Coolant systems are a staple at virtually all major manufacturing and power plants, protecting the vital equipment resources from the effects of overheating. However, maintaining a coolant system is incredibly time consuming.
With any coolant system, the operator needs to perform daily checks of the tank volume, adding fresh emulsion if necessary. Manual checks of the fluid concentration must also be done daily and re-dosed if needed.
These steps are tedious, time consuming, and resource intensiveโbut are critical to maintaining tool life. If the concentration of coolant falls by just 2%, the equipmentโs service live can decrease by up to 40%.
To simplify the tedious process of sustaining a coolant system, Schroeder Industries is proud to introduce these unprecedented, automated solutions: The FCU5000 and FC5000.
These sophisticated, automated coolant management tools are calibrated to deliver the appropriate amount of coolant when necessary, preventing overdosing of coolant and controlling concentrate usage. Automated alert configurations keep you informed and ready to respond to any potential issued with the coolant system.
Fluid Control Unit – FCU5000
The FCU5000 offers unparalleled, comprehensive monitoring and automatic maintenance solutions for coolant applications, ensuring the coolant system is properly managed and freeing up valuable personnel bandwidth for other tasks.
Continuous monitoring of essential fluid parameters including PH, conductivity, refractive index, and temperature
Easy to use; connects directly to an emulsion mixer and automatically dispenses coolant when the fluid level drops below the target level
Configuration available for automated alerts and recommendations via email to a defined distribution list and data collection and distribution directly to customer systems
Reduces or eliminates need for daily laboratory analysis and manual documentation, freeing resources for other important business operations
Fluid Controller – FC5000
The FC5000 can function as a stand-alone unit or in conjunction with the FCU5000 to maximize your coolant management coverage.
Automation of coolant lubricant supply for up to two tanks
Automatically refills machine reservoirs with ready-mixed coolant, lightening the load of plant staff who would otherwise need to check and fill manually
Monitors coolant levels in the reservoir and provides documentation of system specific data
Solutions from Schroeder Industries can help keep you cool! Ask the experts if the FCU5000 or FC5000 are right for your application.
Winter technically doesn’t begin until late December in the Northern Hemisphere, but cold temperatures are already setting in. Work carries on regardless of the chilly weather, but for those operating in the extreme cold, there are some important considerations when it comes to your equipment.
Winter Is Coming, Is Your Equipment Ready?
When dealing with fluid powered equipmentโlike hydraulic-powered machines and diesel-powered enginesโcold temperatures can be detrimental to your equipment longevity and performance. Let’s explore how cold impacts hydraulic fluid and diesel fuel, and what you can do to keep your business running hot:
1. Bypass Blues: Hydraulic Cold Start Conditions
The most consequential effect of cold temperatures on hydraulic fluid is the increase in fluid viscosity.
As the fluid thickens in low temperatures, its ability to freely flow is reduced, resulting in higher differential pressure upstream of the filter. This means that until the machine warms up and the fluid viscosity is lowered, the machine may enter bypassโwhere the fluid passes around the filter element. The conditions that cause machines to go into bypass due to higher fluid viscosity are commonly known as cold start conditions.
So, What’s The Issue?
If the fluid is bypassing your filter and filter element, that means that unfiltered fluid is entering your system, putting critical components at risk!
Most filters on the market position the bypass at the bottom of the filter, where contamination settles as the machine sits idle. This means that when the machine goes into bypass, all that contamination is pushed straight into the hydraulic lines. Until the machine reaches sufficient temperatures and exits bypass, allowing your filtration to kick in, the contaminants will flow through the system and cause wear and tear.
What Can I Do About It?
Choosing the right filter can help protect your equipment when it inevitably enters bypass due to cold conditions. With the risks of contamination through the bypass in mind, Schroeder has designed filters that protect your equipment in cold start conditions, including:
QF5i with Ferrous Contamination Protection
Ferrous, metallic particulates are among the most damaging types of contamination.
Designed for added protection in cold start conditions, the QF5i includes a magnetic filter rod suspended within the coreless element configuration.
This ensures that even while the equipment is in bypass, damaging metallic particulates accumulate on the rod rather than flushing into the hydraulic system.
The key to the GPT’s effectiveness is its unique bypass placement.
Unlike other filters on the market, the GPT includes its bypass in the top of the filter within the diverter cap.
During cold start conditions when a machine enters bypass, loose contaminants that have settled into the bottom of the GPT are isolated below the bypass and are not pulled into the hydraulic lines.
When the fluid reaches adequate temperature and normal filtration resumes, those contaminants are then contained safely within the filter element.
Tank Optimization has many benefits, such as reducing fluid costs and increasing available machine space. It can also improve the efficiency of equipment in cold conditions.
With less fluid in the system and improved flow efficiency, the fluid warmup window is reduced, as fluid can reach operating temperature faster.
When the desired fluid temperature is reached more quickly, that means less time is spent in bypass, which reduces risk of contaminant exposure and lets you get to work faster.
2. De-aeration Diminished: Increased Air Contamination
When the viscosity of hydraulic fluid increases, it also reduces the fluid’s ability to de-aerate. Thicker fluid means that air bubbles are less able to coalesce, rise, and exit the hydraulic fluid, leaving an increased amount of gas suspended in the fluid. When the system restarts, that suspended air will flow through the hydraulic system and even expand as the fluid temperature rises.
So, What’s The Issue?
Air contamination has several negative effects on equipment performance and longevity:
Gaseous cavitation, which occurs as air bubbles coalesce, grow, and collapse within the hydraulic circuit. This can cause jarring noises and potentially damage the internal components.
Unlike fluid, gas can be compressed. Too much air in the hydraulic system can cause delayed reactions in the hydraulic system rather than instant movement, sometimes referred to as a ‘spongy’ feeling in the hydraulics. This results in system performance that is at best inefficient and at worst unpredictable or even dangerous to bystanders and workers.
Air contamination also accelerates the oxidation of hydraulic fluid. When oxygen reacts with hydraulic fluid, a sludgy byproduct known as varnish is created. Excess varnish not only decreases the life of the hydraulic fluid, but can build up on internal components, causing blocked return lines, stuck valves, and other serious problems.
What Can I Do About It?
Deaeration occurs in the hydraulic reservoir, so ensuring you have the most effective de-aerating in-tank filtration on the market can help prevent air-related issues in cold conditions!
These rotomolded reservoirs combine beautifully with AFT filtration for improved de-aeration!
The TNK series of reservoirs are ultra light yet exceptionally durable, with internal baffling engineered for reduced fluid turbidity and improved de-aeration.
TNK reservoirs can also tough out temperature extremes, including conditions as cold as -40ยฐF (-40ยฐC) while withstanding heavy impacts and rugged working conditions. See one in action below!
Paraffin is a type of petroleum-based wax, commonly used in cosmetics, candles, and industrial applications.
As it happens, there’s also paraffin in your diesel.
Diesel fuel contains molecules of dissolved paraffin, and depending on the blend of fuel, there may be more or less paraffin in the mix.
So, What’s The Issue?
In warm temperatures, the paraffin stays dissolved, with little impact on the fuel system.
However, when temperatures drop, the paraffin begins crystallizing into a solid, which is known as diesel ‘gelling’. As these paraffin crystals begin forming, they can accumulate on dispensing filters and primary onboard filters, causing several potentially serious issues:
Blockages in filters and filter elements, which can reduce flow and drive up the costs of filter element replacements due to accelerated clogging.
Slow engine starts and engine stalls, which can range from simply disruptive to productivity to potentially damaging for internal engine components.
Reduced fuel efficiency overall, driving up emissions and fuel-related expenses.
What Can I Do About It?
There are several ways to cut down on the harmful effects of diesel gelling when temperatures start to plummet, including the following:
Use the Right Seasonal Blend of Fuel: Summer Diesel vs. Winter Diesel
Choosing the right fuel blend matters when temperatures drop.
Summer diesel blends are a more efficient fuel source, but due to the higher biodiesel content, there is more paraffin contained in summer blends.
As a result, in cold conditions, summer diesel is much more prone to diesel gelling.
Winter diesel blends, on the other hand, contain additives that hinder the formation of wax crystals, making them more effective in cold conditions.
You may be wondering: In that case, why not use winter diesel all year round? There are two main reasons. First, the energy content of winter diesel is actually lower than that of summer diesel, and second, due to the difference in the refining process, it is also less cost effective than summer diesel.
By selecting the appropriate fuel blend for the season, you can ensure that you are purchasing and utilizing fuel in the most cost-effective way, as well as protecting your equipment and your productivity from the effects of cold weather diesel gelling!
Monitor Fuel Condition with Regular Bottle Sampling & Testing
Regular sampling is vital for detecting problems before they become more serious!
When it comes to winter performance, here are two of the most important characteristics to monitor in your diesel testing regimen:
Cloud Point (CP): The temperature at which paraffin/wax crystals begin forming in the fuel. The crystal formation gives the diesel a cloudy appearance.
Cold Filter Plugging Point (CFPP): Measures the low-temperature operability of diesel by determining the lowest temperature at which the fuel passes easily through the fuel filter within a certain time range.
Schroeder Industries offers advanced testing for diesel and hydraulic oil! Ask about our testing services and stay on top of your fluid condition:
Not all filters and filter media are created equally! Choose the best protection for your fuel system:
Choose Diesel Filters with Integrated Heater Options
Some diesel filters come with an optional heater, which can be utilized in cold conditions to warm the fuel as it approaches the engine, reducing the formation of paraffin crystals.
Schroeder’s HDP series of high-performance fuel filters offer proven effectiveness, and come with optional heaters to increase protection in cold conditions.
Choose Elements with Layered, Gradient Filter Media
The filter element is the core of every filtration system and it’s important to select layered media that provides increased surface area to counteract the wax crystals binding to the media.
Schroeder’s BestFit FBO Elements utilize layered media that provides optimal filtration in all climates, from standard temperatures to extreme heat and cold.
Offers advanced particulate filtration or coalescing filtration with proven performance.
When you think about it, a hydraulic machine is a bit like a human body.
The motor and pump act as the equipmentโs heart, driving the oil throughout the hydraulic system like blood in a personโs veins. When a person is feeling unwell, or are monitoring an ongoing medical condition, blood testing gives critical insights into what is happening inside their body and helps chart a path forward for their care.
Just like a blood test does for a human being, a fluid sample is the best way to begin assessing the health of your equipment and diagnosing any underlying issues related to contamination.
Some of the most common causes of equipment inefficiency, failure, and reduced lifespan of components come down to contaminants and varnish that build up in the oil and travel throughout the machineโs โbodyโ. In fact, itโs estimated that over 70% of hydraulic system failures are related to fluid contamination. Fuel sources and process fluid are also susceptible to damaging contamination.
Schroederโs Oil Analysis Program offers a simple way to stay on top of the health of your equipment!
Whether your operation has only a handful of machines, or you manage a massive fleet, Schroeder Industries offers an array of accurate lab testing services and easy digital tracking that keep you informed of your machine’s health.
Advanced laboratory testing provides accurate insights. Our expert testing encompasses a variety of critical fluid health factors.
Multiple test kit options. Schroeder Industries offers three standard testing options, ranging from just the essential fluid values to more in-depth insights.
Receive early warnings on fluid condition. Our testing services will advise you when your fluid parameters fall outside industry standards or customized targets/baselines, allowing you to enact preventative maintenance before downtime or failure occurs.
Receive personalized support from the experts in fluid health. Our fluid condition experts can help you interpret your results and recommend corrective and preventative measures, improving your equipment’s performance and longevity.
Easy fluid test report management through the Fluid Care Portal. Grappling with paper reports and spreadsheets can make tracking fluid condition trends challenging. This user-friendly web application makes monitoring your fluid health simple, no matter the number of machines you operate.
To satisfy virtually every application, Schroeder Industries offers several different test kit options, all backed by the powerful Fluid Care Portal.
Basic Analysis Kit
Our most cost-effective testing option, focusing on the most essential fluid condition factors.
Advanced Analysis Kit
Achieve deeper understanding of your fluid condition with a more expansive testing package.
Premium Analysis Kit
Our most comprehensive testing kit, for the most advanced insights into your fluid.
Below is a detailed breakdown of what the different Oil Analysis Program test kits offer.
How does the Fluid Care Portal enhance your fluid analysis program?
Regular testing is vital for monitoring trends in your fluid health and preventing problems before they arise. However, tracking results over time for many pieces of equipment takes time and hassle. As part of our testing and fluid analysis services, Schroeder Industries is now offering a smart digital solution for detecting trends in the quality of your hydraulic oil, diesel fuel, process water, and more.
Part of Schroeder Industries’ Oil Analysis Program, the Fluid Care Portal is a new, powerful digital tool for easily tracking the health of your equipmentโs fluid as you test over time:
All your data is in one place, versus scattered over spreadsheets or various paper reports.
Easily monitor trends in fluid testing data over time, allowing you to detect and resolve contamination issues before they begin impacting your bottom line.
Monitor as many equipment assets as you need. Whatever the size of your operation, the Fluid Care Portal allows you to individually monitor the testing results for each piece of equipment.
Receive alerts when ISO Code, Water Content, or other parameters are exceeded. In the Fluid Care Portal, users can set target limit profiles for various parameters, creating customized criteria for your most critical components.
For decades, Group I oils dominated the market for hydraulic and lubricating fluid, particularly for industrial applications. Because they are created through a simpler refining process, they are the least costly hydraulic base oils available. However, the chemical composition of these less refined oils can have consequences for the environment and even potentially for the workers exposed to them.
Group I โLightly Refinedโ Oils have been deemed an environmental hazard.
These oils contain aromatics and toxic, potentially carcinogenic heavy metals. Due to this toxicity and the potential threat to the environment, Group I oils do not comply with newer, international environmental standards.
Group II & III โHydrocrackedโ or โSyntheticโ oils are replacing Group I oils as a more eco-friendly alternative.
Group II and III oils contain no toxins or carcinogens, as the toxic heavy metals have been removed.
Between 2012 and 2020, the market share of Group I oils halved. As environmental concerns drive industry standards towards more eco-friendly ends, this trend is expected to continue. But while this transition towards Group II and Group III oils benefits environmental and worker safety, there are some impacts on hydraulic equipment that operators must account for.
In Group II and Group III oils, these heavy metals have been removed, which lowers their conductivity. As a result, electrostatic discharge (ESD) can build up to potentially damaging levels. This can have serious impacts on the condition of the hydraulic system, and even pose a hazard to other electrical systems or even personnel in close vicinity to the affected equipment.
ESD damages filter elements, decreasing their lifespan, efficiency, and effectiveness.
Filter element failure results in increased contamination, which reduces oil life and exposes components to accelerated wear.
In extreme cases, ESD can arc and discharge outside of the hydraulic system, potentially damaging nearby electrical components or shocking workers.
High amounts of ESD can even cause gas combustion within the hydraulic reservoir, turning the system into a fire hazard.
Schroeder Industries Solutions for Static:
To combat the increasing presence of ESD in hydraulic equipment, Schroeder Industries developed cost-effective solutions for moderate and major cases of static buildup.
Depending on the level of conductivity in your hydraulic fluid, different element options are best suited to High, Medium, or Low/Critical conductivity.
Below is a selection of commonly used oil types, and the media Schroeder Industries recommends for each. Remember: higher conductivity means less static, and lower conductivity means more static.
Another side-effect of the reduced conductivity in Group II and Group III oils is the increase of varnish formation. Due to the lower conductivity, oxidation is more likely to occur, causing the oil to deteriorate into sticky compounds that settle throughout the hydraulic systemโnot unlike plaque in human arteries. This has a variety of impacts on the functionality and condition of the hydraulic system including:
Varnish deposits on hydraulic valves and other components can cause the components to stick, or even become fully jammed.
Machines can malfunction as components lose efficiency or fail entirely, leading to lost productivity and safety hazards.
Hydraulic filters and filter elements may become prematurely blocked due to varnish buildup.
Schroeder Industries Solutions for Varnish:
Bust varnish before it can tarnish your equipment! Schroeder Industries offers a series of filtration solutions specifically targeting varnish and varnish precursors, including:
VEU – Varnish Elimination Unit
The service-friendly Varnish Elimination Unit (VEU) is used to prepare mineral oils and is particularly effective at removing varnish.
Removes solid and gel-like oil aging products/varnish for reservoirs < 2,000 gallons
Increased operating reliability of the system by decreasing deposits in hydraulic valves
Overheating is a common, constant issue for hydraulic equipment, especially when working in scorching summer conditions. Over time, this can have negative consequences for critical machinery:
Overheating accelerates oil degradation, causing varnish and sludge to coalesce in the system and cause blockages and reduce operating efficiency.
Shortened oil lifespan forces more frequent oil change-outs, increasing both downtime and oil-related expenses for new purchases and recycling.
Oil degradation products can damage system components and force the equipmentโs engine to overcompensate.
Keep Cool and Collected with the FTC
Schroederโs new Filter Tank Cooling Unit (FTC) is a compact solution for mobile fleet vehicles that combines a hydraulic tank assembly and cooling unit in one complete package.
Condensed, efficient footprint ideal for the space limitations of mobile vehicles; most optimized tank/cooler combination currently available
Integrated cooling unit maintains safe operating temperature, extending fluid life and preventing overheating in the hydraulic system
Reduces weight, space utilization, and oil usage; provides associated cost savings
Air Fusion Technology filtration and a robust, rotomolded 7-gallon TNK design to reduce weight and increase the efficiency of the reservoirโs performance and deaeration capabilities
Schroeder Success: FTC Unit Increases Machine Space on Mobile Fleet Vehicles
An OEM producing mobile fleet units sought a lighter, more space-efficient alternative for their 25 gallon hydraulic unit and separate cooling unit, which took up considerable room on the mobile unit.
Schroeder Industries engineered the FTC unit to utilize space as efficiently as possible while delivering optimal performance from the hydraulic reservoir and cooling unit, allowing OEMs to further streamline and improve their equipment designs.
Here’s how this customer benefited!
Tank + Cooling Assembly Footprint Substantially Downsized
18 Gallon Reduction in Reservoir Size; Reduced Oil Usage Per Unit
Increased Machine Space for Further Design Improvements
Can the FTC Unit help you beat the heat? Ask the experts!
The product experts at Schroeder Industries can help you find the optimal solution for your application. Let us know how we can help!
Equipment failures within warranty and product recalls are a major headache for both end users and manufacturers, ranging from costly and inconvenient to downright dangerous. One common cause of issues and even catastrophic failures is contamination present in the equipment the moment it exits the assembly line.
The risks of contamination-related, premature equipment failures to both end users and original equipment manufacturers are clear. So, how can these issues be prevented?
What is Roll Off Cleanliness?
Roll off cleanliness is commonly referred to as the overall contamination level of the fuel system, hydraulic system, and hydraulic fluid in the equipment at the time of release from an assembly line or re-build line, after testing and before shipping to customers and/or end users.
Built-in contamination, or contamination that enters a vehicle or piece of equipment during assembly, is a common cause of premature failure. A high standard of roll-off cleanliness ensures that new equipment is free of contamination which can cause failures within warranty, triggering returns, recalls, and other negative outcomes that inconvenience consumers and impact a brandโs reputation.
Where Does Built-In Contamination Come From?
For hydraulic, lubrication, and fuel systems with sensitive components, even contaminants measured in microns can cause damage. For optimal roll-off cleanliness, there are several avenues of contamination that must be monitored and addressed, depending on the application:
Machining Debris
As the automotive manufacturers mentioned above are all too aware, machining debris, or particulates left over from the process of manufacturing and assembling components, can be catastrophic.
Tiny fragments of metal and other particulates produced in the manufacturing process can cause both localized damage to engines or critical system components and spread downstream of the original contamination source, causing wear and tear throughout the system.
Environmental Component Contamination
The overall cleanliness of the manufacturing setting at every stage of production is also vital for ensuring overall roll-off cleanliness. Dust, debris, and moisture present in the environment can settle into components as they are being manufactured, packaged, transferred, or assembled.
Most manufacturers source at least some components from third party vendors, so the condition of other facilities should also be examined, and incoming components should be tested to ensure they comply with a manufacturerโs standard of cleanliness.
Contaminated Hydraulic and Lubricating Fluid
Contamination from newly added hydraulic or lubricating fluids is another common source of contamination at the start of a machineโs life. Oil producers generally adhere to strict ISO standards, but throughout the process of production, transfer, and filling, contaminants may ingress into the hydraulic fluid.
New oil should be tested before being added to any system. It is also recommended to utilize an offline filtration system or kidney loop filter to cycle the oil through the system and ensure its cleanliness.
Contaminated Fuel
For plants which produce diesel-powered mobile equipment, fuel management for on-site testing and end-of-line filling equipment is a critical part of their operations. Fuel is a common vector for water, bacteria, and particulate contamination to enter a fuel system, as there are many potential points of exposure throughout the fuel production and transfer processes.
Inbound fuel, on-site storage tanks, and distribution systems should be carefully monitored and filtered. Filtration units specialized for maintaining diesel quality are a must to ensure clean fuel, protecting new equipment from an influx of contamination into the fuel system.
Schroeder Industries’ Roll Off Cleanliness Arsenal
Schroeder Industries understands the importance of setting end users up for success through roll-off cleanliness. We offer a variety of filtration solutions and diagnostic tools that ensure your equipment is putting its best foot forward from a cleanliness standpoint when it leaves the assembly line.
Testing cabinets like Schroeder’s CTU 1000, CTU-SC, and CTU-EB are used to analyze individual machine components and provide detailed analysis of the type, size, and quantity of contaminants. Analyzing components throughout the production, storage, and system assembly process ensures that individual contaminants are clean when entering the equipment.
If a testing cabinet is outside your budget, Schroeder Industries offers turnkey testing services and expert analysis!
Contaminated hydraulic fluid or oil is a common cause of premature machine failure. Offline filtrations systems such as Schroeder’s array of filter carts (including the MFS, FS, and AMFS) allow for flexibility and mobility when testing the hydraulic fluid and lubricating oil across a variety of machines.
Ranging from streamlined-but-reliable basic cart systems to advanced systems with onboard particle counting and recording capabilities, these filter carts ensure the cleanliness of fluid within the equipment and can be customized for your specific needs.
Diagnostic tools like the TFC are used for establishing ISO counts for fluids in real-time. Due to the technology included in the TFC, it is able to distinguish air bubbles from particulate contamination, removing the counted air from the particle count, thus providing a more accurate ISO code. With shape and size recognition software, determining the type of the contamination present in the hydraulic fluid is now even easier.
Schroeder’s Fuel Filtration division specializes in coalescing and particulate filtration for diesel fuel.
Products like the BDF, GHCF, and more provide superior filtration at every stage of the fuel supply chain, including during transfer, point of fueling, and kidney loop circulating filtration for bulk storage tanks.
Fuel filtration carts like the BDFC combine our world-class fuel filters with integrated pumps, hoses, and a mobile cart chassis.
These turn-key, complete systems offer increased flexibility and enable easy transitions from application to application around a manufacturing plant or storage facility.
As a provider of critical filtration components and accessories, Schroeder Industries is all-too aware of the importance of providing clean parts to our manufacturing partners.
Our manufacturing facilities in Leetsdale, PA and Cumberland, MD maintain high standards of cleanliness, creating a comfortable working environment and minimizing the risk of particulate contamination.
Our products are subject to stringent standards which include proprietary, rigorous testing and cleaning methods that ensure our filters, rotomolded reservoirs, and other components arrive to our partners in clean condition.
Let the experts at Schroeder Industries help you reach your roll off cleanliness goals!
Years of careful research and thoughtful development have yielded the new HY-HV-S120, the latest in Schroeder’s diagnostic arsenal. This revolutionary sensor is much more than just a digital particle counter, offering detailed insights into the possible source of contaminants.
As hydraulic oil oxidizes and degrades, a sticky substance known as varnish is deposited throughout the hydraulic system. Changing oil chemistry in modern hydraulic systems and the high pressure & temperatures achieved during equipment operation are leading to increased varnish deposits.
How Does Varnish Affect Your Hydraulic System?
Varnish accumulation in a hydraulic system causes a variety of potentially serious issues:
Varnish deposits on hydraulic valves and other components can cause the components to stick, or even become fully jammed.
The operating temperature of the machine may increase as the machine tries to compensate for its reduced efficiency, which can accelerate oil degradation and cause overheating.
Machines may malfunction at critical moments as components lose efficiency or fail entirely, leading to lost productivity or safety hazards.
Hydraulic filters and filter elements may become prematurely blocked due to varnish buildup.
Lost productivity and frequent repairs or part replacements due to varnish buildup can become very costly.
VEU Compact: Bust Varnish Before It Can Tarnish Your Equipment!
The new VEU Compact has been specially engineered to tackle varnish and protect hydraulic systems from its harmful effects. As the risk of varnish contamination and related problems proliferate, having a specialized filtration solution can save you and your system considerable trouble.
A cost-effective, accessible varnish mitigation solution
Compact design and small footprint makes installation simpler on machines with smaller reservoirs or in areas with limited space
Dual stage filtration combines ultra-efficient synthetic media and a high density cellulose layer for maximized particulate capture while maintaining filter efficiency
Does not require a cooler for optimal varnish extraction
Increases oil service life by removing contaminants
Backed by the technology, engineering experience, and quality assurance of Schroeder Industries
Schroeder Industries is no stranger to the effects of varnish, and the VEU Compact isn’t the only solution we have to offer. Learn more about our other specialized varnish removal systems!
VEU – Varnish Elimination Unit
The service-friendly Varnish Elimination Unit (VEU) is used to prepare mineral oils and is particularly effective at removing varnish. By reducing the oil temperature with an onboard cooler, the VEU allows for exceptional varnish precursor extraction.
Available as both a complete service unit and modular system for retrofits, the VMU traps varnish particulates on the surface of an active filter element via adsorption
One of the most debilitating problems a vessel can face at sea is an unexpected loss of control. In rough seas, working engines can mean weathering the storm or succumbing to it. Shipping delays due to engine failures and repairs can have an impact on supply chains, and result in major disruptions and financial loss. More importantly, loss of control can have devastating consequences on crew and bystander safety.
When considering ways to prevent an unexpected loss of power for marine applications, controlling fuel contamination is an effective way to eliminate one of the greatest factors affecting diesel engine reliability today.
What Causes Fuel Contamination in Marine Applications?
Fuel systems in marine applications are vulnerable to water contamination due to the operating environment and liabilities in the fuel supply chain.
By virtue of operating at sea, on the coast, or in rivers, ships are exposed to high levels of humidity and water, which is the most common type of contamination that sea-going fuel systems face.
Diesel fuel is transported through a long network of refineries, bulk fuel suppliers, and dispensing stations before reaching its destination. At every stage, water, humidity, bacteria, pollen, and other contaminants can enter through open breathers, improperly sealed vessels, and other points of ingress.
Fluctuations in temperature can result in high levels of free water in a fuel system, which is more damaging than water that has dissolved into the fuel.
How Can Fuel Contamination Cause Engine Failure?
Contamination can affect engine operations in a variety of ways:
Buildup of bacterial sludge in the fuel due to water and bacterial contamination, also called diesel bug, can plug the engine filtration system and starve it of fuel
Small amounts of particulates and water can wear out an engine’s components over time, reducing its overall efficiency and eventually causing the engine to fail.
What Other Impacts Can Contamination and Contamination-Related Damage Have?
Besides total engine failure and its potential consequences, contamination has a range of direct and indirect impacts on equipment and operations:
Costly maintenance and repair of engines and equipment
Increased fuel-related expenses between acquiring clean fuel, disposing of contaminated fuel, and remediating/polishing contaminated fuel
Reduced fuel economy due to inefficiencies in the engine/high pressure common rail injection systems caused by contamination
Reduced engine and equipment longevity
Overall reductions in vessel or fleet profitability due to compounding expenses and downtime for repairs
How Can I Control Diesel Contamination?
Having a system in place to proactively monitor and prevent contamination where possible, plus a solution to remediate whatever contamination occurs, is key for controlling fuel contamination and protecting your engine.
Obtain fuel from a reputable source. Fuel is often contaminated before it enters a shipโs fuel system, but reputable suppliers who are familiar with contamination and take fuel cleanliness into consideration will provide higher quality fuel and prevent large, immediate influxes of contamination.
Ensure storage/fuel tank cleanliness. Before filling a fuel tank or bulk storage tank, be sure the tank is clean and dry.
Take precautions when transferring fuel/filling your system. Water and other contaminants are most likely to ingress during fuel transfer, so ensure that your transfer system is properly sealed.
Monitor the fuel quality levels of your storage tanks to determine the condition of the fuel being delivered to your engine and remediate or replace contaminated fuel before it can affect your equipment. Test kits such as Schroeder’s Diesel Fuel Quality Analysis Kits can provide important insights into the condition of your fuel, especially if you’re experiencing issues consistent with fuel contamination.
Closely monitor your fuel water separators and engine filters and empty them as often as needed. But remember: don’t rely solely on these separators and filters to completely resolve your contamination issues!
Acquire a fuel polishing system. A fuel polishing system/kidney loop attached to your system or to your storage tanks can help address contamination in real time.
Some degree of water contamination is inevitable, especially in a marine setting. However, proactive maintenance and preventative measures will significantly reduce your chances of catastrophic contamination-related equipment failure!
Schroeder Solutions for Diesel Contamination Control
Schroeder Industries understands all too well the negative impacts of fuel contamination. Our fuel filtration experts have developed a range of filtration products and services to maintain diesel fuel quality, with proven success in the maritime industry and beyond.
Here are just a few of our featured solutions:
BDFP – Bulk Diesel Filtration Panel
BDFP: Exceptional Quality, Turn-Key Stationary Fuel Filtration System
This simple-but-mighty filtration panel combines the power of our particulate GHPF filter and the exceptional water removal capabilities of our coalescing GHCF filter to defend against particulate and water contamination.
With an integrated pump, the BDFP is ready to use without requiring a new pump purchase for the filter panel.
The streamlined BDFP design is easy to integrate into new and existing fuel storage systems, and the minimal element change clearance makes maintenance easy.
Flow Rating (Electric Motor Option):
14 gpm or 25 gpm (53 or 95 L/min)
Flow Rating (Air-Operated Option):
16 or 25 gpm (53 or 95 L/min)
Ambient Temperature Range:
32ยฐF to 104ยฐF (0ยฐC to 40ยฐC) Standard; -20ยฐF to 140ยฐF (-29ยฐC to 40ยฐC) Heater Option
BDFP Prevents Water Contamination-Related Engine Failures in Workboat Fleet
When a fleet operator in the Mississippi River region launched a new pushboat with a brand new engine, the pushboat experienced sudden engine failure just a single mile into its maiden voyage.
Analysis revealed water contamination in the fuel source as the primary cause of this failure. When the customer approached Schroeder Industries for help, our experts recommended a kidney loop setup featuring the BDFP to ensure fuel quality, reduce engine maintenance, and protect against further costly, dangerous failures. Its performance was so outstanding that the customer implemented the BDFP across their three fleets.
Here’s how the BDFP helped this customer save money and protect their assets!
Reduced Downtime & Maintenance
Eliminated Contamination-Related Engine Failures
Prevented Major Engine Repairs (Saving Up To 100K+)
Schroeder’s particulate GHPF filter and coalescing GHCF filter combine for exceptional defense against particulate and water contamination. With the option of adding a second GHCF in parallel on the BDF, flow rate and coalescing capabilities can be doubled!
This compact filter excels in marine applications, fleet and mobile vehicle applications, railroad applications, and much more!
Flow Rating:
BDF1: up to 25gpm (95 L/min) BDF2: up to 50gpm (189 L/min)
Max Operating Pressure:
150 psi (10 bar)
Temperature Range:
w/ water sump heater: -20ยฐF to 225ยฐF (-29ยฐC to 107ยฐC); w/out heater: 32ยฐF to 225ยฐF (0ยฐC to 107ยฐC)
Due to poor fuel quality, a Class 1 Rail Carrier was experiencing frequent in-field failures of their MOW (Maintenance-of-Way) equipment, including their Fuel & Lube Trucks.
This lack of fuel quality control was costing the customer thousands of dollars in parts and labor, downtime, and lost revenue overall. Schroeder’s experts retrofitted the customer’s MOW fleet with BDF2 filters (BDF with dual GHCF filters), providing immediate improvements.
Here’s how the BDF2 helped this customer save money and protect their assets!
57% Increase in Particulate Filtration Efficiency
19% Reduction in Absolute Water Content (52ppm Below World Wide Fuel Charter Maximum Water Content)
BestFitยฎ Elements: Superior Coalescing & Particulate Filtration
With options for both coalescing and particulate filtration and all the advantages of Schroeder’s powerful filter element technology, the BestFitยฎ series provides improved diesel filtration performance.
SBFC element uses patented, three stage coalescing filtration technology
Synthetic filtration media eliminates degradation due to high water content fuel
Use of stainless steel support structure and polymer components prevent corrosion from high water content exposure
Direct fitment into existing installations allow for immediate performance improvements with no modifications
Differential Pressure Rating:
75 psid
Max. Operating Temperature Range:
225ยฐF (107ยฐC)
Filtration Rating:
225ยฐF (-29ยฐC to 107ยฐC); w/out heater: 32ยฐF to 225ยฐF (0ยฐC to 107ยฐC)
BestFitยฎ Elements Stabilize Inventory Crisis & Improve ROI
An oil & gas drilling contractor struggled to source a critical diesel fuel filter element required on all their job sites, resulting in company-wide operational impacts.
Not only was Schroeder Industries able to provide a seamless transition and stable supply of vital elements using our BestFitยฎ Element series: The BestFitยฎ Elements ended up outperforming the drilling company’s previous elements!
Here’s how BestFitยฎ Elements improved ROI and helped this customer’s business return to smooth sailing!
Element Inventory & Supply Stabilized
Increased Service Life of Filter Elements vs. Previous Elements
Competitive Price Point & Improved Element Performance Provided Immediate ROI Increases
Damp, Dirty Diesel Deals Damage: Fix It with Fuel Filtration Solutions from Schroeder Industries!
Our experts can help you monitor and decontaminate your marine vessel fuel supply and prevent the costly, potentially dangerous effects of water contamination and more. Contact us for a consultation, quote, or more information!
Contact-Blog-Water Contaminated Diesel In Marine Applications: Fix It With Filtration!
Compressed Natural Gas, or CNG, is one of the best known and most widely used alternative fuel options currently available. As CNG and CNG-powered technology escalates, filtration is necessary to ensure optimal fuel quality and operational efficiency.
In this post, we will explore:
The projected growth of CNG
Examples of CNG applications
The unique considerations of CNG filtration
The products that Schroeder Industries has engineered for excellence in the realm of CNG filtration
CNG Surge: Compressed Natural Gas Market Projected to Grow
According to a June 2023 report from The Business Research Company, Compressed Natural Gas Global Market Report 2023, the global CNG market was valued at 147.16 billion USD in 2022. By 2027, the market is expected to grow 83.5%, for a total estimated value of 269 billion USD.
CNG is one of the major players in alternative fuels for several reasons, including:
1. Improved sustainability compared to traditional fuels.
It also delivers comparable torque and power to traditional diesel engines, making it viable for intensive work such as construction and mining.
3. Relative ease of integration into current systems.
CNG can largely utilize existing technology such as vehicle designs and transportation infrastructure, making transitions and retrofits more straightforward compared to other alternative fuel sources, such as electric power.
Part of this growth in the compressed natural gas market is being driven by CNG fueling and other related applications, including power generation and fueling CNG-powered vehicles for commercial fleets. Delivery vehicles, refuse collection trucks, and other commercial vehicles are seeing increased adoption of CNG. Compressed gas dispensing stations and virtual pipelines are expanding to satisfy the growing need for CNG fuel.
In order to ensure optimal performance of both CNG dispensing units and the vehicles that utilize it, CNG must be filtered to remove damaging contamination such as water vapor, residual oils, and solid particulates.
CNG Filtration 101
Despite being a compressed gas, CNG is also susceptible to contamination and requires filtration just like diesel and conventional liquid fuel to maintain its quality.
Water Vapor: Water vapor is found in all compressed gases and air. When under pressure, the water vapor becomes more concentrated.
Oil: Oil can leach into the compressed gas via lubrication in the compressor system. Hydrocarbon contamination is also present even in gas drawn through oil-free compressors.
Solid Particulates: Compressed gas systems can also ingest particles of rust, dirt, and other solid contaminants, just like a liquid fuel application.
Just like conventional fuel contamination, contaminated CNG can negatively impact equipment and its performance:
Reduced Desiccant/Dehydrator Absorption: Compressed gas systems include dehydrating components, but high contamination levels can more quickly overwhelm these dehydrators.
System Component Wear: Sensitive system components, fuel injectors, and seals can be abraded and damaged overtime by contaminants, leading to costly repairs and replacements.
Reduced Efficiency Overall: Worn components reduce operational efficiency and increase maintenance-related downtime for CNG-powered equipment.
And More!
However, filtering compressed gas requires extra consideration compared to conventional liquid fuel. Adequate gas filtration must, among other things:
Account For Different Gas Types. Filter housings size selection must consider not only the system flow but also the type of gas as well as the operating pressure and temperature of the system.
Account For Smaller Gas Molecules. Gas molecules are much smaller than liquid fuel molecules, so material selection and porosity are a major consideration in filter construction. A gas filter must be exceptionally well-sealed and utilize low porosity materials. Ductile iron and aluminum are common material choices for CNG filters.
Tackle Ultra-Fine Particulates. Contamination in compressed air is often under 1 micron in size, which is substantially smaller than typical contamination in liquid fuels. Gas filters must be capable of trapping tiny particulates without compromising the differential pressure in the compressor system.
CNG Filtration Solutions from Schroeder Industries: Engineered for Excellence
Schroeder Industries offers comprehensive solutions for CNG filtration and filling stations, from generation to dispensing.
Generation
Transportation
Storage
Dispensing
Learn more about our CGF Series for CNG filtration, as well as our premium replacement elements!
Compressed Gas Filters
Schroeder’s premier filtration series for compressed air and compressed gases like CNG
CGF filter series provides cost-effective, robust filtration solutions for a broad range of applications.
Unlike other compressed gas filters, the CGF series utilizes pleated microglass media construction for more reliable performance and greater capacity.
CGF50
CGF8
CGF1.5
up to 5,000 psi
up to 800 psi
up to 150 psi
Compressed Gas Filter Panel
The CGFP50 provides twice the filtration power for your bulk filtration needs!
High Pressure Compressed Gas Polishing Panel for dispensing & transfer filtration
Uses two stages of the Schroeder CGF50 Compressed Gas Filters to remove particles and aerosols of oil and water.
Stainless Steel valves, connections, and tubing with flareless crimp connections are used for longevity and durability.
Replacement Elements
Premium replacement filter elements for the CGF series and more!
Replacement element kits designed for competitor housings in common sizes and media grade equivalents.
Currently available in 4C, 10C, and WS media grade equivalents, using pleated microglass media for extended service life with exceptional performance.
The element kits include the replacement bowl seals, designed to fit the competitor housings in the full range of sizes.
CGF Series: Beyond CNG
The versatile CGF Series also offers exceptional performance in other compressed gas applications besides just CNG!
Air Dryer Pre-Filtration
Paint Sprayer Booths
Air Cylinder / Air Valve Protection
And More!
The filtration experts at Schroeder Industries can help find the perfect filtration fit for your CNG or compressed gas application! Let us know how we can help:
