The experience of designers, manufacturers and users of hydraulic and lubrication systems, is that 75% of machinery failure is as a direct result of contamination. Knowing the cleanliness level of the fluid is the basis for contamination control.
The origin and effect of contamination in these systems is now known and understood.
Coarse particles (>15 micron) will cause sudden and catastrophic breakdown of system components. Fine contamination (between 5 and 15 micron) will cause wear and tear of components which lead to internal valve and pump leakages, control valve inaccuracies and blockages and eventually failure of these expensive components.
Systems with over 500 parts per million of water which is equivalent to 100% saturation will cause corrosion of components and acceleration of the ageing of the oil. Measuring and monitoring dirt levels in hydraulic systems, ensures a greater reliability, improved lifetime of components, reduced warranty claims and above all, end customer satisfaction. System cleanliness levels are expressed in the ISO 4406 code.
The first number is the number of particles in a millilitre sample of fluid which are larger than 4 micron. The second number is the number of particles larger than 6 micron - and the third number is the number of particles larger than 14 micron.
Hydraulic systems should follow the recommendations shown in Table 1.
MP Filtri design and manufacture a range of particle counter products specifically for measuring solid contaminants in systems. The LPA2 particle counter works online to 40 MPa working pressure. The unit is portable, designed to be easy to use and the twin laser design ensures accuracy. Other features include:
* Rugged, light weight, portable.
* Instant results - test completed in 1 minute.
* Large display screen.
* Full QWERTY keyboard.
* Flush valve to ensure validity of sample avoiding cross contamination.
* Easy to use.
* Windows-based software package for trend monitoring.
Instant laboratory results
Essential for site work where the LPA2 cannot be directly connected, the customer can use sample bottles. Bottle sampling can be achieved using the LPA2 in conjunction with a bottle sampler. The sampler also provides a vacuum option to ensure complete integrity of the sample.
Extec applications
Extec is a manufacturer of a well known range of mobile crushers, screeners and shredders. These machines are to be found across the globe in quarrying, mining and recycling applications. Exec uses the MP Filtri LPA2 laser particle analyser for measuring the cleanliness levels of its hydraulic systems. Prior to completion, each Extec machine is flushed with ultra-fine filtration and the LPA2 particle analyser is used to ensure that the hydraulic systems meet the required cleanliness standards. Extec demands quality products and quality control systems for its high technology machines.
PML2 and PML2 W Particle Counter is designed to be permanently installed in automated test rigs and flushing units where continuous contaminant monitoring is essential. The system yields instant results with moisture and temperature option available - as well as remote display module option. There is a permanent record of contamination levels and the necessary Windows software package is included with these products.
Aerospace application
DARA (Defence Aviation Repair Agency) has completed a state-of-the-art Aircraft Servicing Facility at St Athan in South Wales. At the heart of the facility are the Hydraulic Ring Main Systems that allow the aircraft hydraulic systems to be fully functionally tested, filled, drained and flushed. The ring mains and associated equipment are primarily designed to operate the hydraulic systems incorporated into fast jets that use either self pressurising reservoirs (Tornado, Eurofighter and Jaguar) or pressurised reservoirs (Harrier and Hawk).
System contamination monitoring is achieved by using an in-line particle counter (PML2) manufactured by MP Filtri. Incorporating the particle counters into the hydraulic system was achieved using Modbus protocol, which enables the PML2 to be programmed to communicate with a programmable logic controller (PLC). This has been used to measure and report the cleanliness of various aircraft hydraulic systems. Achieving and monitoring the correct cleanliness standards for the reliability of today's aircraft is critical.
Expensive down-time and unexpected breakdowns can be eliminated with the correct use of contamination monitoring products and by specifying and installing suitable filtration products.
The use of cost-effective particle counters is essential for machinery manufacturers to enable them to produce high performance, reliable quality products. MP Filtri also design and manufacture a full line of hydraulic filtration and accessory products.
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