INTRODUCING THE PENHINE FILTRATION SYSTEM · Entrained or emulsified water in fuels and industrial...

I N T R O D U C I N G

THE PENHINE FILTRATION SYSTEM

Solutions with a Difference

Terms & Conditions Apply © Copyright Penhine Group 2016

Introducing The Penhine Filtration System

Contents1. 6000 Hour Fluid Maintenance System 12. This Custom System Operates Under the Following Parameters: 13. The Evo Filter Description 24. Properties of the Filtration Media for Fuels and Oils: 35. Benefits Proven in the Industry 36. Online Filtration System 47. Kidney Type Filtration System 58. Simple Saving Example 69. Proven Reduction of 32 Services @ 250 Hours Down to 8 a Year 610. Filtration Technologies FAQ 611. Warranty Statement 912. Sample Reports From Wear Check Africa 1013. Contact Details 27

Terms & Conditions Apply © Copyright Penhine Group 2016 1


1. 6000 HOUR FLUID MAINTENANCE SYSTEM

The Penhine Filtration System is a system specific lubrication maintenance package that enables clientele to maintain lubricant quality with considerably lower moisture and particulate contamination levels than traditional applications, which results in extended oil drainage intervals to create a 4000 hour service cycle benchmark for all applications.

The system is not mineral or synthetic lubricant type specific so it can be applied to any Differential grade lubricant. For high temperature applications and high acidic applications only seals are adapted to the application.

The system can be set up as a Real-time Monitored Application which enables the supplier and client to continuously monitor lubricant quality over the full maintenance period.

The specification maintained meets and exceeds Original Equipment Manufacturer quality standards and is verifiable with all OEM’s.

This innovative system will remove moisture and particulate material from Engine Oil, Gearbox Oil, Differential Oil, Hydraulic Oil and maintain the lubricants viscosity index with excellent temperature properties, good anti- wear performance, and excellent chemical stability.

Features and Benefits

The system is designed to meet the demanding requirements of mining applications in an ever increasing difficult financial environment. The system meets this demand by:

• Maintaining Quality and Standards to Reduce Down Time• Increasing Profit Ratios per Ton• Reducing Waste Management of Old Oil by 50%• Reduce Cost of Lubricants by 50%

Initial calculations based on current results and years of experience estimate a total of approximately 64% operational saving on machinery fitted with the complete maintenance package.

2. THIS CUSTOM SYSTEM OPERATES UNDER THE FOLLOWING PARAMETERS:

Service Intervals:

As with any filtration system the service interval is directly proportional to the level of contaminant ingress over a specific period. The Penhine Filtration System is specifically designed to maintain a very high level of cleanliness with ultra-low particulate and moisture contamination levels. Due to the ability to maintain these levels this system will enable well maintained systems up to 2000 litres to run on annual or bi-annual service intervals. This means between 4000 hours and 6000 hours based on continuous lubricant analysis and on approval or recommendation of the client.

Out of the Norm Element Change-outs:

A situation may arise with a critical event or out of the ordinary high ingress period such as with the test runs and simulations where we create very fine particles that get in everywhere. The MTR-MT-0001 online monitoring system will show us as well as the client if this has occurred and then we will do a duel set element change-out. This will be performed by a trained and certified artisan.



Operating Parameters:

The Penhine Filtration System 0001 will manage well in the following temperature ranges:Ambient Temperature Range: -5°Celsius to +55°CelsiusLubricant Temperatures over 120 second cycle: -1°Celsius to 80°Celsius (Pump Safety Conditional for application)

Filtration Level:

Particulate contamination in accordance with BS 5540 part 4: 1981 and ISO/DIS 4406:

ISO equivalent to NAS 1638 class 4/5 (Differential oil specification)Average Accepted Differential Rate is: NAS: 6 or ISO:17 I 15 I 12MTR-MT-0001 Average operating Range: NAS: 4 or ISO:15 I 13 I 10

Moisture Measured according to ASTM D1533 Karl Fischer method: >10ppm

Moisture Sensors and other tests such as Wearcheck moisture show up as 0% Moisture in oil.

3. THE EVO FILTER DESCRIPTION

The filter consist of four (4) components: 1. The filter housing2. The strainer3. The micron felt bag4. The filtration medium

Filter Housing

The Filter Housing’s are two PVC end caps that screw on a HDPE pipe. One end cap is fixed and one is screwed on. Both end caps are fitted with male quick release couplers for easy access to replace the filters. These housings are tested at a pressure rating of 12 bar. The system operating pressures are at maximum 6.5 bar.

The Strainer

The strainer is a cylindrical steel mesh with 3mm holes, open top and a closed bottom. This strainer is located in the filter housing and kept in place with the screw on cap.

The Micron Felt Bag

The bag is made of felt material and is widely used in the filtration industry as bag filters. The bag in this application is a 10 micron medium and is specially made to contain the filtration medium.

Filtration Medium

The filtration medium is a high performance absorbent media. The media is an unique, naturally occurring



attapulgite. In the presence of water the media doesn’t swell and break down but absorbs and contains the water. Entrained or emulsified water in fuels and industrial oils are dangerous and harmful to machinery and reduces their life time. This media efficiently removes surfactants to meet the manufacturer’s specifications.

The media effectively removes color bodies, surfactants, water, free fatty acids, organic oxides, and other polar contaminants from a wide range of oils, liquids and waxes.

4. PROPERTIES OF THE FILTRATION MEDIA FOR FUELS AND OILS:

Typical properties for fuel:

Product: 8/16 meshDensity: 31 lbs./ft3Free moisture: 1.0Volatile classification: lvmLoss of ignition at 1000° c: 4.6 wt%Ph: 6.7Hardness: 76.0 resistance to attritionParticle count: 0.4 million/lb.

Typical properties for oils:

Product: 30/60 meshDensity: 32 lbs./ft3Free moisture: 1.0Volatile classification: lvmLoss of ignition at 1000° c: 4.6 wt%Ph: 6.7Hardness: 78.2 resistance to attritionParticle count: 8.8 million/lb.

5. BENEFITS PROVEN IN THE INDUSTRY

• The Filtration System filters up to 1300 liters per hour on average• The life expectancy of the filter is 4000 hours• 50 to 65% Less maintenance costs• 50% Savings on filter costs• Reduced inventory costs and simplified logistics• +80% Reduction in oil usage• +50% Reduction of particulate Co2.• Extended equipment life• Increases machine availability • Significant reduction of fuel consumption • Reduced costs of disposal



6. ONLINE FILTRATION SYSTEM



7. KIDNEY TYPE FILTRATION SYSTEM



8. SIMPLE SAVING EXAMPLE

Trackless mining operation example:

• LHD with 500HP Cummins Engine• Using standard 15W-40 Mineral Oil with sump capacity of 68 liters • Diesel unit using 100litres per hour standard 500ppm SANS Diesel • System usage for Fuel (230 000 liters) and Oil (12 800 liters)• Fuel distribution via 2000 liter trailer tankers pulled by UG tractor • Standard 250 hour service intervals• Cost of Fuel: R13.40/ liter; Cost of Oil: R28.00/ liter; • +/-7000 hours per year/28 services a year/4 hour service = 112 hours service

9. PROVEN REDUCTION OF 32 SERVICES @ 250 HOURS DOWN TO 8 A YEAR

Before: After Fitment:

Annually: Annually:Number of Service: 32 Number of Services: 8Oil Cost: R 60 928.00 Oil Cost: R 15 232.00Fuel Cost: R 3 087 360.00 Fuel Cost: R 2 932 992.00Down Time: 768 hours Down Time: 192 hours

Savings on Machine :

Service Fees: 24 Services @ Average of R 4 000.00/Service = R 96 000.00Fuel Costs: +/- R 154 368.00Oil Cost: +/- R 45 696.00Downtime: 576 hours @ Average cost of R 635.00/hr Wet Cost = R 365 760.00

Total Saving: +/- R 661 824.00 per Annum

10. FILTRATION TECHNOLOGIES FAQ

Why Would You Hesitate?

All capitalized machinery is subject to warranty and extended warranty products either from the OEM or from a 3rd party vendors. It is a known fact that this together with other frequently asked questions the biggest stumbling block for owners and operators to benefit from quality aftermarket products that either improve performance or reduce costs effectively. In this brief summary we will touch on the critical few that we have encountered over the years.

Why do I need more than the factory recommended in-line filtration on capital equipment?

The factory filtration usually installed on capital equipment is put in place as “protective” filtration. This in-line turbulent flow filtration will capture the large particles quickly so that catastrophic failures and heavy wear do not occur. The Penhine Filtration System will remove the silt-size, emulsified sludge in-line filtration cannot remove, thereby preventing the everyday wear on machine components and dramatically prolonging the life of the lubricant and ultimately the equipment.



So, isn’t my in-line filtration good enough from the manufacturer?

No, otherwise you would have a 1000 or higher hour lubricant change interval already. The standard spin on filter does not have the capacity to maintain the original cleanliness standard of the lubricant past the old 250 hour lubricant change interval set in the 1930’s. Better lubricant developed can extend this, but you still have to remove the contamination. Performance of LUBRICANT and FUEL is directly proportional to the level of contamination.

I don’t have a problem in my machine now. Why would I want to add another filter to the machine?

Filtration removes contaminants from your lubricant, if you have to change you lubricant and filters let’s say every 250 hours and the filters and lubricant is very dirty, you already have excessive wear. First step is analysis. You need to know what is going on in your equipment. Typical spin on filters filter between 10 and 40 micron. Absolute rated spin on filters can filter down to as low as 1 micron, BUT, they don’t remove emulsified moisture and emulsified sludge that is the Cancer of the internal combustion equipment today. Lubricant cleanliness is displayed as an ISO code. New lubricant has an ISO code of around 18/16/11. Industry guidelines and valve manufacturers advise that an ISO code worse than 16/14/11 contains too many contaminants which cause excessive wear on components and increase lubricant deterioration. We run at an average of 12/10/7 on Differential Applications. The question to you is, if the required cleanliness is lower than what you are being supplied, why do you not clean it in any case? Know what you are getting and what you should be using, it’s your capital investment you should be looking after.

Okay, so now I want it, what about voiding the manufacturers guarantee and warranty?

According to law in Europe, USA and a few other countries, probably where your equipment actually comes from, there is legislation that stops OEM’s from forcing warranties or voiding warranties when it comes to the use of aftermarket products on original equipment manufacturers products. In the USA it is the Magnuson-Moss Warranty Act, Title 1, _101- 112, 15 U.S.C. _2301 et seq. This act, effective July 4, 1975, is designed to “improve the adequacy of information available to consumers, prevents deception, and improves competition in the marketing of consumer products ....” and in the EU is Article 101 TFEU (Former EC81), Vertical Restraints BER no. 330/2010 and Automotive BER no. 461/210 which says that one of the major improvements in the new competition law framework in comparison with the expired Motor Vehicle Block Exemption

Regulation 1400/2002 is the clarification by the European Commission that vehicle manufacturers may not make the warranties conditional on the repair and servicing of a vehicle within their network, or on the use of their own branded spare parts. But, please don’t go throwing the book at them now; you still want a decent working relationship with the people that sold you the machine. But, you will still have someone saying it voids warranty even though we have confirmation from just about every OEM that is does not void warranty. Typical reason is if they are servicing your machine every 250 hours and charging you an arm and a leg, why would they want you to go onto a 1000 hour service interval? They are farming backwards then! So, it’s actually the owner operator’s choice. Yes it’s good to let the OEM know what you are doing and support the performance via independent analysis, but we can assist you with that.

Keep in mind that the manufacturers state that all their parts they make are covered by their warranty, and fitting a bypass or extra filtration does not alter this, but they cannot be held responsible for the warranty on the bypass/added filter. Therefore Penhine has its own warranty and will cover any malfunction or breakage proven to be caused by the Penhine system, even on the OEM parts. Obviously this is outside the realm of normal wear a tear and on old machines that already have problems. Penhine is not a magic potion that turns old machines into new ones!



Will the Penhine Filtration System Lower Equipment Lubricant Pressures or System Pressures?

No. Never under any conditions unless there is a critical event such as a pipe that is cut and the lubricant is drained out.

Will the Penhine Filtration System remove Acid from the Lubricant?

No paper filter in the world can remove acid from a lubricant during operation. Not even Penhine. BUT, the Penhine filter system breaks the acid cycle by removing free moisture and emulsified moisture which in turn prevents the formation of corrosive acid. Without water, corrosive acids like Sulphuric Acid (H2S04) cannot be formed. Lubricant is a Hydrocarbon and is hygroscopic in nature so it will attract the water and combine with the CH4 molecules to form these acids that cause sludge and wear in the lubricant wedge of the equipment.

Laymen’s terms please?

Penhine removes ALL types of moisture out the lubricant and thereby stops the lubricant from creating acids that break down the lubricant and cause that black sludge accumulate in the bottom of the sump that wears out your equipment’s critical components.

What are the recommended Service Intervals for a Penhine Filters?

The Penhine Service Intervals are based on specific predetermined lubricant analysis. This means on your application of the Penhine System, we have either tested it or will test it to see what the benchmark is for that specific equipment. Determining factors would include the age, usage, type of lubricant you use, quality of the fuel you use, type of fuel you use, where and how the equipment is being used and what you want to achieve at the end of the day. We have done this many times, so it easy to give you a specific proposal for your type of equipment.

We start by halving the service intervals and then extend it further when taking into account the factors that influence the equipment. So, we would quite easily go from 250 hours to 500 hours after fitting the full system. But, we will progressively analyze the quality of fuel and lubricant when we want to extend the service intervals to 1000, 1500 and even as high as 8000 hours on bigger machines.

In some instances we can extend the lubricant drainage intervals while only changing the filter elements, but once again that is determined by the type of equipment application. So, sorry we actually can’t say until we have assessed your individual equipment application.

What Savings can I expect with a Penhine System?

As explained, we determine the application and then the solution. We have achieved drainage and service interval increases on small generators using mineral lubricant from 250 hours to 1000 hours and thereby saving 60% plus on operating costs.

On some of the bigger applications we have successfully extended lubricant drainage intervals from 250 hours to a massive 5500 hours. Here we change out the elements quite regularly, but still get over 60% savings. Rule of thumb as they say in the classics, we cut it in half for you to start with! So start with 50% and work your way up.

What do you mean Penhine System?

No point cleaning your lubricant and you put filthy Fuel into your equipment. That’s why Penhine manages and maintains the Fuel and Lubricant that is used by your equipment. Most of the moisture enters through the Fuel



system in any case, so if you don’t take care of that you are defeating the whole point of filtration. Penhine Fuel Filtration does the same job as the lubricant system and removes the free and emulsified moisture and assists in breaking the acid cycle we mentioned earlier.

The other benefit is that you reduce risk of injector failure and other issues that get really technical. You could even achieve a minimum 5% fuel saving. Confirmed results from clients have been 7%; 13% and on a Land Cruiser as high as 17%. It obviously is determined by the age of the machine and how it has been maintained. The holistic approach of maintaining fuel and lubricant cleanliness is the reason Penhine outperforms single application fuel- of just lubricant filter systems.

Is it easy to maintain a Penhine Filtration System?

Only once you have been trained, The Penhine Filtration System is easy to maintain. Industrial applications are not DIY jobs however and care is taken to use qualified and trained personnel.

11. WARRANTY STATEMENT

Penhine Fuel and Oil Maintenance Systems guarantees that it’s uniquely designed and developed branded filtration systems meets or exceeds the standard Original Equipment Manufacturer (OEM) specifications at all times for each individual application for each of our products, and that they are free from defects.

Therefore, Penhine will pay for parts and labour deemed reasonably necessary to repair damage to engines or other pieces of equipment if it can be demonstrated that the damage was caused solely and directly by a breach of this warranty by Penhine.

This warranty protects your equipment against filtration-related failure as long as:

• It is serviced with a Penhine Replacement Element only and NO OTHER brand or type of media and provided the equipment is used under normal operating conditions and maintained according to the manufacturer’s recommendations.

• The product used is confirmed by Penhine to be a Penhine Filter and Replacement Element and Filtration Media.

• The product that was used is the correct Penhine Filter for your application.• The engine or equipment was operated as specified by the original engine or equipment manufacturer

maintenance schedule or by agreed extended drainage interval in writing from yourself and Penhine.• The replacement element was changed as specified by Penhine Service regime for that specific engine

or piece of equipment.• Written documentation or maintenance records are provided that show the engine or equipment was

serviced and maintained at regular intervals as specified by the manufacturer and or through the benchmark set after approved evaluation with Penhine.

• The proper lubricant level has been maintained in the engine or equipment through documentation of frequency of oil make-up.

• Penhine is provided with a new and used sample of the lubricants and fuels used, with the plant fill codes, that are believed to be the cause of the engine or equipment failure due to filtration failure, and that Penhine personnel are allowed to inspect the damaged engine or equipment, take samples, and perform lab tests on the samples.

• Prompt notice of the problem is given to allow Penhine to investigate the problem.• This warranty shall be void if: (1) a NON-Penhine Replacement Element is used for the specific filter



application; (2) the damage is related to use of other sub-standard filters; (3) the damage is related to engine or equipment modification; or (4) the owner/operator has failed to operate or maintain the engine or equipment as required by the manufacturer or new approved regime.

PENHINE IS NOT RESPONSIBLE FOR (AND HEREBY DISCLAIMS ALL LIABILITY FOR) SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES OR LOSSES. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES REGARDING PENHINE BRANDS, EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

12. SAMPLE REPORTS FROM WEAR CHECK AFRICA

Mr B Nortje [Ben]Trichardt Hydraulic Solutions & MaintenancePO Box 247Secunda 2302

KWAZULU-NATAL:P. O. BOX 15108WESTMEAD 3608TEL: (031) 700 5460FAX: (031) 700 5471

GAUTENG:P.O. BOX 284ISANDO 1600TEL: (011) 392 6322FAX: (011) 392 6340

Diagnoses

3.) Sample Number X912422 on 29.08.2014 smr 200 HRS. Wear rates are normal. Debris analysis normal. The oil in use appears to be an ISO 68. Please confirm oil grade.

Machine : 143 Alt. ID : --Description : -Component : HYDRAULICS TANKModel : PIT VIPER

Code : 1THSSAJob No. : -Location : MOKOPANIEOil : SHELL CORENA S4 R 46Queries : PLEASE CONTACT DIAGNOSTIC DEPARTMENT.



Previous History

Diagnoses Feedback

1.) Sample Number X912426 on 06.08.2014 smr - HRSWear rates are normal. Debris analysis revealed evidence of coarse dirt ingress, check for point of entry.Coarse dirt contamination makes the oil unfit for further use. Recommend filtering the oil to remove contaminants. Please return feedback.

2.) Sample Number X912430 on 14.08.2014 smr 95 HRS. Wear rates are normal and the sample provided appears free from unacceptable contamination or degradation. Debris analysis normal.

Machine: 143 - Hydraulics Tank - Alt. ID: --

Sam

ple

Num

ber

Date

Sam

pled

Lab

Dat

e Oil

Cons

uptio

n No

rmal

SMR

Units

Oil In

Ser

vice

Filte

r Cha

nge

Oil D

rain

PRI

1 X912426 06.08.14 11.08.14 Normal - HRS - No No 500

2 X912430 14.08.14 19.08.14 - 95 HRS - Yes No 500

3 X912422 29.08.14 08.09.14 - 200 HRS - No No 500

Wear Metals

Sam

ple

Iron

Chro

miu

m

Nick

el

Mol

ybde

num

Alum

iniu

m

Copp

er Tin

Lead

Bism

uth

PQ In

dex

1 4 1 0 0 7 0 0 1 0 15

2 1 0 0 0 0 0 0 0 0 13

3 0 0 0 0 0 0 0 0 0 11

30 spectrometric analyses are carreid out on all samples but only relevent results are reported in parts per million.

Particle Quantifier Index



Contaminants

Sam

ple

Silic

on

Sodi

um

Wat

er (%

)

Wat

er (p

pm)

1 15 3 153

2 2 0 ND

3 0 0 ND


Particle Count /Ml

4 m

icron

6 m

icron

14 m

icron

20 m

icron

25 m

icron

50 m

icron

75 m

icron

100

micr

on

Clea

nlin

ess

33503 28515 61 1 0 1 0 0 23/22/13

10057 4347 59 6 2 5 0 0 21/19/13

7666 1497 18 1 1 1 0 0 20/18/12


Additives And Lubricant Conditions

Sam

ple

Mag

nesiu

m

Calci

um Zinc

Phos

phor

ous

Boro

n

Sulp

hur

1 32 115 275 237 0 8725

2 26 126 298 250 0 7707

3 30 101 309 261 0 7872


Viscosity



Graphic Representation of Key Data

Mr B Nortje [Ben]Trichardt Hydraulic Solutions & MaintenancePO Box 247Secunda 2302

KWAZULU-NATAL:P. O. BOX 15108WESTMEAD 3608TEL: (031) 700 5460FAX: (031) 700 5471

GAUTENG:P.O. BOX 284ISANDO 1600TEL: (011) 392 6322FAX: (011) 392 6340

Machine : 143 Alt. ID : --Description : -Component : FILTERModel : PIT VIPER 351

Code : 1THSSAJob No. : -Location : MOKOPANIEOil : -Queries : PLEASE CONTACT DIAGNOSTIC DEPARTMENT.



Diagnoses

1.) Sample Number X912423 on 29.08.2014 smr 200 HRS. Please supply lubricant brand and grade. Both the unit and oil conditions are satisfactory. Wear metals are within acceptable range and tests showed no abnormal lubricant contamination or degradation. Debris analysis normal.

Previous History

Diagnoses Feedback

Machine: 143 - Filter - Alt. ID: --

Sam

ple

Num

ber

Date

Sam

pled

Lab

Date

Oil C

onsu

mpt

ion

SMR

Units

Oil in

Ser

vice

Filte

r Cha

nge

Oil D

rain

RRI

1 X912423 29.08.14 08.09.14 - 200 HRS - No No 500

Wear Metals

Sam

ple

Iron

Chro

miu

m

Nick

el

Mol

ybde

num

Alum

iniu

m

Copp

er Tin

Lead

Bism

uth

PQ In

dex

1 2 0 0 0 0 0 0 0 0 11


Particle Quantifier Index

Too few values to plot PQ Index

Contaminants

Sam

ple

Silic

on

Sodi

um

Wat

er (%

)

1 0 1 ND


Silicon

Too few values to plot Silicon

Additives & Lubricant Condition

Sam

ple

Mag

nesiu

m

Calci

um Zinc

Phos

phor

ous

Boro

n

Sulp

hur

1 28 81 283 240 0 8093




ViscosityVi

scos

ity in

cSt @

40

C

63.0

Too few values to plot Viscosity in cSt @ 40 C


Graphic Representation Of Key Data

Too few values to plot Oil in ServicesToo few values to plot iron



13. CONTACT DETAILS

Physical Address

9A Chopin StreetKlarinet, Industrial AreaWitbank, 1035Mpumalanga (Province)South Africa

Postal Address

PO Box 7789Tasbet Park Witbank, 1040Mpumalanga (Province)South Africa

Contact Person

Hein Fourie:Tel: +27 (0)83 656 1405Email: [email protected]

Solutions with a Difference

INTRODUCING THE PENHINE FILTRATION SYSTEM · Entrained or emulsified water in fuels and industrial...

Documents

Transcript of INTRODUCING THE PENHINE FILTRATION SYSTEM · Entrained or emulsified water in fuels and industrial...