Proactive Strategic Reliability Sdn Bhd provides primary solutions for fluid contamination challenges in the major industries and applications that we served.
Hydraulic & Lube System Filter Element Upgrades.
Hy-Pro DFE rated elements yield cleaner fluid for hydraulic system including HPU pump discharge, return line, servo pilot filters and side loop filtration systems. Prevent servo valve, pump and bearing failures caused by contamination related surface degradation. Applications include:
- URTF & Melt shop DC furnace
- Automatic gauge control
- Roll stand hydraulic system
- Caster & Oscillator hydraulics
- Roll change hydraulics
- Conveyer lube & hydraulics
- Reheat furnace
- Cold roll mill hydraulics
- Hot strip hydraulics
- Extrusion press hydraulics
- Forging
Case Study – Aluminium Refinery Gearbox Oil
The Problem
An Australian aluminum refinery was consistently performing premature gearbox lube oil changes on 7 base drive units due to oil and particulate contamination. With an average operating ISO code of 20/18/16 and average water levels of 4742ppm, the 360 liters / 90 gallons of ISO VG320 gear oil was being changed far too often. Cost per gearbox oil change (excluding crane, lost production, labor) is $17,962.60 which adds up to $125,738.20 for all 7 units.
The Solution
Conditioning gearbox lube oil is a huge opportunity for savings. By removing dirt and water the lube oil can be used until another characteristic of the oil fails (ie viscosity or additive) which can result in exponentially longer fluid life and prevent gearbox failure. To remove the particulate and water from the oil a Hy-Pro V5 vacuum dehydrator was selected to remove all phases of water (free, dissolved, emulsified) and remove particulate with an oversized 3M (β5[c] > 1000) filter element. The V5 was rotated between the 7 top drives on a 2-day service interval rapidly purifying the oil by turning the sump volume 75 times daily.
The Results
On each unit, water was rapidly reduced an average of 98% from 4742ppm to 96ppm. Particulate contamination size 4μ[c] and larger decreased by 95% as average ISO code decreased from 20/18/16 to 15/13/8. The refinery increased reliability and profitability while reducing the environmental impact of premature oil disposal. Oil life has been extended reducing the need for oil changes. Gearbox life should also triple under these conditions leading to even more substantial savings.
What HY-PRO provided:
- DFE Rated G8 Dualglass Filter Elements
- Vacuum Dehydration
Download case study Aluminum Refinery Gearbox Oil
Gearboxes used in the mining industries must be carefully maintained to ensure reliability and expected performance for optimum production output. Gearboxes health is very much dependent on an effective filtration system. Our filtration systems are highly engineered with superior efficiency to reduce maintenance downtime and costs while extending the life of capital equipment.
Break the drain and refill gearbox oil change cycle and improve reliability, extend useful oil life and avoid premature contamination gearbox rebuilds by installing Hy-Pro FSL dedicated off-line filter skids specifically designed for high viscosity lube oils. High flow LF housings are also a good fit for adding high efficiency filtration to existing re-circulation lines on coal mils to control particles and water contamination.
Learn More: FSL, FCL, Water Removal Elements, Coal Pulverizer GearboxFiltration Upgrade Case Study
PM Main Bearing Lube Element Upgrades.
Hy-Pro DFE rated high efficiency glass media element upgrades are field proven to improve single pass ISO Codes through the main bearing filter duplex and also to lower overall paper machine lube system ISO Codes. Hy-Pro manufactures three versions of the PM main bearing lube element depending on the relationship to clean element pressure drop and terminal ΔP alarm on the housings which allow you to maximize and greatly extend element usage.
Learn more: Lube Design Element Media, DFE, Paper Machine Main Lube Element Upgrade, Paper Machine Lubrication Filter Element Upgrade
Lube & Hydraulic Reservoir Water Removal, Reservoir Conditioning. Paper machine lube reservoirs frequently have problems with water in lube oil. Hy-Pro Vac-U-Dry vacuum dehydration systems rapidly remove free and dissolved water to control lube oil water levels to < 30ppm. On-board over-sized particulate filtration allows the application of high efficiency filter elements down to 1 micron absolute to lower overall lube oil reservoir ISO Codes and take pressure off of the main bearing lube duplex filters. Large Vac-U-Dry systems are available to condition large lube oil reservoirs and the V1 Mini Vac-U-Dry is suitable for smaller reservoirs (vacuum pump, super calendar, etc).
Learn more: VUD, V1 Case Study, VUD Steel Mill Lube Oil Case Study
In-Plant Paper Mill & Wood Yard Hydraulic System Filter Element Upgrades. Upgrade hydraulic control filter elements on HPU pump discharge, return, re-circulation and pilot servo valves to Hy-Pro DFE rated elements to improve reliability, lower ISO Codes and reduce hydraulic component repair & replacement (i.e. bailing machine, body dump). Hy-Pro offers the most complete range of element upgrades for sensitive paper mill lube & hydraulic systems.
Learn more: DFE, Cleaner Fluids Extend Bearing & Hydraulic Component Life
Power House Turbines. Hy-Pro has a full complement of solutions for lube & hydraulic contamination challenges in power generation. For more information on turbine related products and strategies please select the turbine type to visit the industry applications for Combustion or Steam turbines
Power Generation- Combustion Turbines, Power Generation- Steam Turbines
Gearbox Filtration. High viscosity industrial gearbox lubricants are typically treated with coarse on-board strainers or not filtration at all since the oil is commonly changed on a drain & refill routine. Hy-Pro’s innovative FSL off-line systems with generously sized filter elements are ideal for conditioning high viscosity lube oil with high efficiency glass media down to 1 micron absolute and also with water removal medias. Save big money by avoiding premature gearbox fluid replacement and rebuilds.
Learn more: FSL, Coal Pulverizer Gearbox Filtration Upgrade Case Study
Boiler Water Feed Pumps. Many BFP systems utilize antiquated coarse (edge wound or mesh) filtration resulting in dirty fluid and higher than acceptable ISO Codes. Upgrade elements and housings to DFN series duplex or MF3 simplex housings featuring DFE rated high efficiency elements for years of reliable performance.
Bulk Fluid Handling. Dedicated filtration and breathers on bulk storage tanks for lube and hydraulic oils and stand-by diesel fuels is the first line of defense in preventing one of the worst sources of particulate and water contamination, new fluids. Bulk storage tanks collect contaminants from delivery vehicles and through ineffective breather arrangements. Eliminate this dangerous source of contamination and before transferring new fluids into critical power plant operating systems. Filter Carts are also a valuable tool for keeping fluids clean when transferred from storage to critical live systems.
Learn more: FSL, FCL, Breathers, VUD, COT, COD
Compressors. Large compressors typically utilize the same turbine oils used in the turbine lube reservoirs and are susceptible to many forms of contamination including varnish, particulate contamination and water contamination. Hy-Pro has a suite of solutions available to improve compressor reliability including DFE rated element upgrades, Water Removal Elements, varnish mitigation and acid removal.
Learn More: DFE, SVR, ICB, Water Removal Elements
Molding Machine Hydraulic Filter Element Upgrades.
Upgrade hydraulic control filter elements on HPU pump discharge, return, re-circulation and pilot servo valves to Hy-Pro DFE rated elements to improve reliability, lower ISO Codes and reduce hydraulic component repair & replacement. Hy-Pro offers the most complete range of element upgrades for sensitive plastic molding machine hydraulic systems.
Learn more: DFE, Cleaner Fluids Extend Bearing & Hydraulic Component Life
Hydraulic Reservoir Water Removal, Reservoir Conditioning. Hydraulic reservoirs on molding machinery are susceptible problems with water in oil from cooler leaks and condensation. Hy-Pro Vac-U-Dry vacuum dehydration systems rapidly remove free and dissolved water to control water levels to < 30ppm. On-board particulate filtration allows the application of high efficiency filter elements down to 1 micron absolute to lower overall ISO Codes and take pressure up to 300 gallons / 1125 liters. Filter Carts can feature two DFE rated Hy-Pro cartridge style elements in series to condition hydraulic fluids with two filter passes with each pass through the filter cart. Media options available down to 1 micron absolute, water removal media and stainless mesh media.
Learn more: V1, V1 Case Study, FC
Fluid Cleanliness in Plastic Injection Molding
Download the Complete Case Study Here
Varnish Prevention & Removal For Plastic Molding Machines. The building blocks of varnish come from oxidation by-products that overcome the solubility of the oil, and thermal degradation from system hot spots, element sparking or pressure induced dieseling (micro-dieseling). AW type hydraulic oils may require a different solution than what has been successful in turbine lube oil. Contact us to learn more about our solution for varnish in AW hydraulic oil.
Bulk Fluid Handling. Dedicated filtration and breathers on bulk storage is the first line of defense in preventing one of the worst sources of particulate and water contamination, new fluids. Bulk storage tanks collect contaminants from delivery vehicles and through ineffective breather arrangements. Eliminate this dangerous source of contamination before transferring new fluids into critical diesel applications. Filter Carts are also a valuable tool for keeping fluids clean when transferred from storage or tote to critical live systems.
Contamination Solutions for Power Generation
Developing a Total System Cleanliness approach to control contamination and care for fluids from arrival to disposal will ultimately result in more reliable plant operation and save money. Several steps to achieve Total Systems Cleanliness include: evaluate and survey all hydraulic and lubrication systems, establish a baseline and target fluid cleanliness for each system, filter all new fluids upon arrival and during transfer, seal all reservoirs and bulk tanks, install high quality particulate and desiccant breathers, enhance air and liquid filtration on existing systems, wherever suitable use portable or permanent off-line filtration to enhance existing filtration, improve bulk oil storage and handling during transfer, remove water and make a commitment to fluid cleanliness.
Hydraulic System Filter Element Upgrades. Hy-Pro DFE rated elements yield cleaner fluid for hydraulic system including HPU pump discharge, return line, servo pilot filters and side loop filtration systems. Prevent servo valve and pump failures caused by contamination related surface degradation. Applications include:
- Melt shop DC furnace
- Automatic gauge control
- Roll stand hydraulic system
- Planetary & ring rolling, cold pilger mill
- Caster & Oscillator
- LMS hydraulics
- Tundish gate
- Roll change hydraulics
- Peel bar hydraulics
- Reheat furnace
- Tandem cold roll mill hydraulics
- Hot strip hydraulics
- Long products & rod finishing hydraulics
- Extrusion press hydraulics
- Forging
- Pipe & tube plant lube & hydraulics
Learn more: DFE, Steel Mill Hydraulic Element & Breather Upgrade Case Study, Oscillator Hydraulic Filter Element Case Study
Steel Mill Oil Lube – Successful Application
Download the Case Study
Lube Oil Water Removal by Vacuum Dehydration. Steel mill roll mill stand and Morgoil lube reservoirs are commonly plagued with high water ingression from leaky back-up bearings leading to high oil consumption and premature fluid replacement due to degradation from high water and particulate contamination. Decanting a mixture of free water and oil from the bottom of lube reservoirs is all in a typical day at many steel mills. The other problem with high water levels in lube oil is the loss of lubricating properties leading to bearing failures that can cost up to $30,000 each excluding downtime. Hy-Pro Vac-U-Dry vacuum dehydrators rapidly remove free and dissolved water to < 30ppm combining heat, vacuum and intuitive design for ease of operation. VUD skids include high efficiency on-board particulate removal filters to achieve more suitable ISO fluid cleanliness codes yielding longer bearing and fluid life. Vac-U-Dry is optimized to perform on lube oil viscosity up to and above 680cTs
Learn more: VUD, VUD Steel Mill Lube Oil Case Study
Gearbox Filtration. Break the drain and refill gearbox oil change cycle and improve reliability, extend useful oil life and avoid premature contamination gearbox rebuilds by installing Hy-Pro FSL dedicated off-line filter skids specifically designed for high viscosity lube oils. High flow LF housings are also a good fit for adding high efficiency filtration to existing re-circulation lines on coal mils to control particles and water contamination.
Learn more: FSL, FCL, Water Removal Elements, Coal Pulverizer Gearbox Filtration Upgrade Case Study
Bulk Fluid Handling. Dedicated filtration and breathers on bulk storage tanks for lube and hydraulic oils and stand-by diesel fuels is the first line of defense in preventing one of the worst sources of particulate and water contamination, new fluids. Bulk storage tanks collect contaminants from delivery vehicles and through ineffective breather arrangements. Eliminate this dangerous source of contamination and before transferring new fluids into critical power plant operating systems. Filter carts are also a valuable tool for keeping fluids clean when transferred from storage to critical live systems.
Learn more: FSL, FCL, Breathers, VUD, COT, COD
Compressors. Large compressors typically utilize the same turbine oils used in the turbine lube reservoirs and are susceptible to many forms of contamination including varnish, particulate contamination and water contamination. Hy-Pro has a suite of solutions available to improve compressor reliability including DFE rated element upgrades, water removal elements, varnish mitigation and acid removal.
Learn More: DFE, SVR™, ICB™, FPL, WaterRemoval Elements
Power House Turbines. Hy-Pro has a full complement of solutions for lube & hydraulic contamination challenges in power generation. For more information on turbine related products and strategies please select the turbine type to visit the industry applications for combustion or steam turbines.
Power Generation- Combustion Turbines, Power Generation- Steam Turbines
Sawmill Distributor Testimonial: “Since the completion date (of Hy-Pro total system cleanliness upgrade) they have had zero pump or servo valve failures. This has related to huge savings on the cost of repairs of servos and pumps and also the loss production caused by the unscheduled downtime due to these failures. He said the best part was when the pump repair vendor stopped in to see him and asked if he had done something wrong as to have had them take their rebuild business to another vendor. Dave told him they had not changed, just were not having anymore failures, which they now realize is because of the work we have done getting them to clean oil.”
In-Plant Sawmill, Wood Yard & Logging Equipment Hydraulic System Filter Element Upgrades. Upgrade hydraulic control filter elements on HPU pump discharge, return, re-circulation and pilot servo valves to Hy-Pro DFE rated elements to improve reliability, lower ISO codes and reduce hydraulic component repair & replacement. Hy-Pro offers the most complete range of element upgrades for sensitive paper mill lube & hydraulic systems. Hydraulic applications include:
- Edger system
- Trimmer & Debarker
- Curve saw hydraulics
- Sorters & Stackers
- Carriage hydraulics
Learn more: DFE, Cleaner Fluids Extend Bearing & Hydraulic Component Life
Lube & Hydraulic Reservoir Water Removal and Conditioning. Hydraulic and lube reservoirs frequently have problems with water in lube oil. Hy-Pro Vac-U-Dry vacuum dehydration systems rapidly remove free and dissolved water to control lube oil water levels to < 30ppm. On-board over-sized particulate filtration allows the application of high efficiency filter elements down to 1 micron absolute to lower overall lube oil reservoir ISO codes and take pressure off of the main bearing lube duplex filters. Large Vac-U-Dry systems are available to condition large lube or bulk oil reservoirs and the V1 mini Vac-U-Dry is ideal for smaller hydraulic reservoirs in-plant or on mobile equipment.
Learn more: VUD, V1 Case Study, VUD Steel Mill Lube Oil Case Study
Power House Turbines. Hy-Pro has a full complement of solutions for lube & hydraulic contamination challenges in power generation. For more information on turbine related products and strategies please select the turbine type to visit the industry applications for combustion or steam turbines
Power Generation- Combustion Turbines, Power Generation- Steam Turbines
Gearbox Filtration. High viscosity industrial gearbox lubricants are typically treated with coarse on-board strainers or not filtration at all since the oil is commonly changed on a drain & refill routine. Hy-Pro’s innovative FSL off-line systems with generously sized filter elements are ideal for conditioning high viscosity lube oil with high efficiency glass media down to 1 micron absolute and also with water removal medias. Save big money by avoiding premature gearbox fluid replacement and rebuilds.
Learn more: FSL, Coal Pulverizer Gearbox Filtration Upgrade Case Study
Bulk Fluid Handling. Dedicated filtration and breathers on bulk storage tanks for lube and hydraulic oils and stand-by diesel fuels is the first line of defense in preventing one of the worst sources of particulate and water contamination, new fluids. Bulk storage tanks collect contaminants from delivery vehicles and through ineffective breather arrangements. Eliminate this dangerous source of contamination and before transferring new fluids into critical power plant operating systems. Filter carts are also a valuable tool for keeping fluids clean when transferred from storage to critical live systems.
Learn more: FSL, FCL, Breathers, VUD, COT, COD
Compressors. Large compressors typically utilize the same turbine oils used in the turbine lube reservoirs and are susceptible to many forms of contamination including varnish, particulate contamination and water contamination. Hy-Pro has a suite of solutions available to improve compressor reliability including DFE rated element upgrades, water removal elements, varnish mitigation and acid removal.
Learn More: DFE, SVR™, ICB™, Water Removal Elements
Thermal Oil Heating & Drying Systems. Thermal oil heating and kiln drying systems operate at high temperatures (~500F) and utilize very expensive specialty fluids. Keeping these fluids clean can double their useful life creating a huge cost avoidance savings. Contact us about specialty thermal oil filtration systems that can condition thermal oils while still hot and in use.
High Efficiency Off-Line Filtration Systems are ideal for achieving and maintaining target fluid cleanliness in bulk oil and fuel storage tanks. FSL skids feature over sized filter assemblies to optimize single pass efficiencies to hit target ISO Codes whether you are re-circulating tank fluid or dispensing. Dedicated filtration and breathers on bulk storage tanks for lube and hydraulic oils and stand-by diesel fuels is the first line of defense in preventing one of the worst sources of particulate and water contamination, new fluids. Bulk storage tanks collect contaminants from delivery vehicles and through ineffective breather arrangements. Eliminate this dangerous source of contamination and before transferring new fluids into critical operating systems. Filter Carts are also a valuable tool for keeping fluids clean when transferred from storage to critical live systems. Customizable designs are available to satisfy any bulk oil contamination challenge.
Learn more: FSL, FCL, Breathers, VUD, COT, COD
Vac-U-Dry Vacuum Dehydration Oil Purifiers. Reclaimed fluids from sumps or contaminated fluids removed from service can be restored to useable condition by removing particulate and water contamination. Hy-Pro Vacuum Dehydrators rapidly remove free and dissolved water to < 10ppm while on-board high efficiency filtration elements featuring media down to 1 micron absolute rapidly reduce ISO Codes. Vacuum Dehydrator flow rates available up to 60 gpm / 225 lpm and viscosity range up to 680 cSt. Water sensor reporting in percent saturation and optional on-board particle monitor let you know when the fluid is dry and clean. For oils only needing particulate removal Hy-Pro Filter Carts for hydraulic or lube viscosity grade oils can handle flow rates up to 22 gpm / 82 lpm and higher with custom design flushing skids with or without heat. Applications include traditional hydraulic and lube oils, phosphate ester, and even used motor and crankcase oils.
COD Diesel Fuel Particle & Water Coalesce Conditioners rapidly particles and water with > 97% single pass efficiency to ensure that fluids in emergency stand-by reservoirs are clean and dry so hospital and other emergency response generators start when needed.
Today’s diesel engines require cleaner fuel with injector pressures approaching 30,000 PSI and the evolution of injectors into sophisticated expensive electronic components. Diesel engine manufacturers have learned that ultra fine particles that were of little consequence at 3,000 PSI are now causing premature failures at 30,000 PSI. Diesel fuel lubricity has also decreased with the move to ULSD (ultra low sulfur diesel) fuels. These changes and others have resulted in:
- Premature fuel injector and pump failures
- Reduced on-board fuel filter life
- Increases in diesel fuel consumption
- Increased down and operating costs
- Lost production
Hy-Pro solutions to these problems include:
- DFE rated filter element upgrades to replace antiquated cellulose media elements
- FSL and COD bulk tank circulating and dispensing skids
- High flow low pressure housing upgrades for all fuel dispensing points
COD Diesel Fuel Particle & Water Coalesce Conditioners rapidly remove particles and water with > 97% single pass efficiency to ensure that fuels in tank farms and fueling trucks are clean and dry. These fluids should be dewatered from bulk tank to service truck and should at least be filtered while dispensed into mobile equipment to ensure high fuel efficiency and extend injector life. We also have solutions for periodic or continuous conditioning of emergency stand-by reservoirs so hospital and other emergency response generators start when needed. For existing diesel fuel delivery systems we have particulate & water removal skids that can be fitted downstream of the existing dispensing pump. Customizable solutions to fit your application up to 500 gpm / 1,875 lpm and higher.
High Efficiency Fuel Filter Element & Housing Upgrades feature G8 DualglassMedia optimized for high single pass efficiencies to ensure cleanliness not previously achieved by antiquated cellulose media or bag filters. Hy-Pro DFE rated elements are available in a wide range of sizes to fit into the particulate filter housing at the fuel dispensing point. Upgrade housings to Hy-Pro LF series filters with generously sized high efficiency coreless elements to remove the particles and have long element life too.
Learn more: LF, Life Extension
Bulk Fluid Handling. Dedicated filtration and breathers on bulk storage and stand-by diesel fuels is the first line of defense in preventing one of the worst sources of particulate and water contamination, new fluids. Bulk storage tanks collect contaminants from delivery vehicles and through ineffective breather arrangements. Eliminate this dangerous source of contamination before transferring new fluids into critical diesel applications. Filter Carts are also a valuable tool for keeping fluids clean when transferred from storage to critical live systems.
Vac-U-Dry Vacuum Dehydration Oil Purifiers. Reclaimed fluids from sumps or contaminated fluids removed from service can be restored to usable condition by removing particulate and water contamination. Hy-Pro Vacuum Dehydrators rapidly remove free and dissolved water to < 10ppm while on-board high efficiency filtration elements featuring media down to 1 micron absolute rapidly reduce ISO Codes. Vacuum Dehydrator flow rates available up to 60 gpm / 225 lpm and viscosity range up to 680 cSt. Water sensor reporting in percent saturation and optional on-board particle monitor let you know when the fluid is dry and clean. For oils only needing particulate removal Hy-Pro Filter Carts for hydraulic or lube viscosity grade oils can handle flow rates up to 22 gpm / 82 lpm and higher with custom design flushing skids with or without heat. Applications include traditional hydraulic and lube oils, phosphate ester, and even used motor and crankcase oils.
Phosphate Ester, Polyol Ester & Vegetable Based Fluid Restoration. If phosphate ester fire-resistant (Fyrquel), polyol ester or other fire-resistant (i.e. BioSyn) fluids have been condemned for high acid number, gelling & deposits, water, dark color (sub-micron carbon by-products of thermal degradation) or high levels of dissolved metals Hy-Pro has a solution to recondition the fluid on-board or even if it has been removed from service. Contact us for evaluation and, if suitable, a strategy to recondition these expensive such fluids to useful condition.
High Efficiency Flushing Skid Filter Element Upgrades feature G8 Dualglass Media optimized for high single pass efficiencies to hit target ISO Codes faster so you can get on to the next flushing job. Hy-Pro flushing elements are available in a wide range of sizes to fit into the particulate filter housing on any type of oil conditioning or flushing skid.
COD Diesel Fuel Particle & Water Coalesce Conditioners rapidly particles and water with > 97% single pass efficiency to ensure that fluids in emergency stand-by reservoirs are clean and dry so hospital and other emergency response generators start when needed.
Industrial gearbox fluids are typically not filtered on-board and are changed on a time interval instead of keeping these oils clean and changed based on oil condition and remaining additive package. Hy-Pro has the solution from large coal mill gearboxes to small conveyor gearboxes.
Coal Mill Gearbox Filtration. Break the drain and refill gearbox oil change cycle and improve reliability, extend useful oil life and avoid premature contamination gearbox rebuilds by installing Hy-Pro FSL dedicated off-line filter skids specifically designed for high viscosity lube oils. High flow LF housings are also a good fit for adding high efficiency filtration to existing re-circulation lines on coal mils to control particles and water contamination.
Learn more: FSL, FCL, TMR™, Water Removal Elements, Coal Pulverizer Gearbox Filtration Case Study
Cooling Tower Gearbox service often comes with confined space requirements. Changing the oil by traditional gearbox drain and refills can and should be avoided by using portable or permanent dedicated filtration systems that feature particulate and water removal filtration. Avoid premature gearbox rebuilds and replacements, keep cooling towers turning, and avoid premature fluid replacement with Hy-Pro’s range of off-line fluid conditioning solutions for gearboxes.
Learn more: FPL, FSL, FCL, Water Removal Elements
Windmill Gearbox Filtration. Transforming the motion of the wind into usable energy requires complex gearing and reliable lubrication. Windmill gearing needs to maintain longer than normal component life because of the difficulty in servicing these remotely located and elevated gearboxes. When a $1,500 bearing fails it can lead to production and revenue losses and replacement costs up to $200,000 (gearbox and crane). Hy-Pro DFE rated lube and hydraulic elements deliver lower ISO Codes (cleaner fluid). Dedicated FSL off-line skids keep fluids clean when undersized OEM side loops don’t because they go into bypass in under 6 months. The Hy-Pro V1 Mini Vacuum Dehydrator is ideal for conditioning in-service lubricants removing particles and water. It’s small enough to fit and runs on 120VAC 3P 60Hz < 15 amps.
Learn more: FSL, Water Removal Elements, CoalPulverizer Gearbox Filtration Case Study, V1
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
GET STARTED NOW
Fee-based for continued monitoring, failure investigation/analysis and comprehensive testing
REQUEST PREPAID SAMPLE KIT
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
FSTO Turbine Lube Oil Varnish Removal
Ideal for Maintenance of Small Turbine Lube Oil & Compressor Reservoirs
- Prevent varnish related servo valve failures on small gas turbines and compressor lube oil applications (ie gas transmission compressor units).
- Remove & prevent varnish deposits with ICB™ element technology (Ion Charge Bonding).
- Achieve & maintain MPC value < 20 (lower varnish potential).
- Lower ISO codes to 14/12/9 with high efficiency post filter element.
- Extend life of anti-oxidant additives & prevent premature oil replacement.
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.
SVR™ Soluble Varnish Removal Skid
When combustion and steam turbines fall victim to unit trip or fail-to-start condition varnish is the usual suspect. The SVR™ (Soluble Varnish Removal) is the proven solution to make varnish vanish!
When combustion and steam turbines fall victim to unit trip or fail-to-start condition varnish is the usual suspect. SVR™ Soluble Varnish Removal skids prevent and remove varnish deposit formation in lube oil by removing oxidation by-products as they are formed and while they still in solution (dissolved). By removing the soluble varnish feed stock SVR™ is addressing the primary cause of varnish before varnish deposits can form. Stop varnish before it stops you!
SVR™ restores the solubility of the oil by removing the soluble varnish causing contamination that other technologies can’t. By restoring solubility SVR™ enables the oil to chemically remove previously formed varnish deposits and reduce QSA® or MPC varnish potential numbers from condition critical red to condition normal green. Ask Hy-Pro how the SVR™1200 can reduce and maintain a 6000 gallon GE Frame 7 lube reservoir MPC value to single digits in approximately 45 days.
OA-TO Turbine Oil Analysis
Two levels of analysis; MPC only for trending varnish potential monthly & a deeper analysis for periodic monitoring.
- MPC (membrane patch Colourimetry)
- MPC patch weight (mg)
- RULER (remaining anti-oxidant level)
- ICP spectrometric element analysis ppm
- Water Content by KF (ppm)
- ISO4406:1999 particle count (4/6/14)
- AN (acid number)
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.
Gearbox & Bearing Lube Elements. Hy-Pro DFE rated lube elements improve fluid cleanliness to avoid premature gearbox failure. Hy-Pro lube elements are specifically designed with wind turbine gearboxes in mind to minimize clean element pressure to extend useful element life with the ultimate goal of extending service intervals beyond 12 months. Water removal elements are ideal for wind mill gearboxes with water contamination where using off-line equipment is not suitable because of remote location or space requirements. remove free water down to saturation with Hy-Pro A media water removal elements.
Learn more: NSD, DFE, Water Removal Elements
Hydraulic Control Element Upgrades. Hy-Pro DFE rated elements yield cleaner fluid in wind turbine hydraulic speed, braking and pitch control systems on pump discharge and servo pilot filters. Prevent servo valve failures caused by contamination related failure. Hy-Pro Dynafuzz element upgrades feature stainless steel fiber media that is impervious to the effects that acid formed in phosphate ester can have on some glass medias. DFE rated non-sparking Dynafuzz elements provide superior fluid cleanliness and solve the media migration issue in phosphate ester EHC fluid.
Learn more: DFE,
Gearbox Filtration. Break the drain and refill gearbox oil change cycle and improve reliability, extend useful oil life and avoid premature contamination gearbox rebuilds by installing Hy-Pro FSL dedicated off-line filter skids specifically designed for high viscosity lube oils. High flow LF housings are also a good fit for adding high efficiency filtration to existing re-circulation lines on coal mils to control particles and water contamination.
Learn more: FSL, FCL, Water Removal Elements, CoalPulverizer Gearbox Filtration Upgrade Case Study, Gamesa Wind Turbine Filter Element Upgrade
Bulk Fluid Handling. Dedicated filtration and breathers on bulk storage tanks for lube and hydraulic oil is the first line of defense in preventing one of the worst sources of particulate and water contamination, new fluids. Bulk storage tanks collect contaminants from delivery vehicles and through ineffective breather arrangements. Eliminate this dangerous source of contamination and before transferring new fluids into critical power plant operating systems. Filter carts are also a valuable tool for keeping fluids clean when transferred from storage to critical live systems.
Learn more: FSL, FCL, Breathers, VUD
Gear Lube Water Removal by Vacuum Dehydration. Gearboxes reservoirs are susceptible to problems with water in lube oil. Hy-Pro Vac-U-Dry vacuum dehydration systems rapidly remove free and dissolved water to control lube oil water water levels to < 30ppm. On-board particulate filtration allows the application of high efficiency filter elements down to 1 micron absolute to lower overall lube oil ISO codes and take pressure off of gearbox filtration side-loops. Large Vac-U-Dry systems are available to condition reclaimed lube oil from drain and fill collection. The V1 mini Vac-U-Dry is for transport into wind mill cabinet at < 250 Lbs and small enough to fit through a hatch. V1 runs on 120 Vac 1P 60Hz < 15 Amps.
Learn more: V1 Case Study, VUD
