Fuel Tank Wash System
Company Name: Permoid Industries Ltd
Location: Newton Aycliffe, UK
Eclipse Product Installed: FiltraMag+ FM2.5
Industry: Automotive Components
Process Type: Fuel Tank Wash System
Permoid Industries Ltd produces several hundred diesel fuel and hydraulic tanks for Caterpillar earth moving vehicles each year to precise and demanding specifications. During the finishing process fuel tanks are inserted into a sealed flushing rig where wash solution is sprayed at pressure via rotating nozzles to both the interior and exterior of the tank. Water collects in a holding tank and is then pumped out to spray the next tank in the sequence. The water is at 60°C (140F) and pumped at approximately 4 to 6 bar (58 to 87 PSI)pressure. Before returning to the holding tank the wash solution passes through a paper barrier filter to remove contamination.
The paper filters only removed particles down to 5 micron size, this meant that smaller particles continued to be re-circulated in the process. The ferrous particles caused damage to the product surface and caused a build of ferrous debris within the tanks. As a result a high proportion of tanks failed the demanding inspection process. Permoid were issued an ultimatum from Caterpillar - to solve the problem or cease being a supplier. In addition to the quality problems there were operational problems such as barrier filters were being changed on a 4 weekly basis and pumps were failing prematurely due to damage from ferrous particles.
FiltraMag+ FM2.5 units were fitted, one in the flow circuit prior to the re-circulating pump and one on the drain back to the holding tank. Since fitting FiltraMag+ the ferrous contamination has greatly reduced to a point whereby finished product reject rates are virtually zero. Barrier filters remain fitted but only have to be changed every 10 months. An additional benefit is that the pump life was greatly improved as metal particles were no longer able to damage the pump internals.
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