basic hydraulic training - dp filter
TRANSCRIPT
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Basic Hydraulic Training
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Agenda
●Welcome
●Donaldson
●Filtration
●Media
●Clean
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Donaldson Company Inc. (DCI)
Leading worldwide provider of filtration systems and replacement parts
Founded in 1915
Technology-driven company
Customers served in the industrial and engine markets
10500+ employees worldwide
Locations in 37+ countries worldwide
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Strong Performance
$530
$1.092
$1.919
$2.200
$1,877
$ 2.294
0
500
1000
1500
2000
2500
'93 '94 '95 '96 '97 '98 '99 '00 '01 '02 '03 '04 '05 '06 '07 '08 '09 '10 '11
U.S
. Do
lla
rs in
Mil
lio
ns
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Donaldson Business Units
• Engine Systems & Technologies
• Advanced Filtration: High Purity Products and
Membranes (Tetratex PTFE Technologies)
• Gas Turbine Filtration
• Industrial Air Filtration (IAF) (Torit DCE product brands)
• Compressed Air and Process Filtration (CAP)- ( Ultrafilter product brands)
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Engine Systems & Technologies
The World’s leading first fit supplier of air filtration, exhaust and hydraulic systems for off-road equipment requiring heavy-duty protection. Products also used in the roughest aircraft and military applications. Leading truck & bus manufacturers around the globe rely on our superior quality engine protection products.
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Advanced Filtration
Membranes Manufacturers of
Tetratex® expanded microporous PTFE Membranes, utilised in manufacturing plants to provide pollution control & dust collection. The inherently hydrophobic characteristics make Tetratex also an excellent choice for technical products.
Semi Conductor Focusing on critical applications
that require a high degree of cleanliness and protection for processes.
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Advanced Filtration
Imaging Filters that remove
toner, ozone and other gases, generated within copying machines and high speed printers.
IVS (Integrated Venting Systems)
• Combining filter media and absorbent technologies, developed for contamination control, as either roll goods or as integrated devices.
• Used in a wide range of critical applications, incl. Sensors, hearing aids, gas vents, headlamps, critical enclosures….
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Gas Turbine Filtration
Custom-engineered complete air intake systems for gas turbines and industrial compressors, for new and retrofit applications protect turbines from airborne contaminants.
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Industrial Air Filtration (IAF)
Filtration systems to capture dust, fumes or oil mist generated by manufacturing operations. We market these products under the brand names Torit® & Torit® DCE®
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Compressed Air & Process Filtration (CAP)
Compressed Air & Gas Systems include air intake
and oil filters to deliver clean, dry compressed air
and gas throughout our customer’s manufacturing facilities. We market these products under the brand
name Donaldson Ultrafilter.
Our Process Filters purify steam, liquids, gases and air
used in food, dairy, beverage, paint and other industries.
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Industrial Hydraulics & Bulk Filtration
Industrial liquid filters clean oil based fluids to keep stationary applications running longer and more cost effective by using innovative technology.
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Quality Certification Programs
Diverse customers and electronic commerce tools
Strong Customer Relationships
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Europe/Africa/ Middle East Carrieres Sur Seine, Domjean, France Klasterec, Kadan,Czech Republic Ostiglia, Italy Hull, Leicester, UK Dülmen, Haan, Flensburg, Germany Cape Town, Johannesburg, South Africa Dammam, Saudi Arabia (JV)
Asia Pacific Gurgaon, India Gunma, Japan Jakarta, Indonesia (& JV) Rayong, Thailand Wuxi, P.R.C. Wyong, Australia
Worldwide Manufacturing
Auburn, AL Aguascalientes, Mexico Athens, Ontario, Canada Baldwin, WI Champaign, IL (JV) Chillicothe, MO Cresco, IA Dixon, Il
Frankfort, IN
Greeneville, TN Grinnell, IA Ivyland, PA Maryville, TN Monticello, IN Monterrey, Mexico Nicholasville, KY St. Charles, MO
Stevens Point, WI
Americas
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Our European Distribution Center In Brugge (Belgium)
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Agenda
●Welcome
●Donaldson
●Filtration
●Media
●Clean
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Basic Filtration Principles
The ideal filter performances should have:
● high efficiency in particle removals
● high dust holding capacity (life)
● low pressure drop (loss of energy of the oil flow) The real filter offers a balance of these 3 features with a cost effective solution
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Filtration Principles
Small particles are diffused within the flow stream. They collide with the fiber and then collected.
Mid-sized particles particles follow the flow stream. They are intercepted or captured when the touch a fiber.
Heavy particles continue in a straight line and collides fibers when fluids change direction
It is the most common mechanism in hydraulic filtration. The particles are too large to fit between the fiber spaces.
Diffusion
Interception
Inertial
Impaction
Sieving
Total
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Agenda
●Welcome
●Donaldson
●Filtration
●Media
●Clean
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Filter Media
• 90+ years filter media expertise • Media formulated for specific
applications
• R&D target 2% - 3% of gross sales
• >1500 patents
• > 500 engineers worldwide
Product Engineering
Innovative Filtration solutions
• Particulate filtration (Ultra-Web® Nanofibers - PTFE Membranes)
• Chemical filtration
• Fluid mechanics
• Acoustics
• Structural dynamics
Synteq®
Media Filter Test Lab
Filtration Media
Media - Superior Filtration Technology
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Media Types:
A. Synthetic Media • synthetic fibre glass • synthetic melt blow • synthetic nanofibers
B. Cellulose Media (natural fibres)
C. Wire-Mesh Media (screen, net) The dimensions of the opening between wires define the
efficiency all the particles smaller than that size will pass the filter. Stainless steel, Epoxy-coated, Zinc plated
D. Water Removal Media Has resin an desiccant to remove moisture and
condensation (for concentration of water till 0,05%)
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Filter Media
Donaldson Focus
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Relative Fiber Sizes
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Conventional Cellulose Synteq®
Contaminant Particle
Liquid Proper Filter Application Fiber Spacing Comparison
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Our new innovative Laboratories in Leuven (Belgium)
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The Multipass Test ISO 16889
Is a procedure to evaluate the filter element performances.
Performance characteristics:
● Beta Ration ● Dirt holding capacity ● DP element
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What is a MICRON ?
● Micron = unit of measurement ● 1 Millionth of a Meter (micrometer) or 0.000039” ● µ = micron Symbol
● Particle Size ● 100µ = grain of table salt ● 40µ = lower limit of visibility ● 10µ = talcum powder ● 2µ = bacteria
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ß-ratio
The ß-ratio is an average of the test period
Vs competition, make sure you compare equal ratio’s
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Compatibility of media with Hyd. Fluids
Type of seal
Fluid
Buna-N
Petroleum based
and high water
Viton
Diesters;
phosphate ester
Compatibility test per ISO 2943 is recommended, Critical points: Media, Seals, Glue, Seam
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Agenda
●Welcome
●Donaldson
●Filtration
●Media
●Clean
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Types of Contaminant
Particulate Water Air
Silt (0 – 5 mic.)
Failu
re
Ove
r Ti
me
Chips (>5 mic.)
Imm
edia
te
Cat
astr
op
hic
fa
ilure
Free
(Damage)
Dissolved (No problem)
Air Damage:
• Loss of transmitted power • Reduced pump output • Loss of lubrication • Increased of operating
temperature • Reservoir fluid foaming • Chemical reactions
Free
Dissolved
Water Damage:
● Corrosion of metal surface
● Accelerated abrasive wear
● Bearing fatigue
● Fluid additive breakdown
● Viscosity variance
● Increase in electrical conductivity
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Types of Contaminant
Particulate contamination:
●Silt (0-5μm) System components failure over time
●Chips (>5μm) Immediate Catastrophic failure
●Typical particle size range on Liquid Circuit is (2-100μm)
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Where Contamination Comes From
● Added with New Fluid
● Built-in during manufacturing assembly processes
● Ingressed from outside the system during operation (breather, hydraulic cylinder, etc)
● Induced by maintenance procedures
● Rubber and Elastomers particles from hoses seals, etc, due to temperature, time, fluid stream
● In-Operation main sources are pump, motors and actuators. Contamination is generated Wear.
● High water Based fluids get biological growth and organic contamination
● Replacement of Failed Components there could be big particles down stream
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ISO 4406/99 Cleanliness
ISO 4406/87 (disavowed): 2μm; 5μm; 15μm; Other measurement is performed with NAS 1638
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Contamination Control
ISO 4406Class
NAS1638 system type
suggestedefficiencyISO 4572
Media(closer)
15/13/10 4 servo-valves for pressure
>20MPa, laboratory &
aerospace2 75
/00
#1
16/14/11 5 high perf. & high press.
long life components, i.e.
small gearbox2 75
5 75
/00/01
#1
#2
17/15/12 6 i.e. servo-valves, general
power transmission
gearbox5 75
/00/01
#1
#2
18/16/13 7 high quality reliable,
general purpose mach.,
vane & piston pumps,
prop. valves, large
gearbox
5 75
10 75
/01/02
#2
#2 1/2
19/17/14 8 gear pumps 10 75
12 75
/02
#3
#3 1/2
20/18/15 9 mobile equipment,
medium pressure i.e.
motors, valves & control
12 75
15 75
/02
#3
#3 1/2
21/19/16 10 low-medium pressure
systems, heavy industry,
cylinders, steering
unit(load sens.)
15 75
20 75
#3 1/2
#4
#7
22/20/17 11 low pressure systems 25 75
10 2
/03/1
#5
#9
23/21/18 12 low pressure systems
with large clearance25 75
10 2
/1
#10
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Cleanliness
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ISO Codes vs Life of Components
ISO Codes Average Hours in
Service Life Cycle
22/19 325 0.31
21/18 430 0.41
20/17 600 0.57
19/16 800 0.76
18/15 1050 1
17/14 1400 1.33
16/13 1900 1.81
15/12 2800 2.43
14/11 3800 3.62
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HM1 Cleanliness Level
20
16
17
14
13
17
19
14
16
13
11
16
15
11
15
10
8
14
56789
101112131415161718192021
30/0
8/2
007
6/0
9/2
007
13/0
9/2
007
20/0
9/2
007
27/0
9/2
007
4/1
0/2
007
11/1
0/2
007
18/1
0/2
007
25/1
0/2
007
1/1
1/2
007
8/1
1/2
007
15/1
1/2
007
22/1
1/2
007
29/1
1/2
007
6/1
2/2
007
13/1
2/2
007
20/1
2/2
007
27/1
2/2
007
3/0
1/2
008
10/0
1/2
008
Date Sample taken
Cle
an
lin
es
s L
ev
el
Iso 4 micron
Iso 6 micron
Iso 14 micron
By monitoring these Cleanliness Levels
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Cleanliness report
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Cleanliness report
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Seeing is believing
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Oil Sampling Kit
●X009329 kit
●Fluid Conditional Monitoring
●Problem detection
An excellent return on investment
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