby-passingit.Usinganelbow,oraTeeturnedby90degreesisideal.

ForaTCMwithManifold,highpressureisdefinedbyanyapplicationwithpressureinexcessof 150psiandlessthanthemaxallowableworkingpressureof3,500psi.ProperinstallationrequiresinletflowthroughoneofthetwoHighPressureSAE4threadinletsandreturnflowthroughoneofthetwoSAE4threadoutlets.TheflowthroughtheTCMiscontrolledbyadjustingtheflowcontrolvalvetoachieveadifferentialpressureofminimum70psi.Whilethemanifoldblockisdesignedforusewithlowpressure/flowsituations,anoptionalneedlevalvecanbeplacedimmediatelyfollowingthesensor,especiallywhenreturningfluiddirecttoreservoir/tank,tocreateaback/differentialpressureacrossthesensor.TwogaugescanbeattachedtotheSAE4TestPoints,allowingtheoperatortoseethepressure at the inlet and outlet.

Toachieveidealoperatingconditions,theTCMshouldbeinstalledfollowingthefactoryrecommendedprocedureoutlinedbelowandnotedintheTCMSeriesUserManual:

1.InstallTCMinaverticalposition,eitherthein-lineversionorthemanifoldmount version(preferred)

2.Directionofflow:fromIN(bottom)toOUT(top) 3. Select hydraulic hose -MinimessDN2(2mmID)atIN,max.630mm -MinimessDN4(4mmID)atIN(whenDN2producesanoverlylargepressureloss) -Thehoseshouldbekeptasshortaspossible(630mm);whenmeasuringthree

virtuallyidenticalISOvalues(e.g.16/16/15=airinoil)thehydraulichoseatINcanbeextended to 2 m in length or try to increase the system pressure to reduce air bubbles.

4.ConnecttheTCMviaMinimesshosetoIN - Shut system off -First,connectreturnline(≥4mmID)(OUT) -ThenconnectIN



Asoutlinedearlier,thehoselengthshouldbetheshortestpossiblerunandinastraightlineavoidingbendsintheline:

Ingeneral,MosterrorsinTCM(orTIM)readingsaredueto installationerrorswhichcanbecorrectedwithsimple system/hook-upchanges!



Hardware and Accessories

TCM

Schroeder’sTestMate®ContaminationMonitor(TCM)isthenewestgeneration of particle monitors that continuously measures solid contaminationinfluid.Enclosedina4-inchdiametercase,theTCMutilizesanopticalsensorandmeasuresparticlesinfoursizes:>4,>6and>14microns. Measurement results can be output as a contamination code accordingtoISO4406:1999orSAEAS4059(D).

TheTCMisdesignedforconnectiontohydraulicandlubricationlineswithpressuresupto4,350psi(300bar)andviscositiesupto4,635SUS

(1,000cSt).Theunitrequiresthatasmallflowofoil(between30mL/minand300mL/min)isdivertedformeasurementpurposes.TCMisshownwithoptionalmanifoldforflowandpressurecontrolandoptionalwatersensor(TWS-C).

TheTCMprovidestheuserwithasmall,tough,andmoreversatilestationarysensor.Itprovidesinstantaneousreadingsandisabletoself-diagnosecontinuouslywitherrorindicationviathestatusLED. The attractive cost-to-performance ratio makes it especially applicable for OEM applications. Online“real-time”conditionmonitoringallowstopracticetotalpredictivemaintenance.TheTCMcanbeprogrammedwithacriticalISOcode,andifreached,anoutputsignalcanbeusedasawarningortocontroltheequipment(e.g.shutdownapump).

HY-TRAX® is a sampling system that integrates Micro-VSD gear pump andflowcontrolintoourTCMmanifoldblock.TheTCMmonitorsfluidISOcodesandanoptionalwatersensormeasuresfluidtemperatureandwatersaturationlevels.TheVSDPump,designedforcontinuousdutyoperationandtheverysmallcompactfootprint,isidealformobileapplications.Designedformonitoringfluidconditionsinreservoirsorlowpressurelines.

Itisavailableintwoversions,amanualcontrolledunitwherepumpspeedismanuallyadjustedforproperflowthroughTCMandatelematicsversion

withaCommunicationModulewherepumpspeedisautomaticallycontrolledbythemodule(TCMsignaladjustsmotor/pumpspeed),andTCM&TWSdataissentviaGSMcellulartoasecurewebbaseddashboard.Thefluidconditiondataisarchivedonthewebsiteandstoredforuptooneyear.ThisprovidestrueremoteaccesstoFluidconditionandallowstosetwarninglevelsbytheuser.Ifthewarninglevelsarereached,amessage(bycellore-mail)willbesentimmediately.



TIMThe TestMate®In-lineMonitor(TIM)fromSchroederisanin-linecontamination counter capable of transmitting information regarding fluidcleanlinessinvariousformatstoawidevarietyofdevicesinrealtime.SoftwareisincludedtotransmitdatatoaPC.Alternative user-suppliedoutputdevicesincludePLCs,individualdisplayunits,andwarninglightsviatriggerpoints.Thisunitisintendedforcriticalsystemswherecontinuouscontaminationmonitoringisamustandforfluidswithhigherviscosityranges(upto2,000cSt).ATIMversionisEthernetcapable for easy in-plant system integration.

TSUThe TestMate®SensorUnit(TSU)combinestheTCM,orTIMcontaminationsensors,withapump/motorgroupforindependentoperationwheresystempressureisinsufficientornon-existing(e.g.tank)andforteststandapplicationswhereairisintroducedintothefluidduetoa high circulation rate. It includes an air suppression system to counter act theinfluenceofairduringtheparticulatecontaminationmonitoring.

TMUThe TestMate®MonitoringUnit(TMU)seriescombinestheadvantagesoftheportablecontaminationmeasurementunitswiththemeasurementtechnology of the TCM and TWS. The TMU is a portable service unit and isdesignedfortemporarymeasurementofsolidparticlecontamination,watersaturationandfluidtemperatureinhydraulicsystems.Theintegratedpumpandthehoseswithtestpointconnections,whichareincludedwiththeTMU,allowoperationonreservoirs,controlcircuits,andhigh pressure circuits. The tests are stores inside the unit and can be downloadedtoaPCorontoaUSBdrive.

TPM The TestMate®ParticleMonitor(TPM)isaportableparticlecounterwith,orwithoutanintegratedpumpthatcanbeusedindependentlyorin-linetomeasurecontaminationlevelsofhydraulicfluids.Particlesaremeasuredatthe4,6,and14micronsizes,withresultsavailableinISO4406(1999)andSAEAS4059.Variousprogrammingoptionsareavailable,includingtheabilitytoactivateordeactivatesystemfunctionswhencontaminationreachesauser-specifiedlevel.Itisequippedwithabuilt-inprintertoprovide instant documentation and an RS-232 serial port for data transfer. AcustomsoftwarepackageisalsoincludedfortrendanalysisonaPC.Theunit’srobustpackagingincludesafoldinghandlewhichdoublesasastandtoprovideoptimalviewing.



TMS The TestMate®MetallicSensor(TMS)detectsmetallicsolidparticlecontaminationinlubricationfluid.Theparticlesaredeterminedaccordingtotheinductivemeasurementprocess,inwhichacoil system is the key element of the sensor. Metallic particles (ferromagneticFeandnonferromagneticnFe)inthe>70,100or 200μmsizerangearedetected(particlerangedependsonMTSsensorsize).TheTMSisafullflowsensorandisavailableinsizes of¼”,½”and1”borediameter.

TheTMScontinuouslymonitorsthestatusofthefluidconditioninregardstolargerparticulatesandallowspredictiononimminentsystem damage. This makes the sensor a reliable instrument for status-oriented,predictivemaintenance.

TWS The TestMate®WaterSensors(TWS)areonlinesaturationand

temperature sensors for the monitoring of hydraulic and lubrication fluidsaccuratelyandcontinuously.Theymeasurethewatercontentrelativetothesaturationconcentration(saturationpoint)andoutputsthedegreeofsaturation(saturationlevel)intherangeof0to100%asa4to20mAsignal.Areadingof0%wouldindicatetheabsenceofwater,whileareadingof100%wouldindicatethatafluidhasfreewater.

TheTWS-Dhasa4-digitdisplaythatshows“real-time”measuredvaluesandallowsforparameteradjustments.Itcanalsoberotated/alignedontwoaxis.TheTWS-Dcanbeprogrammedwithatemperatureanda%-valuewatersaturation,andifreached,anoutputsignalcanbeusedasawarningortocontroltheequipment(e.g.shutdownapump).

ThespecialcapacitancesensorusedintheTWSabsorbswatermoleculesfromthefluidandchangesitscapacityvaluethatisdirectlyrelatedtothesaturationlevelinthefluid.Anintegratedthermoelementonthesensormeasuresthetemperatureofthefluidintherangeof-13°Fto212°F(-25°Cto100°C)andoutputsitasa4to20mAsignal.

TWS-C

TWS-D



HMG The HMG 2500/4000 data recorder is a portable unit for measurement and data capturing tasks involving hydraulic and pneumatic systems. Applicationsextendprimarilytomaintenanceandservicing,troubleshooting,teststands,andqualityinspecting.TheHMG3010can concurrently evaluate signals from up to 10 sensors. The unit features5inputjacksforconnectingthesensors.Ifnecessary,this number can be doubled using a Y adapter for measurement operations involving more than 5 sensors. Schroeder offers HSI sensors(HSI=HydraulicSensorInterface)forpressure,temperatureandflowrate,whichareautomaticallyrecognizedbytheHMG.Standard,andthirdpartyanalogsensorscanalsobeused,butthesesensorsmustbemanuallyconfigured.CANbuscapablesensorcanbehooked-upaswellwiththehelpofa CANAdapter.

EPK ThenewPatchTestKitfromSchroederprovidesthenecessarytools

todeterminelevelsofbothwaterandsolidparticulatecontaminationpresentinaparticularfluidsample.Thekitisnamedforthepatchmethod used to visually assess the amount of solid contaminants. Usingthevacuumpumpcontainedinthekit,thefluidsampleisdrawnthroughamembranepatch.Theresidualdirtleftonthepatchisviewedunderamicroscopeandcomparedtophotosofknowncontamination levels in the Schroeder Contamination Handbook (included)foravisualassessment.Thehandbookalsoprovidesphotos of various contaminants for use in identifying the type of particulateanditspossiblesource(s).

ThewatersensingdeviceincludedinthiskitisanaluminummixingvesselwithasmallLCDdisplayandmicroprocessorbuiltintothelid.Whenthetworeagentssuppliedinthekit(oneliquidandonepowder)aremixedwiththesamplefluidinthecell,theresultingchemicalreactioncausesanincreaseinpressurewithinthevessel.Thischangeinpressureisconvertedintowatercontentanddisplayedonthescreenintermsofpartspermillion(ppm)or%byvolume.

SMU TheSensorMonitoringUnit(SMU)isadisplayunitforfluidsensors

andisdesignedtodisplayandstoremeasureddata.Thefollowingcombinationsoffluidsensorscanbeconnecteddirectly:

•ContaminationSensor(TCM)andWaterSensor(TWS-C/D)•MetallicContaminationSensor(TMS)andWaterSensor(TWS-C/D)

TheSMUallowssimpleinstallationparalleltoacustomersystemusing the magnetic holder or top hat rails. The housing has a high protectionclassIP67.Therefore,installationinaswitchcabinetisnotnecessary.ItisPlug&Playreadywithsimplekeypadoperation.



Bottle Samples (Hydraulic fluids & Diesel Fuel)

Schroeder offers Troubleshooting and Quality test packages. All packages include pre-paid testing and the required number of fuel containers for sample.

Schroederalsoofferssamplekitsforhydraulicfluid(P/NTHF)andkitsforwaterglycol(P/NTWG).Thebottlesare4ozinsize:

Fuel analysiscanidentifypotentialcausesforfuelfilterplugging,smoking,lossofpower,poorinjectorperformance,malfunctioningthrottlepositionsensorsandstickingvalves.Testingalsoconfirmsadieselfuel’ssulfurcontent,biodieselcontentandcompliancewithmanufacturerspecificationsandstandardsforcleanlinessthatcouldaffectequipmentwarrantyrequirements.Totalsamplevolumeof32ozisrequiredforalltestslistedonthenextpage:



Complete Diesel Fuel Analysis Schroeder P/N: 02098012 Includes

• Complete fuel quality, fuel filter-ability, fuel stability and bio content test (8 critical ASTM tests with a single comprehensive relational summary

NOTE: Test 0209812 only can be run with as little as 14 oz. (402 mL) sample

Filter Plugging Free Contamination

Computability | Loss of Power

Filter Plugging | Injector Scoring | Corrosion

Flowability | Filterability | Di or Tri Glyceride Fall Out

All Cultures of Microbes Microscopic Composition

Filter Plugging | Injector Scoring | Microbial Promoting | Cause of Water

Biodiesel Content

Contamination Tests Schroeder P/N: 02098006 Includes Sample Amount

• Identifies contamination from external sources - oil, biological growth, water, sediment

ICP 2mL

Flash Point 200mL

• Identifies contamination to be the result of a change in the fuel’s physical properties - low thermal stability may require use of an asphaltene conditioner

Thermal Stability 120mL

Water and Sediment 200mL

Bacteria, Fungi, Mold 120mL Smoking Tests Schroeder P/N: 02098007 Includes Sample Amount

• Identifies low cetane index or water contamination - loss of power, white smoke

Sulfur 50mL

Cetane Index 100mL

• Identifies excessive sulfur content - black smoke API Gravity 400mL

Distillation 200mL

Water and Sediment 200mL Filter Plugging Tests Schroeder P/N: 02093395 Includes Sample Amount

• Identifies contamination from external sources specific to filter plugging - high particle count, biological growth

Thermal Stability 120mL

Bacteria, Fungi, Mold 120mL

• Identifies contamination due to a change in the fuel’s physical properties - low thermal stability or insufficient cold weather capability for operating environment

Pour Point 100mL

Cloud Point 100mL

Cold Filter Plug Point 100mL

Particle Count 80mL

Cleanliness Tests Schroeder P/N: 02098008 Includes Sample Amount

• Identifies water contamination - can lead to smoking, biological growth and corrosion

Karl Fischer 10mL

Particle Count 80mL

• Identifies particulate contamination - can result in extreme wear in high pressure fuel systems which may cause premature injector failure

Wear Prevention Tests Schroeder P/N: 02098009 Includes Sample Amount

• Identifies cause of wear - water contamination, excessive particles or insufficient lubricity

Karl Fischer 10mL

Particle Count 80mL

Lubricity 20mL



Data Integration

Facility / Equipment Monitoring Systems

Individual Sensor Interfacing

TheSchroederContaminationSensorshaveoutputsignalsthatcanbeusedindifferentways.ThesignalscanbefedintoaPC(desktoporlaptopcomputers)formonitoringanddatacollection,orintoexistingsystems(e.g.PLC)formonitoring,datacollectionanddecisionmaking.Some,liketheTCMorTWS-D,canbeprogrammedwithathresholdvalue.Ifthethresholdvalueisreached,thesensorwillprovideanoutputsignalthatcanbeusedforwarningsand/orcontrols(e.g.shutdownapump).

Examplesofsensorinterfacing:



The HY-TRAX®systemprovidesanindependentfluidcontaminationmonitoringability.Itispump/motordrivenwithaTCMContaminationSensorandoptionalTWSWaterSaturationSensor.Becauseofitssmallbuild,compactsize,itisidealforon-boardapplications.

The HY-TRAX®TelematicCommunicationsModulewithRemoteControlledSamplingSystemaddsgreatflexibilitytotheenduser.TheVSDpumpisautomaticallyadjustedbytheCommunicationModuletoprovideoptimalflowtotheTCMparticlecounter.ThefluidsamplingsystemcollectsdataandtheCommunicationsModuletransmitsthisdata,viaGSMcellularcommunications,atscheduledintervals.AlldataistransmittedthroughasecureVPNandisarchivedinaprotecteddatabase.Theinformationisdisplayedonacustomdashboardwithuserselectableparameters.HY-TRAX®willevensendalertemailswhenprogrammedthresholdsarereached.Thiswillprovidemaintenancemanagerswiththevisibilityandinformationtopro-activelyschedulepreventativemaintenanceonlocal and remote equipment.

Example of HY-TRACommunicationModuleDashboardContaminationChart:

CM-Expert

CM-ExpertisapowerfulmonitoringandcontrolsystemforusewithanystandardPC.Itsdecentralizedconfigurationmakesthesystemextremelyreliableandflexibleforuseinfluidpowersystems.Sincethecontrollerisspecifictotheparticularpurpose,thereisnolimittothenumber/typeofsensors,actuators,operatingandsignalcomponentswhichcanbeconnected,ortothecontroltasksanddataexchangewithothersystems.Allcommonphysicalparameterscanberecordedbythedataacquisitionunitandprocessed:temperature,pressure,differentialpressure,viscosity,watercontent,particles,flowrate,etc.



CM-Expert monitors and stores the data recorded by sensors and detects changes emerging in the systemofmachinesandwithinsystems.Experiencedevelopedoverdecadesandthereferencedataaccumulatedenableanalysesandforecastsforproduction-relevantparameters,suchasremainingservicelife,serviceintervalsandrisks,tobemadeandevaluated–ingoodtimeandlongbeforeastandstillthreatens.TheCM-ExpertsoftwaredoesnotjustworkwithSchroedersensorsbutalsoofcoursewithotherthird-partysensorwithoutrestriction.



Equipment Management and Validation

Roll-off Cleanliness

Moreandmoremanufacturingfirmsdiscoverthehighcostofwarrantyclaimsaftertheproductshavebeendelivered.Asignificantreasonhasbeeninsufficientlycleanedhydraulicsystemsandfluids,whichcausedfailurewithinthewarrantytime.Byaddressingthefluidcleanlinessofnewoils,appropriatefluidprocessingintheplant,fluidfilteringandflushingofthesystemsduringassemblyand/orfinaltesting,thewarrantycostscanbesubstantiallylowered.BesidescleaningthefluidstorecommendedISOlevels,themonitoringwithcontaminationsensorsandrecordingofdataforqualitycontrol play an important role.

Roll-offCleanlinessiscommonlyreferredtoastheoverallcontaminationlevelofthehydraulicfluidintheequipmentatthetimeofreleasefromanassemblylineorre-buildline,aftertestingandbeforeshipping to customers and/or end users.

Roll-offCleanlinessdealswithcontamination(particulates)thatis“Built-In”theequipmentatthetimeofassembly:• Duetocontaminationthatalreadyexistsinthenewfluid• Due to contamination that is already in supplied components• Due to contamination introduced during the build process

Thiscanbeconsidered‘InitialContamination’,presentevenbeforetheequipmenthasbeenrunningat all.

The objective is to reduce this Initial Contamination Level. The investment in time and equipment isworthwhilebecauseofareductionofcostlywarrantyclaimsandforqualitycontrolandtracingpurposesofproducts.Incomingwarrantyclaimscanbeinvestigatedandconnectedtomaintenanceactivitiesatthecustomerlocation.Ifthefluidwasnotmaintainedtorecommendedcleanlinessstandardsduringuse,e.g.whatwasachievedwhentheequipmentleftmanufacturing,awarrantyclaimcouldbedeniedbasedonthisinfo.Overall,manufacturershavefoundthatcleanhydraulicsystemswillreducetheoccurrenceoffailureduringthewarrantyperiod,resultingin: • Happy Returning Customers• AswellasaHealthierBottomLine

BenefitsofConditionMonitoring:

Thebreakdownrateishighduringthestart-upphaseofequipment.Problemscanoftenbedetectedwhilemachineryisinthetestingphaseafterassemblyorinthebeginningafterinstallationshavebeenstarted-upandcommissioned.Thoseimmediatefailuresareoftencausedbydefectiveparts,butdefectsduetocontaminationmightnotshowupinthestart-upphase,butsometimeinuseandoftenduringwarrantyperiod.



AKidneyLoopSystemscanflushasystemduringassembly.E.g.aKidneyLoopCompactSystemisusedtoclean-upfluidreservoirsontractorswhilethetractormovesthroughtheassemblyline,andaportable Particle Counter is used to document the ISO cleanliness level before shipping.

Filtercartscanbeusedtoflushasystemafter assembly(intesting).UseaFilterCarttoflushthesystemattheendofassemblyandduringfunctionaltesting,withhighefficiency,highcapacityelementsforparticulateand/orwaterremoval.ThisisasimpletimebasedmethodforRoll-offCleanliness.Afterthedesignatedfiltrationtimehaspassed(basedonexperience),theISOcodeischeckedwithamobileParticleCounterUnitforverification.

AbetterpracticeistheuseofafiltercartafterassemblythatincludesaContaminatingSensorthatmeasurestheISOlevelcontinuouslyandstopsthefiltrationafterthepreselected,targetcleanlinesslevel has been reached. The Filtration Station®isanoff-linesystemwithintegratedmotor/pumpgroupthatincludesdualstagefiltrationforwaterremovaland/orstagedfiltrationforfastcleanupoffluids.ItcomeswithaContaminationSensorandWaterSensorstandard,withafixedflowrateof9gpmorvariableof3-8gpm(optional).

Mobile Particle Counter TPM (withPrinterincluded)Kidney Loop Compact System KLC

Filtration Station®withintegratedTCM® Particle Counter and TWS® Water Sensor



Pump-lessversionsofthistypeofcarthavebeensuccessfullyappliedonsystemsthatallowexternalhook-uptothehydraulicsystem(e.g.3,000psisystems)whiletheequipmenttobecleanedisrunning.Thefluidisthencirculatedthroughthefiltercartuntilthetargetcleanlinesslevelisreached.

WhiletheFiltrationStationiscollectingtheISOdata,itstillneedstobehandledbypersonnelforevaluation and storage. The next generation Filtration System is the Asset Management Filtration Station®thatcombinesthefilterandsensortechnologywithstateoftheartdatacollectionbymeansof an on-board computer system.

TheTouchScreenterminalallowsforeasyuserinterface,continuousmonitoringandprogressdisplayofcleanlinesslevelsandprogrammablecleanlinesslevelsandautomaticswitch-off.ThedataisstoredinanMSExcelfilefordatamanagement(e.g.byS/N),recordkeepingandqualitycontrol.

Exampleofafiltercyclefrom23/21/18to16/15/14withautomaticshutdown:

Asset Management Filtration Station®



QualityControlandVerification

BesidescleaningthefluidstorecommendedISOlevels,themonitoringwithcontaminationsensorsand recording of data for quality control play an important role.

Duringassemblyand/orfinaltestingofnewproducts(e.g.OEM’s)thehydraulicfluidisfilteredandthe cleaning process is documented and recorded for Quality assurance. The OEM can claim that theyproduct‘clean’products.Inaddition,warrantyclaimscanthenbeverifiedwiththerecords,customertreatmentoffluidanduseofequipmentforappropriateresponsesandactionsbecausethequalitydatawascollectedandstored.

The same importance must be applied to in-plant hydraulic systems used for production. Condition monitoringoffluidcontaminationreducesunscheduleddowntime,repairandmaintenancecostsandallowsapro-active,preventivemaintenanceapproach.

Contamination Monitoring for Predictive Maintenance

Therealworldapproachtocontaminationcontrolinvolvesfluiddiagnosticsandtreatment.Theobjectiveofdiagnostics,orConditionMonitoring,ismeasuringanddeterminingthestatusofsystemcomponentsandfluidhealthtopreventfailure,optimizemaintenancepracticesandfluidprocessingand/orreplacementintervals.Itallowsmovingthemaintenanceprocedureinaplantfromareactive(failureoriented)toapredictive(statusoriented)one.Reactivemaintenance(failureoriented)hashighoverallassociatedcosts,mainlyduetoproductionfailureandunplannedservices.Preventivemaintenance(timeoriented)reduces the overall costs by focusing on scheduled services. These scheduled services might be premature and not yet needed,addingunnecessarilytothecosts.ThisiswhereCondition Monitoring comes in. An investment in Condition Monitoringequipmentallowsthemonitoringofequipment andfluidtodeterminethestatusandschedule maintenance accordingly.

Benefits of Condition/Contamination Monitoring:• Reducedunscheduleddowntimes• Reduced loss of production• Reduced consequential damage



Contamination Monitoring

Extends to checking the cleanliness status of all manufacturing and assembly pro-cesses considered relevant in this connection

Contamination Sensor

Adevicethatcontinuouslymeasurescontaminantsinfluid

Emulsified Water A particular example of a dispersion comprising a continuous and a dispersed phase

Fluid Any liquid or gas

Free Water Waterthatwillsettlefromoilrapidly

Initial Contamination Level

Thestartingcontaminationlevelofthefluidbeingtreated

Laminar Flow Influids,asmooth,layeredflow

Laser LightAmplificationbyStimulatedEmissionofRadiation,whichishigh-intensitycoherent light

Liquid Afluidthatisnotgaseousorsolid

µm, micrometer Unitofmeasureequalto10-6meter(1/1000of amillimeter)

Particle Counter A device that counts particles

Particles Very small pieces made of diverse substances

ppm Unit of measurement; parts per million

Pressure Differential

Pressure difference from the inlet to the outlet

Saturation Thestateorprocessthatoccurswhennomoreofsomethingcanbeabsorbed,combinedwith,oradded

Turbulent Flow Non-smoothmovementofairorfluid

TAN TotalAcidNumber

Vacuum The absence of gas or liquid in a given volume

Water Sensor Adevicethatcontinuouslymeasureswaterlevelsinfluid

Glossary

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L-4532 Contamination Guide for Hydraulic Fluids, Oils and ......L-4532 L-4532 | Created 10.2016...

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Transcript of L-4532 Contamination Guide for Hydraulic Fluids, Oils and ......L-4532 L-4532 | Created 10.2016...