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Donaldson's Smarter Filtration for Tougher Operations
In demanding industries like aggregate, energy, and mining, equipment downtime and premature wear can lead to costly delays and lost productivity. Donaldson offers a proven solution with advanced filtration technologies designed to protect critical systems and extend equipment life.
Donaldson can help maximize equipment availability and life; while reducing your total cost of ownership. They can recommend solutions tailored to your equipment, environment, and duty cycle; ensuring optimal performance and long-term reliability.
Problems
Dust ingestion
• A major West Virginia coal mine operation faces extremely abrasive dirt and coal dust
• In the highly competitive coal industry, an operation must be efficient and cost-conscious, knowing an abrasive mixture of air contaminants could quickly destroy an engine
Injector Wear
• A south-central producer of ready-mixed concrete with 20+ sites and 250 mixer trucks had fuel-related downtime
• Premature fuel-filter plugging and fuel-injector wear was the culprit and source of contamination was its diesel fuel
• Although it met D975 fuel-delivery standards, the diesel was not clean enough for production equipment with Tier 4 engines and mixer trucks with HPCR engines
Gearbox Wear
• Large east coast aggregate producer operates five Metso® crushers in extremely dirty operating conditions
• Gearbox oil and lubrication systems required a sufficient cleanliness level to protect gears, bushings and steel shafts in a crusher
• Ineffective original filters resulted in downtime and high levels of wear metals in oil
Short Service Interval
• A mega oil and gas company wanted to significantly extend its oil drain intervals
• Their service schedule was based on the standard OEM recommendation
• Customer wanted to reduce scheduled maintenance, while protecting equipment and mitigating the risk of unplanned downtime
Solutions
Donaldson® Bulk Filtration Solutions
• Designed for extended maintenance intervals, minimizing dust exposure during filter changes
• Ultra-Web® high-efficiency media delivers greater protection from the moment it’s installed
• Premium Donaldson Blue® Clean Solutions filters provide unsurpassed cleanliness in a single pass. They are perfect for inlet and outlet filtration applications. Their spin-on design enables fast and simple filter changes without special tools and provides greater protection from contamination during service than traditional cartridge style filters.
Donaldson Clean Diesel Kit
• Implemented comprehensive approach to fuel storage
• T.R.A.P.™ breathers on bulk tanks limit additional in-tank contamination
• Filters at the point of fuel dispensing polish the fuel before it’s pumped into equipment
FEATURES
• High efficiency air filtration
• Longer life and lower airflow restriction than typical silica gel breathers
• Self-regenerating moisture adsorption
• Easy to service
APPLICATIONS
• For use with all fuels and lubricants
• Above and below ground tanks
• Mobile service trucks
• Indoor or outdoor applications
• Most tanks up to 37,854 L / 10,000 gal (large tanks may require multiple units)
Donaldson® Offline Filtration
• Filter manifold applied to meet flow/pressure needs
• Donaldson Blue® high-efficiency filters chosen to remove particulate and protect sensitive components
• Oil was continuously cleaned to protect the gearbox from wear
FEATURES
• Fast, easy and safe to service
• Requires no electrical or air hook-ups
• Large capacity in small footprint
• Flexible mounting options (horizontal or vertical)
• Cost effective high capacity system
APPLICATIONS
• Bulk fuel and lubricant filtration and water removal
• High flow transfer into or out of tanks and dispensing equipment
• Hard-to-filter high viscosity oils
• Inline industrial filtration of gear oils and lubricants
• Kidney loop applications
Donaldson Lube Filters
• Conducted fleet evaluation and provided a recommendation to meet service interval need
• Donaldson Blue® lube filters offer seals that last longer and have high-efficiency Synteq™ media
FEATURES
• Highly efficient, state-of-the-art filter media and design
• Unsurpassed filter efficiency
• Cleans to target ISO cleanliness in a single pass
• Modular design can be configured for virtually any flow rate or usage level
• Fast and easy to service
APPLICATIONS
• Single pass filtration for clean fluid transfers
• High efficiency kidney looping
• Inlet and outlet filtration at bulk storage tanks
• Dispenser “polishing” filtration on fuel pumps and hose reels
• Mobile and stationary applications
Outcomes
Engine overhaul interval extended significantly with Donaldson Blue® air filters.
One MTU 4000 Series engine has seen nearly nine consecutive years of continuous use with virtually no downtime. Overall, the team has maintained a 90% fleet availability while cutting maintenance downtime and filtration costs by up to 75%.
There were no unscheduled injector replacements.
With Donaldson Clean Diesel Kits, the company has not had to replace a single fuel injector outside of the normal preventative maintenance schedule of once every four years. Once filters were installed, the diesel fuel was 60x cleaner than before. Plus, service intervals were doubled from 400 to 800 hours.
The Donaldson filtration system increased the crusher gearbox life by 3.5 times.
The amount of contaminant reaching the gearbox was reduced by 8 ISO codes and the oil was 125x cleaner, thereby extending the gearbox life by 3.5x.
By switching to Donaldson Blue® lube filters, service intervals were doubled.
The company upgraded their lube filters and doubled previous drain intervals, for significant savings on filters and service.
DISCLAIMER: The above content is provided by the supplier. Applied® does not guarantee the accuracy or timeliness of the content.
The above content is provided “AS IS”, AND ANY AND ALL EXPRESS AND IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS ARE HEREBY EXCLUDED.
All warranties, if any, are solely from the supplier.
