Destiny International

Case Study - Filtration - Principles : For Industrial Hydraulic Oil

For maintaining industrial oils it becomes necessary for the end-user to identify the system and principle that would be most apt in relation to result in performance, economic viability as per application, maintenance monitoring, etc.

OBJECTIVE-HOW TO ASCERTAIN OIL FILTRATION PRINCIPLE /TECHNOLGY TO BE USED.

For industrial hydraulic and lubrication oils following three principles are generally considered for use -before any system is put in use.

1)ELECTROSTATIC SYSTEMS

2)FILTER MEDIA-BASED SYSTEMS

a)Depth filters

b)high flow surface filters

3)centrifugal systems

ELC’S OR ELECTROSTATIC LIQUID CLEANERS

Electrostatic oil filtration was a pioneer in introducing the concept of oil filtration and the end-user became well accustomed to the practice of filtering oil-whether it was done by outsourcing as service job work or by purchasing ELC filtration machines.

As traditional wire mesh filters and conventional filters were in use in industrial machines, the concept of ELC filtration systems introduced by the Japanese was well appreciated by the industry and it got recognized by excellent service and oil patch testing done by the manufacturers of ELCs and service providers.

The benefits were evident to the end-user since lesser oil-related issues made justification for oil cleaning. Portable easy to manoeuver oil filtration machine -set a trend for oil maintenance.

One major drawback was the incompatibility of the moisture in oil and the electrostatic principle.

Which till today is a major concern if ppm of moisture increase above 500 for ELCs.

CELLULOSE DEPTH FILTER MEDIA

Japanese also pioneered filter media, especially the Depth filtration technology which was comparatively simpler but overcame the drawback that the electrostatic systems faced.

A depth filter was smarter to handle dirtier oils, remove moisture from oil and give equal if not better polish to machine oils.

The depth filter technology was not well explained to the end user since less work was done in this aspect as compared to ELC which being the first had placed itself well with the end-user.

Overtime depth filters were introduced as permanent installations on the most hydraulic machine of makes made in Japan, Taiwan, China, the US, etc.

As end-user saw the depth filtration systems as standalone units installed directly on machines as bypass units without any electrical consumption as TRANSFERABLE OR MOVEABLE OIL FILTRATION UNIT and a mechanical gauge to monitor the status of filter, the benefit was well improved than the ELCs.

Most molding machines, casting machines, and hydraulic presses had a canister or few that were maintain oil cleanliness in bypass or motorized kidney loop 24×7.

They were rightly called silent performers.

SURFACE MEDIA FILTER

Surface high flow filters have been used as online high-pressure filters with robust strength fiberglass depth media and follow the principle of the increased number of passes due to higher flow rate and absolute beta ratings.

These are well used in transfer units or flushing applications also.

These have been pioneered by the EU primarily due to their expertise and R &D.

CENTRIFUGAL FILTRATION

Centrifugal filtration systems were exclusive for high volume and moisture-related applications such as turbine oils in cement/power/marine applications.

For industrial hydraulic oils, the level of oil cleaning is not achievable by centrifugal systems hence it has not been a preference in the industrial sector.

Quality centrifugal systems due to their pricing concerns do not fit in the ROI of the segment end-user.

All the more it becomes tedious and unencouraging for the end user to clean the centrifugal bowl frequently.

INDUSTRIAL HYDRAULIC OIL
INDUSTRIAL HYDRAULIC OIL
INDUSTRIAL HYDRAULIC OIL

DEPTH AND SURFACE FILTERS

USED IN OIL FILTRATION TROLLEY OR BYPASS /PRESSURE ONLINE FILTER

INDUSTRIAL HYDRAULIC OIL
INDUSTRIAL HYDRAULIC OIL

CENTRIFUGAL FILTER PERFORMANCE

INDUSTRIAL HYDRAULIC OIL
FILTRATION -PRINCIPLES :FOR INDUSTRIAL HYDRAULIC OIL

ELECTROSTATIC ELC PERFORMANCE GRAPH

COMPARISION OF OIL FILTRATION SYSTEMS FOR INDUSTRIAL HYDRAULIC/MINERAL OILS

COMPARISION—ELECTROSTATIC ELC /DEPTH FILTER MEDIA/CENTRIFUGAL/SURFACE FILTER

CRITERIA

ELECTROSTATIC

FILTRATION

DEPTH FILTRATION SYSTEMS

SURFACE FILTER

CENTRIFUGAL FILTERATION

 

 

 

 

 

EFFICIENCY

FOR DIRTY OIL NAS 11 AND ABOVE

LOW

HIGH

LOW

VERY HIGH

EFFICIENCY IN CLEANER OILS BELOW NAS 11-8

HIGH

HIGH

HIGH

LOW

EFFICIENCY IN ULTRA FINE FILTRATION BEOW NAS 7

HIGH

HIGH

HIGH

VERY LOW

PERFORMANCE -MOISTURE LESS THAN 500 PPM

HIGH

HIGH

HIGH

NA

PERFORMANCE-MOISTURE ABOVE 500 -2000 PPM

POOR

HIGH

POOR

NA

COST OF CLEANING/LTR

LOW

LOW

LOW

VERY LOW

COST OF MICROPROCESSOR

VERY HIGH

NA

NA

NA

COST OF TRANSFORMER REPLACEMENT

VERY HIGH

NA

NA

NA

COST OF PUMP

SAME

SAME

SAME

SAME

OPERATION OF MACHINE

AVERAGE TECHNICIAN

TOUGH TO UNDERSTAND CONTROLS/PROCESSOR

EASY

EASY

LABOUR INTENSIVE/FREQUENT CLEANING

EASE OF FILTER/COLLECTOR CHANGE

TIME CONSUMING

EASY

EASY

TIME CONSUMING

SAFETY SCALE 1-10

8

9

9

10

ELECTRICAL CONSUMPTION

COMPARITIVELY MORE

STANDARD

STANDARD

STANDARD

SELF SERVICE BY ENDUSER

COMPARITIVELY TOUGH

EASY

EASY

EASY

OEM INSTALLATIONS

NO

YES

YES

NO

BRAND VALUE

HIGH

MODERATE

MODERATE

LOW

CONCLUSION-As per application the suitability of filtration technology remains at the forefront to be considered for any user to maximize its output and maintain oil condition as per desired standards.

Ease of continuous use through automation and  a planned maintenance system certainly encourages the culture to maintain oil hygiene.