Redefining Oil Quality Management The Context Todays industry: - - PowerPoint PPT Presentation

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

Our Vision

Engine/Machine Health 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 (β3 >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

• il 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

Axial Flow More solids are trapped as they progress through multi-layered media Radial Flow Greater chance of particles passing through the media or premature plugging

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

• f 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

• xidation 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
• il 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

• f 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

• il 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
• il 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 performance Increase by 15% 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