Understanding the Hydraulic Oil Separation Method: Techniques, Applications, and Benefits

Introduction
In the realm of industrial machinery and equipment, hydraulic oil plays a pivotal role in ensuring seamless operation and efficient power

Understanding the Hydraulic Oil Separation Method: Techniques, Applications, and Benefits

Introduction
In the realm of industrial machinery and equipment, hydraulic oil plays a pivotal role in ensuring seamless operation and efficient power transmission. However, the presence of contaminants such as water, dirt, and other particles can degrade the oil’s quality, leading to reduced equipment performance and potential failures. This is where the hydraulic oil separation method comes into play. In this article, we will delve into the significance of hydraulic oil separation, various techniques used in the industry, and the benefits it offers for maintaining optimal equipment health and productivity.

Hydraulic oil separation is a process designed to remove impurities from hydraulic oil, restoring its original properties and ensuring it meets operational standards. By employing specialized separation techniques, contaminants like water, air, and solid particles are effectively eliminated, prolonging the oil’s service life and reducing the risk of component wear and failure.

Regular hydraulic oil separation offers multiple advantages. First and foremost, it prevents the buildup of harmful substances that can cause corrosion, oxidation, and sludge formation. This not only enhances the oil’s lubricating properties but also contributes to maintaining the overall efficiency of the hydraulic system. Furthermore, hydraulic oil separation helps minimize maintenance costs, extend equipment lifespan, and reduce downtime, making it a crucial practice for industries relying on hydraulic systems.

Why is Hydraulic Oil Separation Important?
Oil testing serves as a diagnostic tool to evaluate the condition of the insulating oil used in transformers. By analyzing the oil’s composition and properties, experts can detect potential issues such as contamination, oxidation, or degradation. This enables early detection of problems, facilitating timely preventive maintenance or repairs.Hydraulic systems are the backbone of numerous industries, powering critical machinery and equipment used in construction, manufacturing, and transportation. These systems rely on hydraulic oil for power transmission, cooling, and lubrication. Over time, the oil can become contaminated with water, air, and particles, which can significantly impact its performance and the efficiency of the entire system. This is where hydraulic oil separation comes into play, providing a reliable solution to maintain oil quality and system performance.

Oil contamination can lead to various problems, such as reduced lubrication, increased friction, and accelerated component wear. Water, in particular, poses a significant threat as it can cause emulsification, leading to reduced oil viscosity and poor lubrication. Additionally, solid particles can cause abrasive wear on hydraulic components, leading to costly repairs and replacements.

Hydraulic oil separation is essential because it allows for the removal of these contaminants, ensuring that the oil remains in optimal condition. By using appropriate separation methods, industries can achieve cleaner oil, which translates to improved system efficiency, enhanced equipment reliability, and extended service life. This proactive approach not only prevents potential failures but also contributes to cost savings in terms of maintenance and replacement expenses.

Types of Hydraulic Oil Separation Techniques
Several techniques are employed to achieve effective hydraulic oil separation, each catering to different types of contaminants and operating conditions. The most common methods include:

1.Centrifugation:Centrifugation is a widely used technique that utilizes centrifugal force to separate contaminants based on their density. When hydraulic oil is spun at high speeds in a centrifuge, heavier contaminants such as water and solid particles are forced to the outer edges, while the purified oil collects in the center. This method is highly effective for removing water and solid particles from hydraulic oil.

2.Coalescence:Coalescence is a technique that involves passing the contaminated oil through a series of coalescing elements. These elements attract and merge small water droplets into larger ones, which are then separated from the oil due to their higher density. Coalescence is ideal for separating water from oil and is commonly used in systems where water contamination is a concern.

3.Filtration:Filtration involves passing the contaminated oil through a filter media that traps solid particles, dirt, and debris. This method is effective in removing solid contaminants and is often used in conjunction with other separation techniques for comprehensive oil purification.

Vacuum Dehydration: Vacuum dehydration is a process that uses vacuum pressure to remove dissolved water and gases from hydraulic oil. By lowering the pressure, the boiling point of water is reduced, allowing it to evaporate at lower temperatures. This technique is particularly useful for removing both free and dissolved water, as well as entrained gases from the oil.

Applications of Hydraulic Oil Separation
Hydraulic oil separation finds its application in a wide range of industries where hydraulic systems are used, such as:

Manufacturing: Hydraulic oil separation is essential in manufacturing industries to maintain the efficiency and reliability of hydraulic presses, injection molding machines, and other critical equipment.
Construction and Heavy Machinery: Construction equipment like excavators, loaders, and bulldozers rely on hydraulic systems for their operation. Regular oil separation helps prevent failures and downtime, ensuring that the machinery performs optimally even in demanding conditions.
Marine and Offshore: Hydraulic systems used in marine and offshore applications are exposed to harsh environments and the risk of water contamination. Hydraulic oil separation is vital to prevent emulsification and ensure the reliable operation of cranes, winches, and steering systems.
Aerospace: Aerospace applications require precise control and high performance of hydraulic systems. Oil separation ensures that the hydraulic oil remains free from contaminants, enabling safe and reliable operation.
Benefits of Regular Hydraulic Oil Separation
Implementing a regular hydraulic oil separation program offers numerous benefits for equipment owners and operators, making it an integral part of a comprehensive maintenance strategy:

Enhanced Equipment Performance: By removing contaminants, hydraulic oil separation restores the oil’s original properties, ensuring that it provides adequate lubrication, cooling, and power transmission. This results in smoother operation, reduced friction, and improved overall performance.
Extended Equipment Lifespan: Contaminants can accelerate wear and tear on hydraulic components, leading to premature failure. Regular oil separation helps minimize component wear, extending the lifespan of equipment and reducing the need for costly replacements.
Reduced Maintenance Costs: Preventing contamination-related issues reduces the frequency of maintenance and the need for repairs. This translates to lower maintenance costs and minimizes unplanned downtime.
Improved System Efficiency: Clean hydraulic oil allows the system to operate at peak efficiency, reducing energy consumption and improving productivity. This is especially important in industries where high efficiency and productivity are key performance indicators.
Minimized Environmental Impact: Proper hydraulic oil separation and purification reduce the need for frequent oil changes and disposal, contributing to a more sustainable and environmentally friendly operation.
Common Issues Detected Through Hydraulic Oil Separation
Hydraulic oil separation can help identify a range of issues that may affect the performance and longevity of hydraulic systems, such as:

Water Contamination: Water in hydraulic oil can cause emulsification, reduced viscosity, and poor lubrication, leading to accelerated component wear and potential failure.
Particle Contamination: Dirt, metal particles, and other debris can cause abrasive wear, leading to damage to hydraulic components and reduced system efficiency.
Oxidation and Sludge Formation: Oxidation of hydraulic oil can lead to the formation of sludge and varnish, which can clog filters and reduce the oil’s cooling and lubricating properties.
How to Interpret Hydraulic Oil Separation Results
Interpreting the results of hydraulic oil separation is crucial to understanding the condition of the oil and making informed maintenance decisions. Professionals with expertise in oil analysis and system maintenance evaluate the results to determine the type and extent of contamination present.

For example, high water content detected through centrifugation or coalescence tests may indicate leaks or condensation issues, requiring further investigation. Similarly, the presence of solid particles identified through filtration may suggest a need for improved filtration or system flushing.

Minimac Systems' Hydraulic Oil Filtration Solutions
To ensure optimal performance and reliability of hydraulic systems, Minimac Systems offers Hydraulic Oil Filtration Systems designed to remove contaminants like water, dirt, and particles that degrade hydraulic oil. Our systems are built to handle the most challenging industrial environments, utilizing advanced separation techniques such as filtration, vacuum dehydration, and coalescence to purify the oil and restore its original properties.

With our filtration solutions, industries can maintain oil cleanliness levels that meet or exceed industry standards, reducing the risk of equipment failure and extending the service life of critical machinery. The benefits include enhanced equipment reliability, reduced maintenance costs, and lower energy consumption, making Minimac’s filtration systems a crucial part of a comprehensive hydraulic maintenance strategy.

By investing in Minimac Oil Filtration System, industries can significantly reduce downtime, prolong the life of hydraulic components, and maintain smooth, efficient operations even in the most demanding conditions.

Conclusion
In conclusion, hydraulic oil separation is a vital process for maintaining the performance, reliability, and longevity of hydraulic systems. By employing techniques such as centrifugation, coalescence, filtration, and vacuum dehydration, contaminants like water, dirt, and air can be effectively removed, restoring the oil’s quality and ensuring optimal system operation.

The benefits of regular hydraulic oil separation are manifold, ranging from enhanced equipment performance and extended lifespan to significant cost savings and reduced environmental impact. By incorporating oil separation as part of a proactive maintenance strategy, industries can unlock the full potential of their hydraulic systems, ensuring they remain efficient, reliable, and ready to tackle the challenges of modern industrial applications.

Efficiently Eliminating Varnish from 23,500 Liters of Oil in Just 516 Hours

Mitigating a Potential Power Crisis in Western India through Varnish and Solid Contamination Removal

Synopsis
A Power Plant supplying a major 1967 MW of power to the Western

Efficiently Eliminating Varnish from 23,500 Liters of Oil in Just 516 Hours

Mitigating a Potential Power Crisis in Western India through Varnish and Solid Contamination Removal

Synopsis
A Power Plant supplying a major 1967 MW of power to the Western India, based in Dabhol, Maharashtra,and owned by one of the largest PSU’s, faced troubles with recurring turbine trip downs in two of its main turbines due to a sticky oil residue.Varnish and Solid Contaminants were identified with initial MPC values ΔE=38.6 and NAS 1638=Class 12, which needed reduction to ΔE≤15 and NAS 1638≤Class 6.Minimac's FS 500 machine, with a 3-stage system, achieved this in 516 hours, preventing frequent tripping, valve failures, erratic operations, extensive overhauls, and potential losses of ₹50 lakhs.

Initial Findings
Minimac's team conducted a site visit, analyzing the situation and taking an initial oil sample. Third-party lab testing revealed significant findings, with initial oil MPC values at ΔE=38.6 and NAS 1638 classification of Class 12.

Problems
The client encountered frequent turbine shutdowns in two of its primary turbines due to sticky oil residue within the Gas Turbines' (GTs) bearings and valves. A subsequent oil analysis confirmed the existence of varnish in the oil. As a result, Minimac was entrusted with the responsibility of removing the varnish from the main lube oil.

Client’s Requirements
To Purify 23,500 liters of Prime 32 oil.
To remove the varnish and solid contaminants.
To Achieve ΔE≤15 from its initial reading of 38.6.
To achieve NAS 1638≤Class 6 from its initial reading of Class 12.
Smooth & Timely Execution without any downtime.
Customized Solution.
No spillage.
Solutions
Deploying our customized machine at the site along with our trained and skilled engineers

FS 500: A miraculous 500-liter-per-minute machine featuring a 3-stage flushing and filtration system
It encapsulates varnish removal capacity and mechanical filters to effectively give the desired results.
It was connected to the main oil tank (MOT) of unit 3A, which contained 23,500 liters of Prime 32 oil.
Along with the equipment’s installation, our Service Engineer trained the client’s team on the functioning of the machine and the effective handling of the same.
Job executed 24/7, with continuous oil testing. Remarkably, set KPIs achieved in just 516 hours, showing significant improvement, reaching ΔE=7.2 and NAS 1638: Class 6.

Benefits
Prevented the environment from harm by averting the emission of 2,82,000 kilograms of CO2e.
Extended Oil Life.
Elimination of Oil Replacement Costs.
An enormous quantity of oil was cleaned in a limited amount of time.
Increased Machine Reliability.
Cost Saving
This Plant managed to save:

Cost of Oil Replacement: ₹50 Lakhs Approx.

Cost of Downtime : ₹1 Cr. Approx.

CO2e Savings

Total Savings = 2,82,000 kg of CO2e/0.282 gigagrams of CO2e

Graph

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Oil Reclamation project for the largest oil refinery in WB, India

A critical oil reclamation project for the largest oil refinery with a capacity of 8 million tonnes per year in West Bengal, India.

Synopsis
The lube oil used in various industrial

Oil Reclamation project for the largest oil refinery in WB, India

A critical oil reclamation project for the largest oil refinery with a capacity of 8 million tonnes per year in West Bengal, India.

Synopsis
The lube oil used in various industrial equipment such as pumps, compressors, turbines, blowers, turbo generators, recycle gas compressors, wet gas compressors, and coke cutting pumps had critical contamination levels initially. The problem was caused by poor maintenance by a previous service vendor, resulting in the presence of moisture and impurities in the oil tank. To address the issue, Minimac Operations and Maintenance Service (MOMS) carried out a timely service operation to help the plant bring down the moisture count and remove impurities from the oil tank. Before oil purification, NAS ≥ 12, Moisture ≥ 650 PPM; after oil purification, NAS < 5 and Moisture < 200 PPM This helped to improve the quality of the oil used in the equipment and ensure the smooth operation of the plant.

Problems
The oil was contaminated with moisture and mechanical impurities due to insufficient maintenance, which could lead to equipment failure and downtime. The presence of these impurities in the oil could also cause damage to the equipment, reduce its lifespan, and decrease its efficiency. It was essential to address this problem by implementing proper maintenance practices, such as regular oil changes, filtration, and moisture control, to ensure that the industrial oil is clean and free from contaminants. Failure to address this issue could lead to increased costs as well as production losses due to downtime.

Client’s Requirement
The target moisture level must be below 200 PPM.
Target NAS class must be maintained better than NAS class 5.

Solutions
Minimac Systems examined the oil circulation system, which consisted of high impurities.

Machine used: FS 80 LPM - 2 units; FS 40 LPM - 1 unit; FS 20 LPM - 1 unit.

NAS class < 5 and < 200 PPM moisture level was achieved.

Cost Saving
This plant managed to save:

Immediate tangible benefit = ₹9 Cr.*/ $90 Million* * considering the base price of oil as ₹150/lts /$1.83/lts.

Intangible benefits = Equipment reliability - less breakdowns - minimum equipment outage - reduced downtime - minimum hamper to production line.
CO2 e Saving
72,00,000 kg of CO2 e / 7.2 gigagrams of CO2 e.

Benefits
The reliable operation of the system and trouble-free operation of machines.
Sustainable performance of the overall process.
Less Breakdown.
Elimination of new compressor cost.
Reduction in the possibility of product degradation due to lack of proper filtration.
Timely Execution.
Feedback
Minimac believes in delivering the best experience to the clients with result-oriented project execution, hence, as a result, the project was extended further.

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Oil reconditioning project for India’s largest coal-based power producer

Team Minimac successfully executed a critical project to recondition the control fluid (two tanks of capacity 16 kiloliter each) for India’s largest energy conglomerate and

Oil reconditioning project for India’s largest coal-based power producer

Team Minimac successfully executed a critical project to recondition the control fluid (two tanks of capacity 16 kiloliter each) for India’s largest energy conglomerate and coal-based power producer with a capacity of 4760 MW.

Synopsis
The plant was built and is in service as a thermal power generating station, in Vindhyachal. There was a problem with higher Total Acid Numbers (TAN), observed typically when moisture content exceeds the permissible range. They were facing difficulties in stable unit operation because of the sluggish and erratic behavior of the turbine governing system. It was a significant threat to unit outage and generation loss. The situation was examined by Minimac Operations and Maintenance Service (MOMS). Resin skid - Minimac- FS-20-TRIX- 8-25 ltr-1S-FRF-DOL was deployed to address the issue.

Before Oil purification, the TAN value was≥ 0.62 mgKOH/gm, NAS ≥ 8, and Moisture ≥ 1471 PPM. After Oil purification, the recorded parameters were TAN value = 0.08 mgKOH/gm, NAS ≤ 4, and Moisture ≤ 260 PPM. The major challenge faced during the execution was if we charged resin, TAN would reduce, but moisture would increase. So, an analysis was done and implemented to control the moisture first, then charged the second resin cycle. Minimac gave a 100% customized and balanced solution within time.

Problems
The tank capacity was 16 kiloliters, which is huge. The biggest challenge was to execute the project while the system was in operation. Water contamination bubbles were forming, leading to the fluctuation in NAS - as for moisture control, it was necessary to turn off the system. Resin charge in Ion exchange was done intermittently to control moisture increase, and our motto was to hold moisture below 500 PPM so we could plan for the next cycle of resin charge.

Client’s Requirement
To purify the control fluid.
To reduce the TAN value from 0.62 to < 0.10 mgKOH/gm.
To bring down the moisture level < 500 PPM.
To achieve NAS < 5.
Smooth and timely execution without any downtime.
Tailor-made solution.
No oil loss because of processing or spillage.

Solutions
Resin skid - Minimac- FS-20-TRIX- 8-25 ltr-1S-FRF-DOL for NAS & moisture reduction was installed.

Before the oil conditioning process, the TAN ≥ 0.62 mgKOH/gm, which was reduced after oil purification to TAN ≤ 0.08 mgKOH/gm.

The Nitrogen generation unit (TMR 100) was deployed and installed at the client’s site.

For further improvement in TAN, the oil vapor extraction fan (OVEF) was throttled in the range of 70%, with the support of the user.

Minimac provided trained manpower and other consumables under the MOMS (Minimac Operations and Maintenance Service) offering. Minimac had given results far better than the KPIs.

Cost Saving
This plant managed to save:

Cost of oil replacement: ₹ 3.2Cr. approx/ $ 32 Million approx
Cost of downtime: ₹ 3.15 Cr. approx/ $ 31.5 Million approx
By investing ₹ 21 lakh approx/ $ 25.65k approx only.

CO2 e Saving
1,92,000 kg of CO2 e / 0.192 gigagrams of CO2 e

Benefits
Extended in-service oil life.
The smooth functioning of the machines.
Elimination of new oil replacement cost.
Avoiding the risk of fire and explosion.
Reduction in the possibility of product degradation due to blanketing.

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Saved the plant from a major breakdown

The Minimac team successfully completed a critical flushing project in a big fertilizer company with a capacity of 4000 tonnes in Jharkhand.

Synopsis
An installation project was ongoing at the fertilizer

Saved the plant from a major breakdown

The Minimac team successfully completed a critical flushing project in a big fertilizer company with a capacity of 4000 tonnes in Jharkhand.

Synopsis
An installation project was ongoing at the fertilizer plant’s premises. Newly built lube pipelines and tanks were to be flushed to remove the welding debris and other components left inside while fabricating the pipelines. The entire project was delayed due to a very slow flushing process. Minimac Operations and Maintenance Service (MOMS) team evaluated the situation and came out with a solution to expedite the flushing process. The project required flushing their two main compressors, i.e., PSE processed air compressor and carbon dioxide compressor

Problems
Proper flushing had to be done as the pipeline was newly fabricated; otherwise, it would have led to a major breakdown of the compressor, as the impurities would choke the blades and erode/damage the compressor. Other issues were to ensure proper calculation for variable pipe diameters, and if the oil goes to the rundown tank and overflows, 60-65 degree oil will fall, causing a huge mishap.

Client’s Requirement
Fast completion of the job to meet the project timeline.

Solutions
Minimac Systems examined the pipeline, which consisted of a low-pressure pipeline, high-pressure pipeline, and run-down tank.

A proper calculation was done as the work was a bit critical; any negligence could become a mishap

All parameters must be considered, including segment-wise flushing, hammering, thermal showering, etc.

At the end of the flushing, a mesh was installed to check if any impurities were present

Completing the flushing project was ensured as per ISO 18/15/12

Cost Saving
This plant managed to save:

Cost of import caused due to deficit of fertilizer.

CO2 e Saving
1,44,000 kg of CO2 e / 0.144 gigagrams of CO2 e

Benefits
The reliable operation of the system and trouble-free operation of machines.
Sustainable performance of manufacturing process.
Elimination of new compressor cost.
Avoiding the risk of fire and explosion.
Reduction in the possibility of product degradation due to lack of proper flushing
Timely execution.

Feedback
As a result of Minimac's excellent work, another assignment of a similar nature was assigned to them. Minimac achieved the OEM's request for no debris in the mesh.

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