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Frequently Ask Questions of Oil Cleaner Cart (OCC)

Thu, 17 May 2012 02:11:00 -0400

1) What is Oil Cleaner Cart (OCC)?
Oil Cleaner Cart or OCC is portable cleaning device that is very convenient and easy to use with your
in-plant machinery and mobile hydraulic equipment that using mineral based fluid. It serves as
supplement to any existing filtration on a specific hydraulic application with viscosity of oil up to 108 cst.

2) When do you need to change your oil?
Lubrication, deterioration and malfunction are due to damages caused by contamination. In this condition
contaminated oil will normally be replaced with new oil because it is dirty and to avoid further damages
to your system. But with OCC, you don’t have to throw away your oil. Instead, you may clean it and reuse it.

3) Does OCC same as other inline filter?
Any standard hydraulic system has a filter and filter supplier may easily be found anywhere. However,
with OCC it not only just filters your oil. It can guarantee perfect clean oil for your system by removing
all the particles that are not removed by conventional filters.

4) How does OCC filter and clean the oil?
With OCC, your oil will go through 2 stages of filtrations. The first stage will do a pre-cleaning of oil to
remove big particles. The second stage of filtering will not only filter but also clean your oil by removing
solid particle, absorb water, remove sludge and other oil oxidation residues.

5) What makes OCC more efficient and effective compare to other inline filter?
Two units of Triple R bypass oil cleaner are installed in this OCC whereby it operates simultaneously.
The thickness of the filter medium is 114mm which is different and severally thicker than other
conventional inline filter. Because of its specially designed cellulose medium, it allows absorption of
water and oxidation residues.

6) How can OCC help in your investment?
OCC can save your maintenance expenditure. With its filtration specialty, the cleaning process can be
performed. This will save almost 50 percent of your oil cost, where no extra manpower, no rent and
no additional charges need to apply. Additionally, OCC support the environment.

7) Does OCC effortless to use?
OCC is easy to use with your hydraulic system. It is low running cost and easy installation and
maintenance. Owing to its portability, it also can be removed from one machine to another.

8) When is to change the element?
Besides Triple R oil cleaner, standard OCC is installed with Parker filter whereby the pressure gauge is
equipped together. The gauge is for easier to check the element contamination level and let you
know when is to change the element.

9) How can this cleaning device affect the life of your oil?
With OCC, oil contamination level is kept at a 50 to 100 time lower concentration. Cleanliness of oil
can reach up to 67 times cleaner and 67 times less contaminant which gives a longer life to oil. A
normal period of changing oil with conventional filters will require every two months. Nonetheless,
with OCC, it require once every six months.

10) Does the cleaned oil reach the standard of international requirement?
Many manufacturers want to protect their machinery and equipment from breakdown caused by
contamination. OCC effectively guarantee the standard cleanliness of oil grade by ISO of 16/14/11
and NAS standard of 7 or better. This cleaning cart can also be very effective to reach and maintain
the cleanliness level of other components of the system. This will improves machine reliability and
productivity.

What is a Rotating Joint?

Fri, 24 Feb 2012 13:06:00 -0500

ROTOTECH rotating joints are used to transfer steam, water, hot oil, hydraulics, air, etc. from stationary supply lines to rotating machine parts such as shafts, drums or rolls.

In textile, rotating joints are used to heat or cool drums/rolls without energy lose. In paper sector; rolls which used to dry the wet paper, must be heated. To heat these rolls; hot oil or steam is used. While rolls rotate, supply and return lines are stationary. Rotating joints are used to connect these stationary pipes to rotating rolls without any leakage.

Another example may be iron & steel industry. In continuous casting process hot steel is cooled with rolls. These rolls are cooled from inside and outside. Demineralized water is used to cool these rolls from inside. While hot steel passes, these rolls rotate and rotating joints are used to transfer water from stationary supply lines to rotating rolls. Design of Rotating Joints: While rotating joint design, configuration and applications are changed, they have four basic components; housing, shaft, bearings and seals. The most important component of the rotating joint is the seal. Seal prevents the medium to leak from the joint. Rotating joints has one static seal (o-ring or lip seal) and one dynamic seal (mechanical seal).

Second most important component of the rotating joint is the bearing. Rotating joint may have one or multiple bearings. There are two types of bearings; 1) Roller bearings (which has rolling components inside like ball bearings); 2) Non-roller bearings (which doesn't have rolling components inside, like carbon graphite or bronze bearings) Shaft is the component that allows the medium to flow inside the joint to the drum or roll. In most cases shaft will rotate with the roll. In some cases where the size of the rotating joint is bigger, shaft will be stationary and the housing will rotate with the roll. Housing is the component that holds all internal parts together. The housing has an inlet port (threaded or flanged) where inlet hose is assembled. If the rotating joint is dual flow, housing will also has a second port to remove the medium from the roll. In small rotating joints, the housing is stationary and shaft rotates with the roll. And in larger models, the housing is assembled to the drum with flange and bolts and so that housing will rotate with the drum. When choosing the right product, pay attention to • Application parameters • Temperature of the surroundings • Medium pressure • Spare parts and warranty • Consultancy Please bear in mind that all factories have different application parameters and wrong product selections will cause bigger problems that increases the maintenance costs.

Selecting A COOLBIT Cooling System Example

Sun, 10 Apr 2011 13:06:00 -0400

A COOLBIT Cooling System Selection

Sun, 10 Apr 2011 11:17:00 -0400

1 Determination of input data

1.1 Heat Rejection

N = Installed power in the hydraulic system in kW

Q = Heat Rejection (heat to be dissipated) in kW

Hydraulic pump driven by an electric motor, then

Q = ¾N or 0.75 x N

If there is hydraulic motor in the system, then

Q = N

1.2 V = Oil flow in ℓ/min

1.3 T oil = Oil inlet temperature or maximum allowed Oil temperature in °C

1 4 T amb = Cooling air flow temperature or ambient temperature in °C

1.5 ETD = Entering temperature difference

ETD = T oil ‐ T amb

2 Specific Heat Rejection

Q sp = Specific heat rejection, the required performance of the heat exchanger

in kW/°C or kcal/h°C

Q sp = Q / ETD

3 Select according to diagram

4 Determination of Oil Temperature Difference from selected cooler

Q act = Actual heat rejection in kW

Q sp act = Actual specific heat rejection in kW/°C or kcal/h°C (from diagram)

ΔT = Oil temperature difference in °C

Q act = Q sp act x ETD

Thus,

ΔT = 33 x (Q a c t / V)

5 Pressure Drop

Obtain ΔP = Pressure drop @30 cSt oil viscosity from diagram

4.1 Obtain pressure drop for other oil viscosities

The pressure drop curves are based on viscosity of 30 cSt.

Thus, use conversion factor f to calculate pressure drop at other viscosities.

cSt	10	20	30	40	50	60	80
f	0.5	0.75	1	1.2	1.4	1.6	2.1

Pressure drop of type AH0608T is 0.55 bar @30 ℓ/min & 30 cSt.

Assume an oil type ISO VG46 is used @60°C having a viscosity of 20 cST

Then,

New ΔP = 0.55 x 0.75

= 0.41 bar

Example of the use of Pressure Intensifier

Sat, 05 Mar 2011 08:14:00 -0500

Since the pressure intensifier came onto the market, it has been used in a large number of systems.The list below gives an idea of its versatility and shows its typical areas of application :

Hydraulic clamping tools
Maintenance equipment for railways
Injection moulding machines: locking of mould parts, core holder
Hydraulic tools of various kinds, for example: cutting, spreading & clamping tools
Torque wrenches, bolt drawers, etc.
Rotating couplings for lathes
Test equipment up to 3,000 bar
Fork turners on trucks
Concrete crushers
Offshore: wellhead control panels (WCW, MCW, SSSV), blowout preventors
Hydraulic tools on ROVs (Remotely Operated Vehicles)
Power packs
Filter presses

You may click to enlarge the picture:

Use of the Pressure Intensifier

Sat, 05 Mar 2011 07:58:00 -0500

In principle, the pressure intensifier can be used wherever there is a need for an unusually high pressure at a given time. In general, the system will be as shown in Figure 1, in which one cylinder is controlled with an ordinary 4/3 directional valve. The pressure intensifier is mounted directly on the cylinder, and the expensive high‐pressure connection is reduced to a minimum. In the example, the pressure intensifier is expanded with an integrated pilot‐operated check valve.

If the cylinder has to move forwards at a higher speed than the volume flow through the pressure intensifier allows, the integrated pilot‐operated check valve can be replaced with an external valve.

In systems in which the pump is dimensioned not only to operate a single cylinder, as shown in Figure 1, but must also supply a number of other consumers, the volume flow supplied can increase the pressure intensifier's operating frequency to a level at which its life will be reduced. In such systems, it would be a good idea to place a throttle valve before the pressure intensifier.

In some applications, it is necessary to shut off the pump either to preserve energy to prevent heat build up or because the application is moved (e.g. pallets for machine tools). In these situations it is adviseable to insert a leak proof pilot operated check valve after the intensifier, refer Figure 2 as the integrated check valves in the intensifiers are not designed to be leak proof in 2., these situations.

A particularly well‐suited area of application for the pressure intensifier is in existing systems where there is a need for a higher pressure than original design allows. The costs of expanding such a system in the traditional fashion to achieve a higher pressure are generally very high and involve a lot of trouble.With the pressure intensifier, an existing system can be upgraded to the increased operating pressure just by integrating an intensifier. The necessary volume flow must, of course, be available.

The advantages of Pressure intensifiers

Sat, 05 Mar 2011 07:36:00 -0500

Using pressure intensifiers, designers have greater flexibility with regard to choice of operating pressure. The hydraulic load becomes more uniform throughout the machine's cycle. The pressure intensifier starts to work only when there is a need for a high pressure.The rest of the time it is passive, has no internal consumption and thus does not influence the performance of the system.

Pressure intensifiers offers a number of advantages over traditional high pressure and low pressure system :

Higher performance and longer life on account of a lower operating pressure
More compact system
Greater safety due to lower pressure in general
Integrated valves
No dynamic seals
Intensififcation ratio adapted to requirements

Pressure Intensifiers in Hydraulic Systems

Sat, 05 Mar 2011 07:28:00 -0500

In hydraulic systems, it is often necessary to use varying operating pressures. A system which works perfectly with a high rate of efficiency can be achieved only if it is possible to adjust the pressure precisely to the load in question.

You often see systems in which most of the pump station oil flow passes through a pressure relief valve which is set to an unnecessarily high pressure This is because for a short time there is a need for high pressure. because, time, pressure at a certain time in the cycle of the machine in question. The rate of efficiency of such systems is very low, and the integrated components are subject to a high level of wear because the pressure drop creates a high surface pressure between the moving parts.

In order to counter this problem, a system is often constructed from several pumps which are connected in such a way that the volume flow delivered depends on the operating pressure in question. In a large system, the pump may have a variable displacement, and its regulator is then able to operate at several different operating pressure.

However, in many machines, the high pressure is only required for very short interval of the machine's cycle. This is the case, for example, in all machines used for compression tasks. In these machines, a large part of the energy is used to move tools, mould plates or press plates and only a small part for the pressing operation itself because this does not involve any movement, just compression of the oil in the cylinder.

How the Hydraulic Pressure Intensifier works ?

Wed, 02 Mar 2011 07:09:00 -0500

1). The oil is supplied to the "P" port and pases through the check valve CV1, CV2 and pilot operated check valve POV (option) to the high‐pressure side. At the same time, the "T" port is connected to the tank.

Now the entire flow of the pump will pass straight through the intensifier, and a cylinder on the high‐pressure side "H" will move rapidly forwards.

2). When the pressure rises on the high‐pressure side, CV2 and POV close, and the oil will now fill Vol.1.

In Fig.1 Vol.2 is connected to PCV, which is connected to the tank. The pressure build‐up in Vol.1 causes the piston HP and LP move left.

3). When the high‐pressure piston HP passes pilot string 1, the latter is pressurised, and PCV changes position. This occurs because the right area of PCV is greater than the left of it, where pilot string 2 is constantly pressurised.

Vol.2 is thus connected to the pump, and the piston LP and HP move right as the area LP is depressurised, and PCV returns to its original position.

4). This continues until the pressure on the high‐pressure side has increased by a factor equivalent to the ration between the areas of LP and HP.

If the pressure on the high‐pressure side falls, a new cycle starts automatically.

5). Pressure can be relieved from the high‐pressure side by leading the pump flow into the "T" port and connecting the "P" port to the tank. Pilot string 3 is thus pressurised and POV opens.

The oil from the high‐pressure side is now led directly back to the tank through POV and the "P" port.

How to choose a good condition DC motor and Pump?

Wed, 23 Feb 2011 06:06:00 -0500

The dimensioning of DC motors and electro‐hydraulic pumps are based on the duty types.

In particular,the output power depends on the temperature reached by the motor.

When required pressure, flow and available voltage (12 or 24V DC) are known, select the motor by checking the diagram below. If a pump displacement is available at the intersection of pressure and flow valves the electrical current can be obtained on the "I" curve.

EXAMPLE:

For this application we have the following data:

Flow=5.0 l/min, max. pressure=100 bar, not clearly defined cycle.

Please check the above diagrams and see if there is a pump available. When the intersection point is not on a pump curve, choose the closest intersection pump.

Using a pump of 2.3 (a 2.3 c.c/rev pump) On the "I" curve we read that a 165A current is known. With these conditon on the S2/S3 diagram note that:

S2=4.3 minutes ; S3= 13%

If S2 and S3 valves are not enough for a required cycle, choose a bigger motor and repeat the calculation on the new motor curves.

Short time‐duty type : S2

Operation at constant load, of short duration, without thermal equilibrium being reached. A no load period follows, sufficient for the motor to return to ambient temperature.

Example: S2=3.5 minutes

The motor runs continuously for 3.5 minutes, and stops a time sufficient to return to ambient temperature.

Intermittent periodic‐duty type : S3

Operation which consist of a sequence of uniform cycles (duty cycle 10 minutes) consisting of a period at constant load and a no load period.

Example: S3=12%

The motor runs 1.2 minutes and stops 8.8 minutes.

Chart 1:

Chart 2:

What is Insulation Class?

Wed, 23 Feb 2011 05:23:00 -0500

Insulation systems are rated by standard NEMA classifications to maximum allowable operating temperatures.

Allowable temperature rises are based upon a reference ambient temperature of 40°C.

Operation temperature is reference temperature + allowable temperature rise + allowable for "hot spot" winding.

Example of Temperature Tolerance Class F :

40°C + 105°C + 10°C = 155°C

In general, a motor should not operates with temperatures above the maximum.
Each 10°C rise above the rating may reduce the motor lifetime by one half.
Temperature Tolerance Class B is the most common insulation class used on most 60 cycle US motor.
Temperature Tolerance Class F is the most common for international and 50 cycle motors.

**IEC insulation winding classes parallel those of NEMA and in all but very rare cases, use the same letter designations.

NEMA Ratings

Wed, 26 Jan 2011 00:03:00 -0500

There are many NEMA ratings available for enclosures.

Below, is a brief explanation of each NEMA rating.

NEMA 1 General Purpose ‐ Indoors
Enclosures are intended for general purpose indoor use primarily to provide a
degree of protection against contact with the enclosed equipment or locations
where unusual service conditions do not exist.

NEMA 2 Drip Proof ‐ Indoors
Enclosures are intended for general purpose indoor use primarily to provide a
degree of protection against limited amount of falling water and dirt.

NEMA 3 Dust Tight, Rain Tight, & Ice / Sleet resistant ‐ Indoors / Outdoors
Enclosures are intended for general purpose outdoor use primarily to provide a
degree of protection against windblown dust, rain and sleet; and to be undamaged
by the formation of ice on the enclosure.

NEMA 3R Rain Proof & Ice / Sleet Proof ‐ Indoors / Outdoors
Enclosures are intended for general purpose outdoor use primarily to provide a
degree of protection against falling rain; and to be undamaged by the formation
of ice on the enclosure.

NEMA 3S Dust Tight, Rain Tight & Ice / Sleet Proof ‐ Outdoors
Enclosures are intended for general purpose outdoor use primarily to provide a
degree of protection against sleet; and to be undamaged by the formation of ice
on the enclosure.

NEMA 4 Water Tight & Dust Tight ‐ Indoors / Outdoors
Enclosures are intended for general purpose indoors and outdoor use primarily to
provide a degree of protection against windblown dust and rain, splashing water,
and hose directed water, and to be undamaged by the formation of ice on the
enclosure.

NEMA 4x Water Tight, Dust Tight & Corrosion Resistant ‐ Indoors / Outdoors
Enclosures are intended for general purpose indoors and outdoor use primarily to
provide a degree of protection against corrosion, windblown dust and rain,
splashing water, and hose directed water, and to be undamaged by the formation
of ice on the enclosure.

NEMA 5 Superseded by NEMA 12 for Control Apparatus

NEMA 6 Submersible, Water Tight, Dust Tight & Ice / Sleet Resistant ‐ Indoors / Outdoors
Enclosures are intended for general purpose indoors and outdoor use primarily to
provide a degree of protection against the entry of water during temporary
submersion at a limited depth; and to be undamaged by the formation of ice on
the enclosure.

NEMA 7 Underwriters Lab Class I ‐ Groups C & D ‐ Explosion Proof ‐ Indoors
Enclosures are for indoor use in locatios classified as Class I, Group A, B, C or D,
as defined in the National Electrical Code.
Enclosures shall be capable of withstanding the pressure resulting from an internal
explosion of specified gases, and contain such an explosion sufficiently that an
explosive gas‐air mixture exisitng in the atmosphere surrounding the enclosure
will not be ignited. Enclosed heat generating devices shall not cause external surface
to reach temperatures p capable of igniting explosive gas‐air mixtures in the
surrouding atmosphere. Enclosures shall meet explosion, hydro‐static, and
temperature design tests.

NEMA 8 Underwriters Lab Class I ‐ Groups C & D ‐ Explosion Proof ‐ Indoors
Same as NEMA 7, except the unit is oil‐immersed.

NEMA 9 Underwriters Lab Class II ‐ Groups E, F, G ‐ Explosion Proof ‐ Indoors
Enclosures are intended for special purpose indoor use in locatios classified as
hazardous (Class II, Group E, F, or G, as defined in the National Electrical Code)
Enclosures shall be capable of preventing the entrance of dust. Enclosed heat
generating devices shall not cause external surfaces to reach temperatures
capable of igniting or discoloring dust on the enclosure or igniting dust‐air mixtures
in the surrounding atmosphere.
Enclosures shall meet dust penetration and temperature design tests, and aging
of gaskets (if used)

NEMA 10 Bureau of Mines

NEMA 11 Corrosion Resistant & Drip Proof ‐ Oil Immersed ‐ Indoors

NEMA 12 Industrial Use ‐ Dust Tight & Drip Tight ‐ Indoors
Enclosures are intended for industrial indoor use primarily to provide a degree
of protection against dust, falling dirt, and dripping noncorrosive liquids.

NEMA 13 Oil Tight & Dust Tight ‐ Indoors
Enclosures are intended for industrial indoor use primarily to provide a degree
of protection against dust, spraying of water, oil, and dripping noncorrosive
coolant.

What is IP Ratings?

Tue, 25 Jan 2011 23:57:00 -0500

The protection of enclosures against ingress of dirt or against the ingress of water is defined in
IEC529 (BSEN60529:1991). Conversely, an enclosure which protects equipment against ingress of particles will also protect a person from potential hazards within that enclosure, and this degree of protection is also defined as standard.
The degrees of protection are most commonly expressed as "IP" followed by two numbers, e.g. IP65,
where the numbers define the degree of protection. The first digit (Foreign Bodies Protection) shows
the extent to which the equipment is protected against particles, or to which persons are protected from
enclosed hazards. The second digit (Water Protection) indicates the extent of protection against water.
The wording in the table is not exactly as used in the standards document, but the dimensions are
accurate.
The 1st digit in the rating is the protection against contact and foreign bodies.
The 2nd digit in the rating is the water protection factor.
The 3rd digit in the impact protection factor. It is normally displayed in the format below.

How an Electric Motor Load and its Efficiency?

Tue, 25 Jan 2011 23:45:00 -0500

Most electric motors are designed to run at 50% to 100% of rated load. Maximum efficiency is usually
near 75% of rated load. Thus, a 10‐horsepower (hp) motor has an acceptable load range of 5 to 10 hp;
peak efficiency is at 7.5 hp. A motor's efficiency tends to decrease dramatically below about 50% load.
However, the range of good efficiency varies with individual motors and tends to extend over a broader
range for larger motors.
A motor is considered underloaded when it is in the range where efficiency drops significantly with
decreasing load. Power factor tends to drop off sooner, but less steeply than efficiency, as load
decreases.
Overloaded motors can overheat and lose efficiency. Many motors are designed with a service factor that
allows occasional overloading. Service factor is a multiplier that indicates how much a motor can be
overloaded under ideal amibient conditions. For example, a 10‐hp motor with 1.15 service factor can
handle an 11.5‐hp load for short periods of time without incurring significant damage. Although many
motors have service factor of 1.15, running the motor continuously above rated load reduces efficiency
and motor life. Never operate overloaded when voltage is below nominal or when cooling is impaired
by altitude, high ambient temperature, or dirty motor surfaces.
By definition, a motor of a given rated horsepower is expected to deliver that quantity of power in a
mechanical form at the motor shaft.
Figure 5 is a graphical depiction of the process of converting electrical energy to mechanical energy.
Motor losses are the difference between the input and output power.

Do you know IEC Duty Cycle Ratings?

Sat, 21 Aug 2010 01:40:00 -0400

There is various standards exist which specify various operating and constructional parameters of a motor. The International Electrotechnical Commission (IEC) is one main standard in the world.

The International Electrotechnical Commission (IEC) is a European-based organization that publishes and promotes worldwide, the mechanical and electrical standards for motors. It's the international counterpart of the National Electrical Manufacturers Association (NEMA).

Usually, IEC Duty Cycle Ratings are different from NEMA's. Where NEMA specifies continuous, intermittent, or special duty (typically expressed in minutes), yet IEC uses 8 different duty cycle designations to describe an electrical motors operating conditions.
Below are the eight - (S1 - S8 ) IEC duty cycles of operating electrical motors:

S1 - Continuous duty.
The motor works at a constant load for enough time to reach temperature equilibrium.

S2 - Short-time duty.
The motor works at a constant load, but not long enough to reach temperature equilibrium, and the rest periods are long enough for the motor to reach ambient temperature.

S3 - Intermittent periodic duty.
Sequential, identical run and rest cycles with constant load. Temperature equilibrium is never reached. Starting current has little effect on temperature rise.

S4 - Intermittent periodic duty with starting.
Sequential, identical start, run, and rest cycles with constant load. Temperature equilibrium is not reached, but starting current affects temperature rise.

S5 - Intermittent periodic duty with electric braking.
Sequential, identical cycles of starting, running at constant load, electric braking, and rest. Temperature equilibrium is not reached.

S6 - Continuous operation with intermittent load.
Sequential, identical cycles of running with constant load and running with no load. No rest periods.

S7 - Continuous operation with electric braking.
Sequential, identical cycles of starting, running at constant load and electric braking. No rest periods.

S8 - Continuous operation with periodic changes in load and speed.
Sequential, identical duty cycles of start, run at constant load and given speed, then run at other constant loads and speeds. No rest periods.

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Frequently Ask Questions of Oil Cleaner Cart (OCC)

What is a Rotating Joint?

Selecting A COOLBIT Cooling System Example

A COOLBIT Cooling System Selection

Example of the use of Pressure Intensifier

Hydraulic clamping tools

Maintenance equipment for railways

Injection moulding machines: locking of mould parts, core holder

Hydraulic tools of various kinds, for example: cutting, spreading & clamping tools

Torque wrenches, bolt drawers, etc.

Rotating couplings for lathes

Test equipment up to 3,000 bar

Fork turners on trucks

Concrete crushers

Offshore: wellhead control panels (WCW, MCW, SSSV), blowout preventors

Hydraulic tools on ROVs (Remotely Operated Vehicles)

Power packs

Filter presses