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HIAC Portable Oil Diagnostic System (PODS) Overview

HIAC Portable Oil Diagnostic System (PODS) Overview. PODS Applications. Military fluid power Industrial fluid power Construction and mining Aerospace. Introduction to PODS. Measures, stores and reports oil condition parameters essential for reliable hydraulic systems operation

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HIAC Portable Oil Diagnostic System (PODS) Overview

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  1. HIAC Portable Oil Diagnostic System (PODS)Overview

  2. PODS Applications • Military fluid power • Industrial fluid power • Construction and mining • Aerospace

  3. Introduction to PODS • Measures, stores and reports oil condition parameters essential for reliable hydraulic systems operation • Analyzes fluids and lubricants in online or bottle sampling modes to determine the machine’s operating condition immediately • Instant analysis is as accurate and precise as traditional laboratory analysis that normally takes weeks • Real-time assessment of the oil under operating conditions

  4. Results of Contamination Damage • Power loss • Loss of surface lubrication • Degradation of operation • Intermittent operation • Catastrophic failure • Costly repairs • Costly downtime • Costly rework

  5. PODS “Elevator/Lift Description” • Offers flexibility in sampling with an online or lab/bottle mode for multi-variant analysis of particle counts, viscosity and temperature. • Capable of calibration to full ISO 11171 standards, the PODS performs in harsh environments, accurately monitoring hydraulic and lubricating fluids.

  6. PODS Features • 8-channel display • Bottle and online sampling • Viscosity and temperature measurement • 500 sample memory • High speed thermal printer buffer • Flash programmable • Aluminum alloy sheet metal casing • Built-in bottle sampler pressure chamber • Compact power supply • Refillable CO2 bottle or shop air operation • Multiple language capabilities • Full ISO 11171 calibration capability

  7. Method of Operation • Online mode • Sample fluid directly from the hydraulic system using the online sample adaptor • After pressing the start key: • Fluid flows through the particle counter, purging the fluid path • After sampling the required purge volume, the instrument begins the particle count • Flow is regulated automatically • No propulsion or mechanical interference required; system utilizes hydraulic system pressure • Upon completing specified number of runs, flow stops and instrument prints out results

  8. Method of Operation • Bottle Mode • Place bottle of fluid for analysis into the bottle sampler adaptor, which is then fitted to the PODS • Press the start key • Air or gas flows into the bottle sample adaptor, and pressurizes it to 7 bar (90 psi) • Fluid begins to flow through the instrument • After sampling the required purge volume, the instrument begins the particle count • Flow is regulated automatically • No mechanical interference to the sample • Upon completing specified number of runs, instrument stops, releases pressure and prints results

  9. Performance • Fluid Compatibility • Phosphate ester based fluids AND petroleum and synthetic based fluids • Online sampling at pressures of 7 to 420 bar (9 to 6000 psi) • Maximum fluid viscosity of 434 cSt • Concentration limit: 30,000 particles/mL @10% • Sample fluid temperature: Up to 90C (194F)

  10. Sampling Modes • Online Samples • The Online Sample Adaptor allows online sampling of fluids of pressures between 7 bar (90 psi) and 420 bar (6000 psi) • During online operation, the air/CO2 supply is not used • Flow rate is regulated automatically PODS Online Adaptor

  11. Sampling Modes • Bottle Samples • PODS can analyze bottle samples by using the Sample Bottle Adaptor • Bottles hold approximately 120 ml of fluid • Flow is regulated automatically

  12. Pressure Sources • PODS requires an external pressure source. • This can be either: • Attachable CO2 bottle • Shop air

  13. CO2 Bottles • Fill CO2 bottle prior to use (ensure the CO2 bottle is fully discharged prior to shipping) • Inspect threads for damage and apply clean lubricant to O-ring • Thread the bottle clockwise into the CO2 port, continue ¼ turn after pressurization • Turn bottle counterclockwise to disengage the CO2 bottle • Each bottle will holds enough gas for approximately 60 runs

  14. Shop Air • Connect PODS only to known CLEAN and DRY air source • Ensure the air pressure is between 6.2 and 7.6 bar (90 to 110 psi)

  15. Atmosphere Pressure Regulator – 90 PSI/7 bar Regulator Air/CO2 Supply Sensor Flow Controller Sample Chamber To Waste Bottle Sample Operation

  16. Pressure Regulator – 90 PSI/7 bar Regulator Sensor Online Adaptor Flow Controller 90-6000 PSI To Waste 7 to 420 bar Online Operation

  17. Flow Control • Sophisticated flow control system • True volumetric flow • Pressure transducer reduces purge volume to 15mL minimum • Flow is controlled by a stepper motor driven needle valve opening or closing as required • Flow regulation is automatic or manual depending on the counter setup

  18. Keypad Features

  19. Typical Setup Menu Page • Parameters • SAMPLE LABEL: Up to 10 characters • MODE: BOTTLE or ONLINE • STD: ISOMTD, ISOACF, NAS, MIL, NAVAIR • VOL: 5, 10, 20, 50 or 100 mL • FLOW: Between 15 and 50 ml/min or AUTO • PRINT: ENBL, DSBL or SETUP

  20. Calibration • ISO MTD and Latex Spheres in MIL-H-5606 as per procedures based on ISO 11171 • ACFTD in MIL-H5606 as per procedures based on ISO 4402 without the need to change software or hardware • Calibration is performed using NIST traceable ISO Medium Test Dust (MTD) • The only portable that can be calibrated FULLY to ISO 11171

  21. Competitors • Parker UCC—LCM20, PLC3000 • Pall—PFC200, PFC400W, PCM 400 • PAMAS—S40 • Eaton Vickers—TargetPro • MP Filtri—LPA2 • Hydac—FCU2100/2200 • Internorman—CCS 2 • Klotz—Abakus

  22. What Parker Offers • UCC LCM 20 portable particle counter • PLC3000 portable particle counter(manufactured by HU) • MCM 8000 online particle monitor (PM4000 OEM) • IQ200 online counter • MCM 20 online monitor based on the LCM20

  23. What Pall Offers • PFC400W—laser particle counter manufactured by PAMAS with water content measurement • PCM pore blockage counters • PIM 400 online monitor

  24. What PAMAS Offers • Pamas offers a range of particle counters for the laboratory and for field use.

  25. Stoplight Analysis

  26. Where We Win • PODS is the instrument of choice for the US Navy—not one of many but the only one • No one else offers ISO 11171 calibration for a portable particle counter • No other portable particle counter currently on the market measures viscosity and temperature • HIAC name continues to carry great weight in the hydraulics industry • Only on-line and bottle mode liquid particle counter • SUPERIOR VALUE PROPOSITION

  27. PODS Monetization (Parker UCC LCM 20: $8,000 - $10,000)

  28. PODS Benefits • Proactive maintenance • Tracking and trending multiple system’s cleanliness • Certification to ISO, SAE and NAS requirements • On-site sampling • Reducing maintenance costs • Bottle samples • Roll-off cleanliness • Fluid analysis • System qualification

  29. HIAC PODS Overview

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