Centrifugal Bypass Filter

Centrifugal Bypass Filter

 

What is the primary cause of fluid system failures?

Harmful contamination is the primary cause of fluid system failures. Contamination alters the properties of the fluids, causing damage to fluid systems and preventing systems and components from attaining the desired reliability and durability. Particle contaminants are visible to the naked eye if the particles are approximately 40 microns and larger, while smaller micron particles are not visible. Particle contaminants can cause damage even if the particles are not visible to the naked eye. Using an appropriate filtration system and following contamination control practices will assist in lowering the total cost of ownership and extend the engine’s useful life. 

Proper lube oil maintenance is imperative to keeping engines operating at peak performance. Lube oil maintenance includes scheduled oil change intervals and lube oil analysis. Lube oil analysis is important because the performance of engine lube oil slowly degrades with time and severe operational conditions. This degradation occurs as the amounts of wear metals and particulate contaminants increase.

For a diesel engine, severe operational conditions are defined as one or more of the following: high load factor, extended oil drains, excessive cycling, dusty air, high altitude, high sulfur fuel, prolonged idle, and low jacket water temperatures. In both normal and severe conditions, crankcase oils eventually lose the ability to adequately lubricate and protect engine parts from accelerated wear and damage. Therefore, analyzing the lubrication oil at regular service intervals is essential. 

Soot is the insoluble residue of partially burned fuel. It is held in suspension by the lube oil additive package and causes engine oil to turn black. When soot drops out of suspension in the lube oil, it contributes to additive depletion and eventually increases oil viscosity. The heavy concentration of soot can cause bearing damage by starving contact surfaces of lubrication. 

 

Lubricating Oil Systems

Normal engine operation generates various contaminants, ranging from microscopic metal particles to corrosive chemicals. If the engine lubrication oil is not kept clean through filtration, this contamination is carried throughout the engine via the oil. Oil filters are designed to remove these harmful contaminants (debris particles) from the lubrication system. Using a filter beyond its intended life cycle can result in a plugged filter. A plugged full-flow oil filter will cause the bypass valve to open, releasing unfiltered lubrication oil. Any debris particles in the oil will flow directly to the engine.

When a bypass valve remains open, the particles previously trapped by the oil filter may also be flushed from it and then through the open bypass valve. This allows unfiltered oil containing wear particles, dirt, soot, and debris to flow to the bearings, scratching and damaging their surfaces. A new oil filter element should be installed any time the engine sump oil is drained and the engine sump is filled with new oil.

Lessen your chances of oil-related failure by taking the initiative to protect your engine.

Successful engine operation is dependent on proper lubrication. The modern engine lubrication system accomplishes the following functions:
– To minimize friction losses, the lubricating oil system lubricates surfaces.
– It is used to cool internal engine parts that the engine’s water-cooling system cannot directly cool.
– It cleans the engine by flushing away wear particles within the lubrication oil.
– It cushions the engine’s bearings from the shock of cylinder firing.
– It neutralizes the corrosive elements created during combustion.
– It seals the engine’s metal surfaces from rust and corrosion.

A positive displacement gear pump maintains a continuous flow of lubricant under pressure to all moving parts. The lubricating oil systems require clean oil that is free from abrasive particles and corrosive compounds. The lubricant must be capable of neutralizing harmful combustion products and holding them in suspension for the duration of the oil change period or until the oil filters remove them. Full-flow oil filtration is provided by replaceable cellulose filters. Caterpillar oil filters are sized to provide reasonable time intervals between filter element changes.  

Lube oil cleaning determines equipment life!

Lubricating oil systems may be equipped with additional or optional supplemental bypass filter components. Supplemental bypass filters generally fall into two (2) categories: centrifugal filters and absorptive filters.

Centrifugal bypass filters (centrifugal filters) have proven beneficial and helpful in extending the primary filter life. Centrifugal bypass filters, using centrifugal force, remove a wide range of contaminated particles extending into the sub-micron range. The greater the centrifugal force, the greater the separation efficiency. 

Centrifugal force separates the contaminants from the lube oil based on their relative particle density, not only large particles but also fine, submicron solid contaminants. The oil flow rate through a centrifuge filter remains consistent throughout the service interval. Centrifugal bypass filters can increase the number of engine operating hours before the primary filters become restricted.  

Absorptive filters have an absorbent media, such as cotton or cellulose fibers, which absorb acids and moisture and remove contaminants from the lubricating oil. Supplemental bypass absorptive filters increase oil capacity and may allow oil and filter change periods to be extended. However, the oil drain intervals cannot be extended arbitrarily. Adequate monitoring systems must verify the oil and filter life.

 

Centrifugal Bypass Filters | Lubricating Oil Centrifuges

Certain Caterpillar diesel engine models are provided with engine-mounted centrifugal bypass filters. Typically with a Caterpillar centrifugal bypass filter, centrifugal filters receive 3-4% of the oil pump flow. If your Caterpillar engines have been supplied without a lubricating oil centrifuge filter, a customer-supplied lubricating oil centrifuge (centrifugal bypass filter) can be installed. When selecting a reputable centrifugal bypass filter manufacturer, we recommend the lubricating oil centrifuge filters manufactured by IOW Group. To learn more about IOW Group’s innovative solutions, visit our IOW Group Centrifugal Bypass Filter webpage.

It takes nearly three (3) Mann Hummel FM200 centrifugal oil cleaners to outperform an IOW MP200 centrifugal filter!

When considering a centrifugal bypass filter, you must consider the new technology’s features, advantages, and benefits. What makes the IOW Group lubricating oil centrifuges the market-leading centrifugal bypass filter?

• Bowl Disc Technology – Increasing efficiency by removing even more contaminants. The only pressure powered centrifuge of their size to use bowl disc – usually associated with much larger centrifuges – allowing the IOW centrifuge to remove significantly more small particles than any other competitor.
• Fully Sealed Centrifuge Bowl – Reduced risk of cross-contamination between cleaned and dirty oil. 
• Remote Monitoring – Provides operators and systems with valuable insight into its speed, cleaning, and service requirements. The IOW oil cleaning centrifuge is the only product on the market that provides operators with a choice of remote monitoring. Remote monitoring helps the operator ensure that the oil cleaning centrifuge runs optimally. This reduces servicing man hours and increases productivity.
• Distributor Impeller – Eliminates back pressure by drawing in contaminated oil. Oil enters the centrifuge at the base of the oil cleaning centrifuge and, while spinning, draws the oil into the centrifuge by the distributor impeller. This reduces the risk of back pressure causing cross contamination and increases the centrifuge bowl (rotor) speed.
• Increased Centrifugal Force – Higher centrifugal force produces a higher separation efficiency.

At 58 PSI (4 bar) pressure, the IOW Group centrifugal bypass filter operates 15-30% RPMs faster than the Mann Hummel centrifugal oil cleaner. With the increase in centrifuge RPMs, the centrifugal separation efficiency is increased. The IOW Group centrifugal filter removes particles as small as a tenth of a micron. This can reduce engine wear by up to 50% and more. If you are looking to enhance your engine lube oil cleanliness, reduce service downtime, and lower operating costs, the IOW Group centrifugal filter is the best centrifugal bypass filter on the market.

IOW Group’s centrifugal bypass filters provide proven reliability!

Lubricating oil centrifuges are commonly used in marine and offshore applications, where the availability of clean lubricating oil may be limited. Engine-mounted centrifugal filters or kidney loop bypass centrifugal filters remove micron-size solids from the oil, such as sludge, wear materials, soot, and carbonous materials. Centrifugal bypass filters can increase the number of operating hours before the primary oil filters become restricted (clogged).

When setting up a kidney loop centrifugal bypass filter, it is recommended that the centrifuge take the lubricating oil from the rear of the engine and return it to the front of the engine so that clean oil is as close to the engine oil pump suction as possible. The IOW centrifugal bypass filters are designed to operate when the engines are running; therefore, a preheater is not required.

Proven Impact. Proven Uptime. Proven Savings.

 

Case Studies and real-world examples of the IOW centrifugal bypass filters on Caterpillar engines

 

Caterpillar 3208

We retrofitted a Caterpillar 3028 engine with an IOW MP090 centrifugal bypass filter and a CentriClean SCU 0003 Bluetooth remote monitor. Due to the limited space in the engine room, the IOW MP090 oil centrifuge was installed above the engine for gravity drain.

Unlike conventional centrifugal bypass filters, IOW Group separators use bowl discs to increase separation efficiency, dramatically reducing the time that contaminants can stay in the oil. The IOW MP090 centrifugal bypass filters provide superior contamination removal over the Mann Hummel FM090 centrifuge or Glacier GF060 centrifuge. 

 

Caterpillar C13

Looking to increase engine reliability, this Caterpillar C13 engine owner installed an IOW MP09002-05 centrifuge bypass filter. Centrifuge bypass filters are designed to remove contaminants from the engine oil using centrifugal force. IOW Group centrifuge bypass filters help extend the engine’s life by keeping it clean and reducing wear on engine components. 

At 35 PSI engine lube oil pressure, the IOW CentriClean SCU 0002 remote monitor displayed 4,098 RPMs (IOW MP090 centrifuge RPMs). The IOW Group centrifuge bypass filters are the only centrifugal bypass filters on the market with remote monitoring capabilities. 

Superior Technology = Superior Outcomes = Impacting Cleaner Lube Oil

 

Caterpillar C15 Acert

The 2004 Caterpillar C15 Acert diesel engine is mounted on a 2004 Peterbilt. This trucker uses Shell Rotella T6 15W-40 full synthetic lubrication oil. This diesel engine came with a factory-supplied Spinner II 560 HE oil cleaning centrifuge. The trucker replaced the Spinner II 560 centrifuge with an IOW MP090 centrifugal bypass filter. The IOW MP090 centrifuges are designed as a “drop-in” replacement system.

At 61 PSI engine lube oil pressure, the IOW CentriClean SCU App displayed 6,906 RPMs (IOW MP090 centrifuge RPMs). Due to the innovative design of the IOW centrifugal bypass filters, they have superior contamination removal over the Spinner II oil cleaning centrifuges. At the same engine oil pressure, the IOW centrifugal bypass filter spins faster than any competitive centrifugal bypass filter.

Higher Centrifugal RPMs = Higher Centrifugal Force = Increased Reliability

The combination of protection, improved engine performance and reliability, remote monitoring, and the ability to extend oil drain intervals has many turning to IOW Group as their centrifugal bypass filter solution.

 

Caterpillar 3406

On a 2015 Kenworth truck with a 1999 Caterpillar 3406 2WS 14.7 liters diesel engine, a trucker added an IOW MP090 centrifugal bypass filter. Before installing the IOW MP090 oil centrifuge filter, the ISO 4406 particle count was 23/20/11. After installing the IOW centrifugal bypass filter, the ISO 4406 particle count dropped from 23/20/11 to 21/28/12 to 19/17/12. Based on Noria Corporation’s Life Extension Table, the IOW MP090 centrifugal bypass filter extended the engine life by 2-3 times.

In another installation, the trucker’s Caterpillar 3406 engine was fitted with a Glacier centrifugal bypass filter. He has a 1998 Kenworth W900 truck and uses Schaeffer’s Synthetic Blend 15-40W lubricating oil. After 31,000 miles driven with the old technology of the Glacier centrifugal filters, there was very limited contamination removal. With the IOW MP090 centrifugal bypass filter, the oil centrifuge bowl had 3/16″ sludge cake collected in about 56,000 miles driven. At 70 PSI engine oil pressure, the IOW CentriClean SCU App displayed 6,582 RPMs (IOW MP090 oil centrifuge RPMs). 

Aggressively controlling particle contamination in lubrication oil is one of the best strategies for extending machine life.

 

Caterpillar C18 Acert

The Caterpillar 390F Hydraulic Excavator has a Caterpillar C18 Acert diesel engine. This copper mining customer installed the IOW MP090 bypass oil filtration system to extend oil changes, reduce new oil purchases, extend the life of the primary filter, maintain oil viscosity, and improve equipment reliability and efficiency to maximize productivity. The IOW MP centrifugal bypass filter will remove the dirt, dust, soot, sludge, ash, wear materials, carbonous material, and solid contaminant particles from the lube oil. Using an IOW MP090 centrifugal bypass filter ensures your lubricating oil system is free from abrasive particles.

At 4.8 bar (69.61 PSI) lube oil pressure, the IOW CentriClean App displayed 6,726 centrifuge RPMs (the CAT 390F excavator was under load). In 450 hours, the IOW MP090 centrifugal bypass filter removed 0.0475 kg (1.05 lbs).

Remove solid particles permanently from the lube oil!

 

Caterpillar C32

Onboard the Wight Ryder catamaran foot passenger ferry, the IOW MP200 centrifugal bypass filter was retrofitted to the Caterpillar C32 diesel engine. The oil centrifuge filter was mounted to gravity-drain the lube oil back into the sump. The IOW MP200 oil centrifuge was supplied with the CentriClean SCU 0002 remote monitoring system. IOW Group is the worldwide leader in bypass centrifugal filtration solutions. The IOW oil centrifuges remove large debris and ultra-fine particles, improving the ISO Cleanliness Code. IOW centrifugal bypass filters have higher separation/filtration capacities and eliminate much smaller particles than a full-flow oil filter.

Improvements in the ISO Cleanliness Codes provide superior wear reduction, increasing the engine’s reliability.

 

Caterpillar C32 Acert

The Caterpillar C32 Acert industrial diesel engines are offered in ratings ranging from 746-895 bkW (1000-1200 hbp) @ 1800 rpm. These ratings meet US EPA Tier 4 Final emission standards. The lube oil system is 68 liters (71.9 US quarts). This customer retrofitted this Caterpillar C32 engine with an IOW MP090 centrifugal bypass filter with the CentriClean SCU 0003 Bluetooth remote monitor.

The IOW MP090 centrifugal bypass filter is designed for a lube oil sump of 15-90 liters (3.96-23.7 US gallons). Spinning the lube oil at high rotational velocities allows the suspended particles and other high-density contaminants to be efficiently separated. Upgrade your filtration system with the IOW MP090 centrifugal bypass filter – they are impressively effective.

 

Caterpillar 3516C

Due to high soot problems with their Caterpillar 3516C diesel engines, this maritime customer installed an IOW MP200 supplemental bypass filter with a CentriClean SCU 0002 remote monitor. Soot and other solid particles do not dissolve in the oil, causing filters to become plugged and depleting dispersant additives. The IOW Group centrifugal bypass filter is extremely effective at removing micron-size solids from the oil, such as sludge, wear materials, soot, and carbonous materials.

Better Technology = Better Results

Unlike the centrifugal filter (part number: 1W-4191 centrifugal filter) supplied by Caterpillar, the IOW centrifugal filters come standard with the IOW CentriClean remote monitors. The CentriClean remote monitors are designed to monitor the centrifuge’s performance and make oil filtering simple. They will continuously display the centrifuge’s RPMs and run hours. 

 

Caterpillar G3608

Due to the high levels of contamination in the lube oil systems of these Caterpillar G3608 natural gas engines, the customer wanted to effectively remove micron-size solids from the lubrication oil, such as sludge, wear materials, carbonous materials, and soot. Two IOW MP200 centrifugal bypass filters are installed on a double mounting bracket with a large gravity drainpipe on the inspection platform. Before installation, the ISO 4406:99 cleanliness level code was 22/19/11. After installing the two (2) IOW MP200 centrifugal filters, an ISO 4406:99 code of 18/16/12 was obtained in the last data recording. These oil cleanliness levels remained in line with Caterpillar’s recommended 18/16/13 baseline.

Cut your engine oil filter usage and increase your uptime!

Based on Noria’s Life Extension Table, by improving the ISO 4406 cleanliness level code from 22/19/11 to 18/16/12, the Caterpillar G3608 engine’s life extension is ~ (3X) tripled! The IOW MP200 centrifugal bypass filters maintained the level of cleanliness of the oil required by Caterpillar for proper lubrication, extending the primary oil filter life, prolonging the oil change intervals, and improving the internal engine with less abrasive wear.

 

Caterpillar 3512

If your Caterpillar 3512 engine has a Mann Hummel FM200 oil conditioning system (formerly known as Glacier Filter Products), it is time to upgrade it to the IOW MP200 centrifugal oil cleaner. At the same engine oil pressures, the IOW Group bypass filters spin faster than the Mann Hummel FM200. The higher centrifuge bowl RPMs generate greater centrifugal force, which produces greater separation efficiency. 

Are you looking to extend the time between engine overhauls and increase lube oil durability? The IOW Group lube oil centrifuge, by separating harmful wear metals and debris from the lube oil, extends engine component life and oil service intervals, saving operating and maintenance costs.

 

Caterpillar 3612

Our customer’s Caterpillar 3612 diesel engines came from the factory with three (3) Mann Hummel FM200-12 centrifugal oil cleaners (Caterpillar 1W-4191 filter). This customer was looking to lower their operating total cost, extend service intervals, and increase engine reliability. The customer replaced the Mann Hummel FM200-12 centrifuges with IOW MP200 centrifugal bypass filters.

The IOW MP200 centrifuge filters are designed for a lube oil sump of 35-175 liters (9.24-46.23 US gallons). The IOW Group centrifugal filters are proven to extend the primary filter life. They remove micron-size solids from the lube oil, such as sludge, wear materials, soot, and carbonous material. The IOW centrifugal filters can increase the number of operating hours before the primary filters become restricted and extend oil change intervals. 

Extend Equipment Life and Reduce Maintenance!

 

Caterpillar C280-12

These Caterpillar C280 diesel engines came from the factory with three (3) Mann Hummel FM200-12 centrifugal oil cleaners. Looking for increased engine reliability and improved contamination removal, the customer replaced the Mann Hummel FM200 centrifuges (Caterpillar 1W4191 centrifugal filter) with IOW MP200 centrifugal bypass filters. At 70 PSI lube oil pressure, the IOW MP200 oil centrifuge filters are spinning at 6,354, 6,444, and 6,324 RPMs.

Complete Centrifugal Bypass Filter Upgrade!

This maritime customer is using Mobil DelVac 1640 lubrication oil. With new lubrication oil and only after 506 hours (centrifuge run time), the IOW MP200 oil centrifuge bowls had approximately 1/2″ sludge cake collected in each centrifuge bowl. By upgrading the filtration system, this customer’s lube oil analysis reports better results with the IOW centrifugal bypass filters than the Mann Hummel centrifugal oil cleaners.

The IOW Group has the BEST oil centrifuges for the separation of soot particles and harmful contaminants.  

 

Caterpillar MaK 8M20

The service life of the engine depends on the lube oil quality. The owner of a container ship equipped with Caterpillar MaK 8M20 auxiliary engines sought to enhance engine reliability and eliminate extra wear and tear contaminants from the lubricating oil. These MaK 8M20 engines burn heavy fuel oil (HFO). The customer changed the lube oil approximately every 500 hours.

For this installation, the customer selected to set up a kidney loop system with the IOW MP600 centrifugal bypass filter and a designated feed pump.  

Results: During 500 run hours, the IOW MP600 centrifuge was serviced three (3) times:
– At 375 run hours, the sludge thickness was 17 mm, and it weighed 2,600 grams (5.7 lbs)
– At 434 run hours, the sludge thickness was 25 mm, and it weighed 3,900 grams (8.6 lbs)
– At 500 run hours, the sludge thickness was 20 mm, and it weighed 3,100 grams (6.9 lbs) 

Ensure Engine Performance!

 

Caterpillar MaK 12CM32

This Caterpillar MaK 12CM32 medium-speed engine customer wanted to improve and upgrade their lube oil filtration system. The IOW MP600 centrifugal bypass filter with the CentriClean SCU 0002 remote monitor was installed next to the engine.

At 48 PSI lube oil pressure, the CentriClean SCU 0002 displayed 3,278 centrifuge RPMs. At the same engine oil pressures, the IOW Group centrifuges have faster bowl speeds than any existing centrifugal bypass filters on the market. Higher centrifuge RPMs provide greater separation efficiencies. 

Better Oil Filtration with the IOW Group Centrifugal Bypass Filters!

 

Caterpillar MaK GCM34

The Caterpillar G16CM34 gas compression engine is built on the standard G3300 platform. The G16CM34 is a natural gas, spark-ignited, V-style, turbocharged, and aftercooled engine.

This Caterpillar G16CM34 gas compression customer utilizes Mobil Pegasus 1005 lubrication oil. At their natural gas compression facility, each Caterpillar GCM34 engine has a 1,5000-gallon lube oil reservoir. The customer needs to increase engine reliability and remove contaminant metals from their lubricating oil. To achieve this, they upgraded their fluid purification equipment and added a kidney loop system with four (4) IOW MP600 centrifugal bypass filters and one (1) IOW Mechline feed pump.

Enhance Performance and Protect Your Engine!

 

Caterpillar MaK 8M453

This roll-on/roll-off cargo ship has MaK 8M453AK engines. It also has Alfa Laval MOPX 205 centrifuges and Bollfilter 6.64 self-cleaning lube oil filters. To improve engine lube oil filtration, this customer installed IOW MP600 centrifugal bypass filters on all four of their MaK 8M453 engines. 

Each engine was set up with a kidney loop system, which included an IOW MP600 centrifuge, an IOW Mechline feed pump, and a control panel. The CentriClean SCU 0002 remote monitor was mounted inside the kidney loop control panel and requires 12-24 volts DC to operate. The CentriClean SCU 0002 (separator control unit) is designed to monitor the centrifuge’s performance. During normal operation, it continuously displays the current centrifuge RPMs and monitors centrifuge run hours.

Empower your oil filtration with cutting-edge technology!

 

 

Clean lubricating oil (clean oil) is the lifeblood of your equipment, and keeping it clean can mean the difference between a smooth-running machine and a costly breakdown. IOW Group is a world leader in centrifugal bypass filter technology. To learn more, visit our IOW Group centrifugal bypass filter webpage or IOW Group’s centrifugal bypass filter webpage.

 

How does an IOW Group centrifugal bypass filter work?

 

When repair parts become scarce, the best investment a company can make is ensuring their existing equipment runs for as long as possible before breaking. Investing in reliability is a smart target for companies moving forward. Not all engine oil centrifuge filters are created equal. The engine oil centrifuge filter manufactured by IOW Group is the only disc stack centrifuge filter on the market. Visit our IOW Group – Disc Stack Centrifuge Filter webpage or the IOW Group Oil Cleaning Centrifuge website.