Pocket

Book
Enabling a Greener Future
Businesses worldwide are challenged
to conserve energy and resources while
protecting the environment. Pall Corporation
helps customers achieve these goals by
providing leading-edge filtration and
separation technologies that purify and
conserve water, consume less energy, make
alternative energy sources possible and
practical and minimize emissions and waste.
Our collective efforts are enabling a greener,
safer, more sustainable future.
www.pall.com/green

2
Equipment Life Expectancy Factors
A study by Dr. E Rabinowicz at M.I.T. observed that 70% of component
replacements or ‘loss of usefulness’ is due to surface degradation. In hydraulic
and lubricating systems, 20% of these replacements result from corrosion with
50% resulting from mechanical wear.

100 %
LOSS OF USEFULNESS
0 %

SURFACE DEGRADATION (70 %)

ACCIDENTS OBSOLESCENCE
(15 %) (15 %) MECHANICAL WEAR (50 %)
CORROSION (20 %)
ABRASION I FATIGUE I ADHESION I EROSION

Presented at the American Society of Lubrication Engineers, Bearing Workshop.

Sources of Contamination
Built-in contaminants External ingression:
from components: • Reservoir breathing
• Assembly of system • Cylinder rod seals
• Cylinders, fluids, hydraulic motors, • Bearing seals
hoses and pipes, pumps, reservoirs, • Component seals
valves, etc. Contaminants introduced
Generated contaminants: during maintenance:
• Operation of system • Disassembly/assembly
• Break-in of system • Make-up oil
• Fluid breakdown

The Micrometre “µm”

‘Micron’ = micrometre = µm Human hair
Limit
The micrometre is the standard for of vision
measuring particulate contaminants Clearance
in lubricating and fluid power systems. size
particle
1 micron = 0.001 mm (0.000039 inch) Unit of
10 micron = 0.01 mm (0.0004 inch) reference
Smallest dot you can see with the
naked eye = 40 µm 1 µm 5 µm 40 µm 75 µm

Thickness of a human hair = 75 µm “You cannot manage what you do not measure”

3
Mechanisms of Wear
Abrasive Wear LOAD

Dynamic Fluid Film

Thickness (µm)

Abrasive Wear Effects: Typical components subjected

• Dimensional changes to Abrasion:
• Leakage • All hydraulic components: pumps,
• Lower efficiency motors, spool valves and cylinders
• Generated wear: more wear • Hydraulic motors
• Journal bearings

Adhesive Wear
LOAD

Surfaces weld and shear

Adhesive Wear Effects: Typical components subjected

• Metal to metal points of contact to Adhesion:
• ‘Cold Welding’ • Hydraulic cylinders
• Adhesion and shearing • Ball bearings
• Journal bearings

4
Mechanisms of Wear (continued)
Fatigue Wear
LOAD LOAD

Particle caught, surfaces After ‘N’ fatigue cycles, cracking spreads,

dented and cracking initiated surface fails and particles are released

Fatigue Wear Effects: Typical components

• Leakage subjected to Fatigue:
• Deterioration of surface finish • Journal bearings
• Cracks • Hydrostatic bearings
• Rolling element bearings
• Geared systems

Erosive Wear

Particles impinge on the

component surface or edge
and remove material due to
momentum effects

Erosive Wear Effects: Typical components

• Slow response subjected to Erosion:
• Spool jamming/stiction • Servo valves
• Leakage • Proportional valves
• Solenoid burnout • Directional control valves

5
Typical Dynamic (Operating) Clearances
Component Details Clearances

Servo 1 - 4 µm

Valves Proportional 1 - 6 µm

Directional 2 - 8 µm

Variable Volume Piston to Bore 5 - 40 µm

Piston Pumps Valve Plate to Cylinder Block 0.5 - 5 µm

Tip to Case 0.5 - 1 µm

Vane Pumps
Sides to Case 5 - 13 µm

Tooth Tip to Case 0.5 - 5 µm

Gear Pumps
Tooth to Side Plate 0.5 - 5 µm

Ball Bearings Film Thickness 0.1 - 0.7 µm

Roller Bearings Film Thickness 0.4 - 1 µm

Journal Bearings Film Thickness 0.5 - 125 µm

Seals Seal and Shaft 0.05 - 0.5 µm

Gears Mating Faces 0.1 - 1 µm

*Data from STLE Handbook on Lubrication & Tribology (1994)

9 µm

LOAD

Dynamic Clearance 1µm

Load, Motion and Lubricant

6
Fluid Analysis Methods for Particulate
Method Units Sampling Benefits Limitations

Optical Number/mL/ Off-line; Provides size Sample

Particle Cleanliness Laboratory distribution. preparation time
Count code Unaffected by fluid
opacity, water and
air in fluid sample

Automatic Number/mL/ Off-line; Fast and Sensitive to ‘silts’,

Particle Cleanliness “Sip” from repeatable water, air and gels
Count (APC) code containers;
On-line

Filter / Mesh Cleanliness Off-line; Not affected by Does not

Blockage code “Sip” from the presence of provide the size
Technique containers; air or free water in distribution of the
On-line the fluid sample contamination

Patch Test Visual Off-line; Rapid analysis Provides

and Fluid comparison/ Point of use of system fluid approximate
Contamination Cleanliness cleanliness levels contamination
Comparator code in field. Helps to levels
identify types of
contamination
Ferrography Scaled Off-line; Provides basic Low detection
number of Laboratory information on efficiency on
large/small ferrous and non-magnetic
particles magnetic particles e.g.
particles brass, silica
Spectrometry PPM Off-line; Identifies and Limited detection
Laboratory quantifies above 5 µm
contaminant
material

Gravimetric mg/L Off-line; Indicates Cannot distinguish

Laboratory total mass of particle size. Not
contaminant suitable for moderate
to clean fluids. i.e.
below ISO 18/16/13

7
Monitoring and Measurement Equipment
Automatic Particle Counters (APCs) Principle:
Automatic particle counters are the As a particle passes through the light
most common method used by beam, the light intensity received
industry for particulate contamination by the photo detector is reduced in
analysis. proportion to the size of the particle.

Laser Light Beam

Flow

Flow
Blocked Light

ctor
Dete
Photo

Mesh Blockage Devices Principle:

Filter/mesh blockage devices are Filter/mesh blockage devices determine
an alternative to APCs, especially in particulate contamination levels by
conditions where the fluid is opaque passing a specifed flow of sample fluid
or where free water or air is present in through a series of calibrated mesh
the fluid. screens in a specified sequence. Pressure
drop build-up (or flow degradation) is
dependent on particulate contamination
levels. The mesh is cleaned by
Calibrated mesh filter (X µm) backflushing.

Flow

Flow

∆P
8
Monitoring and Measurement Equipment
Obtaining accurate and reliable fluid cleanliness data quickly in order to detect
abnormal contamination is a key factor in ensuring the efficiency of industrial
processes and reducing downtime.

Reliable Monitoring Solutions...

...Whatever the Conditions...Whatever the Fluid

Pall Cleanliness Monitors

Provide an accurate, reliable
assessment of system fluid cleanliness
• Proven mesh blockage technology
• On-line and off-line modes of
operation
• Results not affected by free water
or undissolved air contamination
• Designed for use with dark or cloudy
PCM500 fluids
• ISO 4406 (3-digit Code), or AS4059
(NAS1638) data output
• Water sensor option
Mesh Blockage

Flow

Flow
∆P

α PCM500

α: Rate of pressure drop increase

(slope) across the mesh is
Time based on the level of particulate
contamination in the fluid (at
constant flow and temperature)

9
 Understanding the ISO 4406 Cleanliness Code
Range Code*
20,000 20,000
15,000 21
10,000 10,000
Particle Count
Number of Particles Greater than Size Per Millilitre

20
5,000 5,000 Summary
4,000
19 Particle
3,000
2,500 ISO
2,000
1,500 18 count per 4406
1,300
1,000
17 mL greater Range
640 than size code
500
400 16
300 320
200 15 4 µm(c)230 15
150 160
100 14
80
50 13 6 µm(c) 70 13
40 40
30 12
20 20
15 11
10 10
10 14 µm(c) 7 10
5.0 5
4.0
3.0 9 (c) designates ‘certified’
2.5 calibration per ISO 11171,
2.0
1.5 8 traceable to NIST
1.3
1.0
7 * Note: each increase in
0..6
range number represents
0.5
0.4 6 a doubling of the
2 5 15 Microscope particle sizes, µm contamination level.
4 6 14 APC particle sizes, µm (c)

Fluid cleanliness levels found in modern hydraulic systems (typically ISO code
<15/13/10 - see the area highlighted in orange) requires on-line monitoring.

The ISO Cleanliness code references the number of particles greater than 4, 6
and 14 µm(c) in one mL of sample fluid.
To determine the ISO Cleanliness code for a fluid, the results of particle counting
are plotted on a graph. The corresponding range code, shown at the right of
the graph, gives the cleanliness code number for each of the three particle
sizes. For the example above the data becones ISO 15/13/10. Where there is not a
requirement for data at the first size or the technique used does not give this data
e.g. microscope counts and PCM data,”-” is used, e.g. ISO -/13/10.
The ISO 4406 level for a system depends on the sensitivity of the system to
contaminant and the level of reliability required by the user. A method for
selecting the level for an individual system (called the “Required Cleanliness
Level” or “RCL”) is described on Pages 37 and 38.

10
ISO 4406 Cleanliness Code 13/11/09
Sample Volume: 25 mL using Ø25 mm membrane
filter or 100 mL using Ø47 mm
membrane filter
Magnification: 100x
Scale: 1 division = 10 µm

Particle Count Summary

Particle ISO SAE
Size Count Range 4406 AS40591,2
per mL Code (NAS1638)
>4 µm(c) 52 13 3A
>6 µm(c) 16 11 3B
>14 µm(c) 4 09 3C

Contaminants: Description
Some black metal System with ß5(c)>1,000 wear control filtration

ISO 4406 Cleanliness Code 19/16/11

Sample Volume: 25 mL using Ø25 mm membrane
filter or 100 mL using Ø47 mm
membrane filter
Magnification: 100x
Scale: 1 division = 10 µm
Particle Count Summary
Particle ISO SAE
Size Count Range 4406 AS40591,2
per mL Code (NAS1638)
>4 µm(c) 4,200 19 10A
>6 µm(c) 540 16 8B
>14 µm(c) 20 11 9C

Contaminants: Bright metal, Description

Black metal, Silica, Plastics System with inadequate filtration.
1
AS4059 is based on 100 mL. 2AS4059 classes are for the 3 ISO 4406 size ranges

11
ISO 4406 Cleanliness Code 21/19/16
Sample Volume: 25 mL using Ø25 mm membrane
filter or 100 mL using Ø47 mm
membrane filter
Magnification: 100x
Scale: 1 division = 10 µm
Particle Count Summary
Particle ISO SAE
Size Count Range 4406 AS40591,2
per mL Code (NAS1638)
>4 µm(c) 12,345 21 11A
>6 µm(c) 3,280 19 11B
>14 µm(c) 450 16 11C

Contaminants: Silica, Black Description

metal, Bright metal, Plastics New oil from barrel

ISO 4406 Cleanliness Code 22/20/19

Sample Volume: 25 mL using Ø25 mm membrane
filter or 100 mL using Ø47 mm
membrane filter
Magnification: 100x
Scale: 1 division = 10 µm

Particle Count Summary

Particle ISO SAE
Size Count Range 4406 AS40591,2
per mL Code (NAS1638)
>4 µm(c) 31,046 22 12A
>6 µm(c) 7,502 20 12B
>14 µm(c) 1,960 19 12C

Contaminants: Bright metal, Description

Black metal, Rust, Silica, Plastics New system with built-in contaminants
1
AS4059 is based on 100 mL. AS4059 classes are for the 3 ISO 4406 size ranges
2

12
On-line Particulate Cleanliness Monitoring
We cannot control what we cannot measure
Modes of Analysis
Flow
Off-line Off-line
analysis analysis

Cleanliness
Monitor
Pre-cleaned
sampling
bottle

Comparison of on-line counting and off-line counting

25
ISO Code - Off-line counting

4µm (c)
20

6µm (c)
15

10
14µm (c)

5
Theoretical
0
0 5 10 15 20 25
ISO Code - On-line counting

Source : Tampere University of Technology, Finland

At the higher contamination levels (higher ISO codes) there is little difference
between the two modes of analysis, but as the oil gets cleaner, the level
recorded by the off-line analysis inaccurately shows the oil to be dirtier
compared to on-line analysis.

Factors influencing the accuracy of the off-line analysis:

• Introduction of environmental dirt into sample bottle
• Incorrect cleaning of sample bottle
• Inadequate flushing of sampling valve
• Effectiveness of sampling process

13
Fluid Sampling Procedure
Introduction
There are four methods for taking fluid samples, three for extracting samples
and one for on-line analysis. Method 1 is the best choice followed by Method 2.
Method 3 should only be used if there is no opportunity to take a line sample.
DO NOT obtain a sample from a reservoir drain valve. Always take the sample
under the cleanest possible conditions and use pre-cleaned sample bottles.
If there are no line mounted samplers, fit a Pall sampling device to the
Pall filter.

Method 1 Method 2
Small ball valve with PTFE Valve of unknown contamination
or similar seats, or a test point shedding capabilities
1. Operate the system for at least 30 1. Operate the system for at least 30
minutes prior to taking sample in minutes prior to taking sample
order to distribute the particulate in order to distribute particulate
evenly. evenly.
2. Open the sampling valve and flush 2. Open the sampling valve and
at least 1 litre of fluid through the flush at least 3 to 4 Litres of fluid
valve. Do not close the valve after through the valve. (This is best
flushing. accomplished by connecting the
3. When opening the sample bottle, outlet of the valve back to the
be extremely careful not to reservoir by using flexible tubing).
contaminate it. Do not close the valve.
4. Half fill the bottle with system fluid, 3. Having flushed the valve, remove
use this to rinse the inner surfaces the flexible tubing from the valve
and then discard. with the valve still open and fluid
5. Repeat step 4 a second time flowing. Remove the cap of the
without closing the valve. sample bottle and collect sample
according to instructions 4 to 6 of
6. Collect sufficient fluid to fill 3/4 Method 1.
of bottle (to allow contents to be
redistributed). 4. Cap the sample immediately and
then close the sample valve.
7. Cap the sample immediately and Caution: Do not touch the valve
then close the sample valve. while taking the sample.
Caution: Do not touch the valve
while taking the sample. 5. Label the sample bottle with
system details and enclose in a
8. Label the sample bottle with suitable container for transport.
system details and enclose in a
suitable container for transport.

14
Fluid Sampling Procedure (continued)

­­­­­­Method 3 Method 4
Sampling from Reservoirs On-line Analysis
and Bulk Containers
This procedure is for portable
Applicable only if Methods instruments that have to be connected
1 and 2 cannot be used to the system
1. Operate the system for at least 30 1. Check that the sampling position
minutes prior to taking sample satisfies the reason for sampling and
in order to distribute the particles the sampling valves/points complies
evenly. with the requirements of Method 1;
2. Clean the area of entry to the reservoir 2. Check that there is sufficient supply
where sample will be obtained. pressure to avoid instrument
3. Flush the hose of the vacuum starvation or cavitation;
sampling device with filtered (0.8 µm) 3. Operate the system for at least 30 min
solvent to remove contamination that
may be present. 4. Remove any covers, caps etc from
the sampling position and, if practical.
4. Attach a suitable sample bottle to clean the exterior of the connection
the sampling device, carefully insert point with a clean solvent.
the hose into the reservoir so that it is
mid-way into the fluid. Take care not 5. Carefully connect the instrument to
to scrape the hose against the sides the sampling point and minimise the
of the tank or baffles within the tank generation of dirt
as contamination may be sucked into 6. Operate the instrument in accordance
the hose. with the manufacturer’s instructions
5. Pull the plunger on the body of the and flush the sampling lines and
sampling device to produce vacuum instrument with a suitable volume of
and half fill the bottle. fluid, as specified by the instrument
manufacturer. If not a volume
6. Unscrew bottle slightly to release equivalent to 10 times the volume of
vacuum, allowing hose to drain. the connection pipes and instrument
7. Flush the bottle by repeating steps is appropriate;
4 to 6 two or three times. 7. The analysis shall be continued until
8. Collect sufficient fluid to 3/4 fill the the data from successive samples is
sample bottle, release the vacuum either:
and unscrew the sample bottle. a) within the limits set by the
mediately recap and label the sample instrument manufacturer; or
bottle. b)the difference is less than 10 % at
the minimum particle size being
monitored if the required output is
particle count; or
c) the same cleanliness code has
been recorded.

15
 Water Contamination in Oil
Water contamination in oil systems causes:
• Oil breakdown, such as additive precipitation
and oil oxidation
• Reduced lubricating film thickness
• Accelerated metal surface fatigue
• Corrosion
Sources of water contamination:
• Heat exchanger leaks
• Seal leaks
• Condensation of humid air
• Inadequate reservoir covers
Corrosion in the resevoir
• Temperature reduction (causing dissolved
water to turn into free water)
• Equipment cleaning via high pressure hose

Typical Water Saturation Curve

Oil Temperature (°F)
0 77 122 167
100
Water Concentration (PPM)

150 Free
Water
100

50 Dissolved
Water
0
0 25 50 75 Dissolved, emulsified
and free water in oil
Oil Temperature (°C)
Ref: EPRI CS-4555 Turbine oil
Water Concentration
To minimize the harmful effects of
10,000 PPM 1%
free water, water concentration in
oil should be kept as far below the 1,000 PPM 0.1%
oil saturation point as possible.
100 PPM 0.01%

16
Water Content Analysis Methods
Method Units Benefits Limitations

Crackle Test None Quick indicator Does not permit

of presence of detection below
free water saturation

Chemical Percentage or A simple Not very accurate

(Calcium hydride) PPM measurement for dissolved water
of water content

Distillation Percentage Unaffected by Limited accuracy

oil additives on dry oils

FTIR Percentage or Quick and Accuracy does not

PPM inexpensive permit detection
below 0.1%
(1,000 PPM)

Karl Fischer Percentage or Accurate at Not suitable for

PPM detecting low high levels of
levels of water (10 water. Can be
- 1,000 PPM) affected
by additives

Capacitive Sensor Percentage of Accurate at Cannot measure

(Water Sensor) saturation or PPM detecting water levels above
dissolved water saturation (100%)
(0 - 100%
of saturation)

17
Water Sensor Technology
Water contamination in fluids can cause numerous problems such as additive
depletion, oil oxidation, corrosion, reduced lubricating film thickness, microbial
growth, and reduction of dielectric strength. Water sensors incorporate a probe
that can be directly immersed in the fluid to monitor dissolved water content
and temperature.
A variety of water sensor models are available including explosion proof options.
Contact Pall to determine the most appropriate model for your application.

WS12
WS18DS In-Line
In-Line Water
Water Sensor Sensor

Capacitive Sensor
Sensing Porous
Polymer Top
Electrode Protective
Housing
WS19
Portable
Water Sensor

Electrical
Connections
Main
Electrode
Glass
Substrate

Capacitive Sensor Principle:

The electrical resistance of the dielectric polymer changes as the relative
humidity changes. The water sensor probe is protected to avoid erratic results
from solid contaminants settling on the porous top electrode.

18
Operating Principle of Pall Fluid Conditioning Purifiers
Principle: Mass transfer by evaporation under vacuum

Inlet Outlet
Contaminated fluid Exhaust air

Vacuum:
Expansion
of air causes
the Relative
Very thin Humidity to
film of oil Dry air
decrease

Inlet
Pvacuum
Vacuum Chamber Ambient air
≈ -0.7 bar

Outlet
Dry fluid

Removing free water is never enough!

1 Typical Oil
Saturation
Water Content (PPM)

Curve

5 2
Oil Saturation
Oil Saturation Point at Initial
Point after Temperature
Cooler

4 3

Oil Temperature Temperature Initial Oil

after Cooler Temperature
1 Initial water content is above saturation (free 4 Water content achieved with mass transfer
water). dehydration remains below the oil’s saturation
2 Maximum water removal capability of point even after oil is cooled. This prevents the
“free water removal” devices (coalescers, formation of harmful free water.
centrifuges, etc.) is to the oil’s saturation point. 5 If only free water is removed at initial
3 Water content achieved with mass transfer temperature, when oil is cooled the amount
dehydration is significantly below the oil’s of harmful free water in the oil can increase
saturation point. significantly.

19
Pall Portable Oil Purifiers

Pall HDP10 Pall HNP023 Pall HNP076

HDP Series HNP Series HNP Series

Pall oil purifiers are available in a wide range of flowrates:

from 10 L/min to 200 L/min (2.6 USgpm to 52.8 USgpm).

Contact Pall for special variants such as explosion proof,

ATEX, or fully remote controlled purifiers

Oil Purifier Features Typical

• Removes 100% free and up to 90% dissolved water Applications
• Removes 100% free and up to 90% dissolved gases • Hydraulic oils
• Unlimited water and air removal capacity • Lubrication oils
• Wide fluid compatibility • Dielectric oils
• Fully portable for multiple site application • Phosphate-
• Simple to operate esters
• No heating required - does not burn oils • Quench oils
• Low power consumption
• Low operating costs
• Automatic control of the main operating parameters
• Robust and reliable under harsh conditions
• Easy maintenance

20
Lube and Hydraulic Filter Locations
Pressure Line Reservoir Air Breather
• To stop pump wear debris from • To prevent ingression of airborne
travelling through the system particulate contamination
• To catch debris from a catastrophic • To extend system filter element
pump failure and prevent secondary service life
system damage • To maintain system cleanliness
• To act as a Last Chance Filter (LCF) Additional filters should be
and protect components directly placed ahead of critical or
downstream of it sensitive components
Return Line • To protect against catastrophic
• To capture debris from component machine failure (often non-bypass
wear or ingression travelling to the filters are used)
reservoir • To reduce wear
• To promote general system cleanliness • To stabilize valve operation
Kidney loop/off-line (prevents stiction)
• To control system cleanliness when Flushing Filter
pressure line flow diminishes • To remove particles that have been
(i.e. compensating pumps) built-in to the system during assembly
• For systems where pressure or return or maintenance before start-up
filtration is impractical • To remove large particles that will
• As a supplement to in-line filters to cause catastrophic failures
provide improved cleanliness control • To extend ‘in-service’ filter element life
and filter service life in high dirt
ingression systems

Return line series

off-line loop High
pressure
series

Air
filter Return line
series
In-tank
series

Reservoir

Fluid conditioning purifier

21
 Pall Total Cleanliness Management (TCM) for Industrial Manufacturing
Enhancing Fluid Cleanliness, Advancing productivity, Assuring Reliability

Pall TCM program Pall Purification,

for process improvement

Clarification Solution
KEY TARGETS
Customized solutions

Fluid Cleanliness Component Cleanliness

Management Management Pall Diagnostics
Solution

Water Supply

Improved Enhanced Improved Enhanced Coolant

Increased Water Supply
Product Equipment Health & Environment Delivered Oil /
Production
Quality Reliability Safety Protection Process Fluid

Wash Fluids

Pall provides customized contamination Parts Machining

control solutions to improve system
performance and reduce operating costs.
Challenge us to deliver sustainable
and cost-effective solutions to all Parts Bulk Oil /
Process Process Fluid
Washing
your contamination problems. Water Operations
Treatment
Hyd & Lube
Systems

Waste
Waste Disposal
Disposal

Examples of applications where the Pall TCM

program can be implemented
Typical Fluids
• Parts washing • Coolants • Lubrication oils
fluids • Water glycols • Dielectric oils
• Cutting fluids • Fuels • Phosphate-
• Process fluids • Solvents esters
• Water • Hydraulic oils • Quench oils

22
23
Short Element Life Checklist

OLD APPLICATION OR
NEW OLD
NEW APPLICATION

INCREASE
CHECK FILTER Clean ∆P SURFACE AREA HAS ANYTHING
SIZING too high - Longer Bowl ALTEREDINTHESYSTEM?
- Larger Assembly - Recent maintenance
­­OK - New oil added
- Change in oil type
CHECK SYSTEM Above SYSTEM CLEAN-UP - Change in
CLEANLINESS required OCCURRING temperature
level - Change in flow rate
OK
NO
CHECK Faulty CHANGE
INDICATOR INDICATOR CHECK SYSTEM
CLEANLINESS LEVEL
OK
VERIFY SYSTEM
Higher
FIT ∆P GAUGE AND SPECIFICATIONS
than OK Above
VERIFY CLEAN ∆P PARTICULARLY
expected required
FLOW RATE
level
OK
CHECK
INDICATOR
SPECTROGRAPHIC

OK
WATER CONTENT CHECK FLUID
CHEMISTRY

VERY POSSIBLE
FILTERABILITY SYSTEM/
TEST ON NEW AND COMPONENT
SYSTEM OIL PROBLEMS
- Other analysis tests
- Wear debris
CHECK FOR GELS INSPECT SYSTEM - SEM/EDX
AND PRECIPITATES FILTER ELEMENT - Check by-pass valve

24
Flushing Recommendations
The aim of flushing is to remove contamination from the inside of pipes and
components that are introduced during system assembly or maintenance.
This is accomplished by passing clean fluid through the system, usually at a
velocity higher than that during normal operation to pick up the particles from
the surface and transport them to the flushing filter.

Omission or curtailment of flushing will inevitably lead to rapid wear

of components, malfunction and breakdown.

Reynolds Number (Re): A

 non-dimensional number that provides a qualification
of the degree of turbulence within a pipe or hose.

Laminar Flow Turbulent Flow

Laminar Flow - Re < 2,000

Transitional Flow - Re 2,000 - 4,000
Turbulent Flow - Re > 4,000

For effective flushing procedures the Reynolds Number (Re)

should be in excess of 4000
The flow condition in a pipe or hose can be assessed using Reynolds Number
(Re) as follows:

U
 d
Re = x 1,000 or Re = 21,200 x Q / ( x d)
Re =
Reynolds Number
U = Mean flow velocity (m/s)
d = Pipe internal diameter (mm)
­­­­­ = Kinematic viscosity of fluid in cSt (mm2/s)
Q = Flow rate (L/min)

25
Filters for Hydraulic and Lubricating Fluids
Whatever your application in Pall Filtration Milestones
hydraulics or lubrication, Pall offers the 1965 – Ultipor Filters
most innovative filtration technology 1966 – Ultipor Dirt Fuse Filters
available to achieve the optimum 1986 – Ultipor II Filters
cleanliness levels of your fluids. 1986 – Ultipor II Dirt Fuse Filters
1991 – Ultipor III Filters
Pall Filters Offer: 1991 – Ultipor III Dirt Fuse Filters
1993 – Coreless Ultipor III Filters
• Up to ßx(c)≥2000 removal efficiency 2000 – Ultipor SRT Filters
• Low, clean differential pressure 2004 – Ultipleat SRT Filters
2014 – Coralon Filters
• Long service life 2014 – Coralon Dirt-Fuse Filters
• Environmentally friendly coreless 2015 – Athalon Filters
filter pack 2021 – Supralon Filters

A History of ‘Industry Firsts’

• Glass fiber filter media 1965
• Fixed pore filter media 1965
• ß≥75 filtration ratings 1965
• 3000 psid collapse-rated filters 1966
• Tapered pore filter structure 1986
• Polymeric drainage meshes 1986
• ß≥200 filtration ratings 1986
• Helical outer wrap 1990
• Coreless/cageless construction 1993
• ß≥1000 filtration ratings 1999
• Stress-resistant filter medium 2000
• ISO Code (CST) filtration ratings 2004
• Laid-over pleating 2004
• Triboelectric charge-resistance 2004
• In-to-out flow path 2004
• Life-extending drainage meshes 2009
• ßx(c)≥2000 filtration ratings 2015

The Ultimate in Filter Performance

Stress resistant technology, ßx(c)≥ 2000
ratings, anti-static construction. Keep fluids
cleanest, longest, for the greatest value

Supralon Filters
Advanced Equipment Protection
Stress resistant technology, ßx(c)≥ 2000
ratings.
26
Supralon Filters - Advanced equipment protection
TM

New SupralonTM filters are a direct

upgrade (same form, fit, and function Supralon Filters
including fluid and temperature
compatibility) for current UltiporTM
and CoralonTM filter elements. They
represent a significant advancement in
equipment protection for existing users.
Features
• Advanced pack design incorporating
Stress-Resistant media Technology (SRT)
• Low clean element pressure
drop for longer life
• Optimum performance under system
stresses at all stages of filter life for
consistently cleaner fluid
• Anti-static properties to prevent ESD and
varnish formation
• Fan pleat configuration
Filter element hardware available with SRT Media pack* for increased resistance
either corrosion protected carbon steel to system stresses such as cyclic flow and
endcaps and core (as shown) or polymer dirt loading
endcaps for Ultipor III and Coralon Coreless Benefit: Improved performance over the
housing designs. life of the filter for more consistent fluid
Benefit: Comprehensive upgrade range, cleanliness
environmentally friendly designs for
reduced disposal costs and ease of element
changeout.

Pall Housing &

Pall Ultipor® III
Filtration for improved protection
Element and reduced cost of ownership
Pall Supralon Filtration
• Rapid system clean-up to desired cleanliness levels
• Consistent, reliable performance throughout the filter’s service life
Pall Housing • Long service life even in applications subject to system upsets
& Competitor
Element • Low pressure drop to reduce energy consumption
• Anti-static capabilities throughout the full range

27
The Ultimate in Filter Performance
Pall’s Athalon™ hydraulic and lube oil
filters combine Betax(c)≥2000 rated,
stress-resistant filter technology and a ‘Setting new standards in filter
full range of housings to provide the element design’
greatest overall filter performance and
Betax(c)≥2000 rated Stress Resistant
value available in industry today.
media Technology in a Laid-Over Pleat
• Laid Over Pleat (LOP) Filter Media configuration: Inert, inorganic fibers
Geometry securely bonded in a fixed, tapered pore
• Stress-Resistant Filter Medium structure with increased resistance to
• Anti-Static Construction system stresses such as cyclic
• Coreless/Cageless Construction flow and dirt loading.
• Simple to Install and Inexpensive to
Maintain

High pressure,
return line and
intank Athalon filter
housing designs

Filter
er Element Cost Energy Cost from Higher ∆P Component Wear Cost

System Requires Filter Change Out

ISO 14/13/11 (Reached Replacement ∆P)
Cleanliness to Ensure Eliminate
Proper Equipment Pall Athalon Filters
Contamination
Protection Induced
Downtime

Eliminate
ISO 20/19/17 ISO 12/7/2 ISO 12/7/2 ISO 13/11/9 ISO 14/13/11
Contamination
Related
Costs
Point where filter should be Filter Change Out
changed to provide desired (Reached
component protection Replacement ∆P)
Other
Filters

ISO 20/19/17 ISO 13/12/10 ISO 15/14/12 ISO 17/15/13 ISO 13/12/10 ISO 15/14/12

Time

At no time can you assess

the fluid condition with the
naked eye. All bottle
Keeping Fluids the Cleanest, Longest, for the Greatest Value. samples look the same.

28
Advanced Test Method for Measuring Filter Performance
Cyclic Stabilization Test*
Schematic
Flowmeter Downstream
Test Dust Sample
Slurry Cyclic Stabilization
Test (CST) measures
a filter’s ability
Bypass Automatic
Particle to clean up a
Valve
Counter contaminated
∆P Test system under cyclic
Filter
Reservoir flow (25 to 100%
of rated flow) and
contaminant
loading conditions
Automatic
Upstream Particle
Sample Counter
Variable Speed Pump
*based on SAE ARP4205

Concept:
As opposed to ISO 16889 that only tests filters under steady state conditions, the
Cyclic Stabilization test is used to evaluate hydraulic filter performance under
typical stressful operating cyclic conditions such as:
• Flow surges
• Pressure peaks
Injection stopped after ∆P
• Cold starts increased to 80% of terminal

10,000 CST ISO 4406

Stabilize Cleanliness Code
Particles/mL > 5 µm(c)

80% ∆P ratings are based

1,000 on the stabilized
cleanliness
100 achieved at
Stabilize 80% of the
2.5% ∆P net terminal
10 Stabilize pressure drop,
Stabilize Clean considered the
Clean worst operating
Upstream Particl
1
condition
For clarity, only
0 the number of
Steady Cyclic Flow, 0.1 Hz particles/mL
Flow >5µm(c) are
Time
shown

29
Pall Athalon Filter Performance Data TM

Athalon ßx(c)≥2000 Cleanliness Code Rating (ISO 4406)

Grade per ISO 16889 from Cyclic Stabilization Test*
AZ 3 07/04/01
AP 5 11/08/03
AN 7 13/09/04
AS 12 15/11/06
AT 25 16/14/08

* CST: Cyclic
Stabilization Test to Multi-Pass Filter Ratings (ISO 16889)
determine filter 10,000
rating under stress
conditions, based on AP AS
SAE ARP4205 AZ AN AT
2,000
Filtration Ratio (ß)

Note these ISO codes

are laboratory
measurements under
standard conditions. 100
Cleanliness measured
in actual operation
will depend on
10
operating conditions
and sampling method.

1
0 2 4 6 8 10 12 14 16 18 20 22 24 26
Particle Size (µm(c))

Traditional Fan-Pleat Filter Pall Athalon Filter

The optimized pleat geometry of SRT filtration provides:

• Uniform flow distribution and increased flow capacity
• Maximum filter surface area and element life

30
 Triboelectric Charging Effect on Filtration
Triboelectric Charging Resistant (TCR) Filters
• Designed to dissipate triboelectric charge build-up
• Produce only minimal triboelectric charging of the fluid
(as measured by the fluid charge)
• Minimize fluid degradation and varnish formation
Electrical discharge
450 occurring inside oil
417.5
tank
400

350
301
300
Voltage

239
250
190.5
200
151.5
150 170
115.5 145 158
97 131.5
100 114.5
96.5
77
0
40 50 60 70 80 90 100
DTE797 Oil Flow (USgpm)
Standard Filter TCR Filter

Filtration and Contamination Standards

ISO 2941 Filter elements - Verification of collapse/burst pressure rating
ISO 3968 Filters - Evaluation of differential pressure versus flow characteristics
ISO 4021 Extraction of fluid samples from lines of an operating system
ISO 4407 Determination of particulate contamination by the counting
method using an optical microscope
ISO 11171 Calibration of automatic particle counters for liquids
ISO 16889 Filter elements - Multi-pass method for evaluating filtration
performance of a filter elem­ent
ISO 18413 Component cleanliness - Inspection document and principles
related to contaminant collection, analysis and data reporting
ISO 21018-3 Monitoring the level of particulate contamination of the fluid -
Part 3: Use of the filter blockage technique
SAE ARP4205 Filter elements - Method for evaluating dynamic efficiency
with cyclic flow
Note: This is a small selection of ISO standards relevant to hydraulic and lubrication applications.

31
Differential Pressure Indicators and Switches
Differential pressure (∆P) indicators and switches notify the operator of the filter
condition. This allows a replacement filter to be installed before filter element
bypass occurs.

B
(Physical Collapse)
Filter Element ∆P

A
(ISO 2941 Collapse)

Bypass valve opens

P2
Filter element changeout
∆P indicator actuates
P1

Service Hours T1 T2
(T2 - T1 = 5 to 10 % of Filter Life)

∆P across the filter increases as contaminant is trapped within the filtration

medium. A ∆P indicator actuates at P1, signalling the need for element change
before the bypass relief valve opens at P2. The bypass valve protects the filter and
system from excessive differential pressure.
Without a bypass valve, continued operation at higher ∆P risks degradation of
filtration performance (point A) and filter element collapse (point B) where the
integrity of the filter element is lost.

32
Differential Pressure Indicators and Switches
Mechanical and Electrical Options Available

Filter - Clear Filter - Blocked

Indicator
Button
Label /
Cover

Button
Spring

O-ring Magnet

O-ring
Upstream Slipper
Port Seal

O-ring

Range
Spring

Down Stream Port Piston

Pressure Side

Technical principle of the mechanical indicators:

Differential pressure indicators operate by sensing the ∆P between ports
upstream and downstream of the filter element. When the ∆P across the
internal piston/magnet assembly reaches a preset value, determined by the
range spring, the piston assembly moves downward, reducing the attractive
force between the magnet and indicator button.
The indicator button spring then overcomes the reduced magnetic force and
releases the button to signal the need for element change. Activation can be
visual using a button as shown here or electrical using a microswitch.
A variety of differential pressure indicator models are available. Contact Pall to
determine the most appropriate ∆P indicators or switches for your applications.

33
Filters for Process Fluids
Recommended for industrial applications to treat
water, fuels, aqueous solutions, and low viscosity
process fluids.
Recognizing that different applications have different fluid
cleanliness and filtration requirements, the Pall range of
Melt Blown filter products is simply defined to help you
choose the best solution at the most economic cost.

Highly Critical Cleanliness

For applications such as fluid make-
up, cleanliness control, polishing or
clarification, where the full range
of solid contamination removal
including silt is required.

Critical to General Particulate Control

Cleanliness control in wash
applications, machining applications
where high surface finish is required,
single pass in-line last chance
filtration applications, and for general
purpose fluid clarification.
General Particulate Control
Coarser ratings for primary or pre-
Particulate Efficiency Recommended filtration applications, or higher
Control Rating% Range (µm) fluid flow applications where a fluid
Highly Critical 99.98% 1, 3, 6, 12, 20 cleanliness level is not specified.
Critical to General 99.9% 40, 70, 90
General 90% 100, 150, 200

Applications
Different medium • Component wash fluids
1 configurations can • Cutting fluids
be applied to specific • Process fluids
2 user requirements. • Water
The Pall filter element • Coolants
range is available in - • Water glycols
1 Depth
• Mineral and synthetic oils
2 Fan pleated • Lubricants
3 Patented laid over • Fuels
3 pleat (Ultipleat®) • Solvents
designs.
34
Separation Systems for Process Fluids
Crossflow Filtration Systems H2O Molecules

Pall Clarisep crossflow filtration systems remove tramp oil, Emulsified

Cross Flow
UF
suspended solids and bacteria from water-based fluids Oil Droplet
Dirt Membrane

to maintain the fluid in optimum condition for extended

service life. These systems can also be used to process

Permeate
oily wastewater, minimizing the volumes that have to be
disposed of off-site.

Pall Clarisep
Process Fluid
Membrane
Pall crossflow
systems direct
fluid flow across
the surface of a
porous membrane.
Emulsified oil
and grease,
bacteria, fungi and
suspended solids
are larger than the
membrane pores
Clean Fluid and are, therefore,
held back, allowing
clean fluid to pass
downstream.

Concentrated Contaminants
Pall offers a range of membrane technologies, allowing the optimum solution
to be selected for a specific application. All Pall Clarisep systems automatically
regenerate in-situ for extended life.

35
Diesel Fuel Purification
Diesel Engine Fuel Cleanliness Control -
From delivery, to storage, to pump, to injector
The latest injection technology for diesel powered engines requires superclean
fuels. Fine filtration and liquid/liquid coalescence are strategically required along
the diesel supply chain.

Example of a Basic Mining Fuel Distribution System

Fuel Delivery

Main
Storage
Tank
Mobile Surface Fleet

Secondary
Storage
Tank

Mobile Fuel
Truck
Shovels and Loaders

Underground
Storage
Underground Fleet Tank

Bulk Diesel Liquid/Liquid Point of use Mobile support On board Air breather
Fuel Filtration coalescer fuel filter fuel filter fuel filter filter

Pall Ultipleat® Diesel Plus Pall Athalon™ Pall Ultipleat® Diesel

Fuel Filter Elements Filter Elements Fuel Filter Elements

36
Component Cleanliness Management

CLEAN
Component Cleanliness Management Design it
(CCM) is a comprehensive program Build it
designed to help clients achieve desired Keep it
component cleanliness. After working
with you to validate processes and set cleanliness specifications, the program
follows a defined path to assess component cleanliness and identify areas
for improvement. We then provide recommendations and assist in their
implementation

Your route to component cleanliness

Manufacturing

Engineering
Extraction Analysis Training Process Component
Quality
Consultancy Cleanliness

Pall Cleanliness Cabinets

Pall Component Cleanliness Cabinets
facilitate the accurate, reliable
and repeatable determination of
component cleanliness.
• Stainless steel construction
• Controlled extraction environment
• Automated cleaning to “blank” values
• Pressurized solvent dispensing and
recycling circuits
• Meet ISO 18413, ISO 16232 and
VDA 19 procedures
• Available in small, medium or large
cabinet options

PCCM Cleanliness Cabinet

37
Required Fluid Cleanliness Level Worksheet*
Selection of the appropriate cleanliness level should be based upon careful
consideration of the operational and environmental conditions. By working
through this list of individual parameters, a total weighting can be obtained
from the graph on page 39, to give the Required Cleanliness Level (RCL).
Table 1. Operating Pressure and Duty Cycle
Duty Examples Operating Pressure (bar (psi)) Actual
0-70 >70-170 >170-275 >275-410 >410
(0-1000) (>1000-2500) (>2500-4000) (>4000-6000) (>6000)
Light Steady duty 1 1 2 3 4
Medium Moderate pressure 2 3 4 5 6
variations
Heavy Zero to full pressure 3 4 5 6 7
Severe Zero to full pressure with 4 5 6 7 8
high frequency transients

Table 2. Component Sensitivity

Sensitivity Examples Weighting Actual
Minimal Ram pumps 1
Below average Low performance gear pumps, manual valves, poppet valves 2
Average Vane pumps, spool valves, high performance gear pumps 3
Above average Piston pumps, proportional valves 4
High Servo valves, high pressure proportional valves 6
Very high High performance servo valves 8

Table 3. Equipment Life Expectancy

Life Expectancy (hours) Weighting Actual
0-1,000 0
1,000-5,000 1
5,000-10,000 2
10,000-20,000 3
20,000-40,000 4
>40,000 5

Table 4. Component Replacement Cost

Replacement Cost Examples Weighting Actual
Low Manifold mounted valves, inexpensive pumps 1
Average Line mounted valves and modular valves 2
High Cylinders, proportional valves 3
Large piston pumps, hydrostatic transmission motors,
Very high 4
high performance servo components

Table 5. Equipment Downtime Cost

Downtime Cost Examples Weighting Actual
Low Equipment not critical to production or operation 1
Average Small to medium production plant 2
High High volume production plant 4
Very high Very expensive downtime cost 6

Table 6. Safety Liability

Safety Liability Examples Weighting Actual
Low No liability 1
Average Failure may cause hazard 3
High Failure may cause injury 6

* Adapted from BFPA/P5 Target Cleanliness Level Selector 1999 Issue 3.

38
Table 7. System Requirement
Cleanliness Requirement Total Weighting Total
Sum of ‘Actual’ weighting from sections 1 through 6

Using the chart below, determine where the ‘Cleanliness Requirement Total Weighting’ number from
Table 7 intersects the red line. Follow across to the left to find the recommended ISO 4406 Code.
Table 8. Environmental Weighting
Environment Examples Weighting Actual
Single Multiple
Filter Filters*
Good Clean areas, few ingression points, filtered fluid filling, air breathers 0 -1

Fair General machine shops, some control over ingression points 1 0

Minimal control over operating environment and ingression
Poor 3 2
points e.g. on-highway mobile equipment)
Potentially high ingression (e.g. foundries, concrete mfg.,
Hostile 5 4
component test rigs, off-highway mobile equipment)
* Single filter or multiple filters with the same media grade on the system.
Table 9. Required Filtration Level
Filtration Requirement Total Weighting Total
Add Environmental Weighting (Table 8) to System Requirement Total (Table 7)

Using the chart below, determine where the ‘Required Filtration Level’ total in Table 9 intersects the
red line. Follow across to the right to find the corresponding recommended Pall filter grade.

20/18/15
19/17/14
18/16/13
17/15/12 AS
ISO 4406 Code†

16/14/11
15/13/10
14/12/09
AN
13/11/08
12/10/07
11/09/06
AP
10/08/05
09/07/04
08/06/03
AZ
07/05/02
06/04/01
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Weighting
†Using on-line particle counting

39
Common Fluid Power Circuit Diagram Symbols
ISO1219-1: Fluid power systems and components - Graphic symbols and circuit diagrams -
Part 1: Graphic symbols for conventional use and data processing applications.
Cylinders and Semi-rotary Actuators

Double Acting Bi-directional Cylinder with Single Acting

Cylinder Semi-rotary Actuator Adjustable Cushioning Telescopic Cylinder

Pumps and Motors

Fixed Displacement Pump Variable Displacement Pump

Uni-directional Flow Bi-directional Flow
Anti-clockwise Rotation Anti-clockwise Rotation

Pressure Compensated Pump

[Shortform Symbol]
Uni-directional Flow
Fixed Displacement Motor Variable Displacement Motor External Case Drain
Anti-clockwise Rotation Bi-directional Rotation Clockwise Rotation
External Case Drain Electric Motor Driven

Directional Control Valves (Unspecified Actuation)

2 Port, 2 Position 2 Port, 2 Position 3 Port, 2 Position 3 Port, 2 Position

Normally Closed Normally Open Spring Return Spring Return
[Poppet type]

4 Port, 2 Position 4 Port, [3 Position] 4 Port, 3 Position, Spring Centred

Spring Return Proportional (See Below for Centre Conditions)

Closed Centre Open Centre Tandem Centre Float Centre Regeneration

Centre

40
Directional Control Valve Actuation

Switching Proportional Electro-Hydraulic Hand Foot Palm

Solenoid Solenoid (Pilot) Operation Lever Pedal Button

Pressure Control Valves

Direct Operated Pilot Operated Direct Operated Pilot Operated

Relief Valve Relief Valve Reducing Valve 3 Way Reducing Valve

Isolation and Flow Control Valves

Isolator Isolator Diverter Orifice Throttle

(Open) (Closed) Valve (Jet) Valve

Throttle-Check Pressure Compensated

Valve Flow Control Valve

Check Pilot-to-Open Shuttle Valve

Valve Check Valve

Filters and Coolers

Filter with Visual Filter with Duplex Filter with Cooler

Clogging Indicator Bypass Valve Manual Valve (Heat Exchanger)

Instrumentation and Pipeline Components

Flow Line, Symbol Enclosure
Pilot Line, Drain Line
Symbol Enclosure
Flexible Hose
Lines Connecting Connections Temp. Pressure Test Flow Gas loaded
To Tank Gauge Gauge Point meter accumulator
Lines Crossing

41
Corporate Headquarters Asia-Pacific Headquarters
Port Washington, NY, USA Singapore
+1-800-717-7255 toll free (USA) +65 6389 6500 phone
+1-516-484-5400 phone
European Headquarters
Fribourg, Switzerland
+41 (0)26 350 53 00 phone

Visit us on the Web at www.pall.com/industry

Contact us at www.pall.com/contact

Pall Corporation has offices and plants throughout the world. To locate the Pall office or distributor
nearest you, visit www.pall.com/contact.
The information provided in this literature was reviewed for accuracy at the time of publication.
Product data may be subject to change without notice. For current information consult your local
Pall distributor or contact Pall directly.
IF APPLICABLE Please contact Pall Corporation to verify that the product conforms to your
national legislation and/or regional regulatory requirements for water and food contact use.

© Copyright 2022, Pall Corporation. Pall, , Athalon, Coralon, Phasesep, Supralon, Ultipor,
Ultipleat and are trademarks of Pall Corporation.
® Indicates a trademark registered in the USA.

M&EPOCKETENg March 2022