Cleaner Than New
“Don’t throw away your used hydraulic and lubrication fluids. Our exclusive state-of-the-art FluidCare Technology™ filtration can successfully transform used and contaminated fluids into better condition than when you first emptied them out of the drum or oil pack. New fluids are not without contaminants because their containers are often exposed to the elements or simply dust and dirt when stored indoors. We can purify oil to much higher ISO cleanliness levels than new oil and you have the added advantage of being able to purify your oil while your equipment is running. There is no down time. No need to take equipment off line. This is a far superior method to draining the reservoir and filling it with new oil, which does not remove contaminants trapped in the system pipe-work, valves and cylinders. If there is any moisture in your operating system from condensation or worn seals it has a detrimental effect on the fluids. Just a hundred millilitres of water can compromise many thousands of litres of fluid.”
Founder & Director
Excel Hydraulics™ & FluidCare Technology™
Multiplied Benefits From Lubricant Filtration
FluidCare Technology™ offers your business multiplied cost savings which more than cover the cost of the on-site filtration.
- No machinery downtime
- Minimal disruption to operation
- No costly disposal of used oil
- Cleaner system than when the machinery was newly installed (enabling optimum capacity and extended life expectancy)
- Less than the cost of new replacement oil
BONUS: Plus we include complimentary flushing of pipe work, valves and system components.
On-Site Purification Without Shutting Down Your Equipment
Excel Hydraulics’ FluidCare filtration technology is transported to your work site via a mobile rig or a more permanent compact unit which can be plumbed in to your equipment. We utilise a centrifuge to remove the bulk of solid contaminants and suspended water. This does harm oil additives. A vacuum dehydrator removes all emulsified water and gasses which can be a major cause of cavitation. The oil is filtered down to 3 microns (or lower) which is the size of bacteria.
Removal Of All Types Of Contaminants
A large number of assets (equipment, plant or vehicles) have built-in filtration units to remove solid contaminants but very few are capable of removing highly-damaging water, chemicals and gases. This is why our FluidCare Technology is based around the most effective methods of filtration: centrifugation and vacuum dehydration.
By combining these processes we are able to transform your hydraulic oil to “cleaner than new”. Our centrifuge removes the bulk of solid particles and water.
On top of that, vacuum dehydration removes free and dissolved water and gasses.
Fluid Care Technology™ is ideal for purifying a variety of oil types:
- Hydraulic oil
- Cutting oil
- Quenching oil
- Thermal oil
- Turbine oil
- Gear oil
- Mould oil
The tiniest of particles and the smallest amount of water can contaminate tens or hundreds of thousands of litres of fluid rendering it useless.
Hydraulic experts estimate that 70% of component failure is due to surface degradation caused by excessive dirt and water contamination in hydraulic systems. Clean oil is one of the most important factors affecting the service life of lubricated components of all machinery. In hydraulic systems, clean fluid is absolutely essential for long-term operation. Even the slightest change in cleanliness can dramatically improve the life expectancy of equipment.
The British Hydromechanics Research Association (BHRA) has conducted a three year case study to determine the correlation between fluid cleanliness and breakdown frequency. This involved a controlled ‘field’ study of 117 hydraulic machines including: injection moulding; machine tools; materials handling; mobile equipment, (for example, earth moving;) and marine hydraulics. They determined that:
- Increasing the oil cleanliness by one place in the ISO code halves the amount of contaminants.
- Moving up five places means there are thirty two times less contaminants – which increases life expectancy by nearly 500%!
The Contamination Culprits
These can be introduced or self generated. They can also be in the system from new. Many are introduced during filling and topping up unless extreme care is taken. Most of these can be abrasive.
Ingression can also be caused by oil film on seals. Worn seals will increase this possibility.
Reservoir openings not fitted with appropriate breathers are common sources of contaminants.
Entrained air is a cause of cavitation and can damage pumps. When compressed to 2000PSI or more it could become locally very hot and cause the fluid surrounding the bubble to burn. The products of combustion are both fluid and solid contaminants which further reduce the life of equipment.
Moisture and Chemicals
The detrimental effects of these can be even greater than a dirty system. When combined with solid contaminants, damage is accelerated and it causes:
- Accelerated corrosion
- Reduced bearing life
- Thinner load-bearing oil film
- Material fatigue
- Accelerated oil oxidation
- Change in viscosity
- Deterioration of oil additives
- Bacterial problems
There are two distinct phases of water that can be present in oil – free and dissolved. Free water can also be present in the form of an emulsion – that is, microscopic droplets of water distributed throughout the fluid.
Water, in excess of the oil’s saturation point, damages a system through accelerated abrasive wear, corrosion and fluid breakdown.
The saturation point of water at 65 Deg C is about 200 ppm, (0.02%.). Higher levels than this will result in the formation of free water in the system. This can react with products of lubricant oxidisation and additives to form organic acid compounds and sludge that compromises hydraulic performance.
Water is a cause of great wear rate within a system. Not only free running, but dissolved and emulsified water causes cavitation, internal corrosion and very high pump wear.
Water does not evaporate from the oil during operation. Condensation forms at the top of the storage tank and falls back into the oil.
Water held in suspension, in the molecules, can only be removed by using heat (100deg C) but heating endangers the oil, so this must be carried out by a filtration expert. Oil at working temperature attracts more moisture thus intensifying the problem, especially in humid areas. All of this has a domino effect; filters go into by-pass mode, emulsification of the oil may occur thus setting up cavitation, in turn causing total destruction of hydraulic pumps.
The solution to all of these contaminants is FluidCare Technology™.