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The outdated method of attaining to diagnosing and monitoring of commercial filters was done by trusting and relying on the experience of skilled personnel or diagnosis with the aid of suitable measuring instruments. Moreover, several attempts need to be made in order to collect data regarding the filter faults and diagnose their trouble. Hence the safety, energy efficiency, and performance of the application are questionable. In recent years, more and more users are looking for low-cost and smarter ways to diagnose and monitor the filters. The developing world is enquiring for more groomed techniques that perform its functions while self-diagnosing its conditions and indicate diagnostic results to the filter operators and maintenance personnel which allows optimum maintenance plan without delay.
What is diagnosing and monitoring?
Diagnosing and monitoring equipment is the process of tracking the parameters of condition in machinery (Pressure drop, temperature, vibration, moisture content, etc…), in order to recognize significant changes that could be indications of developing a fault. Monitoring and diagnosing is a crucial component in predictive maintenance.
Why diagnosing and monitoring is done?
At the end of diagnosing and monitoring of machinery allows you to practice scheduled maintenance or other precautionary actions to be taken in order to prevent serious damages. Further this also massively helps to identify conditions that would strongly affect to shorten the normal lifespan of the machine. Identification of such adverse conditions helps to find necessary steps that should be taken to address the issues before they develop into a major failure.
What are the parameters monitored in filters?
Usually, filters are applied in order to prevent impurities from entering the process. It is obvious that filters gradually get clogged during normal operation resulting in decreasing the feed flow. Hence the cleaning of the filters should be done periodically and predictively in order to prevent equipment damage and unnecessary process downtime. Relying on visual observations or rudimentary differential pressure switches are truly outdated techniques.
In the last few years, the world moved from condition-based maintenance to smarter methods to achieve these goals. visual observations and rudimentary differential pressure switches are replaced with sensors where they completely attain the job of observing the state of different parts in the filter and maintenance of the filter are only performed when certain indicators alarm the signs of decreasing performance or upcoming failure. This advanced technology has shifted the filtration industry to a new heights and will help to introduce and commercialize new filter monitoring technologies.
In filtration industry Differential pressure and the degree of clogging are mainly monitored by using novel sensor techniques.
FLTR always offers you the best filtration solutions that satisfy all your contamination removal needs. A variety of diagnosing and monitoring systems are available in FLTR which ensures safety, efficiency in performance, and efficiency in energy consumption at an economical cost. The technically advanced filtration solutions available in FLTR are always prompt as new processes develop with time.
Differential Pressure Devices Threaded Deltadyne® Differential Pressure Indicators and Switches
These are widely used to indicate when the filter element is becoming clogged and needs to be changed.
Differential pressure devices show their function by sensing the differential pressure between ports upstream and downstream of the filter element. The differential pressure acts on a piston/ magnet assembly that is enclosed in the Deltadyne device. When the differential pressure across the internal piston/ magnet assembly reaches a defined preset value, determined by the range spring, the piston assembly will move downward sufficiently to reduce the attractive force between the magnet and indicator button or switch actuator lever. The indicator or switch spring then beat against the reduced magnetic force to release the button or actuate the switch to alarm the need for element change. A magnet coupling isolates the pressurized fluid from the electrical or mechanical actuator. This eliminates dynamic seals and exposed cams, thus avoiding a leakage point common to other types of warning devices, particularly those which are connected to the bypass valve. Deltadyne devices respond only to differential pressures; they can tolerate system pressures up to the design limit of 6000 psi (414 bar).
- Can operate at a range of pressure settings
- Visual ‘Pop’ Up button or Electrical Indication or both
- Thermal lockout device (optional)
- Presence of advanced alarming system at filter element blockage
- Thermal lockout device prevents false indication at cold start conditions
- Aerospace OEM approved
Deltadyne electrical switches have a self-regulating reset function that allows them to be used as system warm-up monitors. The higher pressure drop will occur across the filter element at high fluid viscosity along with low-temperature start-ups. In such situations, these switches will signal high differential pressure until the system comes up to operating temperature. At the same time when the differential pressure is reduced due to system warm-ups, the switches will signal low differential pressure until it system comes back to normal operating conditions.
These switches are incorporated with a single pole double throw switch (SPDT) which allows this device to be used with a green-red light circuit. Greenlight signals pressure drop below the predefined pressure and the red light signals pressure drop above the pre-defined value, either a cold start or the need for an element change. The two-light circuit also serves as a continuity check; one of the two lights should always be on.
Moisture PPM Sensor
Water in the oil can cause serious issues to engines and machinery with quick and costly breakdowns. Oil contamination with water can also impact negatively by occurring corrosion, oil oxidation, and speed up component wear rates. Hence the best practice is to employ a filter with a moisture PPM sensor to enjoy safe filtration. Moisture PPM Sensor offers you an accurate online measurement of moisture in oil.
- Real-time moisture detection.
- Easy to install and operate
- Can detect moisture in oil without sampling
Particle Counter is a high precision Online oil particle counter which adopts the principle of laser blockage method (laser shading method) to detect the size and number of solid particles in the oil. It does the analysis and then displays the oil contamination level according to the measurement in various standards.
PCM400 Series Portable Cleanliness Monitor
Cleanliness Monitor is specifically developed as portable diagnostic monitoring that provides a measurement of system fluid cleanliness.
- Proven mesh blockage technology
- Results not affected by water or air
- Monitors dissolved water content (% saturation or PPM output for specific fluids PCM400W only))
- High and low pressure online or off-line sampling
- Continuous monitoring
- 500 test memory
- ¼” test point hose connection
- PC-based trending software included
- Viscosity output in centistokes (cSt)
- Real-time graphical representation
PCM Trender Software Features
- Graphical and spreadsheet reporting
- Trending capabilities
- Customer defined alarm limits
- Printable reports
- Quickly reports test data so that ongoing assessments can be made.
- Early detection of abnormal fluid cleanliness allows for timely investigation and corrective actions to be implemented.
- Can be permanently installed to monitor critical applications
- Used as a portable device for routine condition monitoring of various fluid systems.
- Component wash fluids
- Cutting fluids
- Aqueous solutions
- Water glycols
- Mineral and synthetic oils
- Hydraulic and lubricating fluids
WS09 Series Water Sensor
This sensor is an ideal, low-cost sensor for measuring dissolved water content in hydraulic, lubricating, and insulating fluids. Specifically designed for use in industrial environments, readings are shown on an LCD display and can be used as a key component in the predictive maintenance of plant and machinery.
- A sensing probe directly immersed in the fluid to monitor dissolved water content and temperature
- Water content output in % saturation or PPM
- Temperature in °C or °F
- Plug and play connectivity
- Simple to operate and calibrate
- Robust housing and sensing probe designs.
- Rod Mill High-Speed Lube Systems
- Cold Mill Tandem Mill
- Tilt Furnace HPU’s
- Gear Box Lube Oil
- Turbine Lube Oil
- Transformer Oil
Pulp and Paper
- Dryer Section Lube Systems
- Wet End Lube Systems
- Press Section Hyd/Lube Systems
- Powerhouse – Steam Turbine Lube Systems
- Main propulsion lubrication
- Hydraulic active fin stabilization
Offshore / Petrochemicals
WS18DS Water in Oil Sensor
Water in oil sensors is designed to offer reliable measurement of water content in oils in Parts Per Million (PPM) level in demanding industrial applications. In addition to water content measurement, they are capable to measure both relative humidity and temperature to highly accurate and precise levels.
- Display alarms for customer-specific limits.
- Display measurement in either % saturation or PPM.
- Instrument data can be viewed from the 3.5″ color display and can also be downloaded to an external computer for more in-depth data analysis
- Display alarms for customer-specific limits
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