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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.