Case Study 8 | Intrinsically Safe Oil Filtration

OS200 Air Lubemaster for High Explosive Zones

The QNI Hydrogen Plant needed an oil filtration solution that could operate safely inside a high explosive zone.

The site experienced severe contamination problems in its high-capacity hydrogen compressors. Oil analysis results regularly exceeded acceptable contamination limits. As a result, contamination threatened compressor reliability and increased maintenance costs.

To solve the problem, Clean Oil Services developed a Lubemaster oil cleaning system that met intrinsic safety requirements.

Air-Driven Oil Cleaning Solution

Clean Oil Services supplied the OS200 Air Lubemaster to meet all site requirements.

The OS200 operates completely without electricity. Instead, compressed air powers both the centrifuge and the vacuum system. Therefore, the unit removes the need for hazardous area-rated electrical equipment.

In addition, operators can move the portable system easily between compressors without interrupting production.

Immediate Improvement in Oil Cleanliness

The OS200 Air Lubemaster produced strong results almost immediately after commissioning.

Within two days, the system removed very large volumes of contamination from the compressor oil systems. At the same time, oil analysis results showed rapid improvements in cleanliness levels.

Oil consumption also decreased dramatically once filtration commenced. Consequently, cleaner oil improved lubrication performance and reduced contamination-related wear inside the compressors..

Customer Feedback from QNI Maintenance Newsletter

A QNI company newsletter distributed to Fixed Plant Maintenance staff in March 2007 highlighted the success of the project:

“Several months ago, an issue was raised regarding oil contamination in the Gas Plant Syngas Compressors.  Oil changes were done annually and this required a shutdown period with obvious production impacts.  Even after the oil changes, oil contamination levels still remained high – potentially reducing the compressors mechanical life.  To address this contamination, an innovative centrifugal oil cleaner was installed.  This has successfully been used to filter the oil from a Syngas Compressor.

The cleaner is interchangeable between both Syngas compressors, portable, and can be installed without interruptions to operations.  It is manufactured locally, and is the first of it’s kind to be made with an air driven motor, which removes the need for any hazardous area rated electrical equipment.  Thanks to our staff and Bob Smith from Clean Oil Services, who was instrumental in making the project a success.”

Benefits of Intrinsically Safe Oil Filtration

Using the OS200 Air Lubemaster provides several important operational benefits:

• Operates safely in explosive environments
• Removes heavy oil contamination
• Improves oil cleanliness levels
• Reduces oil consumption
• Extends compressor oil life
• Supports equipment reliability
• Reduces shutdown requirements
• Eliminates the need for electrical equipment in hazardous zones

Oil Cleaning Solutions for Hazardous Areas

The OS200 Air Lubemaster suits hazardous and explosive environments where traditional electrically powered equipment cannot operate safely.

By combining air-driven operation with high-efficiency oil filtration and centrifuge technology, the system delivers safe and effective oil cleaning for compressors, lubrication systems and industrial equipment operating in critical process environments.