Technical Handbook Fluid Management e

7/27/2019 Technical Handbook Fluid Management e

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Fluid Management

Technical Handbook

The ARGO-HYTOS guideto uid management andoil condition monitoring

S o l u t i o n s f o r c l e a n o i l


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I n d e x

Damaging Factors.................................................................4-5

Contamination Ingress..........................................................6-7

Visualizing Contamination ....................................................8-9

Water Content ................................................................ 10-11

Solutions or Clean Oil ..................................................... 12-13

Products ......................................................................... 14-15

Cleanliness Standards .......................................................16-17

Target Cleanliness Levels ........................................................18

Return on Investment Calculation ..........................................19

Viscosity/Temperature Diagrams ...................................... 20-23

ARGO-HYTOS worldwide ......................................................24


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D a m a g i n g F a c t o r s4


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5


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Contaminant/Problem Cause

Dirt Startupcontamination,oilcontaminationfromenvironment,

dirtingressduringmaintenance/repair,component

breakdown,wear

Water Leakingcooler,damagedseals,

no/insufcientllercap,condensation

Air Productdesign,leaks,

damagedseals,lowoillevel

Heat Blockedvalve,

damagedcooler

Mixture Wronguidaddedtosystem

Shear Overstresseduid

Condensation

Wearparticlesgenerated

Damagedseals

allowairingress

Dirtandwateringress

romenvironmentthroughwornseals

C o n t a m i n a t i o n I n g r e s s

Spraywateringress


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EffectonSystems Detectedby Solution

Earlybreakdown, Particlecounter Filteroiltocorrect

increasedwear,reducedsystem targetcleanlinesslevel

performance/lifetime (TCL)

Lossofoilperformance, Watersensor Waterremovalelement,

oillifeshortened,corrosion vacuumunit,oilchange

Cavitation,oxidation, Dielectricity/conductivity/ Sealsystem,

oillifeshortened viscositysensor add/changeoil

Lossofoilperformance, Temperaturesensor Check/repairsystem,

oillifeshortened, changeoil

componentdamage

Damageduid, Dielectricity/conductivity/ Drainsystem,ush,

lossofsystemperformance viscositysensor rellwithlteredoil

Oillifeshortened, Viscositysensor Checksystem,

damageduid changeoil

Contaminationromunlterednewoil,

oroilmixtures

Insucientltration

Sludgebuildup

Blockedvalvecaused

bycontamination

Wateringressromleakingcooler

Dirtandwateringress


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75 m

Criticalsolidparticlesresponsibleorwear

14 m

4 m

Not Visible

Particles passing throughthe laser beam block lightrom shining onto the

detector, generating asignal proportional to theparticle size. Electronicsinterpret the signal.

Lightblockingsensor

V i s u a l i z i n g C o n t a m i n a t i o n

Visible

Humanhair

(40120m)

40 m

Fine particles are not visible to the human eye.

mv

t


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Visually the oil in thesebottles looks the same.One is considerablydirtier than the other.

Automatic particlecounters give a ast,accurate and repeatablecontamination pictureo your oil.

Bearingdamagedbypitting

Shatdamagedbyerosion

Damagecausedbyoilaging

Clutchcasedamagedbyoilaging

Oilmixturedamagecausingfoculation

Bearingsealdamagedbymicrodieseleect

Source:KraussMaei

Verschlei der Laufchen

lalterungsprodukte


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W a t e r C o n t e n t10

Water absorbing capacities of different fluid types

The water absorbing capacity varies rom oil to oil.At saturation point (>100 % Relative humidity) ree waterwill cause the uid to have a cloudy appearance.

Mineraloilcontaining Syntheticestercontaining

500ppmH2O 500ppmH2O

ppm=partspermillion,500ppm=0,5lwaterin1000loil

10,000ppm 1%

1,000ppm 0.1%

100ppm 0.01%

ppmH2

O

2500

2000

1500

1000

500

0

Mineraloil Syntheticester


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An installed moisture sensor gives early warning, permittingast action to extend the oil lietime and machine availability.

11

Consequences of water contamination

Negativeinuenceon:

CapacityofairseparationAntifoamsLubricationperformance

Acceleratedoiloxidation

Degenerationofadditives

Accelerates:

CorrosionWear

ShortenedoillifetimeSystemfailure


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OilTransfer

with/withoutparticlemonitoring

Mobileoff-lineltration


Permanent

off-lineltration


PeriodicOilCondition

Monitoring

PermanentOilCondition

Monitoring

Process

Singlepassltrationwithorwithoutparticlemonitoringduringllingofnewhydraulicequipment/systems

Multipassltrationwithorwithoutparticlemonitoringduringoilushing

Permanentmultipass

ltrationwithorwithoutparticlemonitoring

Periodicoilconditionmonitoring,eitheronline,on-machineorinlaboratory

Permanenton-lineoilconditionmonitoring

S o l u t i o n s f o r C l e a n O i l12


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Reason

Removecontaminationfromnewoilreducesstartupfailures,reduceswarrantyclaims

Product

Mobileltersystems

Removeweardebris,contami-nationand/orwatertoextendoillife,reducebreakdowns

Removeweardebris,contami-

nationand/orwatertoextendoillife,reducebreakdowns.Roll-offcleanlinesscertication.

Regularmonitoringtounder-standhowtheuidandsystemworktogether.Reduceexternallabcostsbyupto90%.Trouble-shootingtool.Rolloffcleanlinesscertication.Startupweardebrisanalysis.

Followproactive/predictivemaintenanceregimes.Reduce

breakdowns.Reducelabcosts.Roll-offcleanlinessverication/certication.Systemcontrol.

Mobileltersystems

Stationaryoff-linelter

systems

Particlemonitors

Portableparticlecounters

Particlemonitors

Oilconditionsensors

Stationaryoff-lineltersystems

1


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1. Stationary off-line filter systems

Simply and rapidly ft to your existing systems. Get maximumuid perormance and lietime with permanent o-linecleaning. Flow rates rom 4 to 370 l/min, flter fnenessesrom 3 m upwards. Water removal elements available.

P r o d u c t s14

FAseries UMseries

FNseries FNAseries

2. Mobile filter systems

Easy to use systems or through flter flling and cyclic cleaningwith or without particle monitoring. Flow rates rom3 to 45 l/min, flter fnesses rom 3 m upwards. Water removalelements available.


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. Online oil condition monitors

Prevent damage with early stage diagnosis by using OPCom orcontinuous real time online particle monitoring, OPCom ASor particle counting in aerated uids, and LubCos H

20+ or

moisture content and oil ageing measurement.

4. Portable particle counters

Our wide range o particle counter and monitors meet all yourrequirements. Use PODS Pro or bottle and online particle

counting with viscosity and temperature measurement, in yourlab or in feld. Use OPCom Portable or plug and play onlinesampling, with built-in battery and memory, or day to daymonitoring and as a troubleshooting tool.

15

OPCom LubCosH2O+ OPComAS

OPComportable PODSPro


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ISO4406:1999isa3digitcode,representingthecumulativecountspermlat4,6and14m(c).The

countsateachsizearecomparedwiththetabletondthecontaminationcode.Thecodeiswrittenas3numbersseparatedbya'/'.Forexample:19/17/14.Therstnumberrepresentsthecountat4m(c),thesecondat6m(c)andthethirdat14m(c).MoredetailscanbeoundinISOStandard4406:1999.

C l e a n l i n e s s S t a n d a r d s1

Counts/ml, Cumulative

ISO 440:1

AlthoughthereisnodirectrelationshipbetweenISO4406:1999andNAS1638aroughguidecanbeoundbelow.

NAS ISO

3 -/12/9

4 -/13/10

5 -/14/11

6 -/15/127 -/16/13

8 -/17/14

9 -/18/15

10 -/19/16

11 -/20/17

ISOClass Particles/ml

0 0 0.01

1 0.01 0.02

2 0.02 0.04

3 0.04 0.08

4 0.08 0.16

5 0.16 0.32

6 0.32 0.647 0.64 1.3

8 1.3 2.5

9 2.5 5

10 5 10

11 10 20

12 20 40

13 40 80

14 80 160

15 160 320

16 320 640

17 640 1,300

18 1,300 2,500

19 2,500 5,000

20 5,000 10,000

21 10,000 20,000

22 20,000 40,000

23 40,000 80,000

24 80,000 160,000

25 160,000 320,000

26 320,000 640,000

27 640,000 1,300,000

28 1,300,000 2,500,000

x28 2,500,000

Note:NAS1638hasbeenreplacedbySAEAS

4059in2001.


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1

Differentialparticlecountsper100mlatvarioussizeranges.Forexample,foraclassicationofNAS6,theparticle

countsineachparticlesizerangemustbebelowthecounts/100mlshowninthetableforNASclass6.*ClassesandcontaminationlimitsidenticaltoNAS1638.

Counts/100 ml, differential*

Classes 5to15 m 15to25 m 25to50 m 50to100 m over100 m

00 125 22 4 1 0

0 250 44 8 2 0

1 500 89 16 3 1

2 1,000 178 32 6 1

3 2,000 356 63 11 2

4 4,000 712 126 22 4

5 8,000 1,425 253 45 8

6 16,000 2,850 506 90 16

7 32,000 5,700 1,012 180 32

8 64,000 11,400 2,025 360 64

9 128,000 22,800 4,050 720 128

10 256,000 45,600 8,100 1,440 256

11 512,000 91,200 16,200 2,880 512

12 1,024,000 182,400 32,400 5,760 1,024

SAEAS4059 Maxcontaminationlimits.Particles/100ml

Size,ISO4402calibration

oropticalmicroscope >1m >5m >15 m >25 m >50 m >100 m

Size,ISO11171calibration

orelectronmicroscope

SizeCode

000

000

1

2

3

4

5

6

7

89

10

11

12

Dataissortedintocumulativeparticlecountsper100ml,andisexpressedeitherasthetotalnumberof

particlesforagivensize(forexampleAS4059Class6)orbydesignatingaclassforeachsizerange(for

example6B/5C/4D/3E/3F).

>4 m(c) >6 m(c) >14m(c) >21m(c) >38m(c) >70m(c)

A B C D E F

195 76 14 3 1 0

390 152 27 5 1 0 780 304 54 10 2 0

1,560 609 109 20 4 1

3,120 1,217 217 39 7 1

6,250 2,432 432 76 13 2

12,500 4,864 864 152 26 4

25,000 9,731 1,731 306 53 8

50,000 19,462 3,462 612 106 16

100,000 38,924 6,924 1,224 212 32

200,000 77,849 13,849 2,449 424 64

400,000 155,698 27,698 4,898 848 128

800,000 311,396 55,396 9,796 1,696 256

1,600,000 622,792 110,792 19,592 3,392 512

3,200,000 1,245,584 221,584 39,184 6,784 1,024

SAE AS 4059 ECounts/100 ml, cumulative

NAS1638hasbeenreplacedbySAEAS4059in2001.


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RecommendedTargetCleanlinessLevels(TCL)accordingtoISO4406:1999ordierentsystemcomponents.

1 T a r g e t C l e a n l i n e s s L e v e l s

Pumps

Axialpistonpumps 21/18/15

Radialpistonpumps 21/18/15

Gearpumps 21/18/15

Vanepumps 20/17/14

Motors

Axialpistonmotors 21/18/15

Radialpistonmotors 21/18/15

Gearmotors 21/18/15

Vanemotors 20/17/14

Valves

Directionalcontrolvalves 21/18/15

(solenoidvalves)Pressurevalves 21/18/15

Flowcontrolvalves 21/18/15

Checkvalves 21/18/15

Proportionalvalves 20/17/14

Servovalves 17/14/11

Cylinders 21/18/15

Byimprovingsystemcleanlinessthelietimeothehydraulicorlubricationsystemcanbeextended:

Operating

0-100bar

100-160bar

160-210bar

210-250bar

250-315bar

315-420bar

420-500bar

500-630bar

Changeinoil

3classesworse

1classworse

none

1classbetter

2classesbetter

3classesbetter

4classesbetter

5classesbetter

Iftheoperatingpressureisincreasedinasystem,itisnecessarytoimprovetheoilcleanlinessinordertoachievethesamewearlifetimeforthecomponents.

cleanlinesspressure

Typeof Initial Target Lifetime

System ISOCode ISOCode extendedby:

Hydraulic -/19/17 -/14/11 x4

Lube -/21/19 -/15/12 x3


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1

Calculateyourreturnon your

investment Example Formulagures

R e t u r n o n I n v e s t m e n t C a l c u l a t i o n

Noofmachines (a) 3

Annualoperatinghours (b) 4000

Hourlymachinecosts (c) 45

Hourlylabourcost (d) 45

Currentmachineuptime% (e) 95

Currentmachinedowntime% (f) 5

Downtimehourstotal: (g) 4000x3x0,05=600 (bxa)/100xf

Mechanical/electricalfailure (h) 500

Hydraulicfailure (j) 100

Causedbytheuid (k) 80 jx0,8

Fluidrelateddowntimecosts (l) 3600 kxc

Labourcostsforrepair (m) 3600 kxd

Totalmaintenancecost (n) 7200 l+m

Fluidservicewillpreventupto80%ofuidrelatedfailuresleaving20%

Remainingdowntimehours 16 kx0,2

Reductionindowntimecosts 720 lx0,2

Reducedlabourcosts 720 mx0,2

Totalnewmaintenancecost (o) 1440 nx0,2

Totalsavingsforyour

facility,simplybycaringforyouroil: 5760 n-o


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20 V i s k o s i t y - / T e m p e r a t u r e D i a g r a m

100,00050,000

20,000

10,000

5,000

3,000

2,000

1,000

500400

300

200

150

100

75

50

40

30

20

15

10

98

7

6

5

4-20 -10 0 10 20 30

ISOVG7

kinematicviscosity[mm2/s]


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21

40 50 60 70 80 90 100 110 120

ISOVG10

ISOVG15

ISOVG22

ISOVG32

ISOVG46

ISOVG68

ISOVG100

ISOVG150

ISOVG220

ISOVG320

ISOVG460

ISOVG680

ISOVG1000

ISOVG1500

temperature[C]


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22 V i s k o s i t y - / T e m p e r a t u r e D i a g r a m

Hydraulic oils, motor vehicle transmissionoils, automatic transmission fluid oils and oilsaccording to MIL - PRF - 50

H-L/H

-LP68x

H-L/H

-LP32

H-L/H

-LP46

ATF

SAE80

SAE90

accordingtoMIL-PRF-5606

200,000100,000

50,000

20,000

10,0005,000

2,000

1,000

500400300

200

150100

5040

30

20

16

10987

6

5

12

-25 -20 -15 -10 -5 0 5 10 20 30 40 50 60 70 80 90 100 110 120

temperature[C]

kinematic

viscosity[mm2/s]


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2

Motor oils

200,000100,000

50,000

20,000

10,0005,000

2,000

1,000

500400300

200

150100

5040

30

20

16

10987

6

5

12

-25 -20 -15 -10 -5 0 5 10 20 30 40 50 60 70 80 90 100 110 120

temperature[C]

SAE30SAE20W-20

SAE10W-30

SAE10W

kinematicvis

cosity[mm2/s]


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A R G O - H Y T O S w o r l d w i d e

ARGO-HYTOS subsidiaries

Benelux ARGO-HYTOSB.V. Phone+31105926149

[email protected]

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(Beijing)Co.Ltd.

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[email protected]

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[email protected]

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[email protected]

GreatBritain ARGO-HYTOSLtd. Phone+441709839300 [email protected]

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[email protected]

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[email protected]

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Polskasp.zo.o. [email protected]

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Technical Handbook Fluid Management e