l-4532 contamination guide for hydraulic fluids, oils and ... · an iso 9001:2015 certified company...
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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
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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).
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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.
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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
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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
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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.
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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.
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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).
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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
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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
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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%.
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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
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• 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
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Asoutlinedearlier,thehoselengthshouldbetheshortestpossiblerunandinastraightlineavoidingbendsintheline:
Ingeneral,MosterrorsinTCM(orTIM)readingsaredueto installationerrorswhichcanbecorrectedwithsimple system/hook-upchanges!
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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.
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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.
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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
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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.
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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:
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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
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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:
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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.
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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.
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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.
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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
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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®
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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
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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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