checking & maintenance . engineering & manufacturing

Fluids life time extension

Life increase of parts and equipment

Reducing downtime and maintenance cost

Contamination management of systems and fluids

Fluids monitoring and laboratory analysis

POWER GENERATIONOIL&GAS DIVISION

OilSafe provides services, facilities and operative support for the overall management of hydraulic and lubrication fluids and systems. Reliable solutions over time, developed to suit specific needs.

Reliability is always the first target of OilSafe, whose action plans are the r ight t radeof f between maintenance costs and established risk level achievement.

OilSafe predictive maintenance programs ar ises f rom the consideration that 80% of failures and breakdowns are caused by oil pollution, result from inadequate monitoring and maintenance.

OilSafe maintenance programs allow to reduce fluids and electrical power consumpt ion, system failures, wear and breakdowns costs.

OilSafe f luids contamination management increases the lubricant life, reduce lubricant consumption and polluting fluids disposal. Services include the catalyst reduction for oxidation that involve the lubricant aging, like solid particles, water, fluid oxidation and degradation by-products.

Highly specialized design of flushing, filtration and dehydration systems, completes a suite of services that assists the customer even in more critical situations.

The cooperation and support of University, research and innovation centers, allows to acquire specific knowledge in conducting studies and in-depth analysis.

checking & maintenance . engineering & manufacturing

ON SITE ANALYSIS SERVICEUnderstand the state of health of hydraulic or lubrication system, is the first step to avoid forced downtime as well as a preventive measure to determine efficiency and productivity of the whole system. This is the reason why OilSafe laboratory makes analysis services on site or plants, aimed to detect fluid contamination in the hydraulic and lubrication systems.

MONITORING AND TRIBOLOGICAL ANALYSISIn order to monitor the quality and efficiency of the fluids, OilSafe makes audits of the state of oxidation and contamination of the oil charge. The equipments maintenance services are supported by laboratory tests conducted in compliance with international methods, evaluated and correlated with the main ASTM regulations (American Society for Testing and Materials).

checking & maintenance . engineering & manufacturing

CONTAMINATIONS MANAGEMENT OF HYDRAULICS AND LUBRICATIONS FLUIDS AND SYSTEMSOilSafe performs inspections activities and targeted operations:>>> monitoring and fluids analysis for periodic quality control, and related certifications>>> decontamination and fluid regeneration in storage tanks or in stock tanks>>> decontamination of hydraulic and lubrication piping

DECONTAMINATION AND OIL RECLAIM IN SYSTEM RESERVOIR OR STORAGE TANKS

In order to bring the cleanliness level of fluid to the values characteristic of new oil filtered, OilSafe provides services filtration and ultrafiltration online and offline by means of specialized equipment to eliminate particles of all sizes.The range of proposed solutions is integrated by many services:>>> electrokinetic adsorption for removing sludge and varnish with

a size less than 1 µm>>> full decontamination of polluted fluid from oxidizing agents and

strenuous without risk of removal additives fluids >>> polluted fluids full decontamination from oxidizing and wearing

agents without risk of additives removal from fluids

>>> offline and online dehydration by means of vacuum technology for removing water contamination below the saturation point

>>> reclaiming by means of additives addition, of the organoleptic properties of fluid and anti-wear, antioxidants, anti-foaming, anti-rust characteristics

>>> internal cleaning of gas and steam turbine tanks, presses and rolling mills for removal of solid contamination deposits

>>> removal of oxidation by-products and residues of oil degradation >>> pipings pickling and flushing for

residual contamination removal as a result of hydraulics and lubrications systems manufacturing and maintenance

FLUSHING OF PIPING WITH HYDROBLASTING HIGH PRESSURE OIL CLEANERSOilSafe flushing procedure, by means of detergent lubricating fluid with turbulent motion, is one of the most effective methods for cleaning, to preserve the integrity of hydraulic systems, improve efficiency and reduce the forced downtime. During this process, a high speed fluid is introduced inside the pipes by specific oil cleaners, alternating with high-pressure jets and thermal shocking. This develops vibrations that detach and remove deposited contaminants such as rust, scale, corrosion, carbon deposits, sludge and varnish. The advanced flushing system developed by OilSafe provides:>>> maximum decontamination>>> improving the flow through heat exchangers>>> technology for introductions into hydraulics and lubrications

circuits of thermal shock which allows further removal of stubborn dirt

>>> use of high pressure injections and beating by means of hydroblasting high pressure cleaner, for removal of stubborn contaminants

>>> total cleaning of lubricated components pedestals>>> total filtration before reaching the bearing head and other

lubricated components>>> use of auxiliary units to preserve the existing equipmentsFast and efficient, the OilSafe advanced flushing system is the only procedure that cleanses the entire pipes diameter.

SUPPORT AND MAINTENANCEConsolidated experience and inspection procedures, allow at OilSafe predictive and proactive maintenance programs the best performance for hydraulic and lubrication systems.>>> Specific maintenance plans, aimed to reduction of wear and

failure of lubricated components and elimination of losses>>> Troubleshooting>>> Planning and implementation of restoration>>> Systems improvement and technological update>>> Reliability increase>>> Hydraulics system modifications depending on environmental

conditions>>> Upgrading of existing dehydration, temperature control, and

fluid filtration systems

ENGINEERING AND MANUFACTURINGAccording the needs of customers in terms of size, on-board instrumentation, safety, CE certification and functionality, OilSafe designs and produces “Turnkey” units and systems for filtration, dehydration and refrigeration, in addition to hydraulics control units “customized” for customers needs.

THE TECHNICIANS EXPERIENCEOilSafe makes use of the expertise of highly qualified engineers with years of activity: an experience that provides short term intervention and long-lasting and reliable results. MLT Certified – Machine Lubrication Technician from International Council for Machinery Lubrication, OilSafe technicians performs systems maintenance and fluids analysis using the most modern equipment and technologies for the qualitative diagnosis, ensuring the prevention of downtime and extending the life cycle of fluids, components and systems.

checking & maintenance . engineering & manufacturing

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20

16

12

109876

5

30

4050

100

150200

300400500

1.000

2.000

5.000

10.000

20.00030.00050.00070.000

100.000200.000

-5 0 5 10 20 30 40 50 60 70 80 90 100 110 120

KIN

EMA

TIC

VISC

OSI

TY

Temperature

SAE80

ATF SAE90

ISO VG46

ISO VG32ISO VG68

MIL - H - 5606

°C

mm

2 /s [

cSt]

1100

1111

1122

11

22

33

44

55

66

55000000

22550000

1133

1144

1155

1166

1177

1188

2222

22334400000000

2200000000

1100000000

00,, 0088

00,, 0044

00,, 0022

2200

1100

55

22,, 55

11,, 33

00,, 6644

11330000

664400

332200

116600

8800

44

33

22

11

1111

1100

99

88

77

66

1177

1166

1155

1144

1133

5500,, 3322

00,, 1166

77

88

99

1122

2233

2222

2211

2200

1199

1188

4400

55000000

22550000

4400000000

2200000000

1100000000

00,, 0088

00,, 0044

00,, 0022

2200

1100

55

22,, 55

11,, 33

00,, 6644

11330000

664400

332200

116600

8800

00,, 3322

00,, 1166

4400

1199

2200

2211

ISO Code

0,01

0,10

1,00

10

100

1000

10000

100000PA

RTIC

LES

NU

MB

ERS

PARTICLES SIZE µm

4 5 6 7 8 9 10 11 12 13 14

12

65

43

“ISO 11171 Calibration”

> 4 µm(c) > 6 µm(c) > 14 µm(c) > 21 µm(c) > 38 µm(c) > 70 µm(c) “corresponding to ISO class 6,

14 µm©”

SAE CODE A B C D E F

3 6,250 2,430 432 76 13 2 12/9

4 12,500 4,860 864 152 26 4 13/10

5 25,000 9,730 1,730 306 53 8 14/11

6 50,000 19,500 3,460 612 106 16 15/12

7 100,000 38,900 6,920 1,220 212 32 16/13

8 200,000 77,900 13,900 2,450 424 64 17/14

9 400,000 156,000 27,700 4,900 848 128 18/15

10 800,000 311,000 55,400 9,800 1,700 256 19/16

11 1,600,000 623,000 111,000 19,600 3,390 512 20/17

12 3,200,000 1,250,000 222,000 39,200 6,780 1,020 21/18

Number of particles per 1 ml

Codenumbers

over up to

80,000 160,000 24

40,000 80,000 23

20,000 40,000 22

10,000 20,000 21

5,000 10,000 20

2,500 5,000 19

1,300 2,500 18

640 1,300 17

320 640 16

160 320 15

80 160 14

40 80 13

20 40 12

10 20 11

5 10 10

2.5 5 9

1.3 2.5 8

0.64 1.3 7

0.32 0.64 6

0.16 0.32 5

0.08 0.16 4

Classe ISO 4406

Micron Particelle con-tate nella classe

(per ml)

18 >4 1.300 ÷ 2.500

16 >6 320 ÷ 640

13 >14 40 ÷ 80

OilSafe SrlVia Toscanini, 20941122 Modena (IT)

Phone: +39 059 285294 Fax: +39 059 2860142

info@oilsafe.it www.oilsafe.it

Classification class with the corresponding

particle numbers for the definition of the cleanli-

ness classes according to ISO 4406.

Recommended cleanliness levels according to ISO 4406 in different hydraulic systems.1. Worst cleanliness grade in new oil. Capacity control valves. Cylinders/rolls Turbines. ISO

20/18/15 NAS 92. Gear pumps/motors Mobile Units. General Mechanical Engineering at medium pressure/

capacity. ISO 19/17/14 NAS 83. Directional valves Pressure valves. Piston pumps/Motors. High quality reliable systems.

ISO 18/16/13 NAS 74. Proportional valves. Machine tools. High performance pressures. ISO 17/15/12 NAS 65. Servo-valves. Formula one car racings. Very high reliability systems. ISO 16/14/11 NAS 56. Laboratory Aviation and aerospace. ISO 15/13/9 NAS 4 Viscosity Temperature Diagram.

Cleanliness classes according to SAE AS4059 and conversion to corresponding cleanliness classes according to NAS 1638 and ISO 4406

ISO 4406

ISO CODE 18 / 16 / 13

Particle> 4 micron

Particle> 14 micron

Particle> 6 micron