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80% of the hydraulic system and pump failures are due to contamination caused by dirt particles under 10 micron. More effective filtration means 

MONEY IN THE POCKET and FAILURE FREE OPERATION

 

WHY DEPTH FILTER 

 APPLICATION AREAS

EXTENDING OIL LIFE: DIFFERENT FILTRATION FOR DIFFERENT RESULT

It is difficult to use very fine filters as full-flow on hydraulic machines due to higher flow rates vs filter size. That's why we use 10 or 25 micron surface filters at best to cope with higer pump flows.

Off-line or on-line, wee need finer filters if we need to extend oil life as the contamination level is measured counting particles in the range of 4 - 6 - 14 microns. 

Depth filter elements used off-line or by-pass as on-line, can trap much lower particle sizes and varnish down to 1 micron, hence the oil life extntion.  The result is extended oil service life, extended OEM filter life and much lower failure rates and wear

PRES OIL - MACHINE-TOOL OIL FILTRATION 

CONSTRUCTION MACHINES HYDRAULIC OIL 

FUEL FILTRATION

DIESEL ENGINE OIL

GEAR AND HUB-DIFFERENTIAL OIL

TRANSFORMER OIL

VEGETABLE OIL

Contamination level is determined by counting of dirt particles in the range of 4-6-14 microns in accordance with ISO4406 and NAS1638/AS4059 standards. The highest value determines the contamination level.

COOKING OIL

WIND GENERATOR  HYDRAULIC OIL

 


    

 

PRESS OIL - MACHINE-TOOL OIL FILTRATION

  

CONSTRUCTION MACHINES - HYDRAULIC OIL FILTRATION

 AREA OF USE

- Hydraulic Presses

- Plastic Injection Molding

- Extrusion Tools

- Machine-Tools

There is a potential for a considerable saving on these equipment as they use large amount of oil. 

Besides, as the pressures are high and the hydraulic equipment are sensitive to contamination, good fiiltration is a MUST for protection from wear and filure-free operation.  

 

APPLICATION

Ankara Sugar Plant cleans 9000 liter of turbine oil by our filter.

The construction machines are off road applications that work in dusty environment on tight schedules. The high flow, high pressure pumps and valves are very sensitive to contamination due to clearances in the range of 3-5 microns.

Pump failure, pressure loss and erratic operation in hydraulic system result mostly due to contamination under 10 microns blocking orifices and valve clearances.

On-board and off-line cleaning is possible.

On-board by-pass conection to hydrauli circuit

On-board by-pass application will keep the oil in better-than-new condition (new oil is as dirty to the point of drain limit).

1- MOBILE FILTRATION UNIT

Organizations with multiple machine-tools can clean their oil by use of filtration buggies alternately on each machine.

Oil is withdrawn from tank and returned to tank (kidney loop) after filtering. It is possible to use filter while the machines are operating.

 

2- ON-BOARD BY-PASS USE:

This type of use is preferrable when the machine's hydraulic components are very sensitive to dirt (servo valves, piston pumps), or when amount of oil justiifies a dedicated use of filter to that machine.

A press oil is cleaned by 2 micron filter at Atılım Üniversitesi Teknokent

Above: Left- Hydraulic oil from an excavator with hydraulic oil on 1400 hours. Right- Hydraulic oil from an excavator with hydraulic oil on 5000 hours installed with 2 micron by-pass filter.

APPLICATION

1- By-PASS Application: The filter is suitably connected to a low pressure section of the hydraulic system. The advantages are low cost (without a need for additional pump-motor) and continuous cleaning hence protection of the system. Consult for correct application.

2- OFF-LINE Maintenance: Used during new oil filling and for cleaning of used oil in the hydraulic tank.

It is strongly advised by the experts to filter new oil with at least 3 micron filter. 

IMPORTANT

1- New oil is not clean; New oil from drum is in general dirty around NAS9-10 levels. This is already the contamination limit prescribed by the manufacturers of these OEM components. It is strongly advised by the hydraulic experts to clean the new oil using at least 3 micron filtration system.

2- Changing oil does not warrant cleanliness:  Hydraulic systems on construction machines use various cylinders that hosts hydraulic oil no matter the system is working or dead. Add to this the miles of hydraulic lines that rae filled with oil all the time. Keep in mind that this oil in the system is necessary for quick response of the hydraulic system; i.e. to run the machine without delay. This oil which amounts to between 25% to 35% of the total system oil, will remain dirty even though you drain the used oil. It is obvious that this oil will mix with the new oil making it further dirty.

 

ADVANTAGES

- Extension of hydraulic oil life (5000 hours for off-road construction machines is reasonable; may be longer in industrial applications)

- OEM hydraulic filter element life bir increase.

- Considerable reduction in hydraylic system and pump failures (80% of the failures are attributable to particle contamination from wear and dust )

- Wear on hydraulic system components such as pump and valves is reduced (wear means loss of hydraulic power)

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FUEL FILTRATION SYSTEMS

  

DIESEL ENGINE OIL FILTRATION

WHY CLEAN FUEL MATTERS

- Fuel injection system components (injectors and pressure pumps) on new generation motors are manufactured to very tight tolerences (3-5 microns).

- Contamination in fuel will cause ineffective combustion hence carbon emmissions. Carbon out of tail-pipe is MONEY OUT OF CHIMNEY.

ADVANTAGES:

- Injector and pump wear, and injector blockage is reduced .

- Fuel saving: Users report 3,5 - 7% of fuel saving in total.

- OEM fuel filter element life increases.

- Emmissions are reduced (which shows that all injected liquid is contaminant-free fuel and all the quantity is burnt.) and diesel particle filter life is improved. 

 

APPLICATION 

- Fuel dispenser pump outlet

- On fuel dispensing tanker

- On-board in-line on vehicle/machine fuel system. 

- As a mobile filtration buggy (with or without motor-pump).

 

  EFFICIENT COMBUSTION:  

Considerable reduction in emmision values has been reported after a research conducted by the Berkeley University in California where effect of filtration on combustion efficiency was tested...>>>

Yakıtını kendi pompa istasyonundan sağlayan işletmeler için yakıt pompa istasyon çıkışına filtre bağlantısı

 

Left: Euro-diesel fuel as commercially available  Right: Filtered by 2 micron depth filter. 

Filtration system assembled on fuel dispenser tanker

OFF-LINE FILTRATION FOR MAINTENANCE

Oil in the sump may be periodically cleaned by filtering (suction from and return into sump) by use of 2 or 4 Lpm 2 mobile filtration unit.  

A frequent filtration is strongly suggested as clean oil will prevent bearing and crankshaft journal wear, increase oil life and avoid engine power loss.

Kirli dizel motor yağı ve filtremizden geçmiş görünümü. Cam çeperlerinde kirli yağda puslu görünüme karşılık filtreli yağda berrak görünüm (Büyük fotograf için bkz......>>>)

 

WHY DO WE DRAIN ENGINE OIL:

Two different aspects are considered:

Oil's properties: TBN and viscosity

Engine's wear risk: soot and contamination level are observed.

Analysis show that engine oil is changed due to contamination and soot accumulation before the oil properties are depleted. As a general rule, halving of TBN (Total Base Number) or change of viscosity by more than 10% are considered as limits for changing the oil. Read more.>>>>

BY-PASS CONNECTION ON LUBE CIRCUIT

 

A by-pass in-line connection on a truck-mixer lube oil circuit

A by-pass in-line connection on a construction machine's engine lube oil circuit

Contamination and soot makes the oil more viscous, which means heat and reluctance to flow. Overheat is a killer. Remember piston heads are cooled by spraying of oil jet.

ADVANTAGES

- Extend diesel engine oil life

- Extend engine OEM oil filter by 4-5 times

- Reduce engine bearing life

- Reduce wear and friction to improve engine performance 

 

COALESCER WATER REMOVAL - WATER HOLDING ELEMENT

Coalescing water removal

Coalescing principle is a way of combining tiny water particles into bigger droplets to increase its mass and to enhance separation.

Water absorbing elements

These polymere elements wil absorb water and keep inside (water is not in a seperate phase). The water absorbant granulations will not release the water even under pressure. 

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GEAR OIL- CRUSHER - DIFFERENTIAL - AXLE HUB OIL FILTRATION

TRANSFORMER OIL FILTER

Gear teath surfaces run under heavy load resulting in high frictin forces. Oil cleanliness is of utmost importance as contamination (metal and sand particles) in oil will cause cause and accelerate wear. Wear produces particles and particles aggrevate wear. This will result in increase in viscosity and temperature. Overheat is an oil killer. 

Contamination causes

- wear in gears

- wear is regenerative (wear pushes up wear)

- oil is more viscous, resists to flow which cause it to keep the heat resulting in depletion of additives. 

Gear oils are more vulnerable to environmental conditions.

Left: Jaw crusher oil Right: Same oil filtered by 2 micron elements. See movie>>>

Different filtration and dehydration systems are used to clean and dehydrate transormer oil.

1- Vacuum dehydrater filtering systems

2- Water absorbant filtration system 

 

Filtration/water absorption system (with heater)

  Filtration buggy to clean the oil

 

  Vacuum dehydrater

Applied in two ways: 

- Off-line application for maintenance purpose

- On-board by-pass application for continous cleaning.

 
  
  

WIND GENERATORS

Gear oils are highly viscous oils which make them difficult to pass through a fine filter;  therefore they need to be filtered while hot, or a heater system must be used. 

 

Sources of Contaminants

3 types of contamination may be cited regarding the wind generators. 

1- Particle contamination due to Si in blowing environment and particles from wear.

2- Water and humidity ingress.

3- Varnish in gear oil due to high temperature.

Wind generators operate at faraway regions and higher levels which make them vulnerable to dust and humidity. Maintenance-repair and replacement costs are very high. 

The sedimentation of larger dirt particles become difficult as the viscosity of oil increases which hold them in suspension in oil aggravating the wear. Allowing heavy dirt particles suspended in gear oil will cause accumulation of EP (Extreme-Pressure) additives on their surface by adsorption process which will finally be held by the filters together with the particles. 

Oil with these heavy particles will act like a sand-paper between gear teeth surfaces and accelerate the wear process. Therefore it is very important to eliminate dirt particles (especially ferrous) travelling with the oil in the system, hence the necessity of finer filtration. 


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      ABOUT DEPTH FILTERS

 

Surface filter element (Conventional pleated cellulose elements)

Depth cartridge

Oil flow through filter windings

 

Advantages

- Better dirt holding capacity by means of depth winding layers.

- High dirt holding capacity through much higher filtration surface.

- Longer element service life.

- No risk of puncture/tunelling when the elements are blocked; to the contrary filtration accuracy will increase.

 

Difference with surface elements;

- Can not be used (except for fuel) as full flow filter due to high pressure drop because of resistance of depth of filtration. It is usually used as by-pass filter and off-line filter.

- At higher flow capacities cost may seem high due to higer surface requirement.

Surface elements are used as full flow OEM filters in hydraulic and lube oil systems to be able to carry high pump flows.

These elements carry risk of tunelling and puncture hence loss of filtration in case of blockage by dirt of the filter element.

The return line filters have by-pass valves in order to avoid collapse of the element in case the filter is clogged due to dirt. Opening of the by-pass valve will mean loss of filtration effect without any indication to the operator.

Depth filter cartridge

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