IPU Extended Oil Life System

Evaporation and FiltrationBypass Oil Cleaning System

Oil Conditioning

IPU Oil Conditioning products can help to extend the life of engine, transmission and hydraulic oils by

removing harmful contaminants and by monitoring and analysing contamination levels and properties.

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Typically, around 80% of engine failures are related to oilcontamination, with indigenous full-flow filters unable toremove small particles of soot (carbon), liquid and gaseouscontaminants below 10 microns. With higher levels of oilcontamination, wear and tear on the engine increases withphysical damage to even the hardest metal surfacesalongside chemical wear caused by reduction in lubricityand an increased rate of oxidation within the oil.

When installed in parallel with the existing full-flow filter theIPU extended oil life system can significantly reduce costsby extending oil service intervals and lowering oil usage.The system is suitable for engine, hydraulic andcompressor oil applications and is highly effective atpreventing the accumulation of harmful contaminationbelow 1 micron by filtering solid particles, significantlyreducing acid formation and evaporating liquid and gases.Combining the dual-action of filtration and evaporation in asingle system, the IPU extended oil life system is capableof reducing all contaminant groups and deliveringsignificant cost savings for operators by:

• Extending oil drain intervals by at least 4 times

• Reducing wear and damage to the engine

• Reducing oil usage and escalating disposal cost

• Minimizing filter replacement and ongoingconsumable costs

• Limiting the likelihood of unpredictable maintenance.

Typical oil contaminants

Solid contaminants: Wear metals, soot (carbon), dirt(silicon) and sludge

Liquid contaminants: Water and fuel (NB lighthydrocarbons)

Gaseous contaminants: Sulphur dioxide, sulphur trioxideand nitrous oxide

Acidic contaminants: Sulphuric and nitric acid

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Predictable maintenance, emergency call-outs androutine oil and filter changes represent thelargest controllable expenditure for operatorsof plant and machinery. The IPU extended oillife system offers a simple and reliable solutionto managing these controllable costs aswell as reducing waste disposal costsand ultimately, total cost of ownership.

The IPU extended oil life system continuously maintains oil quality reducing costs and the likelihood of engine failure.

Prevention is better than cure.How the unique dual-action system worksThe IPU oil life system combines the dual-action of filtrationand evaporation to remove all oil based contaminants. The contaminated oil, with abrasive particles, soot, liquidsand oxidation by-products such as gum or varnish, entersthe unit through a small metering jet under normal engineoil pressure supplied by the engine's oil pump.

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The oil then passes through long-strand, protein richcotton, a highly efficient filtration medium capable of

absolute filtration down to 1 micron. At this stage acidiccontaminants react with the protein rich cotton thereby

removing them completely from the oil. Once filtered, the oilthen enters the heated evaporation chamber where liquid

contaminants and gases are evaporated and immediatelyvented. The unit features a unique patented diffuser plate

design, which provides a large heated surface area relative tothe volume of oil – resulting in thin film evaporation effect

removing the precursors to acid formation.

After these contaminants are removed, the clean oil is gravity-fedback to the engine oil sump. For hydraulic applications such as

bow thrusters the system incorporates its own electrically poweredpump to provide oil circulation through the cleaning system and back

to the hydraulic tank.

Why is 1 micron filtration important?

• Particulate size of less than one micron will not have an abrasiveeffect in an engine or hydraulic oil

• Most quality engine and hydraulic oils will keep solid contaminants(such as sludge) in suspension to a particle size of 3-4 microns. When

the particles combine to a size greater than this the contaminant will fallout of suspension to be deposited in the sump / tank or other areas of

the engine / hydraulic system, with resultant detrimental effect on thequalities of oil and engine / hydraulic system performance.

Heating element

Vapour vent valve to release gas and evaporated liquid contaminants

Patented evaporation chamber

Thin film evaporation plate removesliquid & gas contaminants

Natural protein rich cotton retains solidand acid contaminants

Regulated flow 40l/hr

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Unique features of the IPU dual-action system

EVAPORATION• Unique thin film evaporation chamber design

• Heating element

• Thin film evaporation effect removes water, diesel fuel(light hydrocarbons) and sulphur dioxide / trioxide

FILTRATION• Long-strand, unbleached, unprocessed cotton

• Solid contaminants filtered down to 1 micron

• Slow flow rate (40 litres per hour) in order to retain solidcontaminants and allow chemical reaction with cotton(acid retention)

• Prevents build up of sludge

EXAMPLE COST ANALYSISBased on 1,000 kva generator, running 3,000 hours a year, 180 litres oil capacity, industry average labour, oil andfilter prices

Engine oil and filter maintenance costs before oil life extender fitted (with standard service

interval of 400 hours)

= £2,350.00

Engine oil and filter costs after oil life extender fitted

(with extended service interval of 1,600 hours)

= £658.00

Operationalsavingsper year

= £1,692.00*

per generator

* Figures are for guidance only.

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PRODUCT COMPARISON – Why choose the IPU extended oil life system…

IPU extended oil life system

IPU system effectively extends oil service interval at leastfour times

IPU system removes at least 98.4% of solid contaminantsdown to 1 micron in a single pass

The IPU system’s thin film evaporation effect is five timesmore effective than comparable diffuser plate designs

The IPU system is a more versatile solution effective acrossa wide range of applications including transmission fluids,hydraulic oils, compressor and engine oils

Greater cost savings – lower unit cost, lower consumption in filter media and 2 stage disposal process

Suitable for a wide range of high and medium speed engines

Alternative systems

Centrifuge models extend oil service interval by two times

Centrifuge models are partially effective at removing sub 5 micron contaminants

Most alternative by-pass systems are application specific

Higher unit cost and up to six stage disposal process

Alternative models cover a lower application range

TECHNICAL INFORMATION

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OP15 OP25 OP50 OP80 OP100 MOCS

Maximum engine hp (guide) 150 250 500 800 1000 N/A

Max oil capacity litres (engines) 15 25 50 80 200 N/A

Max oil capacity gallons UK (engines) 3 6 11 18 44

Max oil capacity gallons US (engines) 4 7 13 21 53

Maximum oil capacity litres (hydraulics) 200 500 1000 2000 3000 2000

Maximum oil capacity gallons UK (hydraulics) 11 33 110 441 661 440

Maximum oil capacity gallons US (hydraulics) 15 40 100 500 1000 528

Dimensions (cms) 27 x 32 x 19 27 x 27 x 44 32 x 32 x 41 32 x 32 x 52 29 x 29 x 76

Flow rate litres/hour 40 40 40 40 40 40

Flow rate gallons UK/hour 9 9 9 9 9 9

Flow rate gallons US/hour 11 11 11 11 11 11

Current draw amps

12 VDC 12.5 12.5 12.5 12.5 12.5 N/A

24 VDC 6.25 6.25 6.25 6.25 6.25 N/A

110 VDC 1.36 1.36 1.36 1.36 1.36 N/A

220 VDC 0.68 0.68 0.68 0.68 0.68 N/A

OP100OP15 OP25 OP50 OP80

2003/372

IPU GROUP Oil ConditioningVisit our Group website www.ipu.co.uk

IPU Group, Churchbridge, Oldbury, West Midlands, B69 2AS EnglandT: +44 (0) 121 511 0400 F: +44 (0) 121 511 0401 E: ipu@ipu.co.uk

© IPU Group June 2012

Useful contact numbersKevin DaviesDivisional DirectorOffice: +44 (0) 121 511 0400Fax: +44 (0) 121 511 0401Mobile: +44 (0) 7901 006465Email: kevin.davies@ipu.co.uk

Robert Ralphs MIDGTE

Technical DirectorOffice: +44 (0) 121 511 0400Fax: +44 (0) 121 511 0401Mobile: +44 (0) 7811 360374Email: robert.ralphs@ipu.co.uk

• Fuel filtration (Fuel/water separators)

• Mobile and fixed fuel polishing systems

• Air filtration systems

• Hydraulic filtration systems

• Extended oil life systems

IPU Group provides a wide range of engine and industrial filtration solutions including:

Case studies

IPU Extended Oil Life Systems help to extend the life of your engine,transmission and hydraulic oils...

Landfill gas generatorsA national operator of landfill gasgenerators fitted EOLS systems totheir engines. As a result, the serviceinterval for this application doubled.Benefits included:• The EOLS saved the landfill

company in excess of £7,300 peryear, per engine

• The unique ability of the EOLS to vent off siloxane basedgases before they convert to deposits within the engine was vital; protecting the engines against major breakdown

• The EOLS was suitable for fitment to the company’s entirefleet, including Caterpillar, Cummins and Jenbacher engines

International construction and earthmovingequipment manufacturer – repair andmaintenance contractsThis manufacturer offers Repair and Maintenance Contractsworldwide; therefore keeping costs low is always a priority. Itinstalled IPU EOLS systems to its fleet of 100 ton dump trucksused for construction and earthmoving, its experience to date:• Service intervals were increased from 250 hours to up to 1,000

hours – this has created a knock on effect for the companywith savings of >£5,000 per truck per year

• Since the manufacturer concerned offers Repair andMaintenance Contracts worldwide, this oil life systeminstallation represents a significantsaving and a boost to bottom lineprofit

• A knock on effect has been created forthis company; the manufacturer is nowin a strong position to win more Repairand Maintenance contracts from theircompetitors as they have a significantmaintenance cost saving advantage

National transport companyBefore the installation of an IPU OP25 onto a series of CumminsISC Euro 3 engined buses, our customer was changing oil at aninterval of 42 days. They were also experiencing costly enginereliability problems, as soot levels in the engine oil were typicallytested at 2.8%. The installation of the IPU EOLS had a hugeimpact: • Oil change intervals were

doubled going from 42 days to 84 days and engine oil sootlevels were reduced to only 0.2%

• After an extensive testprogramme, it was demonstratedthat the IPU EOLS had increasedthe service interval for the busesup to 84 days

• Importantly the soot levels in theoil were reduced to 0.2%. As aresult, camshaft failures caused by contaminated lubricantwere virtually eradicated

National bus companyFor this company, service intervals were extended from a quarterlychange per vehicle, to a single change per year.

• Service intervals extended from 35,000 km to up to 165,000 km

• Apart from considerable savings on oil and filters, theincreased service interval meant availability of the busescontributed significantly tooperating profits

• As the oils are now beinganalyzed on a frequent basisas part of the oil life extensionprogramme, minor technicalproblems are being identifiedbefore they manifest intoserious breakdowns – againensuring further knock onsavings