Secure hydraulic system performance. Smart solutions for cooling and cleaning hydraulic oil

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Valerie Hannah Wilkins
5 years ago
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1 Secure hydraulic system performance Smart solutions for cooling and cleaning hydraulic oil

The products and the global support you need How can you ensure that your hydraulic systems achieve their full performance potential in terms of reliability, safety and working lifetime?

2 The products and the global support you need How can you ensure that your hydraulic systems achieve their full performance potential in terms of reliability, safety and working lifetime? Simple invest in Alfa Laval s smart cooling and cleaning solutions. They will secure the performance of your hydraulic systems and provide your end-customers with a level of reliability they have not experienced before. Hydraulics expertise and a broad product range Achieving reliable system performance requires a comprehensive understanding of hydraulics and fluid power. Alfa Laval has the know-how. Hydraulic Power Unit (HPU) with a compact copper brazed oil cooler In many hydraulic systems it is necessary to remove some surplus energy. The most efficient way to do this, in terms of space versus efficiency, is to cool the oil with an oil cooler of the plate heat exchanger type. For cleaning the hydraulic oil Alfa Laval has solutions for all needs. Highly efficient, Alfa Laval separators remove water and particles down to one micron that can cause hydraulic system failure. Alfa Laval has a broad portfolio of oil coolers designed to maintain safe fluid operating temperatures and protect the components in your systems. Compact and cost-effective, they deliver solid performance and make a major contribution to system reliability. Prompt delivery Alfa Laval delivers what you need, when you need it straight from the warehouse. Our regional distribution centres and wide network of distributors and service partners ensure fast, cost-effective delivery worldwide. Most standard products ship within days of order receipt. Sizing made easy with AlfaSelect When designing a modern hydraulic system it is essential to select the right oil cooler in terms of effect in relation to size, and to utilize the entire specified pressure drop. AlfaSelect sizing software makes it simple to select the Alfa Laval oil cooler that matches your specifications. Total sevice commitment Alfa Laval s global customer support network comprises more than 100 sales offices, 50 service centres and hundreds of field engineers. 2 Cooling and cleaning solutions for hydraulic oil Rapid response Contact us and you will receive a fast, professional response to all types of inquiries, and comprehensive support for sizing, installing and servicing both Alfa Laval equipment and other brands.

Brazed heat exchangers (BHE) High thermal efficiency Extremely compact design One-third of the size/weight of comparable shell-and-tube units Low pressure drop over the oil inlet and outlet Range

Pick the oil cooling solution that matches your needs A lot of cooling in a small package Looking for high cooling efficiency in a compact design?

3 Brazed heat exchangers (BHE) High thermal efficiency Extremely compact design One-third of the size/weight of comparable shell-and-tube units Low pressure drop over the oil inlet and outlet Range includes DOC BHE specifically designed for hydraulic conditions. Pick the oil cooling solution that matches your needs A lot of cooling in a small package Looking for high cooling efficiency in a compact design? Look no further Alfa Laval copper brazed heat exchangers offer unparalleled efficiency for hydraulic oil cooling. oil cooler is the ideal choice for in-line installation on the return side. Copper brazed heat exchangers are only one-third of the size and weight of comparable shell-and-tube heat exchangers and use one-third less water major advantages that will enable you to optimize the design of your systems. Dedicated oil coolers Alfa Laval s basic range of brazed heat exchangers includes the DOC BHE series of dedicated oil coolers. These models are specifically adapted to hydraulic conditions and have a convenient solution for pipe connection and fastening that reduces installation costs. Type of connection versus installation cost 4 Installation costs Efficient cooling provided by a correctly sized, space-saving installation helps ensure a wellfunctioning hydraulic system. Our products can handle all hydraulic fluids from regular hydraulic oils to synthetic oils and emulsions. Whatever your needs we have the solution. Standard BHE 3 HEX DOC Purchase cost 4 Purchase cost versus type of brazed heat exchanger. Connections adapted for hydraulics. On a medium size Hydraulic Power Unit (HPU), a compact copper brazed type Brazed heat exchangers, BHE - Stainless steel - Outstanding cooling efficiency, cost efficient - Smooth plate surfaces and highly turbulent liquid flow reduce the risk of particle build-up or deposits - Rugged, with compact design for easy installation BHE HEX Oil Cooler - Hexagonal connections with inner threads - Cost efficient, standard component - Easy to install: rugged connection, internal threading BHE DOC Dedicated Oil Coolers All the benefits of BHEs plus - Extra sturdy construction that can withstand the toughest operating conditions - Low pressure drop over the connections - Reliable operation under continuous high pressure and high temperature - Highly rugged connection, with internal threading Applications: Suitable for most hydraulic systems for cooling capacities ranging from 10 up to 360 kw. Applications: Suitable for most hydraulic systems for cooling capacities ranging from 10 up to 360 kw. Applications: Suitable for most hydraulic systems for cooling capacities ranging from 10 up to 360 kw. Cooling and cleaning solutions for hydraulic oil 3

Alfa Laval oil coolers Reliable, easy to clean, less downtime Compact, smaller footprint Clean installation, easy to maintain Easy to connect, lower installation costs High thermal efficiency Rugged

Maybe seawater or poor quality water is used for cooling, which could affect the heat exchanger. Or the working conditions involve aggressive media and high temperatures and pressures.

Where copper is unacceptable While our copper brazed heat exchangers have major advantages, with some qualities of cooling water, copper is simply not an option. No problem.

4 Alfa Laval oil coolers Reliable, easy to clean, less downtime Compact, smaller footprint Clean installation, easy to maintain Easy to connect, lower installation costs High thermal efficiency Rugged designs. Whatever the working conditions What are your needs? Perhaps copper is not acceptable in the hydraulic cooling system. Maybe seawater or poor quality water is used for cooling, which could affect the heat exchanger. Or the working conditions involve aggressive media and high temperatures and pressures. Whatever the conditions, Alfa Laval has oil coolers to match them. Where copper is unacceptable While our copper brazed heat exchangers have major advantages, with some qualities of cooling water, copper is simply not an option. No problem. We offer a range of compact, all-stainless steel heat exchangers that are corrosion resistant, resistant to pressure fatigue and highly thermally efficient. We call them AlfaNova. AlfaFusion technology patented by AlfaLaval offers high mechanical strength and corrosion. 4 Cooling and cleaning solutions for hydraulic oil No risk of corrosion AlfaNova heat exchangers are impervious to acidity, alkalinity or hard water. Unlike coolers with copper components, they are not at risk for corrosion caused by elevated levels of chloride and sulphate in the cooling water. With stainless steel there is no release of metal ions that contaminate or colour the water, no bi-metallic corrosion downstream, and the galvanic effects of combining different metals are eliminated. Resistance to pressure fatigue Since AlfaNova heat exchangers have outstanding resistance to pressure fatigue, they can withstand variations in flow or pressure much better than other types of oil coolers. Where cooling water quality is low Is the available cooling water likely to contain contaminants that can cause fouling or scaling of the heat exchanger plates? We have a broad portfolio of gasketed plate heat exchanger models, PHEs, that can be opened and cleaned quickly and easily. They can also be cleaned without opening by in-line chemical cleaning using the Alfa Laval CIP system shown on the facing page. Compact, modular design Gasketed PHEs provide full flexibility to meet the demands of any oil cooling duty. In larger HPU systems they can be installed off-line in the cooling circuit. The Alfa Laval PHE: Gasketed corrugated plates are compressed in a rigid frame to create an arrangement of parallel flow channels. Compact and modular in design, they weigh less, cost less to install and occupy up to 50% less space than comparable shell-and-tube units. For applications with aggressive media, such as seawater, Alfa Laval can supply PHEs with plates in corrosion-resistant materials. Where the going gets tough For heavy duty use in industrial applications Alfa Laval offers brazed shell-and-tube heat exchangers. These units are designed for use with contaminated cooling water where fouling is a risk factor or for seawater applications where there is a risk of corrosion. Brazed shell-and-tube heat exchangers are high-efficiency oil coolers that will contribute to long, maintenance-free life-times for hydraulic power pack cooling systems.

Whatever the application Hydraulic systems for car manufacturing, plastic moulding, wind power, pulp and paper, steel mills and other industrial or offshore situations Standard hydraulic power packs

Fusion-bonded heat exchanger, AlfaNova - 100% stainless steel, produced by AlfaFusion, a patented fusion-bonding process - High thermal efficiency - Corrosion resistant - Outstanding resistance to

corrosive. Alfa Nova is the right choice where copper is not acceptable.

C for seawater and other corrosive media Applications: Gasketed oil coolers for bigger HPUs (Hydraulic Power Units) with big flow and low pressure drop demands.

Enter your capacity and performance specifications and let AlfaSelect choose the right oil cooling solution to optimize the performance of your hydraulic system. Request a copy of AlfaSelect.

5 Whatever the application Hydraulic systems for car manufacturing, plastic moulding, wind power, pulp and paper, steel mills and other industrial or offshore situations Standard hydraulic power packs Lube oil heating, cooling and cleaning. There s an Alfa Laval oil cooler for the job! Fusion-bonded heat exchanger, AlfaNova - 100% stainless steel, produced by AlfaFusion, a patented fusion-bonding process - High thermal efficiency - Corrosion resistant - Outstanding resistance to pressure fatigue - Resistant to copper corrosion - Easy to install Applications: AlfaNova is an efficient solution for industrial hydraulic oil cooling, where the cooling media and/or the oil is corrosive. Alfa Nova is the right choice where copper is not acceptable. Plate heat exchangers, PHEs - Compact modular design - High cooling capacity - Easy to open and clean - Flexible, tailor capacity to your needs, easy to extend - Plates in titanium, SMO and Hastelloy C for seawater and other corrosive media Applications: Gasketed oil coolers for bigger HPUs (Hydraulic Power Units) with big flow and low pressure drop demands. Also suitable for seawater cooling with titanium plates. AlfaSelect sizing software The AlfaSelect software program helps you select the Alfa Laval oil coolers that match your specifications. Enter your capacity and performance specifications and let AlfaSelect choose the right oil cooling solution to optimize the performance of your hydraulic system. Request a copy of AlfaSelect. If you need further assistance, just call your local Alfa Laval office. One of our design engineers can help you determine the right solution for your needs. Brazed shell-and-tube heat exchangers Alfa Laval Shell & Tube series BAS. - Can withstand high flow rates with low pressure drop - Easily customized - For nominal pressure up to 25 bar - For seawater cooling Applications: Small and mid-size HPU hydraulic oil cooling, industrial and offshore, ships and harbor equipment, e.i cranes winches. Also suitable for seawater cooling with CuNi tubes and have the option for brass bonnets. Alfa Laval cleaning-in-place unit The Alfa Laval Cleaning-in-Place (CIP) system makes cleaning oil coolers easy, convenient and cost-effective. Cleaning in place improves performance by effectively removing scale and bacterial growth that reduce heat transfer. No dismantling is required. Cooling and cleaning solutions for hydraulic oil 5

Invest in an Alfa Laval oil cleaning system High system reliability, reduced wear Less clogging and corrosion Decreased oil consumption Reduced oil replacement and disposal costs Reduced costs for

Take system reliability to a whole new level Almost all system failures can be attributed to water or solid particles found in hydraulic oil.

6 Invest in an Alfa Laval oil cleaning system High system reliability, reduced wear Less clogging and corrosion Decreased oil consumption Reduced oil replacement and disposal costs Reduced costs for filter cartridges Payback time is often less than one year! Take system reliability to a whole new level Almost all system failures can be attributed to water or solid particles found in hydraulic oil. Efficient cleaning of the oil makes a major contribution to the reliability of sensitive hydraulic systems, while saving money on oil consumption, filter cartridges and used oil disposal costs. Based on high-speed separators, Alfa Laval oil cleaning modules effectively remove particles down to one micron and water from hydraulic and lubricating oils. A level of reliability that other technologies cannot match Alfa Laval mobile and stationary oil cleaning modules are based on centrifugal separation. This technology offers such a high level of cleaning that it will raise the reliability of your hydraulic system to a whole new level. Breakdowns due to solid particles that clog pumps, sensitive valves and other equipment will be things of the past. Also, since the separator removes 100% of all free water, corrosion in the system is avoided. It adds up to longer production runs without unscheduled production stops and longer system lifetime. Decreased oil consumption Cleaning using an Alfa Laval cleaning module also prolongs the service lifetime of oil, thereby reducing oil consumption. Water in the oil causes additives to oxidize and decompose, reducing the lifetime of the oil. Removing the water will drastically increase the lifetime of your oil. Reduced disposal costs An Alfa Laval oil cleaning module reduces costs for the disposal of used filter cartridges and used oil. By effectively removing particles from the oil, the unit prolongs the intervals between filter replacement. Effective particle removal also increases the service lifetime of the oil, thus reducing the need to replace used oil. Three main module types The Alfa Laval range of oil cleaning modules includes: Emmie mobile systems, OCM Oil Cleaning Modules, and Flex Oil Cleaning Modules. All three types are easy to install and operate, and offer short payback times. Cleaning capacities for hydraulic oil and lubrication oil for the steel and paper industries Tank size > 50 m3 OCM 206 OCM 305 > 30 m3 OCM 304 > 20 m3 OCM 104 > 15 m3 > 10 m3 OCM litres per hour 6 Cooling and cleaning solutions for hydraulic oil

For tanks of all sizes Alfa Laval has high-speed separator based cleaning systems for hydraulic oil tank sizes of up to 50 m³.

Emmie 2 mobile oil cleaning unit - The most compact oil cleaning unit for the removal of particles and water - Removes 100% of the free water - Removes more than

Lightweight, compact, easy to use, simple to maintain - Voltage 100 to 230 V, single-phase OCM oil cleaning module - Stationary high speed separator module

equipment is in operation - Removes 100% of the free water - Removes more than 99% of all particles between 2 and 5 μm - No supervision required Flex oil cleaning

builder, user or Alfa Laval - Patented discharge system improves separation efficiency and reduces metal-on-metal wear Applications: For cleaning mineral

7 For tanks of all sizes Alfa Laval has high-speed separator based cleaning systems for hydraulic oil tank sizes of up to 50 m³. All remove particles in accordance with ISO cleanliness code 13/11/8. Emmie 2 mobile oil cleaning unit - The most compact oil cleaning unit for the removal of particles and water - Removes 100% of the free water - Removes more than 99% of all particles between 2 and 5 μm - Mobile unit that can be wheeled from tank to tank - Easy connection, hook up and switch on - No supervision required - Lightweight, compact, easy to use, simple to maintain - Voltage 100 to 230 V, single-phase OCM oil cleaning module - Stationary high speed separator module suitable for larger systems - Modular, fully integrated oil cleaning system preconfigured on a skid - Designed for continuous cleaning while the hydraulic equipment is in operation - Removes 100% of the free water - Removes more than 99% of all particles between 2 and 5 μm - No supervision required Flex oil cleaning modules - Supplied as a single separator with ancillaries, or as up to a four separator modules to serve several hydraulic systems - Can be assembled by system builder, user or Alfa Laval - Patented discharge system improves separation efficiency and reduces metal-on-metal wear Applications: For cleaning mineral hydraulic oil and lubricating oil in tank sizes up to 2 m³. Applications: For cleaning mineral hydraulic oil and lubricating oil in tank sizes up to 50 m³. Applications: Flexible high speed separator modules that can be designed and expanded to suit the operation. Cooling and cleaning solutions for hydraulic oil 7

8 Alfa Laval in brief Alfa Laval is a leading global provider of specialized products and engineering solutions. Our equipment, systems and services are dedicated to helping customers to optimize the performance of their processes. Time and time again. We help our customers to heat, cool, separate and transport products such as oil, water, chemicals, beverages, foodstuff, starch and pharmaceuticals. Our worldwide organization works closely with customers in almost 100 countries to help them stay ahead. How to contact Alfa Laval Up-to-date Alfa Laval contact details for all countries are always available on our website at EFU00125EN 1104

Mastering the elements

100% Stainless Steel Mastering the elements AlfaNova Fusion-brazed plate heat exchangers AlfaNova Extreme elements extreme technology From the extreme heat of our brazing process comes AlfaNova, the world