Revolutionizing Phosphate Ester Fluid Filtration

Welcome to the latest EPT Clean Oil Newsletter, where we bring you the most recent innovations and advancements in Lubricant Chemistry Management.

This edition focuses on the evolving landscape of phosphate ester fluid maintenance programs for critical steam turbine applications, including Electro-hydraulic Control (EHC) systems, exploring best practices and innovative solutions to:

• Elevate turbine maintenance standards.
• Enhance the integrity of phosphate ester fluids.
• Ensure optimal EHC system performance and longevity.

Phosphate Ester Fluids (EHC Fluids)

Phosphate ester fluids are the lifeblood of hydraulic control systems in steam turbine applications, facilitating smooth operation, minimizing wear, and mitigating the risk of oil-related fires. However, these fluids are susceptible to contamination from particulates, water, and degradation products, which can compromise EHC system performance and integrity.

Ensuring the reliable performance and longevity of EHC systems that use phosphate ester fluids demands meticulous maintenance and care. These critical systems play a pivotal role in regulating steam turbine operations, making it imperative to adhere to best practices for phosphate ester fluid management. Robust filtration systems are essential to remove contaminants and maintain fluid purity, thus mitigating the risk of equipment failures and downtime.

Introducing the Next Generation of Lubricant Chemistry Management Solutions for Critical Phosphate Ester Fluid Applications

Advanced Multi-Stage Phosphate Ester Fluid Filtration Technology

ECR 10000 is an all-in-one integrated skid-mounted kidney loop filtration system equipped with four proprietary technologies: 

1. ECR® Electrostatics
2. Patented ICB® ion-exchange
3. High-efficiency particulate removal
4. TMR® N2 water removal

Together, these allow EHC users to achieve the fluid standards outlined in ASTM D8323 with a single filtration skid.

Comprehensive and encompassing in its abilities, ECR 10000 effectively captures contaminants, including water, particles, ultrafine carbon and soot, to safeguard critical EHC components against wear and degradation. It also improves fluid colour, increases resistivity, and removes acids and varnish.

Step One: Proprietary electrostatic filtration removes the ultra-fine particulate (as small as 1/100th of a micron) created by micro-dieseling, sparking, and thermal breakdown.  These ultrafines are too small for conventional filtration to address.

Step Two: Patented ICB® filters target dissolved contamination within the fluid, removing acids and soluble varnish at the molecular level. Other acid-scavengers are unable to remove phosphate ester varnish and its precursors. This allows the fluid to work ‘for’ the system, utilizing chemical equilibrium to re-dissolve any contaminants that may have already plated out onto metal components.

Step Three: Larger particulates, which may exist or have fallen out of the fluid, are removed through a high-efficiency particulate filter.

The ECR 10000 is also manufactured to include a constant-flow dry nitrogen system. The TMR® N2 provides a blanket of ultra-dry, > 97% pure nitrogen. When passed over the fluid surface within the reservoir, this dry nitrogen blanket actively removes dissolved water while preventing the fluid from exposure to air. This effectively stops both primary pathways to phosphate ester breakdown (hydrolysis and oxidation).

Combining all these technologies into an integrated system powered by a simple and intuitive user interface, the ECR 10000 achieves superior contaminant removal, maximizes filtration performance, extends service intervals, and reduces maintenance requirements and operational costs.

Unlocking the Potential of ECR® 10000

Enhanced System Reliability: Minimize the risk of component wear, corrosion, and fluid degradation, ensuring uninterrupted operation and the longevity of critical EHC systems.

Improved Performance: Optimize fluid cleanliness and stability, enhancing hydraulic efficiency and system responsiveness for superior turbine performance and control.

Cost Savings: Reduce maintenance costs, downtime, and fluid replacement frequency, maximizing operational efficiency and lifecycle value of turbine assets.

Compliance and Sustainability: Meet stringent industry standards while promoting sustainable fluid management practices and resource conservation.

Conclusion

Prioritizing phosphate ester fluid filtration and conditioning is essential for maintaining the integrity and performance of turbine control systems. By adopting a holistic approach to contamination control, leveraging advanced multi-stage filtration technologies, and embracing continuous monitoring practices, operators can uphold fluid cleanliness standards and safeguard critical assets against premature failure.