Coal Company Commands Custom Mobile Filtration Cart
Ron called me and left a message on a Saturday afternoon. He was working for one of the world’s largest producers and suppliers of coal, with coal mines and preparation facilities all over the mid-Atlantic and mid-West regions. His company supplies thermal coal to electric utilities and the manufacturing industry. They also supply metallurgical coal for use in the production of steel. Ron just happened to be rather close to us, in western Pennsylvania. He seemed to know exactly what he needed for his project – a new portable hydraulic filter cart.
Ron had hydraulic reservoirs of varying capacities between 80 to 200 gallons. These were the reservoirs that had particulate contaminants which needed to be removed. Particulate in hydraulic systems can lead to a myriad of problems, such as accelerated abrasive wear, corrosion on metal surfaces, and bearing fatigue. Ron was looking for a portable filtration unit that was well-built, compact, light-weight, and capable of displaying ISO 4406 codes on a visual particulate counter, which was not possible with his current oil filtration system. He also wanted to be able to set up a dedicated side-loop system with hoses and wands that would allow him to service several machines.
I was initially skeptical of the potential to help out Ron since he had called on a Saturday, which is a bit out of the ordinary for this type of business. However, I decided to call him back that Monday morning to hear more about what he specifically wanted to do. After talking in depth about his application over the phone I ended up giving him a verbal cost estimate to build a custom filter cart. He seemed to think that it was a reasonable price as long as the machinery was high-quality and lasted a long time. The oil Ron needed to filter was very light weight (10W hydraulic), so I figured spin-on filters would be appropriate for his application. And since Ron specifically requested a unit with a particle counter, our SFC mobile filtration cart was a perfect fit for his application.
After I sent Ron a formal quote for the SFC, he sent me back a few photos of the unit that he currently had in-house. I made sure to go over the advantages of the SFC portable filter cart versus what he already had on site. I specifically highlighted that our unit was built from light-weight aluminum and it was more compact, thus more portable than his current system. Our SFC unit also had it’s own sampling ports, and true differential pressure indicators. Our SFC unit is one of the best filtration carts out on the market today, and I was glad that he was able to understand and appreciate the value of such a heavy-duty filtration cart made in the USA. Ron initially purchased one SFC and just three months later he purchased another one! The final result? He left me with the following feedback, which says it all: “Beautiful piece of equipment…very well made” – Ron, happy PFP customer.
Do you have a question about mobile filtration systems or filtering hydraulic oil? Feel free to contact us anytime. Our friendly team of experts will be happy to help you out with your particular issue.
Until next time!
Sean at Precision Filtration Products
P.S. Have you seen our latest videos? If not, click here to check them out now!
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A Low-Pressure Solution for High-Pressure Hydraulic Oil
Thursday afternoon. I received a call from Mike, the shop foreman at a fluid management company in Canada that designs, builds, and operates systems for construction and mining projects. Mike said that he had a large hydraulic system which needed some major oil filtering. He needed a permanent in-line filtration system to be installed.
The hydraulic oil that needed to be filtered was MV46 Petro Canada, which was going to be pumped by a submersible pump. The system needed to operate at a very high pressure and flow rate: 1450 PSI at 200 liters per minute (approximately 50 GPM). They wanted to remove from the oil both water and particulate down to 5 micron in size. Based on the high pressure, I knew he needed a pretty heavy duty filter housing to handle that type of pressure… the question was how big. Mike also wanted to have a “dual setup” where the first stage would remove particulate and the second stage would remove water. The key was to match the 2″ NPT connection that he needed to match the size of his hoses.
With the help of our engineering team I was able to narrow in on a few high-pressure filter assemblies that could handle that 1450 PSI. I eventually chose our base-ported pressure filter (PDF) because it can handle the high-pressure required. Its housing base and cap are made of ductile iron and it has a carbon steel case for its filter element. It also had a 2″ NPT connection, which is exactly what Mike needed. Once we provided him with a price quote, we were able to deliver the equipment within 4 weeks. I spoke with Mike after he received the housings and he ordered additional replacement internal filter elements. Since then he has been obtaining oil quality samples and he has reported that he is very happy with the results.
Do you have a question about high-pressure filtration systems or how to filter lube oil? Feel free to contact us anytime. Our friendly team of experts will be happy to help you out with your particular issue.
Until next time!
Sean at Precision Filtration Products
P.S. Have you seen our latest videos? If not, click here to check them out now!
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Another “Green” Filtration Victory on Top of a Wind Tower
Over the past few years we’ve been getting many more inquiries from wind farms. One day recently I received a call from Jim, the lead mechanic at a wind farm on the west coast. He was specifically looking for gearbox oil change filter systems and he came across our website.
Jim had already been successfully changing the gearbox oil in the past, but he was looking for a better way of filtering it before adding it to the gearbox. His goal was to filter the oil to the gearbox manufacturer’s specifications before filling the reservoir. Gear oil that is “out of spec” increases the risk for equipment failure, which results in lost revenue and added repair costs. Jim decided that he wanted to filter the lube oil to 6 micron, which he based on industry standard gearbox oil cleanliness specifications.
Within hours of first listening to Jim’s goals, I provided him with a price quote in which I recommended our “drum-top” filter system (see image to the left) with a drum recirculating kit. The optional recirculating kit creates a sealed reservoir and would allow Jim to filter oil in a 55-gallon barrel without the oil being exposed to outside contaminants such as dirt or moisture. Also, since the drum-top unit is portable it would allow him the option of filtering either at the ground level or even in the nacelle of the wind tower itself. The drum-top system can be configured as a filtering transfer pump or as a kidney-loop system. With the help of the equipment that I recommended, and proper filter elements, Jim was able to exceed the recommended ISO cleanliness code set by the gearbox manufacturer. He is now very happy with the oil quality going into the wind turbines, and now other wind farms in the company’s fleet are looking to purchase their own portable drum-top filter systems.
Do you have a question about wind turbine services or mobile filtration systems? Feel free to contact us anytime. Our friendly team of experts will be happy to help you out with your particular issue.
Until next time!
Paul at Precision Filtration Products
P.S. Have you seen our latest videos? If not, click here to check them out now!
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Green Filter Carts Helping to Keep the Planet Green
Helping to clean up the environment, one filter cart at a time…
Green Portable Filtration System
In our line of work we are often called upon to solve on-going, costly problems that are associated with fluid contamination. Our job is to identify and analyze all of the available data, the fluid type, the nature and severity of the contamination, as well as the historic costs associated with the fluid contamination. We look at the frequency and expense of repair and replacement of critical system components. We discuss downtime, man-hours exhausted dealing with the issue, and when applicable, we perform filtration services such as fluid analysis and/or field or laboratory testing. The goal, based on our research, is to prescribe and implement the most cost-effective solution for our customer in need. Typically, our customers are most concerned with how our solution will provide a return on their investment of time and financial resources. Simply put, they want the biggest bang for their buck.
In our experience we have found that, when dealing with issues concerning hydraulic and lube oil quality, beyond used oil disposal costs, when choosing how to solve a given problem the environmental impact of the economic decisions is often overlooked. However, a basic oil quality program that incorporates quality mobile filtration equipment can be fairly simple to implement. Such a program can provide a positive environmental impact and at the same time providing measurable results that improve a company’s bottom line.
In industry today, companies find themselves dealing with ever increasing governmental regulations regarding plant emissions and waste practices. As a result and in response, there has been much activity in scientific circles and among both environmentalists and engineers to seek out methods of compliance. While our industry acknowledges the impact that water and air filters can have in promoting and effecting positive environmental stewardship and regulatory compliance, there has been little notable commentary on how a company’s oil quality and handling practices can also affect the environment for good or bad. We are striving to bring that dialog mainstream and to help our customers make environmentally-friendly decisions related to handle and recycle oil in a sustainable manner.
In recent years, we have noticed that awareness has increased dramatically regarding hydraulic and lube oil fluid quality. Specifically, we know that our customers are educating themselves on the importance of establishing, achieving, and maintaining critical ISO cleanliness codes as a means of prolonging oil and critical equipment service life. The fact is that there is a correlation between a good oil quality program, with an emphasis on maintaining ISO cleanliness codes, and improved storage and handling of bulk oils, and having a positive effect on the environment. In other words, the products and services that our customers employ to solve their oil quality, handling , and storage issues, have features and benefits that provide tangible and measurable environmental benefits.
When we prolong the life of our hydraulic and lubrication oils in service, we are able to reap savings related to eliminating premature replacement costs of both oil and machinery. In addition, there are many savings in the form of reduced energy consumption, both as a result of the more efficient operation of existing machinery and also eliminating consumption of the energy required to manufacture and transport replacement goods. There are even more savings associated with fewer incidents of equipment failures that cause fluid leaks, and of course, lower costs associated with the disposal and removal of waste oil products. Finally, there is a realization of the ability to allocate otherwise unavailable capital to projects and measures which can taut similar or even more significant positive environmental benefits.
Ultimately, we must realize that the benefits that come from solving any oil quality problem can have a net positive impact on the environment. Additionally, whenever we solve an oil quality issue, implement a new oil quality program, or improve the quality of existing oil, there is a cumulative effect. If you are looking for a win-win-win, where you can improve oil quality and its handling practices, achieve a net positive gain in your environmental footprint, and improve your bottom line, feel free to contact us any time and a friendly member of our team will be glad to help you with your project.
How I Saved Another Metal Manufacturer from Equipment Failure
Last month I was looking for some new business. I ended up reaching out to yet another metal manufacturer, this one located on the East Coast. They were producing specialty metals for equipment manufacturers and industrial companies. I eventually got in touch with Ken, the predictive maintenance technician, and I inquired about how they were managing the lube oil for their machinery. It turned out that I called at just the right time since they were having an issue with one of their metal processing machines.
Ken and the other technicians were using high-viscosity gear oil on one of their metal processor’s chuck heads, in the forging area. Extremely high heat, engine vibrations, and the general nature of this metal-shaping process causes a good amount of wear on the components, and the metal particles often get into the gear oil reservoir. These metal particles then recirculate through the machine, which causes premature pump failures. When the pumps fail the machine stops. This down time results in a loss of revenue and expensive repairs. Not good.
In order to help Ken and his company as soon as possible, I visited the plant and conducted a test using ISO 680 gear oil from the chuck head that had the seized pump. I connected our liquid cartridge portable filter cart (PDF) with a 50-micron filter element (the size recommended by the manufacturer of the metal processing machine) to the oil tote in a kidney-loop configuration. I then ran the lube oil through our filter cart for several hours. Immediately after I started up the cart I took a sample of unfiltered oil in order to obtain a baseline reading. I subsequently took two more oil samples during the filtering process in order to verify the efficiency of the filter media.
Ken was rather pleased with the results. As a final solution for preventative maintenance, I recommended that they consider installing the LCFC as a dedicated stationary kidney-loop system for continuous in-line filtration of each chuck head. Ken took my advice, and he requested to start out with not just one but two LCFC filter carts so he could maximize versatility and availability of the units in the plant. Good thing I reached out to them!
Do you have a question about filtering lube oil or mobile filtration systems? Feel free to contact us anytime. Our friendly team of experts will be happy to help you out with your particular issue.
Until next time!
Paul at Precision Filtration Products
P.S. Have you seen our latest videos? If not, click here to check them out now!
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Manufacturer Clears Out Construction Debris with Hydraulic Flushing
Monday morning. I called on a prospect that visited our website who was looking for a hydraulic oil flushing service. Eventually I got in touch with Larry, the plant engineer at a metal manufacturer on the east coast. Their company processes specialty metals for equipment manufacturers, mostly in the aerospace and defense sectors.
Larry told me that they had just finished building a new plant that was going to be used for a metal grinding operation. All of the hydraulic lines needed to be flushed in order to clear out the construction debris before the metal grinding machine could be safely started. If they didn’t remove the debris before starting it could cause failures with the pumps or servo valves in the hydraulic cylinders. Given their particular situation, I thought it would be best to visit the company’s plant in person prior to quoting the service work. We needed to measure fittings and determine the best way to bypass/jump the valve blocks and hydraulic cylinders. Within just a few days of my first conversation with Larry I traveled to their plant and performed a thorough on-site inspection.
Within a week after our preliminary assessment I organized the equipment needed to perform the entire service job. I made a second visit with a colleague to confirm our measurements of all the system components that needed to be flushed. We also brought with us a 75-GPM portable oil flushing skid and all the appropriate fittings and hoses to flush out the metal grinder’s hydraulic system. This turned out to be a more complex job than we anticipated. Believe it or not, we ended up working 11 days straight while overcoming numerous technical challenges. Alas, by the time we were finally done, all the valve blocks and hydraulic cylinders were bypassed/jumped. We also made sure to flush all the individual line sections and the entire hydraulic circuit. We helped Larry and his team to achieve a minimum ISO cleanliness code of 16/14/11 or better on each hydraulic line and the overall system. We verified our results by using a portable laser particle counter (PDF), which we kept by our side during the operation. We worked long and hard, and in the end Larry and his team were very happy with the results of the oil flushing service that our crew provided.
Do you have a question about hydraulic oil flushing or portable filter systems? Feel free to contact us anytime. Our friendly team of experts will be happy to help you out with your particular issue.
Until next time!
Paul at Precision Filtration Products
P.S. Have you seen our latest videos? If not, click here to check them out now!
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Vacuum Dehydrator Rental
I received a call from the manager of the molding department at a car battery manufacturer. His team had a major issue with one of their plastic molding machines. Water had contaminated its lubricating oil and caused the equipment to unexpectedly break down.
Apparently, the water got into the oil reservoir through a leak in a heat exchanger. The water reduced the lubricity of the hydraulic oil, which then caused the oil pump to fail and eventually the entire machine shut down. When the maintenance crew inspected the machine, they noticed a bunch of free water in the lube oil reservoir and plumbing system, which immediately alerted them to a water contamination problem. This equipment failure cost the company thousands of dollars per day in lost revenue. It was a urgent to say the least.
Several months prior the same manager had informed me that they occasionally have problems with moisture in their hydraulic oil. At that time I let him know that we offer vacuum dehydrators for rent and for sale. Now that they had an immediate need I suggested that they rent a 20-GPM vacuum dehydrator with a variable-frequency drive in order to purify and dehydrate their lube oil of the molding machine ASAP. I was actually out of town on business during this whole process, so I was glad to coordinate everything with our reliable customer service team. Since this was an emergency for the company we made sure to ship the unit right away. Shortly after the manager received the dehydrator, I received some very positive feedback from him. He reported that approximately 30 gallons of water were removed from 750 gallons of hydraulic oil and that the molding machine was back to normal operation. Success once again!
Do you have a question about lube oil filters or vacuum dehydrators? Feel free to contact us anytime. Our friendly team of experts will be happy to help you out with your particular issue.
Until next time!
Paul at Precision Filtration Products
P.S. Have you seen our latest videos? If not, click here to check them out now!
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