EPT - Lubricant Conditioning Systems for FRF (Fire Resistant Fluid)

EPT specializes in conditioning systems for FRFs, also know as Phosphate esters. The most common brand names for FRF include Fyrquel™, Durad™ and Reolube™, Turbo DR™, Pyrogard 53™, Anvol PE 46™, and OMTI. These lubricants are used in critical applications including hydraulic control systems and gas turbines.

EPT products upgrade existing fluid conditioning system that use Fullers Earth or Selexsorb™. The EPT upgrade process will allow FRF users to update existing filtration equipment to current filtration standards. The EPT upgrade will significantly improve filtration performance and lower operating costs.

PHOSPHATE ESTER FLUID CONDITIONING

Most FRF conditioning systems use a filter product called Fullers Earth which is a clay based product packaged in filter cartridges. This product has very negative side effects that are not generally understood.

The most negative side effect is that the metal composition of Fullers Earth is dissolved into the FRF. Once these dissolved metals (Calcium, Magnesium and Iron) are in the fluid they cause a number of lubricant problems. These problems include deposits on servo valves, air entrainment and a general deterioration of lubricant properties. Activated Alumina, an alternative to Fullers Earth, causes similar problems as a result of sodium contamination. An essential step in FRF conditioning is to eliminate the source of dissolved metal contamination.

EPT FRF LUBRICANT CONDITIONING

EPT Ion Charge Bonding (ICB) for FRF is a fluid conditioning system based on a form of ion exchange technology. EPT ICB conditions FRFs without adding any metals and will remove the dissolved metals added by the Fullers Earth. These are two essential steps in proper FRF conditioning.

EPT ICB filter replacement is a function of FRF volume and existing contamination levels. Once FRFs are returned to specification, EPT ICB filters are usually changed annually. EPT ICB filters have 700% more capacity to remove acids than Fullers Earth and 300% more capacity than Activated Alumina or Selexsorb. EPT ICB will return Acid Number (AN) to <0.09. Results are fully guaranteed.

BENEFITS OF ION EXCHANGE BONDING FOR FRF

EPT ICB Filters have the following benefits:

• Acid Number (AN) will be restored to <0.09 very quickly
• Dissolved metals from Fullers Earth and Activated Alumina are removed without neutral salt splitting
• EPT ICB filters are available in almost any size allowing existing filtration equipment to be used
• EPT ICB filters are non burstable which provides optimal integrity and are completely reusable and can be repackaged onsite
• EPT ICB products are the most experienced in the market with over 10 million hours of operating experience on FRF

FRF CONDITIONING - RESULTS

In 2000 Reliant Energy, Houston, converted ten large generating stations, including W.A. Parish, from Fullers earth to EPT ICB filters on EHC fluid conditioning systems. Prior to installation of the EPT ICB filters, FRF was due to be replaced from high Acid Number and high dissolved metals. The fluid in each of these EHC systems was returned to new fluid specification. Since 2000, FRF consumption has been reduced by 80% and servo valve problems have been significantly reduced. Since installing EPT ICB filters there have been no forced outages as a result of fluid operating problems.

In 1994, Peter E Dufresne, founder of EPT, was awarded the “President’s Award” by TransCanada Pipelines for the significant cost savings on a fleet of 100 gas turbines from the development of ICB for FRF.

As of 2003, EPT ICB filters are installed on 60GW of generating capacity and on 150 gas turbines. Cost savings to these customers is estimated to be over €3 million annually.

If your company is using Phosphate ester FRF contact EPT to immediately improve FRF system reliability and reduce costs. EPT also offers conditioning systems for other FRFs including polyol ester based lubricants.

For a detailed review of typical FRF problems and solutions for GE and Westinghouse EHC systems, download the following technical publication from Lubrication and Fluid Power, Feb 2002, written by Reliant Energy "Mega $'s Saved by Using Ion Exchange Filtration Process" (available for download at www.cleanoil.com)

For a detailed review of FRF problems and solutions on ABB/Rotring hydraulic control systems download the following publication from Lubrication Excellence 2003, presented by Tucson Electric Power "FRF Fluid Maintenance" (available for download at www.cleanoil.com)