Active Reservoir Vent Fluid Users Active Reservoir Vent may be - - PDF document

▶
active reservoir vent
SMART_READER_LITE
LIVE PREVIEW

Active Reservoir Vent Fluid Users Active Reservoir Vent may be - - PDF document

Mar 03, 2023 189 likes •594 views

Active Reservoir Vent Fluid Users 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? Does your oil analysis indicate water

slide-1
SLIDE 1

Active Reservoir Vent™

Fluid Users

slide-2
SLIDE 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?

  • Does your oil analysis indicate water contamination?
  • Is your operation in a high humidity environment?
  • Do you operate around wash water, spray down

i t i d ff h i t ? 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

Are you concerned that your water saturated desiccant isn’t changed until it is too late?

slide-3
SLIDE 3

How Water Ingresses Into Systems

  • Humid Air

Incoming Humid Air

  • Humid Air
  • Marine
  • Pulp&Paper
  • Steam Turbines
  • Hydro Turbines

Oil

h2o h2o h2o h2o h2o h2o h2o h2o h2o h2o h2o h2o h2o h2o h2o

  • Hydro Turbines

R i

Oil In Reservoir Out

2

h2o h2o

  • Rain
  • Splashing
  • Washing
  • System Leaks
slide-4
SLIDE 4

Oil Humidification When Not Protected

Air around reservoir controlled at 90oF & 80% RH Air around reservoir controlled at 90oF & 80% RH

80

%)

50 60 70

midity (%

30 40 50

ive Hum

10 20 30

Oil Relat

8 16 24

Ti (H ) O Time (Hours)

slide-5
SLIDE 5

Problems With Water

  • Dissolved Water  Humidity in the oil

( il i l ) (oil remains clear)

  • Accelerates Bearing Fatigue
  • Accelerates Oil Oxidation
  • Cleaves Ester-Based Synthetics
  • Free Water  Bulk (settles to bottom)
  • r Emulsified (fluid is cloudy)
  • r Emulsified (fluid is cloudy)
  • Corrosion
  • Loss of Lubricity
  • Depletes Additives
  • Microbial Growth
slide-6
SLIDE 6

NASA/STLE Bearing Life Factors for Water

120 % )

100 120 e (%)

80 100 120 Life (%

n

Dissolved Water Free Water

20 40 60 80 100 ative Bearing Life

40 60 80 earing

aturation

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

20 40 ative B

Sa

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

slide-7
SLIDE 7

ARV™

4

Dry Air Purging System System

2 3 1 1. Incoming compressed air 2. Ultrafilter Ultrapac Heatless Regenerative Dryer 3. Customer’s Reservoir 4. T.R.A.P.™ Outlet Vent Kit

slide-8
SLIDE 8

Ultrapac 2000

Na12 [(AlO2)12(SiO2)12] x H2O - 10 Angstrom Molecular Sieve

slide-9
SLIDE 9

Ultrapac 2000 – How it makes dry i ti l 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,

  • r "adsorbed". The higher the pressure, the more gas is

adsorbed; when the pressure is reduced, the gas is released, d b d

  • r 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 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. U i t d b t l ll ti d ti f d i Using two adsorbent vessels allows near-continuous production of dry air.

slide-10
SLIDE 10

ARV™ – How it Works

  • Humid Air
  • Saturated Oil
  • Purging

Humid Air

  • Saturated Oil
  • Dry Air
  • Moisture

Desorbing

  • Dry Air
  • Dry Oil

g from Oil

Time

slide-11
SLIDE 11

ARV™ Test System

Compressed Air Supply Coalescer/Filter, Pressure Regulator & Gauge

Heatless Regenerative Dryer

Flow Meter

Environmental Chamber Environmental Chamber T=90oF, RH=80%

Air Temperature & Humidity Mixer Breather Head Space Mixer Oil Oil Temperature & Humidity Reservoir

slide-12
SLIDE 12

ARV™ Performance

140 90 100

Oil Temperature

140 90 100

Oil Temperature Turned on

100 120

F)

70 80

Headspace Air Temperature

100 120

F)

70 80

Headspace Air Temperature Turned on Heater & Mixer

80

ature (deg

50 60

RH (%)

80

ature (deg

50 60

RH (%)

40 60

Tempera

30 40

R

40 60

Tempera

30 40

R

Added Turned on Ultrapac

20 10 20 20 10 20

Headspace Air Relative Humidity Added Water

6:00 7:12 8:24 9:36 10:48 12:00 13:12 14:24 15:36

Time (Hour:Minute)

6:00 7:12 8:24 9:36 10:48 12:00 13:12 14:24 15:36

Time (Hour:Minute)

slide-13
SLIDE 13

Air Exchange Rate

  • Air Exchange Rate,

E, is the number of times the air in the head space is

Q E 

head space is flushed per hour.

hs

V E

Wh

  • Where
  • Q = ARV Flow Rate
  • V = Head Space Volume
  • Vhs= Head Space Volume
slide-14
SLIDE 14

ARV™ Performance

70 80 (%)

Reservoir Head Space Air 70 80 Reservoir Oil

50 60 70 Humidity (

50 60 70 ation (%)

30 40 50 ir Relative

2 30 40 50 ent Satura 2

Exchanges/hour

10 20 30 d Space Ai

6 20 10 20 30 Oil Perce 20 200 6

10 8 16 24 Head

20 200 10 0.0 8.0 16.0 24.0 200

Time (Hours)

Time (Hours)

slide-15
SLIDE 15

Case 1: Hydraulic Press

slide-16
SLIDE 16

Hydraulic Press Details

  • Press Hydraulic Reservoir

3000 ll ISO 46 il 100 ft3 i h d

  • 3000 gallons ISO 46 oil, 100 ft3 air head space
  • Significant air exchange due to large

hydraulic cylinders on this system Humid hydraulic cylinders on this system. Humid air ingress.

  • History of moisture issues  stalactites
  • History of moisture issues  stalactites
  • Vacuum dehydrator prior to trial
  • 8 ft3/min Dry Air Flow for

y ~5 Air Exchanges per Hour

  • Data Measurement & Logging

H d i t t & l ti h idit

  • Headspace air temperature & relative humidity
  • Oil temperature & water saturation
slide-17
SLIDE 17

Hydraulic Press Installation

Breathers Flow Meter Air T & RH Pressure Swing Adsorption Dryer Sensor Oil Saturation Sensor

slide-18
SLIDE 18

60

Dry Air ON Dry Air OFF Dry Air ON

50

(%) and ation)

y y y

40

Humidity % Satura

30

Relative H

  • ntent (%

20

ace Air R

  • isture C

10

Head Spa Oil Mo

6/16 6/26 7/6 7/16 7/26 8/5 8/15 8/25 9/4

H

slide-19
SLIDE 19

Hydraulic Press Summary

Dry Air Blanket

ON

Dry Air Blanket

OFF ON OFF

Head Space Air Relative Humidity (%) <10% 50% and Rising Oil Moisture Content (% Saturation) <10% 20% and Rising

slide-20
SLIDE 20

Case 2: Bulk Fuel Storage

slide-21
SLIDE 21

Bulk Fuel Storage Installation

  • Location: Northern Iowa
  • Excavation company with history of

short fuel filter life. short fuel filter life.

  • Tanks cleaned during summer and

filter systems added for delivery and filter systems added for delivery and

  • ff loading.

Tank Si es 12 000 gallons filled ith

  • Tank Sizes: 12,000 gallons filled with

Off Road Diesel in August, 2009.

  • 2 tanks used for test, one had dry air

blanket, one just a breather

slide-22
SLIDE 22

Bulk Fuel Storage: Head Space Air

2 cfm 1 cfm

slide-23
SLIDE 23

Bulk Fuel Storage

70 80 90

  • ntent

n)

Top Surface Water Content Versus Time

40 50 60 70 Moisture Co % Saturatio 20 30 40 10/14 10/24 11/3 11/13 11/23 12/3 12/13 12/23 1/2 Fuel M (% 100 10/14 10/24 11/3 11/13 11/23 12/3 12/13 12/23 1/2 80 90 100 Content ion)

Average Water Content Versus Time

50 60 70 l Moisture C (% Saturat 40 50 10/14 10/24 11/3 11/13 11/23 12/3 12/13 12/23 1/2 Fuel (

slide-24
SLIDE 24

Bulk Fuel Storage Summary

Tank with

Breather

Tank with

Dry Air Blanket Breather Only Dry Air Blanket

Avg Head Space Air R l ti H idit (%) 92% with f t 9% Relative Humidity (%) frequent saturation Avg Fuel Moisture Content (% Saturation) 65% 50% (% Saturation)

slide-25
SLIDE 25

Case 3: Paper Machine Crown Roll Press

slide-26
SLIDE 26

Crown Roll Press Details

  • Crown Roll Press Reservoir

500 gallons oil 23 ft3 head space

  • 500 gallons oil, 23 ft3 head space
  • Feeds press roll, gearbox, and some lube points.
  • Scavenge pump returns oil (and saturated air) from

hi 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
  • Headspace air temperature & relative humidity
  • Oil temperature & water saturation
slide-27
SLIDE 27

Crown Roll Press Installation

Fl M t Flow Meter Pressure Swing P R l t Pressure Swing Adsorption Dryer Pressure Regulator

slide-28
SLIDE 28

Manifolded vents on Manifolded vents on Machine up and away.

Oil Sensor Issues Oil Air Air Air

slide-29
SLIDE 29

Crown Roll Press Summary

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

slide-30
SLIDE 30

Payback Model: ARV™ vs Desiccant

Cumulative Dry Air Cost

$10,000 C ost $5,000 erating C Total O pe

ARV-3 Desiccant every month

$- T

Desiccant every month Desiccant every 2 weeks Desiccant every week

$ year 1 year 2 year 3 year 4 year 5

slide-31
SLIDE 31

ARV™ Ordering

  • Order two parts

1 ARV™ Vent Kit

  • 1. ARV

Vent Kit

  • 2. ARV System:

Ult & M l Ultrapac & Manual (Ultrapac set up

ARV™-3 & ARV™-10

Active Reservoir Vent™ Installation and Operation Manual

for 70 psi)

slide-32
SLIDE 32

ARV™ Ordering

  • ARV™ Vent Kit*: P568793
  • Std 3cfm Unit (2700 gal reservoir)
  • Ultrapac & Manual: P568790

Ultrapac & Manual: P568790

  • Std 10cfm Unit (9000 gal reservoir)
  • Ultrapac & Manual: P568791
  • Ultrapac & Manual: P568791
  • 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

slide-33
SLIDE 33

ARV™ Sizing Simplified

  • Q = ARV™ Flow (ft3/min)
  • E = Exchange Rate Per Hour

(usually target between 2 and 10) (usually target between 2 and 10)

  • Vhs = Head Space Volume

If Vhs is unknown, assume 25% of reservoir volume.

Vhs Vhs Vhs

reservoir volume.

(ft3) (gallons) (liters)

EV

EV

EV

60

hs

EV Q 

2 . 1699

hs

EV Q 

8 . 448

hs

EV Q 

60

8 . 448

slide-34
SLIDE 34

System Sizing

Air Exchange Rate

  • Air Exchange Rate, E, is the

g number of times the air in the head space is flushed per p p hour.

  • Where

Q E 

Where

  • Q = ARV Flow Rate
  • Vhs= Head Space Volume

hs

V E

Vhs Head Space Volume

  • “Static” Oil Volume: <3/hour

“V i bl ” Oil V l 5/h

  • “Variable” Oil Volume: >5/hour
slide-35
SLIDE 35

ARV™ Sizing Examples

  • Example 1
  • E = 10: High moisture environment,

g variable oil volume

  • Vheadspace= 67 ft3
  • Use 10 cfm unit

cfm Q 1 . 11 60 ) 67 ( 10  

  • Use 10 cfm unit

60

  • Example 2
  • E = 2: Normal moisture static oil volume
  • E = 2: Normal moisture, static oil volume
  • Vreservoir = 2000 gallons
  • Therefore, assume reservoir is 75% full or 25% head

space: V = 0 25(2000) = 500 gallons space: Vhs = 0.25(2000) = 500 gallons

  • Use 3 cfm unit

cfm Q 2 . 2 8 448 ) 500 ( 2  

  • If in doubt, call your Donaldson District Manager

8 . 448

slide-36
SLIDE 36

ARV™ Applications

  • Hydraulic System Reservoirs

y y

  • Gearboxes
  • Lube System Reservoirs
  • Lube System Reservoirs
  • Small Storage Tanks
  • Divide Flow to Protect Multiple

Reservoirs

slide-37
SLIDE 37

ARV™ Installation

slide-38
SLIDE 38

ARV™ Maintenance

Description Recommended Change Interval Part Number Change Interval T.R.A.P.™ breather 6 Months P564669 Ultrapac 2000 Carepack (prefilter 1 Year ARV-3: P568796 element, afterfilter element, desiccant cartridges, set of seals) for Ultrapac adsorption dryer. ARV-10: P568797 * See Ultrapac 2000 Operation Manual for detailed description of replacement * See Ultrapac 2000 Operation Manual for detailed description of replacement procedure. * See Ultrapac 2000 Operation Manual for additional replacement t if i d components if required.

slide-39
SLIDE 39

ARV™ Advantages

ARV™ Membrane Dryers

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

slide-40
SLIDE 40

Questions?