Capture metal wear particles.
Clean the filter without stopping generation.
During a hydropower gearbox rebuild, Kommunbräu installed an FMF 240/1 filter that captured a surprisingly large quantity of circulating metal debris. Its bypass installation allows the magnetic rods to be cleaned without stopping electricity generation. Continuous capture of ferromagnetic particles helps reduce wear and the risk of failures.
Case Background
Kulmbacher Kommunbräu e.G. uses a nearby watercourse to drive its hydropower installation, generating almost all the brewery’s electricity in an environmentally friendly way.
The Challenge
The gearbox at Kommunbräu’s historic hydropower station had recently been rebuilt following damage. Protecting the new investment from circulating ferromagnetic wear particles was therefore a priority.
The risk is particularly high during the run-in period, when elevated quantities of wear debris may be released into the lubricating fluid. If these particles continue to circulate, they can accelerate wear in gears, bearings and other precision components and increase the risk of expensive unplanned downtime.
The Solution: FRIESS FMF 240/1 Magnetic Filter
Hydropower Generator with a FRIESS FMF 240/1 Magnetic Filter in the Foreground
During the rebuild, a FRIESS FMF 240/1 magnetic filter was installed to capture ferromagnetic wear particles from the system. Removing these particles from the circulating fluid is expected to reduce mechanical wear and the risk of subsequent failures. The filter has a wear-resistant stainless-steel housing and high-strength neodymium permanent magnets. It requires neither filter consumables nor an electrical supply, keeping maintenance and operating costs extremely low. This makes the FMF magnetic filter an excellent fit for the brewery’s sustainable and environmentally responsible operating philosophy. Depending on the selected FMF model, the system can treat up to 500 litres per hour and remove extremely fine ferromagnetic particles from the process fluid. The filter was installed in a bypass line. When the magnetic rods need cleaning, the bypass can be isolated without stopping the hydropower generator, allowing electricity production to continue.Metal-Particle Capture Performance
After installation, the FRIESS magnetic filter captured a surprisingly large quantity of metal particles from the system.
If these particles had continued circulating, they would have accelerated wear in the gearbox and related components. The FMF magnetic-filtration solution provides reliable, long-term control of this contamination.
Advantages
- Reduces wear on mechanical components in the hydropower system
- Reduces failures and unplanned downtime
- Provides a sustainable, long-term solution with no ongoing consumable or energy costs
Project Results
The FMF 240/1 magnetic filter removed a substantial amount of metallic wear debris from the system. The quantity generated during the initial operating phase was far greater than expected and would otherwise have continued circulating through the gearbox.
By continuously capturing ferromagnetic particles, the filter protects the gearbox and associated components and supports reliable long-term operation.
Customer Benefits
✓ Reduced wear on hydropower-generator components
✓ Lower risk of failures and unplanned downtime
✓ No filter consumables and no additional energy consumption
✓ Low operating costs and a sustainable long-term solution
Removes iron, steel and stainless-steel particles from a wide range of process fluids.
Increasing metal wear particles in your hydropower generator's lubricating oil and greater bearing wear risk?
Please share your oil type, reservoir volume, circulation flow rate, ferromagnetic particle concentration and size, current filtration system, target cleanliness and installation space. Our China engineering team can recommend FMF 240/1 magnetic filter specifications, bypass flow rate and maintenance interval for your conditions.