The ORBITRON 3000

Electrostatic Oil Purification System Orlando Utilities Commission BETA Test and Lab Results

December 13th, 2016

ABSTRACT It is well known that contamination in oil is always harmful to hydraulic and lubricating systems. Contaminants inevitably exist in the oils of hydraulic and lubrication systems and cause tribological problems. In order to prevent such tribological problems due to contaminants, various oil cleaners have been developed and applied to hydraulic and lubricating systems. They have greatly contributed to improving the reliability of the systems. Since sophisticated hydraulic systems with proportional valves or servo valves, which are more sensitive to oil contamination, became popular, fine filters like 3 micron or 1 micron have seen increased use. However, contamination problems have been revived. The authors have investigated the causes of hydraulic and lubricating problems and found that polymerized oil oxidation products were as harmful as solid particles. They are of molecular size and cannot be removed by mechanical filtration. The authors have developed electrostatic oil cleaners, which can remove not only micron sized particulate contaminants but also polymerized oil oxidation products. This paper discusses the principle of electrostatic oil cleaning technology and demonstrates it’s increased level of performance. A BETA test was performed at the Orlando Utilities Commission, Stanton Energy Facility, Steam Plant # 2. The tests were conducted from October 5th, 2016 through October 13th, 2016 on a 2,000-gallon reservoir of contaminated turbine oil, Diamond Class # 32. A static reservoir was chosen for the test, since an active reservoir if being continually contaminated by the operating turbine would make it impossible to get an accurate “Before and After” test result. This is because the ORBITRON Electrostatic technology would be perpetually attempting to remove new contaminants as well as any that were contained in the original dormant reservoir. The intent of the test was to determine if the technology and equipment could dramatically improve the ISO codes and related cleanliness of the contaminated turbine oil. INTRODUCTION “Hydraulic systems generate large forces with relatively small particles and are excellent for handling heavy objects with accurate control. However, contaminants in oils cause

continual problems for and with hydraulic systems. The majority of users of hydraulic systems are industrial. Oil cleaning is a subordinate item to them. The management is not interested in oil cleanliness but care about uptime and reliability of the hydraulic systems. They pay attention to oil cleaning only when hydraulic systems are in trouble. In the past, contamination control specialists have paid most attention to particulate contaminants of micron size and little attention to polymerized oil oxidation products, submicron size. In order to prevent hydraulic problems due to oil contamination, almost all hydraulic systems incorporate mechanical, or membrane, filters in the main stream of oil, either at the pressure side or at the return side. However, hydraulic problems due to oil contamination still exist. Modern hydraulic systems are used for motion control that requires accurate and precise motions. Such systems use servo valves and proportional valves, which are very sensitive to contamination of oils. Therefore, use of fine by-pass mechanical filters has been recommended in addition to the in-line filters. However, contamination problems not only still exist, but they are also increasing by using fine filters. The authors have investigated the causes of hydraulic problems and found that polymerized oil oxidation products play a large part in these hydraulic issues. The authors also have found that mechanical filters generate static electricity when oil passes through filter media. This static electricity accumulates in either a filter or in the oil and causes spark discharges and accelerates oil oxidation. As the temperature of a spark discharge is high, (in the range of several thousand to over 10,000 C.) oils will deteriorate because of these high temperatures and this oil deterioration leads to hydraulic system failures. The management, who is responsible for past, current and future investment, deplores downtime of production machinery, as their capability is evaluated by the “Return on Assets (ROA)” ratio. In order to comply with such requirements placed on plant management, we have developed an advanced technology for protecting the assets. This paper discusses the ORBITRON 3000 electrostatic oil filtration system and the technology of electrostatic oil purification, employing the use of static electricity.” *1 Orbitron 3000 Install & Beta Test - Orlando Utilities Commission Stanton Energy Center - Steam Plant #2 Orlando, Florida October 5th thru 13th, 2016 Orbitron International, LLC. was granted permission by the Orlando Utilities Commission (OUC), Stanton Energy Center, Steam Plant #2, to conduct a BETA test on their static 2,000-gallon reservoir from October 5th thru October 13th, 2016, an 8-day trial. The Reservoir: Each time OUC determines, from independent lab tests, that the turbine oil is either deficient in additives or does not meet the required ISO level of cleanliness, they remove 10% of the lubricant and replace it with new, in this case Diamond Class 32. The 10% withdrawn is stored in a 10,000–gallon holding tank, currently filled to 2,000 gallons. Therefore, the holding tank had a combination of lubricant oils withdrawn from various turbines over a number of years. Some of it was 5 years old, some 10 years old and some was 20 years old. This formed the perfect platform to fully test the

ORBITRON 3000’s electrostatic oil filtration parameters as the reservoir contained a mixture of lubricant ages and all of it was contaminated from significant use. The Environment and Conditions: The ORBITRON 3000 was transported to OUC by Orbitron International, LLC. technicians on October 5th, 2016. It was a 90-degree day and Hurricane Matthew was predicted to hit the East coast of Florida by the following day. Unpacking the ORBITRON 3000: The ORBITRON 3000 weighs 300 pounds with dimensions of 2’0” X 3’0” X 4’0” and is packaged and sealed in a sturdy wooden crate measuring 4’0” X 4’0” X 5’0”, weighing in total, approximately 500 lbs. Upon arrival, the crate was forklifted off the transport by OUC engineers. The crate was then disassembled by Orbitron International, LLC. staff and the unit moved into position next to the holding tank. The unit has a recommended clearance of 2 ft. The apparatus was fully inspected to insure it sustained no damage during transport and was prepared for install. Initial Test Run and Midpoint Check: The ORBITRON 3000 had a 1¼” “Quick Connect” mechanism off either end of two 1” diameter 30’0” hydraulic hoses. One end of the first hose was connected to the port labeled "Intake” of the ORBITRON 3000 and the other end was connected to the holding tank. Then one end of the second hose, was connected to the port labeled "Output" and the other end secured into a stand alone flushing container. At this point the apparatus was filled with turbine oil, flushed and emptied into the stand alone container to insure no contaminants were introduced into the holding tank. Finally, the end of the second hose, formerly in the stand alone container, was then connected to the holding tank, completing the loop. The ORBITRON 3000 is powered by a 110-volt 60-Hz US standard outlet. Once the machine was installed, powered up and readied, the pump was turned on to fill the filter cylinder with turbine oil. This took approximately 10 minutes. Air was bled out of the tank while it filled via a hand operated valve at the top of the filter cylinder. Once completely filled, the valve was turned off and the ORBITRON 3000 was ready to begin its initial setup. The computer touch screen, which is located on the front of the unit, prompts the operator through each step. These steps were followed as presented by the Orbitron Quick Start

1. This is the welcome screen that tells you your machine's model number and software version. 2. Select “Electrostatic Filtration” mode. “Maintenance Mode” is for ORBITRON CO. technicians only. 3. Remove the V-band clamp from the tank lid, remove the lid, rotate filter counterclockwise to unscrew filter from

high voltage feed. Reinstall tank lid, V-band clamp, and open all ball valves.

4. The system is now being flush Select “Electrostatic Filtration” mode. “Maintenance Mode” is for ORBITRON CO. technicians only.

5. The system is now being flushed with oil. This process takes 10 minutes. 6. Click next to begin draining the tank.

7. The tank is now draining. Open valve on tank lid. This will take 2 minutes. 8. Remove v-band clamp, remove lid, re-install filter. Click next when complete and leave valve OPEN. 9. The tank is now refilling itself. Make sure the tank lid vent valve is open to allow air to escape.

10. The high voltage system is now charging. This process takes 5 minutes. 11. Startup is now complete.

Initial Test Run and Midpoint Check: The Orbitron International, LLC. technicians met with OUC Plant Engineers and confirmed that the apparatus was properly installed and operating according to plan. To avoid the oncoming storm, the Orbitron personnel then left the Stanton Energy Center, and returned to the Tampaarea. Thepowerplantwentintoemergencymode,asiscustomaryduringhurricanes,butdidtakeregularsamplesfromtheORBITRON3000’ssamplingport,aswaspreviouslyagreed. TheOrbitronInternational,LLC.techniciansreturnedtoOUConMonday,October10th,tomeetwiththeplantengineers,checkontheoperationsofthemachine,insurethestormhadnotaffected theapparatusor testproceduresand retrieve the samplestaken to date. The ORBITRON 3000 was operating perfectly, unaffected by thestorm,andthetechniciansleftonceagain.CompletingtheTest,Pack-Up&Transport:TheOrbitronInternational,LLC.techniciansreturnedtoOUConThursdayOctober13th,aspreviouslyagreed,toconcludethetest,pack-upandtransporttheORBITRON3000backtothemanufacturingfacilityoutsideofTampa,Florida.Uponarrivalthemachinewasinspectedforoperationalintegrity,theengineeringstaffwasalertedandtheapparatuswastakenoffline,drained,disconnectedfromtheholdingtankandre-

crated.OUCstaffloadedtheORBITRON3000onthetransportandprovidedthetechnicianswiththeremainingsamplesthathadbeentakensincethepreviousMonday.TheOrbitronInternational,LLC.techniciansconductedanexitsurveywiththeplant’sengineeringstaffandreceivedhighmarksforcleanliness,efficiency,achievingoperationalexpectationsanddisassemblyandremoval.JeffStarlin,TheSteamPlant#2ChiefEngineer,reportedthathewaspleasedwiththetestandanxioustolearnofthelabresultsfromthesamplestakenduringthetest.TheORBITRON3000wastransportedbacktotheshopandthesamplesshippedtoboththeUniversityofLouisiana,PetrochemicalDepartmentandtoR&GIndependentTestingLabforanalysisandtestingtodeterminetheoveralleffectivenessoftheBETAtestwiththeORBITRON3000onthestaticreservoir.SUMMARY:TestResultsandConclusion:Thetestresultsandassociatedanalysis(seeattached)fromboththeUniversityofLouisianaandR&GLabssurpassedtheinitialexpectationsofOrbitronInternational,LLC.managementandstaff.ThetreatedoilfromthereservoircamebackcleanerthanthenewDiamondClass32originallytestedtoestablishastandardizedplatformfromwhichtomeasure.Inonlyfour(4)days,themidpointinterval,thesamplesshoweddramaticimprovementovertheinitialreservoirsamplestakenbeforetheORBITRON3000wasinstalled.Bythefinalsample,takenonThursdayOctober13th,theentire2,000-gallonholdingtankhadanISOcodelowerthanthenew(neverused)oilandshoweddramaticcontaminantreductionbyspecificmetalliccategory.Pleaseseetestresultsattachedhereto.AppendixA–UniversityofLouisianaTestDataReport...Pg..6AppendixB–R&GIndependentLabTestExplanation......Pg..12AppendixC–R&GIndependentLabTest...............................Pg..16*1AkiraSasakiandShinjiUchiyama2002–“ANewTechnologyForOilManagement:ElectrostaticOilCleaner”

Appendix AUniversity of Louisiana

Test Data Report

ORBITRON  3000  

 TEST DATA REPORT

 

The  Energy  Institute  of  Louisiana  located  on  the  campus  of  The  University  of  Louisiana  in  Lafayette,  LA  conducted  various  analysis  detailed  below.  The  goal  of   the   testing  was   to  ascertain  areas  of  potential  improvement,   or   detrimental   effects   to   the   oil   processed   through   the   Orbitron   3000.   The   tests   are  standard   laboratory   analysis   of   metals,   and   organic   chemicals   present   in   the   oil.   The   sample   was  provided  covering  the  entire  oil  process.  New,  unused  oil  was  opaque  and  light  yellow  color.  The  used  oil   from  the  turbine  process  and  the  oil   from  the  Orbitron  filtration  unit  was  the  same   in  color.  These  samples   were   also   opaque   but   darker   in   color   as   expected   from   oxidation   and   exposure   to   high  temperature  in  normal  operations.  All  oils  were  tested  under  the  same  conditions  to  allow  a  comparison  of   the  Orbitron  3000  efficiency.    Because  of   the  third  party   taking  and  delivering   the  subject  samples,  The  Energy  Institute  of  Louisiana  can  only  verify  the  test  results  obtained.      

 

 

The  analysis  of  the  metals  by  XRD  analysis  shows  a  reduction  of  levels  from  the  used  oil  at  about  a  45  to  60%  reduction.    Some  of  these  metals  were  not  present  in  the  new  oil  and  will  only  show  up  during  operational  conditions.    Levels  of  Sulphur  showed  the  highest  PPM  concentration  and  may  be  formed  by  breakdown  of  oil  under  high  pressure  conditions.    The  Oribtron  3000  did  remove  45%  of  the  sulfur  in  the  used  oil.    Aluminum  was  the  only  element  to  show  up  in  the  fully  treated  Oribtron  oil  and  not  in  the  new  or  used  oil.    There  could  be  an  exposed  aluminum  metal  in  the  cleaning  process  that  results  in  this  small  concentration.    All  other  metals  were  at  very  low  concentrations.  

Note:  The  test  utilized  to  generate  the  above  results  is  capable  of  detecting  trace  amounts  of  the  following  elements:  Ag,  Al,  As,  Au,  Ba,  Bi,  Ca,  Cd,  Cl,Co,  Cr,  Cs,  Cu,  Fe,  Hf,  Hg,  K,  Mg,  Mn,  Mo,  Nb,  Ni,  P,  P,  Pd,  Rb,  Re,  S,  Sb,  Sc,  Se,  Si,  Sn,  Sr,  Ta,  Te,  Th,  Ti,  U,  V,  W,  Zn,  Zr    

 

 

 

 

 

 

SAMPLE

Units

Aluminum

Chlorene

Chromium

Copper

Iron

Magnesium

Molybdenurr

Niobium

Phosphorus

Sulphur

Stronium

Uranium

Vandium

Tungsten

Zinc

Zirronium

New Oil ppm 0 93 277 98 43 0 12 15 0 0 4 4 69 448 0 12Used Oil ppm 0 118 251 89 0 0 11 15 397 15746 4 6 57 420 49 11

Fully Treated ppm 271 72 109 53 0 0 11 14 192 8669 4 6 22 281 44 11

ORBITRON  3000  

 TEST DATA REPORT

 

 

 

 

The  water  analysis  was  conducted  by  a  Metter  moisture  balance  using  1  gram  of  sample.    The  results  show  a  reduction  of  30%  in  water  content  from  the  used  oil  to  the  Orbitron  processed  oil.    This  process  has  shown  a  marked  improvement  of  7%  lower  water  concentration  than  current  new  oil  specifications.    

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Sample  Type Proportion  Oil Proportion  Water Percent  WaterNew 0.9954 0.0046 0.4600Untreated 0.9939 0.0061 0.6100ORBITRON  Treated 0.9957 0.0043 0.4300

WATER  CONTENT

ORBITRON  3000  

 TEST DATA REPORT

 

COMPARISON  OF  ORBITRON  FILTERED  OIL  TO  NEW  OIL  OF  SAME  TYPE      

 

 

 

 

 

The  new  oil  (never  used)  in  the  process  shown  in  the  red  trace  is  a  standard  hydrocarbon  profile  from  the  gas  chromatograph  coupled  to  a  mass  spectrometer.    As  the  used  oil  from  the  turbine  process  was  analyzed  under  the  same  conditions,  it  shows  a  higher  degree  of  response.    This  is  due  to  the  removal  of  water  from  the  filiter  process  and  thus  oil  content  is  higher  per  mass  of  oil  injected.    The  used  trace  does  show  a  shift  to  the  right  side  of  the  chromatograph.    This  indicates  that  a  higher  molecular  weight  content  is  present  in  the  oil.    This  presence  is  normal  with  wear  and  heat  exposure  over  time  in  the  turbine  process.    Value  could  be  added  to  the  filtering  techology  by  adding  an  engineered  process  to  remove  the  waxes  and  higher  weight  contaminants.  

 

 

                                       New  Oil  

           Orbitron  Filtered  

ORBITRON  3000  

 TEST DATA REPORT

 

 

 

 

 

 

The  plot  at  the  top  shows  a  standard  Electron  Impact  (EI)  spectra  of  a  hydrocarbon.    This  oil  sample  is  a  makeup  of  various  molecular  weight  hydrocarbons  and  over  time  will  produce  more,  due  to  oxidation  and  wear  of  the  oil.  The  bottom  trace  shows  new  oil  in  red  and  a  pronounced  increase  in  these  hydrocarbons  in  the  used  oil.  

ORBITRON  3000  

 TEST DATA REPORT

 

 

COMPARISON  TO  USED  OIL  OF  PRIOR  TO  ORBITRON  FILTERING  

 

 

 

 

 

The  trace  above  shows  the  untreated  oil  in  red  and  Orbitron  treatment  in  green.    The  two  traces  show  very  little  difference  in  chemical  composition  and  due  to  removal  of  water  the  Orbitron  shows  a  higher  amount  of  oil  response.    If  not  for  the  removal  of  water,  the  two  traces  could  almost  be  super  imposed  on  one  another  showing  no  chemical  degradation  resulting  from  Orbitron’s  filtering  process.  

 

           Untreated  Oil  

           Orbitron  Filtered  

 

Appendix BR&G Independent

Lab Test Explanation

INTERNAL  ORBITRON  INTERNATION,  LLC.  MATRIX  OF  BETA  TEST  RUN,  AND  RELATED  LAB  TEST  RESULTS,  OF  THE  ORBITRON  3000  APPARATUS  AT  THE  ORLANDO  UTILITIES  COMMISSION,  STANTON  ISLAND  POWER  GENERATION  STATION  IN  ORLANDO,  FLORIDA  OCTOBER  5TH  THROUGH  OCTOBER  13TH,  2016.    THIS  WAS  A  2,000  GALLON  STATIC  RESERVOIR  FROM  STEAM  PLANT  #  2.    LAB  RESULTS  FROM  R&G  LABS,  OF  TAMPA,  FLORIDA  ATTACHED  FOR  COMPARISON.    These  are  the  lab  results  performed  for  us  by  R&G  Labs  in  Tampa,  Florida.    For  the  sake  of  understanding  and  simplicity,  we  have  cut  and  pasted  the  critical  information  in  a  logical,  sequential  and  consecutive  manner.    The  full  reports  are  included  here  with,  such  that  you  might  verify  the  information  contained  herein  with  the  original  lab  reports.      TEST  #  1:    R and G LABORATORIES Existing OUC Reservoir (Untreated)

Severity: (MH) - Moderate High Sample Date 10/5/16 (Collected on the 5th, sent to lab on the 10th) Oil Type: USED DIAMOND CLASS 32 Description: Used Turbine Oil # 2 Steam Boiler 4 /ml 6329 6 /ml 1475 14 /ml 526 20 /ml 349 30 /ml 172 40 /ml 111 ISO Code 4/6/14 um 20/18/16 ADDITIONAL TESTS Karl Fischer H2O ppm 77.7 R and G LABORATORIES New Diamond Class 32 supplied by the plant TEST # 2:

Severity: (N) - Normal Sample Date 10/5/16 (Collected on the 5th, sent to lab on the 10th) Oil Type: DIAMOND CLASS 32 Description: NEW DIAMOND CLASS 32 PARTICLE COUNT 4 /ml 7183 6 /ml 1936 14 /ml 275 20 /ml 98 30 /ml 43 40 /ml 32 ISO Code 4/6/14 um 20/18/15 NO WATER PRESENT, SO NO Karl Fischer-H20 ppm tests performed

TEST # 3: FIRST TEST RESULTS 12 HOURS R and G LABORATORIES Severity: (N) - Normal Sample Date 10/06/16 (Collected on the 6th, sent to lab on the 10th) Oil Type: DIAMOND CLASS 32 Description: Treated with ORBITRON 3000 for approx. 12 hours PARTICLE COUNT 4 /ml 2208 6 /ml 166 14 /ml 8 20 /ml 3 30 /ml 0 40 /ml 0 ISO Code 4/6/14 um 18/15/10 ADDITIONAL TESTS Karl Fischer H2O ppm 21.4 TEST # 4: SECOND TEST RESULTS 22.5 HOURS R and G LABORATORIES Severity: (N) - Normal Sample Date 10/06/16 (Collected on the 5th, sent to lab on the 12th) Oil Type: DIAMOND CLASS 32 Description: Treated with ORBITRON 3000 for approx. 22.5 hours PARTICLE COUNT 4 /ml 1984 6 /ml 94 14 /ml 7 20 /ml 3 30 /ml 1 40 /ml 1 ISO Code 4/6/14 um 18/14/10 ADDITIONAL TESTS Karl Fischer H2O ppm 18.3

TEST # 5: THIRD TEST RESULTS 7 DAYS R and G LABORATORIES Severity: Severity: (N) - Normal Sample Date 10/12/16 Collected on the 6th, sent to lab on the 12th Oil Type: DIAMOND CLASS 32 Description: Treated with ORBITRON 300 for approx. 7 days PARTICLE COUNT 4 /ml 595 6 /ml 79 14 /ml 10 20 /ml 3 30 /ml 0 40 /ml 0 ISO Code 4/6/14 um 16/13/10 ADDITIONAL TESTS NO WATER PRESENT, SO NO Karl Fischer-H20 ppm tests performed  

Appendix CR&G

Independent Lab Test

Lab Number SeverityName Description Date

October 12, 2016

Oil Analysis Severity Summary

R and G LABORATORIES

October 12, 2016Report Printed Date:Report Issue Date:

N = Normal O = Observe M = Moderate S = SevereMH = Moderate High

641282 10/08/201610/8/16 1630HR N

641280 10/10/2016NEW DIAMOND CLASS 32 N

641281 10/10/2016USED DIAMOND CLASS32 MH

October 12, 2016

R and G LABORATORIES

Report Issue Date: Report Printed Date: October 12, 2016

Oil Analysis Severity Report

641282

Recommended Action:

Data Interpretation:

10/8/16 1630HR 10/08/2016 Normal

Continue sampling to track/trend data.

Based on the results of the analyses performed on this sample the unit and lube appear satisfactory for continued usage.

Severity:Date:Name:Lab Number:

641280

Recommended Action:

Data Interpretation:

NEW DIAMOND CLASS 32 10/10/2016 Normal

Continue sampling to track/trend data.

Based on the results of the analyses performed on this sample the unit and lube appear satisfactory for continued usage.

Severity:Date:Name:Lab Number:

641281

Recommended Action:

Data Interpretation:

USED DIAMOND CLASS32 10/10/2016 Moderate High

Check for possible sources of water contamination.

The sample from this unit contained trace water contamination.

Severity:Date:Name:Lab Number:

Oil Analysis Data Sheet Report

R and G LABORATORIES (N) - NormalSeverity:

Manufacturer:

Sample ID:

Units

Lab Number

Sample Date 10/08/16

Oil Type:

Description:

Grade:

10/8/16 1630HR

641282

PARTICLE COUNT

1207/ml 4

101/ml 6

7/ml 14

2/ml 20

1/ml 30

0/ml 40

17/14/10 ISO Code 4/6/14 um

Recommended Action:

Continue sampling to track/trend data.

Data Interpretation:

Based on the results of the analyses performed on this sample the unit and lube appear satisfactory for continuedusage.

Oil Analysis Data Sheet Report

R and G LABORATORIES (N) - NormalSeverity:

Manufacturer:

Sample ID:

Units

Lab Number

Sample Date 10/10/16

Oil Type:

Description:

Grade:

NEW DIAMOND CLASS 32

641280

PARTICLE COUNT

7183/ml 4

1936/ml 6

275/ml 14

98/ml 20

43/ml 30

32/ml 40

20/18/15 ISO Code 4/6/14 um

Recommended Action:

Continue sampling to track/trend data.

Data Interpretation:

Based on the results of the analyses performed on this sample the unit and lube appear satisfactory for continuedusage.

Oil Analysis Data Sheet Report

R and G LABORATORIES (MH) - Moderate HighSeverity:

Manufacturer:

Sample ID:

Units

Lab Number

Sample Date 10/10/16

Oil Type:

Description:

Grade:

USED DIAMOND CLASS32

641281

PARTICLE COUNT

6329/ml 4

1475/ml 6

526/ml 14

349/ml 20

172/ml 30

111/ml 40

20/18/16 ISO Code 4/6/14 um

ADDITIONAL TESTS

77.7ppm Karl Fischer H2O

Recommended Action:

Check for possible sources of water contamination.

Data Interpretation:

The sample from this unit contained trace water contamination.