Filtek offers a tried, tested and proven solution whereby savings in excess of 60% on annual DG maintenance costs are realised.
This is achieved by extending service intervals on DG’s from the current 250hrs to 1,000hrs.
Oil as such does NOT breakdown at 250hrs but rather becomes contaminated to a degree where engine wear becomes a concern.
The 30micron OEM spin-on filter is no longer able to effectively cope with contaminates and an oil change is recommended
7. • Oil Filter (cont.)
Superior Filtration Solutions
1) Element gauge ‐ provides an
external view or indictor on the
condition of the element.
(Measures the difference in
pressure between input and
output).
2) Pressure limiter ‐ the input has
a very small orifice so as as not to
affect engine pressure in anyway
or void engine warranty
3) Pressure regulator ‐ limits the
internal canister pressure to 3bar. Any
excess will be ‘bypassed’.
4) Mounting bracket – includes
mounting screws.
8. • Fuel Filter
Superior Filtration Solutions
Fuel from bulk or day tank with water trap
‘clean’ fuel to engine (installed before or after fuel pump)
9. Filter Elements
Superior Filtration Solutions
• Filtration accuracy <1micron (NAS
class 9 ‐12)
• Common for both Oil and Fuel
• Cellulose fibre composition (no dyes
or reagent used)
• Removes free and emulsified water
• Plastic bag provided for easy
disposal of old element
• Suitable for most fluids such as
hydraulic fluid, cooking oil, transformer
oil etc
• Does not impact on additives or
viscosity
10. Filtek Auto‐Oil Dispenser (FAD)
Superior Filtration Solutions
• Experience has shown that when certain older
generators (>6,000hrs) are retrofitted with a
Filtek system they MAY shut‐down due to a low
pressure alarm before 1,000hrs is reached.
• The FAD will automatically continue to top‐up
the generator sump to ensure correct levels are
maintained for the full period.
• The FAD reservoir capacity can be 1, 2 or 3
litres.
• 10% of sump capacity or 1litre is standard
• Generally not required on NEW generators but
is fitted by several entities
Sump level
Reservoir
11. Why can the normal OEM filter not run for 1,000hrs?
Superior Filtration Solutions
• OEM spin on Oil filters rarely filter
particulate/contaminants below 30 micron.
• The standard gap between a new piston ring
and the cylinder wall (sleeve) is around
5micron
• These particles of carbon and metal chaffing
between 5‐30micron are primarily responsible
for causing engine wear.
• After 250 run hours the volume /density of
these contaminants is considered high and the
only way to remove them is an oil change.
Gap +/‐ 5micron
14. How are the Oil savings achieved/calculated?
Superior Filtration Solutions
Assumptions:
1. Cost of a 250hr service for a 17‐27KVA DG is $100‐00
2. The average duty cycle of all generators is 90% which will equal
365days x 24hrs = 8,760 * 90% = 7,884 run hours PER ANNUM
3. Generator service interval @ 250hrs, 7884/250 = 31.54 services PA
4. Average sump capacity is 10 litres
5. $100 x 31 = $3,100‐00 total annual service cost per Generator
6. Example for 100 sites.(used to simplify savings illustration)
• 100 x 31 = 3,100 total services per annum
• Total oil consumed 3,100 x 10L = 31,000 litres per annum
• 3,100 x $100‐00 = $310,000‐00 total service cost per annum
15. Superior Filtration Solutions
Oil system (@ price break 1)
1. Filtek Oil Canister (OC‐1000) $108‐00
2. Filtek Replacement Element (RE‐1000) $ 43‐00
3. Filtek Installation Kit (INT‐008) $ 52‐00
4. Installation cost average* $ 30‐00
Total U$D (ex‐works) $233‐00
Fuel system (@ price break 1)
1. Filtek Fuel Canister (FC‐1000) $ 86‐00
2. Filtek Replacement Element (RE‐1000) $ 43‐00
3. Filtek Installation Kit (INT‐009) $ 29‐00
4. Installation cost average* $ 20‐00
Total U$D (ex‐works) $178‐00
*Note: installations generally performed by generator supplier (for new units) or by the
contractor responsible for generator maintenance (existing retrofits)
16. Filtek fitted (maintenance savings)
Superior Filtration Solutions
1) Generator service intervals decrease from 31 (@250hrs)
to 7 (@1,000 hrs) per annum
2) Cost per generator in the first year (Incl Capex cost of canisters)
• $100 +$233 = $333‐00 (Standard service + Filtek installed )
• $100 + $43 (element only) = $143.00 x 6 (balance for yr) = $858‐00
• $333 + $858 = $1,191‐00 total per Generator PA
• 100 * $1,191 = $119,100.00 total cost per annum
• Savings of $190,900.00 PA or 57%
3) Cost per generator for subsequent years (canisters already fitted)
• Subsequent years will require a replacement element only
• $143 x 7 x 100= $100.1000 total cost per annum
• Savings of $209,900.00 PA or 64%
17. Superior Filtration Solutions
Filtek fitted (fuel savings)
• Extensive field trials via the use of high accuracy flow rate meters have
proven a fuel saving of between 7 – 13%
• Due to increased efficiency as a result of cleaner combustion
• The ‘norm’ seems to be the older the generator the greater the saving
• Blocked injectors are no longer a factor
Assumptions:
1. Ave consumption (flow rate) is 4 litres per hour (17‐27KVA)
2. Ave cost for a litre of diesel fuel delivered is $1.35
3. 100 sites x 7,884hrs x 4 litres x $1.35 cost is
$4.257 Million per annum (total fuel cost)
• Filtek Capex cost 100 x 7 x $43 = $30,100.00
• A 7% fuel saving on the above less Filtek Capex costs is
• $267,915.00 total fuel saving per annum
18. Superior Filtration Solutions
Summary
1. Extends service intervals from 250 to 1,000hrs on diesel generators.
2. Fitment will result in >60% savings on annual generator maintenance
costs
3. Return on investment in under 3 months. System hardware purchase
can be secured from Opex savings (budget)
4. Prolonged engine life resulting in huge Capex savings
5. Does NOT void OEM warranty
6. Significant Fuel savings can be achieved
7. Drop Box options available. One stop kit for a complete service
8. Savings can be shared with contractors to ensure services are
completed at the correct intervals
9. 75% less waste oil disposed into the environment
20. Superior Filtration Solutions
Way Forward
If so desired, Filtek could provide:
1. A trial within your region
2. Full technical support including installation manuals etc
Client to provide:
1. Dedicated technical staff member for the project
2. Flow rate meters if a fuel saving trial is required
THANK YOU FOR YOUR TIME
WWW.FILTEK.CO