Why Filtration & Condition Monitoring Matter
Contaminants—solid, liquid, and gaseous—are the bane of hydraulic engineers. Over time, systems become less efficient and ultimately break down, which is costly.
Contamination arises both externally and internally through fluids, component corrosion and wear, and reduced maintenance and housekeeping. In difficult economic times, system maintenance is often given a low priority and cost-saving exercises take precedence. Users seldom consider the time and cost savings that an effective maintenance regimen can deliver.
Contamination control is a long-term process that requires ongoing monitoring. Below are key points showing how investing in effective filtration and condition monitoring can improve system efficiency and performance.
The Scale of the Problem
Industry studies indicate that roughly 70–90% of hydraulic system breakdowns are attributed to particulate contamination. If systems engineers incorporate appropriate filtration and contamination control equipment to reduce contaminants, overall efficiency improves and component life is extended.
Chris Banks, Hydrasales Sales Engineer: “Filter sizing with the MP Filtri software helps with correct filter selection. Nothing is left to chance—it allows simulation under different flows and pressures, and the report computes pressure drops to maximize the opportunity for selecting the right filter.”
How Contaminants Damage Components
Before outright failure, components are continually exposed to contaminants, so a system begins losing efficiency from commissioning. When new, a hydraulic system runs at full pressure and flow, meeting load and speed requirements. Over time, contaminants cause wear and micro-cracking on critical surfaces. With typical clearances in the range of 0.5–50 microns, it doesn’t take much dirt to block an orifice. Any blockage or impairment reduces—and can eventually restrict—flow, slowing or halting the application.
Designing for Cleanliness
The first step is to incorporate effective filtration at the design stage. Depending on the required sophistication and outputs, designers should consider pressure-line, return-line, suction, and offline (kidney-loop) filtration to protect components. Each filter type has a job—ensure they are the right filters for the application.
Do You Understand Your Filtration Needs? Training Is Essential.
Lucas Thela, Hydrasales: “A word of caution on system design: the cheapest design may meet minimum operating parameters, but without effective filtration to match peak operating pressures and conditions, it can become expensive later.”
“There’s a lack of understanding about the importance of filtration and contamination control. A basic grounding goes a long way.”
Hydrasales provides full support at the design stage and offers free training on filtration, contamination monitoring, and accessories.
Elvira Caripis, General Manager: “With technology, we can reach even the most remote customers via online platforms—only internet access is required. This is especially beneficial for maintenance and field staff. Training helps teams troubleshoot filter efficiency and performance.”
Online Particle Monitoring
Online particle monitors analyze systems 24/7, triggering internal and external alarms if contamination or moisture levels deteriorate. They provide an early-warning system.
Benefits of Online Particle Counting
- Lower total cost of filtration by eliminating unscheduled filter changes.
- Constant monitoring enables predictive maintenance and cost savings.
- Continuous tracking of system cleanliness improves reliability and reduces costs.
- Longer component life thanks to proactive intervention.
- Time savings through efficient oversight of high-cost processes.
Predictive control is a cost-effective, efficient method of system monitoring whenever cleanliness levels are exceeded.
About Hydrasales
Hydrasales supplies a full range of hydraulic filters, filter elements, and system accessories. We represent MP Filtri, Faster Couplings, and Badger Meter’s Hedland range of flow meters. These leading manufacturers meet international quality standards, with certified products. Direct technical support from these brands is key to application development and innovation in African markets.
Get in Touch
Email harpo@hydrasales.co.za for help with filtration, contamination monitoring, quick-connect couplings, flow meters, and other accessories. Or visit www.hydrasales.co.za.
