Oil and Gas

Phosphate Ester Fluid Solutions

Dynafuzz Stainless Fiber Media Element Upgrades

Dynafuzz stainless fiber media element upgrades are impervious to strong acids that can form in phosphate ester fluids and compromise glass media integrity.  Ideal for steam turbine EHC systems that have had problems with media migrations.

Hy-Pro Dynafuzz stainless fiber media element upgrades were developed to solve a steam turbine EHC system problem where glass media fibers were migrating and clogging servo screens.  Strong acids can develop in phosphate ester fluids and compromise media integrity in cases of high acid number and long term exposure.  Once OEM glass media pump discharge and servo pilot filter elements were upgraded to Hy-Pro Dynafuzz elements the problems with clogged servo screens went away.

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ECR™ Electrostatic Contamination Removal Skid

ECR™ electrostatic removes submicron particles created by thermal degradation in hydraulic or lube oil.  Ideal for steam turbine EHC systems with dark fluid.

ECR™ electrostatic contamination removal system captures sub-micron carbon based particles that are the by-product of hydraulic and lube oil thermal degradation. ECR™ uses a high voltage electrostatic field and proprietary collector elements to remove the sub-micron particles.  Typical causes of thermal degradation are pressure induced dieseling and element spark discharge.

ECR™ will return phosphate ester fluid that has turned dark back to its original color in hydraulic or lube oil.  Ideal for steam turbine EHC systems with dark fluid.  Visit the phosphate ester fluid maintenance products page to learn more about the complete solution for years of trouble free EHC system operation and how to extend the life of phosphate ester fluid indefinitely.

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FSA(PE) Fluid Conditioning for Phosphate Ester

Ideal for Maintenance of Steam Turbine EHC Fire Resistant Fluids

• Prevent contamination related variable geometry valve failures, extend useful oil life.
• Remove & maintain Acid Number to < 0.05 with ICB™ element technology.
• Prevent & remove gels & deposit caused by other acid removal technologies (ICB™ technology removes dissolved metals).
• Integrated TMR™ N₂ (Nitrogen generator) prevents airborne water & metal ion ingression, and removes combustible dissolved gasses (prevent micro-dieseling).
• Particulate & insoluble gel / sludge removal with high efficiency on-board filtration.
• Maintain water content below 200 ppm with TMR™ N₂ and minimize acid producing hydrolysis.

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ICB™ Acid Scavenging Elements

ICB™ acid scavenging elements featuring EPT media technology are critical to maintaining low acid number and removing dissolved metals added to fluid by other acid removal technologies that lead to gels & deposits and poor air release properties.

ICB™ (Ion Charge Bonding) acid scavenging elements featuring EPT media technology are critical to maintaining low acid number, avoiding servo valve failure and years of trouble free operation for EHC and other systems utilizing phosphate ester (PE) and POE fluids. Traditional Clay and Alumina based acid remediating medias have low acid scavenging capacity and contribute dissolved metals and ultra-fine particles that lead to the formation of gels and deposits. The metals also cause poor air release properties which leads to thermal degradation from pressure induced dieseling. With over 30 million successful operating hours ICB™ is used to solve million dollar problems in some of the largest fossil fuel power plants in North America, Europe and Asia. Extend useful life and avoid premature fluid replacement and bleed & feed routines by properly maintaining PE fluids with our total solution including ICB™,TMR™, ECR™, and NSD™ (non-spark filter element upgrades).

ICB™ technology is also suitable for PE alternative fluids such as BioSyn, POE, Skydrol, and EcoSafe.

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NSD™ Non Spark Discharge Filter Element Upgrades

Filter element spark discharge is a recognized cause of fluid degradation in hydraulic and lube oil systems creating soluble by-products and sub-micron carbon particles that deplete additives, cause fluid darkening and lead to varnish deposits.  Hy-Pro NSD™ (Non Spark Discharge) elements are the solution.

Filter element spark discharge is a recognized cause of fluid degradation in hydraulic and lube oil systems creating soluble by-products and sub-micron carbon particles that deplete additives, cause fluid darkening and lead to varnish deposits.  Oil formulation changes from Group I base stocks to Group II-III base stock oils has yielded fluids with reduced conductivity characteristics which enhance the effects of element sparking especially during cold start conditions.  Hy-Pro NSD™ (Non Spark Discharge) elements prevent one of the primary causes of thermal fluid degradation and is an important part of varnish deposit formation and phosphate ester fluid maintenance.

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TMR™ Reservoir Headspace Dehydrator

TMR™ introduces air with 150°F dew point suppression into reservoir headspace to maintain water levels < 300 ppm in EHC reservoir phosphate ester (to 1,000 gal / 3,750 liter reservoirs).

TMR™ reservoir headspace dehydrator is a key component of the phosphate ester total contamination solution. TMR™ introduces 150°F dew point suppression air into headspace where the oil releases water to the air to achieve relative humidity equilibrium.  Ideal for EHC phosphate ester reservoirs up to 1000 gallons to maintain a constant water level below 300 ppm.

Water is the major catalyst in the production of acid in phosphate ester fluids commonly used in steam turbine EHC systems and aviation fluid.  Visit our phosphate ester fluid maintenance product page to learn more about our total contamination solution for phosphate ester and polyol ester fluids.

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TMRN2 Active Headspace Dehydrator + Nitrogen Generator

TMR™ N₂ is an active breather system that maintains the air in the head space that continuously introduces clean dry Nitrogen. As the dry N2 transfers through the head space at RH < 1% the oil gives up its water striving to achieve equilibrium with the dry Nitrogen in the head space.

Nitrogen is an inert gas so it will also remove combustible gases (ie CO2, C2H2, CO, C2H4, C2H6, CH4, H2) from the oil to reduce oxidation and fluid breakdown.

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VTK Varnish Potential Test Kits

VTK varnish potential test kits yield Membrane Patch Colorimetric for lube oil varnish potential (MPC ΔE) per ASTM D7843-12.

VTK varnish potential test kits yield Membrane Patch Colorimetric for lube oil varnish potential (MPC ΔE) per ASTM D7843-12.  Use the VTK to identify hydraulic and lube oil reservoirs with a high potential for varnish formation and trend the effectiveness of varnish mitigation efforts on each turbine.

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Phosphate Ester Fluid Solutions (EHC System)

Transforming EHC fluid maintenance in four simple steps.

Despite the excellent lubricating and safety properties of phosphate ester lubricants, many turbine and Electro-Hydraulic Control (EHC) users struggle with their maintenance.

EHC fluid quality related failures and their resulting production losses can be virtually eliminated through EPT’s industry leading fluid maintenance and testing program – the result of over 20 years of specialization in EHC fluid applications. EPT’s 4-part approach is comprehensive in scope, targets common weaknesses, and removes the contamination responsible for servo valve deposits. Our program offers turbine owners and operators a clear path forward to protect their equipment from failure and reduce costs.

Step 1 Oil Analysis for EHC

Standard lab analysis is missing key information necessary to manage EHC fluids.

• Standard testing (ISO4406) only measures particles greater than 4 microns; however, up to 90% of the total solids by weight can be below this range. For proper servo valve operation, particles
• Metals in EHC fluids are not routinely tested for, which is problematic because metals instigate the fluid breakdown pathways that increase the rate of acid production by up to 10 times (or the inverse, reduce fluid life by 10 times). Metals are also involved in the formation of gels and other solid deposits.
• Dissolved contaminants, including fluid break down products, accumulate over time and eventually come out of solution to form deposits on servo valve components. This contamination is not measured in standard testing and frequently impairs servo valve response time, elevating the risk of servo valve malfunction or failure.

EPT offers research-grade laboratory testing that provides a complete picture of your fluid condition.

• Specialized for EHC
• Complementary initial assessment
• Flag problem areas
• Recommend course of action

Download our complimentary ACE™ Oil Assessment form or Prepaid Analysis form.

Complimentary EHC initial assessment or new install monitoring
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Fee-based for continued monitoring, failure investigation/analysis and comprehensive testing
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Step 2 ICB™ Filters for EHC

Existing acid filters do not remove the contamination responsible for servo valve sticking. This contamination accumulates over time and is deposited on valve surfaces because of the localized pressure changes.

EPT’s Ion Charge Bonding (ICB™) filters take filtration to the next level by not only removing acids, but by removing the contamination responsible for failure. ICB™ filters offer unmatched performance that will resolve servo valve problems and, when used as part of our phosphate ester fluid maintenance and testing program, will significantly reduce the risk of production losses.

ICB™ filter products are supported by a team of world-class experts, who are specialists in the maintenance of phosphate ester fluids. With 1000s of global installations to date, many operating for over 20 years, ICB™ filters have achieved over 100 million hours of operating performance history on some of the largest power stations and super-critical applications worldwide.

Key Benefits of ICB™ Filters

• Remove the dissolved breakdown products that are responsible for servo valve failures
• Dramatically increase fluid resistivity values which eliminates a common servo valve failure mode referred to as electro-kinetic-wear or valve erosion
• Unlike conventional products, ICB™ filters do not contribute fine particulate, or add dissolved metals that contribute to increased rates of fluid breakdown
• ICB™ filters are available in standard size cartridges or as part of a complete EHC fluid treatment system (see SVR™)
• Complete stainless steel construction featuring robotic, spiral welding which provides maximum filter integrity adding a new fail-safe in the EHC fluid conditioning system

EPT has tailored the capabilities of ICB™ filters according to the in-service quality of the phosphate ester lubricants (sold under the brand names: Fyrquel®, Fyrquel® EHC, Fyrquel® EHC Plus, Fyrquel® GT, Reolube® TurboFluid 46XC, Reolube® TurboFluid B, Castrol Anvol® 46 XC, Shell Turbo® Fluid DR 46, Mobil Pyrotec® HFD 46, and many others) as follows:

• ICB™ A for phosphate ester maintenance with Acid Numbers
• ICB™ C for phosphate ester restoration with Acid Numbers >0.5 mg KOH/g (contact EPT for additional technical support)

Fyrquel is a registered trademark of ICL, Reolube is a registered trademark of Chemtura, Anvol is a registered trademark of Castrol. Shell Turbo is a trademark of Shell Oil Company. Mobil Pyrotec is a trademark of Exxon Mobil Corporation.

Step 3 TMR™ N₂ System

Most water removal systems use heat, vacuum, and pumps, which are all expensive to operate and maintain, to force the separation of the water from the lubricant.

What is not understood is that in many applications, the primary mode of water ingression is atmosphere itself. When the moisture content of the atmosphere is higher than the moisture content in the lubricant, the atmosphere provides an unlimited source of water.

Using mechanical separation systems in this scenario, simply dehydrates the lubricant to an unsaturated state so that it can absorb more water from atmosphere. This creates an energy intensive cycle that fails to address the primary cause of water ingression.

Total Moisture Removal Nitrogen systems (TMR™ N₂) cost effectively remove all three forms of water (free, emulsified and dissolved) from lubricants and hydraulic fluids through mass transfer, which is a highly effective, non-mechanical process.

Key Benefits of TMR™ N₂ Systems

• High purity, dry, inert N₂ (98%) is generated at the source, providing unlimited capacity to reduce existing moisture
• Will maintain water at very low levels
• Free flowing N₂ is exhausted out the breather element or building exhaust reversing the typical flow configuration and eliminating one of the key ingression points for water and particulate contamination
• Eliminates lubricant contact with oxygen, reducing oxidation and promoting the removal of H₂, CO, C₂H₄, and other harmful breakdown gases
• Normally eliminates the need for expensive vacuum dehydration equipment or disposable filter elements when water ingression rates are low or solely from atmosphere
• Very low maintenance requirements (30 minutes per year)
• Quick return on investment (ROI)
• For applications where N₂ is not appropriate – i.e. confined spaces, TMR™ Air systems, which work in a similar fashion are available

Step 4 ECR™ System

EHC fluids generally darken over time as they accumulate fine particles that are less than 1 micron in size. This contamination is not measured with ISO particle code analyses, nor is it removed via mechanical particulate filters.

Fine particulate contamination accounts for up to 90% of system contamination suggesting that as little as 10% of the EHC particulate contamination is being removed with existing filtration. This type of contamination is harmful in EHC applications as it causes increased air entrainment, accelerating fluid breakdown and leads to a more serious form of breakdown called micro dieseling.

EPT’s Electrostatic Contamination Removal (ECR™) fluid conditioning systems are an essential tool for EHC fluid maintenance. When used as directed and as part of proper fluid maintenance program, ECR™ systems remove up to 90% of particulate contamination below 5 microns, decrease air entrainment, improve fluid color and increase resistivity.

Key Benefits of ECR™ Systems

• Removes the sub-micron particles responsible for fluid darkening
• Reduces total dirt load typically by 75% (by mass) or more
• Protects servo valves from mechanical wear