Filters

A filter is a device whose primary function is to remove insoluble contaminants from the fluid, by use of a porous medium. Filter cartridges have replaceable elements made of nylon cloth, paper, wire cloth or fine mesh nylon cloth between layers of coarse wire. These materials remove unwanted particles, which collect on the entry side of the filter element. When saturated, the element is replaced. The particles sizes removed by the filters are measured in microns. One micron is one-millionth of a meter or 0.000039 of an inch. Filters can remove particles as small as 1 . Studies have proved that particle sizes as low as 1 can have a damaging effect on hydraulic systems and can also accelerate oil deterioration. Figures 7.3 gives details of the relative sizes of microscopic particles magnified 500 times.

Figure 7.3 Relative mesh sizes

Micron ()
The particle sizes or clearances in hydraulic systems are usually designated in terms of micron which is equal to 39 millionths of an inch. To further simplify the process of understanding the concept of the micron, the smallest dot that can be seen by the naked eye is about 40 m. Beta ratio It is a measure of a filter's efficiency. It is defined as the number of particles upstream from the filter that are larger than the micron rating of the filter, divided by the number of particles downstream from the filter larger than the micron rating of the filter. The example illustrated below demonstrates the concept of beta ratio quite clearly.

Figure 7.4 Comparison of filter efficiencies through beta ratio

From Figure 7.4, it is seen that there are 200 particles upstream from the filter which are larger than 3 m in size. A filter having a lower beta ratio is less efficient because it allows more particles through it. Again referring the example above, it is seen that while the filter at the top allows 100 particles through, only 1 particle is allowed to pass through the filter at the bottom. The beta ratio for the filter at the top is given by = 200/100 = 2 which is a less efficient value, whereas the beta ratio for the filter at the bottom is given by = 200/1 = 200 which is a more efficient value. The following equation is used to determine the efficiency value of a filter, known as beta efficiency.

Beta efficiency = where the particle size is greater than a specified value of N m. The relationship between beta ratio and beta efficiency can thus be represented as: Beta efficiency = 1 - 1 For example a filter with a beta ratio of 40 would have an efficiency of 1/40 = 97.5%.The higher the beta ratio, higher is the beta efficiency. Fluid cleanliness level Fluid cleanliness can be defined according to ISO, NAS and SAE standards. ISO 4406 defines contamination levels using a dual scale numbering system. The first number refers to the quantity of particles over 5 per 100 ml of fluid and the second number refers to the number of particle over 15 per 100 ml of oil.For example, a cleanliness level of 15/12 indicates that there are between 214 and 215 particles over 5 and 211 and 212 particles over 15 , per 100 ml of fluid

Let us consider another example based on a 1 ml fluid sample. A particle count analysis is done for this sample using specific particle sizes of 4 m, 6 m and 14 m. By selecting these three sizes, an accurate assessment of the amount of silt from 4 m and 6 m particles can be obtained, while the number of particles above 14 m is an indication of the amount of wear type particles in the fluid.

No. of particles per 1.0 ml ISO 4406 code

From the ISO 4406 table shown, let us consider a rating of 22/18/13. This indicates the following: 1. 22 indicates that the number of particles greater than or equal to 4 m in size is more than 20 000 and less than or equal to 40 000, per ml. 2. 18 indicates that the number of particles greater than or equal to 6 m in size is more than 1300 and less than or equal to 2500, per ml. 3. 13 indicates that the number of particles greater than or equal to 14 m in size is more than 40 and less than or equal to 80, per ml. The ISO contamination code is applicable to all fluid types and provides a universal expression of relative cleanliness, between the suppliers and the users of hydraulic fluid. This code is meaningful, only if it is related to the required cleanliness level of the hydraulic system under consideration. It is usually based on the manufacturer's requirements for the cleanliness levels in which a component may operate. For example, most gear pumps may sufficiently operate in fluids having a rating of 18/16/15 ISO, while servo valves require an ISO code 15/13/12 or better.

Filter location
Filter location in a hydraulic system is critical to ensuring acceptable levels of fluid cleanliness and adequate component protection. Figure 7.5 shows the location of the various filters in a hydraulic system.

Figure 7.5 Location of filters in a hydraulic circuit

The function of breathers in a hydraulic system is to prevent entry of airborne particles which are drawn into the system due to changes in the fluid level of the reservoir. They are usually mounted on the reservoir. Components such as servo valves which are located immediately downstream of the filter are protected from wear and silting-related problems by pressure filters. These pressure filters are designed to withstand high pump pulsations and the system pressure. Return hne filters provide protection against entry of particulate matter when the fluid is returned to the tank. An off-line filter also known as kidney loop is often provided in a hydraulic system especially when fluid circulation through the return-line filter is minimal. Off-line filters operate on a continuous basis. The chief advantage associated with these filters is the flexibility they offer with regard to their placement. Since these filters are independent of the main system, their location in a hydraulic circuit can be chosen in such a way that easy serviceability is ensured.

Filtration methods
There are three basic types of filtering methods used in hydraulic systems.

Mechanical
This type normally contains a metal, a cloth screen, or a series of metal disks separated by thin spacers. Mechanical type filters are capable of removing only relatively coarse particles from the fluid.

Absorbent type These filters are porous and contain permeable materials such as paper, wood pulp, diatomaceous earth, cloth, cellulose and asbestos. Paper filters are normally impregnated with a resin, to provide added strength. In this type of filter, the particles are actually absorbed as the fluid permeates the material. As a result this method is used for extremely small particle filtration. Adsorbent type Adsoiption is a surface phenomenon and refers to the tendency of the particles to cling to the surface of the filter. Thus the capacity of such a filter depends on the amount of surface area

available. Adsorbent materials used, include activated clay and chemically treated paper. 7.4.4 Types of filters Some filters are designed to be installed in the pressure line and are normally used in systems where high-pressure components such as valves are more dirt sensitive than the pump Return line filters are used in systems, which do not have large reservoirs to permit contaminants to settle at the bottom. A return line filter is needed in systems contemning close tolerance highperformance pumps. Let us now study some of the common filters normally used in hydraulic systems. Duplex-type filters Figure 7.6 shows a filter designed for either a suction line or a pressure line. This is a duplex filter.

Figure 7.6 Cross-section of a duplex filter

A duplex filter, as the name suggests consists of two filters out of which only one is in use all the time. When the filter element gets clogged, the second filter is put to use. Dirty fluid comes into the middle section and passes down through the filter element. The filter element can be of fine gage nylon cloth or wire cloth or finely perforated stainless steel. From the filter element, the fluid passes out of the unit and

into the line. This unit has a 'telltale' indicator, which indicates when the filter element is excessively clogged and requires cleaning. If the filter is not cleaned after indication, the fluid bypasses the filter element and there is no filtering action. Such a bypass mechanism is important for a filter because, when the filter element is clogged heavily, the pump in line may get damaged due to starvation of hydraulic fluid.

Edge-type filters
This is also referred to as a full flow filter, which means that all the oil in the system passes through it. Figure 7.7 illustrates an edge-type filter.

Figure 7.7 Cross-section of an edge-type filter

The edge-type filter consists of a stack of disks with holes in their center, like flat doughnuts, with very little separation between them. When entering the filter, fluid is guided from the bottom at the outer side of the stack. Before leaving the filter, it comes out of the center of the stack having passed through the disks. Impurities in the oil are left behind on the outer edge of the stack. A scraper blade moves over the outer surface of the stack, wiping off all the dirt collected. The blade is operated manually by means of a handle at the top of the filter housing.

Tell-tale filters

This is a versatile filter, which can be directly welded into a reservoir's suction and return line or conversely installed in pipes with a maximum pressure of 10 kg/cm^ (142 psi). This filter can remove particles as small as 3 |LI. It consists of an indicating element, which indicates the time when cleaning is required. That is why this filter is referred to as a telltale filter (Figure 7.8). The operation of a tell-tale filter is dependent on the fluid passing through the porous media, which traps the contaminants. The tell-tale indicator monitors the pressure differential buildup due to dirt, which gives an indication of the condition of the filter element.

Figure 7.8 Cross-section of a tell-tale filter (Courtesy of ParJcer Hannifin Corp., Michigan)

Principle of working Fluid enters the inlet at the bottom of the tube, passes from the inside to the outside through the filter element and exits at the side outlet. When a new and recently cleaned filter element is fitted in the housing, the tell-tale indicator will indicate that it is 'clean'. As dirt deposits on the surface of the element, the pressure differential across the inlet and outlet of the element rises. The bypass piston senses this difference in pressure. The piston is held seated by a spring. When the element requires cleaning, the pressure differential is high enough to compress the spring, forcing the piston off its seat. The piston movement causes the tell-tale indicator to point towards the 'needs cleaning' position. When the filter element is not cleaned when this signal comes on, the pressure differential continues to rise, causing the piston to uncover a bypass passage in the cover. This action limits the rise in the pressure differential to a value equal to the spring tension and the fluid bypasses the filter element. A cutaway view of a tell-tale filter is shown in Figure 7.9.

Figure 7.9 Cutaway view of a tell-tale filter

The following schematics show a few of the typical methods used for filtration. Figure 7.10(a) shows the location of a proportional flow filter. As the name implies, proportional flow filters are exposed to only a percentage of the total flow in the system. The primary disadvantage of this type of filtration arrangement is that, there is no positiveprotection of any specific component within the system and there is no way to know that the filter is dirty. Figures 7.10(b)-(d) show full flow filtration in which all the flow from the pump is accepted.

Figure 7.10(b) Full flow filter in suction line

Figure 7.10(c) Full flow filter in pressure line

Figure 7.10(d) Full flow filter in return line

Strainers
A strainer is a device made of wire mesh screens, which seek to remove large solid particles from a fluid. As part of standard engineering practice, strainers are installed on pipelines ahead of valves, pumps and regulators, in order to protect them from the damaging effects of fluid and other system contaminants. A common strainer design uses two screens, cylindrical in shape. One cylinder is inside the other and the two are separated by a small space. The outer cylinder is a coarse mesh screen and the inner one is a fine mesh screen. The fluid first passes through the coarse mesh screen and filters the larger particles. It then passes through the fine mesh screen, which blocks the smaller particles. Figure 7.11 shows the crosssectional view of a typical strainer.

Figure 7.11 Strainer

The bottom of the strainer serves as the sump (or pot) for the solids to collect. The strainer can be cleaned out easily at intervals, by two different procedures: 1. The cleanout plug can be removed and the pressure in the line can be used to blow the fixture clean. 2. The large retaining nut at the bottom is to be removed for pulling the mesh out of the strainer in order to clean it and putting it back in line.