GmbH RIESS Cost reduction and environment protection FRIESS EFC Electrostatic Fluid Cleaning fachefr.neuetecheng.doc
How to reduce maintenance costs of hydraulic systems Maintenance of hydraulic systems causes high costs, which may be reduced by modern technology. Before reducing the operation and maintenance cost of a hydraulic system it is necessary to check the total operation cost of the system. While making a detailed check of the maintenance and operating costs you will find out soon, where are the highest potential for significant savings. Maintenance and repairing costs for hydraulic systems buying of new oil disposal of waste oil 1. oil change storaging of new and waste oil labour cost for oil change production loss because of machine stop 2. consumable parts cost for filter elements labour cost for changing filter elements cost for spare parts 3. repairing cost for storaging spare parts labour cost for failure detecting production loss because of machine stop efr.maintenance-tabelle1.xls This is just a part of the maintenance costs, which are caused by running an hydraulic system. In addition there are other costs, for example costs for managing personal planning cost for additional machine capacity labour cost for buying parts 2 Michael Friess
The following sample show the high potential for cost reduction in hydraulic systems. Especially the cost for oil, filters and labour costs have a high saving potential. hydraulic cost 1 year 5 years oil HLP46 number of machines 40 pc total oil volume 18.500 l life time of oil 1 year cost for oil change incl. cost for waste oil 0,75 EU /l 13.875,00 EU 69.375,00 EU leak oil 1.800 l cost for leak oil 0,75 EU /l 1.350,00 EU 6.750,00 EU consumption of filter elem. 1 /J, Masc 40 200 cost for filter 100,00 EU /St 4.000,00 EU 20.000,00 EU wear maintenanc parts 1.000,00 EU 1.000,00 EU 5.000,00 EU labour cost per hour 25,00 EU /h planed machine stop to change oil 50 h/jahr 50 250 labour cost for changing oil 1.250,00 EU 6.250,00 EU malfunction / machinestop 15 h/jahr 15 75 cost for machinestop 375,00 EU 1.875,00 EU cost for production of waste 0,00 EU 0,00 EU cost for downtime 0,00 EU 0,00 EU total 21.850,00 EU 109.250,00 EU The anual maintenance cost for 2 hydraulic systems with 18.500 l hydraulik oil are around 21,000.00. When using modern technologies these running costs may be reduced. Reducing the cost for oil up to 90 % Reducing the cost for hydraulic trouble up to 70 % 3 Michael Friess
Longer operating time of hydraulic oils Lifetime of hydraulic oils depend on different factors viscosity acid number 1. chemical condition neutralization number oxydation number additives 2. contamination particles bigger than 4 µm ( ISO 4406) particles smaller than 4 µm 3. water non emulsified water emulsified water temperature 4. general conditions mobile system stationary system efr.maintenance-tabelle1.xls 4 Michael Friess
1. Chemical condition The chemical condition of hydraulic oil changes during operation only under very special circumstances. To change the chemical condition of the hydraulic oil you need presupposition as follows: 1. high temperature 2. oxygene 3. catalyst In normal operation single oil molecules will react with oxygene. The oil molecules become much longer. This reaction may be accelerated when the oil temperature is higher than 60 C and the oil is in contact with a catalyst. When the oil temperature is lower than 60 C and the dirt particles, which act as catalyst, are removed from the oil, the reaction of the oil with oxygene can be reduced to nearly zero. As long as there are dirt particles, specially microparticles less than 2 µ are in the oil, the oil will react very fast with oxygene and you have to change the oil after short time, for example one year or less. 2. Dirt particles Dirt particles will be found in every hydraulic system. Even new systems are contaminated because of mounting with dirt particles. The new oil, which is filled into the hydraulic system also contains a lot of dirt particles. During operation the systems produces particles because of friction. Dirty air also brings in dirt particles into the oil. Many companies try to remove the dirt particles by filtration. Filters may operate in mainstream or in bypass. Mainstream filter may protect single hydraulic valves or parts from particles, which are in the oil. Bypassfilter are able to remove small particles and big number of particles. Filter select the particles by size. That means particles, which are bigger than the pore size will remain in the filter element. Smaller particles can pass the filter without problems. The number of particles rises with lower size. That means, that the big number of particles remain in the oil. During operation this number of particles grows very fast. Finally the big amount of dirt in the oil makes it necessary to change the oil. Because of the big numbers of small particles all particles together have a very big surface, which may act as catalyst and accelerate the oxydation of the oil. 3. Water Water is able to accelerate the oxydation in the oil. For this reason free water has to be removed from the hydraulic system. 4. General conditions The oil temperature must not be higher than 60 C. If the oil temperature is higher the oxydation of the oil will accelerate. Rising the oil temperature more than 10 C over 60 C will double the speed of oxydation and thus reducing the lifetime of the oil. If the temperature in the oil changes, condensation water is the result. To avoid condensing water the temperature of the oil should be kept on a level of 45 C 50 C. For this reason oils that are used in mobile systems have a shorter lifetime than oils that are used in stationery systems. To make sure that the oil can be used very long time it is necessary that 1. the chemical condition of the oil does not change 2. number of dirt particles is as low as possible 3. the amount of free water is reduced 4. the oil temperature is kept below 60 C. 5 Michael Friess
How to reduce running cost of hydraulic systems For a longer lifetime of the hydraulic oil it is necessary to use the best technologies for oil maintenance. Conventional filters cannot remove microparticles from the oil. To keep the oil quality for long time on a high level and to run the hydraulic system without malfunction it is necessary to remove not only the big, but also the small particles from the system. This can be done by electrostatic oil cleaning. Electrostatic oil cleaning machines can remove microparticles down to 0,05 µ from the oil. The oil is much cleaner than new oil. In addition the oxydation of oil is reduced. The chemical condition of the oil is kept on the same level. Because the high quality of the new oil is kept over a long time it is not longer necessary to change the oil. Dirt particles in used hydraulic oill Operating range FRIESS EFC coarse dust ( ca.10 % of total number of particles) fine dust ( ca. 90 % of total number of particles) operating range filter 70% 0,3 % 1,5% 8% 20% size of particles> 25 µm 15-25 µm 5-15 µm 1-5 µm < 1 µm Electrostatic oil cleaning is the only possibility to remove smallest particles from the hydraulic oil. fil3eng.cdr fil3eng.wmf The dirty oil is lead through an electric field. The dirt particles are attracted by the electric fieldforce. The particles are drawn towards the electrode with opposite charge and are collected on a special formed cleaning element. The electrostatic field attracs only solids, for example metal, steel, plastic, glas, sand and so on. The special form of the cleaning elements deform the electric field. When using the cleaning elements the attraction is higher than in a field without cleaning elements. The special form of the cleaning elements causes a turbulence in the floating oil. The dirt particles follow the oil flow into zones with highest fieldforce. The electrostatic oil cleaning does not select by size of the particle but by solid or liquid. Particles, independent from their size, are charged because of natural effects, for example friction. Electrostatic oil cleaning removes particles in any size. 6 Michael Friess
EFC cleaning element demo3eng.cdr demo3eng.wmf The electric field has no influence on liquids. Liquids consist of single molecules will path the electric field and are not influenced by the electric field. Liquid additives remain in the oil. Solids consist of a number of molecules which cannot move within the solid. Solids may have an electric charge because they consist of more than one molecule. To remove free water from the hydraulic oil a dewatering filter is added to the electrostatic oil cleaner. 7 Michael Friess
Reducing cost by FRIESS EFC When cleaning the hydraulic oil continuously the hydraulic oil can be used for more than 10 years. The hydraulic system is reduced by 70 %. The payback-time for FRIESS EFC is between 6 12 months. When using 40 machines with 18.500 l hydraulic oil up to 15.000 /year can be saved. cost without cost with FRIESS EFC FRIESS EFC 1 year 5 years 1 year 5 years oil HLP46 number of machines 40 pc total oil volume 18.500 l life time of oil 1 year cost for oil change incl. cost for waste oil 0,75 EU /l 13.875,00 EU 69.375,00 EU leak oil 1.800 l cost for leak oil 0,75 EU /l 1.350,00 EU 6.750,00 EU 1.350,00 EU 6.750,00 EU consumption of filter elem. 1 /J, Masc 40 200 8 40 cost for filter 100,00 EU /St 4.000,00 EU 20.000,00 EU 800,00 EU 4.000,00 EU wear maintenanc parts 1.000,00 EU 1.000,00 EU 5.000,00 EU 300,00 EU 1.500,00 EU labour cost per hour 25,00 EU /h planed machine stop to change oil 50 h/jahr 50 250 15 75 labour cost for changing oil 1.250,00 EU 6.250,00 EU 375,00 EU 1.875,00 EU malfunction / machinestop 15 h/jahr 15 75 3 15 cost for machinestop 375,00 EU 1.875,00 EU 75,00 EU 375,00 EU cost for production of waste 0,00 EU 0,00 EU 0,00 EU 0,00 EU cost for downtime 0,00 EU 0,00 EU 0,00 EU 0,00 EU SUMME 21.850,00 EU 109.250,00 EU 2.900,00 EU 14.500,00 EU Investition Friess EFR D8 13.802,00 EU Abschreibung 5 Jahre 2.760,40 EU 13.802,00 EU Zinssatz (Mittelwert) 10 % 276,04 EU 1.380,20 EU Reinigungselemente 5 Satz/Jahr Kosten Reinigungselemente 178,00 EU /Satz 890,00 EU 4.450,00 EU Zeitraum 1 Jahr 5Jahre 1Jahr 5Jahre Gesamtkosten 21.850,00 EU 109.250,00 EU 6.826,44 EU 34.132,20 EU 8 Michael Friess
The owners of the FRIESS EFC Electrostatic Fluid Cleaners that have been produced up to now save per year around 4.000.000 l of hydraulic oil. That means 1. ressources will be saved 2. oil consumption is reduced 3. waste oil production is reduced 4. less transportation and less CO2-production 5. instead of deposing a big amount of waste oil customers have to dispose only the cleaning elements with concentrated sludge. 9 Michael Friess