effective varnish free maintenance for turbine lubricants - clean oil...

When Results Matter

Peter Dufresne Jr.Executive Vice President,EPT

EFFECTIVE VARNISH FREE MAINTENANCE FOR TURBINE LUBRICANTSWe are pleased to provide you with our information package on Turbine Lubricant Varnish.

Lubricant varnish production is a problem that will affect most rotating equipment at some point in its normal service lifetime, leading to production losses. In this package we provide a white paper overview of lubricant varnish, the underlying root cause and strategies to mitigate it. We have also included a white paper on MPC varnish potential to help users establish an effective testing program.

EPT’s Lubricant Maintenance Programs combine best-in-class technology with world-class expertise to provide a guaranteed solution. Please review our Product Specification Sheets for details on how our technology can improve your maintenance program.

As a starting point, we offer a complimentary oil analysis and comprehensive evaluation (ACE™) assessment that will allow our experts to review your current situation and make practical recommendations to alleviate common issues that frequently impair equipment reliability.

Thank you for your interest.

Peter

Package Details

1. White Paper – Lubricant Varnishing and Mitigation Strategies2. White Paper – MPC Varnish Potential Testing (ASTM D7843)3. Product Specification Sheets

a. SVR™ Soluble Varnish Removal Systemb. NSD™ Non-Spark Discharge Filtersc. Varnish (MPC) Field Test Kitd. Ci7 Spectrophotometer

4. Varnish Removal Case Studies5. Complimentary ACE™ Assessment form

WHITE PAPER

Lubricant Varnishing and Mitigation Strategies

EPT_WhitePaper-Varnish.indd 1 2016-09-09 3:02 PM

Approximately one in three large industrial gas turbines (GTs) shows signs of oil varnishing. Because this condition affects the availability and reliability of GTs, the original equipment manufacturer (OEM) recommends the use of varnish removal systems. Despite this, varnish-related turbine outages remain a significant issue for the industry.

The primary reason varnish is an ongoing problem is that strategies aimed at correcting or mitigating varnish-related problems are often misdirected, resulting in less than ideal outcomes. The following is a summary of an article published in Combined Cycle Journal to improve understanding of varnish by discussing its specific cause and how various mitigation alternatives work to minimize operational impacts.

VARNISH FORMATIONASTM D7843-12 defines lubricant varnish as a thin, hard, lustrous, oil-insoluble deposit composed primarily of organic residue. It is most readily defined by color intensity and is not easily removed by wiping.

Varnish begins its life as a soluble/dissolved degradation product before converting to particulate form and depositing on metal surfaces. As such, varnish is a shape-shifter; it can be “insoluble” (particulate – conventionally recognized form) or soluble (dissolved) in the fluid. .

An understanding of lubricant solvency is the key to understanding the mechanism by which varnish deposits are formed and, more importantly, the mechanism by which they can be removed.

“ Varnish begins its life as a soluble/dissolved degradation product before converting to particulate form and depositing on metal surfaces.”


1 When Results Matter


LUBRICANT SOLVENCYUnder normal operating conditions, turbine lubricants oxidize producing polar molecules (varnish precursors) from non-polar ones (mineral oil base stocks). These polar precursors represent the starting point of the varnish life cycle. As a result, lubricants in service are a complex combination of base stocks, additives, contaminants and breakdown products.

A lubricant’s solvency is defined as its ability to dissolve these distinct components. Everything in the oil has a finite solubility, which is affected by numerous factors (see next section). This solubility determines if a particular molecule will remain dissolved or if it will precipitate to form a potentially damaging deposit (Fig. 1).

Factors affecting lubricant solvencyThe following factors play a role in determining the solubility of varnish precursors in lubricants.

Molecular polarity Although varnish precursors produced by oxidative oil degradation are polar, they possess a finite solubility in a lubricant’s non-polar mineral oil matrix. Degradation products that are more polar will be correspondingly less solu-ble. The most basic concept of solvency is that “like dissolves like.”

Contaminant levelsLubricants have a finite capacity to dissolve other molecules (e.g. additives, contaminants and varnish precursors). As the oil degrades and oxidation products accumulate, the solvency of the fluid decreases accordingly. Beyond a certain point (saturation point), the fluid can no longer dissolve additional varnish precursors and varnish will begin to precipitate as a solid.

TemperatureAs temperature decreases, so too does the solubility of varnish and its precursors. This process is responsible for the formation of varnish deposits in cooler regions of a turbine’s lubricant circulation system. Because metals are more polar than the lubricant’s base stock, the precipitated polar varnish prefers to adhere to the metal and form potentially damaging deposits. When the level of varnish precursors in a lubricant is near the fluid’s satura-tion point, varnishing in cooler regions is very likely to occur.

Fig. 1—Varnish is shown here in its deposited form

Varnish formation inside a GE 7FA turbine reservoir




THE VARNISH CYCLEThe typical varnish formation cycle in a gas turbine involves the following three steps (Fig. 2). 1. Oxidation is a chemical reaction between the lubricant base stock and

oxygen in the air. When a new fluid is put in service, it is exposed to high-er temperatures and experiences an increase in oxidation rate. Oxidation products build up in the lubricant over time, but remain dissolved at oper-ating temperatures until they exceed the fluid’s saturation point.

2. As the oil moves from hotter regions within the system to cooler ones, its temperature falls and the solubility of varnish precursors decreases. These precursors begin to precipitate from solution in the form of particulate. This precipitation of varnish is a physical change and not a chemical reaction.

3. Once formed, varnish particles collect and form deposits, preferentially coating metal surfaces. These deposits are often the cause of unit trips or fail-to-start conditions. Like precipitation in Step 2 above, this process is a physical change.

While the chemical reaction that leads to the formation of varnish precursors (Step 1) is irreversible, the physical changes (Steps 2 and 3) which lead to the formation of varnish deposits are reversible. Therefore, once varnish parti-cles/deposits form, they can be reabsorbed if the solvency of the lubricant is increased. Successful varnish mitigation strategies use this fact to their advantage.

TESTING FOR VARNISHDue to the potential for costly turbine downtime associated with varnishing, it is critical to test lubricants for varnish potential. Varnish potential testing, also called MPC (membrane patch colorimetry, ASTM 7843, Fig. 3) is recom-mended by ASTM to be performed quarterly at a minimum. Other collabora-tive tests, like patch weight, may be helpful in determining oil condition.

Lubricant

Step 1:SolubleVarnish

Step 2:InsolubleVarnish

Step 3:VarnishDeposit

PHYSICAL

CHEMICAL

PHYSICAL

Fig. 2—Varnish formation cycle is summarized in three steps

Fig. 3—MPC scale

Good < 15

Monitor 15 – 25

Abnormal 25 – 35

Critical > 35




It is important to follow the ASTM method, otherwise MPC results may vary significantly depending on the length of time the oil sample was “aged,” or stored. MPC values generally increase during storage or when exposed to ultraviolet (UV) light as oxidation reactions initiated from when the lubri-cant was in service continue to occur. This highlights the necessity of using varnish removal systems on a continuous basis – oil reservoirs with accumu-lated break-down products can continue to form varnish when the turbine is not operating.

STRATEGIES TO COMBAT VARNISHINGMost modern turbine lubricants are made with API (American Petroleum Institute) Group II mineral oil base stocks, which contain an antioxidant additive package. The chemistry of Group II base stocks makes them more oxidatively stable than the traditional Group I base stocks (Fig 4.).

AntioxidantsAntioxidants are added to the lubricant as a built-in varnish mitigation strat-egy. These additives commonly comprise two classes of chemicals: phenols and amines. These chemical additives are sacrificial and will oxidize more readily than the oil base stock. Unfortunately, both phenols and amines are consumed as they oxidize. Once the additives are consumed, the rate of fluid degradation accelerates, returning to that of the non-additized base stock (Fig. 4). Antioxidants limit the rate of oxidative degradation and, therefore, delay varnishing, but they cannot prevent it.

When the lubricant inevitably oxidizes and varnish precursors are formed, varnish removal systems are necessary to prevent degradation products from accumulating to the point where varnishing occurs. There are two main types of varnish removal systems: those based on the removal of suspended particles and those based on the removal of soluble varnish and its precursors.

Suspended particle removal systemsDepth filtration, Balanced Charge Agglomeration (BCA™), electrostatic oil cleaning or combinations of these techniques are advanced forms of partic-ulate removal. Since solvency decreases at lower temperatures (favoring the formation of particulates), the maximum benefit using these systems is achieved when the turbine is not operating and the lubricant is at ambient temperatures. Therefore, these systems are of more use when employed periodically, during outages; they are less effective when used continuously during turbine operation. When used during normal turbine operation, these systems are incapable of removing soluble varnish and its precursors.

To overcome this limitation, oil coolers can be used to accelerate the varnish formation cycle and precipitate particulate from the lubricant immediately before it passes through the varnish removal system. However, cool oil is more viscous making it difficult to pass through these filtration systems. The oil cannot be cooled to the temperatures required for complete removal of all soluble varnish. Therefore, lubricant solvency is never improved to the point where existing varnish deposits can be re-dissolved into the fluid.

Fig. 4—Oil degradation over time

Group I

Group II

Time Time

Additivesbecomedepleted

Oil

degr

adat

ion

Oil

degr

adat

ion

“ When used during normal turbine operation, these systems are incapable of removing soluble varnish and its precursors.”

Group I

Group II

Time Time

Additivesbecomedepleted

Oil

degr

adat

ion

Oil

degr

adat

ion




Soluble varnish removalSoluble Varnish Removal (SVR™) systems use specialized Ion Charge Bond-ing (ICB™) ion exchange resins that contain billions of polar sites capable of adsorbing soluble varnish and its precursors (Fig. 5). Conventional ion-ex-change resins function by exchanging one chemical for another. Unlike these resins, which essentially exchange one contaminant for another, ICB™ resins are engineered to adsorb the entire contaminant without returning any other to the fluid.

A key benefit of the ICB™ adsorption principle is that harmful oxidation products can be removed at any operating temperature, meaning that SVR™ systems can be used continuously. The continuous removal of soluble varnish ensures that degradation products do not accumulate in the lubricant, elim-inating the risk of varnish formation during normal turbine shut down cycles. Moreover, the continuous removal of soluble varnish produces a lubricant with extremely high solvency.

Since the physical changes that resulted in the formation of varnish particles and deposits are reversible, the high solvency of the SVR™-treated lubricant forces varnish already present on turbine surfaces back into the soluble form where it can be adsorbed and removed. With all the remaining oxidation by-products removed, the varnish formation cycle is halted.

SUMMARYVarnish particles and deposits are created from reversible physical changes that begin with soluble oxidation products and end with varnish deposits. For these changes to be reversible, the chemistry of the deposits has to be similar to the chemistry of the lubricant from which the deposits originat-ed. Once fluid solvency has been increased (by removing soluble varnish at normal operating temperature), deposits will simply dissolve back into the fluid and be removed.

ADDITIONAL RESOURCES1. Combined Cycle Journal: Lubricant Varnishing and Mitigation Strategies2. MPC Varnish Potential Testing White Paper3. SVR™ 1200 Varnish Removal System

CONTACT INFORMATIONFor additional information contact:

E [email protected] T +1.403.246.3044

Fig. 5—SVR™ systems are the preferred choice in industry with over 400 installations and an average MPC value of 3.1

09/16

BCA is a trademark of ISOPur Fluid Technologies, Inc. SVR and ICB are trademarks of EPT.© 2016 EPT. All Rights Reserved.




WHITE PAPER

MPC Varnish Potential Testing (ASTM D7843)

Membrane patch colorimetry (MPC) varnish potential testing (ASTM D7843) is an essential analytical test to determine the propensity for a lubricant to form varnish deposits. With the probability of varnish-related failures reported to be as high as 100% (GE TIL 1528-3), monthly MPC testing is recommended for all critical turbine installations. The ASTM-approved MPC test is straightforward and can be completed as part of your existing lubricant analysis testing program. It can also be performed on-site using a modified test method for rapid assessment of potential varnish-related problems.

MPC TEST OVERVIEWThere are two main parts to the MPC test: filtration and color measurement. During the first part, 50 mL of the lubricant to be tested is diluted with an equal volume of petroleum ether. This mixture is then filtered through a 0.45 μm nitrocellulose patch which is then rinsed with petroleum ether and dried. The intensity and color of the patch are then measured against a control patch using a spectrophotometer that calculates the color difference, or ΔE value. The ΔE value and the corresponding propensity for the formation of lubricant varnish deposits are then assessed according to an MPC scale (Fig. 1).

MPC ScaleEPT’s MPC scale is then used as a guideline to help users assess their lubri-cant’s potential for varnish formation. There are 4 levels on the varnish potential scale: Good (ΔE<15), Monitor (ΔE = 15-25), Abnormal (ΔE = 25-35) and Critical (ΔE >35). The higher the MPC value, the higher the amount of varnish deposits and precursors dissolved in the lubricant and the greater the propensity for the lubricant to form harmful varnish deposits.

“ Monthly MPC testing is recommended for all critical turbine installations.”

Watch EPT’s video demonstration of the MPC test method at www.cleanoil.com/products/varnish-potential-testing-mpc.html. The full test procedure for ASTM D7843 can be purchased from: www.astm.org.



OPERATING TARGET MPC VALUEIdeal lubricant operating condition (from a varnish perspective) is achieved when the MPC ΔE value is <15. When the MPC ΔE value is continually main-tained at below this value, the lubricant‘s solvency characteristics are maxi-mized, which prevents varnish deposit formation and forces existing depos-its back into their less harmful dissolved form.

MPC values increase as dissolved oil breakdown products (varnish precur-sors) accumulate. These breakdown products are produced by oxidation and begin to accumulate from the first moment that the lubricant goes into service. Each lubricant has a finite capacity (saturation point) to hold these dissolved oxidation products in solution. Once this point is reached, the lubricant becomes saturated and excess breakdown products are forced from the fluid, forming harmful lubricant varnish deposits. Once formed, lubri-cant varnish has a natural attraction for metal surfaces because of the polar nature of both the varnish and the metal. As varnish begins to coat metal surfaces, mechanical clearances are reduced, decreasing equipment perfor-mance and, ultimately, leading to failure.

Complicating matters, the saturation point varies with lubricant tempera-ture, pressure and flow. These parameters are dynamic in most mechanical systems. For this reason, varnish is often deposited in sensitive mechanical areas prior to appearing in the oil reservoir. It is, therefore, important to select a varnish prevention program that addresses the issue during normal turbine operation when the varnish precursors are dissolved in the oil.

When MPC values are maintained at ΔE <15, the lubricant contains very few varnish precursors and is not prone to deposit formation. Moreover, the lubricant will have high solvency characteristics under all system operating conditions and will actively remove any existing varnish deposits from metal surfaces.

Good <15

Monitor 15 – 25

Abnormal 25 – 35

Critical >35

Fig. 1—MPC scale to determine lubricant potential for varnish formation

Fig. 2—Sample MPC trending data from an EPT SVR™ system gas turbine lubricant reservoir installation

Sample MPC Trending Data—Gas Turbine Lubricant Reservoir

Sample Date

MPC

∆E

50

40

30

20

10

60

0

Varnish Removal Unit(SVR™) Installed

SVR™ ElementsChanged MPC ∆E

High Risk ofVarnish-RelatedFailure

Target



REQUIRED MATERIALS FOR MPC TESTINGThe following apparatus and consumables are required to complete the MPC test. There are three primary components: Patch test kit apparatus, vacuum pump, and spectrophotometer. EPT offers two different MPC test kit appara-tus (glass or heavy duty stainless steel), two vacuum pump options (hand or electric) and one type of spectrophotometer.

APPARATUS REQUIRED

47 mm Patch Kit Apparatus Assembly to hold one 47 mm patch. 100 mL reservoir capacity with waste container. There are two options:

1. Standard laboratory glassware (p/n 601504)

2. Durable stainless steel for portability and field use (p/n 601480)

Both MPC test kits come with all consumables listed in table below, except solvent.

Vacuum Pump There are two options:

1. Hand pump for field use with plastic tubing

2. Electric vacuum pump for laboratory use (purchase locally)

Spectrophotometer Model Ci7, gas-filled tungsten lap, 6 silicon photocell detector to measure (L*a*b*)/ΔE*ab; Δ(L*C*H*)/ΔE*ab, L*: 10 to 100.

Oven The ASTM test method requires that the lubricant sample be heated at 60°C for 24 hours and then aged at room temperature for 68 – 72 hours. Any laboratory grade oven is sufficient.

The modified field test method can achieve similar results by aging the sample at room temperature for 68 – 72 hours.

CONSUMABLES REQUIRED

Petroleum Ether 50 – 100 mL petroleum ether required per test.

Not offered.

Filter Patch 47 mm, 0.45 μm nitrocellulose patch.

25 patches included with MPC test kits (p/n 601496).

Plasticware 1. Graduated beaker to mix solvent and lubricant, >100 mL capacity

2. Solvent wash bottle to rinse patch after test, 100 mL capacity

One each included with MPC test kits (p/n 601509).

Expert SupportIncluded with the purchase of our MPC varnish potential testing products is access to our expert chemistry team, who have completed 1000s of MPC tests. From answering a quick question to in-depth technical support, you will have invaluable access to experts to ensure that your varnish potential testing program is successful.



ADDITIONAL RESOURCES1. Lubricant Varnishing and Mitigation Strategies White Paper2. Patch Kit Apparatus Product Sheet3. Hand Pump Product Sheet4. Electric Pump Product Sheet5. Spectrophotometer Model Ci7 Product Sheet

CONTACT INFORMATIONFor additional information contact: E [email protected] T +1.403.246.3044

08/16SVR is a trademark of EPT.© 2016 EPT. All rights reserved.



4772 - 50 AVE SE, Calgary AB T2B 3R4, Canada T 403.246.3044 E [email protected]

When Results Matter

SVR™ SOLUBLE VARNISH REMOVAL SYSTEMINDUSTRY-LEADING SOLUTION FOR REMOVING AND PREVENTING LUBRICANT VARNISH

OverviewLubricant varnish is frequently misunderstood as being an oil quality issue. The truth is that all lubricants form dissolved breakdown products, which if allowed to accu-mulate will eventually form varnish deposits. Varnish forms when a lubricant’s capacity to hold dissolved oil breakdown products is exceeded. The key to prevent and remove varnish is to stop the accumulation of these breakdown products and maintain the lubricant’s solvency.

EPT’s Soluble Varnish Removal (SVR™) system continu-ously removes and prevents accumulation of dissolved breakdown products during normal turbine operation, so that lubricant varnish cannot accumulate and form – period. Unlike particulate removal based technologies that must wait for varnish to fall out of solution to work, the SVR™ system removes contamination during normal equipment operation when the varnish is dissolved, preventing harmful varnish deposits from ever forming.

EPT-Specsheet_SVR.indd 1 2016-09-16 5:28 PM


When Results Matter

Key Benefits of SVR™ Systems• Features EPT’s industry leading ICB™ filter purification

technology for soluble varnish contaminant removal - Over 40 million successful operating hours - ICB™ filters will not affect turbine oil additives1

- 4-6x more capacity than competing varnish removal systems

- Unlike competing systems, SVR™ purifies 100% of reservoir volume each day

• Quickly reduces and prevents servo valve sticking• SVR™ system quickly reduces varnish potential in

large gas turbines as measured by the MPC or QSA® tests

• Unlike particulate removal technologies, SVR™ works all the time including operating conditions when varnish is dissolved in the oil

• Eliminates the varnish formation cycle that typically occurs when the oil cools during turbine shut down

• Removes all forms of varnish (solid and dissolved)• Low cost of ownership over 10 years with defined

consumable costs• ICB™ filter cartridges are changed annually when

installed on common sized reservoirs and used in maintenance mode

• Small footprint and straight-forward operation • Low maintenance: Turn it on and let it run, that’s it! • Guaranteed to work with comprehensive analysis

included at no charge until results are documented

ConsumablesOne complete set of filters are included with SVR™ system purchase.

P/N 600524V ICB™ filter†

P/N 600524T ICB™ filter for lubricants <12 months old

P/N 600699 3 μm β200, micro glass particulate filter‡

Lowest Cost of Operation Over 10 years80% of all sites clean up with 2 sets of consumables over 3-4 month period, with annual replacement thereafter. See real-life example on next page.

Best Warranty in Industry3 years on all parts.

1 Lubricants less than 12 months old should use EPT- 600524T series filters for additional protection.

† Recommend stock level of 2 each. 2 filters used during operation.‡ Recommend stock level of 4 each. 1 filter used during operation.



When Results Matter

MPC ΔE Reduction Using SVR™ SystemM

PC Δ

E

DATE

6-Fe

b-12

6-Ja

n-12

6-De

c-11

6-No

v-11

6-O

ct-11

6-Se

p-11

6-Au

g-11

6-Ju

l-11

6-Ju

n-11

6-M

ay-11

6-M

ar-12

30

25

20

15

10

5

35

0

SVR™ System Gas Turbine Application Case StudyThe above example demonstrates typical SVR™ system performance in a varnish-contaminated turbine lubricant reservoir.

• Lubricant solvency is quickly improved after SVR™ system installation due to removal of dissolved breakdown products. - This initial period of operation is known as the

restoration phase where previously deposited varnish is re-dissolved by the lubricant because of its improved solvency characteristics.

- Varnish testing is recommended bi-weekly during the restoration phase as monthly testing will not show the initial dramatic VPN decrease or subse-quent deposition removal shown by MPC value increases/decreases.

• The length of the restoration phase is based on the amount of varnish and contamination that has accu-mulated in the lubricant reservoir. - 3 – 4 months is common in most systems, longer

for heavily varnished systems. - ICB™ filters may need to be replaced 1x in normal

restoration phase situations, or 2x in situations with heavier contamination levels.

• Observe varying MPC value increases/decreases. - Increases are expected in situations where varnish

deposits are present; the increase is showing the impact of deposited varnish being dissolved back into the lubricant.

• The second MPC value decrease is a positive indica-tion that suggests the restoration phase is coming to an end. - In the example above, there is a third increase/

decrease showing that additional varnish deposits were still being dissolved and then removed.

• 4 months after SVR™ installation, the restoration phase is complete, and the lubricant enters the “stability phase” where MPC values are extremely low and stable (>7 months in this example). - Varnish precursors are removed as they are

produced during the stability phase, eliminating the normal accumulation cycle and the potential for varnish formation.

- Operating in the stability phase should be the goal of all turbine operators as it optimizes lubricant/additive performance, and reduces the associated risk of lubricant related turbine failures.



When Results Matter

SVR™ System SpecificationsSVR SYSTEM SIZE SVR 150 SVR 300 SVR 600 SVR 1200 SVR 2400

Dimensions LxWxH (cm/in.) 122 x 81 x 185/ 48 x 32 x 73

122 x 81 x 185/ 48 x 32 x 73

122 x 69 x 188/ 48 x 27 x 74

122 x 69 x 239/ 48 x 27 x 94

122 x 152 x 239/ 48 x 60 x 94

Weight (kg/lb) 159/350 181/400 201/550 273/600 454/1000

Connections: Inlet/Outlet FNPT (in.) 1.0/1.0 1.0/1.0 1.5/1.0 1.5/1.0 2.0/1.5

Electrical Options 120 VAC 1P, 230/ 380/ 475/ 575/ VAC 3P 50/60 Hz. Standard unit is general purpose. Class 1 Div. 1 and Div. 2 options are available.

Current 12.8 Amps

Oil Temperature 38-70°C/100-158°F. Heater and cooler options are available.

Certifications ASME Certified Vessels @ 150 psi / UL, CUL, CSA

SVR™ System Sizing for Turbine and Compressor Lubricant MaintenanceFor normal turbine or compressor oil maintenance, the desirable flow rate is to exchange the fluid reservoir volume 1 – 2x per day. For recovery projects, higher exchange rates are desired.

SVR SYSTEM SIZE SVR 150 SVR 300 SVR 600 SVR 1200 SVR 2400

Reservoir Volume (L/gal) For larger volumes contact factory.

1600/420 3200/845 6400/1690 20000/5280 40000/10560

Flow Rate (LPM/GPM) 2/0.5 4/1 8/2 16/4 32/8

Reservoir Exchange Rate per 24 hr 1.8x 1.8x 1.8x 1.44x 1.44x

Estimated Acid Reduction Capacity Per Set of Filters

2 2 2 2 2

Note: Using the above sizing, 80% of sites are typically restored with 2 sets of filters with a replacement interval of 6 weeks. The clean-up or restoration period is typically 3 – 4 months. Heavily contaminated sites normally require 3 sets of filters with a replacement interval of 1 month. After lubricant restoration is complete, the normal fluid maintenance mode requires that filters are replaced annually. All installations include detailed monthly analysis until clean-up period is complete. See SVR™ Case Studies for additional information.

Additional Resources1. 20 Case Studies: Turbine Lubricant Varnish Removal using SVR™ Systems 2. Combined Cycle Journal: Lubricant Varnishing and Mitigation Strategies3. Modern Power Systems: Turbine Lubricant Maintenance for Varnish Free Operation4. White Paper: MPC Varnish Potential Testing (ASTM 7843)5. ICB™ filters for SVR™ systems, ICB™ 600524

SVR™ and ICB™ are trademarks of EPT. QSA® is a registered trademark of Analysts Inc.© 2016 EPT. All rights reserved.

09/16



When Results Matter

Overview As fluid passes through the typical tortuous filter media fiber matrix, turbulence increases. This results in thermal events as the fluid layers shear, creating static accu-mulation on filters that can lead to high-voltage spark discharge from the filter media to the support tube. Figures 1A and 1B show evidence of sparking on the filter support tube (pitting and burning), and Figure 1C shows the filter media and support mesh from a lube filter with spark discharge burn damage.

The change from Group I to Group II base stock oils has enhanced the effect of spark discharge. Group I oils could conduct low levels of static charge out of the system to ground. The changes in resistivity with Group II oils mean that static charges stay in the system and can yield higher levels of static charge on filters. If the filter cannot minimize and dissipate the charge, static will build until it eventually arcs to a nearby surface.

NSD™ NON-SPARK DISCHARGE FILTERS

Fig. 1—Filter support tube pitting (A) and burning (B) due to sparking. (C) Filter media and mesh damage from spark discharge.

A B C


When Results Matter

Key Features of NSD™ Filters• G8 element and media technology is optimized to

prevent spark discharge and minimize potential energy in bearing lubrication and hydraulic control systems.

• Prevents oil degradation caused by thermal events associated with element spark discharge.

• Prevents antioxidant additive depletion and extends useful fluid life.

NSD™ Filters, Cleaner Fluid Without Sparking For some, the answer to preventing element sparking and high potential energy is to use coarse strainer type filters (Stat-Free) in the main bearing lube filter duplex. Although this may prevent sparking, the compromise between reduced filtration and risk of catastrophic bearing failure is not a reasonable trade off, nor neces-sary. Independent lab analysis proves that Hy-Pro high efficiency 3 micron absolute (β5[c] > 1000) NSD™ filters are resistant to spark discharge.

The degree to which filter spark discharge contributes to overall varnish problems is misunderstood. Varnish is caused from oxidation. Spark discharge causes a severe form of oxidation called thermal degradation. Thermal degradation prematurely consumes additives and reduc-es fluid life. With NSD™ filters, spark-induced thermal degradation is significantly reduced or eliminated there-by maximizing fluid additive life.

ORIGINAL PART NUMBER HY-PRO PART NUMBER

*03384509 Stat-Free HP101L18-12EV-NSD

200EB10 HPQ20082S-12EV-NSD

234A6578P0002, 234A6579P0002 HP41L13-3EV-NSD

254A7220P0008 HP41L13-3EV-NSD

254A7229P0005 HP41L13-3EV-NSD

258A4860P002 HP61L11-2EV-NSD

258A4860P004 HP61L21-2EV-NSD

315A2600P003 HP21L4-15EV-NSD

361A6256P010 HPK3L18-3EV-NSD

363A4378P003 HPQ20082S-17EV-NSD

363A4378P004 HPQ20082S-12EV-NSD

363A7485P0001 HPQ20082S-12EV-NSD

932683Q HPK3L18-3EV-NSD

B984C302P012 HP21L4-15EV-NSD

FQ19165 HPQ20082S-12EV-NSD

HC0101FAP18ZYGE HP101L18-3EV-NSD

HC0101FAS18Z HP101L18-12EV-NSD

HC0101FAS18ZYGE HP101L18-12EV-NSD

HC101FAP18Z HP101L18-3EV-NSD

HC2006FAS28Z HPQ20082S-12EV-NSD

HC2006FAT28Z HPQ20082S-25EV-NSD

HC2006FKS28Z HPQ20082S-12EV-NSD


HC2006FKT28Z HPQ20082S-25EV-NSD

HC2006FMS28Z HPQ20082S-12EV-NSD

HC2006FMT28Z HPQ20082S-25EV-NSD



HC2618FKP18Z HP102L18-3EV-NSD

HC2618FKP18ZYGE HP102L18-3EV-NSD

HC2618FAS18Z HP102L18-12EV-NSD

HC2618FAS18ZYGE HP102L18-12EV-NSD

HC2618FKS18Z HP102L18-12EV-NSD

HC2618FKS18ZYGE HP102L18-12EV-NSD

HC8900FMN26HY550 HPQ98320L26-6EB-NSD

HC8900FMN26ZY550 HPQ98320L26-6EV-NSD

HC8900FMN39HY550 HPQ98320L39-6EB-NSD

HC8900FMN39ZY550 HPQ98320L39-6EV-NSD

HC8900FMS26HY550 HPQ98320L26-12EB-NSD

HC8900FMS26ZY550 HPQ98320L26-12EV-NSD

HC8900FMS39HY550 HPQ98320L39-12EB-NSD

HC8900FMS39ZY550 HPQ98320L39-12EV-NSD




NSD™ is a trademark of EPT.© 2016 EPT. All rights reserved.


When Results Matter09/16



HC9021FAT4Z HP21L4-15EV-NSD

HC9021FAT4ZYGE HP21L4-15EV-NSD



HC9021FDP4Z HP21L4-2EV-NSD

HC9021FDP4ZYGE HP21L4-2EV-NSD



HC9021FDT4Z HP21L4-15EV-NSD

HC9021FDT4ZYGE HP21L4-15EV-NSD

































HC9701FAP18Z HPK3L18-3EV-NSD

HC9701FAP18ZYGE HPK3L18-3EV-NSD

HC9701FDP18Z HPK3L18-3EV-NSD

HC9701FDP18ZYGE HPK3L18-3EV-NSD

HP9560FAP16Z HP50L16-3EV-NSD

HP9560FAP16ZYGE HP50L16-3EV-NSD

PH718-05CNVGE *HP101L18-17EV-NSD

PMG528-10 HPQ20082S-17EV-NSD

PMG528-10B200-GE HPQ20082S-12EV-NSD

PMG528-10-GE HPQ20082S-17EV-NSD


When Results Matter

MPC TEST KIT (ASTM D7843) – PORTABLE FIELD UNITAPPARATUS AND MATERIALS FOR PREPARING MEMBRANE PATCH USED TO DETERMINE MPC VARNISH POTENTIAL

OverviewTo complete membrane patch colorimetry (MPC) varnish potential testing, you require the MPC Test Kit apparatus, Vacuum Pump and Spectrophotometer. Each component is sold separately. Please see our MPC Varnish Potential White Paper for a detailed overview and link to a video demonstration.

The EPT MPC Test Kit has been carefully assembled to include the key items required for preparing a 47 mm membrane patch. The portable filter assembly has been selected for its high durability and quality, which make it ideal for field use. An alternative laboratory kit based on standard glassware is also available. Either style kit is used to prepare a membrane patch for varnish potential determination as outlined in ASTM D7843.


When Results Matter09/16

Key Features of the MPC Test Kit• High quality, rugged design and stainless steel

construction.• Includes all materials and consumables required

(excluding solvent) to prepare the patch used for measuring MPC varnish potential.

• Simple to use, with step-by step instructions and video demonstration.

• Packaged in water-tight, Pelican™ brand case.

Expert SupportAccess to our expert chemistry team is included with the purchase of our MPC varnish potential testing prod-ucts. Our chemistry team has completed 1000s of MPC varnish potential tests. From answering a quick question to in-depth technical support, you will have invaluable access to experts for all aspects of MPC testing.

Warranty1 year.

Pelican is a trademark of Pelican Products, Inc.© 2016 EPT. All rights reserved

Apparatus and Consumables (Excluding Solvent) to Prepare 47 mm Patch

APPARATUS

Part Number 601480 • Stainless steel sample reservoir, 100 mL capacity

• Stainless steel waste container, 200 mL capacity

• Stainless steel patch assembly with support backing

• Water tight storage and transport case, Pelican™ brand

Vacuum Pump, and Spectrophotometer sold separately (see Product Sheets).

CONSUMABLES

Petroleum Ether 50-100 mL petroleum ether required per test (not offered).

Filter Patch 47 mm, 0.45 μm nitrocellulose patch.

Quantity 25, included with patch test kit.

Replacement part number 601496.

Misc. Accessories • Graduated beaker to mix solvent and lubricant, >100 mL capacity

• Solvent wash bottle to rinse patch after test, 100 mL capacity

• Waste container, >100 mL capacity

• Mixing rod and laboratory tweezers

Quantity 1 each, included with patch test kit.

Replacement part number 601509.


When Results Matter

CI7 SPECTROPHOTOMETERFOR MPC VARNISH POTENTIAL TESTING (ASTM D7843)

OverviewThe Ci7 is a lightweight, portable, palm-sized spectropho-tometer used to measure MPC varnish potential. This unit replaces the I-LAB spectrophotometer that is no longer offered. MPC varnish potential readings are obtained by using the Ci7 to scan 47 mm (0.45 μm) nitrocellulose patches, which have been prepared according to ASTM D7843. The materials and filtration apparatus required to produce the membrane patch are sold separately. See MPC Test Kit Product Sheet for an overview of the test including the apparatus and consumables required.

Key Features of the Ci7 Spectrophotometer• Excellent correlation with I-LAB predecessor, R2 value

of 0.9951.• Repeatable MPC varnish potential results in less than

1 second.• This durable instrument is a significant upgrade in

terms of reliability and precision from other instru-ments (including I-LAB).

• The high quality Ci7 spectrophotometer comes ready-to-use right out of the box without the need for addi-tional programing or calibration between samples.

• Includes certification document verifying that the instrument is producing accurate MPC value readings.

• Includes expert technical support.

EPT-Specsheet_Ci7.indd 1 2016-09-16 5:22 PM

Turbine Lubricant Varnish Removal Case Studies using SVR

As of May 2014 there are over 400 SVR installations on turbine lubricant reservoirs operating throughout the world. These systems have gained an industry leading reputation for reducing and maintaining low varnish potential including many sites where competing systems have failed.

Each SVR installation is supported by a team of experts who will ensure that results are achieved and documented at your facility. This support is included with the purchase of each SVR.

Attached are 20 case studies that demonstrate typical results. Once an SVR is installed, the lubricant enters a “Restoration phase” that last 3-4 months on average. During this phase, previously deposited varnish dissolves back into the purified lubricant where it is removed by SVR. During this clean-up period, the MPC values fluctuate as the varnish content of the fluid varies. Once varnish deposits are removed, varnish is continually removed as it forms and the lubricant enters a “Stability phase” where MPC values are maintained at <15 (ASTM 7843). Because varnish is continually removed as it forms during the stability phase, varnish does not accumulate in the lubricant reducing the risk of varnish formation to nil. For privacy, all customer specific information has been removed.

For additional information, and a complimentary turbine lubricant assessment with lab scale demonstration please contact us at: http://www.cleanoil.com/contact/distributors.html

For additional information contact: [email protected]

Case StudiesTurbine Lubricant Varnish Removal Using SVR

10/15


When Results Matter

Case Study #1Location: MD, USA

MW: 350 MW

Turbine Type: ST, GE

Oil Type: Mobil DTE 732

Volume: 8,000 Gallons/30,283 Litres

BACKGROUND:This site was experiencing a build-up of varnish on mechanical components. An SVR was installed and initial results described a three-month stabilization period as varnish deposits were adsorbed back into the lubricant. A significant decreasing trend began after four months of operation, which means that varnished mechanical components had been completely cleaned. SVR treatment reduced the fluid varnish potential value to below 10 over the subsequent three months. Varnish potential values are now stable and at historically low values.

MP

C ∆

E

DATE

7-Nov

-11

18-O

ct-1

1

28-S

ep-1

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8-Sep

-11

19-A

ug-1

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30-J

ul-11

10-J

ul-11

20-J

un-1

1

31-M

ay-1

1

11-M

ay-1

1

17-D

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27-N

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5-M

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15-A

pr-12

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eb-1

2

26-J

an-1

2

6-Ja

n-12

14-J

un-1

2

25-M

ay-1

2

50

40

30

60

20

10

0

MPC ∆E Reduction Using SVR Mobil DTE 732


10/15


When Results Matter

Case Study #2Location: MD, USA

MW: 685MW

Turbine Type: ST GE



BACKGROUND:This site had a history of varnish problems; the customer consistently experienced build-up of varnish on mechanical components. Once SVR was installed, varnish potential numbers fluctuated over a two month period while varnish deposits were adsorbed into the lubricant. Notable reductions were achieved by month three. Consistent reductions continued over the next six months. Permanent use of SVR has been able to reduce varnish potential values by another 60% and to be maintained at 15 or below. Varnish potential values are now stable and at historical low values.

MP

C ∆

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DATE

6-Ju

n-12

6-M

ay-1

2

6-Apr-1

2

6-M

ar-12

6-Fe

b-12

6-Ja

n-12

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-11

6-Nov

-11

6-Oct

-11

6-Sep

-11

6-Aug

-11

6-Ju

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6-Ju

l-11

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n-11

6-M

ay-1

1

6-Apr-1

1

50

40

30

20

10

60

70

0



10/15


When Results Matter

Case Study #3Location: PA, USA

MW: 190MW

Turbine Type: GE 7FA

Oil Type: Shell Turbo CC 32


BACKGROUND:This site had a history of varnish problems with QSA® varnish potential values at 75 or higher. Previous efforts on the part of maintenance staff were unable to control varnish potential values, which was a significant concern for the turbine owner. Upon installation of SVR, varnish potential values were quickly reduced. MPC varnish potential values are now at 10 or lower.

MP

C ∆

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DATE

19-O

ct-1

1

12-O

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1

5-Oct

-11

28-S

ep-1

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21-S

ep-1

1

14-S

ep-1

1

7-Sep

-11

31-A

ug-1

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24-A

ug-1

1

26-O

ct-1

1

5

30

35

20

25

10

15

0

MPC ∆E Reduction Using SVR Shell Turbo CC 32


10/15


When Results Matter

Case Study #4Location: CA, USA

MW: 40MW

Turbine Type: GT, GE 6FB

Oil Type: Shell Turbo TX 32


BACKGROUND:This turbine is used as the primary generator at an oil and gas production facility. High varnish potential values were of concern due to the critical nature of the turbine and the potential loss in production associated with any turbine outage. SVR was installed and quickly reduced varnish potential values by >50%. Further decreases were observed with continued SVR use. Varnish potential values are now less than 5.0 and stable.

MP

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DATE

6-Ja

n-13

6-Nov

-12

6-Sep

-12

6-Ju

l-12

6-M

ay-1

2

6-M

ar-12

6-Ja

n-12

6-Nov

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-11

6-Ju

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6-M

ar-13

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ay-1

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5

30

35

20

25

10

15

0

MPC ∆E Reduction Using SVR Shell Turbo TX 32


10/15


When Results Matter


MW: 210MW

Turbine Type: GT, GE 7FA

Oil Type: Mixture Mobile DTE 832/Shell Turbo CC 32


BACKGROUND:This unit had a history of varnish problems with multiple unit TRIPS and fail-to-start conditions. SVR systems were installed on all turbines and quickly reduced varnish potential by over 50% with no further turbine failures occurring. Continued long term use of SVR has been able to reduce varnish potential values by another 40% with values now at <15. Varnish potential values are now stable and at historical low values.

MP

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30-J

un-1

2

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29-F

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30-D

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31-A

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30-J

un-1

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30-A

pr-11

28-F

eb-1

1

30-D

ec-1

0

31-A

ug-1

2

50

40

30

60

20

10

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MPC ∆E Reduction Using SVR Mobil DTE 832/Shell Turbo CC 32

Mix


10/15


When Results Matter


MW: 185MW

Turbine Type: GT, GE 7FA CC

Oil Type: Mixture Mobile DTE 832/Shell Turbo CC 32


BACKGROUND:Unit had a history with multiple trips and fail-to-start conditions. SVR system was installed on this unit and within six months had produced downward trending MPC results. No turbine failures occurred after the SVR system was installed. The length of time prior to decreasing MPC is based on the amount of varnish on system components. The varnish potential is now below 15 and continues to decrease.

MP

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30-J

un-1

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30-A

pr-12

29-F

eb-1

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1

30-J

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30-A

pr-11

28-F

eb-1

1

30-D

ec-1

0

31-A

ug-1

2

50

40

30

60

20

10

0

MPC ∆E Reduction Using SVR Mobil DTE 832/Shell Turbo CC 32

Mix


10/15


When Results Matter

Case Study #7Location: AB, Canada

MW: 100MW

Turbine Type: GT, GE 7EA

Oil Type: Teresso GTC 32


BACKGROUND:An electrostatic oil cleaner was operational on this system full-time since turbine commissioning in 2009. Within 18 months of initial operation, varnish potential values had increased above 40 to critical levels. SVR was installed February 2011 and reduced varnish potential, which then increased as system deposits were adsorbed back into the lubricant. Subsequent element changes performed annually have achieved stable and historically low varnish potential values.

MP

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22-A

ug-1

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22-J

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22-J

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pr-11

22-F

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22-D

ec-1

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22-O

ct-1

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50

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30

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20

10

0

MPC ∆E Reduction Using SVR Teresso GTC 32


10/15


When Results Matter


MW: 520MW

Turbine Type: ST



BACKGROUND:When initially contacted, this site had extreme varnish potential values. SVR was installed and immediately reduced varnish potential values by >60%. Existing system deposits were then adsorbed back into the lubricant which increased varnish potential values. Based on the level of increase, the results suggest that existing system varnish deposits were above average. Secondary decreases followed by increases also suggest above average levels of varnish deposits were present. The system stabilized after eight months of SVR treatment. No additional operational problems have been experienced and varnish potential values remain at historically low levels.

MP

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9-Fe

b-12

9-Ja

n-12

9-Dec

-11

9-Nov

-11

9-Oct

-11

9-Sep

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9-Ju

l-11

9-Ju

n-11

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ay-1

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1

9-M

ar-11

9-Fe

b-11

9-M

ar-12

50

40

30

80

70

60

90

20

10

0

MPC ∆E Trending Using SVR Shell Turbo CC 32


10/15


When Results Matter

Case Study #9Location: LA, USA

MW: Base load—185MW



Reservoir Size: 6,200 Gallons/23,470 Litres

BACKGROUND:At this facility, three GE7FA Gas turbines provide the primary power and steam for the chemical plant. Plant reliability was negatively impacted from elevated varnish potential numbers in the gas turbine. To reduce the risk of outage maintenance staff tried a number of varnish removal systems without success. SVR was installed and had an immediate impact, reducing varnish potential numbers and within three months, values had been reduced by 80% to a varnish potential value of <5. Based on these successful results, SVR has been installed on all three gas turbines at this site.

MP

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28-A

pr-10

21-A

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14-A

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ar-10

5-M

ay-1

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25

20

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10

5

0

MPC ∆E Trending Using SVR Mobil DTE 724


10/15


When Results Matter

Case Study #10Location: TX, USA

MW: 160 MW

Turbine Type: GT, GE 7EA

Oil Type: Chevron GST 32


No specific site notes recorded.

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6-M

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MPC ∆E Reduction Using SVR Chevron GST 32


10/15


When Results Matter

Case Study #11Location: GA, USA

MW: 185 MW

Turbine Type: GT

Oil Type: Chevron GST 32



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-12

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20

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30

10

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MPC ∆E Reduction Using SVR Chevron GST 32


10/15


When Results Matter


MW: 550 MW

Turbine Type: ST




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10/15


When Results Matter


Turbine Type: GT, Westinghouse




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10/15


When Results Matter

Case Study #14Location: VA, USA

MW: 151 MW


Oil Type: Texaco Regal R&O 32



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8-Sep

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10

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0

MPC ∆E Reduction Using SVR Texaco Regal R&O 32


10/15


When Results Matter

Case Study #15Location: SK, Canada

MW: 300 MW

Turbine Type: GT, Hitatchi

Oil Type: Esso Teresso GTC 32



MP

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4-Aug

-13

5-Ju

l-13

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3

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b-13

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15

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MPC ∆E Reduction Using SVR Esso Teresso GTC 32


10/15


When Results Matter



Oil Type: ConocoPhillips Hydroclear 32



MP

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(mg

KO

H/g

)

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ep-1

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3-Sep

-13

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20

10

0

0.25

0.20 MPC

AN

0.15

0.30

0.35

0.10

0.05

0.00

MPC ∆E and AN Reduction Using SVR ConocoPhillips Hydroclear 32


10/15


When Results Matter



Oil Type: ConocoPhillips Hydroclear 32



MP

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KO

H/g

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-13

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25

20

15

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35

30

45

10

5

0

0.25

0.20MPC

AN

0.15

0.30

0.35

0.10

0.05

0.00

MPC ∆E and AN Reduction Using SVR ConocoPhillips Hydroclear 32


10/15


When Results Matter

Case Study #18Location: WI, USA

MW: 250 MW





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14-A

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10/15


When Results Matter

Case Study #19Location: WI, USA

MW: 185 MW





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10/15


When Results Matter

Case Study #20Location: WV, USA





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7-Dec

-12

11 A

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4-Aug

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31-D

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10/15


When Results Matter

EPT Lab: 4772 - 50 AVE SE, Calgary AB T2B 3R4, Canada | [email protected] | (403) 450-1764

ACE™ OIL ASSESSMENTPlease complete this editable pdf form to avoid delay in ACE™ (Analysis and Comprehensive Evaluation) assessment and reporting. This assessment includes key testing required for your application. The ACE™ Plus assessment includes a demonstration of ICB™ (Ion Charge Bonding) filter cleaning of your sample.

A 50 mL new oil sample is required with each submission for baseline testing.

Problems / Comments / Requests (PLEASE COMPLETE):

ACE™ (send 250 mL)

ACE™ Plus (send 1000 mL)

CONTACT INFORMATION

Name: Email address:

Phone: State, Province or Country:

EQUIPMENT INFORMATION

Company Name:

Plant:

Unit ID:

Application:

(if other)

OEM & Model:

Reservoir Volume:

OIL INFORMATION

Brand Name (Exact):

Sample Date:

Oil Age:

Purification System(s):

Installation Date (if recent):

Last Filter Change Date:

ADDITIONAL INFORMATION

EPT Lab: 4772 - 50 AVE SE, Calgary AB T2B 3R4, Canada | [email protected] | (403) 450-1764

OIL SAMPLE SHIPPING INSTRUCTIONSWhen shipping oil samples for lab analysis, please carefully follow the instructions below. All shipping is to be prepaid.

Preventing leaking oil samples is the sole responsibility of the shipper/customer.

These additional steps are suggested as guidelines:

1. Only use proper lab sample containers; NEVER ship glass bottles or improperly sealed containers. If you require sample containers, please contact us at [email protected].

2. Fill sample bottle 90% full. There should be no air gap.

3. Secure lid and tape lid closed with electrical tape so the lid cannot loosen during transport (scotch tape or masking tape is not sufficient).

4. Place the sample bottle in a sealable plastic bag (e.g. Ziploc®).

5. Place sample inside box with appropriate internal packing material so that the sample cannot move inside the box. Paper packing materials are preferred as they can absorb oil in the event of a leak.

6. Include all relevant MSDS/SDS on the outside of the box for easy reference and a copy of them inside the box in case the box gets destroyed in shipment. If you do not have the proper MSDS/SDS, please contact EPT and we can help find the correct one.

7. On the shipping waybill, under description state “oil sample for lab testing,” indicate volume of sample and value of sample as $10 per liter.

SHIPPING ADDRESSDirect to EPT lab in Canada (for rush shipments) 5 business day results turn around

EPT 4772 - 50 AVE SE Calgary AB T2B 3R4 Canada

Attention: EPT Lab - [email protected] 403-450-1764

INTERNATIONAL SHIPMENTSTo satisfy international customs requirements, all shipments must have the following information included on the air waybill:

Description: Sample for lab testingVolume: 1 Liter (or actual volume being shipped)HS Number: 2707.03Value: $10.00 per literTax ID of Receiver: TAX ID 821128428

USA GROUND SHIPMENTS10 business day results turn around

Hy-Pro Filtration 6810 Layton Road Andersen, IN 46011 USA

Attention: Curt Martin [email protected] 317-849-3535

effective varnish free maintenance for turbine lubricants - clean oil...

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