IPU Extended Oil Life System

Bypass system of oil purification through evaporation and filtering

Our oil monitoring systems can help to extend engine and industrial machinery life by removing harmful contaminants and guaranteeing monitoring and analysis of contamination levels in hydraulic and gearbox oils while maintaining the chemical-physical characteristics of the oil used.

Predictive Maintenance, emergency call-outs, routine oil and filter changes all represent the largest controllable expenditure by plant, hydraulic engine and general engine operators.The IPU Extended Oil Life System (EOLS) system  offers a simple and reliable solution for managing these controllable costs as well as reducing waste disposal costs and, ultimately, total cost of ownership.

Typically, around 80% of engine failures are related to oil contamination. Indigenous full-flow filters are unable to remove small particles of soot (carbon), liquid and gaseous contaminants below 10 microns. The higher levels of oil contamination, wear and tear on the engine increases with physical damage to even the hardest metal surfaces alongside chemical wear caused by reduction in lubricity and an increase in oxidisation of the oil.

When installed in parallel with the existing full-flow filter the IPU EOLS extended oil life system is able to reduce wear-related issued, avoid breakages and thanks to an efficient filtration system, reduce the oil draining intervals and can significantly reduce relative costs.This oil filtering system is suitable for engine, hydraulic and compressor oil applications. This highly efficient solution prevents the build up of harmful contaminants to below 1 micron by filtering solid particles and significantly reducing acid formation and evaporating gas and liquids.By combining filtering and evaporation in one system the IPU oil life extension system is able to reduce all groups of contaminants guaranteeing the following benefits:

● Extending oil drain intervals by at least 4 times● Reducing wear and damage to the engine● Reducing oil usage and escalating disposal costs● Minimizing filter replacement and ongoing consumable

costs● Limiting the likelihood of unpredictable maintenance

Typical oil contaminants

Acidic contaminants: Sulphuric and nitric acid

Gasseous contaminants: Sulphur dioxide, sulphur trioxide and nitrous oxide

Liquid contaminants: Water and fuel (NB lighthydrocarbons)

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

The IPU oil life extender maintains the oil quality constant, reducing costs and the probability of breakdowns

Prevention is better than cure.

How the unique dual-action system works

The 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.

Heating element

The oil passes through long-strand, protein enriched cotton, a highly efficient method capable of reaching filtration of down to 1 micron. At this stage the acid contaminants react with the protein rich cotton and in doing so are completely removed from the oil.Once filtered, the oil enters the heated evaporation chamber where liquid contaminants and gasses are evaporated and immediately vented.The unit is distinguished by a patented diffusion plate which ensures a unique heated area with respect to the input volume of oil; this permits thin-film evaporation which removes the precursors to acid formation.After the contaminants have been removed the clean oil is reintroduced into the oil pan through gravity.For hydraulic applications such as bow thrusters the EOLS has a pumping system incorporated to ensure the circulation of oil during purification and to guarantee its return back to the hydraulic cistern.

Why 1 micron filtration is important

● Particulate below 1 micron will not have an abrasive effect in an engine or hydraulic oil.

● The majority of quality engine and hydraulic oils will keep solid contaminants such as sludge in suspension to a particle size of 3-4 microns. However, when these particles combine to a size greater than 4 microns the contaminant will fall out of suspension, to be deposited in the tank or other areas of the engine/hydraulic system causing a detrimental effect on the qualities of oil and engine/hydraulic system performance.

Capacity regulated at 40 litres/hour

Protein-rich natural cotton for retaining both contaminating solid particles and acids

Thin film evaporation plate for removing contaminating liquids and gasses

Patented evaporation chamber

Vapour ventilation (dump) valve which releases gas and evaporated contaminating liquids

Unique features of dual-action IPU system

EVAPORATION

● Unique design of the thin-plate evaporating chamber

● Heating element● The thin-plate evaporation removes water,

diesel, simple hydrocarbons, sulphur dioxide and trioxide

FILTRATION

● Long-strand natural cotton● Solid contaminants filtered up to 1 micron● Low capacity (40 litres/hour) so that solid

contaminants are captured and chemically react with the cotton (acid retention)

● Averts build-up of sludge/residues

COST ANALYSIS EXAMPLEBased on a 1.000 KWH generator, working 3.000 hours a year, 180 litre capacity, average work cost, price of mineral oil and filters.

Maintenance cost of oiland filters before IPU (400

hour average oil life)

= €2.800,00

Maintenance cost of oiland filters after fitting IPU

(1.600 hour average oil life)

= €780,00

Cost saving per year

= €2.020,00

IPU Extended Oil Life System Alternative system

Extends oil drain intervals by at least 4 times Some centrifuge models double oil drain intervals

Removes up to 98,4% of solid contaminants of up to 1 micron in one phase

Centrifuge models are partially efficient in removing contaminants under 5 microns

The thin-film evaporation is up to 5 times more efficient than other evaporation plates on the market

It is the most versatile solution covering a wide range of applications from gearbox fluids to hydraulic oils, from compressors to engine oils

Most by-pass systems are for specific application

High savings due to the low cost of the unit, reduced filter average wear and 2-stage disposal process

Expensive units with disposal processes of up to 6 stages

Available for a wide range of high and medium speed engines

Alternative models cover a low range of application

OP15 OP25 OP50 OP80 OP100 MOCS

Max engine hp (steering) 150 250 500 800 1000 N/A

Max capacity oil in litres (engines)

15 25 50 80 200 N/A

Max capacity oil in litres (hydraulics)

200 500 1000 2000 3000 2000

Dimensions (cm) 27x32x19 27x27x44 32x32x41 32x32x52 29x29x76

Capacity litres/hour 40 40 40 40 40 40

Electrical absorption

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

PRODUCT COMPARISON – WHY CHOOSE THE IPU OIL LIFE EXTENDER?

TECHNICAL FEATURES

OP15

OP25 OP50

OP80

OP100

MEL SYSTEMS SRLwww.mel-systems.itVia Ornago, 2420882 Bellusco (MB) ItalyTel: +39 039 2914704info@mel-systems.it

Case studies

The IPU oil life extending system helps to lengthen the life of your gearbox or hydraulic engine oil

Landfill Generators

A British operator of landfill generators installed the IPU EOLS system on their engines and the interval between one routine servicing and another was doubled. The benefits of this installation Include:

● EOLS utilization reduced costs for each engine by € 8.000 per year;

● EOLS' ability to allow siloxane gases to disperse before they transform into sediment within the engine was essential.

● EOLS was chosen for its compatibility with the entire fleet of engines including Caterpillar, Cummins and Jenbacher.

Public Transport Company

Before the IPU OP25 system was installed on a bus with a Cummins ISC Euro 3 engine, our client changed oil every 42 days. The client had expensive reliability problems, the level of particles in the engine oil was usually measured at around 2,8%.

The subsequent installation of the OP25 system had an enormous impact, such as:

● the oil drain interval was doubled from 42 to 84 days and the

● amount of particles was reduced to just 0,2%;

● the consequent reduction of particles in turn improved reliability of the bus and constant problems regarding the camshafts were eliminatedEarth Moving Machinery Constructor

– Maintenance and Repair contracts

The constructor offers repair and routine service contracts on a global scale. It is their priority to keep costs low and under control. The IPU system was installed on a fleet of 100-ton dumper trucks used for earth-movement and construction, with the following results:

● the lubricating oil drain intervals were increased from 250 hours to 1000 hours which saved the company by roughly €6000/dumper;

● given that this construction company offers routine servicing and repair services globally, the IPU system represents an important growth factor as regards profit;

● the savings made thanks to the installation of the IPU EOLS system has allowed the construction company to adjust its price list and has become extremely competitive within the routine servicing and repair market globally.

National Bus Service

This company extended its engine oil changes from once every four months to once per year.

● Oil substitution increased from 35.000 km to 165.000 km.● Important savings were made due to the reduced

consumption of lubricating oil and oil filters and the extended oil changes resulted in an improved reliability of the buses and consequently increased operating profit.

● Thanks to constant monitoring of the state of the oil using a specific programme, the national bus company is able to step in promptly to maintain its vehicles before failures occur which would have otherwise created an increased expenditure.

For further information:

Raoul MarinoSales ManagerTel: +39 039 2914704Mobile: +39 335 498424Email: r.marino@mel-systems.it