There is an old saying, “the proof is in the Pudding.”  What does this mean?  This is an old proverb that has joined the microwave generation!  It has been clipped down from the original phrase which was: ‘The proof of the eating is in the eating.”  It means that the true value or quality of something can only be judged when it’s put to use or in this case, tried and tested.  The meaning is often summed up as: “Results are what counts…it’s not how you start, but how you finish.”

For years hydraulic users have known that the number one cause of hydraulic component failure is contamination.  It has been reported that anywhere from 75%-90% of failures are related to contamination.  It has also been proven that 85% of those failures can be solved with proper filtration.

QMedia offers superior protection from contaminants that can cause costly component failures.  Its microglass fibers are smaller in diameter than those in typical cellulose media to provide much lower restriction.  QMedia also has greater efficiency and higher capacity.  You can always rely on QMedia to protect your valuable equipment from contamination.

ISO Cleanliness Code ISO4406-1999

The ISO cleanliness code is used to quantify particulate contamination levels per milliliter of fluid at 3 sizes 4µ[c], 6µ[c], and 14µ[c]. The ISO code is expressed in 3 numbers (ex. 19/17/14). Each number represents a contaminant level code for the correlating particle size. The code includes all particles of the specified size and larger. It is important to note that each time a code increases the quantity range of particles is doubling.

Understanding ISO Cleanliness Codes

When setting target ISO fluid cleanliness codes for hydraulic and lubrication systems it is important to keep in mind the objectives that you are trying to achieve. Such as maximizing equipment reliability and safety, minimizing repair and replacement costs, extending useful fluid life, and minimizing production down-time are attainable goals. Once a target ISO cleanliness code is set, following a progression of steps to achieve that target, monitor it, and maintain it should be easy.

Below is the table out of ISO 4406:1999.  It shows the code number associated with the contamination level.

ISO Cleanliness Codes at work

Now that we have an understanding of what ISO Cleanliness Codes are we should look at what happens when you put these numbers to use.  We have tested our new QMEDIA in the lab per ISO Code 16889-1999 and found that we were getting excellent dirt capacity and Beta numbers; but we wanted to see how our media would hold up in a real world application.

For this we needed to find a resource willing to test the elements and share with us the results.  We partnered with Rob Estill; he is an, "Oil Purification Specialist”, out of Atlanta Georgia.  He set us up to be used on some Oil reclamation trucks.  Below is an outline of how the tests were processed and the results that came about.

Truck Number One

Truck No.1: Initial test of QMEDIA on 6x36” elements using one micron media, 6-10-08 on a truck owned by an oil reclaimer in South Carolina. (Note: Operating conditions and process vary from truck to truck and from customer application to customer application)

Operating conditions:

20 GPM at 150 degree F, Shell Tellus 68 Hydraulic Oil. Batch Size = 1025 gallons.

Starting ISO 23/22/20 water content >1% = 10,000 PPM.

Operating Process:

The oil is brought on board the truck via a 2" air diaphragm pump suctioning from the customer's "dirty oil tank", pumping through two bag filters in series (100micron>50micron), then continues under low pressure to a centrifuge for gross water and solids removal, then continues through four 36" vessels in series containing the subject 1micron filters, then continues through two vacuum dehydrators in series for further water removal / polishing, then continues through two more 36" vessels in series containing the subject QMEDIA1 micron filters, then continues into an "on board" storage tank. This is considered the "first pass". The operator then switches the valving so the process is repeated (less the bag filters) as the tank contents are transferred through the "treatment train" to a second "on board" tank. This is the "second pass". This process is repeated between the two tanks for a "third pass" and "fourth pass". At this point the "cleanliness numbers" are met, and the batch is "done", verified by the 'on board' particle counter. A sample is taken for independent lab analysis / verification. Finally, the batch is pumped off of the truck through a final 36" vessel containing the subject QMEDIA 1 micron filter, into the customer's "clean oil" storage tank

Target Oil Cleanliness (Specification):

17/15/13 with <50 PPM remaining total water content = .005%

Results: Four batches were run that day = standard throughput

Typical numbers achieved with the Competitors 1 micron filter were 12/11/7 after 4 passes.

The Quality Filtration numbers, after the same four passes were:

Batch #1:  12/7/6

Batch #2:    9/8/4

Batch #3:    9/7/4

Batch #4:    8/5/4

Generally speaking, and  being conservative, the filters were similar on the first pass, but the QMEDIA's elements got better numbers much quicker on ensuing passes and lasted 25% longer.

Truck Number Two

This truck runs the same flow path as Truck Number one. The flow rate is 15 GPM on this truck. This truck services many different oils from very light hydraulic with a tight specification, to heat treat and cutting oils (very dirty).

Here are the operator’s comments about the QMEDIA elements:

"The QMEDIA 1 Micron, 12 Micron and 25 Micron elements (everything he used) last at least twice as long as the competitor’s elements. He achieves his numbers in 15 to 20 minutes vs. 1 hour (if at all) with the competitors seeing single digit ISO codes with the QMEDIA 6x36 elements, typical 10/8/4 where he could never get below 17/14/9 with the competitors elements.

Conclusion

In this industry time is money; and the cleaner you get the fluid, the faster is money in your pocket.  We have developed what we believe is the right solution for oil reclaimers; and have tested this media with ISO standards and the real world, having excellent results in both situation.

Our breakthrough media element technology is revolutionizing the oil reclamation industry is real, or as we should say, “The proof is in the Pudding.

Ivan Sheffield                            Rob Estill
Vice President                          Oil Purification Specialist
Quality Filtration, LLC              Cell 770-841-3815