In the 21st century living, you can automatically monitor every aspect of your life and business, and the ease of use has so many advantages that benefit us every day. Many of us use text alerts, on-site security systems, financial software, and fitness watches are all examples of monitoring tools that enable us to save time and access data that help improve processes. What about when that system could create savings within your organization?
The oil-driven centrifuge filter is one of the industry’s most reliable and economical oil cleaning technologies.
More and more companies are focusing on creating efficiency-based savings by utilizing both remote and self-monitoring systems. In the past decade, advances in performance monitoring capabilities have improved industrial processes.
To achieve optimum efficiency within your organization, you must look back to the basics and at the lifeblood of your machinery, the lubrication oil. Lube oil is essential in all processes and key to your machinery running smoother for longer; it can either decrease or extend the lifespan of your engines depending on cleanliness levels. Harmful particles in lube oil circulating around your engine cause abrasion and unnecessary wear of engine components, which in turn increases expenses and unexpected downtime.
Unfortunately, it is still common practice in some organizations to change oil at set intervals. However, this does not stop oil contamination and is also an expensive and time-consuming option! An effective filtration system for your engine’s oil is essential to protect your engines and engine components from this damage and helps improve your engine’s reliability and efficiency. The key is then to monitor the performance to ensure you are getting the best results.
What is a centrifuge filter?
A centrifuge filter utilizes the cleaning capabilities of a centrifuge. The centrifuge filter is installed as a bypass system, working in conjunction with the cleanable filter elements. A bypass centrifuge filter can also be used with standard filter elements or an automatic backwash (self-cleaning) filter. The engine’s oil pressure (or external feed pump) drives the centrifuge filter. The spinning action of the centrifuge bowl proves the centrifugal force to separate solids particles from the contaminated oil. Bypass centrifuge filters are more environmentally friendly than systems that utilize disposable filter elements. Cleaning the bypass centrifuge filter eliminates the expense of replacement elements and the cost of hazardous waste disposal. Centrifuge filters have an effective particle size removal below 1 micron and have a filtration efficiency that does not deteriorate with time.
IOW Centrifuge Filters
Installing an IOW centrifuge filter and CentriClean SCU monitoring unit removes the maximum amount of contaminants from your oil, meaning your oil lasts longer and your engine components are protected from excess wear. The CentriClean SCU unit is a revolutionary approach to processing reliability, effectiveness, and efficiency within your oil filtration systems by reducing maintenance costs, reducing machine downtime, and reducing wasted man-hours. Instead of servicing a centrifuge filter that may not need it, or may not have been working effectively, simply check the external monitor or app to see the running status!
The IOW centrifuge filter range can have huge improvements on your processes. The IOW centrifugal filters are designed to be retrofitted to replace old centrifuge oil filters. As a result of extending oil change intervals, less oil is consumed, and extending component lifespan means less carbon footprint on the environment. Using CentriClean monitoring systems to move to a condition maintenance program makes the IOW MP centrifuge filters a sustainable and environmental choice. By monitoring and responding to the data from the CentriClean SCU monitor, customers can remove more sludge from the oil, increase machine uptime and increase productivity.
IOW Group’s centrifugal filter devices are 150% more efficient than any other centrifugal filter available.
The combination of remote monitoring and patent-protected technology inside makes the IOW Group’s centrifuge filter range 150% more efficient than any other product available. Helping customers succeed within their business sectors and gain an advantage over their competition by opting for the most up-to-date filtration and monitoring technology.
Ultimately successful businesses are measured on productivity and profit, which are determined by the efficiency of your machinery, staff, and processes. Remote monitoring options are the choice of the future and one which will be a deciding factor in whether businesses grow in success and separate from the competition.
How does a centrifuge filter work?
The dirty oil is introduced into the centrifuge filter bowl by engine oil pressure through holes drilled in the vertical spindle and via the accelerator channels in the bearing distributor. The centrifuge bowl then fills up, and oil overflows into the top turbine, where it exits the bowl via the four-speed turbine channels and then out via the nozzles. This, in turn, rotates the centrifuge bowl, generating the centrifugal force required to remove the contaminants from the oil. The contaminants migrate toward the outside of the centrifuge bowl, where they are deposited on a removable oil-resistant insert. The cleaned oil migrates towards the center of the centrifuge bowl, where it is expelled by the nozzles in the top turbine, thus perpetuating the cycle.
– Bowl Disc Technology: Increasing centrifuge efficiency by removing even more contaminants.
– CentriClean Separator Control Unit (SCU): Monitors the centrifuge filter and provides operators and systems with valuable insight into its speed, cleaning, and service requirements.
– Fully Sealed Centrifuge Bowl: Reducing the risk of cross-contamination between cleaned and dirty oil.
– Distributor Impeller: Eliminates back pressure by drawing in contaminated oil.
– 150% more efficient
– Reduce Engine Wear
– Reduce Maintenance
– Reduce Costs
The IOW centrifuge filter devices have been tried, tested, and proved to be the most innovative and efficient pressure-driven centrifugal technology currently available. To learn more about the IOW Centrifugal Filters and their related products, visit IOWGroup.com or visit our IOW Group Centrifuge Filter webpage.
Centrifuge filters take a small amount of this oil and harness centrifugal force to draw out contaminants forming a sludge cake on the outer bowl wall. These units must be completely sealed to avoid losing oil and contain the soot. Traditionally, these oil centrifugal filters are cleaned at set intervals, but how do you know your oil centrifuge filter is running optimally between these intervals? What if the centrifuge filter is full and no longer filters your oil? Is the centrifuge filter turning at high enough RPMs to be filtering efficiently?
There are a variety of oil centrifuge filter brands available, but all contain old, outdated technology. The IOW Group MP range of centrifugal filters is the only product of its kind to offer a choice of sludge monitoring units. The CentriClean Separator Control Unit (SCU) that monitors the centrifugal filter is supplied in two different forms, dependent on the environment you work within, and each unit offers different features.
CentriClean SCU0002 Remote Monitor
The CentriClean SCU0002 Modbus Remote Monitor allows the operator to connect this device to the engine control room or engine management system via the Modbus protocol. The digital screen on the SCU unit gives the operator the real-time running status of the centrifugal oil separator. Illustrating when the oil separator is working optimally or when the centrifugal filter requires servicing, indicating using a traffic light system on the SCU. Other functionality also includes the operator setting run hours and checking when the service was last carried out.
Continuously display the current RPMs of the centrifuge filter and monitor run hours.
The CentriClean SCU0002 is designed to monitor the performance of the centrifuge filter. During its normal operation, it will continuously display the current RPMs of the centrifuge filter and monitor run hours.
CentriClean SCU0003 Bluetooth Remote Monitor
The CentriClean SCU0003 Bluetooth Remote Monitor was designed with mobile device users in mind. Checking your filtration system is so convenient using an everyday device that is available and accessible to a majority of people and gives the advantage of connecting and monitoring several engine oil centrifuges—using Bluetooth technology to connect to the SCU and obtain real-time information on the engine oil centrifuge in the palm of your hand!
IOW Group has designed the CentriClean app to connect to the SCU0003 unit. The app has some great features, from checking the status of the centrifuge filter and whether it requires servicing to accessing manuals, ordering spare parts, and making and sharing notes on the current status, all on the go!
Ideal for those operators who want to access the data via Bluetooth® on a mobile device.
To learn more about the CentriClean App, visit CentriClean.com.
How to extend the lifespan of your engine?
Contaminants in lubrication oil could be costing you your machinery! These tiny particles contaminate the lube oil, eventually making it no longer fit for purpose. Instead of lubricating surfaces and assisting smooth processes, the oil is actually causing corrosion and damage to engine components. How do we measure, control, and eliminate these harmful contaminants within lube oil?
Improving ISO Cleanliness Codes
Regular oil analysis allows the users to monitor the levels of contaminants in the lube oil, see trends and react accordingly. Contaminant levels are measured and represented using ISO cleanliness codes. The ISO cleanliness codes are derived from the International Standard ISO 4406:2017. The ISO code shows three sets of separated numbers. Reviewing these codes at regular intervals gives a good indicator of the condition of your oil. It’s not only oil you could be saving on, by improving your ISO codes you’re also extending the lifespan of your engine!
Analyzing oil samples can also assist in diagnosing where contamination occurs in your engine. Preventing damage before it can become an expensive repair is an essential part of implementing a controlled maintenance program. Targeting the root cause of machine wear and failure before the damage is done can create impressive savings, not just in the cost of parts, but also in labor costs. By achieving the desired ISO cleanliness codes, machine uptime is increased, sustainability and system operations are improved, maintenance costs are lowered, and most importantly, equipment and machinery lifespans are extended, increasing their return on investment!
Another aspect of improving lube oil quality to protect your machinery is an effective filtration system, particles in oil are inevitable, but centrifugal oil filters can help to remove these and improve your ISO cleanliness code. Centrifugal filters are bypass filters taking a small percentage of oil out of circulation and use centrifugal force to draw out harmful contaminants that are then collected and disposed of when the centrifugal oil filter is full.
Following the ISO cleanliness code based on ISO 4406 oil analysis testing, for these Alco 18-251 engines, the cleanliness level had dropped three (3) levels. With the Mann+Hummel FM600 centrifuge filters, these engines ran an ISO cleanliness code of 22/19. With the IOW MP600 centrifuge filters, these engines run an ISO cleanliness code of 19/16. When lowering the ISO codes from 22/19 to 19/16, the ALCO 18-251 engine life extension is expected to double!
Add the best oil centrifugal filter on the market when adding an oil centrifugal filter to your engine. Add IOW Group’s Oil Centrifugal Filters. To learn more about the IOW Centrifugal Filters and their related products, visit IOWGroup.com or visit our IOW Group Centrifuge Filter webpage.
How can the IOW Group centrifuge filter extend the lifespan of your engine?
The IOW Group’s centrifugal filters have unique patent-protected features that make them 150% more efficient than any other centrifugal filter available. The IOW market-leading centrifuge filters are designed to stop any cross-contamination of clean and dirty oil. They use bowl disc technology to harness superior separation. With bowl disc technology, it can remove the smallest of contaminants. Combined with CentriClean remote monitoring units to ensure reliability and efficiency, the IOW centrifuge filters will have profound effects on processes and help your organization achieve ISO cleanliness code targets. IOW Group’s centrifuge filters run two-three ISO cleanliness codes better than the competition!
Due to the high levels of contamination in the lube oil system, this customer wanted to effectively remove micron-size solids from the lubrication oil, such as sludge, wear materials, carbonous materials, and soot. Two (2) IOW MP200 centrifuge filters are installed on a double mounting bracket with a large gravity drainpipe on the inspection platform.
On the first IOW MP200 centrifuge filter, the CentriClean SCU0002 control panel displayed 6,438 RPMs at 85 PSI lube oil pressure. On the second IOW MP200 centrifuge filter, the CentriClean SCU0002 control panel showed 6,318 RPMs at 84 PSI lube oil pressure.
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.
Proactive Maintenance Approach to Extend Engine Life
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 oil centrifugal filters maintained the level of cleanliness of the oil required by Caterpillar for proper lubrication, extending the primary filter life, prolonging the oil change intervals, and improving the internal engine with less abrasive wear.
ISO cleanliness codes are essential key indicators to improving reliability within your organization’s equipment. Those that are focused on increasing reliability strive to improve these codes. The IOW centrifugal devices are available in several different sizes. To learn more about the IOW Centrifugal Filters and their related products, visit IOWGroup.com or visit our IOW Group Centrifuge Filter webpage. The IOW centrifugal devices are available, ready for shipping, and ready to use. Contact us today for an IOW Centrifuge Filter System!