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Gear Box Filtration

Gear Box Filtration Success

Coal pulverizers are constantly exposed to heavy coal dust in extremely dirty and dusty environments, which makes routine maintenance a costly and time-consuming process. Critical components such as gears and roller element bearings often face performance challenges as the pulverizers operate under high temperatures. It is evident that maintaining high-quality lubricants poses critical challenges for productivity, reliability, and availability, as well as personnel safety.

 

It is recommended to install an online gear box filtration system to fix the problems.

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The PSR online gear box filtration skid has helped our client to improve the coal pulverizer's lube oil within 2 weeks with proven high-performance and cost-effective Dynamic Filter Efficiency (DFE) filter technology.

Introduction

A major independent power producer (IPP) in Malaysia has commissioned the one super-critical conventional coal-fired thermal power generating unit of 1,000MW.  The plant is equipped with seven gravimetric raw coal feeders and seven pulverisers with dynamic classifiers.

The Problem

The plant is equipped with seven gravimetric raw coal feeders and seven HP 1103 pulverizers with dynamic classifiers.

 

The gearboxes that run these coal mills are lubricated with extra high-performance gear oils having outstanding extreme pressure characteristics and load-carrying properties Mobilgear 600 XP320 high viscosity oil.

 

Meeting OEM recommended operating gear oil cleanliness target of ISO -/19/16 is a tough challenge ahead.  Plant personnel began searching for a better lubrication system to break the wear chain reaction.

 

An offline filtration was installed and commissioned by a local filtration company representative.

 

Unfortunately, fluid cleanliness could not meet either system OEM or customer set target even though experienced high filter replacement.  Plant personnel began to address these issues on multiple fronts.

The Solution

During a site assessment and thorough system audit by Proactive Strategic Reliability Sdn Bhd (PSR), a local Hy-Pro Filtration representative, it was revealed that the pulverizers were experiencing significant high coal dust ingression. In response to this issue, it is both necessary and practical to apply a total system cleanliness approach to maximize uptime, extend gearbox and fluid life, reduce limited maintenance resource demands, and even save money on power consumption and fluid disposal costs.

 

One effective solution is installing a dedicated filtration system and implementing the following strategies. Firstly, utilizing offline filtration to remove contaminants and debris from fluid systems during routine maintenance or component replacement can significantly improve system cleanliness. Secondly, implementing real-time online filtration can provide continuous filtration, removing contaminants as they enter the system and preventing them from accumulating. Finally, utilizing breathers and desiccant breathers can prevent moisture and particulate ingression, further improving system cleanliness.

By adopting these strategies and installing a dedicated filtration system, coal-fired power plants can effectively reduce system downtime, extend the life of critical components, and ultimately reduce maintenance costs. With the expertise of PSR and the superior filtration technology of Hy-Pro, coal-fired power plants can experience improved productivity, reliability, and availability, ensuring the highest level of operational performance.

Immediate Measurable Results

A fluid cleanliness target was established.  System OEM has set a cleanliness target of ISO -/19/16 and the customer has set a cleanliness target of ISO -/17/14.

We helped the client to set a target of ISO 18/16/13.

 

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Less than two (2) weeks after the installation, gearbox oil contaminant levels were reduced significantly and the cleanliness target was achieved (see below table).

 

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The graph below provides a visual representation of the table above and shows the dramatic change in contaminant levels that resulted from installing the PSR total cleanliness system.

 

The graph shows the particle counts for the 4 microns, 6 microns, and 14-micron channels. In this case, the system OEM and the customer did not include the 4-micron channel in the fluid cleanliness target which is the first reported channel in the current ISO Code.

online-filtration

It is necessary and practical to apply a total system cleanliness approach to maximize uptime, extend gearbox life, extend fluid life, reduce limited maintenance resource demands, reduce fluid disposal costs, and even save money on power consumption.

Installing a dedicated PSR online filtration system and applying our get it done for you DFY 6 STEPS C-S-S-C-F-I strategies can prove to be very effective.

Step 1 – Commit

 

Step 2 – Set target

 

Step 3 – Stop

 

Step 4 – Condition

 

Step 5 – Filter

 

Step 6 – Install 

We will prove it in your system.

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