active reservoir vent™ - coastal hydraulics · 2014-04-24 · active reservoir vent™ may be the...
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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 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 desiccantAre you concerned that your water saturated desiccant isn’t changed until it is too late?
How Water Ingresses Into Systems
●Humid Air
Incoming Humid Air
●Humid Air• Marine• Pulp&Paper• Steam Turbines• Hydro Turbines
Oil
h2oh2o
h2o
h2oh2o
h2o
h2oh2o
h2o
h2o
h2o
h2o
h2o
h2oh2o • Hydro Turbines
R i
Oil In ReservoirOut
2
h2o h2o
●Rain●Splashing●Washing●System Leaks
Oil Humidification When Not ProtectedAir around reservoir controlled at 90oF & 80% RHAir around reservoir controlled at 90oF & 80% RH
80%
)
50
60
70m
idity
(%
30
40
50
ive
Hum
10
20
30
Oil
Rela
t
00 8 16 24
Ti (H )
O
Time (Hours)
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)or Emulsified (fluid is cloudy)or Emulsified (fluid is cloudy)• Corrosion• Loss of Lubricity• Depletes Additives• Microbial Growth
NASA/STLEBearing Life Factors for Water
120%)
100120
e (%
)
80100120
Life
(%
n
DissolvedWater
FreeWater
020406080
100
ativ
e Be
arin
g Li
fe
406080
earin
g
atur
atio
n
0 200 400 600
Water Content in Oil (ppm)
Rel
a
Study Oil Saturates at 500 ppm
02040
ativ
e B Sa
0 200 400 600
Water Content in Oil (ppm)
Rel
(pp )Study Oil Saturates at 500 ppm
ARV™4
Dry Air Purging SystemSystem
23
11. Incoming compressed air2. Ultrafilter Ultrapac Heatless Regenerative Dryer3. Customer’s Reservoir4. T.R.A.P.™ Outlet Vent Kit
Ultrapac 2000
Na12 [(AlO2)12(SiO2)12] x H2O - 10 Angstrom Molecular Sieve
Ultrapac 2000 – How it makes dry i ti lair 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,
d b dor 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 reacheswill 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 iUsing two adsorbent vessels allows near-continuous production of dry air.
ARV™ – How it Works
• Humid Air• Saturated Oil
• Purging Humid Air
• Saturated Oil
• Dry Air• Moisture
Desorbing
• Dry Air• Dry Oil
gfrom Oil
Time
ARV™ Test SystemCompressedAir Supply
Coalescer/Filter, Pressure Regulator
& Gauge
Heatless Regenerative
Dryer Flow Meter
Environmental ChamberEnvironmental ChamberT=90oF, RH=80%
Air Temperature & Humidity
MixerBreather
Head Space
Mixer
Oil
Oil Temperature & Humidity
Reservoir
ARV™ Performance140
90
100
Oil Temperature
140
90
100
Oil TemperatureTurned on
100
120F) 70
80Headspace Air Temperature
100
120F) 70
80Headspace Air Temperature
Turned on Heater & Mixer
80
atur
e (d
eg
50
60
RH
(%)80
atur
e (d
eg
50
60
RH
(%)
40
60
Tem
pera
30
40
R
40
60
Tem
pera
30
40
R
Added
Turned on Ultrapac
2010
2020
10
20
Headspace Air Relative Humidity
AddedWater
06:00 7:12 8:24 9:36 10:48 12:00 13:12 14:24 15:36
Time (Hour:Minute)
006:00 7:12 8:24 9:36 10:48 12:00 13:12 14:24 15:36
Time (Hour:Minute)
0
Air Exchange Rate
●Air Exchange Rate, E, is the number of times the air in the head space is
QE head space is flushed per hour. hsV
E
Wh●Where• Q = ARV Flow Rate• V = Head Space Volume• Vhs= Head Space Volume
ARV™ Performance
70
80(%
) Reservoir Head Space Air70
80Reservoir Oil
50
60
70
Hum
idity
(
50
60
70
atio
n (%
)
30
40
50
ir R
elat
ive
230
40
50
ent S
atur
a
2Exchanges/hour
10
20
30
d Sp
ace
Ai
620 10
20
30
Oil
Perc
e
20200
6
0
10
0 8 16 24
Hea
d 20200
0
10
0.0 8.0 16.0 24.0
200
Time (Hours) Time (Hours)
Case 1: Hydraulic Press
Hydraulic Press Details
●Press Hydraulic Reservoir3000 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 Humidhydraulic 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
Hydraulic Press Installation
Breathers
FlowMeter
Air T & RHPressure SwingAdsorption Dryer
Sensor
Oil Saturation Sensor
60
Dry Air ON Dry Air OFF Dry Air ON50
(%) a
nd
atio
n)y y y
40
Hum
idity
%
Sat
ura
30
Rel
ativ
e H
onte
nt (%
20
ace
Air
Roi
stur
e C
10
Hea
d Sp
aO
il M
o
06/16 6/26 7/6 7/16 7/26 8/5 8/15 8/25 9/4
H
Hydraulic Press Summary
Dry Air BlanketON
Dry Air BlanketOFFON OFF
Head Space AirRelative Humidity (%)
<10% 50% and Rising
Oil Moisture Content(% Saturation)
<10% 20% and Rising
Case 2: Bulk Fuel Storage
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 andfilter systems added for delivery and off 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
Bulk Fuel Storage: Head Space Air
2 cfm 1 cfm
Bulk Fuel Storage
708090
onte
nt
n)Top Surface Water Content Versus Time
40506070
Moi
stur
e C
o%
Sat
urat
io
203040
10/14 10/24 11/3 11/13 11/23 12/3 12/13 12/23 1/2
Fuel
M (%
10010/14 10/24 11/3 11/13 11/23 12/3 12/13 12/23 1/2
80
90
100
Con
tent
io
n)
Average Water Content Versus Time
50
60
70
l Moi
stur
e C
(% S
atur
at
40
50
10/14 10/24 11/3 11/13 11/23 12/3 12/13 12/23 1/2
Fuel (
Bulk Fuel Storage Summary
Tank with Breather
Tank withDry Air BlanketBreather
OnlyDry Air Blanket
Avg Head Space Air R l ti H idit (%)
92% with f t
9%Relative Humidity (%) frequent
saturationAvg Fuel Moisture Content(% Saturation)
65% 50%(% Saturation)
Case 3: Paper MachineCrown Roll Press
Crown Roll Press Details
●Crown Roll Press Reservoir500 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
himachine.• 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
Crown Roll Press Installation
Fl M tFlow Meter
Pressure Swing
P R l t
Pressure SwingAdsorption Dryer
Pressure Regulator
Manifolded vents onManifolded vents on Machine up and away.
Oil
SensorIssues Oil
AirAir
Air
Crown Roll Press Summary
Before Dry Air Blanket
After Dry Air Blanket and BreatherBlanket and Breather
Manifold InstallationHead Space AirRelative Humidity (%)
Saturated air returned to tank by
<10% on average, maximum of 40%y ( ) y
scavenge pumpOil Moisture Content(% Saturation)
100% Saturated with free water. Even
42 % on average and still improving
vacuum dehydrator not able to keep up!
Payback Model: ARV™ vs DesiccantCumulative Dry Air Cost
$10,000C
ost
$5,000erat
ing
CTo
tal O
pe
ARV-3Desiccant every month
$-
T Desiccant every monthDesiccant every 2 weeksDesiccant every week
$year 1 year 2 year 3 year 4 year 5
ARV™ Ordering
● Order two parts1 ARV™ Vent Kit1. ARV Vent Kit
2. ARV System:Ult & M lUltrapac & Manual (Ultrapac set up
ARV™-3 & ARV™-10 Active Reservoir Vent™
Installation and Operation Manual
for 70 psi)
ARV™ Ordering
●ARV™ Vent Kit*: P568793●Std 3cfm Unit (2700 gal reservoir)
•Ultrapac & Manual: P568790Ultrapac & 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
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 EVEV60
hsEVQ 2.1699hsEVQ
8.448hsEVQ
60 8.448
System SizingAir Exchange Rate●Air Exchange Rate, E, is the g
number of times the air in the head space is flushed per p phour.●Where
QE Where•Q = ARV Flow Rate•Vhs= Head Space Volume
hsVE
Vhs Head Space Volume
●“Static” Oil Volume: <3/hour“V i bl ” Oil V l 5/h●“Variable” Oil Volume: >5/hour
ARV™ Sizing Examples
●Example 1• E = 10: High moisture environment, g
variable oil volume• Vheadspace= 67 ft3
• Use 10 cfm unitcfmQ 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 gallonsspace: Vhs = 0.25(2000) = 500 gallons• Use 3 cfm unit
cfmQ 2.28448)500(2
● If in doubt, call your Donaldson District Manager
8.448
ARV™ Applications
●Hydraulic System Reservoirsy y●Gearboxes●Lube System Reservoirs●Lube System Reservoirs●Small Storage Tanks●Divide Flow to Protect Multiple
Reservoirs
ARV™ Installation
ARV™ Maintenance
Description Recommended Change Interval
Part NumberChange Interval
T.R.A.P.™ breather 6 Months P564669
Ultrapac 2000 Carepack (prefilter 1 Year ARV-3: P568796element, 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 dcomponents if required.
ARV™ Advantages
ARV™ Membrane DryersAir Dryness 1% Up to 30%Air Humidity
RangeConstant 1% Varies with inlet air
Durability Rugged molecular sieveDifficult to damage
Fragile membrane1 hole defeats membrane
Maintenance Annual change of sieveCannot be fouled
Can’t be maintained. Must be replaced
Easily fouledy
Questions?