Industrial Oil Filtration
Industrial oils include a fairly large group of petroleum products used in the manufacturing industries for lubricating equipment friction units. Operational properties depend on their hydrocarbon composition or the content of functional additives used to attribute certain properties to the oil product.
The presence of alien impurities changes the physicochemical properties of the oil. Consequently, it ceases to perform its functions effectively. The risk of breakdowns, accidents and unscheduled downtime periods of expensive equipment is significantly increased.
Industrial oil filtration from harmful impurities allows prolonging the service life of both the petroleum products and the parts they lubricate.
Industrial manufacturing uses a wide range of fluids for lubrication of friction parts in various machines. The chemical composition and various additives influence the performance and properties of these industrial oil fluids; additives are used to improve or adjust the properties of the oil.
Industrial oil is mainly produced from fractions with boiling temperature above 350oC. The oil contains a wide variety of hydrocarbons and derivatives that are high-molecular compounds of various groups.
Over a hundred brands of industrial oil can be found in the manufacturing facilities today, with 46.6% powering hydraulic systems and 41% lubricating various friction mechanisms and heavy duty industrial machinery.
High quality industrial oil must comply with certain requirements:
- High anti-wear performance;
- Hydraulic system compatibility;
- Good filtration properties;
- Low tendency to form emulsion.
KEY TYPES OF OIL FILTRATION
Filtration is a process of capturing particulate impurities from the oil to improve its quality and protect the machines the oil is used in, increasing reliability.
A key parameter of filtration is the size of the impurities removed. Filtration can be either coarse or fine. Coarse filtration focuses on direct protection of oil lubrication and hydraulic systems; this type of filtration, which can only capture relatively large particles with the size of 25 µm and above, is often implemented by the manufacturers of the equipment.
Coarse filtration’s main purpose is to extend the life cycle of industrial oil, it also improves equipment operation and protection.
Hydraulic Oil Filtration: the choice of filter
Hydraulic oils are used in various industrial equipment (manipulators, machine tools, robotic machines, presses, etc.). Their main purpose of hydraulic fluid is to transfer power for operation of machinery.
The cleaner is hydraulic fluid the better it performs its function. Cleanness of hydraulic oil is achieved by filtration.
A multistage filtration produces a proper level of oil purity:
- Filtration before installing into the system;
- Stationary filtration during operation;
- Filtration of used oil for future reuse.
Each of the stages has its own aspects. In this article, we will consider in detail the basic recommendations for selecting filters for hydraulic systems.
The first rule recommends installation of filters on suction pumps. It protects all nodes of hydraulic drive, including centrifugal pumps. If this is not possible for technical reasons, the filters are installed in the input and output lines.
The most protection should be given to the parts of a hydraulic drive (spools, chokes), which is installed in the output line. The fineness of the oil filtration should be selected depending on the operating conditions.
Installation of filters should be carried out without removing pipelines, opening of an oil tank or dismantling individual components of hydraulic system. If there are automatic flow lines, it is advisable to install filters on the suction lines, which can be replaced without stopping the pump operation.
The filter size is calculated according to the following parameters: pressure drop in the line, flow rate and viscosity of the working fluid. Usually the listed characteristics are indicated in the filter passport data.
Oil filtration is an important process; therefore it is necessary to test the filters before installation. The testing is done at laboratories and at acceptance control. In the first case, all necessary actions are performed at the factory. The acceptance control tests is a simplified program that determines the hydraulic strength characteristics of both the filter and the filter element.
Laboratory tests, in addition to the listed characteristics, also determine geometric dimensions and accuracy.
Turbine Oil Filtration
The modern electric power industry is very difficult to imagine without turbines. They are actively used in hydropower, wind power and nuclear power energy.
The operational efficiency of turbines is provided by special oils that provide lubrication of bearings and gearboxes, prevent and reduce friction, reduce wear and tear.
The cleaner is the oil, the better it performs the functions assigned to it. The turbine and the oil itself operate in heavy conditions. The oil accumulates various harmful impurities and aging products that can lead to unscheduled repairs, increased costs for oil replacement and loss of power.
Turbine oil filtration can correct the situation. GlobeCore is the major player in the business of oil filtration equipment for industrial use. For turbine oil cleaning GlobeCore specially designed CMM-T plant. Its principle of its operation is based on the complex effect of high temperature and deep vacuum, as well as a repeated oil filtration through the filter unit. The fineness of the filtration is less than 5 μm, and the mass moisture content of the oil is less than 10 g / t.
Depending on the required tasks, CMM-T can be used in one of three modes:
- Oil filtration and heating;
- Oil filtration, drying and degassing;
- Vacuum treatment of equipment.
It is also possible to choose the unit in stationary or mobile design.
On-time filtration of turbine oils avoids a number of unpleasant consequences and provides:
- Cost reduction for operation of power turbines;
- Reduced consumption of turbine oils by prolonging their service life;
- Reduction of waste, in the first place, waste oil;
- Elimination of unplanned shutdowns of power units;
- Decrease of repairs to bearings, pumps and other parts.
At customer request, GlobeCore equipment for turbine oil filtration can be customized and includes a number of options:
- Additional sensors and meters (humidity, particle count, etc.);
- Remote control and process monitoring via smartphone or PC;
- Mounted on a trailer, on rollers or pneumatic wheels;
- Possibility of adjusting parameters.
Explosion-proof and corrosion-proof design is also possible.
Transformer Oil Filtration
Insulation fluids are used in many types of high voltage equipment: capacitors, cables, switches, transformers etc. The fluids usually perform two main functions, i.e. electrical insulation and cooling. Some extra functions are arc extinguishing in switchgear and protection of the internal solid insulation from moisture in the environment.
It is difficult to imagine modern processes of transmission and distribution of electric energy without power transformers. This equipment should be protected from possible breakdowns by protecting its hard insulation and cooling. This function is assigned to mineral oils.
Usually a long-term operation of transformer equipment leads to oil aging.
The process above has several limitations:
- long settling time;
- low filtration throughput;
- the need to replace filter media often;
- possible contamination of oil with cellulose fibers which reduce its dielectric strength.
It is a consequence of a complex impact of a number of factors:
- water ingress in free and emulsified forms;
- large particles increase viscosity;
- degradation products in solid insulation;
- decomposition of additive products;
- decomposition of hydrocarbon products.
The aging process can be slowed down by oil filtration and to prolong the service life of insulating liquid.
At incorrectly selected frequency of processing, the following negative phenomena may occur:
- Decreased cooling efficiency;
- Reduced dielectric strength;
- Corrosion of transformer core and windings housing;
- Sediment on internal surfaces;
- Risk of emergency situations.
Oil filtration of power transformers removes mechanical impurities.
They are not the only pollutant, but, nevertheless, pose a great risk:
- form sludge layers on transformer winding and magnetic circuit;
- form emulsified water;
- disrupt the heat removal and reduce the cooling efficiency;
- -contribute to corrosion and destruction of insulation.
GlobeCore developed CFU mobile oil filtration plants. This equipment is easy to maintain and operate. It implements complex oil filtration through coarse and fine filters, as well as temperature and vacuum. This approach cleans transformer oil not only from mechanical impurities, but also from water.
After filtration the oil obtains the following parameters:
- dehydration up to 98%;
- purification from mechanical impurities up to 97%.
GlobeCore filtration equipment increases the reliability of power transformer, eliminates unscheduled repairs and downtime, and also saves money on purchases of fresh oils.
GlobeCore produces customized oil filtration plants for individual orders, supervise installation and commissioning and assist with the startup of equipment. In addition, it is possible to add new features and functions (for example, a particle counter or Remote control and process monitoring via smartphone or PC).
GlobeCore Filtration Systems
This small scale machine is equipped with a filtration pod: a small tank with sorbent which regenerates flowing oil. The pod is loaded with sorbent from the top, oil also enter the pod from the top and flows to the bottom.
The CFU is a mobile filtration cart for on-site operation. The filters in the unit remove particulate matter from various oil products, such as dielectric and lubrication oil. To operate this unit, the viscosity of processed oil must be below 70 cSt at 50oC/122oF.The unit can be successfully used under the following environmental conditions:
The vacuum filling cart can prepare oil by degassing it, providing a simple means of transporting the oil safely and adding it into transformer and switchgear high voltage bushings. This unit is will be of most benefit to transformer substations and power plants, as well as many other power generation and distribution related facilities.READ MORE
GlobeCore Secondary Oil filtation
Equipment of secondary oil filtration produced by GlobeCore enables to remove mechanical impurities, soot (coal), free and part of dissolved water, and also water-soluble acids and alkalis from industrial oils. This equipment has a compact size and is sufficiently mobile, therefore it can be used in those sites where oil products are used directly. A desired degree of purification is achieved in just one operation cycle. Simplicity of design and operation does not set high qualification requirements for the maintenance staff.The filtration systems are efficient enough to achieve the required rate of impurity removal even in one pass of the oil through the system, yet the simple and convenient design makes operation of these units extremely easy.
GlobeCore manufactures and supplies equipment for transformer oil filtration, industrial oils, turbine and other types of oils. GlobeCore oil recycling plants are convenient, practical and functional.