Tag Archives: hydraulic oil

Industrial Oils and Purification

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Industrial oils are used as a lubricant reducing friction and wear of parts and components in various industrial machines.  The main functions of this type of oil is anti-corrosion protection, dissipation of heat from friction parts, removal of contaminants and reduction of foaming.

Industrial oils can also be used as the base for hydraulic fluid, as well as grease, that extends durability and service life of industrial equipment.

Despite the fact that practically all industrial oils are thoroughly tested in laboratories before dispatch to the user, the oils will become contaminated during use and operation.  Industrial oil, just as with any other oil, can become contaminated by atmospheric oxygen, water and particulate matter.  Interaction with aggressive media may accelerate oil oxidation that is accompanied by the accumulation of even more unwanted contaminants in the oil.

Saturation of oil by contaminants degrades the oil’s performance.  Due to aging and contamination,  industrial oils lose the ability to efficiently dissipate heat and protect equipment from corrosion.

It would seem that the aging process is natural and nothing can be done about it except replacing the used oil with new and disposing of the old oil.  A practical operator however, will be concerned by the additional costs of used oil disposal, as well as the frequent cost of oil changes.

Fortunately, aging of oil is not all that critical with the advent of modern additives and oil processing equipment.  The aging process therefore, can be significantly slowed and the service life of the lubricating oil can be significantly extended.

It is however, necessary to regularly take oil samples to know and understand the oil’s condition and to detect and identify the contaminants degrading the performance of the oil and to purify the oil in a timely manner.

GlobeCore is one of the leading manufacturers and suppliers of industrial, turbine and dielectric insulating oil purification systems.

The CMM-CM type units and  CFU-M filter carts made by GlobeCore are successfully operated in more than 70 countries around the world.  They are efficient for the purification and regeneration of industrial oils.

The ability to purify and regenerate industrial oil was made possible by using modern technologies and maximizing and customizing the processing operations for the individual client.

The CMM-CM units are designed for removal for water and solid particles from oil by using a special zeolite sorbent and subsequent reactivation of this sorbent in the system.

The CFU-M filtration carts are designed for removal of solid particles from industrial oil.  These units can purify the product in one cycle.

Both types are simple in service and operation and facilitate a significant extention of industrial oil service life cycle.

Industrial Oil: Wholesale or Retail?

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The volume of oil required to be purchased is defined by the needs of the company or the facility.  Normally, a large amount of oil is purchased wholesale, while a smaller amount needed for the replacement of oil fir one or several machines, is usually purchased retail.

Based on price, it would seem that wholesale purchases are better for your company financially.  The price of a large batch of oil per liter purchased wholesale will be lower than purchasing smaller retail volumes pre liter.

There are however, problems with large amounts of oil.  Wholesale volumes of oil must be stored somewhere. Industrial oil is obviously sensitive to various contaminants such as water, particulate matter and other unwanted contaminants.  Apart from allotting storage facilities, the oil also requires constant monitoring of purity and and water content.

Purity of industrial oil purchased wholesale or in smaller retail batches can be ensured by two methods:

  • Prevention of contamination in storage; and
  • Purification of contaminated oil.

Both include a whole range of measures.  As stated above, purity of industrial oil can be ensured by prevention or purification, but the best results are achieved by combining the two.  This also allows savings of money since preventive measures require quite less investment than actual purification and regeneration.

Prevention alone however, cannot maintain industrial oil’s purity in the long run.  It requires a complex approach to transportation and storage using the following equipment:

  • air-tight tanks;
  • equipment made from non-corroding materials;
  • correct temperature in storage and transportation;
  • and the use of inert gases to fill gas space.

This increases the cost of prevention.  The goal therefore, is to reduce the amount of contaminants as much as possible in the oil going to purification devices, which finalize the required purity of the product.

The following systems from GlobeCore GmbH are recommended for the purification and regeneration of industrial oil:

●      Mobile oil unit CММ-1.7 CM;
●      Mobile oil unit CММ-3.5 CM;
●      Mobile oil unit CММ-5 CM;
●      Filter cart CFU-0.8М;
●      Filter cart CFU-1.7М, (CFU-4).

Industrial Oil Sales: Preserving the Oil’s Performance Characteristics

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So, you have decided to sell industrial oil?  Let’s assume that you already have found a storage facility for the product.  One thing remains however, knowing what the consumer needs and how to provide that need.

Besides better terms of supply, lower price, and various discounts, the client is mostly interested in the quality of the product.  Industrial oil quality in our case.  The quality is a combination of many parameters and characteristics that must not fall below regulated specifications during storage, transportation and operation.

Let us look into the characteristics, which define the quality of industrial oil and are important for the client’s choice:

  • Viscosity.  This is the first thing to consider about oil.  It is very important for the use of the majority of industrial oils.  When friction parts are designed and calculated, the parameter taken into consideration is the dynamic viscosity of the oil.  This is a regulated parameter of all oil made from crude base stock.  Dynamic viscosity used be defined at between 50ºС/122ºF and 100ºС/212ºF. That has changed and now all measurements are made according to ISO 3448-75 (instead of measuring viscosity at 50ºС/122ºF, the reference temperature is now 40ºС/104ºF).  When choosing industrial oil, the buyer usually considers three critical viscosity values: optimal at working temperature, minimal at maximum working temperature and maximum at the lowest working temperature;
  • Pour Point. This parameter is defined by testing a sample of the oil.  The Pour Point is the lowest temperature that the oil will continue to flow.  This temperature does not entirely indicate the dynamics of the oil in operating conditions at low temperatures.  That is shown better by actual viscosity at a given temperature. To reduce the pour point of industrial oil, it is mixed with special additives. This parameter is meaningful to the buyer planning his storage operations, dispatch, and draining and for using the oil in low temperature environments;
  • Flashpoint. This is the temperature at which the vapor of the oil can form a flammable mixture with the air. It defines the relative fire hazard of the oil and shows the presence of volatile fractions within it.  It is measured in special open or closed type devices;
  • Ash content. This parameter indicates the amount of non-organic contaminants left after burning a sample of the industrial oil. It is expressed in percentage of weight.  If ash content of oil without additives is too high, it indicates insufficient purification.  In most cases, ash content of industrial oil is from 0.002% to 0.4%;
  • Content of particulate matter, solvents, water, water-soluble acids and bases. This indication is extremely important in controlling the oil quality after production as well as determination of its further usability.  Mobile oil purification units for treatment and regeneration of oil can significantly increase the service life of the oil and improve reliability of machinery;

In practice, GlobeCore products are used for the purification and regeneration of industrial oil.

  • Color.  The color is a visual indication of the purity of industrial oil.  It also allows the buyer to make a judgment on the oil’s origins.  Keep in mind that some additives can make the oil darker.  If the color of the oil changes during use however, this is an indirect indication of its oxidation and/or contamination;
  • Acid number. Knowing this important neutralization number allows the buyer to determine the oil’s purity as well as the stability in use and in storage.  Additives can increase the acidity of the oil, but can also increase the stability of oil for long term use and storage;
  • Sulfur content.  The amount of sulfur initially depends on the amount of sulfur in the crude base stock the oil was blended from and the degree of purification and refinement.  After purification of industrial oils made from sour crude, sulfur remains in the oil in organic compounds and under normal conditions does not cause corrosion of metals.  Sulfur may become aggressive in elevated temperatures.  The content of sulfuric compounds is higher in oil with additives. This is due to the fact that additives containing sulfur are mixed with industrial oil to increase their lubrication qualities.

Oil filtration

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During operation, transformer oil accumulate contaminants, which can form various chemicals. These substances reduce the oil’s performance and are, of course, undesirable.

Operation of the transformer becomes unstable. To prevent this, transformer oil is filtered and purified. Some of the methods are discussed in more detail below.

The first stage of transformer oil purification is mechanical. This is a superficial treatment to remove particulate matter and water. The next step is deeper purification performed in vacuum with heating.

The first two stages are, in fact, preliminary. The main process involves various chemicals.

One of the methods is purification of oil with a 98% sulfuric acid solution.

In comparison to other chemical purification methods, the use of sulfuric acid has a significant drawback. Beside reacting with the contaminants, the acid also adversely influecnes the structure of the oil, making it somewhat unstable. Additional processes are required to resolve that problem.

The nature of selective purification is evident from the title. Speical solvents are introduced into the oil to remove specific impurities.

De-waxing is another widely accepted process. In this process, oil is treated with special solvents: acetone, toluene, bensol etc, to remove solid contaminants.

It should be noted that chemical methods influence oil’s stability, but extend the oil’s service life at the same time.

It should also be remembered that any purification process should end with finishing purification, closing the cycle of oil processing and filtration. This is usually done by contact method.

This means that the oil is mixed with special materials, usually clay or bleaching earth. The materials are then mixed and heated. Heating facilitates acviation of all sorbents in the clay.

These absorbents capture contaminants. Deep filtration separates oil from the clay. When selecting adsorbent, it is necessary to pay attention to the content of moisture. It should be suffucient to make production efficient and to make processed oil compliant with specifications.

The most interesting technology today involves the use of bleaching clays (Fuller’s earth). Globecore manufactures a range of CMM type units for filtration of various oils with the use of Fuller’s earth. The advantages of the design are the ability of multiple reactivation of the sorbent, mobility, simplicity of operation and high quality of the output product.

Downtime is significantly reduced by the ability to reactivate the sorbent without the need for frequent replacement, thus increasing process efficiency.

Improving Hydraulic Fluid Operation

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Hydraulic Fluids and Oils

The loss of performance by hydraulic fluid systems is a rather important problem because it leads to serious issues with turbine system performance and safety.  The loss of performance is normally caused by failures and damage in the regulation, lubrication and the sealing systems of the generator shafts.

The problem has become increasingly important because many power generation facilities are approaching the end of their service life and require increased attention and maintenance.  But, the current methods and devices for oil quality control, as well as oil purification equipment, are often obsolete and far from efficient further compounding the power company’s problems.

The International Standards Organization (ISO) recommends that reliable operation of turbine systems requires that the amounts of particulate matter in circulating turbine oils be kept to between 3 and 25 microns.  (See ISO 4406).  Anything larger can have adverse consequences on your turbine equipment.  These limitations are due to the fact that the distance between the support and the bearing pad with max load is 10 microns.  At start up, the lubricating layer of oil on the bearings is between 5-8 microns.

Most turbine regulation systems include spools and sleeves with radial clearances of between 50 to 100 microns.   If the spools rotate between them and the bearing box, the clearance should be set to between 10 to 25 microns.  The functioning of the turbine regulation system may be accompanied by failures due to solid contaminants that accumulate in the gaps in the regulation assemblies and spool clearances.  Serious damage may be caused by foreign particles entering the support bearing which may lead to a disruption of the pad setting.

If the turbine oil is contaminated by foreign substances and/or water, it will inevitably lead to over heating during operation and will cause premature failure of the bearings.  Such operation also makes the regulation system operation unstable and will cause additional unscheduled repair costs.

If the oil becomes contaminated and loses its ability to perform its intended purposes, it must be changed.  But, that will significantly increase your equipment operating and maintenance costs.  This can be avoided however, by performing timely scheduled preventive maintenance that includes purification of the hydraulic/turbine oil.  The GlobeCore Purification Process (GlobeCore Process) is designed to extend the service life of your hydraulic oils from 3-5 years to as much as 10 years.  Using The GlobeCore Process therefore, will lead to significant savings in long term maintenance costs.

Hydraulic System Filters

Some of the commonly used filtering elements used in hydraulic equipment are made from fabric, composite membranes, paper, polypropylene, zeolite, fuller’s earth, fiberglass, metal fibers, ceramics, products of powder metallurgy, ion exchange resins and metal meshes.  Each filtering media has both advantages and disadvantages.

Metal Mesh Filters

Considering the high degree of contamination that can be found in hydraulic fluids and oils used in modern equipment, the first filter choice seems to be to use metal mesh filters with between a 10 to 20 micron filtration fineness.  There is a catch however, even a 20 micron mesh filter can only capture particles of this size nominally.   That is because the orientation of particles in the liquid is random.  It should also be remembered that the beta ratio of filtration describing the retention capacity is from 10 to 100 times less than metal mesh filter’s advertised fineness.  Pump vibrations will also serve to further decrease the efficiency of metal mesh type filters.

To restore the functionality of a contaminated mesh filter, it will require rinsing and cleaning.  It is however, a complex process that requires an ultrasonic bath in detergent with heating and a very careful air purge process.  Even rinsing does not fully clear all contaminants from the mesh.  Thus, the life cycle of such elements is limited.

Another point to keep in mind is that the price of a mesh filter is approximately five times that of single-use filter element.

Fuller’s Earth Systems

Fuller’s Earth is not generally used for turbine oil purification since it can capture the inhibitor and salts from the oil causing “dieseling” of the oil.  Fuller’s Earth however, is widely used in transformer oil purification and regeneration.  Its main advantage being the ability to undergo multiple re-activations over hundreds of regeneration and purification cycles.

Centrifuges

Centrifuges are another means of oil purification, but they cannot remove particles smaller than 5 microns from the oil.  If the amount of the particulate matter is large enough, they can significantly degrade oil purity and cause equipment failures.

Electric Purification

For especially clean hydraulic fluids, electric purification is another possible choice.  This is a quickly developing modern method of fluid purification.  It has been tested extensively with oils stored in sealed vessels with excellent results.  There has been sufficient experience in using electric purification methods for petrochemical products and crude oil to gain wide acceptance in the fluid industry.

The process requires the preliminary heating of the liquid, but causes no resistance to the flow of the product and is simple to control.  The intensity of the process depends on applied voltage and the viscosity of the oil product.  The disadvantage of this method is that the equipment for this purification method cannot currently be installed on operating machines.  One of the issues with such systems is the need for protection against electric breakdown.  Another factor is the reduction of the oil’s “interfacial tension” after electric purification process.

There is therefore, no single systematic approach to purification of industrial oils.

Combined Approach

Problems with hydraulic oils and fluids can first arise at the stage of purity control.   Since all facilities are not fully supplied with reagents and the proper required equipment, oils and fluids may not be free from moisture and other forms of contamination at the point manufacture and delivery.

Years if industry experience shows that high quality oil purification requires a combined approach that includes the following:

1. Formation of an independent group of experts and service personnel for the control of oil purity in turbines and hydraulic systems.

2.  Creation of separate of “Chemical Control Departments” at nuclear, hydro and thermal power generating plants.  They will run oil analysis labs and and provide digital moisture meters for oil monitoring.  These departments with be responsible for scheduling and performing preventive and scheduled maintenance.

3.  The best solution for your oil purification problems would include purification by GlobeCore’s UVR oil purification equipment.

4.  Maintenance departments at power generation companies should be equipped with modern service equipment (such as the GlobeCore  UVR purification units) and the personnel should be adequately trained for the use of such equipment.

The GlobeCore Process is most efficient and cost effective oil purification process in the world today!

It’s time to get with the Process.  The GlobeCore Process!

New or Old, Hydraulic Oil Needs Filtration and Purification

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To avoid replacement of contaminated oil that can still be used, it can, and should be be filtered and restored.  Obviously, the objective is to minimize costs while maximizing the result.

For this purpose, GlobeCore offers on site filtration solutions.  The filtration fineness of our UVR plant is 3 microns.

To evaluate just how efficient the 3 micron standard is, let’s take a look at proportional hydraulic systems.  The maximum allowable particle size is 5 microns.  If you were to measure the purity of new replacement oil for this equipment, you will see particles as high as 20 microns in the fluid.  Purification therefore, is not an option, it is mandatory before putting new oil into proportional hydraulic machine systems.

The precise price of oil purification through filtration may be determined directly on site.  The process will be influenced by many factors and the most important ones are (1) the volume or amount of processed oil, and (2) the degree of fluid contamination.

Each equipment manufacturer produces operator’s manuals for hydraulic fluid replacement, but that doesn’t mean that such manuals are always read and followed.  The main principles of a fluid replacement operation are as follows:

Oil should have been be stored in sealed vessels.  Before placing the oil into the hydraulic system, the hydraulic tank should be cleaned and should be absolutely free from all dirt and contamination accumulated during previous operations.

Oil must be filled only from clean canisters by special pumps.  These pumps prevent contaminants from entering the hydraulic system from the surface of the container.  At no time should new fluid be exposed to outside air and poured into the fluid tank.  The new fluid should be pumped though hoses from the top of the container into the fluid tank.  This will prevent any moisture found at the bottom of the container from being placed into the fluid tank.

If the fluid does have contact with air, its maximum storage life is approximately two years.  If a malfunction of the system requires that the fluid be drained, it’s properties should be examined before being returned to the hydraulic equipment fluid reservoir.

This is a relatively inexpensive process, especially in the case of heavy machinery with large volumes of the fluid.

Industry statistics reveal that as much as 70% of all hydraulic failures are caused by contamination of the system’s fluids.  Every professional mechanic learns a a very simple rule: “The purity of hydraulic oil is the basic foundation of reliable operation and long service life of hydraulic systems.” It is however, not the only factor.  Additionally, the careful selection of hydraulic fluid and use of the correct replacement procedures are just as important.

If you wish to protect your hydraulic equipment and extend the service life of the fluid in your circulating hydraulic systems, GlobeCore has your answer.  GlobeCore offers the best and most cost effective alternative to solving your preventive maintenance problems.  GlobeCore is the industry leader and provides you with all the best possible solutions to hydraulic fluid purification.

GlobeCore has several various models designed for purification and regeneration of turbine oil, industrial oil, and transformer oil.  The GlobeCore product and equipment range can tackle any purification problem in the industry today including Offshore and Marine applications.

Oil suppliers rarely provide oil of the purity required for modern hydraulic and lubrication systems. Hence the need for the consumers to take matters in their own hands and bring supplied oils up to spec.  GlobeCore will do this for you because you have enough to worry about.

It’s time to get with the Process, The GlobeCore Process!

Expert Opinion about the Classes of Hydraulic Oil Purity

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Preventive Maintenance to Avoid Corrective Maintenance

Reliable operation of hydraulic equipment, widely used in various industrial facilities, depends mostly on the quality and purity of the internal cooling and lubrication oil.  Industrial machines normally operate under heavy loads and sometimes they operate under very difficult environmental conditions.  Regular maintenance of industrial equipment therefore, can allow maintenance personnel to detect possible equipment malfunctions in a timely manner.  The the essence of Preventive Maintenance is the avoidance of having to perform Corrective Maintenance.

The Problem

The presence of solid particles in oil and hydraulic fluids can quickly degrade the oil and the fluids in your hydraulic equipment.  Also known as particulate matter, among such particles, 70-85% are quartz,  10–15% are aluminum oxide, and  5–10% are iron oxide.  Contamination of hydraulic oil also disrupts the operation of your safety and regulation valves besides causing damage to your hydraulic system.

Although replacing used and/or contaminated oils and fluids is helpful, the complete replacement of oils and fluids is not a complete solution.  That is because the hydraulic system itself is most likely contaminated by metals and sludge.  These “remain behind contaminates” will actually contaminate fresh oil as soon as it is placed into the hydraulic system thereby negating most of the benefits of replacing the oil.  The new oil can also be contaminated during incorrect transportation, storage, handling, and filling of equipment.

Another important point, with regards to your maintenance program, concerns the filtering system of your hydraulic equipment.  The filters built into the hydraulic systems cannot, and do not ensure the required purification of oil circulating in your hydraulic system.

Oil purity class is not an indication of its compatibility with certain industrial equipment types.  Also, a specific purity class cannot give a precise answer as to the oil’s reliable operation.  Equipment loads will always have a direct influence on the rate of degradation of the oil.

The Solution

For reliable operation of hydraulic fluid systems and for the prevention of malfunctions caused by contaminated and degraded oils and fluids, it is necessary to use hydraulic oil purification equipment as part of a comprehensive scheduled maintenance program.

Selection criteria of such systems include consideration of the following attributes: (1) low filtration and regeneration costs; (2) reduction of repair and maintenance costs; (3) high purity level of the processed oil; (4) removal of sludge and contaminants from oil tanks and equipment reservoirs; (5) flexibility through a mobile or stationary design; and (6) compliance with international fire and health regulations.

The Best Solution

In order to provide the hydraulic equipment industry with machines that meet the requirements of the above listed criteria, GlobeCore has developed its line of UVR type units for oil purification and regeneration.  These plants are an efficient one-stop solution for a whole array of filtration and service equipment problems.  One GlobeCore UVR unit on a mobile platform can quickly service several machines regardless of location.  It can easily move around your facility and does not require readjustment for different kinds of oil or equipment.

The use of oil purification and regeneration equipment produced and supplied by GlobeCore increases hydraulic system reliability, reduces your maintenance costs, and extends the service life of your valuable hydraulic equipment.  The GlobeCore Process is a complete regeneration and filtration process and restores your hydraulic oil to its original new specs and reduces the amount of maintenance work and downtime when operating your equipment.

The GlobeCore Process can be used to purify oil before it is placed into your equipment and it can be used to purify and restore your used and contaminated oils and fluids.  GlobeCore equipment is flexible, versatile, reliable, and extremely cost effective.  GlobeCore adds Value to your maintenance program.

It’s time to get with the Process.  The GlobeCore Process!

Hydraulic System Operating Oil – What should we do next?

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The cooling and purification of industrial hydraulic oil is a basic requirement in extending the service life of any hydraulic system.  Efficient cooling and purification solutions increase the reliability and service life of hydraulic equipment systems.  Efficient operation, along with timely prevent maintenance, will increase your long term profits.  To protect your equipment and the components of your hydraulic systems, the GlobeCore company, which operates in more than 70 countries in the field of oil purification equipment, offers a wide range of systems for reclamation and regeneration of any oil type.  This includes transformer insulating oil, hydraulic oils, transmission oils, turbine oils, and industrial oils of all types.

Used oils do not need to be used only as relatively cheap heat or energy sources any longer.  At present, it is possible to restore the used oil to its full market value.  GlobeCore has developed the GlobeCore Process for degassing, drying, and the purification of oils and hydraulic fluids.  Today, GlobeCore regeneration systems will allow your company to profit from used oils instead of having to pay for oil replacement and for the cost of disposing of used oil.

The Problem

Disposal of waste oil is becoming less and less common.  According to the latest expert conclusions, a large amount of waste oil products are constantly being generated in many industrial applications.  This rise in industrial waste oil has led to increases in handling and disposal costs and fines for violations of environmental regulations.

The Solution

GlobeCore offers an excellent solution to the problem.  The GlobeCore Process is now available for the complete restoration of used oil used in commercial applications.  The customer will no longer have to  pay for oil disposal, oil handling and for environmental licenses.  Instead, the customer can now reuse the what used to be a waste product.  A unique oil purification and regeneration process is used in a wide range of GlobeCore products.  The GlobeCore Process is environmentally sound because it does not cause the emission of unwanted gases, liquids and solid materials into the environment.  The use of the GlobeCore Process  facilitates up to a 95% conversion rate and that equates to a tremendous saving for your company in time, labor, oil and money.

GlobeCore has a line of equipment intended for the purification and regeneration of used industrial oil by removing solid particles, water, and other contaminates.  The process produces oil color improvement due to the removal of oil aging products, unwanted additives and finely dispersed asphaltenes.  The GlobeCore machines are quite simple and easy to operate.  They do not require complex adjustments and enjoy the competitive advantage of high mobility and the use of special self-reactivating sorbents for the regeneration of fluids.

Up to 90% of tar, asphaltenes, carbenes and carboids are removed from the used oil in the process of purification with mild effect on the oil’s additives.   Various solid particles and water are removed entirely with complete restoration of the oil to it’s original specification and color.

Complete GlobeCore plants may be used for the filtration and adsorption process of various types of oils, including hydraulic fluids and industrial oils.  The GlobeCore systems does not require readjustment for various oils.  They also do not require filter replacements since the regeneration and adsorption elements automatically reactivate themselves after each cycle of oil restoration/regeneration has been completed.

The uniqueness and affordability of the GlobeCore Process units makes them an excellent and cost effective investment for your company.

It’s time to get with the Process.  The GlobeCore Process!

The laws of hydraulic oil purification

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Oils and other operating liquids, used as lubricants and coolants in various industrial equipment, are prone to degrade under the influence of elevated temperatures, pressures or flow. The functionality of oils depends on viscosity, oxidation stability and purity, lubrication capabilities, corrosion and emulsification. The difference of hydraulic oils from other oils is the relatively higher viscosity of the oil for high pressure hydraulic actuators. High viscosity makes operation of equipment unsafe or impossible. On the other hand, to ensure efficient operation of the systems, oil viscosity must exceed 20 cSt. Otherwise the pumps will experience increased wear, causing rapid loss of efficiency.

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