Active Reservoir Vent Fluid Users Active Reservoir Vent may be - PDF document

Active Reservoir Vent™ Fluid Users

Active Reservoir Vent™ may be the right solution for you. ● Do you have problems with water in your oil? • Does your oil analysis indicate water contamination? Does your oil analysis indicate water contamination? • Is your operation in a high humidity environment? • Do you operate around wash water, spray down maintenance, or marine and off-shore environments? i t i d ff h i t ? • Do you get regular condensation in your reservoirs? • Are you using a desiccant breather now? - How often do you change your desiccant? - Are you tired of service maintenance / short life with your desiccant? - Are you concerned that your water-saturated desiccant Are you concerned that your water saturated desiccant isn’t changed until it is too late?

How Water Ingresses Into Systems Incoming Humid Air ● Humid Air ● Humid Air h 2 o h 2 o h 2 o h 2 o • Marine h 2 o h 2 o h 2 o h 2 o h 2 o • Pulp&Paper h 2 o h 2 o h 2 o h 2 o • Steam Turbines Oil h 2 o • Hydro Turbines • Hydro Turbines h 2 o 2 Oil In Reservoir Out h 2 o h 2 o ● Rain R i ● Splashing ● Washing ● System Leaks

Oil Humidification When Not Protected Air around reservoir controlled at 90 o F & 80% RH Air around reservoir controlled at 90 o F & 80% RH 80 %) midity (% 70 60 ive Hum 50 50 40 30 30 Oil Relat 20 10 O 0 0 8 16 24 Ti Time (Hours) (H )

Problems With Water ● Dissolved Water  Humidity in the oil ( il (oil remains clear) i l ) • Accelerates Bearing Fatigue • Accelerates Oil Oxidation • Cleaves Ester-Based Synthetics ● Free Water  Bulk (settles to bottom) or Emulsified (fluid is cloudy) or Emulsified (fluid is cloudy) • Corrosion • Loss of Lubricity • Depletes Additives • Microbial Growth

NASA/STLE Bearing Life Factors for Water % ) Life (% 120 120 100 Dissolved Free Water e (%) Water 120 80 80 n aturation earing ative Bearing Life 100 100 80 60 60 40 20 40 40 0 Rela Sa ative B 0 200 400 600 20 Water Content in Oil (ppm) Study Oil Saturates at 500 ppm 0 Rel 0 200 400 600 Water Content in Oil (ppm) (pp ) Study Oil Saturates at 500 ppm

4 ARV ™ Dry Air Purging System System 3 2 1 1. Incoming compressed air 2. Ultrafilter Ultrapac Heatless Regenerative Dryer 3. Customer’s Reservoir 4. T.R.A.P.™ Outlet Vent Kit

Ultrapac 2000 Na 12 [(AlO 2 ) 12 (SiO 2 ) 12 ] x H 2 O - 10 Angstrom Molecular Sieve

Ultrapac 2000 – How it makes dry air continuously i ti l The Ultrapac 2000 is a Pressure Swing Adsorption (PSA) device. Pressure swing adsorption is a technology used to separate some gas species from a mixture of gases under pressure according to the species' molecular characteristics and affinity for an adsorbent material. Pressure swing adsorption processes rely on the fact that under pressure, gases tend to be attracted to solid surfaces, or "adsorbed". The higher the pressure, the more gas is adsorbed; when the pressure is reduced, the gas is released, or desorbed. d b d When air is passed under pressure through the Ultrapac, the Sodium Alumina Silicate column attracts water vapor more strongly than the air. Part or all of the water vapor will stay in the bed, and the air leaving the vessel will be dry. When the bed reaches will stay in the bed, and the air leaving the vessel will be dry. When the bed reaches the end of its capacity to adsorb water vapor, it is regenerated by reducing the pressure, thereby releasing the adsorbed water vapor. It is then ready for another cycle of producing dry air. Using two adsorbent vessels allows near-continuous production of dry air. U i t d b t l ll ti d ti f d i

ARV ™ – How it Works • Humid Air • Purging • Dry Air • Dry Air • Saturated Oil Humid Air • Moisture • Dry Oil • Saturated Oil Desorbing g from Oil Time

ARV ™ Test System Coalescer/Filter, Heatless Compressed Pressure Regulator Regenerative Air Supply Flow & Gauge Dryer Meter Environmental Chamber Environmental Chamber T=90 o F, RH=80% Air Temperature & Humidity Mixer Mixer Breather Head Space Oil Oil Temperature & Humidity Reservoir

ARV™ Performance 140 140 100 100 Oil Temperature 90 90 Oil Temperature Turned on Turned on 120 120 Heater & Mixer 80 80 Headspace Air Temperature Headspace Air Temperature 100 100 70 70 F) F) ature (deg ature (deg 60 60 80 80 RH (%) RH (%) 50 50 Tempera Tempera R R 60 60 40 40 Turned on Ultrapac 30 30 40 40 Added Added 20 20 Water 20 20 10 10 Headspace Air Relative Humidity 0 0 0 0 6:00 6:00 7:12 7:12 8:24 8:24 9:36 9:36 10:48 10:48 12:00 12:00 13:12 13:12 14:24 14:24 15:36 15:36 Time (Hour:Minute) Time (Hour:Minute)

Air Exchange Rate ● Air Exchange Rate, E, is the number of Q E  times the air in the E head space is head space is V flushed per hour. hs ● Where Wh • Q = ARV Flow Rate • V = Head Space Volume • V hs = Head Space Volume

ARV™ Performance 80 80 Reservoir Head Space Air Reservoir Oil (%) 70 70 70 70 Humidity ( ation (%) 60 60 50 50 50 50 ent Satura ir Relative 40 40 2 2 Exchanges/hour 30 30 30 30 Oil Perce d Space Ai 6 20 20 20 6 200 200 20 20 Head 10 10 10 10 200 0 0 0 8 16 24 0.0 8.0 16.0 24.0 Time (Hours) Time (Hours)

Case 1: Hydraulic Press

Hydraulic Press Details ● Press Hydraulic Reservoir • 3000 gallons ISO 46 oil, 100 ft 3 air head space 3000 ll ISO 46 il 100 ft 3 i h d ● Significant air exchange due to large hydraulic cylinders on this system hydraulic cylinders on this system. Humid Humid air ingress. ● History of moisture issues  stalactites ● History of moisture issues  stalactites ● Vacuum dehydrator prior to trial ● 8 ft 3 /min Dry Air Flow for y ~5 Air Exchanges per Hour ● Data Measurement & Logging • Headspace air temperature & relative humidity H d i t t & l ti h idit • Oil temperature & water saturation

Hydraulic Press Installation Breathers Flow Meter Air T & RH Sensor Pressure Swing Adsorption Dryer Oil Saturation Sensor

H Head Spa ace Air R Relative H Humidity (%) and Oil Mo oisture C ontent (% % Satura ation) 10 20 30 40 50 60 0 6/16 6/26 Dry Air ON y 7/6 7/16 7/26 Dry Air OFF y 8/5 8/15 Dry Air ON 8/25 y 9/4

Hydraulic Press Summary Dry Air Blanket Dry Air Blanket ON ON OFF OFF Head Space Air <10% 50% and Rising Relative Humidity (%) Oil Moisture Content <10% 20% and Rising (% Saturation)

Case 2: Bulk Fuel Storage

Bulk Fuel Storage Installation ● Location: Northern Iowa ● Excavation company with history of short fuel filter life. short fuel filter life. ● Tanks cleaned during summer and filter systems added for delivery and filter systems added for delivery and off loading. ● Tank Sizes: 12,000 gallons filled with Tank Si es 12 000 gallons filled ith Off Road Diesel in August, 2009. ● 2 tanks used for test, one had dry air blanket, one just a breather

Bulk Fuel Storage: Head Space Air 2 cfm 1 cfm

Bulk Fuel Storage Top Surface Water Content Versus Time 90 ontent 80 n) Moisture Co 70 70 % Saturatio 60 50 40 40 Fuel M (% 30 20 10/14 10/14 10/24 10/24 11/3 11/3 11/13 11/13 11/23 11/23 12/3 12/3 12/13 12/13 12/23 12/23 1/2 1/2 100 100 Average Water Content Versus Time Content 90 ion) 80 l Moisture C (% Saturat 70 60 50 50 ( Fuel 40 10/14 10/24 11/3 11/13 11/23 12/3 12/13 12/23 1/2

Bulk Fuel Storage Summary Tank with Tank with Breather Breather Dry Air Blanket Dry Air Blanket Only Avg Head Space Air 92% with 9% R l ti Relative Humidity (%) H idit (%) f frequent t saturation Avg Fuel Moisture Content 65% 50% (% Saturation) (% Saturation)

Case 3: Paper Machine Crown Roll Press

Crown Roll Press Details ● Crown Roll Press Reservoir • 500 gallons oil, 23 ft 3 head space 500 gallons oil 23 ft 3 head space • Feeds press roll, gearbox, and some lube points. • Scavenge pump returns oil (and saturated air) from machine. hi • History of moisture problems with foggy oil • Vacuum dehydrator not successful in controlling water ● 4 cfm dry air flow or 10 air exchanges/hour ● Data Logging • Headspace air temperature & relative humidity • Headspace air temperature & relative humidity • Oil temperature & water saturation

Crown Roll Press Installation Fl Flow Meter M t Pressure Swing Pressure Swing Adsorption Dryer P Pressure Regulator R l t

Manifolded vents on Manifolded vents on Machine up and away. Oil Sensor Issues Oil Air Air Air

Crown Roll Press Summary Before Dry Air After Dry Air Blanket Blanket Blanket and Breather and Breather Manifold Installation Head Space Air Saturated air <10% on average, Relative Humidity (%) y ( ) returned to tank by y maximum of 40% scavenge pump Oil Moisture Content 100% Saturated with 42 % on average and (% Saturation) free water. Even still improving vacuum dehydrator not able to keep up!

Payback Model: ARV™ vs Desiccant Cumulative Dry Air Cost $10,000 C ost erating C $5,000 Total O pe ARV-3 Desiccant every month Desiccant every month T Desiccant every 2 weeks Desiccant every week $- $ year 1 year 2 year 3 year 4 year 5