I get a lot of questions about ISO standards – and some of the most common questions are about clean diesel, or ISO 4406.
The standard 4406 basically calls for a quantifiable measurement of particulate contamination to achieve a maximization of equipment performance and minimize repair and replacement issues and expenses.
But, there’s a lot more that goes into filtering, conditioning, and monitoring clean diesel. Let’s walk through it.
CoalescingCoalescing deals with removing water and particles from the fuel. The main reason pumps and injectors fail? Water. And keeping the water out can be a challenge. That’s because there are many areas where water can be introduced. To prevent the water from creating damage, it’s important to recognize the signs.
Signs like erratic idling, or if the engine cuts out for a moment. Those are good indicators you may have a problem.
What you can do: try the Parker DI Series coalescer and DSO Series separator; they work with each other to separate and remove water from the fuel. These products meet the ISO 4406 standard and can clean up to 5,000 gallons per minute.
When particulates get into your diesel, it can increase engine wear. That results in extensive downtime for repairs and maintenance – and is often the culprit of early parts failures.
The newer the fuel system, the more quickly particles can do their damage. Hard particulates in the fuel system can create difficulty when trying to start the engine, performance issues, and even complete engine failure.
While getting clean fuel isn’t too difficult, keeping it clean can be a challenge.
What you can do: try the Parker DFO Series filters. They’re a great product to use for particulate filtration, and can even lead to more efficient fuel consumption.
With this method, a chemical is added to the diesel that binds with water and particulates that can then be filtered out. Even the most stringent diesel fuel providers cannot guarantee that water and abrasive particles will not make their way into your system at some point down the line. In fact, there are lots of ways your fuel can become contaminated, from the pipeline it traveled through to the tanks it was stored in. Even the engine the fuel is being used to power can be the culprit of contamination.
As your equipment creates mechanical friction, water particles are being created and carried through the system and into your fuel. If this has happened to you, you’re not alone. Carbon deposits are also a natural result of running your equipment and burning fuel. These deposits can also end up in your tank and start wreaking havoc.
What you can do: try the Aquacon AD Series from Parker. It’s a good example of a chemical binder on the market that works in conjunction with filters to make the cleaning process as effective as possible.
Nothing lasts forever. Sadly, many of the reasons a hose fails has less to do with product life cycle and more to do with avoidable mistakes.
Proper hose maintenance can lengthen the life of the hose and keep your equipment up and running. Let’s take a look at the most common reasons hoses fail – and more importantly, how to prevent your hoses from failing.
1. TemperatureTemperature plays a big role in the life of your hose, but many people forget there is more than one temperature to consider when conducting hose maintenance.
2. PressureThe pressure a hose is subjected to can have prolonged or even immediate failures. As mentioned in the section regarding temperature, running fluid continuously through a hose at maximum pressures will lead to tube erosion. Tip: when selecting a hose that will be exposed to continuous high pressures make sure you choose a hose whose maximum pressure rating is higher than the maximum operating pressure.
Pressure surges can be just as fatal to your hose. When pressure surges exceed the maximum pressure rating for the hose which will shorten its life cycle. If your system has high-pressure peaks you have a few options. You can select a hose that has a higher maximum pressure rating or you can choose a spiral reinforced hose that is designed for pressure surges or pulses.
3. Fluid CompatibilityNot all fluids are compatible with the materials used to manufacture hoses. When the hose and the fluids are incompatible, the inner tube of the hose will begin to deteriorate, swell, and in some cases, wash out. Tip: before selecting your hose, make sure the materials used to manufacture it are compatible with the fluid being pumped through your machinery. Most hoses come in a variety of materials to help avoid incompatibility issues.
4. Bend RadiusYes, hoses are relatively flexible, that does not mean they are designed to be bent in extreme ways. When you exceed the bend radius you can experience a flattening in the bend or even kinking of the hose, all of which will restrict flow.
You will also eventually see ripping of the outer material on the outside curve of the bend. Tip: to avoid this, change the length of the hose, reroute the hose to avoid excessive bending. You may even need to replace the assembly with fittings and hoses that meet the bend radius you need.
5. Dry AirWhen the internal air of the system is too dry it can cause cracks on the inside of the tube. This is hard to spot because the hose will remain flexible and there will be no cracking under the fittings.
You will, however, see signs of external leakage. Tip: the best solution for this problem is to replace your hose with tubing that is rated for dry air. These kinds of hoses typically have PKR or EPDM rubber inner tubes which are preferable for systems with an aggressive drying system. You can also try to raise the dewpoint of the air if that is applicable to your system.
6. Improper AssemblyPutting together your hose and fitting assembly can require cutting a hose. This can lead to debris in the tubing and also cause fractures on the inner tube which will result in leakage. Tip: to avoid leaking and potential contamination, make sure all components of the assembly are completely clean. Once everything is put together, cap the ends until the assembly is installed to avoid potential recontamination.
There you have it. Six of the most common reasons hoses fail. Now you’ll be better equipped when choosing hoses; and if you have any questions, don’t forget our experts are always a call away.
Three Things To Know When Choosing Hydraulic Fittings
Trying to choose the right hydraulic fitting can sometimes feel like you are on a game show. Close your eyes, turn around three times and pick one. The best you can hope for is that the one you land on is not a complete fail. With all of the different types of threading and seal options, it can be overwhelming, to say the least. There really is a method to the hydraulic fitting madness. Here are the three things you need to know when choosing your next hydraulic fitting.
Pro Tip: Part AvailabilityJIC and NPT fittings have been the standard for quite some time. That being said, they are easier to find than some of the newer fittings. If you need one of the newer fittings you may not be able to just pick one up. It’s always good to plan around the possibility of having to order one.
Pro Tip: VersatilityDespite the changes taking place from a manufacturer and rating level, there are still some benefits to using other types of fittings. The versatility of the JIC fitting is important to note. There is a large variety of these fittings and connectors that allow easy conversion to different ports and sizes.
Finding the right hydraulic fittings and seals for your equipment shouldn’t be rocket science, but with all of the evolving standards and applications, it can certainly feel like it. Follow these tips and you will find that making the right selection isn’t that hard. All it takes is a little know-how and an understanding of your system to make choosing your hydraulic fittings a breeze.
The safety of your hydraulic hose assembly is an issue we all keep top of mind. Despite the technological advancements improving the safety of each component, fitting leaks are still a pesky problem that can have disastrous consequences.
Because the pressurized contents in the line can cause a major medical emergency, it’s important to know what not to do when you have a fitting leak.
Step 1: If you suspect it, check itDon’t: ignore the possibility of a leak. The number one thing you can do to ensure hose and fitting failure: blow off a potential leak. It’s common for a small leak to be the first sign of a bigger problem within the system.
Do: perform regular system checks and tracking the overall system performance can help you head off any problems before disaster strikes.
Step 2: Turn it offDon’t: leave the system pressurized; this can increase the risk of an explosive eruption of fluid, leading to possible injury and serious damage to the system.
Do: before you do anything, turn off the system.Remember that just because the system is depressurized doesn’t mean that everything is safe. There can still be pressure build up if any of the fluid became trapped.
Oh yeah – don’t use your hand!Most hydraulic hose assemblies are moving pressurized fluids that can reach pretty extreme temperatures. By using your hand to test for leaks you are exposing yourself to dangerous chemicals, extreme temperatures, and very high-pressure contents.
All of these elements present medical dangers that will result in the need for emergency medical care, surgical solutions, and can even be fatal if not treated right away.
Pro tip #1: Forget the fireMany leaks begin as pin-hole leaks that result in clouds of vapor gathering near the leak. These vapors can be incredibly flammable. The use of welding equipment, cutting torches, or even a simple lighter used to help you see better can cause an explosion. Taking extra precautions with an open flames or equipment that might cause a spark will help prevent an explosive outcome.
Pro tip #2: Tighter doesn’t mean betterWhile it’s true that some leaks can be attributed to a loose nut, over-tightening can be even worse.
When you torque a nut beyond sufficiently tightened, you can actually create a fitting leak and reduce the overall life of the fitting. So while your impulse may be to tighten it as much as you can, it’s a better approach to check the integrity of the fitting first.
Three “dont’s” to keep in mind:1. Don’t forget… Protect the systemOnce you start repairs on the leak, many people forget to protect the system and the components. Something as minor as dropping a part on the ground can introduce contaminants into the system. Even the smallest bit of dirt has the potential to damage the entire system. Taking extra care while making repairs can prevent bigger issues down the road.
2. Don’t… Assume It’s The FittingJust because there is fluid leaking around the fitting doesn’t mean that’s the origination point for the leak. So before you just slap a new fitting on the hose, check the entire assembly to make sure there is not a leak somewhere else in the system.
3. Don’t… Reuse The O-RingThe o-rings should always be replaced whether you are putting a reusable fitting back on or installing a new one. O-rings are easily cracked and should be replaced to ensure a tight and leak free seal.
Similar Doesn’t Mean SameNever replace a fitting with a different one, even if it’s similar. Even though you may have a longer down time while you wait for the right fitting, you will save yourself a lot of wasted time and money by using the correct parts the first time.
To fix it right means to fix it once.
Clean, Clean, Clean!When replacing a fitting, you are risking the introduction of foreign material that can destroy the integrity of your system. By cleaning the connecting ends of the fitting before putting them on you will significantly reduce the potential for dirt or metal shards to enter the system.
While leaks are not always preventable, there are things you can do to keep damage and fluid loss to a minimum. Keeping this list of what not to do on hand could just save you a lot of time and money.