This is a special research on engine lube oil system and lube oil purification strategies used in large diesel/gas engines. This workbook is completely from my own idea to find out the relation between Separator Turn Rate and Solid Removal Rate and also to find out how the Turn Rate directly related with oil engine cleanliness. This analysis will show you how much efficient your cleaning tools compared to your engine capacity/sump size.
This is a plain excel program to simulate the performance of cleaning tools attached in your engines.
If you have any further query regarding the content of this worksheet please feel free to ask.
Finally, your valuable comments would be highly appreciated.
Thanks for viewing the presentation
Engineering Mechanics Chapter 5 Equilibrium of a Rigid Body
Engine Oil Purification - Engine Capacity vs Separator Capacity
1. Lube oil system information
Plant Name: XYZ Power Limited Engine brand and model: User:
Main lube oil pump flow 289.0 m3/h at 500 rpm Rated Capacity Displacement
Oil flow required by engine 260.0 m3
/h No of cylinders Total displacement
Separator's hourly flowrate 1.90 m3
/h Cylinder bore Liner surface area
Automatic filter mesh size 35µ (absolute rating) Stroke length Total liner surface
Safety filter mesh size 60µ (absolute rating) Engine speed
Oil volume in engine's sump 12.00 m3
Pressure after main lube oil pump 8.00 bar (max)
Pressure required by engine 4.00 bar (minimum)
Engine driven lube oil pump summary
Total flowrate 289.0 m3/h at 500 rpm
Oil flow required by engine 260.0 m3/h minimum
Surplus oil flowrate in lube circuit 29.0 m3/h 10.03 % of total flow
Total sump oil circulating to engine 21.67 times/h
Pressure after main lube oil pump 8.0 bar at 500 rpm
Pressure required by engine 4.0 bar minimum
Lube oil separator (Motor Driven Centrifuge) summary Full flow filtration summary
Oil volume in engine's sump 12.00 m3 Self cleaning automatic filter (abs), i.e particles ≥35µ will not pass
Separator turn rate 0.16 tph Manually cleanable safety filter (abs), i.e particles ≥60µ will not pass
Separator cycle time 6.32 hours Full flow filtration rate
Total sump oil centrifuging 3.80 times per day Entire sump oil is filtering Centrifuging only 0.16 times/h
Total surplus flowrate 29.00 m3
/h
% of total surplus oil centrifuging 6.55 % of total surplus
% of total sump oil centrifuging 15.83 % per hour
What is the significance of separator/centrifuge turn rate?
Single Pass Centrifugation cannot be similar to Single Pass Filtration. Centrifuge require more passess to remove solids from liquid stream.
To observe the effects of centrifuge/separator TURN RATE on purification, simulate the chart below by changing trun rate from drop down list
Engine Lube Oil System Analyzer
An interactive workbook designed by Tekasai to evaluate the performance of
your engine oil purification system
Email: sales@tekasai.com | Web: www.tekasai.com
Created by: MMI | Email: mmi@tekasai.com
You are requested to enter data from your engine's manual only in yellow colored cells
580 mm 15.09 sq.m
500 rpm Total scrapped area 4871913.09 sq.ft/h
16.23 MW 96.4 Ltr/cyl
18 in V angle 1735.0 Ltr
460 mm 0.838 sq.m/cyl
260.0 m3/h
35µ
60µ
XYZ 18V46GD MMI
21.67 times/h
What should be the optimum capacity of your centrifuge system?
To find the optimum, calculate how much flow is SURPLUS in your engine's lube circuit which never required by engine. Approx 70% of main pump flow is required by the engine and remaining 30%
returns back to the sump through Pressure Regulating Valve. Your centrifuge system should have the capability of cleaning as maximum as possible of that SURPLUS amount continuously.
Solids removal efficiency by filtration depends on filters mesh size.
Solids removal efficiency of centrifuge depends on its RPM and the how many times the fluid is being circulated
through the centrifuge
Turn Rate , tph (turns per hour) is calculated by dividing the total centrifuge flow per hour by the total oil volume in the system. Higher TURN RATE will increase the probability of contaminants
passing through separator/centrifuge. More centrifuging means more dirt will be removed from the system.
60µ
35µ
2. Tuning the centrifuge turn rate
Selected interval 500 hours Turns per hour 0 1 2 3 4 5 6
Approx. solid accumulation rate 8.00 kg per interval % Solid Removal 0.00 15.83 31.67 47.50 63.33 79.17 95
Selected centrifuge turn rate 1.00 turns per hour Intervals (h) 0 500 1000 1500 2000 2500 3000
Approx. solids removal rate 15.83 % of gross generation Solids removed (kg) 0.0 1.3 2.5 3.8 5.1 6.3 7.6
Total solids generated 40.00 kg in selected period Solids retained in system (kg) 0.0 6.7 13.5 20.2 26.9 33.7 40.4
Total solids removed from system 6.33 kg with current rate Total solids generated (kg) 0.0 8.0 16.0 24.0 32.0 40.0 48.0
Total solids retained in system 33.67 kg
Where is your existing system? 2.51 % solid removal rate with turn rate 0.16 tph
Material Balance in Engine Lube Oil System - How much dirt is entering to the system and how much is being removed by centrifuge?
Lube oil separator operating hours 500.0 h
Selected de-sludging interval 60.00 minutes
Oil draining to sludge tank 3.0 Ltr.
Number of de-sludging triggered 500 times per interval
Total oil drained to the sludge tank 1500.00 Ltr.
How much dirt is removing with the cost of 1500 liters oil?
Contaminants load is directly related with engine's displacement volume. Higher that volume requires more fuel and more air for combustion. Thus more dirt is generated. Cosider the cylinder liner
surfaces which wet with oil and always exposed to combustion products. Oil scrapper rings scrapping combustion residues to the sump.
How much oil is losing through de-sludging od MDC?
Try GLACIER PURIFIER
- Based on Pressure Powered Centrifuge and Mass Transfer
- Extreme cleaning with ZERO oil draining to the sludge tank.
- Independant DIRT and WATER control, operating each at peak efficiency
- Efficient on separating even emulsified water from oil
For more detail, contact Tekasai Services. Mobile: +8801816449869, +8801712280675 | Email: sales@tekasai.com | Website: www.tekasai.com
with current Turn Rate 6.33 kg solids out of 40 kg will be removed in selected period
How much area is being scrapped per hour by oil scrapper rings in your engine? The area is about 4871913.09 Sq. Feet. Can you imagine the dirt load?
0.0 1.3 2.5 3.8 5.1 6.3 7.6
0.0
6.7
13.5
20.2
26.9
33.7
40.4
0.0
8.0
16.0
24.0
32.0
40.0
48.0
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
50.0
55.0
0 500 1000 1500 2000 2500 3000
Solids Removed (kg)
Solids Retained in System (kg)
Total Solids Generated (kg)
Operating Hours (h)
SolidQuantity(kg)
Current Turn Rate: turns per hour
Change Turn Rate to see its effects
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00
%SolidRemoval
Turn Rate (tph)
The rate of ingression of contaminants (Min_Y) should be
balanced with the rate of removal of contaminants (Mout_B) by
the lube cleaning system.
Min_X + Min_Y - Mout_A - Mout_B - Mout_C = Accumulation of Mass
ENGINE SUMP
Contaminants entering to the sump
through combustion and other sources
Oil leaving the sump (burning) through
liner lubrication
Oil leaving the sump with sludge
generated in LO Separator and filter
Oil leaving the sump by evaporation
and other leakage
New lube oil entering
to the system
Min_X
Min_Y
Mout_A
Mout_B
Mout_C
1
3. Our Glacier ACS 6000 centrifuge flowrate 3.5 m3/h
Number of centrifuges 1
Total hourly centrifuge flowrate 3.5 m3/h Max flowrate at 6 bar inlet pressure
Turn Rate achieved by 1 Glacier ACS 6000 unit 0.29 tph
TOTAL TURN RATE 0.45 tph Turn Rate 64.81% increased
New cycle time 2.22 h Cycle Time decreased 4.09 hours and total sump oil will be centrifuged 7 times/day
Total volume of oil will be centrifuged by PPC&MDC 5.4 m3/h
% Surplus oil will be centrifuged by the system 18.62 %
Take a close look on your filtration system
■ Automatic filter trapping particles ≥ 35µ in sizes
■ Safety Filter allowing all particles which are < 60µ
Final Summary Flow Rate Cycle Time Number of centrifuge cycles per day
BEFORE 1.90 6.32 3.80
AFTER 5.40 2.22 10.80
CHANGE 64.81 %↑ -4.09 h ↓ 7.00 times/day more
Red marker before retrofitting; Green marker after retrofitting
■ Carbon soot, dirt, spent additives, and most of
wear debris are < 5µ in sizes. Where are they going?
All are accumulating in your system.
■ Without centrifuge, all these tiny particles are
entering to the system, increasing engine wear and
reducing oil life.
■ With centrifuge, all of these particles will be
trapped. Thus it will reduce engine wear and extend oil
life
Glacier ACS 6000, Capacity 3.5 m3
/h at 6 bar pressure
Installed in Gravity Drain Method
Flow capacity increased 3.5 m3/h
About 12.07% more compared to existing system
Why need centrifuge after having filters?
What will happen after retrofitting your centrifuge system?
Above calculations and analysis are based on empirical data and information provided in your engine manual. To evaluate and optimize the performance of your
purification system we can assist you. Tekasai services has full range of measurement tools to evaluate the efficiency of your purification system.
0.16
0.45
64.81 %↑
Separator Turn
Rate
% Solid Removal
Rate
Total Solids
Removed
2.51
7.13
64.81 %↑
1.20
3.42
64.81 %↑
For more detail, contact Tekasai Services. Mobile: +8801816449869, +8801712280675 | Email: sales@tekasai.com | Website: www.tekasai.com
60µ
35µ
Engine lube circuit equipped with PPC and MDC
1.90
5.40
0.00
1.00
2.00
3.00
4.00
5.00
6.00
BEFORE AFTER
Flow Rate (m3/h)
1.20
3.42
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
BEFORE AFTER
Total Solids Removed (kg)
3.80
10.80
0.00
2.00
4.00
6.00
8.00
10.00
12.00
BEFORE AFTER
Centrifuging cycles per day
6.32
2.22
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
BEFORE AFTER
Centrifuge Cycle Time (h)
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
0 2 4 6 8
%SolidRemoval
Turn Rate (tph)
Number of Glacier ACS 6000 unit: 1
4. Glacier ACS Centrifuge
Glacier Purifier's Benefits
■ Separate processs for dirt & water control
■ No oil drain to the sludge tank
■ No sealing water required
■ 3 in 1 feature: Centrifuge, Refill and Drain Oil
■ Generate solid waste instead liquid sludge
For more detail, contact Tekasai Services. Mobile: +8801816449869, +8801712280675 | Email: sales@tekasai.com | Website: www.tekasai.com
■ It’s cleanable and traps not only large but very fine particles like soot, dirt, wear debris and spent additives
■ It extends oil drain interval, reduces cost of oil, filters and labor
■ It reduces engine wear and lengthens engine service interval. Thus keeps the system productive for longer period
■ Easily mountable at any location around engine with an Oil Transfer Base (OTB)
Pressurized oil expelled through tangentially opposed twin jets which spin the rotor at a speed up to 7000 rpm and generate a
centrifugal force more than 2000 times larger than the gravity. Under this extreme g-force, not only small particles are
trapping by the centrifuge but also very fine particles which easily pass through filters.
How oil cleaning centrifuge works?
Benefits of oil cleaning centrifuge
Glacier Purifier Series - Independant DIRT and WATER control draining any oil to the sludge tank
Would you like to try our centrifuge? Let us know.
We will install a unit in your running engine. After the trial period for a certain operating hours, dirt trapped in the centrifuge will explain about itself and helps you to see how it protects your
engines.
Oil cleaning solutions brought to you by Tekasai
A powerful oil cleaning centrifuge, highly engineered in design and material of construction, converts wasted energy into longer oil life and keeps your system extremely clean and reliable.
1200 lph 4005 lph 8010 lph
Clean Rotor Dirt Trapped in the Rotor
Your Engine or Turbine may be exposed to similar harsh
condition. We would like to invite you to try our centrifuge in
your lubrication system. Trial may reveal the necessity of
upgrading your lube purification system.
Glacied ACS 6000
Glacied ACS 2000
Oil Transfer Base