The complexity of hydraulic systems is continually increasing. As a result, the cleanliness of the installed components is becoming more and more significant. This applies not only to pumps and valves, but also to the pressure lines that connect them. 70 to 80% of all failures can be traced back to contamination in hydraulic fluids. A particular danger is posed by large particles (> 50 µm) that enter the lines during the production process. These are called Primary contaminations.
This contamination can lead to initial damage and spontaneous failures immediately after the start-up of a system. Primary contamination also encourages the formation of further particles during operation. These are called secondary particles.
By using the ptcsystem® the initial level of exposure to primary contamination is reduced. The likelihood of a premature failure is significantly reduced and the operating life of important hydraulic components is extended.
Close the ptcsystem® launcher to the compressed air network or a compressed air cylinder.
Select the appropriate nozzle and insert it into the open retaining ring on the ptcsystem® launcher.
Select a cleaning projectile and insert it into the nozzle. To make selection easier, the designations of the cleaning projectiles are made in accordance with the internal diameter that is to be cleaned.
Close the ptcsystem® launcher and position the nozzle on the end of the pipe or hose. Now press the trigger until the cleaning projectile is discharged from the end of the line.
Tubes are cleaned following cutting, bending and, where applicable, the pre-assembly of the cutting ring. Thoroughly deburr the pipe. A single cleaning process will normally be sufficient. If necessary, cleaning can be made even more effective by using a second cleaning projectile. In order to remove more stubborn deposits or rust, use the abrasive or corundum projectiles. After using corundum projectiles, subsequent cleaning must always be performed using a standard projectile.
Clean the hose after cutting and prior to attachment. This enables optimum cleaning and prevents dirt from remaining on the cross-section transition between the fitting and the inner wall of the hose. Use a suitable device to cut the hose in order to minimise the amount of dirt. Remove any rubber burrs that may have built up. The hose nozzle is inserted into the hose to a depth of a few millimetres. We therefore recommend performing cleaning from both sides.
In some cases, it is necessary to clean the hose assembly after it has already been connected. This may be the case after damage to a hydraulic pump, for example. To clean the hose assembly, use the conical hose nozzles and our FLEX projectiles. Select the nozzle featuring a tip that can be inserted into the fitting. Choose a projectile size that is at least equal to the nominal width of the hose. Test in advance to see whether the projectile can be shot through the selected nozzle.
Use a conical nozzle to clean a tube bundle. For a boss featuring set-back displacement, we recommend using an extended special nozzle. This allows the outer tubes of the boss to be reached. If the heat exchanger is already in operation, use abrasive projectiles in order to remove instances of biofouling. Heat exchangers that are clogged or contaminated with hard deposits cannot be cleaned using the ptcsystem®.
The cleanliness of technical components is frequently determined by means of a gravimetric analysis , which uses a fluid to extract the particles that are adhered to the component . The fluid is filtered and the filter paper is then weighed. The result corresponds to the weight of the residual contamination in mg. If the analysis is extended by means of a microscopic inspection, it is also possible to provide data on the particle size distribution and the particle material. Methods for extraction, analysis and documentation are regulated by guidelines such as the VDA guideline 19 .
The permissible particle exposure is determined based on the complexity of the hydraulic system and the components used. In addition, there are often works standards that define the maximum quantity, size and the permissible particle weight.
The cleaning performance depends on a number of factors, such as the size of the lines and the level of contamination present. Residual contamination analysis can be performed in case of doubt. It can be said that the following rule applies for requirements regarding technical cleanliness : As clean as necessary, not as clean as possible.
We will be happy to advise you.