Paper Mill Lube Filter Element Upgrade

Posted by Jim Harlan on Tue, Jul. 25, 2017

The Application

Large paper mills rely on continuous production to be profitable, thus unplanned down time is a huge financial burden. When unplanned downtime does occur and equipment must also be either repaired or replaced, the damages can feel exponential.

Read More

Topics: fluid cleanliness, dirt, iso cleanliness codes, ISO Fluid Cleanliness Codes, maintenance, ISO 4406, filtration

DFE - Testing Filters Under Real-Life Conditions, Part 4 of 4

Posted by Jim Harlan on Tue, Jul. 18, 2017

Throughout the first three entries in this series we've discussed the difference in two filter element testing methods, ISO16889 and DFE. We've also illustrated how many elements fall short of their stated beta ratio under dynamic flow conditions. Today we'll wrap it up with simulated cold start tests.

DFE Multi-Pass: Cold Start Contamination Retention

Once the element has captured enough contaminant to reach approximately 90% of the terminal ΔP (dirty filter indicator setting), the main flow goes to zero and the injection system is turned off for a short dwell period. Then main flow goes to maximum element rated flow accompanied by real time particle count to measure retention efficiency of the contaminant loaded element. The dynamic duty cycle is repeated to further monitor the retention efficiency of the filter element after a restart.

Read More

Topics: hydraulic fluid, ISO 16889, ISO Fluid Cleanliness Codes

DFE - Testing Filters Under Real-Life Conditions, Part 3 of 4

Posted by Jim Harlan on Tue, Jul. 11, 2017

Last week we covered the differences between the ISO16889 Filter Test Procedure and the DFE Filter Test Procedure. This week we illustrate the difference between elements engineered to retain particles during dynamic flow conditions and those that are engineered only to pass the ISO16889 test.

Quantifying Contaminant Capture and Retention

Figure 2 compares the performance of two identical high efficiency glass media filter elements, one tested to ISO16889 multi-pass and the other to the DFE multi-pass method. The graph expresses the actual number of particles 6μ[c] and larger counted downstream of the filter element from several data points during the tests.

Filter A2 was tested at a constant flow rate and maintained a steady efficiency throughout the test. Filter A1 was cycled between max rated flow rate and half of rated flow with a duty cycle consistent with that of a hydraulic system. The downstream counts for Filter A1 varied and were highest during changes from low flow to high flow. The peaks represent counts taken during flow change and the valleys represent counts taken after each flow change. The alternating high peaks represent counts taken during changes from low flow to high flow. As the amount of contaminant captured by Filter A1 increased, the downstream counts increased most dramatically during the flow changes from low to high. Filter element A1, not properly designed to retain previously captured contaminant during dynamic system conditions, can become a dangerous source of contamination as it captures and then releases concentrated clouds of contaminated fluid.

Read More

Topics: hydraulic fluid, ISO 16889, ISO Fluid Cleanliness Codes

DFE - Testing Filters Under Real-Life Conditions, Part 2 of 4

Posted by Jim Harlan on Tue, Jun. 27, 2017

Last week we briefly discussed how filter elements are rated by manufacturers. This week we're discussing the industry standard ISO16889 multi-pass test and Hy-Pro's standard, the DFE test.

Current Filter Performance Testing Methods

To understand the need for DFE it is important to understand how filters are currently tested and validated. Manufacturers use the industry standard ISO16889 multi-pass test to rate filter efficiency and dirt holding capacity of filter elements under ideal lab conditions.

Figure 1 depicts the test circuit where hydraulic fluid is circulated at a constant flow rate in a closed loop system with and on-line particle counters before and after the test filter. Contaminated fluid is added to the system at a constant rate. Small amounts of fluid are removed before and after the filter for particle counting to calculate the filter efficiency (capture). The capture efficiency is expressed as the Filtration Ratio (Beta) which is the relationship between the number of particles greater than and equal to a specified size (Xμ[c]) counted before and after the filter. In real world terms this test is the equivalent of testing a filter in an off-line kidney loop rather than replicating an actual hydraulic or lube system. It’s basically a filter cart test.

Read More

Topics: hydraulic fluid, ISO 16889, ISO Fluid Cleanliness Codes

DFE - Testing Filters Under Real-Life Conditions, Part 1 of 4

Posted by Jim Harlan on Tue, Jun. 20, 2017

The Dynamic Filtration Efficiency (DFE) Test is Hy-Pro's standard for testing filter elements. Throughout this 4 part series we'll discuss what it is, why it matters and why elements engineered with this test in mind outperform others in real-life applications.

First, let's start with the basics...

Why are filters used? How are they rated?

All hydraulic and lube systems have a critical contamination tolerance level that is often defined by, but not limited to, the most sensitive system component such as servo valves or high speed journal bearings. Defining the ISO fluid cleanliness code upper limit is a function of component sensitivity, safety, system criticality and ultimately getting the most out of hydraulic and lube assets.

Read More

Topics: hydraulic fluid, ISO 16889, ISO Fluid Cleanliness Codes

Paper Machine Lube System Filter Element Upgrade

Posted by Jim Harlan on Wed, Jun. 07, 2017

DFE Rated Filter Doubles Element Life, Cuts Contamination Levels in Half

The Problem

A paper machine was experiencing excessive down time as maintenance personnel was frequently servicing a Brand X filter element installed on the lube system. The element would reach terminal ∆P and require replacement every 8.5 days on average.

Read More

Topics: contamination, fluid cleanliness, dirt, iso cleanliness codes, ISO Fluid Cleanliness Codes, filtration

VUD Prevents Bearing Failure & Unplanned Outage

Posted by Jim Harlan on Tue, May. 16, 2017

Saves >$15,000,000 by removing water and particulate from common reservoir lube oil.

The Application

In boiler water feed pump applications, water often finds its way into the oil lubricating the pump’s bearings. This was the scenario at a paper manufacturing facility that turned to Hy-Pro for help.

The Problem

In this application, the boiler water feed pump bearing lube system was combined with the facility’s steam turbine lube oil system. The water, and the particulate contamination it was bringing with it, were decreasing the fluid’s ability to lubricate the bearings and causing premature wear on the bearings. The facility was attempting to remove free water with water absorbing filters (changed weekly) but the rate of ingression was too high for the filters to be as effective as needed. And since absorbents only remove free water, the filter elements were unable to address the dissolved and emulsified water present in the oil.If the situation were to continue much longer, a premature replacement of the steam turbine and boiler feed pump bearings would be necessary outside of the scheduled maintenance periods. While possible, this solution would cost millions of dollars without addressing the root of the problem. 

Download the PDF

Read More

Topics: water in oil, water, Water Contamination, iso cleanliness codes, ISO Fluid Cleanliness Codes, filtration

Varnish in AW Hydraulic Oil

Posted by Jim Harlan on Tue, May. 02, 2017

Saves >$200K/year by reducing downtime, defective units, idle labor and oil costs.

The Application

During the manufacturing process of refrigerators, isocyanate is hydraulically injected into the body of the appliance to improve insulation. After injection, the chemical transforms from liquid to foam.
Read More

Topics: varnish in hydraulic oil, iso cleanliness codes, ISO Fluid Cleanliness Codes, filtration

Hydraulic Pump Reliability

Posted by Jim Harlan on Tue, Feb. 21, 2017

The Problem

Pumps are the heart of hydraulic systems. When the pump fails, the entire system is down until the pump is operational again. This poses a serious threat to any operation relying on hydraulic systems for productivity. Recently, a hydraulic valve manufacturer was losing 25 pumps a year on their centralized hydraulic system at a cost of $2,440 each. That’s only the pump cost, when you account for maintenance resources, lost oil and lost production each failure costs ~$25,320.

Read More

Topics: hydraulic fluid, contamination, fluid cleanliness, dirt, iso cleanliness codes, ISO 4406, filtration, Fluid Analysis

Cleanliness Requirements for Fluid Transfer

Posted by Jim Harlan on Tue, Feb. 07, 2017

The Problem

Today’s oil suppliers are often required to provide fluid at or below a specified ISO Cleanliness Code. One such supplier was experiencing short filter element life (15 days) on the system (7 element multi-round housing) used to achieve the required ISO Cleanliness Code of 18/16/13 in a single pass as 15W-40 oil is transferred from their bulk storage tanks to tanker trucks for delivery.

Read More

Topics: hydraulic fluid, contamination, fluid cleanliness, dirt, iso cleanliness codes, ISO 4406, filtration, Fluid Analysis