The ORBITRON 3000 Electrostatic Oil Purification System Orlando Utilities Commission BETA Test and Lab Results December 13 th, 2016

Transcription

1 The ORBITRON 3000 Electrostatic Oil Purification System Orlando Utilities Commission BETA Test and Lab Results December 13 th, 2016 ABSTRACT It is well known that contamination in oil is always harmful to hydraulic and lubricating systems. Contaminants inevitably exist in the oils of hydraulic and lubrication systems and cause tribological problems. In order to prevent such tribological problems due to contaminants, various oil cleaners have been developed and applied to hydraulic and lubricating systems. They have greatly contributed to improving the reliability of the systems. Since sophisticated hydraulic systems with proportional valves or servo valves, which are more sensitive to oil contamination, became popular, fine filters like 3 micron or 1 micron have seen increased use. However, contamination problems have been revived. The authors have investigated the causes of hydraulic and lubricating problems and found that polymerized oil oxidation products were as harmful as solid particles. They are of molecular size and cannot be removed by mechanical filtration. The authors have developed electrostatic oil cleaners, which can remove not only micron sized particulate contaminants but also polymerized oil oxidation products. This paper discusses the principle of electrostatic oil cleaning technology and demonstrates it s increased level of performance. A BETA test was performed at the Orlando Utilities Commission, Stanton Energy Facility, Steam Plant # 2. The tests were conducted from October 5 th, 2016 through October 13 th, 2016 on a 2,000-gallon reservoir of contaminated turbine oil, Diamond Class # 32. A static reservoir was chosen for the test, since an active reservoir if being continually contaminated by the operating turbine would make it impossible to get an accurate Before and After test result. This is because the ORBITRON Electrostatic technology would be perpetually attempting to remove new contaminants as well as any that were contained in the original dormant reservoir. The intent of the test was to determine if the technology and equipment could dramatically improve the ISO codes and related cleanliness of the contaminated turbine oil. INTRODUCTION Hydraulic systems generate large forces with relatively small particles and are excellent for handling heavy objects with accurate control. However, contaminants in oils cause

2 continual problems for and with hydraulic systems. The majority of users of hydraulic systems are industrial. Oil cleaning is a subordinate item to them. The management is not interested in oil cleanliness but care about uptime and reliability of the hydraulic systems. They pay attention to oil cleaning only when hydraulic systems are in trouble. In the past, contamination control specialists have paid most attention to particulate contaminants of micron size and little attention to polymerized oil oxidation products, submicron size. In order to prevent hydraulic problems due to oil contamination, almost all hydraulic systems incorporate mechanical, or membrane, filters in the main stream of oil, either at the pressure side or at the return side. However, hydraulic problems due to oil contamination still exist. Modern hydraulic systems are used for motion control that requires accurate and precise motions. Such systems use servo valves and proportional valves, which are very sensitive to contamination of oils. Therefore, use of fine by-pass mechanical filters has been recommended in addition to the in-line filters. However, contamination problems not only still exist, but they are also increasing by using fine filters. The authors have investigated the causes of hydraulic problems and found that polymerized oil oxidation products play a large part in these hydraulic issues. The authors also have found that mechanical filters generate static electricity when oil passes through filter media. This static electricity accumulates in either a filter or in the oil and causes spark discharges and accelerates oil oxidation. As the temperature of a spark discharge is high, (in the range of several thousand to over 10,000 C.) oils will deteriorate because of these high temperatures and this oil deterioration leads to hydraulic system failures. The management, who is responsible for past, current and future investment, deplores downtime of production machinery, as their capability is evaluated by the Return on Assets (ROA) ratio. In order to comply with such requirements placed on plant management, we have developed an advanced technology for protecting the assets. This paper discusses the ORBITRON 3000 electrostatic oil filtration system and the technology of electrostatic oil purification, employing the use of static electricity. *1 Orbitron 3000 Install & Beta Test - Orlando Utilities Commission Stanton Energy Center - Steam Plant #2 Orlando, Florida October 5th thru 13th, 2016 Orbitron International, LLC. was granted permission by the Orlando Utilities Commission (OUC), Stanton Energy Center, Steam Plant #2, to conduct a BETA test on their static 2,000-gallon reservoir from October 5th thru October 13th, 2016, an 8-day trial. The Reservoir: Each time OUC determines, from independent lab tests, that the turbine oil is either deficient in additives or does not meet the required ISO level of cleanliness, they remove 10% of the lubricant and replace it with new, in this case Diamond Class 32. The 10% withdrawn is stored in a 10,000 gallon holding tank, currently filled to 2,000 gallons. Therefore, the holding tank had a combination of lubricant oils withdrawn from various turbines over a number of years. Some of it was 5 years old, some 10 years old and some was 20 years old. This formed the perfect platform to fully test the

3 ORBITRON 3000 s electrostatic oil filtration parameters as the reservoir contained a mixture of lubricant ages and all of it was contaminated from significant use. The Environment and Conditions: The ORBITRON 3000 was transported to OUC by Orbitron International, LLC. technicians on October 5th, It was a 90-degree day and Hurricane Matthew was predicted to hit the East coast of Florida by the following day. Unpacking the ORBITRON 3000: The ORBITRON 3000 weighs 300 pounds with dimensions of 2 0 X 3 0 X 4 0 and is packaged and sealed in a sturdy wooden crate measuring 4 0 X 4 0 X 5 0, weighing in total, approximately 500 lbs. Upon arrival, the crate was forklifted off the transport by OUC engineers. The crate was then disassembled by Orbitron International, LLC. staff and the unit moved into position next to the holding tank. The unit has a recommended clearance of 2 ft. The apparatus was fully inspected to insure it sustained no damage during transport and was prepared for install. Initial Test Run and Midpoint Check: The ORBITRON 3000 had a 1¼ Quick Connect mechanism off either end of two 1 diameter 30 0 hydraulic hoses. One end of the first hose was connected to the port labeled "Intake of the ORBITRON 3000 and the other end was connected to the holding tank. Then one end of the second hose, was connected to the port labeled "Output" and the other end secured into a stand alone flushing container. At this point the apparatus was filled with turbine oil, flushed and emptied into the stand alone container to insure no contaminants were introduced into the holding tank. Finally, the end of the second hose, formerly in the stand alone container, was then connected to the holding tank, completing the loop. The ORBITRON 3000 is powered by a 110-volt 60-Hz US standard outlet. Once the machine was installed, powered up and readied, the pump was turned on to fill the filter cylinder with turbine oil. This took approximately 10 minutes. Air was bled out of the tank while it filled via a hand operated valve at the top of the filter cylinder. Once completely filled, the valve was turned off and the ORBITRON 3000 was ready to begin its initial setup. The computer touch screen, which is located on the front of the unit, prompts the operator through each step. These steps were followed as presented by the Orbitron Quick Start 1. This is the welcome screen that tells you your machine's model number and software version. 2. Select Electrostatic Filtration mode. Maintenance Mode is for ORBITRON CO. technicians only. 3. Remove the V-band clamp from the tank lid, remove the lid, rotate filter counterclockwise to unscrew filter from high voltage feed. Reinstall tank lid, V-band clamp, and open all ball valves.

4 4. The system is now being flush Select Electrostatic Filtration mode. Maintenance Mode is for ORBITRON CO. technicians only. 5. The system is now being flushed with oil. This process takes 10 minutes. 6. Click next to begin draining the tank. 7. The tank is now draining. Open valve on tank lid. This will take 2 minutes. 8. Remove v-band clamp, remove lid, re-install filter. Click next when complete and leave valve OPEN. 9. The tank is now refilling itself. Make sure the tank lid vent valve is open to allow air to escape. 10. The high voltage system is now charging. This process takes 5 minutes. 11. Startup is now complete. Initial Test Run and Midpoint Check: The Orbitron International, LLC. technicians met with OUC Plant Engineers and confirmed that the apparatus was properly installed and operating according to plan. To avoid the oncoming storm, the Orbitron personnel then left the Stanton Energy Center, and returned to the Tampa area. The power plant went into emergency mode, as is customary during hurricanes, but did take regular samples from the ORBITRON 3000 s sampling port, as was previously agreed. The Orbitron International, LLC. technicians returned to OUC on Monday, October 10th, to meet with the plant engineers, check on the operations of the machine, insure the storm had not affected the apparatus or test procedures and retrieve the samples taken to date. The ORBITRON 3000 was operating perfectly, unaffected by the storm, and the technicians left once again. Completing the Test, Pack-Up & Transport: The Orbitron International, LLC. technicians returned to OUC on Thursday October 13th, as previously agreed, to conclude the test, pack-up and transport the ORBITRON 3000 back to the manufacturing facility outside of Tampa, Florida. Upon arrival the machine was inspected for operational integrity, the engineering staff was alerted and the apparatus was taken off line, drained, disconnected from the holding tank and re-

5 crated. OUC staff loaded the ORBITRON 3000 on the transport and provided the technicians with the remaining samples that had been taken since the previous Monday. The Orbitron International, LLC. technicians conducted an exit survey with the plant s engineering staff and received high marks for cleanliness, efficiency, achieving operational expectations and disassembly and removal. Jeff Starlin, The Steam Plant # 2 Chief Engineer, reported that he was pleased with the test and anxious to learn of the lab results from the samples taken during the test. The ORBITRON 3000 was transported back to the shop and the samples shipped to both the University of Louisiana, Petrochemical Department and to R&G Independent Testing Lab for analysis and testing to determine the overall effectiveness of the BETA test with the ORBITRON 3000 on the static reservoir. SUMMARY: Test Results and Conclusion: The test results and associated analysis (see attached) from both the University of Louisiana and R&G Labs surpassed the initial expectations of Orbitron International, LLC. management and staff. The treated oil from the reservoir came back cleaner than the new Diamond Class 32 originally tested to establish a standardized platform from which to measure. In only four (4) days, the midpoint interval, the samples showed dramatic improvement over the initial reservoir samples taken before the ORBITRON 3000 was installed. By the final sample, taken on Thursday October 13th, the entire 2,000-gallon holding tank had an ISO code lower than the new (never used) oil and showed dramatic contaminant reduction by specific metallic category. Please see test results attached hereto. Appendix A University of Louisiana Test Data Report...Pg..6 Appendix B R&G Independent Lab Test Explanation...Pg..12 Appendix C R&G Independent Lab Test...Pg..16 *1 Akira Sasaki and Shinji Uchiyama 2002 A New Technology For Oil Management: Electrostatic Oil Cleaner

6 Appendix A University of Louisiana Test Data Report

7 ORBITRON 3000 TEST DATA REPORT The Energy Institute of Louisiana located on the campus of The University of Louisiana in Lafayette, LA conducted various analysis detailed below. The goal of the testing was to ascertain areas of potential improvement, or detrimental effects to the oil processed through the Orbitron The tests are standard laboratory analysis of metals, and organic chemicals present in the oil. The sample was provided covering the entire oil process. New, unused oil was opaque and light yellow color. The used oil from the turbine process and the oil from the Orbitron filtration unit was the same in color. These samples were also opaque but darker in color as expected from oxidation and exposure to high temperature in normal operations. All oils were tested under the same conditions to allow a comparison of the Orbitron 3000 efficiency. Because of the third party taking and delivering the subject samples, The Energy Institute of Louisiana can only verify the test results obtained. SAMPLE Units Aluminum Chlorene Chromium Copper Iron Magnesium New Oil ppm Used Oil ppm Fully Treated ppm Molybdenurr Niobium Phosphorus Sulphur Stronium Uranium Vandium Tungsten Zinc Zirronium The analysis of the metals by XRD analysis shows a reduction of levels from the used oil at about a 45 to 60% reduction. Some of these metals were not present in the new oil and will only show up during operational conditions. Levels of Sulphur showed the highest PPM concentration and may be formed by breakdown of oil under high pressure conditions. The Oribtron 3000 did remove 45% of the sulfur in the used oil. Aluminum was the only element to show up in the fully treated Oribtron oil and not in the new or used oil. There could be an exposed aluminum metal in the cleaning process that results in this small concentration. All other metals were at very low concentrations. Note: The test utilized to generate the above results is capable of detecting trace amounts of the following elements: Ag, Al, As, Au, Ba, Bi, Ca, Cd, Cl,Co, Cr, Cs, Cu, Fe, Hf, Hg, K, Mg, Mn, Mo, Nb, Ni, P, P, Pd, Rb, Re, S, Sb, Sc, Se, Si, Sn, Sr, Ta, Te, Th, Ti, U, V, W, Zn, Zr

8 ORBITRON 3000 TEST DATA REPORT WATER CONTENT Sample Type Proportion Oil Proportion Water Percent Water New Untreated ORBITRON Treated The water analysis was conducted by a Metter moisture balance using 1 gram of sample. The results show a reduction of 30% in water content from the used oil to the Orbitron processed oil. This process has shown a marked improvement of 7% lower water concentration than current new oil specifications.

9 ORBITRON 3000 TEST DATA REPORT COMPARISON OF ORBITRON FILTERED OIL TO NEW OIL OF SAME TYPE New Oil Orbitron Filtered The new oil (never used) in the process shown in the red trace is a standard hydrocarbon profile from the gas chromatograph coupled to a mass spectrometer. As the used oil from the turbine process was analyzed under the same conditions, it shows a higher degree of response. This is due to the removal of water from the filiter process and thus oil content is higher per mass of oil injected. The used trace does show a shift to the right side of the chromatograph. This indicates that a higher molecular weight content is present in the oil. This presence is normal with wear and heat exposure over time in the turbine process. Value could be added to the filtering techology by adding an engineered process to remove the waxes and higher weight contaminants.

10 ORBITRON 3000 TEST DATA REPORT The plot at the top shows a standard Electron Impact (EI) spectra of a hydrocarbon. This oil sample is a makeup of various molecular weight hydrocarbons and over time will produce more, due to oxidation and wear of the oil. The bottom trace shows new oil in red and a pronounced increase in these hydrocarbons in the used oil.

11 ORBITRON 3000 TEST DATA REPORT COMPARISON TO USED OIL OF PRIOR TO ORBITRON FILTERING Untreated Oil Orbitron Filtered The trace above shows the untreated oil in red and Orbitron treatment in green. The two traces show very little difference in chemical composition and due to removal of water the Orbitron shows a higher amount of oil response. If not for the removal of water, the two traces could almost be super imposed on one another showing no chemical degradation resulting from Orbitron s filtering process.

12 Appendix B R&G Independent Lab Test Explanation

13 INTERNAL ORBITRON INTERNATION, LLC. MATRIX OF BETA TEST RUN, AND RELATED LAB TEST RESULTS, OF THE ORBITRON 3000 APPARATUS AT THE ORLANDO UTILITIES COMMISSION, STANTON ISLAND POWER GENERATION STATION IN ORLANDO, FLORIDA OCTOBER 5 TH THROUGH OCTOBER 13 TH, THIS WAS A 2,000 GALLON STATIC RESERVOIR FROM STEAM PLANT # 2. LAB RESULTS FROM R&G LABS, OF TAMPA, FLORIDA ATTACHED FOR COMPARISON. These are the lab results performed for us by R&G Labs in Tampa, Florida. For the sake of understanding and simplicity, we have cut and pasted the critical information in a logical, sequential and consecutive manner. The full reports are included here with, such that you might verify the information contained herein with the original lab reports. TEST # 1: R and G LABORATORIES Existing OUC Reservoir (Untreated) Severity: (MH) - Moderate High Sample Date 10/5/16 (Collected on the 5 th, sent to lab on the 10 th ) Oil Type: USED DIAMOND CLASS 32 Description: Used Turbine Oil # 2 Steam Boiler ISO Code 4/6/14 um 20/18/16 ADDITIONAL TESTS Karl Fischer H2O ppm 77.7 R and G LABORATORIES New Diamond Class 32 supplied by the plant TEST # 2: Severity: (N) - Normal Sample Date 10/5/16 (Collected on the 5 th, sent to lab on the 10 th ) Oil Type: DIAMOND CLASS 32 Description: NEW DIAMOND CLASS 32 PARTICLE COUNT ISO Code 4/6/14 um 20/18/15 NO WATER PRESENT, SO NO Karl Fischer-H20 ppm tests performed

14 TEST # 3: FIRST TEST RESULTS 12 HOURS R and G LABORATORIES Severity: (N) - Normal Sample Date 10/06/16 (Collected on the 6 th, sent to lab on the 10 th ) Oil Type: DIAMOND CLASS 32 Description: Treated with ORBITRON 3000 for approx. 12 hours PARTICLE COUNT ISO Code 4/6/14 um 18/15/10 ADDITIONAL TESTS Karl Fischer H2O ppm 21.4 TEST # 4: SECOND TEST RESULTS 22.5 HOURS R and G LABORATORIES Severity: (N) - Normal Sample Date 10/06/16 (Collected on the 5 th, sent to lab on the 12 th ) Oil Type: DIAMOND CLASS 32 Description: Treated with ORBITRON 3000 for approx hours PARTICLE COUNT ISO Code 4/6/14 um 18/14/10 ADDITIONAL TESTS Karl Fischer H2O ppm 18.3

15 TEST # 5: THIRD TEST RESULTS 7 DAYS R and G LABORATORIES Severity: Severity: (N) - Normal Sample Date 10/12/16 Collected on the 6 th, sent to lab on the 12th Oil Type: DIAMOND CLASS 32 Description: Treated with ORBITRON 300 for approx. 7 days PARTICLE COUNT ISO Code 4/6/14 um 16/13/10 ADDITIONAL TESTS NO WATER PRESENT, SO NO Karl Fischer-H20 ppm tests performed

16 Appendix C R&G Independent Lab Test

17 Report Issue Date: October 12, 2016 Report Printed Date: October 12, 2016 R and G LABORATORIES Oil Analysis Severity Summary Lab Number N = Normal O = Observe M = Moderate MH = Moderate High S = Severe Name Description Date /8/ HR 10/08/2016 N NEW DIAMOND CLASS 32 10/10/ USED DIAMOND CLASS32 10/10/2016 Severity N MH

18 Report Issue Date: October 12, 2016 Report Printed Date: October 12, 2016 R and G LABORATORIES Oil Analysis Severity Report Lab Number: Name: 10/8/ HR Date: 10/08/2016 Severity: Normal Recommended Action: Continue sampling to track/trend data. Data Interpretation: Based on the results of the analyses performed on this sample the unit and lube appear satisfactory for continued usage. Lab Number: Name: NEW DIAMOND CLASS 32 Date: 10/10/2016 Severity: Normal Recommended Action: Continue sampling to track/trend data. Data Interpretation: Based on the results of the analyses performed on this sample the unit and lube appear satisfactory for continued usage. Lab Number: Name: USED DIAMOND CLASS32 Date: 10/10/2016 Severity: Moderate High Recommended Action: Check for possible sources of water contamination. Data Interpretation: The sample from this unit contained trace water contamination.

19 R and G LABORATORIES Oil Analysis Data Sheet Report Sample ID: 10/8/ HR Manufacturer: Lab Number Sample Date Units 10/08/16 PARTICLE COUNT ISO Code 4/6/14 um Recommended Action: Continue sampling to track/trend data. Data Interpretation: /14/10 Description: Oil Type: Severity: (N) - Normal Based on the results of the analyses performed on this sample the unit and lube appear satisfactory for continued usage. Grade:

20 R and G LABORATORIES Oil Analysis Data Sheet Report Sample ID: NEW DIAMOND CLASS 32 Manufacturer: Lab Number Sample Date Units 10/10/16 PARTICLE COUNT ISO Code 4/6/14 um Recommended Action: Continue sampling to track/trend data. Data Interpretation: /18/15 Description: Oil Type: Severity: (N) - Normal Based on the results of the analyses performed on this sample the unit and lube appear satisfactory for continued usage. Grade:

21 R and G LABORATORIES Oil Analysis Data Sheet Report Sample ID: USED DIAMOND CLASS32 Manufacturer: Lab Number Sample Date Units 10/10/16 PARTICLE COUNT ISO Code 4/6/14 um ADDITIONAL TESTS Karl Fischer H2O Recommended Action: ppm /18/ Check for possible sources of water contamination. Data Interpretation: Description: Oil Type: The sample from this unit contained trace water contamination. Severity: (MH) - Moderate High Grade: