BOOK 2, CHAPTER 9 - Filtration

15/04/2019 BOOK 2, CHAPTER 9: Filtration
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BOOK 2, CHAPTER 9: Filtration
Table of Contents
Oct 10, 2008
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Hydraulic filters
Contaminated fluid causes most hydraulic system failures. Oil in a reservoir may
look clean to the naked eye, but silt contamination particles too small to see can
still wreck pumps, cause valves to stick, and erode cylinder bores. In many
facilities, components may take the blame for problems in error, when
contaminated fluid is the culprit. It is amazing that some plants will change
pumps every six months (believing that is normal component life), when they
could add a proper filtration system and get many times longer pump service
life.
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Fig. 9-1. Suction filter (or strainer)

with bypass check valve.
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A well-filtered hydraulic system should not have particles in the fluid larger than
10 microns. (A micron is 0.000039 inches.) A contamination particle that
measures 0.001 in. across is 25 microns. The smallest dirt particle that is visible
to the naked eye is 40 microns. Simply looking at an oil sample is not a good way
to tell if the filters are cleaning the fluid.
Nominal or absolute are common terms found in hydraulic filter micron ratings.
A filter with a nominal rating takes out most of the particles that measure the
same size or larger than the stated micron size. A filter with an absolute rating
takes out all particles the same size or larger than the rated micron size. A newer
filter-rating system called the beta ratio is replacing the old nominal and
absolute designations.
Fig. 9-2. Return-line filter with a

bypass check valve (and electrical
clogging indicator).
The beta ratio indicates what size particles the filter removes, followed by the
ratio of the number of this size particle in the fluid upstream from the filter,
divided by number of particles that size in the fluid downstream from the filter.
For example: a filter rating of beta 5 = 90 indicates the filter will remove 90 of
every 100 particles of 5 micron or larger size from the fluid passing through it.
The efficiency of this filter would be 98.9% -- or 100 - (100/90).
Most
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wire mesh element to trap particles. While woven wire is more expensive than
paper, the ability to manufacture it with more precisely sized fluid flow openings
makes it a better choice. Also, woven wire elements can withstand higher
pressure drops without collapsing.
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Fig. 9-3. Pressure filter (without

bypass) that has pressure gauges
to indicate pressure drop across
the filter.
Figures 9-1, 9-2, and 9-3 show the symbols used in circuit diagrams for the
common filter types. The hydraulic circuit diagrammed in Figure 9-4 has these
filters in typical locations.
Suction strainers
Figure 9-4 shows a hydraulic circuit with filters in standard locations. Strainer
is a common name for filters with openings of 75 microns or larger. Suction
strainers usually are installed in the pump inlet line to protect the pump from
large, damaging contamination particles that can cause catastrophic failure. The
suction strainer also protects the pump from ingesting any start-up debris left in
the tank and piping. In addition, the suction strainer traps large contamination
particles introduced to the system from external sources or resulting from
internal part failure.
Don’t use filters with low-micron ratings in suction lines because pumps without
supercharged inlets can only tolerate a portion of one atmosphere pressure drop
without affecting inlet flow. With this low-pressure drop (14.7 psi maximum, at
sea level on an average day), a restriction such as a low-micron filter can cause
the pump to cavitate. Cavitation will cause pump failure almost as fast as dirty
oil, so avoid it improve
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Suction strainers are normally available with openings ranging from 75 to 150
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microns. Some manufacturers offer inlet filters with ratings as low as 25
microns. These low-micron elements have large filtering surfaces.
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Fig. 9-4. Typical filter locations – with micron ranges and bypass settings.
If the pump is force-fed by another pump (sometimes called a supercharge

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pump), use of a low-micron rated element is possible. The supercharging pump

will force fluid through a very fine filter to the working pump without cavitation.
A suction strainer or filter should have a bypass relief valve. Set the bypass to
open at a pressure of 1 to 3 psi when the strainer becomes clogged. The
reasoning behind this is that the pump will run many hours on contaminated oil,
but will fail in a few minutes with little or no oil.
Suction strainers can be located inside or outside the reservoir. Internal

strainers are less expensive, but their condition is more difficult to monitor.
External strainers are easy to service and often include an indicator to show
when the filter starts bypassing. The indicator can be as simple as a vacuum
gauge or it might be a vacuum-operated electrical output to a warning light or
controller.
Many older circuits have nothing but a suction strainer for filtration. Retrofitting
these systems with the off-line or kidney filters discussed later in this chapter is
advisable.
Return-line filters
Another common location for filters is in the return line. (See the circled item in
Figure 9-5.) The return-line filter keeps most contamination caused by part wear
from getting into the tank. These filters are offered with ratings ranging from 3
to 25 microns. A common level of filtration is 10 microns. Obviously, if the
desired system cleanliness is 10 microns, use a filter of 10 microns or less.
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Fig. 9-5. Typical filter locations – with micron ranges and bypass settings.
Return-line filters should have integral bypass check valves. If the filter becomes
loaded, return oil needs a flow path to tank until it is convenient to change the
filter. Without a bypass, the filter element may collapse, or the element housing
or seal may rupture. The bypass check valve usually requires 10 to 50 psi to
open. The bypass pressure should be high enough to stop fluid from going
around the filter except under unusual conditions, but low enough to keep the
filter
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Sizing return-line filters just to handle pump flow is a common practice.

However, sizing the filter to pump flow can cause problems if cylinders in the
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circuit have oversized rods, or if one cylinder returns one or more other  SEARCH
cylinders. For example, if a cylinder has a 2:1 rod diameter, flow to tank while
the cylinder is retracting will be twice pump flow. Sizing the filter just for pump
flow will allow contaminated oil to bypass at least -- and may damage the
housing or seals. Paper filters can collapse, have holes blown through the
element, stop filtering, and never indicate they need to be replaced. With pleated
elements, the pleats can collapse, giving a premature “loaded element”
indication.
Even with a correctly sized return-line filter, the flow through it changes
constantly. A steady flow through the element gives the most efficient filtration.
If a filter passes constant flow, the bypass valve will not open until the filter fills
with contaminants. This means only clean fluid leaves the filter.
Visual and electrical indicators also are available to show when the return-line
filter is bypassing.
Pressure line filters
Servo directional control valves normally require pressure-line filters because

these valves have low contamination tolerance, as shown in the lower circle on
Figure 9-6. These valves have small internal orifices, very close-tolerance fits,
and must shift rapidly at low pilot-pressure differential. A servovalve can stop
functioning in as little as two minutes with oil from a typical hydraulic system.
Any servovalve circuit operates best with a pressure filter.
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Fig. 9-6. Hydrostatic transmission circuit with bi-directional filter.
Even when a 3-micron return-line filter is installed, contamination generated by

the pump is enough to shut down a servovalve in a short time. To solve this
problem, place a pressure filter in the line between the pump and the servovalve.
To eliminate servovalve contamination in circuits with long lines, place a
pressure filter at each valve inlet.
Pressure-line filters normally have elements with 1- to 5-micron openings. The

pressure filter should be of the absolute-rated type, or have a beta ratio of 50 or
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A pressure-line filter should not have a bypass. If the filter element clogs, it is
better to stop flow to servovalves than to contaminate them. Indicators on the

filters warn of clogging to allow the elements to be changed before production
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speed is affected. Visual and electrical clogging indicators also are availablefor
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most pressure-line filters.
Pressure-line filter housings must be strong enough to withstand full system

pressure. When there is a high pressure drop across the filter, the element must
not collapse. These requirements make pressure-line filter housings and
elements more expensive than return-line filters. High cost is the main reason
for not using pressure-line filters on all systems.
Figure 9-6 pictures a bi-directional pressure-line filter. Another name for this bi-
directional filter is "last-chance filter." Because it is in the working line to an
actuator, this filter has to withstand maximum system pressure. The only
difference between a bi-directional filter and a standard pressure filter is the
four check valves in the housing. The four check valves cause oil flow to pass
through filter element in the same direction regardless of the direction that the
fluid enters the housing. A bi-directional filter will normally have a 3- to 10-
micron rating for most circuits. Pipe a bypass check externally when required.
Closed-loop hydrostatic transmission circuits are one place to use bi-directional

filters. Note that the oil between the pump and motor can stay in the loop for
long periods. Any contamination in this closed loop will continue to cause
damage, even after changing oil in the tank.
Off-line filtration
The top image in Figure 9-7 shows an off-line filtration circuit. This is an easy
circuit to retrofit to existing hydraulic systems. Also, it is an excellent circuit for
new systems where high cleanliness levels are needed. Sometimes called kidney
filters or bypass filters, off-line filtration systems consist of a separate pump,
motor, and filter that re-circulates oil in the reservoir. Oil from one end of the
tank passes through the filter and returns to the opposite end of the tank.
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Fig. 9-7. Off-line filtration arrangement (top image) and off-line filtration
circuit with heating or cooling capacity (bottom image)
The filter in the off-line circuit should be rated in the 3- to 10-micron range. The
circuit should be set up to filter the volume of fluid in the reservoir every 1 to 3
hours
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When the off-line filter indicator shows a clogged element, the main hydraulic
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circuit can continue to run during filter change. Also, this type filter system can
operate while the main hydraulic circuit is shut off over nights or weekends.
Always filter new oil before use since it not as clean as most hydraulic systems
require. Put new oil into the tank through a pair of shut off valves, or a 3-way
ball valve in the suction line (as diagrammed in the bottom of Figure 9-7).
Rotate the 3-way ball valve 180 degrees, hooking the pump suction to a flexible
hose in an oil drum or fluid container. This set-up filters all oil from the fluid
container before it enters the reservoir.
Any circuit with a servovalve still requires a pressure filter downstream from the
pump. Also, according to the working conditions, a return-line filter may be
helpful to take out system-generated particles before the fluid goes back to tank.
A heating or cooling loop is another function sometimes performed in an-off line

filter circuit. Figure 9-8 shows a bypass circuit with a normally open solenoid
relief valve, a high-horsepower motor, a temperature switch, a heat exchanger,
and a temperature-controlled water valve. These additions can effectively
control temperature while filtering the fluid. (To only filter the oil, leave the
water turned off and the solenoid relief valve open.) If oil temperature drops too
low, the temperature switch will energize the solenoid on the relief valve and
pressure will rise. All electric-motor horsepower converts into heat until the
temperature switch indicates the correct oil temperature. Unlike an immersion-
type electric tank heater, the fluid is being circulated, so there are no hot spots.
For every electric horsepower, there will be 2544 Btu/hour heating capacity.
After figuring the Btu/hour to heat or maintain minimum temperature, divide
by 2544 to calculate the horsepower needed.
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Fig. 9-8. Cross-section of typical air-line filter, left, with symbols that show
drains at right.
If the tank fluid overheats, the temperature-controlled water valve will open,
sending water through the heat exchanger. All filtered flow cools while the
temperature valve indicates elevated temperatures. The heat exchanger always
passes constant flow, so a bypass valve around it is unnecessary. Also, the heat
exchanger passes flow even when a pressure-compensated pump in the circuit is
holding pressure without flow.
Air-line filters
Air-line filters
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cylinders. They also capture condensed water in the air stream. Most air-line
filters have a manual drain to get rid of the trapped water. Several
manufacturers offer an automatic drain at added cost.
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The filter media in air-line filters consists of compressed fibers, ceramics, or
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sintered metal. A standard air filter removes particles 40 microns or larger. Most
manufacturers also can supply filters with ratings as low as 5 microns when
required.
Air entering the filter, Figure 9-8, flows along the walls of the bowl to swirl out
condensed water – which drops to the bottom of the bowl. The air then passes
through the filter media, and on to the regulator and lubricator. A baffle
separates the lower part of the bowl, making a quiet zone for trapped water so it
won’t be picked up again.
To get even better air quality, coalescing filters are available. Coalescing filters
remove up to 99.9% of oil aerosols, as well as particles down to 0.3 microns.
These filters are desirable in instrument air and paint spraying applications, or
any other circuit that requires very clean air. The basic design of a coalescing
filter is the same as a standard filter. The main difference in is the filter element.
The filter element is for one-time use and is quite expensive. Most suppliers
recommend standard filters upstream to remove larger particles and liquids,
thus extending the service life of the expensive coalescing element.
Air filters usually do not come with a bypass check valve. When the filter
becomes clogged, flow restriction increases until air flow finally stops. Pressure
drops on gauges at the inlet and outlet show when to change the filter element.
RELATED
BOOK 2, CHAPTER 13: Pressure intensifier circuits

APR 13, 2009
BOOK 2, CHAPTER 12: Fluid Motor Circuits

MAR 18, 2009
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15/04/2019 BOOK 2, CHAPTER 9: Filtration

TECHNOLOGIES > OTHER TECHNOLOGIES

BOOK 2, CHAPTER 9: Filtration

Oct 10, 2008

Fig. 9-1. Suction filter (or strainer)

Fig. 9-2. Return-line filter with a

Fig. 9-3. Pressure filter (without

If the pump is force-fed by another pump (sometimes called a supercharge

Suction strainers can be located inside or outside the reservoir. Internal

Sizing return-line filters just to handle pump flow is a common practice.

Pressure line filters

Servo directional control valves normally require pressure-line filters because

Fig. 9-6. Hydrostatic transmission circuit with bi-directional filter.

Even when a 3-micron return-line filter is installed, contamination generated by

Pressure-line filters normally have elements with 1- to 5-micron openings. The

better to stop flow to servovalves than to contaminate them. Indicators on the

most pressure-line filters.

Pressure-line filter housings must be strong enough to withstand full system

Closed-loop hydrostatic transmission circuits are one place to use bi-directional

A heating or cooling loop is another function sometimes performed in an-off line

manufacturers offer an automatic drain at added cost.

BOOK 2, CHAPTER 13: Pressure intensifier circuits

BOOK 2, CHAPTER 12: Fluid Motor Circuits

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© 2019 Informa USA, Inc., All Rights Reserved

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