TEST EQUIPMENT & INSTRUCTIONS CONSIGNE for hydraulic

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Page 1/21 Denison vane technology

A-TP-30533

TEST EQUIPMENT & INSTRUCTIONS

for hydraulic fluids performance evaluation

on Parker pumps (Vane and Piston)

Ph. PARREAU

June 25th 1999

Form 1008.2b

DATE

1 TEST TARGETS

Evaluate hydraulic fluids on vane pumps at 3600 psi [250 bar] and on piston pumps at 4000 psi [280 bar], 1700 rpm, and high temperature, with and without presence of water. [Intermittent pressure cycle].

Check in time, the evolution of the following characteristics: viscosity, filterability, thermal stability, shear stability, anti-corrosion fluid capability, pump wear with or without water-addition.

Find a reliable and un-contradictable test method on the evaluations of fluid aptitude, to be used with Parker Denison pumps, in severe duty applications.

Improve performances and characteristics of pump and fluid.

Test with oil ISO 46 grade.

2 TEST PHASES

Phase I: 190 10 liter oil of quality adjusted to NAS 1638 class 7/ 8. - See § 1.9 page 5/ 16. -

Phase II: Same fluid as phase 1 adjusted at 175 5 liters, but with 1% of water (see water specification) added between 307 and 308 hours.

- Water addition procedure:

At the wet phase starting, add water at pump suction level at ambient temperature (30 ml every one minute during one hour total = 1800 ml). Temperature regulation set at 80° C. Maintain test cell temperature at 25 - 35° C.

Vane and piston pumps will run at 700 - 1000 psi [49 - 70 bar] circuit pressure.

Maintain water concentration throughout the phase duration [0.8 to 1.2 % required]

At minimum circuit pressure eventually add water if needed and record.

Water % determination method: Karl Fischer.

Water decantation, when unexpected:

In case of prolonged stop (minimum fixed acceptable time – 1 hour function of fluid quality). No risk if detergent fluid, otherwise the oil manufacturers must define the risk. Drain decanted water is needed at the lower points of circuit. Recuperate either water/ oil mixture in a very clean container or reintroduce 1800 ml of new water in the circuit as specified above.

- Restarting procedure:

1. Stop the cycle mode.

2. Open the delta P through the filter valve

3. Adjust the pressures as following

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4 Close the delta P through the filter valve

5 Switch to cycle mode

After restarting, make sure the quantity of added water is well 0.8 to 1.2 % as required.

Evaluation:

If the vane cartridge is destroyed, remove rotor and vanes. Continue the test for HF-1 evaluation.

If piston rotating group is destroyed, remove barrel, pistons, wear plate and port plate.

Continue the test for HF-2 evaluation.

Test Results

Vane Pump Piston Pump Approval

S S HF-0

S U HF-2

U S HF-1

U U Reject

3 TEST BENCH EQUIPMENT – Pump P/N: R14-10915

Test bench capable to test a T6H20C-M17 pump in the following conditions:

- See scheme of test bench - Appendix A1 - TP-30533 -.

Theoretical constant drive speed 1700 rpm.

Intermittent operating pressure vane pump 3600 psi [250 bar] and piston pump 4000 psi [280 bar] after pre-starting phase, 3000 psi [210 bar] for water base fluid.

Cycle: 2 sec. P mini , 2 sec. P maxi - see Appendix A2

Reservoir, taper at suction, of 150 liter maximum capacity. Oil level 300 mm over the

pump axis. Total circuit capacity 190 10 liters at the test starting (coming from a same

conditioning) and adjusted at 175 5 liters at the beginning of the wet phase (the fluid samples needed at each phase explain this difference).

Filtration 12 m absolute type Parker 926839Q.

Maintain a circuit temperature at suction of

230° F 40 [110° C 5] phase I and 176° F [80° C 5] phase 2, mineral base oil.

113° F 40 [45° C 5] water base fluid.

158° F 40 [70° C 5] vegetable or synthetic base oil.

Heat exchanger: Alfa Laval Plate Heat Exchanger Type M6-MFG.

Circuit open to workshop atmosphere: 3 m filtration Parker H00834/04.

Ensure the circulation into the oil reservoir without aeration of tested fluid.

Vane pump Piston pump Duration

50b 50b 20mn

100b 100b 10mn

150b 150b Till 110°C (or 80°C depending on the phase) is reached

S = Satisfactory U = Unsatisfactory

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Form 1008.2b

DATE

Pressure at suction: -1.40 psi [-0.1 bar] Pe +1.40 psi [+0.1 bar] relative. +1.40 psi [+0.1 bar] for water base fluid.

The flushing of test rig:

Before every test, clean up all the circuit by flushing using a pump not used for the test.

Use one drum of base oil (any group) to run for a minimum of 8 hours with both the

pumps at Pmin and the max temperature set to 70°C. On completion drain the rig.

Use one drum of test oil to run until there is less than 250ppm of water (minimum of

18 hours) with both the pumps at 100 bar and the oil temperature set to 110°C.

Once the above stage is complete run the piston pump for 10 minutes at 280bar so

the compensator is active. On completion drain the rig.

One drum of test oil to be pumped into the rig through a 10μm filter. Check NAS

cleanliness of the oil, and if it is above class 8 then the rig should be run to circulate

the oil through it’s filters until a NAS class 8 is obtained.

If the NAS class is below 8 once it is pumped in to the rig then it was agreed that nothing could be done about it being that clean.

Break-in phase:

- The D1VW stays “OFF” during the break-in. Only the drain flow is passing through the drain flowmeter. - Close the AV700 and screw on the pressure compensator at the maximum (full flow). - Start the break-in at ambient temperature. - Note output flow and drain flow at following steps at continuous pressure and maximum flow, 1 hour in duration:

Vane pump Piston pump

Pmini Pmini

714psi [ 50b ] 714psi [ 50b ]

2143psi [ 150b ] 2143psi [ 150b ]

Pmini 3000 psi [ 210b ]

3000 psi [ 210b ] Pmini

Pmini 3600psi [ 250b ] For displacement

calculation

3600psi [ 250b ] Pmini For displacement

calculation

At the end of break-in: - Set the vane pump @ minimum pressure. - Send an electric signal to the piston pump proportional valve to get 310b - Unscrew the pressure compensator to adjust the 280b.

- Unscrew the AV 700 with D1VW “ON”. The drain flowmeter reads case drain + leakage flow through the AV700 = 15L/mn +/- 2L/mn. Come back D1VW “OFF” to read only the case drain on the flowmeter during the test. Every 100 hours and at the beginning of the wet phase verify the 15L/mn +/- 2L/mn by D1VW “ON/OFF” and readjust if necessary.

Run the whole test (608 hours in duration) with a new measured Parker pump.

Same test fluid used for both test phases.

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Form 1008.2b

DATE

4 TEST RESTRAINTS

Hydraulic measurements:

Time needed to stabilize the system and to measure: 20 sec. < T < 30 sec.) then snapshot or average.

At the end of breaking in, after 7 hours.

1/ 25 hours from 7 to 107 hours (included).and from 308 to 408 hours.

1/ 50 hours from 107 to 307 hours and from 408 to 608 hours.

Q outlet [l/min].Q1 = total flow piston pump + vane pump

Q outlet [l/min].Q2 = vane pump flow.

Q drain [l/min].Q3 = drain piston pump flow.

Q piston pump [l/min] = Q1 – Q2.

T torque[Nm] with vane pump at 3600 psi [250 bar] and piston pump 4000 psi

[280 bar].

Suction, outlet vane and piston pumps and drain temperatures.

Vane and piston pumps outlet pressures.

p measurement through the filter. [P1 – P2] with always (dry and wet phases) P2

= 71.4 psi [5 1 bar], vane pump at P mini and piston pump at P mini.

Maximum p: 100mb dry phase and 600mb wet phase. For safety, this valve can be activated electronically as an option.

Fluid contamination measurement behind the filter (only in dry phase).

New filter cartridge for each phase and kept for all the test duration.

Make hydraulic fluid measurements as close as possible to the following intervals: 7, 107, 207, 307, 308, 333, 408, 508, 608 hours. Report the exact sample time.

Fluid viscosity. Maintain sample temperature at 80 - 90° C for 24 hours to dry it during phase II.

Water percentage into the fluid.

Fluid filterability. – See TP-02100.-

Mechanical measurements: - See test results - .

PARKER TEST RESULT ANALYSIS (New pump pieces measured just before shipment).

Vane pump.

Total weight loss [vanes + holdout pins: 15 mg maxi].

Internal cam ring profile (surface) aspect. (Not any evidence of seizing, burnishing or ripples).

Port plate surface aspect. (Not evident marks of seizing or abnormal wear).

Piston pump.

Piston aspect.

Wear plate surface aspect.

Hanger axis and bushes aspect.

Barrel and port plate aspect.

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Form 1008.2b

DATE

Flow, torque loss and efficiency (mechanical, volumetric) curves.

Drain flow curve = f (time After 20 seconds stabilization :

Drain temperature curve = f (time) ( snapshot or average )

Filter pressure drop curve = f (time). Vane P mini Piston 250 b

Viscosity = f (time). Vane 250 b Piston P mini

Filterability f = f (time). Vane P mini Piston P mini

Total water amount (at start + water added). Vane 250 b Piston 280 b

p Through the filter Vane P mini Piston 280 b

For any tested fluid, identification is required for the file:

Fluid identification, completed by the fluid supplier: TP-30560.

Test results: Appendix B of TP-30533.

Approval form completed by Parker Vierzon, France: Appendix C of TP-30533 -.

TEST STAND CERTIFICATION

The test stand is certified as soon as one test is performed using T6H20C and reference fluid. Test stand is referenced every 2/ 3 years in April.

Only Parker's engineering in Vierzon France can deliver this certification.

TEST SEQUENCES

1) Test rig flush procedure before testing

1.1 Drain oil from stand by opening all drain valves on test rig including heat exchanger, expansion tank. Remove both filters.

1.2 Install flush pump.

1.3 Jog motor to remove residual oil in the circuit.

1.4 Install flush filters and flush with base oil group 1 for 8 - 12 hours. Maintain pressure and temperature at minimum.

1.5 Repeat steps 1.1 - 1.3.

1.6 Install flush filters, charge test rig with flush oil and run at 110° C at test cycle conditions for 24 hours.

1.7 Repeat steps 1.1 - 1.3.

1.8 Install flush filters and charge test rig with oil to be tested.

1.9 Circulate fluid in test rig at minimum pressure and temperature conditions (with

flush pump) until the oil meets NAS 7 to 8.

1.10 Remove the flush pump, install new filters and install the pump test with all internal parts oiled with the tested oil. Do not forget between the hanger and the wear plate.

2) Tare again the pressure compensator at 4000 psi [280 bar].

3) Fluid sample-taking # 1 when filling at half of drum capacity (after 100 liters), report on

Appendix D, step 1.

4) 7 hour break-in period.

5) Test cycle as specified (300 hours in duration).

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DATE

6) Hydraulic measurements and samples # 2 to 10, each 25 hours from 7 up to

107 hours and each 50 hours up to 307 hours, report on Appendixes E, F, G.

7) Open the pump after performing the first phase test. Take pictures and write comments about part aspect.

8) Filling of circuit with water during the 308th hour test period according page 1/ 15

procedure. Make sample # 11 and report it on Appendixes E, F, G.

9) Test cycle as specified (300 hours in duration).

10) Hydraulic measurements and samples # 12 to 19, each 25 hours from 308 up to

408 hours and each 50 hours up to 608 hours then report on Appendixes E, F, G.

11) Remove the test pump used for evaluation

12) Take pictures and write comments about part aspect.

13) Return the pump to Parker in Vierzon France for inspection.

Note: Vane pump.

If the pump discharge at 3600 psi [250 bar] should drop below 52 l/min in dry phase and 68 l/min in wet phase, (piston pump at 0 flow), stop the test.

Piston pump.

If the pump discharge at 3600 psi [250 bar] should drop below 56 l/min in dry phase and 59 l/min in wet phase, or drain flow > 17 l/min in both phases, stop the test.

5 SAFETY PROCEDURE

1) Prior to the individual entering the test cell, reduce the operating pressure of both the vane and piston pumps to the minimum pressure. At this time, the cycling of both pumps will be paused and this time will not be accumulated as part of test.

2) Have the individual enter test cell and perform the necessary task (i.e. pull oil samples or make slight mechanical adjustments).

3) After the individual has completed their task, has exited the test cell, and does not need to re-enter it, ramp the vane and piston pumps pressures back to test conditions and begin cycling again. Once this is done, test time will be accumulated as part of test.

See: Appendix A1 "Test Bench Scheme"

Appendix A2 "Test Bench Scheme – Cycle

Mineral & Biodegradable Hydraulic fluids"

Appendix A3 "Test Bench Scheme – Cycle

Water Base Fluids"

Appendixes B, C, D, E, F, G "Evaluation forms"

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Form 1008.2b

DATE

APPENDIX A1 Recommendations:

Piping should be rubber and stainless steel only.

The pressure P1 and P2 should be recorded down to 1/100 of bar (i.e. : 3.05 bar).

Dual filter stainless steel can be used in case filter elements clogged due to the corrosion by water during test.

Intermittent pressure cycle through proportional pressure relief valve.

TEST BENCH SCHEME

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June 25th 1999

Form 1008.2b

DATE

ENGINEERING

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A-TP-30533




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June 25th 1999

Form 1008.2b

DATE

ENGINEERING

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A-TP-30533




Ph. PARREAU

June 25th 1999

Form 1008.2b

DATE

ENGINEERING

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DATE

APPENDIX A2 CYCLE

Mineral & Biodegradable Hydraulic Fluids

Theoretical: 608 hrs = 547200 cycles (around 540.000 cycles effective)

For piston and vane pumps:

p Pressure rise = 2,500 ----- 3,500 bar/ s.

t

p

Pressure down = 2,500 ----- 3,500 bar/ s.

t

Pressure ramps will be measured following SAE J745 norm between 70b & 225b.

APPENDIX A3

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CYCLE

Water Base Fluids

Theoretical 608 hours = 91200 cycles (around 90.000 cycles effective)

For piston and vane pumps:

p

Pressure rise = 2,500 ----- 3,500 bar/ s.

t

p

Pressure down = 2,500 ----- 3,500 bar/ s.

t

Pressure ramps will be measured following SAE J745 norm between 70b & 225b.

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Form 1008.2b

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APPENDIX B

TEST PERFORMANCES REPORT : N° Pump N°:

Company name :

Fluid identification :

Laboratory test - Name :

Vane pump

Start up after After

Test results to be recorded in phase I 7 hours 107 hours 207 hours 307 hours

Output flow @ 250 bar [l/mn]

Input torque @ 250 for vane pump / 280 bar for piston pump

[Nm]

Inlet temperature [° C]

Outlet temperature [° C]

Delta P through the return filter both pumps at P min

[m bar]

Fluid contamination NAS-1638 - Class

Water content [%]

Fluid viscosity @ 40° C [cSt]


TP-02100 0 %

2 %

After

Test results to be recorded in phase II 308 hours 408 hours 508 hours 608 hours


Input torque @ 250 for vane pump / 280 bar for piston pump

[Nm]



Delta P through the return filter both pumps at P min

[m bar]

Water content [%]



TP-02100 1 %

2 %

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APPENDIX B

TEST PERFORMANCES REPORT : N° Pump N°:

Piston pump

Start up after After

Test results to be recorded in phase I 6 hours 107 hours 207 hours 307 hours

Output flow @ 250 bar [l/min]

Drain flow @ 250 bar [l/min]



Drain temperature [° C]

After

Test results to be recorded in phase II 308 hours 408 hours 508 hours 608 hours


Drain flow @ 250 bar [l/min]



Drain temperature [° C]

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APPENDIX C

"APPENDIX B" form correctly filled : YES NO

"APPENDIX C" form Test report filled : YES NO

"APPENDIXES E & F" measurements : YES NO

Comments on tests Vane pump Piston pump Pump hydraulic performances :

Pump N° : parts inspection :

Fluid filtration aptitude and performances :

Fluid performances : Parker Vierzon France evaluation of fluid type:

Under pump test TP-30533

PASS / REJECT HF (*) Data to be recorded after test finished, to be filled by Parker Vierzon France.

Piston aspect

Piston land Ra roughness [ inch]

Vane pump + pin weight loss [mg]

Cam surface Ra roughness [ inch]

Port plate surfaces

Hanger bushes & axis aspect

Wear plate aspect

Port plate aspect

Test results made by Ph. PARREAU Date:

Approval # :

Company name :

Fluid identification :

Fluid manufacturer :

Additive identification :

Base stock :

Base Group API :

ISO classification (ISO 6743-4) :

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APPENDIX D

COMPANY CONFIDENTIAL

REVIEW OF QUALIFICATION OF HYDRAULIC FLUIDS USED IN T6H20C-M17 PUMP.

In conformity with specification TP-30533.

Fluid test :

Pump # :

Results of fluid measurements taken before test.

Viscosity (cSt]

Water content

[%]

Filterability

TP-02100 Pollution class

NAS 1638 Water

at 104°F

[40°C]

at 212° F

[100°C]

0 % 2%

Results of measurements specified by standard TP-30533.

Flow measurements during breaking of pump:

Vane Pump

P mini =

50 bar 150 bar 210 bar 250 bar

Flow ([/mn]

Piston Pump

P mini =

50 bar 150 bar 210 bar 250 bar

Flow [l/mn]

Drain [l/mn]

Notes: a) Revolution speed is kept up between and rpm.

b) Inlet pressure of pump between…… and mbar.

c) Number of cycles made………………..

d) Total water addition…………………….. mL.

Name : Date:

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APPENDIX D

COMPANY CONFIDENTIAL

REVIEW OF QUALIFICATION OF HYDRAULIC FLUIDS USED IN T6H20C-M17 PUMP.

In conformity with specification TP-30533.

Fluid test :

Pump #

Anomalies remarked

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APPENDIX E

FLUID TEST: Pump #

VANE PUMP PERFORMANCES

Hour running

Flow

[l/mn]

Torque

[Nm]

Fluid Temperature [° C]

Time including breaking

at P mini =

at 250 bar vane pump piston pump at 250 bar at 280 bar

at inlet at outlet

after 20 seconds break-in period

7

32

57

82

107

157

207

257

307

308

333

358

383

408

458

508

558

608

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APPENDIX F

FLUID TEST:

Pump #

PISTON PUMP PERFORMANCES

Hour running

Flow [l/mn] Drain Fluid Temperature [° C]

Time including

breaking

at P mini =

at 250 bar

at 250 bar at inlet at outlet

Flow

[l/mn]

Temperature

[° C]

after 20 seconds break-in period

7

32

57

82

107

157

207

257

307

308

333

358

383

408

458

508

558

608

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APPENDIX G

FLUID FILTERABILITY PERFORMANCES

Hour running

Delta P filtering element

[mb]

Water Content

Time including

breaking

both at

P mini= Vane

Vane pump at

P mini,

[%]

Piston

Piston pump at

250 bar

7

32

57

82

107

157

207

257

307

308

333

358

383

408

458

508

558

608

Name: Date:

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WATER SPECIFICATION

The addition of water in the T6H20C test circuit aims to simulate the

introduction of water into a customer hydraulic circuit. This tap water contains bacteria and minerals. Depending on the location of the laboratory, this water will be more or less

polluted by bacteria and minerals in value and quantity. For the test to be repeatable, we must use water that is close to the customer's use and not water that is free of all bacteria and minerals, such as distilled water.

Use the water closest to Evian water, here are the characteristics:

Mg/L

Calcium Ca2+ 78/80

Magnesium Mg2+ 24/26

Bicarbonates HCO3- 357/360

Sulfate SO42- 10/14

Fluor F

PH 7,2

Nitrate NO3 3,8

Residue à sec 345

Silica SiO2 13,5/15

Chlorides Cl- 4,5/10

Potassium K+ 1

Sodium Na+ 5/6,5

Ohm/cm 1700

Documents

TEST EQUIPMENT & INSTRUCTIONS CONSIGNE for hydraulic