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Received: 27 October 2011 / Accepted: 1 June 2012 / Published online: 28 July 2012
The Institution of Engineers (India) 2012
Introduction
The development of advance technologies to meet todays
requirement for compactness needs sophisticated high
pressure system. For reliable and efficient operation, a high
quality and clean oil is required. Oil contamination is the
major source of failure and wear of Hydraulic system
components. As per literature survey approximately 70 %
of hydraulic system failures are caused by oil contamination [1]. Detailed study reveals that major causes of failure
of pumps, valves, actuators are due to contamination. The
contamination once developed/ingressed in the system,
while circulating in the system, damage the surface of
component or stop the movement of valve spool/other
moving parts resulting in failure of the system.
This paper introduces contamination and its sources of,
damage caused by contamination, types of failure, standards for measurements of oil contamination, examples of
hydraulic system failure due to oil contamination and the
failure preventions of hydraulic systems.
Results are reported for Off Line Filtration System
and also worked out a component rating with regard to
contamination. At the end, the techniques to prevent contaminants are given.
Contamination
M. Singh (&), FIE
VRDE (DRDO), Ahmednagar 414006, India
e-mail: manmohanjs@gmail.com
G. S. Lathkar, FIE
MGMs College of Engineering, Nanded 431605, India
S. K. Basu, FIE
Production Engineering Department, College of Engineering,
Pune 411005, India
123
270
Sources of Contamination
The sources of contamination [2] are given below:
Ingressed
contamination
Built-in
contamination
Internally generated
contamination
Fluid Cleanliness
(iii) During
maintenance
(iv) Chips/debris of
components
(v) Through
atmosphere
123
ISO code
NAS code
16/14/11
Proportional valves
Vane and piston pumps/motors
17/15/12
18/16/13
6
7
18/16/13
Gear pumps/motors
19/17/14
20/18/15
20/18/15
Seals to be changed
144
6
3
Leakage through seals
Ok
90
9
2
No power supply
Ok
84
6
2
Rupture of filter element
72
4
5
8
2
Mech. failure of bearing
240
5
8
Causes of failure
To articulate the
article
IV
Proportional
direction control
valve
Proportional direction
control valve
II
Effect of failure
Pump
Failure mode
Rank of
critical item
Components/systems Function
Causes of failure
Units
Occurrence
of failure
Pump
Ok
271
123
272
a.
b.
Capture
efficiency
Fiber glass
High
High
Moderate
High
Moderate to High
Cellulose (paper)
Moderate
Moderate
High
Moderate
Low
Wire mesh
Low
Low
Low
Moderate
High
123
Dirt holding
capacity
Differential
pressure
Life in
a system
Initial cost
273
provision also exists for hardcopy printout. However similar equipment with other manufacturers are also available.
Figure 2 indicates the number and distribution of 2, 5,
15 l particles per ml, measured through CM-20 equipment,
when hydraulic system was not used for about 20 days. It is
seen that the number of particles increase initially and after
certain time period remains stable. However their behaviour is not consistent. The ISO/NAS contamination level
measured as ISO 21/19/16 or NAS 10.
Figure 3 indicates the number and distribution of 2, 5,
15 l particles per ml in an interval of 1 h after starting the
Off-Line Filtration Systems. It is seen initially that number
of particles particularly 2, 5 and 15 l varies and generally
after 3 h get stabilised. The ISO/NAS level measured was
18/16/13(NAS 8)
1800019500
40504880
15
510590
After filtration
No. of
particles
Cleanliness
level
ISO-21/19/16 43304980
ISO-18/16/13
NAS 10
NAS 8
9901250
80150
123
274
Volume, l (c)
Percentage of
total volume
V1 = (a)/(c)
No. of particles
measured
(515 l) (d)
Percentage of
total contamination
V2 = (b)/(d)
656
54.6
23670
68.244
70.2
5.85
2091
6.03
1.03
Tubes
Hoses
63.6
11.3
5.3
0.94
1427
520
4.26
1.50
0.803
1.595
Reservoir
400
33.33
6933
19.98
0.599
Reservoir
(i)
Component
rating (V2/V1)
1.2498
(i)
Hydraulic system
(i)
(ii)
Conclusion
In this paper, the authors describe the importance of
hydraulic oil contamination, its monitoring, methods of
measurements and techniques to minimize it. Following
points may be considered for prevention of failures of
hydraulic system based on oil contamination.
123
References
1. VickersIndustrial Hydraulics Manual, Second edition, 1989
2. The systematic approach to contamination controlVickers
Fluid Power System, pp. 67
3. NAS 1638National Aerospace Standard
4. ISO 4406-1999 (E) Hydraulic fluid powerfluid methods for
counting the level of contamination by solid particle
5. SAE AS 4059Aerospace Fluid Power-Cleanliness Classification for Hydraulic Fluid
6. Handbook of Hydraulic Filtration, Parker Hannifin Corporation,
Hydraulic Filter Division, HTM-2, USA
7. S.K. Basu, S.K. Sarkhel, S.K. Chakravorty, Oil analysisa tool
for condition monitoring of diesel engines. J. Cond. Monit. Diagn. Technol. 3(2), 4751 (1992)
8. B. Bikash, S.K. Basu, TerotechnologyReliability Engineering
and Maintenance Management (Asian Books Private Ltd., New
Delhi, 2003)
9. D.H. Stamatis, Failure Mode and Effect Analysis: FMEA from
Theory to Execution (ASQ Quality Press, Milwaukee, 2003)
10. T. Nush, Filtrationits the little thing that get you Hydraulics
& Pneumatics, June 1999, pp. 1931
11. W.D. Williamson, Hydraulic component cleanliness testing
method & result. SAE Technical Papers, Paper No. 790867, SAE/
SP-79/447/02.50, 1979
12. MIL STD-00419B, Military standard for cleaning and protecting
piping, tubing and fittings for hydraulic power transmission
equipment
13. P.J. Heney, Effective filtrationbreaking the chain reaction of
wear. Hydraul. Pneum. 51, 4352 (1998)