Professional Documents
Culture Documents
Contamination Control
Overview
Contamination Control
Why Contamination Control?
Contamination Control
Why Contamination Control?
• Industry trends
– Electro-hydraulics
– Higher system pressures
– Tighter clearances
Contamination Control
Why Contamination Control?
Contamination Control
Why Contamination Control?
Contamination Control
Why Contamination Control?
Contamination Control
What Is Contamination?
Contamination Control
Contamination Sources
• Built-in
• New fluids
• Introduced contamination
– Cylinder wiper seals
– Reservoir vent ports
– Poor maintenance
• Generated internally
Contamination Control
Two Types of Contamination
Contamination Control
Small Particle Contamination
2
30
40
MICRONS (µm)
80
Contamination Control
What is a Micron?
1 Millionth of a Meter
Contamination Control
Contamination Control
Video
Fluid Contamination:
The Silent Thief
(10 minutes)
Contamination Control
Effects of Contamination
75 to 85%
of all component failures to particle contamination in the
fluid and not a weakness in the system components
Contamination Control
Pump Manufacturer
ISO
C
22/19
Component Life
o
n
21/17
---- 2,500
t 20/15 -----
a
m 19/16
i
n 10,000
a
t
18/15
------------
i
17/14
25,000
o 16/13
n Clean New Oil
15/12
14/11
13/10
12/09
Contamination Control
EFFECTS of Contamination
• Erratic steering
• Cylinder drift
• Slower performance
• Unreliable operation
• Lower productivity
• Machine downtime
• Higher operating costs
Contamination Control
PREVENTION of Contamination
• Housekeeping
• Oil storage and transfer
• Change filters carefully
• Parts handling and storage
• Hose assembly and storage
• Care in maintenance and repair
• Adhere to proper maintenance intervals
• Particle counting
Contamination Control
Housekeeping
Contamination Control
Housekeeping
Floor Dry Hand Pump
Parts
Parts Cleaner Packaging/Storage
Contamination Control
Housekeeping
Contamination Control
Oil Storage and Transfer
Contamination Control
Kidney-loop Filtration System
Contamination Control
Change Filters Carefully
• Change on schedule
• Remove used filter carefully
• Do not pre-fill new filter
• Use high efficiency filters on serviced machines
• Examine used filters
Contamination Control
Parts Handling and Storage
Contamination Control
Hose Assembly and Storage
Contamination Control
Care in Operation and Maintenance
Contamination Control
Particle Counting
Contamination Control
Measuring Contamination EQUIP. #
JOBSITE
WL701
* BIG SU
MAKE CAT
Henry Walker Contracting P/L MODEL 994
Att: Mr Alan Carson SERIAL No. 9YF0004
PO Box 294 COMPARTMENT PUMP D
Clov erdale OIL BRAND & TYPE BELRAY
WA 6105 OIL CHGD? Y
ORDER No. YANDI
141096 8 211 1 1 7 13 - 11 - #3 1 - N - - - - -
DATE CU
-
FE
-
CONCENTRATIONS IN PPM 14
CR PB AL SI MO NA MG SN
- - -
ZN W F
% OF ALLOWA
A ST OXI NIT SUL TB
181296 8 389 1 2 32 51 - 13 - CUR 1 - N - - - - - - -
201196 15 301 2 5 32 75 - 42 - #1 2 - N - - - - - - -
251096 4 304 1 1 8 18 - 10 - #2 1 - N - - - - - - -
141096 8 211 1 1 7 13 - 11 - #3 1 - N - - - - - - -
Contamination Control
Measuring Contamination
• Particle Count
Particle Count
• Quantifies particle by size Size Category
>4 Microns
>6 Microns
>10 Microns
>14 Microns
>21 Microns
>25 Microns
>38 Microns
>70 Microns
Contamination Control
Understanding Particle Counting
• ISO codes
• 28 code ranges
Contamination Control
ISO Cleanliness Code
Contamination Control
ISO Codes
Contamination Control
ISO Code Chart
24 ISO Codes Number of Particles / mL
24 80,000 - 160,000
23 40,000 - 80,000
22 Dirty 20,000 - 40,000
21 10,000 - 20,000
20 5000 - 10,000
19 2500 - 5000
18 1300 - 2500
17 640 - 1300
16 Clean 320 - 640
15 160 - 320
14 80 - 160
13 40 - 80
12 20 - 40 NOTE:
11 Cleaner 10 - 20
10 5 - 10 Particle count
9 2-5 doubles at
8 1-2 each level
Contamination Control
Compare the Difference
Very Hydraulic/
Dirty Minimum Steering Fill
Oil Target Targets Oils
24 21 18 16
5 Microns
& Greater 160,000 20,000 2,500 640
19 17 15 13
15 Microns
& Greater
5,000 1,300 320 80
Contamination Control
Compare the Difference
Contamination Control
Pamas S-40 Particle Counter
Contamination Control
Particle Counter Printout
Pamas
ID: Hydraulic Oil
Contamination Control
Recommended Cleanliness Targets
Contamination Control
Visualizing Contamination
Contamination Control
Visualizing Contamination
• Half a teaspoon
Contamination Control
Contamination Control Example
Contamination Control
Contamination Control Example
Amount of “Dirt” Flowing
Amount of “Dirt” in Oil Through Pump in One Year
Contamination Control
Contamination Control
Support Available
Tools
Equipment
Methods
Procedures
}
Available for All Products (95%)
Contamination Control
https://nacd.cat.com/infocast/frames/prodsupp/cc/
https://cosa.cat.com/infocast/frames/prod_supp
/service/contamination/
Contamination Control
Contamination Control Tooling
Portable
S-40 Contamination Kit Hose Cleaning Kit
Contamination Control
Cleanliness Responsibility
Contamination Control