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05/03/2012 TWO APPROACHES TO CONTAMINATION CONTROL The capability of a filter to stop contaminants from entering the hydraulic system requires precise technology by design engineers and manufacturers. Their careful precision ensures that the filter you install will do the job it is designed for—keeping your hydraulic system clean. With all the options on the market, choosing the right filter boils down to what your equipment requires to achieve maximum performance and protection. Let’s examine the two basic filter types that trap contaminant: · Surface filters create a barrier between the fluid stream and media to trap solids of a specific size. Media is often one layer of closely-woven fabric or treated paper of uniform pore size that catches contaminants directly on the surface as fluid flows through the pores. This design provides good control of pore size in the wire cloth—contaminant larger than the pore size is trapped on the upstream surface. The accumulation of contaminant over time allows the capture of particles smaller than the pore size as well. Advantage: Surface filters provide low restriction and can serve as initial filtration before a primary filter. Acting as “strainers”, they effectively filter particles greater than 60 micrometers.
· Depth filters force fluid through a complex passage of openings with several layers of fiber media. The media has many more pores of much smaller size than surface filters and is composed of cellulose or fiberglass pleated fiber. Its unique pleat design increases the amount of media in the filter, as well as supports the column strength of the element. This construction provides improved collapse resistance under differential pressure in the hydraulic system. Advantage: Depending on pore size, depth filter media can achieve a very high contaminant capture rate at very small particle sizes and provide finer filtration than surface filter media.
QUALITY FILTRATION CAN HELP YOU SELECT THE RIGHT FILTER TYPE FOR YOUR EQUIPMENT NEEDS! 04/19/2012 PUT THE LID ON LEAKS Every maintenance technician knows that potential plumbing leaks are an inherent problem in hydraulic systems. For maximum efficiency and reliability, it’s critical to stay on top of leakage. Even in the most severe applications, good preventive maintenance and effective contamination control will ensure leak-free service. If your hydraulic equipment is not operating at full power, it could be due to a leak. Use this checklist to identify the source for quick correction: · Make sure the drive belt is working as specified. A slipping belt can keep pumps from achieving full pressure and cause leakage. · Add fluid if needed, but don’t overfill. If your system is repeatedly in need of more fluid, or if you see puddles around machinery, check the fittings attached to the pump, reservoir, filter housing, hoses and pistons. Be sure the reservoir drain plug is tight. · Look for dents or obstructions from metal fatigue. The force of fluid power can cause vibration and adversely affect torque on plumbing connections, leading to leakage. · Check pipe thread connections. Threaded pipes can be unreliable for high-pressure fluids because the thread is often the cause of a leak path. Replacement with soft seal connections solves this problem. · Keep temperature under control. High temperatures can permanently damage the seals in your hydraulic system and lead to leaks. A heat exchanger is a good investment to ensure normal operating temperatures. Finally, remember high quality filtration controls contamination ingress and protects all the components in your system from wear and damage. When the hydraulic filter gets dirty, it can stop the free flow of fluid from the reservoir to the pump and seriously affect power, so be sure to check the filter and replace as needed for maximum efficiency. QUALITY FILTRATION PROTECTS THE CRITICAL COMPONENTS IN YOUR HYDRAULIC MACHINERY. 04/13/2012 KEEP YOUR BEARINGS …. CLEAN! Hydraulic machinery depends on clean bearings to run efficiently and avoid premature failure. Because they are especially vulnerable to the ingress of dust and water from shop environments, bearings need special attention. The bearing housing features an extended shaft, that if not properly sealed, allows the easy entry of dust and moisture. An effective contamination control program is critical to keep bearings clean and protected. The location of machinery in a shop facility is a precursor to dust. Dust is continually generated from equipment handling powders and operation processes. And wet environments are even harder on bearings. Whether from water or a chemical compound, moisture in bearings quickly emulsifies and mixes with oil to set in motion a domino effect—the roller runs through and displaces the mixture, creating contact between the rolling element and the race. Instead of gliding through the loading cycle, the element scrapes against the surface, causing either the roller or the race to fail. That spells trouble for your machinery! In a hydraulic circuit, high quality filters will remove dust and moisture as the liquid cycles through the filters. Enclosed bearings become hot during operation and then cool to ambient temperature when not in use. A good air breather releases hot air out of a confined space, traps contamination from entering the hydraulic fluid and returns clean, dry air to the circuit. If you are experiencing premature failure, it’s time to replace your current breather with a high performance filter that removes particles at least two microns and larger. You can protect the breather from water spray and dampness with a breather extension tube . . . . just be sure that the tube cannot be crushed closed. QUALITY FILTRATION CAN RECOMMEND THE RIGHT AIR BREATHER FILTER TO PROTECT VITAL HYDRAULIC COMPONENTS. 03/29/2012 OIL AND WATER DON’T MIX! Water is essential to the life of the planet….but when it gets into your hydraulic, lubrication and dielectric oils, it has very negative effects. The only way to extend the life of critical wear components in rotational and hydraulic equipment is to maintain absolutely clean and dry oil. In other words, NO WATER. The importance of complete water and air extraction from oil cannot be overestimated. Dissolved water quickly turns to free water from such causes as heat exchanger and seal leaks, condensation, faulty reservoir covers, or sudden temperature drops. Entrained and dissolved gases create foaming that leads to pump cavitation, higher fluid temperatures and slower system response time. The most devastating effect of this contamination is premature component failure due to internal leakage in pumps, cylinders and other critical components. One method that eliminates water contamination is a Vacuum Dehydration Oil Purification System (VDOPS). This versatile equipment cleans and purifies oil by removing free, emulsified and dissolved water, entrained air, and dissolved gases through vacuum distillation. It maximizes water extraction rates and enables processing of high viscosity gear oils to achieve overall content as low as 20 PPM, particle counts as low as ISO 14/12/9 Cleanliness Level, and process flow rates from 3 to 100 GPM. A VDOPS is easy to operate and requires virtually no maintenance. Plus, it saves on water consumption by using only one utility—electricity. Consider an oil purification system for your operation. It is a simple and efficient way to avoid major machine repair/replacement and to ensure these benefits: · Optimal equipment performance and reliability · Reduced equipment downtime · Decreased maintenance costs · Maximum profitability ASK QUALITY FILTRATION ABOUT AN OIL PURIFICATION SYSTEM FOR YOUR FACILITY! 03/22/2012 A CHANGE FOR THE BETTER In a tough economy, we’re all looking for ways to save operating costs and improve the bottom line . . . .and maintenance expense is often the major culprit that sends your budget soaring. A tried and true way to spend a little on the front end and SAVE A LOT in the long run is with regular fluid analysis to monitor the condition of your hydraulic system. Think of fluid analysis as a hired “detective” on the watch-out for potential hazards in your machinery. This operative “detects” abnormal component wear, failing seals or conditions like aeration and cavitation that can all easily be remedied before they cause catastrophic damage. An important function of base oil analysis is to tell you when it’s time to change your hydraulic filter. It reads conditions to determine if oil is degraded or if your oil additive package is depleted. It keeps you from changing filters too soon—or too late! If you change before the filter’s dirt-holding capacity is reached, you’re wasting money on unnecessary changes. If you change after the filter has gone on bypass, the increased contamination is already shortening the service life of every component in your hydraulic system. Sample testing, either in-house or through laboratory analysis, is a small expense that yields big savings: · - Ensures components are fully protected · - Decreases labor expenses · - Minimizes filter disposal costs Remember, fluid analysis yields the critical information you need to support efficient operation and longer machine life. ASK QUALITY FILTRATION TO SET-UP A FLUID ANALYSIS PROGRAM AT YOUR FACILITY TO MONITOR HYDRAULIC PERFORMANCE. 03/08/2012 YOU COULD BE DOING OTHER THINGS .… Wouldn't it be nice to have a machine that handles an important maintenance job while you work on other tasks? That’s the role of the offline hydraulic filter cart. This little portable workhorse is an ideal way to decontaminate new and in-service oil periodically without using extra manpower. The carts are designed with the components specifically needed (i.e., hydraulic gear pump, hydraulic hose and hydraulic filters) to clean hydraulic fluid. The specialized cart is programmed to do the job for your specific system with great success. Keep these factors in mind when choosing a filter cart for your shop: · Tell your supplier about specific requirements intended for your filter cart. For example, using your cart for systems other than hydraulics may be problematic. · Be sure the filter is correct for your machinery (i.e., the available surface area of filtration media and the level of filtration the media provides). Some high efficiency filters may contain media that is too fine for your particular lubricant. · Monitor the pressure differential. As fluid passes through media, a pressure differential is created by media pore size, total media surface area, fluid viscosity and the amount of dirt captured in the media. Most filter assemblies include a relieving valve in the filter head that allows fluid to bypass the filter when pressure exceeds a given rating. This protects the filter from damage during shock-loading and lets fluid continue through the circuit even after the filter has reached maximum dirt-holding capacity. If pressure differential is too high, the relieving valve may be partially open, allowing some or all of the fluid to bypass the filter completely. A good filter cart will do a lot of hard work for you. Talk to your supplier about specific needs—and then spend your time doing other work! ASK QUALITY FILTRATION ABOUT ADDING A FILTER CART TO YOUR OPERATION. 03/01/2012 DOWNTIME: THE SILENT EXPENSE When the whir of machinery stops on a shop floor because of maintenance issues, the deadening sound of silence means mounting expenses for your operation. The bottom line with machinery downtime is financial — lost time is lost money. A lot of money. To keep your equipment up and making money, it is critical to invest in a fluid cleanliness program that uses lubricant at maximum efficiency and keeps equipment running at peak performance. In today’s fast-paced economic climate, your shop equipment has to operate continuously to maintain your supply schedule. Otherwise, you have to build in spare capacity, another big budgeting and space constraint. Keeping fluids clean and contamination-free makes good common sense to achieve sustainable production and take profits to the bottom line. Contamination control maximizes the asset life and reliability of your machinery. Every in-house lubrication maintenance program should include effective contamination control with proper filtration and regular oil analysis for measuring cleanliness levels. Proper filtration includes filtering new, incoming oil as well as in-use oil. The benefits are huge:
Equipment downtime costs a lot more than the small investment to prevent lubrication-related failures. And the good news is . . . . when machinery is running at full capacity and the silence of downtime is gone, your increased bottom line profits will pay for the contamination control program! A CONTAMINATION CONTROL PROGRAM AT YOUR FACILITY TODAY. 02/23/2012 DESIGNED FOR SUCCESS When you use high quality filtration in your machinery, you automatically decrease contamination levels to meet your target cleanliness standards. That’s because filtration engineers design their products with focus on keeping out dirt. For example, they design a system that is sealed to keep out contaminants; they specify better shaft and rod seals; they ensure reservoirs are maintained at a positive pressure; and they incorporate proper breather caps on reservoirs to prevent particulate ingression. Remember, a good filtration system is designed for success to ensure machinery performance and protection. The two basic filtration designs are: · Spin-on filters are self-contained within their own housings or pressure shells and install directly to the hydraulic system through a filter head. Typical nominal working pressures are usually low. Spin-on filters seldom operate in pressures that exceed 150 psig, but specialty spin-on filters can be designed to operate in 1000 psig systems. A bypass valve may be required. · Cartridge elements operate within filter housings consisting of a head, bowl, and inlet and outlet ports allowing installation into the fluid system circuit. The installed location is the main indicator of the operating pressure. Suction and return filters typically do not exceed operating pressures of 150 PSI to 500 PSI respectively. Pressure side filters are more robust since they are installed on the outlet side of the pump. Pressure ratings range from 600 PSI to 6000 PSI. Expert filter design is the key to maintaining system functionality and longer life. Choose a supplier who understands the requirements of your machinery and who can recommend the best filtration design for your hydraulic system. TRUST QUALITY FILTRATION TO RECOMMEND THE MOST EFFECTIVE 02/16/2012 YOU CAN’T AFFORD NOT TO! During tough economic times, everyone tries to cut back on things that seem non-essential …. vacations, weekend trips, big ticket purchases, luxury items, or even little things we may buy every day, like a too-expensive cup of coffee. But when it comes to your business, cutting back on one thing can cost you a lot more money than you save. The biggest watch-out in trimming a tight budget is: You can’t afford NOT to protect your machinery components! You can’t afford to scrimp on high quality filtration and regular oil analysis. These two processes are the most important maintenance tasks you need to avoid the high cost of system breakdown or failure. Protecting your hydraulic components from contamination damage adds up to tremendous cost savings that far outweigh the outlay on the front end. A properly sized, installed, and maintained filter in a hydraulic circuit maintains system functionality, and regular tracking of fluid cleanliness (through on-site or laboratory oil analysis) keeps your system working in balance. Hydraulic system contamination comes with a staggering price tag: · Costly breakdowns or replacements · Unscheduled downtimes · Fluid replacement increases · Disposal cost increases · Unsafe practices increases Remember, you can’t afford NOT to spend money on expert filtration and oil analysis. When you prolong major component life with proper filtration and predictive system maintenance, it’s money well-spent! TRUST QUALITY FILTRATION TO PROVIDE EXPERT CONTAMINATION CONTROL! 02/02/2012 THE HORSE BEFORE THE CART The key to efficient and smooth operation of your machinery is clean and well-maintained lubricant. Sometimes the process of keeping oil clean is done in reverse order, so it is important to remember to do first things first to keep machinery in tip-top condition. Lubrication maintenance involves three critical steps to ensure top performance and longer life: 1. Clean incoming oil to exclude ingressed contaminants 2. Maintain clean oil by removing system-generated contaminants 3. Monitor contamination levels with oil analysis A reminder to maintenance technicians: Don’t put the cart before the horse! The first step in good lubrication maintenance is installation of a proper air breather and hardware. Move this practice to the top of your list . . . . because the best way to ensure clean lubricant is to CLEAN NEW OIL first. An effective breather significantly enhances machine performance and protection by removing airborne contaminants (that invisibly float around in the atmosphere) BEFORE they enter the system. Breathers control the onset of water vapors and prevent water-contamination in oil. Without installation of an air breather, first and foremost, your valuable equipment could experience leaking seals and expensive downtime or failures quickly. Remember, breathers support the other two steps in the cleaning process, so start your maintenance regimen with this important step to ensure maximum protection. QUALITY FILTRATION OFFERS AN ARRAY OF AIR BREATHER OPTIONS FOR YOUR HYDRAULIC APPLICATIONS. 01/19/2012 FILTER LOCATION: WEIGHING THE OPTIONS The optimal location for hydraulic filtration in machinery can be confusing. Filter efficiency, ease of service, component life and cost are all areas affected by where the filter is positioned in your system. Let’s look at the advantages and possible disadvantages of each option: · Return line filtration is a popular location for most hydraulic systems, and high efficiency can be achieved at a reasonable cost. It is beneficial because pressure is high enough to force fluid through very fine media (i.e., 10 microns) with relatively low flow velocity. The only watch-out is that back pressure from the element could affect performance of some components. · Pressure line filtration offers very good protection for downstream components. Filtration rates of 2 microns or less can be achieved as pressure forces fluid through the media. A possible drawback is that efficiency could suffer if high flow velocities and pressure and flow transients disturb trapped particles. · Suction side filtration is also a good location for filters because efficiency is improved by the absence of high fluid velocity and high pressure drop at the pump intake site. The only negative of this location is that the element may create restriction that could adversely affect pump life. · Off-line filtration is a good choice because it provides continuous, multi-pass filtration with controlled flow velocity and pressure drop. High efficiency rates (i.e., 2 microns and less) can be achieved. Polymeric filters and heat exchangers can be included for further fluid conditioning. A slight disadvantage of off-line filtration is that initial investment cost may be higher. Whatever the filtration location, your goal is to maximize the ability of the filter to do its job—removing contamination and extending equipment life! QUALITY FILTRATION CAN HELP MEET YOUR GOALS FOR CONTAMINATION CONTROL AND INCREASED MACHINE LIFE. 01/12/2012 RESOLVE TO SAVE $$$ IN THE NEW YEAR What if you could save up to 40% to take to your bottom line in the New Year by adding a routine maintenance regimen? It sounds too good to be true . . . but keeping the oil in your hydraulic system clean will significantly reduce your equipment maintenance costs and increase your profits. The fact that up to 75% of all hydraulic system failures are caused by particulate contamination is a wake-up call to every maintenance technician. A properly sized, installed and maintained filtration system in a hydraulic circuit can save hundreds of dollars in maintenance repairs every year. High quality filtration yields numerous benefits, including prevention of premature wear, sustained system functionality and better performance. These benefits can easily be achieved with the following maintenance regimen: · Clean incoming oil—From first fill, be sure to filter all new oil to remove airborne contaminants that enter the system. Remember, new oil is not clean oil! · Keep oil contamination-free—During operation, continually filter oil to prevent moisture and wear-causing particles from re-circulating throughout the system and damaging components. · Perform oil analysis—Periodic oil sampling and analysis keeps you on top of potential problems by monitoring contamination control effectiveness. Remember, a high quality filtration system is your first-line of defense to prevent system failure and high repair costs. Start the New Year in the right direction and reduce your maintenance costs with an effective contamination control program. QUALITY FILTRATION IS YOUR BEST SOURCE FOR TOTAL CONTAMINATION CONTROL IN YOUR EQUIPMENT. 01/05/2012 STAY AHEAD OF THE GAME The start of a new year is a good time to resolve to stay ahead of the game with your equipment maintenance. It’s a wise practice to be prepared BEFORE problems arise. You’ll save a lot of time and expense when proactive maintenance practices troubleshoot problems before they create havoc in equipment. The best way to stay ahead of the game is with routine oil sampling and analysis. A regularly scheduled oil analysis program in your lubrication area is a simple and easy practice that yields immeasurable benefits— identifying potential contamination problems in equipment systems that can shut down your operation. Early detection allows problems to be resolved quickly. Lube technicians should set-up a monthly or quarterly schedule to draw oil samples from pumps, gearboxes, and other key pieces of equipment. Samples then undergo a battery of appropriate tests to detect increased levels of dirt, metal, water, and other contaminants that serve as a warning signal of potential mechanical stress, degradation or component failure. Some oil samples may warrant special attention from an outside professional laboratory in addition to in-house testing. Don’t forget oil sampling and analysis during commissioning of equipment. Baseline oil samples before start-up can identify metals like iron or copper already present in the system that could cause eventual problems ahead. STAY AHEAD OF THE GAME . . . . LET QUALITY FILTRATION SET UP AN OIL ANALYSIS PROGRAM AT YOUR FACILITY! 12/16/2011 ABRASIVE WEAR — A COMMON PROBLEM Proactive machinery maintenance can be an all-encompassing task because of the various mechanisms that could cause downtime or failure. Of the many mechanical processes in the system that can potentially harm your equipment, abrasive wear from particles is the most common initiator of component failure. Abrasion sets in motion a damaging cycle. A variety of mechanisms, like rolling element bearings, journal bearings and gear teeth, impact effective clearance. . . .and cause the elimination of lubricating oil film. Even if oil film is not completely eliminated, its thickness is greatly reduced, and that’s a problem. When misalignment reduces oil film thickness in sliding contacts, particle and non-particle abrasion increases. The domino effect occurs when clearance-sized particles get into lubrication film and localize the load transfer. Particles enter the clearance space between two moving surfaces, become lodged in one of the surfaces, and act like cutting tools to remove material from the opposing surface. Particles that cause the most damage are equal to or slightly larger than the clearance space. The load may exceed the fatigue limit of the metal—causing damaging denting and pitting. Abrasive wear particles are work hardened—meaning they quickly become harder than the parent surface. Ultimately, abrasive wear has extremely negative impact on your machinery: · Dimensional changes · Leakage · Lower efficiency If particles are not removed by high quality filtration, they recirculate and continue the cycle of wear. The worst case scenario is a chain reaction of abrasive wear when more and more particles are generated—resulting in premature component failure. QUALITY FILTRATION PROTECTS MACHINERY COMPONENTS BY PREVENTING ABRASIVE WEAR. 12/8/2011 COALESCER TECHNOLOGY: CLEAN and GREEN Environmentally-conscious facility managers are faced with a constant clean-up problem when oil mist is released into the atmosphere and ends up on shop floors. It all starts with the need for oil replenishment on bearing surfaces, requiring oil mist to flow continually. The downside is that oil mist globules can coalesce on bearing components and release oil mist into the atmosphere. Government legislation around the world has mandated that oil mist releases be kept at the lowest level to meet clean-air requirements. And simply from a housekeeping perspective, it is always preferable to eliminate messy oil smudges from the floor around pumps. From a wastewater perspective, machinery oil spills do even more damage—ending up in water sewers. It costs a lot of money to remove the oily mess in sewers before water can be discharged. Ideally, an oil spill-free environment is the optimal choice for every shop operation. Modern filtration technology has kept pace with the need to reduce oil mist from the environment. The latest innovations combine coalescer technology with high efficiency microglass filter media in single systems to achieve optimal fluid cleanliness in steam and gas turbines. Coalescing filters work by separating water and oil from compressed air and additionally remove contaminant particles. Coalescer/separator systems work so well that they can quickly remove large amounts of free water from turbine lube oil and achieve overall water content as low as 150 PPM. Plus, the high efficiency filter elements achieve extremely low particle counts that meet or exceed an ISO 16/13/10 Cleanliness Level. The result is optimal fluid cleanliness with a clean and green approach to shop maintenance and the environment. ASK QUALITY FILTRATION ABOUT THE LATEST TECHNOLOGY IN COALESCER OIL PURIFICATION SYSTEMS. 12/1/2011 BREATHE IN . . . . BREATHE OUT Machine hydraulic parts are expensive, so it makes good business sense to keep your inventory from deterioration by protecting components. Even inside the cozy domicile of a plant or warehouse, hydraulic components can be adversely affected by moisture and contamination that creeps in during storage. Fluid in the container can be harmed by airborne contaminants, such as water vapor and abrasive particles, that are major culprits in equipment damage. One of the challenges in preventing component damage is the control of un-dry air that flows into machinery cylinders. When ambient temperature decreases, air in the cylinder can quickly reach the dew point. This condition allows moisture to form on the inside of the cylinder tube—and it becomes risky business for your machinery. Moisture causes a variety of issues, like spot-rusting and pitting on the tube surface that can quickly reduce the volumetric efficiency of the cylinder and the service life of the piston seal. In business terms, this scenario costs a great deal in downtime, productivity, and maintenance costs. Installing a high quality air breather filter solves these potential problems. An air breather filter should be used on ANY enclosed container that breathes air in and out of your equipment. An air breather ensures the flow of clean and dry air in reservoirs and storage containers wherever air is exchanged during changing fluid levels. In extremely high moisture environments, breather caps with pressure relief and vacuum breakers also provide a positive suction head at the pump inlet. Wherever there is airflow, an effective air breather will ensure a contaminant-free environment.
HYDRAULIC SYSTEM WITH QUALITY FILTRATION AIR BREATHERS! 11/18/2011 WATER CONTAMINATION: THE ROOT CAUSE OF CAVITATION While it
may look harmless, water plays a big role in causing cavitation erosion in your
machinery hydraulic system. The trouble starts, like the old adage goes,
because oil and water DON’T mix. Water is such a completely different substance
from oil that when it becomes contaminated (as it so often does!) and mixes
with the oil, it has a devastating effect on wear rate. This is particularly true in rolling-contact,
elastohydrodynamic lubrication films with higher unit loads. One of the
most damaging results of water contamination is vaporous cavitation. Cavitation
is a form of erosion caused when vapor bubbles implode on metal surfaces. It occurs when pressure transitions rapidly from
a vacuum to high pressure. The implosion is released onto the surface of the
machine with great velocity—leading to erosion. This
action can produce steam at the suction of a pump in a matter of minutes—causing
machinery failure. During maintenance intervals, technicians can quickly spot cavitation erosion: · Obvious cavities or pits appear on the surface. · The tiny “holes” become obstacles to the smooth flow of water through the turbine. The condition leads to a loss of operating efficiency because of surface penetration damage to critical machinery components. The end result is a reduction in capacity that causes major losses in productivity, efficiency and your bottom line. The good news is that cavitation erosion is easily preventable with proper oil/water separation. By removing free and emulsified water from oil with the right filtration, water contamination can effectively be eliminated. QUALITY FILTRATION OFFERS EXPERT OIL/WATER SEPARATION TECHNOLOGY TO STOP WATER CONTAMINATION. 10/28/2011 Sometimes you don’t realize your machinery has a problem until it breaks down—by then, it’s too late to stop production loss and costly repairs. Experienced maintenance technicians can diagnose problem areas before they result in breakdown, and it’s important to detect wear as early as possible. The root cause of most system failure is excessive wear from contamination—and it shows up in symptoms that signal trouble: · Diminished system performance · Shorter component life In pumps and valves, these wear symptoms call for immediate action: · Pump wear causes reduced flow rate. Referred to as increased slippage, the condition makes the pump less efficient than when it was new. As pump flow rate decreases, the entire fluid system becomes sluggish, and hydraulic actuators begin to move more slowly. Pressure in the system may also decrease. Wear can lead to a sudden catastrophic failure of the pump. In extreme cases, it can happen within a few minutes after initial start-up of the system. · Valve wear increases internal leakage. The effect of leakage varies with the type of valve involved. In valves that control flow, increased leakage usually creates increased flow; in valves that control pressure, increased leakage can reduce circuit pressure. Silting interference can make valves and variable-flow pump parts sticky and begin to operate erratically. This shows up in flow and pressure surges that cause jerky motion in actuators—a condition that signals it’s time for quick remedial action. ASK QUALITY FILTRATION ABOUT REDUCING WEAR IN YOUR HYDRAULIC SYSTEM THROUGH AN EFFECTIVE CONTAMINATION CONTROL PROGRAM. 10/21/2011 THE IMPORTANCE OF FILTRATION Your equipment is likely the largest capital investment in your business. That’s why you spend time and money to safeguard machinery from breakdown and failure. With over 75% of hydraulic system failures traced back to contamination, it is obvious why filtration should be an important part of your maintenance regimen. And when you consider the two basic purposes of filtration, there is no question about its benefits to your operation: 1. Filtration keeps machinery running efficiently. You depend on machinery to keep up with production needs, so the vital parts that keep equipment running should be protected. High quality filtration creates a barrier that prevents contaminants from reaching particle-sensitive components. Filters located upstream of components effectively prevent motion impediment and blocked flow caused by contamination. Filtration is the only process that can stop harmful contaminants from invading your machinery. 2. Filtration extends machinery life. Machines release wear metal gradually….and over time, wear metal debris leads to extensive repairs, rebuild or total replacement—an expensive and time-consuming problem. For a reasonable cost, the right filtration prevents progressive wear from abrasion, surface fatigue and other damage caused by contamination. Proactive maintenance using high efficiency filtration can extend your service life as much as tenfold—and that’s savings you can take to the bottom line. THE BEST WAY TO PROTECT AND EXTEND THE LIFE OF YOUR MACHINERY IS WITH QUALITY FILTRATION. 10/14/2011 EXTENDING DRAIN INTERVALS The optimal goal of a maintenance routine is to extend drain intervals. Minimizing drain and fill makes good business sense for increased productivity and decreased maintenance expense. The good news is that extending drain intervals is an achievable goal that can be accomplished by dealing with oil’s worst enemy—contamination. The culprit of contamination makes oil “dirty” and requires more frequent draining and service time. Harmful contaminants like dust, dirt, metal debris, water and oxides can wreak havoc as they enter the system from every direction: -Addition of new, unfiltered fluid · -Uncapped reservoir breather · -Built-in contamination -System-generated particles You may be changing oil too often because of something that can effectively be controlled. Two simple steps will make the difference: · Establish Total Level Cleanliness targets for your equipment · Use proper filtration equipment and methods Your filtration supplier can recommend the right filtration to extend drain intervals. For example, most contamination can be removed using a filter cart equipped with particulate and moisture-stripping filters. The filter cart conducts periodic decontamination while your equipment is still in operation using hook-up connectors—letting it run for a half hour or more. This option allows technicians to spend their valuable time performing other maintenance tasks while the filter cart does the job. Remember, extending your drain intervals is doable using the right filtration to get rid of contamination early. QUALITY FILTRATION CAN HELP YOU EXTEND DRAIN INTERVALS AND IMPROVE SAVINGS AND PRODUCTIVITY! 10/07/2011 “NEW” OIL DOESN’T MEAN “CLEAN” OIL! It’s a common mistake to think that if oil is new, it must be as clean as soapsuds. New oil may look and smell clean, but it is a dangerous assumption that can harm your machinery and affect your bottom line. In many cases of testing new oil before it is dispensed, it is revealed that new incoming oil is dirtier than equipment particle cleanliness targets. New oil gets dirty from built-in contaminants that enter during the handling process. Filtering incoming oil should be the first item on a facility manager’s agenda to prevent contamination and machinery failure. From an operational budget standpoint—filtering incoming oil BEFORE it enters the system is a lot cheaper than removing contaminants once they are inside your equipment and doing their damage. It is a head start that makes a lot of sense for your productivity and your budget. Here are guidelines to ensure that your new oil is clean: The best time to filter
new oil is before it enters the storage area.
Then you should periodically decontaminate the oil while it is in storage and filter the oil again when dispensing
into top-up containers. · The easiest way to filter new oil (incoming and stored oil) is to use a rack-mounted system with integrated filtration and pumping equipment. A good option is to be able to run the storage tank in an incoming circulation and dispensing mode—to make the decontamination process completely hassle-free when receiving, storing and dispensing oil. Remember, it is an erroneous perception that new oil is always clean oil! LET QUALITY FILTRATION HELP YOU CHOOSE THE RIGHT FILTRATION EQUIPMENT TO FILTER NEW OIL AND KEEP IT CLEAN! 09/29/2011 CONTAMINATION ACCELERATES GREASE DRY-OUT One of the unwanted by-products of oil drainage is hardened grease that builds inside the cavities of bearings and gears in your machinery. While it may take several years to do its damage, grease caking can also reach disastrous levels in a very short time, depending on operating conditions. Grease dry-out starts a domino effect that can clog machinery fast:
A major catalyst to this scenario is particulate contamination. When dust, wear debris, dirt, fly ash and other contaminants enter the system, grease thickens. A good preventive measure is to monitor the situation through regular oil analysis. Sample grease can be taken from a catch pan to measure oil content, contamination and oxidation. More sophisticated sampling tools are also available to extract grease samples from running bearing cavities. Any grease with a suspicious appearance – hardened, strange color or presence of contaminant—should be sampled for analysis. Using an experienced lab as your partner is helpful to determine contamination levels and to recommend remedial action. Don’t let grease dry-out hamper equipment efficiency! QUALITY FILTRATION HAS THE RIGHT MEDIA TO CONTROL CONTAMINATION IN YOUR MACHINERY!
09/23/2011 DON’T LET THE BUGS IN! We already know the damage water contamination can cause in your machinery. Added to the problem can be the presence of microscopic life forms—or bugs! These little organisms grow and thrive in water, as well as air. Tiny life forms such as bacteria, algae, yeast, and fungi can range in size from 0.2 µm in single cells to 200 µm in cell colonies. In addition to their mass volume, they produce acid and waste products that attack all the metal surfaces in your system. And they multiply fast! Microbes have the capacity for rapid exponential growth and can double their population every 20-30 minutes. In colonies, they form a thick, mat-like structure that is hard to break apart--and that can totally shut down a fluid system through degradation and component failure. Here are some signs that microbial growth may exist in your system:
Getting the pesky bugs out before they do damage is critical to your operation. Microbes can plug filters quickly and destroy your hydraulic system, requiring a major overhaul or total replacement. There are two methods to stop microbial growth:
QUALITY FILTRATION CAN STOP MICROBIAL GROWTH BEFORE IT DAMAGES YOUR SYSTEM! 09/16/2011 FIELD TESTING vs. LAB TESTING Your TLC goal is to keep contamination levels as low as possible. With a good contamination control program in place, you still need to check regularly to ensure that your protocol is working. Two types of contaminant monitoring, field testing and lab testing, use different approaches to achieve the same goal. Most contaminant screening is done at the facility level by maintenance personnel using field equipment. More precise testing is done in a well-equipped laboratory, performed to exact standards by certified laboratory technicians. Both testing methods screen for three things:
Between two different testing options, the question may arise: which approach is best for my facility—on-site field testing or laboratory testing? The answer is BOTH. It is likely that you will need both methods usin two different types of test equipment—often yielding two different results. Both pieces of data provide critical information for your maintenance routine. Here’s a good approach to testing:
The on-site lab should never replace the commercial lab. Both should work in concert. Your on-site testing can catch problems early, while your commercial lab can confirm results and perform exception testing to hone-in on the root cause of problems. LET QUALITY FILTRATION HELP YOU SELECT THE BEST MONITORING OPTIONS TO SUPPORT TLC GOALS. 09/09/2011 FIELD TESTING vs. LAB TESTING Your TLC goal is to keep contamination levels as low as possible. With a good contamination control program in place, you still need to check regularly to ensure that your protocol is working. Two types of contaminant monitoring, field testing and lab testing, use different approaches to achieve the same goal. Most contaminant screening is done at the facility level by maintenance personnel using field equipment. More precise testing is done in a well-equipped laboratory, performed to exact standards by certified laboratory technicians. Both testing methods screen for three things:
Between two different testing options, the question may arise: which approach is best for my facility—on-site field testing or laboratory testing? The answer is BOTH. It is likely that you will need both methods usin two different types of test equipment—often yielding two different results. Both pieces of data provide critical information for your maintenance routine. Here’s a good approach to testing:
The on-site lab should never replace the commercial lab. Both should work in concert. Your on-site testing can catch problems early, while your commercial lab can confirm results and perform exception testing to hone-in on the root cause of problems. LET QUALITY FILTRATION HELP YOU SELECT THE BEST MONITORING OPTIONS TO SUPPORT TLC GOALS 09/05/2011 GRIME FIGHTERS The role of the facility maintenance manager is usually focused on avoiding the chief culprit in machinery downtime and failure—contamination. Contamination severely affects system operation and can cause component failure due to seizure of sliding or rotating members. When clearances become contaminated, it restricts or prevents movement of parts within the entire system. And that spells trouble for your operation and ultimately your bottom line. Maintenance staffs must quickly turn into grime fighters to stop this destructive force. Since it is the primary root cause of machine breakdown, contamination has to be managed aggressively—before it is ingested into the system. Remember, contamination enters the hydraulic system in a variety of sneaky ways: • Through new, unfiltered fluid • Through an uncapped reservoir breather • Through contamination already “built-in” to the system • Through system-generated particles (i.e., particles that wear a component to the point of breaking away into more particles in the fluid) Grime fighting begins with established Total Level Cleanliness (TLC) goals for your facility. This must be followed by continual monitoring your contamination control program through regular sampling and oil analysis. Be sure to make it the top priority on your maintenance agenda! QUALITY FILTRATION CAN HELP YOU DEVELOP TLC GOALS TO STOP CONTAMINATION BEFORE IT STARTS! 08/25/2011 TIME IS MONEY In the hustle and bustle of daily operation, your time is always at a premium. There is none to waste. One of the areas that can waste your time is in the order and delivery of products to keep your business running efficiently. Minutes and hours spent trying to find the right product and then get it delivered on time to your location can add up to lost revenue. You don’t have time to work around a troublesome supplier. This checklist covers important criteria every supplier should meet to earn your business:
A wise choice is a supplier that meets all your needs efficiently and proficiently with a quick transaction. Remember, your supplier should be a dedicated partner to help solve your business issues—protecting your machinery, troubleshooting maintenance problems, and boosting your profitability with lower cost solutions. If it’s not easy to do business with your supplier—then it’s time to find a new supplier! QUALITY FILTRATION IS READY TO MEET ALL YOUR FLUID POWER AND INDUSTRIAL HYDRAULIC NEEDS! 08/18/2011 ISO STANDARDS: PRECISE TESTING AND REPORTING To support the industry with improved methods for testing products and reporting data, the International Organization for Standardization (ISO) continually takes advantage of technological advances in statistics and metrology. These advancements are a win-win situation for filter manufacturers and customers alike—allowing better data-driven decision-making in product development and customer purchases. The four ISO contamination control standards, ISO 11171, ISO 11943, ISO 16889 and ISO 4406:1999 (introduced around mid-2000), replaced ISO 4402, ISO 4406: 1985 and ISO 4572. New standards evolved quickly due to the unavailability of the AC Fine Test Dust (ACFTD), replaced by ISO medium test dust as an alternative calibration and standard test contaminant. These precise standards led to significant improvements in how filters are tested and how results are reported. For example:
QUALITY FILTRATION USES ISO STANDARDS FOR ALL PRODUCT TESTING AND REPORTING. 08/11/2011 INTERCEPTION! The purpose of a filter is to intercept the smallest contaminants possible as fluid moves through the media. Research shows that reducing the number of 6 micrometers and smaller size particles within the hydraulic system reduces wear and increases component life. Filters that allow the fewest wear-causing particles to circulate in the hydraulic system offer the best protection. One type of filter that intercepts harmful particles is a surface filter. Surface filters are often referred to as “strainers” because they work through direct interception to stop contaminant before it reaches the fluid. They perform like a first-line defense barrier to stop particles from getting any further into the hydraulic system. Here’s how surface filtration works. The fluid stream takes a direct path through the media barrier to capture contaminates on the surface of the filter element barrier that faces the direct path of the fluid flow. This barrier is usually composed of a single layer construction of woven wire mesh. The physical characteristic of the construction provides precise control of the size of the pores in the wire cloth. Contaminant larger than the pore size is trapped on the upstream surface of the media (accumulation of contaminant over time on the media surface may allow obround-shaped particles smaller than the pore size to pass through the media). Surface filters provide several important benefits:
LET QUALITY FILTRATION HELP YOU SELECT THE RIGHT FILTER TYPE FOR YOUR MACHINERY. 08/04/2011 CELLULOSE vs. MICROGLASS When selecting a filter, it’s important to understand the benefits and advantages of the filter media inside the can. After all, the main job of a filter is to trap particulate contamination through the media so that it can’t enter your hydraulic system. A lot is resting on the media’s ability to do its job! There are different reasons for different media choices. For example, the pore configuration in cellulose media lends itself to a broad range of sizes due to the inconsistent shape and sizes of fibers in its construction. Conversely, microglass media is more uniform in shape, and fiber size can be controlled with strands as small as one micrometer in diameter. Smaller pores and thinner strands in microglass media mean more pores can be located in a smaller area than the same number of pores of cellulose fibers. This feature allows microglass media to provide better dirt-holding capacity and filtration efficiency. Many customers choose Quality Filtration QMedia with microglass fibers because it delivers excellent benefits to enhance system protection and performance:
LET QUALITY FILTRATION HELP YOU MAKE THE RIGHT MEDIA CHOICE FOR YOUR FILTRATION NEEDS! 07/28/2011 COMPONENT CARE Component failure is the worst-case scenario for your machinery. It translates into countless hours of operation downtime and hundreds of dollars in repair or equipment replacement. Component care should be a priority in your preventive maintenance routine. The major culprit in component damage is particulate contamination. Harmful particles get into the hydraulic system in various ways: • With the addition of new, unfiltered fluid • Ingested through an uncapped reservoir breather • Built-in contamination before use • System-generated particles that break away into more particles in fluid Contamination adversely affects components through seizure of sliding or rotating members. When component clearances become contaminated, it restricts movement of parts within the system. And that can cause a whole lot of trouble for your machinery! The following illustrates some TYPICAL component clearances to monitor: COMPONENT TYPICAL CLEARANCE IN MICRONS Gear Pump 0.5 to 5 Vane Pump (Tip of Vane) 0.5 to 1 Vane Pump (Side of Vane) 5 to 13 Servo Valve (Spool Sleeve) 1 to 4 Control Valve (Spool Sleeve) 1 to 23 QUALITY FILTRATION PROTECTS COMPONENTS BY ELIMINATING PARTICULATE CONTAMINATION! 07/21/2011 ALL FILTRATION IS NOT ALIKE The basics of filtration are fairly easy to understand. Filtration is the action of capturing small particles (particulate contamination) in fluid as the fluid passes through a porous medium. Sounds simple enough... but filtration is a very carefully (or should be!) designed and engineered process with a very big goal—maximum efficiency in removing wear-causing particles. Harmful particles can destroy your equipment, so it’s a job filter manufacturers take very seriously. But all filtration is not the same! It may appear that any filter can do a decent job of removing contamination….after all, it’s just passing fluid through media. Yet there are many variables that separate adequate filtration from superior filtration. For example, if filter media doesn’t trap all the particles, the process has failed—no matter what else about the filter is sufficient. Quality Filtration provides superior filtration and can help you select a filter that meets or exceeds OEM specs for maximum protection, including:
WITH QUALITY FILTRATION, YOU ALWAYS GET SUPERIOR FILTRATION! 07/14/2011 YOU DON’T HAVE TO SEE IT TO BELIEVE IT Like the air we breathe, air contamination in your hydraulic system is mostly invisible. Yet though you may not see it, it’s a destructive force that can do a lot of damage in your equipment. Air contamination makes its presence known through some troubling signs--your machinery starts foaming and spewing oil from the reservoir, or oil gets dark and soot-like with a varnish build-up on component surfaces. Then you know it’s there. Air contamination can quickly wreak havoc in your system through:
You can check for air contamination in the hydraulic system by periodically testing the oil’s ability to release air and maintain stable foam. If you detect a problem, Quality Filtration can help you select a high efficiency air breather filter for fluid reservoirs…. to stop the contamination in its tracks. RELY ON QUALITY FILTRATION AIR BREATHER FILTERS TO CONTROL AIR CONTAMINATION! 07/07/2011 Workhorse on Wheels A quality portable filtration unit is a great investment for your business due to its versatility. Like the multi-tasking army knife, it serves a variety of useful and important functions in one tool…..and that can save you time and money! The most common uses of a filter cart are to remove particulate contamination from new oil and reduce airborne ingression by maintaining a sealed system. The filter cart does both these jobs very well:
But consider what else the filter cart can do to help you maintain your machinery:
When reviewing your total maintenance program, remember the value a portable filter cart brings to your operation. This high efficiency, high capacity workhorse really does a lot of work. TALK TO QUALITY FILTRATION ABOUT ADDING A FILTER CART TODAY! 07/01/2011 False Economy If you think you’re saving money buying the cheapest filters….think again. The truth is they can cost you a whole lot MORE! It’s like buying an expensive car and putting in the cheapest gas ….it doesn’t pay in the long run. Particulate contamination is serious business—it can shut down your equipment and cause irreparable damage that may result in rebuild or new machinery. The few dollars you save on a cheap filter can end up costing thousands of $$$. All filters are not alike. When a filter costs less, there’s probably a reason. The old adage, you get what you pay for, is never truer than when buying filters. Don’t be trapped by practicing false economy—when you buy a high quality filter, you invest in real savings:
The proof is in the pudding. The best way to verify that your filter is doing its job is to measure its effectiveness through oil analysis. If you aren’t hitting your Target Level Cleanliness (TLC) standard, you’re wasting your money. Be sure to check your TLC level at every service interval. DON’T USE FALSE ECONOMY WHEN BUYING FILTERS…. RELY ON QUALITY FILTRATION FOR MAXIMUM PERFORMANCE AND PROTECTION 06/24/2011 OEM SPECS: THE GOLD STANDARD Equipment manufacturers rely on design engineers to write precise specifications to keep your machinery running at peak performance. These specifications are the gold standard for operation and maintenance. Every supplier must follow OEM specs to the letter….to ensure maximum protection and efficiency in your equipment. When you buy any Quality Filtration cartridge or spin-on product, you have our guarantee that the product meets or exceeds OEM specifications for dependability and reliability. This assurance applies to every custom design or replacement filter in our broad range of global OEM applications: • Pall • Donaldson • Schroeder • Parker • PTI • Fairey-Arlon • Hydac/Hycon • Cummins Filtration • Mahle • Stauff ….and more! To cross an OEM part to Quality Filtration, remember to use Filter Finder in the top left box on this page. The online search engine allows you to find the part you need in seconds! YOU CAN TRUST QUALITY FILTRATION TO MEET OR EXCEED OEM SPECIFICATIONS IN EVERY PRODUCT.
06/17/2011 STOP THE LEAKS! A critical step in a good maintenance program is to quickly correct any potential for leaks in your system. Leaks in system or transfer lines that carry fluid can cause a huge double dip into your bottom line, including:
Think about it—the cost to replace an O-ring is small compared to the cost to replace oil or damaged equipment! Two of the primary sources of water contamination are seal leaks and heat exchanger leaks. Dissolved water (below saturation) can become free water (emulsified or in droplets) that can lead to corrosion of components. Water contamination is destructive—enabling acid formation that causes breakdown of system fluid. Leaks in reservoirs and bulk tanks are another concern. If reservoirs and tanks aren't completely sealed, invisible air contaminant can enter the fluid. Like the O-ring cost/benefit ratio—it’s cheaper to replace a breather than to compromise fluid performance and operating costs! A thorough monthly review to identify and seal leaks boosts Total Level Cleanliness …. that improves system performance and your bottom line! LET QUALITY FILTRATION SET-UP A MAINTENANCE REGIMEN TO IDENTIFY AND PREVENT LEAKS IN YOUR MACHINERY. 06/10/2011 FRESH START When you purchase new or used machinery, then is the time to begin the control and prevention of contamination. It may seem counter-intuitive that contamination can wreak havoc on a brand new system, but it can. Built-in contamination is a hidden enemy that may already inhabit your system without immediate warning signs. Before you know it, contamination can become a very serious problem for your equipment—costing you operation downtime and money. It’s important to create a safety net for your machinery right from the start. Use the following checklist to ensure protection before you begin operation: √ Prevent air ingression by installing a breather √ Conduct thorough analysis of your reservoir oil √ Drain and clean reservoir and refill with pre-cleaned oil √ Connect pump outlet to filter cart and recirculate oil √ Conduct periodic analyses until appropriate TCL is reached √ Connect and clean (through recirculation) one component at a time √ Begin your system operation at low pressure √ Set a schedule for regular maintenance review Quality Filtration can help you with the proper start-up procedures to control and prevent contamination in your machinery. Give us a call today! 06/03/2011 WHY ISO IS SO IMPORTANT Our industry is fortunate to have guidance from experts who study system cleanliness levels and recommend appropriate guidelines for maximum cleanliness. These professionals comprise the global International Standards Organization (ISO)—the most trusted authority for manufacturers, operators and service technicians on the best contamination control for your machinery. The ISO panel includes a member of our Quality Filtration staff. ISO Solid Contamination Code (ISO Standard No. 4406:1999) is the gold standard for providing optimal contamination control in your equipment. This code determines precisely how much particulate can exist in an engine system based on the amount of contaminant in 1 ml of fluid sample in three size ranges (i.e., > 4 microns, > 6 microns, or > 14 microns). A cornerstone of ISO’s Solid Contamination Code is to assign the proper cleanliness levels based on specific filtration media used in a system. That’s why it’s critical to match the ISO 4406 Cleanliness Code to the filter rating specified for your equipment for maximum protection. The chart below illustrates a typical match to a filter rating:
Let Quality Filtration be your guide to establish and maintain appropriate ISO Cleanliness Levels for your machinery. Call us today! 05/20/2011 SAVE YOUR ENERGY! Saving energy is on everyone’s agenda in today's competitive market. It’s a win-win situation. Energy conservation helps the environment—and boosts profits by controlling costs in hydraulic system maintenance. Facility managers see immediate savings with a Total Level Cleanliness (TLC) program that lowers energy consumption:
Maintaining cleaner fluid extends filter service life and reduces the expense of frequent change-outs. Remember, each filter change produces a 5 to 10 percent fluid loss, which carries extra costs in fluid replacement and associated labor.
Pumping clean fluid takes less energy than pumping contaminated fluid. Contamination affects pressure (delta p) and increases fluid viscosity, forcing pumps to work harder. With clean fluid in the system, pressure across the filter takes longer to build, reducing the strain on pumps. Implement a little TLC in your maintenance program— and save energy and costs. Call Quality Filtration today to get started! 05/13/2011
THE RIGHT CHOICE With the wide variety of filter types and media grades available, choosing the right filter for your machinery can be confusing. Yet filter selection is one of the most important things you can do to protect and enhance the performance of your equipment. Filter selection is based on several factors:
One of the most important considerations is the manufacturer’s recommendation for desired fluid cleanliness level. In cooperation with the International Organization for Standardization (ISO), manufacturers have expert help in setting expected cleanliness levels according to operating environments. As filtration experts, Quality Filtration team members regularly attend ISO conferences to help formulate global cleanliness standards. These standards enable end users to make valid comparisons of filter test data obtained from different sources to make the right filtration choices. The following table is a sample of typical ISO cleanliness codes and corresponding Quality Filtration media selection. MEDIA SELECTION FOR ISO CLEANLINESS LEVELS
Remember, Quality Filtration is the filtration expert. Let us help you select the right filtration for your machinery! 05/06/2011 MICRON MANAGEMENT One method to assess performance is to rate a filter’s ability to remove the smallest sized particle—with one micron as the unit of measurement. As its name implies, a micron is the tiniest particle that can pass through the filter media—one one-millionth of a meter or about .000394 inches. There are four basic micron ratings:
To ensure the best filtration protection, rely on Quality Filtration as your expert source to select the right filters for your machinery! 04/29/11 KNOW YOUR TYPE By reducing the number of 6 micrometers and smaller size particles in your hydraulic system, you will significantly reduce wear and increase component life. The best protection comes from choosing the right filter—one that allows the fewest wear-causing particles to get through and begin circulating within the system. Two basic filter types catch these microscopic particles—spin-ons and cartridge elements. Choosing the right filter type depends on your machinery requirements. Here’s a description of each type: § Spin-on filters are self-contained within their own housing or pressure shell and install directly to the hydraulic system through a filter head. Typical nominal working pressures are usually low. Spin-ons seldom operate in pressures that exceed 150 psig, though specialty spin-on filters have been designed to operate in 1000 psig systems. To ensure the safety and integrity of your hydraulic system, a by-pass valve may be required. § Cartridge filters operate within filter housings, the pressure vessels that contain the element. The filter housing contains a head, bowl and inlet and outlet ports that allow installation into the fluid system circuit. The installed location is the main indicator of the operating pressure. Suction and return filters typically do not exceed operating pressures of 150 PSI to 500 PSI respectively. Pressure side filters are more robust since they are installed on the outlet side of the pump with ratings ranging from 600 PSI to 6000 PSI. Remember, the most important part of a successful maintenance program is choosing a filter that traps the smallest wear-causing particles. Quality Filtration can help you determine the right filter type to do the job your equipment requires. Call us today and let’s get started! 04/22/2011 Chain Reaction Like a stack of falling dominoes, particles from abrasive wear can cause a chain reaction in your machinery that creates harmful wear and tear. Abrasive wear particles are potentially more dangerous than ordinary dust or dirt because they are “work-hardened”— over time, they become even harder than their parent surface, which sets the chain reaction in motion. These pesky particles can enter the clearance space between two moving surfaces and become lodged in one of the surfaces, and then they begin to act like cutting tools. Slowly but surely, they slice away material from the opposing surface. The particles that cause the most damage are those equal to and slightly larger than the clearance space. Ultimately, abrasive wear results in numerous and expensive problems for your equipment, including: § Dimensional changes § Leakage § Lower efficiency § Premature component failure The solution to abrasive wear is proper filtration to remove the offending contaminant. Without filtration, the particles simply recirculate and cause additional wear. Quality Filtration can help you protect your valuable machinery from abrasive wear by recommending the right filtration products to remove particles of approximately the dynamic clearance size range. Call us today and stop the chain reaction of abrasive wear ….before it gets started! 04/15/2011 SURFACE DAMAGE: A REAL CULPRIT When particles impinge on component surfaces in your hydraulic system, there can be serious consequences to the performance and life of your equipment. Just like in the process of soil erosion, erosive wear in machinery occurs due to the effects of momentum—particulate contamination removes material from the surface through continual friction. This type of wear is especially noticed in components with high velocity flows, such as servo and proportional valves. The damage is serious. Particles repeatedly striking the surface can cause denting and eventual fatigue on the surface. Clearances on components can become contaminated and restrict or prevent movement of parts within the system. Erosive wear can have a devastating impact on operation uptime AND your bottom line with issues such as: § Dimensional changes to equipment § Leakage § Lower efficiency § Generation of additional particles leading to further contamination and wear
Quality Filtration can help you design a cleanliness program that incorporates the proper filtration to prevent erosive wear in your equipment. Remember, high quality filtration is always the best solution to eliminate the culprit of surface damage.
04/08/11 A POUND OF CURE The old adage reminds us that an ounce of prevention is worth a pound of cure—and it is never more true than with the care your machinery. The cost of particulate contamination in equipment can be devastating, involving such conditions as loss of oil though internal leakage, loss of position-holding characteristics, loss of efficiency, erratic hydraulic system performance, and increased wear rates due to rust and corrosion. The worst scenario is when contamination leads to machinery replacement—at a huge cost to your bottom line. Installing proper preventive maintenance practices at your location will significantly reduce costs and increase your competitiveness. Be sure the following suggested practices are integrated into your maintenance program: • Use high efficiency filters for reservoir air breathers • Filter all NEW fluids before use (new fluid does not imply clean fluid) • Flush all systems before initial start-up (use filter carts for your stationary equipment) • Seal off hoses and manifolds during handling and maintenance • Keep all storage areas, repair areas, and implements clean Quality Filtration can help you design and maintain a preventive maintenance program that protects and enhances your equipment. Remember, an ounce of prevention . . . yields a big payoff! 4/1/2011 A Breath of Fresh Air To keep your hydraulic equipment running at maximum efficiency, system engineers design fluid reservoirs to be maintained at a positive pressure—to prevent contamination from entering the system. This sophisticated design also requires the use of high efficiency filters in reservoir air breathers to trap airborne contaminants like dust and particulate matter that can do serious damage in your machinery. It is an established fact that much of system particulate contamination can be attributed to poorly maintained breather elements in system reservoirs. That’s why it’s critical to install and maintain proper filtration—with a removal rating as good as a system filter. There are important benefits to adding high efficiency air breather filters in fluid reservoirs. They protect your hydraulic system by eliminating build-up of ingressed contaminant and extending service life . . . . benefits that yield significant improvements to your bottom line: § Reduced operating costs § Increased competitive advantage You can rely on Quality Filtration to ensure that airborne contamination does not get through the reservoir air breathers in your machinery. Let us help you integrate high efficiency filtration into your preventive maintenance program today—and stop contamination at its source. 3/25/2011 NEW FLUIDS NEED CLEANING TOO! It may seem contrary to reason that new fluids in your machinery need to be filtered first—but they do. New oil can be tainted with built-in/implanted contaminant from the manufacturing source due to poor housekeeping or dirty material and handling equipment. In your maintenance Cleanliness Program, adding new fluids without the benefit of filtration, or with only minimal filtration, can undermine your entire maintenance program. A good rule of thumb to observe is ALWAYS filter new fluids before use. An investment in high quality, cost-effective filtration up front will cost substantially less than the effects of oil contamination in fluids, including:
Because of cost controls, it has become common practice to bypass this important maintenance step. But remember, it is critical to prevent contaminated oil from entering your equipment operating system. Quality Filtration can help you improve the cost efficiency of this work by specifying high-performance filtration that can quickly achieve your target cleanliness codes. Talk to us about cleaning new oil before it starts to work in your machinery! 3/18/2011 EFFICIENCY EXPERTS Your machinery may need an efficiency expert to improve your bottom line! Consider Quality Filtration as your best efficiency expert—with filters that provide ßx(c)> 1000 removal efficiency. High efficiency filters ensure cleaner fluids in your equipment, longer component life, maximum system reliability, and lower operating costs for your business. That’s because Quality Filtration filters capture more wear-causing particles as fluids pass through the higher efficiency media, keeping contamination from re-circulating throughout the system. Superior filtration doesn’t just clean the fluids in your machinery—it reduces your costs by reducing wear. Contamination in your hydraulic system carries a staggering price tag, including: • Maintenance cost increases • Downtime increases • Fluid replacement increases • Disposal cost increases • Unsafe practice increases Different machinery requires different filtration…. micron ratings, particulate removal efficiency, flow rates, pressure rating, element types, construction materials, and circuit locations. Quality Filtration will help you select the right filtration to meet your specific machinery’s needs. Remember, a properly sized, installed and maintained filter in your hydraulic circuit supports your system’s functionality. Maybe it’s time to call the Efficiency Experts! 03/11/2011 GET INTO ANALYSIS A Total Level Cleanliness program in your facility can extend the life cycle of fluids and hydraulic systems they support. The best way to start a cleanliness initiative is to identify and document target cleanliness standards for fluids in each corresponding piece of equipment in your location. The guideline is ISO Code ISO4406-1999, the Method of Coding the Level of Contamination by Solid Particles—if you don’t have a copy, your OEM can provide it. Another important step in preventive maintenance is to establish an oil analysis program with regularly scheduled sampling. Oil analysis provides critical clues about equipment fluids and hydraulic systems through these three valuable indicators:
This information helps you take the appropriate proactive or reactive steps to support fluid and system performance. For best results, check fluids monthly and keep accurate records—the value of tracking data maximizes over time. For example, changes in element compounds such as iron or brass in fluid could signal equipment wear that is entering and contaminating your system. Quality Filtration can help you establish an oil analysis schedule and data tracking plan. When you identify contaminants early and use the right filtration products to eliminate them, you can prevent subsequent problems. If budget limitations prevent monthly fluid analysis, begin with a quarterly analysis. An ounce of prevention is worth a pound of cure—costs related to spectroanalysis are minimal compared to costs of fluid replacement or equipment repair. It’s time to get into oil analysis! 3/4/2011 KEEPING THE WATER OUT Water contamination in hydraulic, lubrication and dielectric oils can be a nightmare for your equipment. Not only does water attack your machine directly by promoting oxidation of the lubricant’s base oil and reducing viscosity, it also attacks the chemical additives in system fluid. This chemical attack is called hydrolysis, and it can produce corrosive byproducts that lead to excessive wear and eventual equipment failure. The primary sources of water contamination are heat exchanger leaks, seal leaks, condensation of humid air, inadequate reservoir covers, and temperature drops that lead to dissolved water (i.e., below saturation) becoming free water (i.e., emulsified or in droplets). Both free and dissolved water can cause critical component wear and oil degradation. The goal of a good maintenance regimen is to get and keep the water out—to ensure absolutely clean and dry oil. Quality Filtration can provide you with the best filtration options to eliminate and control water contamination in your machinery. Remember, water contamination can seriously compromise your equipment’s performance. By keeping the water out, you can: § Minimize operation downtime § Optimize equipment efficiency § Extend component life § Maximize profitability 2/24/11 OE Filter Specs: Selecting the Right Hydraulic Filter Industrial, mobile, and lubrication system OEMs establish standard hydraulic filter specifications to ensure proper maintenance of your machinery. These specifications are very important to follow in choosing the correct filtration for use in your machinery. Complete filter specifications should include:
Quality Filtration can work with you to select the product that meets your OE hydraulic filter specs. Inadequate filtration can seriously compromise the performance of your equipment and lead to a series of problems, including reduced reliability (i.e., Mean Time Between Repair), decreased production, increased scrap, and higher cost. Let Quality Filtration help you choose the right filtration to keep your machinery running in tip-top shape! 2/18/11 Strength Matters The strength and durability of your machinery filter is important to stop contamination and keep equipment operating longer and stronger. Quality Filtration type “A” filter media contains five layers that effectively filter out contamination to ensure maximum machinery protection. Our innovative wire-backed product is designed in cooperation with top media producers to ensure that each layer does its specific job as contaminant passes through the five layers: 1. Downstream mesh with epoxy coated wire provides strength, pleat separation, and rigidity 2. Downstream scrim of synthetic spun-bonded material protects and cushions the media from the wire mesh 3. Microglass media and other synthetic fibers (in both single and dual phase design) increase dirt-holding capacity 4. Upstream scrim of synthetic spun-bonded material protects and cushions the media from the wire mesh 5. Upstream mesh with epoxy coated wire provides strength, pleat separation, and rigidity Remember, high quality filtration is critical to effective machinery operation and protection. You can always depend on Quality Filtration for the best products in the industry to get the job done! 2/11/2011 Contamination is the worst enemy of your expensive machinery. It can wreak havoc in your system that leads to reduced operation uptime and increased maintenance expense. Harmful contamination affects many areas of your equipment, each causing severe problems, including: Surface scoring and wear that results in:
Fine particle build-up that results in:
Fluid degradation that results in:
The best way to prevent and control contamination is by being proactive. Let Quality Filtration help you design a preventive maintenance program that includes the right filtration products for your machinery. High quality hydraulic filtration will reduce wear, component failure and overall system malfunction . . . . and it will control particulate contamination on a continuous basis to keep your machinery always operating at optimal levels. 2/4/2011 Eliminate guesswork when selecting the correct hydraulic filter for your machinery. Be sure to choose the right filter for your needs based on the following factors:
Remember, TLC is the recommended cleanliness level at which your machine should operate. The ISO Solid Contamination Code (ISO Standard No. 4406:1999) specifies how much particulate can exist based on the amount of contaminant in 1 ml of fluid sample in three size ranges (i.e., > 4 microns, > 6 microns, or > 14 microns). The correct filter for your machinery should always correspond to the filter rating specified for your particular equipment. Quality Filtration can help you select the right filter, including matching filter specs for fluid compatibility, pressure flow drop, dirt capacity, collapse pressure, flow fatigue resistance, and other technical requirements. The right filter makes all the difference in performance and protection! 01/24/2011 To ensure top performance from your machinery, always choose a top quality filter. A faulty filter can compromise filtration effectiveness and hinder contamination control. When evaluating the quality of a filter, issues to look for include: § Stretched pleats in media § Small holes in media § Incomplete edge seal § End cap bonding If you detect poor quality construction, it signals the need for filter replacement to adequately support the filtration requirements of your machinery. Pleat Packing
Typical Pleated Fibrous Cross-Section of Places of Pleat Deformation Medium and Support Mesh Typical Pleated Element Under Differential Pressure As an ISO 9001: 2008 certified supplier, Quality Filtration engineers and manufactures all our products using world-class quality processes. It is your assurance that every Quality Filtration product provides the maximum strength, durability and reliability required to fully protect your machinery. 01/17/2011 One of the disadvantages of oil sampling is the margin of error that can occur during the sampling process. There are several sources of sampling errors*, including: • Leaving sample bottles open too long • Using previously contaminated bottles • Failure to properly flush sampling ports and lines Be sure to follow oil sampling instructions precisely to secure the most accurate reading. The wrong oil sample can lead you to use the wrong filtration for your machinery. Quality Filtration can help you with all these opportunities. *Sampling errors can present higher contamination readings than actual.
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Quality Filtration has completed its certification for ISO 9001:2008