Redefining Oil Quality Management
The Context Today’s industry: ● Faces high pressure to reduce operational costs, and yet have high reliability. Wants to run more efficiently, waste less and be more considerate towards the environment. ● The Reality: 54% of machine failures are caused by poor lubrication ● ● Lab oil analysis, being widely practiced is slow and inaccurate Absolute or nominal filter ratings are vague and unreliable ● ● Post installation, it is impossible to evaluate oil quality in real time - forcing a costly premature oil change Neptunus addresses all these concerns and presents a better way to maintain oil health
The Problem with today’s method Today oil management is restricted to Filtering and not Cleaning ● Filtering - Separation of solids or water from oil Cleaning - Eliminates the cause of oil oxidation (in addition to contaminant separation) Particulate Count is not adequate; it is just one parameter- like platelet count of blood. ● Oil replacement periods are decided intuitively, without qualitative evidence ● No quantifiable way to measure oil quality, so cannot say if oil is clean or no! ● Breakdowns still occur. System is not foolproof. ●
Our Vision To provide customers an accurate and reliable oil condition management system that will: ● Measure and indicate oil quality in real-time Remove sources of oxidation and keep the oil continuously clean ● ● Provide optimal oil replacement period Provide detailed oil quality data based on several key oil quality indicators. ● ● Assist in cost saving by reducing inventory carrying costs Increase reliability of filters ● ● Provide remote accessibility of oil health data
Engine/Machine Health Our Vision Time
How? Through Neptunus’ advanced Continuous Oil Quality Management System ● (OQMS) technology, which is simple and easy to use! RRR filtration system provides absolute filtration till 3μ with ß3 >929 and ● removes all types of contaminants (including water and sludge particles) Tan Delta Oil Condition Monitoring Sensors will accurately measure and ● indicate the oil quality in real-time and also provides optimal oil change time
Why is this important? 90% of particulate matter is less than 5 microns 70% of particulate matter is less than 1 microns
Our belief ● Without continuously monitoring condition of the oil, simply fitting bypass oil cleaning system does not meet the primary requirement of ensuring oil is always clean and the quality of oil is always a certain standard. ● Oil Oxidation causes varnish, which leads to reduced load bearing capacity of oil, increased particulate matter, greater wear and tear, leading to further oxidation, Oxidation is the nemesis of Oil (Mis)Management! ● You cannot manage what you do not measure ●
NORIA CORP. OIL TRIBOLOGY STUDIES
NORIA CORP. OIL TRIBOLOGY STUDIES
What is the solution? Offline kidney loop bypass oil filtration system that cleans oil up to 3 micron/1 micron with an accuracy of 99.75%, integrated with an online real-time oil condition monitoring system
The Neptunus way Neptunus’ OQMS technology consists of two main pillars : ● 1. Micro filtration system (RRR)/Nano filtration System (Europa filter) 2. Real-time oil condition monitoring system (Tan Delta)
RRR Bypass oil cleaning system
RRR Bypass Micro filtration RRR is an offline oil filtration system that: 1. Employs bypass loop (kidney loop) to increase the effectiveness of filtration 2. Is a highly efficient filtration systems ( β 3 >929 ), capable of removing water, solid particles, resins, oxidation sludge, varnish and other organic contaminants from oil 3. Oil Flow is Axial, not radial like in the case of other filters. 4. Uses a patented Depth filtration technology to capture maximum number of contaminants
RRR - Bypass filtration system Bypass filtration: ● A bypass loop is a circuit that draws oil from oil reservoir and delivers it back to the reservoir after filtration. Bypass filtration system enhances efficiency , as ● it operates on below-mentioned ideal conditions: 1. Reduced flow 2. Minimal pressure and 3. No stress by flow and pressure pulsations .
More on Technology Radial Flow Axial Flow More Greater chance of particles passing through the solids are trapped as they progress through media or premature plugging multi-layered media
Beta Ratio Explained Upstream Particles-1,000,000 ● Downstream Particles- 5,00,000 ● Resulting Beta Ratio of 2 and efficiency of ● 50%
One Filter for Solid, Moisture and Oxidation Solid particles The element setup forces the oil to flow through 114 mm. of filtration material, and to pass through 3 stages of different density. The big particles are retained on top of the element, smaller particles in the 1st. stage, and the smallest particles in the lower compressed part. This progressive removal of particles, results in a high ß-ratio and a very high dirt absorption capacity Water Additionally the cellulose material allows the absorption of up to 200 ml. of water in the filter element. Sludge, resins and oxidation products The most remarkable and noticeable feature of the Triple R element is his ability to remove resins and oxidation products. Varnish is half liquid and half solid, it is hard to be removed by ordinary filters but with Triple R filter elements it is easily captured, it will stuck on the special filter paper.
Tan Delta Online Oil Condition Monitoring
Tan Delta Technology Tan Delta is a global leader in real-time oil condition monitoring products employs ● oil quality sensors (OQSx) to detect oil condition in real-time using patented technology Principle of operation: ● 1. Tan Delta sensor generates an electric field within the oil 2. Ratio of capacitance and conductance of oil is calculated by the sensor 3. This ratio is compared with the Tan Delta oil database and a TDN (Tan Delta Number) is generated TDN is a measure of exact oil quality and ranges from 0 to 1200 ●
The Technology - Tan Delta
What you see: TDN variation TDN reflects the overall health of the oil on a scale of 1200 - 0 . Higher the number, better is the oil quality. ● 1200 - Sensor in air 1000 - Fresh sealed oil ● ● 1000 to 600 - Good oil 600 to 300- Worn, replacement needed ● ● < 300 - Debris of the oil shall cause hampering to the engine (Immediate oil change is required) Along with TDN, Tan Delta display provides rate of Change of oil quality (ROC) with time and oil temperature.
Failure Modes - Tan Delta ANY CHANGE IN THESE PARAMETERS, SINGULARLY OR IN COMBINATION WILL ALTER THE CHEMICAL FINGERPRINT OF OIL AND WILL BE DETECTED & INDICATED BY THE SENSOR
Data monitoring options Tan Delta provides the below-mentioned oil quality data monitoring options: ● Oil Quality Display Express (OQD) Oil Quality Display Professional (OQDp) ● ● Monitoring on PC or Laptop Wireless remote monitoring through ● Cloud Analog (4-20 mA) to a PLC ● ● MODbus (RS485) and CANbus
LOCAL AND REMOTE MONITORING OPTIONS
BLUETOOTH MONITORING ● Free Android play store application. Pairs data into it from TanDelta Display through Bluetooth ● Real-Time Data can viewed from Neptunus IoT Platform from any terminal on the internet through secure login Download Oil health data logs ● ● Trends in conjunction with the Rate of Change (ROC) Early Warning Alarms through SMS ● ● Visual indicator alarms
Tan Delta Installation
Mid-Term & Long-Term Benefits Neptunus presents a complete, accurate and reliable oil quality management solution, that: ● Purifies the oil continuously upto 3μ with ß3 >400 (99.75% efficiency) , along with preventing oil oxidation (results in a minimum of 2x to 5x increase in oil life) ● By clean oil, the overall life of the asset and life of individual components increase substantially. ● Provides accurate real-time oil health data, through multiple output options Analyses the performance of filter ● ● Presents a numerical and visual indication for optimal change of oil along with operator friendly warning signals ● Does not interfere with the performance of machine and hence operator and owner friendly
COST BENEFIT ANALYSIS Assumed oil sump capacity 1000 Litres Price of oil (approx) USD 2.5 / Litre Oil change interval 1000 hours Expected increase in the life of oil 200% Expected increase in Machine Increase by 15% performance Return on investment (months) ROI within 9 months
To know more, please contact us Neptunus Power Plant Services Pvt. Ltd. Email : info@neptunus-power.com Call : +91 9594410707
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