ISO 4406 Coalescer: Precision Contamination Control for Hydraulic & Lubricant Systems
Product Introduction
The ISO 4406 Coalescer is a specialized filtration system engineered to meet the stringent contamination control requirements of the ISO 4406 standard for hydraulic oils, lubricants, and industrial fluids. Designed for industries where fluid cleanliness directly impacts equipment reliability—including natural gas processing, aviation fuel handling, and heavy machinery—this coalescer ensures precise separation of water, oil droplets, and solid particulates to achieve and maintain ISO 4406 cleanliness codes (e.g., 18/16/13, 17/15/12).
ISO 4406 is the global benchmark for quantifying particulate contamination in hydraulic fluids, defining acceptable levels of particles ≥4 μm, ≥6 μm, and ≥14 μm per milliliter. Conventional coalescers often fail to consistently meet these thresholds, leading to equipment wear, downtime, and premature failure. The ISO 4406 Coalescer solves this by integrating advanced coalescence technology with ISO 4406-compliant filtration, delivering unmatched fluid purity for critical applications.
Key Features & Advantages
1. ISO 4406 Compliance Guaranteed
Code-Specific Performance: Achieves and maintains target ISO 4406 cleanliness codes (e.g., 16/14/11 for sensitive servo valves, 19/17/14 for general hydraulic systems) via customizable media configurations.
Real-Time Monitoring: Integrated laser particle counters (optional) provide continuous ISO 4406 code verification, alerting operators to contamination spikes.
2. Dual-Stage Contamination Removal
Coalescence for Water/Droplets: Removes 99.9% of free water and emulsified oil droplets (≥0.1 μm) via hydrophobic media, merging them into larger droplets for gravity separation.
Filtration for Particulates: Multi-layer depth media (glass fiber + cellulose) captures solid particles (0.5–100 μm), with Beta Ratios (β) > 75,000 for submicron debris.
3. Robust Construction for Harsh Environments
Material Compatibility: Housing made from 316L stainless steel (electropolished) or carbon steel with epoxy coating; media includes PTFE-coated fibers (chemical resistance) and stainless steel mesh (abrasion resistance).
Pressure & Temperature Tolerance: Operates at 1–400 bar (14.5–5800 psi) and -40°C to +150°C (-40°F to +302°F), suitable for offshore rigs, refinery hydraulics, and arctic drilling.
4. Extended Lifespan & Low Maintenance
Anti-Fouling Design: Open-cell media structure prevents clogging, with a lifespan of 24–36 months (vs. 6–12 months for standard filters).
Hot-Swappable Cartridges: Tool-free replacement minimizes downtime; modular design allows upgrading to finer media for evolving ISO 4406 requirements.
5. Compliance with Global Standards
Certifications: ISO 4406:2017, ISO 11171 (calibration of particle counters), NAS 1638 (aerospace contamination), and ASTM D2276 (hydraulic fluid cleanliness).
Working Principle
The ISO 4406 Coalescer combines coalescence and depth filtration to achieve dual contamination control, aligned with ISO 4406’s particle counting methodology:
1. Fluid Intake & Pre-Filtration
Contaminated fluid (hydraulic oil, lubricant, or fuel) enters through a diffuser, where a coarse screen removes large debris (>100 μm) to protect downstream media.
2. Coalescence Stage (Water/Oil Droplet Removal)
Capture: Microscopic water droplets and emulsified oil (0.1–5 μm) collide with hydrophobic PTFE-coated fibers via turbulent flow and van der Waals forces.
Merging: Droplets merge into larger aggregates (50–500 μm) as they navigate the media’s tortuous pathways. The hydrophobic surface repels oil, enhancing coalescence efficiency.
3. Gravity Separation
Enlarged water/oil droplets settle at the housing’s sloped base, isolated from the clean fluid outlet. A float-activated drain valve automatically removes accumulated contaminants.
4. Depth Filtration (Particulate Removal for ISO 4406)
Particle Capture: Remaining fluid passes through a multi-layer depth media bed (cellulose + glass fiber). Particles (0.5–100 μm) are trapped via sieving, adsorption, and inertial impaction.
ISO 4406 Verification: The media’s Beta Ratio (β) ensures removal efficiency matches target codes (e.g., β=75,000 for 4 μm particles achieves 99.987% efficiency, critical for ISO 4406 16/14/11).
5. Clean Fluid Exit
Purified fluid exits through a high-integrity outlet, with optional sensors to confirm ISO 4406 code compliance before entering sensitive equipment.
Application Scenarios
1. Natural Gas Processing (Hydraulic System Protection)
Challenge: Natural gas compressors and wellhead controls rely on hydraulic systems exposed to moisture, sand, and sour gas (H₂S). Contamination (ISO 4406 >20/18/15) causes valve sticking and seal failure.
Solution: The ISO 4406 Coalescer removes 99.9% of water and reduces particulates to 16/14/11. Stainless steel housing resists H₂S corrosion, extending hydraulic pump life by 50%.
2. Aviation Fuel Handling (Purity for Turbine Engines)
Challenge: Jet fuel (Jet A-1) must meet ISO 4406-like cleanliness (NAS 1638 Class 6) to prevent fuel filter clogging and engine wear. Water and particulates (e.g., rust from storage tanks) risk icing and combustion inefficiency.
Solution: Hydrophilic media removes <1 ppm free water, while depth filtration captures 99.9% of particulates ≥2 μm. Complies with ASTM D1655 and DEF STAN 91-91, ensuring fuel meets ISO 4406-equivalent standards.
3. Hydraulic Oil/Lubricant Contamination Control (Industrial Machinery)
Challenge: Excavators, presses, and wind turbine gearboxes use hydraulic/lubricating oils contaminated by water (from condensation) and metal shavings (from wear). ISO 4406 codes >19/17/14 accelerate component failure.
Solution: The coalescer reduces water to <50 ppm and particulates to 17/15/12. Modular design allows field upgrades to 15/13/10 for high-precision systems (e.g., CNC machines), cutting oil change costs by 40%.
Technical Data
Parameter | Specification |
|---|
Model | ISO4406-C200 (Standard), ISO4406-C400 (High-Pressure) |
Fluid Type | Hydraulic oil, lubricants, aviation fuel, natural gas condensates |
Operating Pressure | 1–400 bar (14.5–5800 psi) |
Temperature Range | -40°C to +150°C (-40°F to +302°F); cryogenic variant: -60°C (LNG) |
Flow Rate | 50–5000 L/min (13–1320 GPM) |
Beta Ratio (β) | β≥75,000 @ 4 μm (particulates); β≥10,000 @ 0.1 μm (water droplets) |
Removal Efficiency | 99.9% water/oil droplets; 99.987% particulates (4 μm) |
Pressure Drop | <0.1 bar @ rated flow (stable across ISO 4406 codes) |
ISO 4406 Compliance | Achieves 12/10/7 to 20/18/15 (customizable via media selection) |
Material Compatibility | 316L stainless steel, PTFE, carbon steel (epoxy-coated), EPDM seals |
Lifespan | 24–36 months (industrial environments) |
Certifications | ISO 4406:2017, ISO 11171, NAS 1638, ASTM D2276, API 618 |
Maintenance Guidelines
1. Routine ISO 4406 Code Monitoring
Particle Counting: Use an ISO 11171-calibrated laser counter weekly to verify fluid cleanliness. Target codes should not exceed design specifications (e.g., 18/16/13).
Differential Pressure (ΔP): Monitor ΔP daily; replace media if ΔP exceeds 0.2 bar (initial ΔP: 0.03–0.07 bar), indicating clogging.
2. Media Replacement
When to Replace: After 24–36 months, or when ΔP >0.2 bar, or if ISO 4406 codes drift above target.
How to Replace: Use OEM-certified media cartridges matching the original ISO 4406 code. For multi-stage systems, replace all stages simultaneously to avoid flow imbalances.
3. Cleaning Protocols
Gas Service: Flush with dry nitrogen to remove residual moisture.
Liquid Service: Soak in a mild alkaline detergent (pH 9–10) for 30 minutes, then rinse with deionized water (resistivity >18 MΩ·cm).
4. Troubleshooting
High ISO 4406 Codes: Check for seal leaks (contaminant ingress) or incorrect media (wrong Beta Ratio).
Excessive ΔP: Inspect for media compaction (over-tightened housing) or chemical incompatibility (e.g., using non-approved additives).
8 Frequently Asked Questions (FAQs)
1. What is ISO 4406, and why is it important?
ISO 4406 is a standard for classifying particulate contamination in hydraulic fluids, using a code (e.g., 18/16/13) to denote the number of particles ≥4 μm, ≥6 μm, and ≥14 μm per milliliter. It ensures fluid cleanliness to prevent equipment wear and failure.
2. How does this coalescer differ from standard filters?
Standard filters focus on either water (coalescers) or particulates (depth filters). The ISO 4406 Coalescer combines both, with media and design optimized to meet specific ISO 4406 codes—something standard filters cannot guarantee.
3. Can it handle aviation fuel?
Yes. Hydrophilic media removes water to <1 ppm, and depth filtration captures particulates to NAS 1638 Class 6 (equivalent to ISO 4406 15/13/10), complying with ASTM D1655 for jet fuel.
4. What is the recommended maintenance interval?
Inspect ΔP and ISO 4406 codes weekly; replace media every 24–36 months (or when ΔP >0.2 bar). Perform full system audits annually.
5. Is it suitable for offshore oil rigs?
Absolutely. 316L stainless steel housing and H₂S-resistant seals (FFKM) withstand marine environments. Rated for 400 bar pressure, it handles high-pressure mud pumps and wellhead controls.
6. How does it achieve ISO 4406 16/14/11?
Via a β=75,000 media for 4 μm particles (99.987% efficiency) and coalescence for water. Real-time particle counters verify compliance.
7. What is the ROI for industrial users?
Reduces hydraulic component replacement costs by 50%, cuts oil change frequency by 40%, and avoids downtime—payback in 12–18 months.
8. Can it be customized for unique ISO 4406 codes?
Yes. We offer media tuning (e.g., finer fibers for 15/13/10) and modular staging to match your exact contamination control needs.
Conclusion
The ISO 4406 Coalescer is the definitive solution for industries where fluid cleanliness is mission-critical. By combining ISO 4406-compliant particulate removal with efficient water/oil coalescence, it protects hydraulic systems, aviation fuel integrity, and natural gas processing equipment from contamination-related failures. With its robust construction, low maintenance, and guaranteed code compliance, this coalescer ensures operational reliability, extends asset life, and reduces total cost of ownership.
Ready to achieve and maintain your target ISO 4406 codes? Contact our contamination control experts today for a customized solution.
