For further details or to order
Telephone: +44 (0) 1926 623 170
or visit: www.magnom.com
© Fluid Conditioning Systems Ltd. All rights reserved.
The information in this leaflet is for guidance only and is not binding.
f l u i d c o n d i t i o n i n g s y s t e m s
REMOVING THE BARRIERS
TO FLUID CLEANLINESS
INDUSTRIAL GEARBOX
PROTECTION
Magnom™ - The Process
The Magnom™ has wide flow channels that allow
the process fluid to pass with minimal pressure drop.
As the fluid flows through the Magnom’s™ field effect
areas, ferrous contaminants are drawn into special collection
zones. These zones hold significantly more contaminant than
a conventional filter - without obstructing fluid flow or risking
“wash-off”. Therefore, the Magnom™ can operate for very
long periods without service (4 years in some power stations)
and - when contaminants need to be removed - is easily
cleaned and re-used.
Large Scale Industrial Gearboxes
some typical applications
(where conventional filtration is limited due to pressure drop)
Coal fired power stations on coal crushing
transmissions
Sugar mills on pulp press, diffuser tower and other
transmissions
Cement plants on kiln transmissions, coal crushing
transmissions and cement pulverising transmissions
Aluminium plants on roller transmissions
(Contaminated Magnom core
after only 6 weeks operation –
Bridgnorth Aluminium Hot
Rolling Mill Transmission)
Rubber manufacturing plants on mixing and
calendaring transmissions
Pharmaceutical manufacturers on mixing and drying
kiln transmissions
Paper, pulp and plasterboard plants on roller and
mixer transmissions
Mining and mineral extraction large scale
transmissions (crushing, grinding, milling)
For case studies relevant to your own application please contact:
The Magnom™, as used in Formula 1 gearboxes,
is a revolutionary product in advanced fluid
conditioning. Using field effect technology, the
Magnom™ reduces operating costs and
simultaneously benefits the environment.
Through its unique patented design, the Magnom™ removes
contaminant particles of less than one micron from a variety
of fluids. This includes the smallest and most abrasive
particles that are responsible for the destructive chain
reaction of wear in many processes, including gears.
Unlike conventional fluid conditioning components,
the Magnom™ produces minimal pressure drop in the fluid.
It has no moving parts and is 100% scaleable.
It also functions in a diverse range of fluid pressures,
temperatures and flow rates.
The Magnom™ is easily installed in a wide variety of
applications - either as part of new systems or as a
replacement to enhance existing processes.
The Benefits
Power Station Application Cement Industry Application
f l u i d c o n d i t i o n i n g s y s t e m s
Rugby Cement at Barrington (UK) employ a conventional rotary
kiln. The kiln utilises a girth gear transmission drive with an
open lubrication system with synthetic lube oil, Mobilgear SHC
3200, spray fed directly onto the gears.
Routine fluid analysis evidenced serious contamination
indicating significant wear to the pump and gear teeth. The
lubrication system had clearly been accumulating and
recirculating damaging debris for a significant period of time
leading to a chain reaction of wear and very likely failure of the
system in the next month.
To alleviate this problem a two inch nominal bore Magnom™
‘Process Unit’ was fitted on the suction side of the
system pump, this being possible due to the negligible
pressure drop characteristic of this non barrier
magnetic device and the system’s effect
was monitored.
After one week’s operation the Magnom™ core was removed
for inspection and was found to be laden with 4 kg of
contaminant. Subsequent analysis showed this to be both
ferrous and non-ferrous with a significant number of large
(5mm+) ferrous particles assumed to
originate from the gear teeth. The unit was
cleaned and returned to operation.
Periodic inspection and cleaning showed a
continuous improvement in system
cleanliness, this has subsequently been
maintained and the gearbox has continued
to operate.
Magnom™ has been successfully employed in diverse stages of
Cement production:
Cement kiln drive Cement mill drive
Coal pulverising mill Slurry pump protection
Hydrostatic conveyor drive
The environmental award winning and
cleanable Magnom™ delivers the following
advantages when used in lubrication
circuits to protect industrial gearboxes:
FAST PAY BACK
(in some cases less than 1 month)
by
reduced transmission failures
(typically £50K refurbishment cost)
increased plant uptime
(major cost benefit!!)
extended lubricant life
(typically three times)
reduced/eliminated filter spares
by
removing the most damaging
wear elements
(from less than a micron up to over 1cm)
without incurring a significant pressure drop
(even in lubricant up to 12,000 CSt)
without contaminant wash-off
and with
cleaning intervals of up to four years
(the Magnom™ is sized to coincide with plant
maintenance intervals)
Didcot A, the 2040MW coal fired power station operated by
Innogy Plc, recently embarked on a project to improve the
reliability of coal pulverising gearboxes (these had been prone
to failure at a rate of four per annum). The company looked at
introducing additional filtration to the system, this was
considered to be particularly challenging due to the high
viscosity of the synthetic lube
oil in use (ISO VG320 and 460).
A Magnom™ Process Unit
was installed, importantly no
discernible pressure drop was
recorded across the unit, this
was subsequently maintained.
More significantly, the
resulting improvement in oil
cleanliness was truly dramatic with a reduction in ferrous
contaminant (450 ppm down to far less than 50 ppm very
quickly) and additional reductions in Aluminium, Silicon,
Copper and Soot levels.
Following this dramatic success, Innogy carried out a
planned schedule to integrate Magnom™ into all 32 coal
mill gearboxes on site. The benefits of extended oil life and
reduced consumption, coupled with exceptional dirt
holding capacity, means that routine maintenance has been
reduced to a minimum, with the units requiring cleaning
every three to four years only, well within the schedule for
routine outages. Innogy has not experienced a single failure
in a Magnom™ gearbox.
No Magnom™ equipped gearboxes have failed since
installation.
Kidney loops available
subject to application
Magnom™ Process Unit
Assembly
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