Project Profiles

Project profiles

Six typical installations, one per industry. Customers are not named.

About these examples

Typical projects, not audited case studies; figures are indicative. Verified site data can be arranged on request.

Power generation Group II turbine oil, 6 years in service

Steam turbine lube system, 30,000 L

Situation

Governor valve response slowing for eight months, with particle counts within limits.

Findings

Varnish: MPC deposit potential well into the alarm zone.

What we fitted

A varnish removal unit on the lube reservoir, plus a depth filtration loop.

Outcome

Deposit potential normal in ten weeks; the 30,000 litre charge stayed in service.

Power generation

Before

After

MPC deposit potentialAlarm → normal

Oil chargeRetained

Time to result~10 weeks

Hydraulic manufacturing Three machines, three shift operation

Injection moulding hydraulics, 1,500 L

Situation

Part sizes varied and inline elements lasted five weeks instead of six months.

Findings

Oil at ISO 21/19/16 against a 17/15/12 valve requirement; silt entering through a failed breather.

What we fitted

A fine filter and desiccant breather on the three worst machines.

Outcome

16/14/11 in a fortnight; element life back to six months and valve replacements stopped.

Hydraulic manufacturing

Before

After

ISO 440621/19/16 → 16/14/11

Inline element life5 weeks → 6 months

Valve replacementsStopped

Cement ISO VG 320, high dust environment

Kiln drive gearbox, cement plant

Situation

Rebuilt twice in three years, silicon and iron rising before each failure.

Findings

Cement dust entering through a blinded breather and worn shaft seal.

What we fitted

A high capacity fine filter for VG 320, plus a desiccant breather.

Outcome

Particle count fell within a week, wear trends flattened, gearbox not opened since.

Cement and mining

Before

After

Silicon trendRising → flat

Gearbox rebuilds sinceNone

Oil changesOn condition

Marine Continuous water ingress at sea

Stern tube and gear oil system, marine vessel

Situation

Water repeatedly above limit; the oil turned cloudy days after each separator run.

Findings

Emulsified water the separator could not remove; Karl Fischer well above saturation.

What we fitted

A filter separator sized to the rate of water entry, running continuously.

Outcome

The oil stayed clear between ports; drain and refill stopped.

Marine and offshore

Before

After

Water contentAbove limit → in spec

EmulsionCleared

Drain and refillDiscontinued

Chemical processing 4 years in service, high temperature duty

Thermic fluid system, 8,000 L

Situation

Rising fuel use to hold process temperature; the strainer kept collecting black solids.

Findings

Carbon and oxidation by-products coating the heat transfer surfaces.

What we fitted

A heat transfer oil filter on a slip stream, rated for the temperature.

Outcome

Solids came out over several weeks; the fluid change was deferred and firing rate fell.

Heat transfer systems

Before

After

Strainer cleaningWeekly → rare

Fluid replacementDeferred

Production stoppedNot at any point

Utility Treated while energised

Power transformer, in-service oil treatment

Situation

Water content and breakdown voltage worsening every year despite an annual outage.

Findings

Moisture entering continuously through breathing and gaskets, faster than annual treatment could remove.

What we fitted

A permanently mounted online filtration and drying unit, low flow, transformer energised.

Outcome

Water stopped rising; the annual treatment outage came off the plan.

Transformer oil

Before

After

Moisture trendRising → stable

Annual treatment outageRemoved

Transformer energised throughoutYes

If this matches your machine

If your machine shows the same symptoms, send the equipment details and the last oil test report.

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