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 ship’s 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:
32°F to 104°F (0°C to 40°C) Standard; -20°F to 140°F (-29°C to 40°C) 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: -20°F to 225°F (-29°C to 107°C); w/out heater: 32°F to 225°F (0°C to 107°C)
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)
BestFit® 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 BestFit® 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:
225°F (107°C)
Filtration Rating:
225°F (-29°C to 107°C); w/out heater: 32°F to 225°F (0°C to 107°C)
BestFit® 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 BestFit® Element series: The BestFit® Elements ended up outperforming the drilling company’s previous elements!
Here’s how BestFit® 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:
Over the last decade, users of hydraulic systems noticed a sharp increase in unusual failures and contamination within their equipment, including:
Burned and discolored filter elements
Rapid oil degradation
Prematurely worn, damaged components
Electrical arcing outside of the system
The culprit? Electrostatic discharge, also known as ESD, was becoming more frequent within hydraulic equipment. Static buildup is already a known issue, but why was it suddenly happening more often, and to greater extremes?
Behind the ‘Electrifying’ Increase in ESD
Fundamentally, static discharge in a hydraulic system is caused by friction—just like how shuffling across carpet in thick socks allows you to lightly zap someone else with static electricity. Oil may be a lubricant, but there is still some friction between hydraulic fluid and the filter media it passes through, and thus, static buildup can occur.
In a system with highly conductive hydraulic fluid or oil, this static buildup is more easily absorbed and evenly distributed. This prevents the worst effects of electrostatic discharge. However, environmental standards driving changes in oil composition meant that low conductivity oil was becoming more widespread.
Group I ‘Lightly Refined’ Oils were once the most common class of hydraulic fluid.
These oils contained aromatics and heavy metals. Due to the presence of heavy metals, Group I oils have high electrical conductivity.
However, the heavy metals within Group 1 oils are mostly toxic. Due to this toxicity and the potential threat to the environment, Group 1 oils do not comply with newer, international environmental standards.
Group II & III ‘Hydrocracked’ or ‘Synthetic’ 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.
Due to the lack of heavy metals, these oils have much lower electrical conductivity than Group 1 oils.
Between 2012 and 2020, the global market share of Group 1 oils fell by half, from 51% to roughly 26% of hydraulic oils in use. This trend is expected to continue. While moving away from Group I oils is much better for the environment, the proliferation of low conductivity oils led to more electrostatic discharge in hydraulic systems.
Effects of Electrostatic Discharge on Hydraulic Systems
Electrostatic discharge and static cause a variety of serious issues in hydraulic systems, including:
Damaged elements. Scorched, degraded filter elements are a hallmark of static buildup in a hydraulic system.
Increased contamination. When damaged, filter elements become unable to filter out contamination as intended, and the filter element itself may become a source of contamination as it degrades.
Reduced oil and component life. The increase in contamination and compromised filtration drastically reduces oil life and increases component wear.
Formation of sludge and varnish. As oil rapidly degrades, varnish is deposited in the system, affecting system function.
Fire risk. High amounts of ESD can potentially cause deflagration, or combustion of gas within the hydraulic reservoir.
Arcing and discharge outside of the system. In extreme cases, the electrostatic discharge can become so intense that it becomes an electrocution hazard to workers, as well as damaging to surrounding equipment.
Anti-Static Solutions from Schroeder Industries
Anti-Stat Premium and Anti-Stat Media from Schroeder industries are engineered to combat static buildup while providing robust filtration. Because levels of ESD can vary based on factors like fluid type and temperature, two levels of protection are available.
Both offer virtually the same efficiency as Schroeder’s standard, exceptionally powerful microglass media. For superior protection from both typical particulate contamination and the effects of electrostatic discharge, look no further!
NEW: Anti-Stat Premium
Anti-Stat Premium: Supercharged Static-Busting Capabilities For Extreme ESD
Specially formulated media dissipates electric charges before they can begin damaging your system
Eliminates all static buildup at the source
Effective for even the most critical cases of ESD, tackling conductivity values lower than 100 pS/m
See how these customers benefited from the static-suppressing characteristics of Anti-Stat Media!
When a paper mill was experiencing a shortened filter element life of just 30 days, Schroeder Industries stepped in to extend the filter life, reduce oil waste, and reduce unscheduled downtime.
A Schroeder expert immediately identified the signs of static discharge in the hydraulic system. As the elements were burned and degraded by the electrostatic buildup, they failed prematurely, forcing the customer to swap out elements much sooner than usual.
Switching to Anti-Stat Media took the shock out of their system, extending their filter life and leading to substantial savings!
An automotive plant contacted Schroeder Industries when, after switching to a new hydraulic oil, their oil lifespan dropped by as much as 80%.
The customer’s new oil blend was zinc and ash-free, meaning its conductivity was lower than their previous hydraulic oil. As we’ve discussed, the lower a hydraulic fluid’s conductivity, the more likely static buildup is to occur!
Burn marks and varnish on the customer’s used elements confirmed that electrostatic discharge was building up in the customer’s system. By switching to Anti-Stat Media, the customer was able to get the most out of their oil and more!
Introducing the latest in Schroeder Industries’ line of powerful in-tank filters!
Using the same cutting edge technology as the Schroeder AFT, the new AFTF provides all the best qualities of Air Fusion Technology with stabilized, fixed-head porting.
Here’s just some of what makes the AFTF one of the most powerful deaerating in-tank hydraulic filters available:
Exceptional deaeration capabilities. Air Fusion Technology reduces fluid velocity and encourages bubble coalescence for substantially more effecting deaeration than other in-tank filters currently available.
Fixed head allows for a breather attachment. The stabilized porting allows the addition of an external breather, further increasing the deaeration potential.
Provides filtration even in bypass. The specialized bypass valve in the head of the filter allows the filter to function even while in bypass for greater filtration efficiency.
Potential for reservoir downsizing. The deaeration of the Air Fusion Technology is so efficient that it may be possible to downsize your hydraulic reservoir by up to 60%!
