2. Superior Filtration Solutions
•The challenges faced by Mobile Operators worldwide
to reduce Operational Expenditure is well documented.
•This is especially so in certain African operations where
cell site power via Diesel Generators is a huge
additional expense.
•Despite several alternatives and new
innovations, Diesel Generators (DG’s) still offer the
lowest cost per KW hour generated.
•The downside of course with DG’s is maintenance
costs, longevity, fuel consumption and delivery thereof
etc.
3. • 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.
Superior Filtration Solutions
4. “Phenomenal results can
therefore be achieved in both
Capex savings (prolonged engine
life) and Opex savings (reduced
maintenance costs ) if one where
able to keep engine oil cleaner
for longer”.
Superior Filtration Solutions
5. The Filtek Solution comprises:-
1. Oil canister connected in by-pass mode to
the generator.
2. Fuel Canister connected in-line (either before
or after the fuel pump)
3. 1mircon filter elements (same for both oil
and fuel)
4. Optional – auto-oil dispenser to maintain oil
sump levels on older DG’s
Superior Filtration Solutions
6. Oil Filter (OC-1000)
• The filter does NOT replace the current OEM
oil filter but rather compliments it (by-pass
mode)
Superior Filtration Solutions
‘contaminated’ engine oil @ high pressure)
‘clean’ engine oil returned to sump @low pressure
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
12. • Understanding a micron (1,000th of a mm)
Superior Filtration Solutions
Human hair – 70 to 90micron
Pollen - 40micron
Dust particle – 4micron
Smoke particle 2.5micron
ONE Micron or 0.001mm
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
19. Superior Filtration Solutions
Commitment to all our customers
With our system fitted, Filtek Industries will
prove (via independent third party oil
analysis) that generator oil at 1,000 hours
will be of a higher quality or standard than at
250 hours without.
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
