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 /TECHNOLOGY TO BE USED.
For industrial hydraulic and lubrication oils, the following three principles are generally considered for use -before any system is put in use.
1) Electrostatic Systems
2) Filter Media-Based Systems
3) Depth Filters
4) High Flow Surface Filters
5) 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 maneuver 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.
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 moulding 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 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 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.
USED IN OIL FILTRATION TROLLEY OR BYPASS /PRESSURE ONLINE FILTER
Comparison Of Oil Filtration Systems For Industrial Hydraulic/Mineral Oils
Comparison—Electrostatic Elc /Depth Filter Media/Centrifugal/Surface Filter
CRITERIA | ELECTROSTATIC FILTRATION | DEPTH FILTRATION SYSTEMS | SURFACE FILTER | CENTRIFUGAL FILTERATION |
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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 |
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.
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