Active Reservoir Vent. Fluid Users

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Teresa James
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1 Active Reservoir Vent Fluid Users

2 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? Is your operation in a high humidity environment? Do you operate around wash water, spray down maintenance, or marine and off-shore environments? 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 isn t changed until it is too late?

In Reservoir h 2 o h 2 o h 2 o h 2 o Oil Out Humid Air Marine

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

4 Oil Humidification When Not Protected Air around reservoir controlled at 90 o F & 80% RH 80 ive Hum midity (% %) Oil Relat Time (Hours)

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

NASA/STLE Bearing Life Factors for Water Life (% ) earing ative B Rel 120 100 80

200 400 600 Water Content in Oil (ppm) Study Oil Saturates at 500 ppm Sa

6 NASA/STLE Bearing Life Factors for Water Life (% ) earing ative B Rel Rela ative Bearing Life (%) Dissolved Water Water Content in Oil (ppm) Study Oil Saturates at 500 ppm Sa aturation Free Water Water Content in Oil (ppm) Study Oil Saturates at 500 ppm

7 ARV 4 Dry Air Purging System Incoming compressed air 2. Ultrafilter Ultrapac Heatless Regenerative Dryer 3. Customer s Reservoir 4. T.R.A.P. Outlet Vent Kit

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

9 Ultrapac 2000 How it makes dry air continuously 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. 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 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.

10 ARV How it Works Humid Air Saturated Oil Purging Humid Air Saturated Oil Dry Air Moisture Desorbing from Oil Dry Air Dry Oil Time

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

12 ARV Performance F) Turned on Heater & Mixer Oil Oil Temperature Temperature Headspace Air Temperature Tempera ature (deg Added Water Turned on Ultrapac Headspace Air Relative Humidity 6:00 7:12 8:24 9:36 10:48 12:00 13:12 14:24 15:36 Time (Hour:Minute) RH (%)

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

14 ARV Performance Humidity (%) Head Space Ai ir Relative Reservoir Head Space Air Oil Perce ent Satura ation (%) 80 Reservoir Oil Exchanges/hour Time (Hours) Time (Hours)

15 Case 1: Hydraulic Press

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

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

18 60 Dry Air ON Dry Air OFF Dry Air ON /16 6/26 7/6 7/16 7/26 8/5 8/15 8/25 9/4 Head Space Air Relative Humidity (%) and Oil Moisture Content (% Saturation)

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

20 Case 2: Bulk Fuel Storage

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

22 Bulk Fuel Storage: Head Space Air 2 cfm 1 cfm

23 Bulk Fuel Storage ontent n) Moisture Co % Saturatio Fuel M (% Fuel Moisture Content (% Saturat ion) Top Surface Water Content Versus Time /14 10/24 11/3 11/13 11/23 12/3 12/13 12/23 1/ Average Water Content Versus Time 10/14 10/24 11/3 11/13 11/23 12/3 12/13 12/23 1/2

24 Bulk Fuel Storage Summary Avg Head Space Air Relative Humidity (%) Avg Fuel Moisture Content (% Saturation) Tank with Breather Only Tank with Dry Air Blanket 92% with 9% frequent saturation 65% 50%

25 Case 3: Paper Machine Crown Roll Press

26 Crown Roll Press Details Crown Roll Press Reservoir 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. 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 Oil temperature & water saturation

27 Crown Roll Press Installation Flow Meter Pressure Swing Adsorption Dryer Pressure Regulator

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

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

30 Payback Model: ARV vs Desiccant $10,000 Cumulative Dry Air Cost T otal Ope rating C ost $5,000 $- ARV-3 Desiccant every month Desiccant every 2 weeks Desiccant every week year 1 year 2 year 3 year 4 year 5

31 ARV Ordering Order two parts 1. ARV Vent Kit ARV -3 & ARV -10 Active Reservoir Vent Installation and Operation Manual 2. ARV System: Ultrapac &M Manual (Ultrapac set up for 70 psi)

32 ARV Ordering ARV Vent Kit*: P Std 3cfm Unit (2700 gal reservoir) Ultrapac & Manual: P Std 10cfm Unit (9000 gal reservoir) Ultrapac & Manual: P Up to 60cfm (54000 gal reservoir) * ARV Vent Kit for flows up to 10 cfm and includes: TRAP, p, 0.5psi Pressure Relief Valve, 1 NPT Tee, and 1 Nipple

33 ARV Sizing Simplified Q = ARV Flow (ft 3 /min) E = Exchange Rate Per Hour (usually target between 2 and 10) V hs = Head Space Volume If V hs is unknown, assume 25% of reservoir volume. V hs V hs V hs (ft 3 ) (gallons) (liters) Q EV EV hs Q hs Q EV hs

34 System Sizing Air Exchange Rate Air Exchange Rate, E, is the number of times the air in the head space is flushed per hour. Where Q = ARV Flow Rate Vhs= Head Space Volume Static Oil Volume: <3/hour E Variable i Oil Volume: >5/hour Q V hs

35 ARV Sizing Examples Example 1 E = 10: High moisture environment, variable oil volume V headspace = 67 ft 3 Use10cfmunit 60 Example 2 10(67) Q 11. 1cfm E = 2: Normal moisture, static oil volume V reservoir = 2000 gallons Therefore, assume reservoir is 75% full or 25% head space: V hs = 0.25(2000) = 500 gallons Use 3 cfm unit 2(500) Q 2. 2cfm If in doubt, call your Donaldson District Manager

36 ARV Applications Hydraulic y System Reservoirs Gearboxes Lube System Reservoirs Small Storage Tanks Divide Flow to Protect Multiple Reservoirs

37 ARV Installation

38 ARV Maintenance Description Recommended Change Interval Part Number T.R.A.P. breather 6 Months P Ultrapac 2000 Carepack (prefilter 1 Year ARV-3: P element, afterfilter element, desiccant cartridges, set of seals) for Ultrapac adsorption dryer. ARV-10: P *SeeUltrapac 2000 Operation Manual for detailed description of replacement procedure. * See Ultrapac 2000 Operation Manual for additional replacement components if required.

39 ARV Advantages ARV Membrane Dryers Air Dryness 1% Up to 30% Air Humidity Range Durability Constant 1% Rugged molecular sieve Difficult to damage Varies with inlet air Fragile membrane 1 hole defeats membrane Maintenance Annual change of sieve Cannot be fouled Can t be maintained. Must be replaced Easily fouled

40 Questions?

Active Dry Air Venting for Water Contamination Control

Active Dry Air Venting for Water Contamination Control . PO Box 1299 Minneapolis, MN 5544 USA Industrial Hydraulics 1-8-846-1846 grphydfilters@donaldson.com Active Dry Air Venting for Contamination Control While required for biological life, water can be extremely