High Purity Oil Maintenance for Steam Turbines

Copyright © EPT 2016, All rights Reserved

High Purity Oil Maintenance for Steam Turbines Western BLR BAC Meeting Wednesday November 2nd, 2016 River Rock Casino


High Purity Oil Maintenance for Steam Turbine

• Brief Introduction to EPT www.cleanoil.com

• Turbine Reliability Issues

• Turbine Oil Testing ACE™

• Oil Degradation

• Contaminants & Removal Solutions

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http://www.cleanoil.com/

Copyright © EPT 2016, All rights Reserved 3

WHEN RESULTS MATTER

EPT is focused on advancing the

science of lubrication filtration

technology.

We’ve specialized for 20 years in turbine applications

where we have developed solutions that prevent lubricant

deposits. We work with some of the largest turbine fleets in

the world achieving unprecedented results and cost

savings.

• 1000 turbines/ compressors

worldwide

• 50 million operating hours

• $100 million proven cost savings

Introduction to EPT


EPT Background- Key Customers

Taichung Fossil Plant, Taiwan

Largest Fossil Power Plant in the World JFK International Airport, New York City, USA

One of the Busiest Airports in the World

TransCanada

1 of the Largest Fleets of Gas Turbines


Our Goal is Exceptional Customer Experience


Providing Expert Service


Building Strong Customer Partnerships


Expert Technical Support

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World Class Research

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Training Course 4x per Year


TURBINE OIL MAINTENANCE

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Challenges for Steam Turbine Oil Maintenance

“the most common turbine reliability issues are bearing and control system failures, which often can be traced back to lubrication-related issues”

They are:

Contamination: Particulate & Water

Water Separation Ability “Loss of demulsibility”

Varnish formation

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What Kills Turbine Bearings ?

Viscosity … Viscosity … Viscosity is critical

Water contaminant reduces lubricity

Should be <200ppm

Particulate contamination results in wear

Oil film thickness are 0.005mm in rolling element bearings

<18/15/12 (ISO4406)

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ACE™ Analysis Comprehensive Evaluation

TAN – Total Acid Number

Metals (ICP)

Water

Demulsibility

ISO Particulate

Patch Weight

MPC - Membrane Patch Colourimetry

Ruler (Additives) Remaining Useful Life

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Example Report

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Oil Degradation

Step 1: Infiltration (Air, Water, Particles)

Step 2: Catalysis (galvanic reactions)

Step 3: Oxidation & hydrolysis

Step 4: Emulsification

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Oxidation

Oxygen

Heat

Metals

Thermal Degradation

Static Discharge

Hot Spots

Micro-dieseling

Hydrolysis (Esters)

Water

Metals

Heat

Lubricant Breakdown Mechanisms


• Attacks all molecules (hydrocarbons, additives, etc.)

• Oxidation is a loss of an electron – Creates a free radical

• Oxidation by-products

– Alcohols, esters, lactones, etc. (all SOLUBLE)

Contaminant Air -> Oxidation


• Hydrogen Induced Corrosion (embrittlement)

• Corrosion (rusting)

• Oxidation

• Additive Depletion

• Oil flow restrictions

• Aeration & Foam

• Impaired Film strength

• Microbial contamination

• Water Washing

Contaminant - Water

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Solubility of Water in Oil

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Water Removal Techniques

• Gravity (Density difference)

• Centrifuge (Free Water)

• Coalescing Filter (Free Water)

• Vacuum Dehydration (Free & Emulsions)

• resin based technology ( SVR – restores demulsibility as breaks emulsion )

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WATER / O2 REMOVAL SOLUTION

NITROGEN BLANKETING

EPT TMR N2™

• Injected into headspace of

flushing reservoir

• No moving parts, no electricity

requirements

• Generates 99% Nitrogen which

eliminates the fluids contact with

O2

• Puts reservoir under slight positive

pressure to prevent contaminant

ingression during flush.

• Removes water

• Reduces/ eliminates CO2, CO,

CH4, C2H2, C2H4, C2H6

Copyright © EPT 2016, All rights Reserved 23 Source: EPT


• ASTM Definition:

• “A thin, hard, lustrous, oil-insoluble deposit, composed

primarily of organic residue, and most readily definable

by color intensity’ .


Varnish causes valve sticking.

Varnish on bore of IGV Valve

from Frame 7FA.


MPC Varnish Potential Test ASTM 7843

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Good Monitor Abnormal Critical

< 15 15 - 25 25 - 35 > 35

4.9 18.6 27.4 46.3


So What Causes Varnish?

• Varnish occurs when the lubricant break-down products (created from Oxidation) accumulate past the point of saturation.

• These oxidation by-products (waste products) are dissolved in the oil until the oil becomes saturated

• When the oil is saturated, these waste products convert to a solid form

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• Mechanical systems have changing temperature and pressure conditions which changes the saturation point of the oil impacting where varnish forms.

• IMPLICATION

– Varnish occurs in hydraulic systems first and not in the reservoir where the filtration systems are set up.

Challenges/ Implications

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Varnish Cycle

• The Varnish Cycle: Particulate Removal vs Soluble Varnish Removal

Varnish Levels

Saturation Point

Step 1: Soluble Varnish

Step 2: Insoluble

Varnish

Step 3: Varnish Deposit

Chemical Change

Physical Change

Physical Change


Reversing Varnish

• Because varnish formation is a physical change of contamination from one form to another (dissolved to solid), the process can be reversed.

• Equilibrium chemistry dictates that if you restore the oils solvency by removing the dissolved waste products you will force varnish deposits back into solution

• STRATEGY

– If you can prevent the oil from getting saturated you can prevent varnish under all operating conditions.

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Varnish Summary

• The starting point of varnish is the accumulation of dissolved oxidation by-products which are created from Oxidation. This occurs in ALL oils.

• Varnish is formed when a lubricant becomes saturated with these dissolved oxidation by-products, with any excess physically changing from the dissolved to solid form.

– Often related to temperature and or pressure changes

• Saturation will eventually occur in all lubricant systems, not a question if, but when.

• Varnish is a reversible process and when the oil is returned to an unsaturated condition, varnish physically changes back into the dissolved form.

– When lubricants are maintained below their saturation point, they cannot form varnish at any pressure or temperature condition in the mechanical system.

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SVR- LUBE OIL PURIFIER

TMR N2 For Water, O2

and Gas

Removal

Particulate Filter

High Efficiency

(99%)

ICB Filter For acid and

varnish pre-cursor

removal


Cleanup Phase Vs Stability Phase


SVR Manage the Variables that Cause Varnish

1. Water Removal, Eliminates catalyst

2. Oxygen Removal, Eliminates catalyst

3. Breakdown products varnish pre-cursor removal

– Prevents accumulation of oxidation by-products so varnish precursors are not present

4. Acid Removal

• Protects mechanical components

• Potential reduction in corrosion inhibitor

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Number of Offerings ”ICB™”

Source: EPT

ICB is a trademark of EPT

Ion Exchange Filters for Dissolved Contamination Removal


ICB ™

36 Source: EPT

* *

NNN R

R

R

R

R

R

* *

NNN R

R

R

R

R

RH

X

HX

ICB media is chemically engineered to be an “acid sponge”. • Media is composed of basic groups supported by a polymer backbone.

• Bases react with acids (HX) removing them from the fluid.

• This reaction forms a chemical bond between N and H producing a positively charged group.

• This new positive charge attracts the negatively charged remaining acid component (X) binding it to the media and removing it from the fluid.


Considerations when replacing oil

• Because all varnish deposits created from a given oil can be dissolved back into that same oil, the easiest way to remove varnish is to use the existing oil.

• IMPLICATIONS

– Cleaning lubricants prior to replacement can avoid the need for flushing

– when changing brands of oil, the varnish from the previous oil may not be able to be removed with the new oil or take a very long time.

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Summary

• Reducing acid levels provides benefits to the mechanical components.

• Removing the accumulation of oxidation by products reduces or eliminates the feedstock necessary to create varnish.

• By controlling the variables to oxidation, and eliminating catalysts, we can better manage oxidation levels and reduce the creation of coking products

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Dedicated Web Page

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http://cleanoil.com/lp/BLRBAC

White Papers

• Water Removal

• Varnish Removal and Prevention

• EHC Fluid Maintenance

Product Information by Application

• SVR/ TMR

Complimentary ACE Assessment

(see next page)

http://cleanoil.com/lp/BLRBAC


Next Steps… Complimentary ACE™ Assessment

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http://cleanoil.com/wp-content/uploads/2016/09/ACE-Oil-Assessment-Sept-2016.pdf













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Thank you

For additional information Please contact:

Claude Gauthier [email protected] Cell: 416-801-1248 Peter Dufresne [email protected] Cell: 403-389-4104

mailto:[email protected]











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High Purity Oil Maintenance for Steam Turbines