Contaminant particles create headaches for hydraulic engineers. Over time, hydraulic systems become less efficient and allow more contaminants to enter. With continued use, this contamination can ultimately cause system breakdowns. The likelihood of catastrophic failure increases significantly when system maintenance is neglected.“That can be very, very costly!” warns Hydrasales’ Elvira Caripis.Contaminants are either generated externally or internally due to harsh environments, dirty fluids, component corrosion, or poor system maintenance and housekeeping. There is a fine line between clean and dirty systems.
Through contamination control and monitoring, ISO cleanliness ratings can indicate the levels of dirt within a system.Unfortunately, system maintenance often gets relegated to low priority. Cost-saving mindsets among buyers frequently lead to neglect. Maintenance personnel forget the “stitch in time saves nine” philosophy and overlook the cost implications of downtime due to system breakdowns. Contamination control is a long-term process that requires consistent monitoring.
Hydrasales sales engineer Chris Banks advises, “If a systems engineer can incorporate appropriate filtration and contamination control equipment to reduce contaminants, the system can achieve efficiencies that prolong equipment working life.”
He prioritises assisting design engineers with filter sizing. “Filter sizing with the MP Filtri software helps with proper filter selection,” says Banks. “It minimises unnecessary errors and enables simulation under different flows and pressures. The end report calculates estimated pressure drops and maximises opportunities for correct filter selection.”
As contaminants continue to circulate within components, system efficiency deteriorates. While a new hydraulic system operates at optimal pressures, flow rates, loads, and speeds, contaminants over time cause wear and cracking at critical component surfaces. Given that tolerances are extremely fine (from 0.5 to 50 microns), it takes only a small amount of dirt to block an orifice. Any blockage or restriction ultimately slows or halts system performance.
How Can We Control Contamination and Extend Component Life?
Incorporate Effective Filtration
Effective filtration must be incorporated during the design stage. Depending on the system’s sophistication and output requirements, designers should include pressure, return, suction, and offline filtration systems to protect critical components. Ensure that filtration is fitted with the correct filter elements for each application.
Hydrasales’ Lucas Thela cautions, “The cheapest design may meet minimum operating parameters, but without proper filters that handle peak pressures, costs can escalate quickly.” He continues, “There is often a lack of appreciation for the importance of good filtration and contamination control. A basic understanding goes a long way.”
Hydrasales provides free design-stage support and offers free training on filtration and fluid condition monitoring. General Manager Elvira Caripis adds, “Technology platforms like Zoom allow us to connect with remote customers. Internet access is a great enabler.” She notes, “Maintenance and field personnel can now access the technical information they need. It’s a form of upskilling and on-the-job training.”
Online particle monitors analyse systems 24/7, triggering internal or external alarms when contamination or moisture levels change. This provides an ideal early-warning system.
Benefits of Online Particle Counting
- Reduces total filtration costs by eliminating unscheduled filter changes
- Enables predictive maintenance through constant system monitoring
- Tracks system cleanliness and reduces long-term maintenance costs
- Prolongs component life through early detection of contamination
- Saves time by monitoring high-cost processes efficiently
- Allows predictive management of contamination levels—an effective and economical system monitoring method
