High Purity Oil Maintenance for Steam Turbines
Transcript of High Purity Oil Maintenance for Steam Turbines
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High Purity Oil Maintenance for Steam Turbines Western BLR BAC Meeting Wednesday November 2nd, 2016 River Rock Casino
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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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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
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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
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Our Goal is Exceptional Customer Experience
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Providing Expert Service
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Building Strong Customer Partnerships
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Expert Technical Support
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World Class Research
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Training Course 4x per Year
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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
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• 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
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• 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
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• ASTM Definition:
• “A thin, hard, lustrous, oil-insoluble deposit, composed
primarily of organic residue, and most readily definable
by color intensity’ .
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Varnish causes valve sticking.
Varnish on bore of IGV Valve
from Frame 7FA.
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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
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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
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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
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Cleanup Phase Vs Stability Phase
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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
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ICB ™
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* *
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.
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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)
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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