Filtration
Systems
SmartFilter
Outdoor, weatherproof, pad-mountable enclosure, also suitable for indoor installation. 2-inch NPT On-board, integrated digital controller, UL508 Inlet, outlet ball-type shutoff valves Check valve Pressure/vacuum gauges Pressure transducers, flow switches, water detector Circulation pump, GPM and HP as per Model Section Filtration elements: Strainer, 100 mesh Pre-filter, 10 micron Final filter, 2 micron Water coalescer Water separator, 5 PPM OVERVIEW Filtration, maintenance system for fuel oil in bulk, long-term storage For permanent, on-site installation, indoor or outdoor Comprehensive system: pump, filter and water removal elements, controller Fully automated 5-50 GPM 2 micron final filtration 5 PPM water removal Single or multiple tank Sales Bulletin |
Intelligent automation
and operator interface is the hallmark of the Simplex SmartFilter.
Each SmartFilter is packaged with a Simplex designed and manufactured
digital controller. This UL508 listed and labeled industrial
control panel features PLC-based digital control and touch-panel
operator interface. The controller provides full automatic operation
of the system and is operator field programmable to set filtration
cycle duration, time of day, day of week operation. Manual override
capability is included. The controller monitors flow, differential
pressure across each filtration element and water level in the
separator collection vessel. Filtration cycle and filter element
maintenance history logs are provided. Operational alarms and
alarm logs are likewise generated. The controller is MODBUS or
Ethernet network compatible for integration with remote Building
Automation Systems or generator control switchgear. The controller
is expandable for multi-tank operation and valve control.
As is typical of Simplex Products, including Simplex Day Tanks,
Packaged Pump Sets and Tank Filling Systems, options are plentiful
and flexible, including:
• Water retention tank
• Automatic water drain to retention tank
• Fuel additive tank and injection pump, with full automation
• Multi-tank filtration
• Multi-tank crossfeed
• Outdoor and stainless-steel construction
• Hazardous environment, explosion-proof construction
• Marine or severe duty construction
SmartFilter
The Simplex SmartFilter Series
comprises a standard, engineered-design family of fuel oil filtration,
conditioning and maintenance systems. These systems are intended
for use with fuel oil held in bulk, long-term storage, including
underground and aboveground main supply tanks, large generator
sub-base tanks and large day tanks. Typical tank capacities are
in excess of 5000 gallons, with 10,000-20,000 gallon or larger
tanks being common. The SmartFilter system provides typical 8-hour
filtration rates to cycle 25%- 33% of tank capacity on a weekly
basis. Principal uses of the SmartFilter are with fuel tanks
dedicated to diesel or turbine engine generator sets or with
oil-fired boiler or process heat systems.
The SmartFilter Series is especially relevant and timely
when considering the stringent fuel quality requirements of modern
industrial engines where fuel quality impacts engine performance,
reliability and emissions. Many studies have indicated poor fuel
quality as a major cause of dispatch failure of standby power
systems. Fuel in long-term storage is subject to degradation
from bacteria, fungi, yeast, mold and algae. Ironically, fuel
oil is a favorable medium for the growth of these microorganisms.
Given water and a source of oxygen, microbes “feed”
on the constituents of fuel, namely carbon, nitrogen, phosphorous,
sulfur and other trace minerals. Persistent water contamination
of fuel oil will allow for the proliferation of these microbes.
Not only is the chemical makeup of the fuel being attacked, these
microbes deposit contaminants which can clog engine filters,
or worse, injectors. Unscheduled downtime is the result.
Where does this water originate? Uncertain quality of fuel deliveries
is one source. However, simple atmospheric condensation and the
resultant accumulation of water in a vented tank certainly represents
the source of long-term and persistent water in fuel.
Particulate contamination is a significant source of fuel oil
degradation as well and can occur in long-term storage due to
tank corrosion or from contaminants accumulating over the course
of many deliveries.
The
SmartFilter is today’s answer to pressing fuel quality concerns:
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Keep in mind a simple fact. There are 8760 hours in a year. A typical standby generator set may run less than 300 hours a year. During the remaining 8500 hours of engine “quiet-time”, microbes and corrosion continue their work of degrading fuel. The SmartFilter attacks and corrects these sources of fuel degradation. The SmartFilter thus becomes a critical element in the chain of reliability of standby power systems.
The SmartFilter combines several elements to form a comprehensive, integrated, automated system:
• Multi-stage, progressive particulate filtration and water removal
• Integrated, high-performance pump
• Flow control and monitoring devices
• Digital, user-programmable controller
The SmartFilter uses a progressive filtration and conditioning regime:
1. Coarse straining through 100 mesh washable screens
2. Pre-filtration through 10 micron disposable media filter
3. Final filtration through 2 micron disposable media filter
4. Water coalescing to 5 PPM
5. Water separation and collection
Fuel circulation and transfer is accomplished via an on-board, high-performance, cast-iron, positive-displacement gear pump direct-driven via an industrial, heavy-duty motor. The pump combines high vacuum prime maintenance with linear flow versus pressure performance. An integral pressure relief valve is included. Drive motors are NEMA class industrial type, conservatively applied and include ball-bearings, class H insulation and continuous duty ratings.
The SmartFilter system includes shutoff ball valves, check valves, flow switches, pressure and differential pressure gauges, and differential pressure sensors across each filtration element. Single or multi-tank valving is available.
SF-010: Water holding tank, 10 gallon, with float switch, integration to controller, vent, drain hand pump, shutoff valves. Manual drain of separator canister. Note: hazardous waste. SF-015: Automatic drain of separator canister to holding tank. Includes integration with controller, electric valves, water differential level sensors, alarms. SF-030: Injection tank and pump for automatic or manual injection of fuel additives. 5-gallon. SF-040: Magnetic fuel conditioner SF-100: Multi-tank controller operation and valving. Multi-tank crossfeed capability. |
SIZING A FILTRATION SYSTEM
Sizing a Filtration System
Most fuel contaminants will settle from still fuel resulting
in a stratification of fuel with contaminants concentrated in
the lower strata. Therefore, it is necessary to circulate and
filter the lower 25-33% of the tank contents. When the Smart-Filter
is properly installed, fuel will be drawn from the bottom of
the tank and returned with minimal disturbance of the settled
strata resulting in good filtration performance and removal of
contaminants and water.
It is recommended to size the SmartFilter
to circulate and filter 25-33% of the tank capacity in a nominal
8-hour run period, once each week.
20,000 gallon tank example:
• 25% of 20,000g = 5000g to circulate and filter in an 8-hour
period
• 5000g/8 hours = 625 GPH or 10.4 GPM
• Use the Simplex SF-10 SmartFilter
• For the same tank filtering 33%, or 6600 gallons, run
the SF-10 for 11 hours or specify the SF-20 and run for 5 hours
There is no absolute rule. If it is desired
to filter greater than 33%, or even 100% of the tank, simply
specify a larger SmartFilter or run the filtration system longer.
These are continuous duty devices. The only limit to run time
is filter condition, which is constantly monitored by the SmartFilter
controller.
STANDARD MODELS
TIME - HRS |
TIME - HRS |
IN. NPT |
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230/460-3-60V, 2.8/1.4A |
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230/460-3-60V, 3.6/1.8A |
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230/460-3-60V, 4.8/2.4A |
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230/460-3-60V, 5.8/2.9A |
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230/460-3-60V, 8.4/4.2A |
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230/460-3-60V, 8.4/4.2A |
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TANK SIZE GALLONS: Single Tank Capacity in Multiple Aggregate Capacity |
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CONTROLLER
Engineer’s Specifications for SmartFilter
Click here
for a text file of these specifications.
1.1 Provide a standard, factory packaged design fuel oil filtration and conditioning system to maintain quality of fuel held in extended storage. The filtration system shall include all specified and necessary components required to effect the specified function and comply with applicable codes, rules and regulations.
1.1.2 The filtration system shall be the standard product of a single manufacturer and be in serial production. Custom, job-fabricated products shall not be acceptable.
1.1.3 The filtration system shall be network compatible with other elements of the fuel supply system and network compatible with the building automation system where applicable.
1.1.4 The filtration system shall consist of the following principle elements, which are described in detail in subsequent paragraphs:
1.1.4.1 Full steel enclosure with containment for indoor or outdoor installation
1.1.4.2 Three-stage filtration and water removal elements
1.1.4.3 Transfer pump
1.1.4.4 Valves and sensors
1.1.4.5 Controller
1.2 Submittals
1.2.1 Comprehensive drawings, descriptive and data shall include:
1.2.1.1 Detailed dimensional drawings
1.2.1.2 Field pipe fitting details
1.2.1.3 Field electrical connection details
1.2.1.4 Filtration and water removal performance data
1.2.1.5 Details of installation clearance, ventilation requirements
1.2.1.6 Warnings, cautions and installation limitations
1.2.1.7 Detailed description of operation
1.2.1.8 One-line piping and electrical drawings
1.3 Spare parts
1.3.1 Include the following field service spare parts
1.3.1.1 Three (3) each particulate filter
1.3.1.2 One (1) each water coalescing elements and gaskets
1.3.1.3 One (1) set replacement fuses
1.4.1 Three-stage filtration
1.4.1.1 Inlet strainer: 100 mesh
1.4.1.2 Pre-filter: 10 micron
1.4.1.3 Final filter: 2 micron
1.4.1.4 Water separation: 5 PPM
1.4.2 Pump performance
1.4.2.1 (Choose one: 600, 900, 1200, 1800, 2400, 3000) gallons-per-hour at 50psi, 32SSU
1.4.3 Power requirements
1.4.3.1 (Choose one: 115-1-60v, 230-1-60v, 230-3-60v, 460-3-60v)
1.4.4 Pipe size: 2-inch NPT
1.4.5 Filtration rate: 6-8 hour nominal filtration cycle once per week.
1.5 Filtration system detail
1.5.1 Enclosure: Provide the filtration system factory packaged within a pad-mountable steel enclosure suitable for indoor or outdoor installation. Enclosure shall have the following attributes:
1.5.1.1 Fabricated steel, monolithic welded construction
1.5.1.2 Enclosure shall be powder-coated for use in an industrial environment
1.5.1.3 Hinged and lockable service access doors, with perimeter rain gutters
1.5.1.4 Leak containment basin integral to enclosure floor, including leak detector
1.5.1.5 Lifting eyes
1.5.1.6 Forklift channels
1.5.1.7 Bolt-down feet
1.5.2 Transfer pump
1.5.2.1 Positive displacement gear pump, cast-iron construction with mechanical shaft seal and integral pressure-relief valve. High-vacuum, prime-maintenance and lift performance.
1.5.2.2 AC direct-drive motor, TEFC construction, 1800 RPM, continuous duty performance, voltage per requirement above. HP as required for 50PSI output at GPH specified
1.5.3 Filtration devices
1.5.3.1 Strainer: Install a simplex basket type strainer on the suction side of the pump. 100-mesh, stainless steel screen, cleanable basket, cast-iron strainer body with NPT screw thread connection. Equipped with pressure differential switch.
1.5.3.2 Pre-filter: disposable micro-glass media, 10 micron, spin-on type. Equipped with pressure differential sensors and gauge
1.5.3.4 Water coalescer and separator: semi-permanent, canister type construction. Equipped with pressure differential sensors and gauge
1.5.4 Valves
1.5.4.1 Main inlet shutoff valve, 2-inch NPT, bronze, ball-type
1.5.4.2 Main outlet shutoff valve, 2-inch NPT, bronze, ball-type
1.5.4.3 Check valve
1.5.5 Controller: The system shall include a UL508 Listed, NEMA enclosed, digital controller with the following features:
1.5.5.1 PLC-based digital controller
1.5.5.2 MODBUS, ETHERNET communications
1.5.5.3 Touch-panel operator interface
1.5.5.4 Time of day, day of week, interval programmable timing
1.5.5.5 Analog-to-digital inputs for:
1.5.5.5.1 Pressure differential across strainer
1.5.5.5.2 Pressure differential across pre-filter
1.5.5.5.3 Pressure differential across coalescer
1.5.5.6 Point-sensing inputs for:
1.5.5.6.1 Flow
1.5.5.6.2 Leak sensing
1.5.5.6.3 Coalescer water detection
1.5.5.7 Display of the following data:
1.5.5.7.1 Pressure differentials as above
1.5.5.7.2 Filtration history
1.5.5.7.3 No flow alarm
1.5.5.7.4 Leak alarm
1.5.5.7.5 Water in coalescer alarm
1.5.5.7.6 Service strainer alarm
1.5.5.7.7 Service pre-filter alarm
1.5.5.7.8 Service coaleser alarm
1.5.5.8 User programmable
1.5.5.8.1 Filtration cycle, as above
1.5.5.8.2 Delivery history
1.5.5.8.3 Fuel quality history
1.5.5.9 User I/O to touch-panel
1.5.5.9.1 System HOA switch
1.5.5.9.2 Alarm reset pushbutton
1.5.5.10 Manufacturer: the filtration and conditioning system shall be a Smart Filter as manufactured by Simplex, Inc., Springfield, Illinois.
