Filtek Industries Product Offering Presentation Superior Filtration Solutions.

Filtek Industries Product Offering Presentation

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.

• 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.


“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”.


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


Oil Filter (OC-1000)• The filter does NOT replace the current OEM oil

filter but rather compliments it (by-pass mode)


‘contaminated’ engine oil @ high pressure)

‘clean’ engine oil returned to sump @low pressure

• Oil Filter (cont.)


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.

• Fuel Filter


Fuel from bulk or day tank with water trap

‘clean’ fuel to engine (installed before or after fuel pump)

Filter Elements


• 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

Filtek Auto-Oil Dispenser (FAD)


• 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

Why can the normal OEM filter not run for 1,000hrs?


• 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

• Understanding a micron (1,000th of a mm)


Human hair – 70 to 90micron

Pollen - 40micron

Dust particle – 4micron

Smoke particle 2.5micron

ONE Micron or 0.001mm

Technical product questions?


How are the Oil savings achieved/calculated?


Assumptions:1. Cost of a 250hr service for a 17-27KVA DG is $100-002. The average duty cycle of all generators is 90% which will equal 365days x 24hrs = 8,760 * 90% = 7,884 run hours PER ANNUM3. Generator service interval @ 250hrs, 7884/250 = 31.54 services PA4. Average sump capacity is 10 litres5. $100 x 31 = $3,100-00 total annual service cost per Generator6. 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


Oil system (@ price break 1)1. Filtek Oil Canister (OC-1000) $108-002. Filtek Replacement Element (RE-1000) $ 43-003. Filtek Installation Kit (INT-008) $ 52-004. Installation cost average* $ 30-00

Total U$D (ex-works) $233-00

Fuel system (@ price break 1)5. Filtek Fuel Canister (FC-1000) $ 86-006. Filtek Replacement Element (RE-1000) $ 43-007. Filtek Installation Kit (INT-009) $ 29-008. 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)

Filtek fitted (maintenance savings)


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%


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 $1.353. 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


Summary

1. Extends service intervals from 250 to 1,000hrs on diesel generators.2. Fitment will result in >60% savings on annual generator maintenance

costs3. 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 savings5. Does NOT void OEM warranty6. Significant Fuel savings can be achieved7. Drop Box options available. One stop kit for a complete service8. Savings can be shared with contractors to ensure services are

completed at the correct intervals9. 75% less waste oil disposed into the environment


Commitment to all our customersWith 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.


Way Forward

If so desired, Filtek could provide:1. A trial within your region2. Full technical support including installation manuals etc

Client to provide:3. Dedicated technical staff member for the project4. Flow rate meters if a fuel saving trial is required

THANK YOU FOR YOUR TIMEWWW.FILTEK.CO

Date post:	23-Dec-2015
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Filtek Industries Product Offering Presentation Superior Filtration Solutions.

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