Active Reservoir Vent™Fluid Users

Active Reservoir Vent™ may be the right solution for you.

●Do you have problems with water in your oil?Does your oil analysis indicate water contamination?• Does your oil analysis indicate water contamination?

• Is your operation in a high humidity environment?• Do you operate around wash water, spray down

i t i d ff h i t ?maintenance, or marine and off-shore environments?• Do you get regular condensation in your reservoirs?• Are you using a desiccant breather now?

- How often do you change your desiccant?- Are you tired of service maintenance / short life with your desiccant?

- Are you concerned that your water-saturated desiccantAre you concerned that your water saturated desiccant isn’t changed until it is too late?

How Water Ingresses Into Systems

●Humid Air

Incoming Humid Air

●Humid Air• Marine• Pulp&Paper• Steam Turbines• Hydro Turbines

Oil

h2oh2o

h2o

h2oh2o

h2o

h2oh2o

h2o

h2o

h2o

h2o

h2o

h2oh2o • Hydro Turbines

R i

Oil In ReservoirOut

2

h2o h2o

●Rain●Splashing●Washing●System Leaks

Oil Humidification When Not ProtectedAir around reservoir controlled at 90oF & 80% RHAir around reservoir controlled at 90oF & 80% RH

80%

)

50

60

70m

idity

(%

30

40

50

ive

Hum

10

20

30

Oil

Rela

t

00 8 16 24

Ti (H )

O

Time (Hours)

Problems With Water

●Dissolved Water Humidity in the oil( il i l )(oil remains clear)• Accelerates Bearing Fatigue• Accelerates Oil Oxidation• Cleaves Ester-Based Synthetics

●Free Water Bulk (settles to bottom)or Emulsified (fluid is cloudy)or Emulsified (fluid is cloudy)• Corrosion• Loss of Lubricity• Depletes Additives• Microbial Growth

NASA/STLEBearing Life Factors for Water

120%)

100120

e (%

)

80100120

Life

(%

n

DissolvedWater

FreeWater

020406080

100

ativ

e Be

arin

g Li

fe

406080

earin

g

atur

atio

n

0 200 400 600

Water Content in Oil (ppm)

Rel

a

Study Oil Saturates at 500 ppm

02040

ativ

e B Sa

0 200 400 600

Water Content in Oil (ppm)

Rel

(pp )Study Oil Saturates at 500 ppm

ARV™4

Dry Air Purging SystemSystem

23

11. Incoming compressed air2. Ultrafilter Ultrapac Heatless Regenerative Dryer3. Customer’s Reservoir4. T.R.A.P.™ Outlet Vent Kit

Ultrapac 2000

Na12 [(AlO2)12(SiO2)12] x H2O - 10 Angstrom Molecular Sieve

Ultrapac 2000 – How it makes dry i ti lair continuously

The Ultrapac 2000 is a Pressure Swing Adsorption (PSA) device. Pressure swing adsorption is a technology used to separate some gas species from a mixture of gases under pressure according to the species' molecular characteristics and affinity for an adsorbent material.

Pressure swing adsorption processes rely on the fact that under pressure, gases tend to be attracted to solid surfaces, or "adsorbed". The higher the pressure, the more gas is adsorbed; when the pressure is reduced, the gas is released,

d b dor desorbed.

When air is passed under pressure through the Ultrapac, the Sodium Alumina Silicate column attracts water vapor more strongly than the air. Part or all of the water vapor will stay in the bed, and the air leaving the vessel will be dry. When the bed reacheswill stay in the bed, and the air leaving the vessel will be dry. When the bed reaches the end of its capacity to adsorb water vapor, it is regenerated by reducing the pressure, thereby releasing the adsorbed water vapor. It is then ready for another cycle of producing dry air.

U i t d b t l ll ti d ti f d iUsing two adsorbent vessels allows near-continuous production of dry air.

ARV™ – How it Works

• Humid Air• Saturated Oil

• Purging Humid Air

• Saturated Oil

• Dry Air• Moisture

Desorbing

• Dry Air• Dry Oil

gfrom Oil

Time

ARV™ Test SystemCompressedAir Supply

Coalescer/Filter, Pressure Regulator

& Gauge

Heatless Regenerative

Dryer Flow Meter

Environmental ChamberEnvironmental ChamberT=90oF, RH=80%

Air Temperature & Humidity

MixerBreather

Head Space

Mixer

Oil

Oil Temperature & Humidity

Reservoir

ARV™ Performance140

90

100

Oil Temperature

140

90

100

Oil TemperatureTurned on

100

120F) 70

80Headspace Air Temperature

100

120F) 70

80Headspace Air Temperature

Turned on Heater & Mixer

80

atur

e (d

eg

50

60

RH

(%)80

atur

e (d

eg

50

60

RH

(%)

40

60

Tem

pera

30

40

R

40

60

Tem

pera

30

40

R

Added

Turned on Ultrapac

2010

2020

10

20

Headspace Air Relative Humidity

AddedWater

06:00 7:12 8:24 9:36 10:48 12:00 13:12 14:24 15:36

Time (Hour:Minute)

006:00 7:12 8:24 9:36 10:48 12:00 13:12 14:24 15:36

Time (Hour:Minute)

0

Air Exchange Rate

●Air Exchange Rate, E, is the number of times the air in the head space is

QE head space is flushed per hour. hsV

E

Wh●Where• Q = ARV Flow Rate• V = Head Space Volume• Vhs= Head Space Volume

ARV™ Performance

70

80(%

) Reservoir Head Space Air70

80Reservoir Oil

50

60

70

Hum

idity

(

50

60

70

atio

n (%

)

30

40

50

ir R

elat

ive

230

40

50

ent S

atur

a

2Exchanges/hour

10

20

30

d Sp

ace

Ai

620 10

20

30

Oil

Perc

e

20200

6

0

10

0 8 16 24

Hea

d 20200

0

10

0.0 8.0 16.0 24.0

200

Time (Hours) Time (Hours)

Case 1: Hydraulic Press

Hydraulic Press Details

●Press Hydraulic Reservoir3000 ll ISO 46 il 100 ft3 i h d• 3000 gallons ISO 46 oil, 100 ft3 air head space

●Significant air exchange due to large hydraulic cylinders on this system Humidhydraulic cylinders on this system. Humid air ingress.

●History of moisture issues stalactites●History of moisture issues stalactites●Vacuum dehydrator prior to trial●8 ft3/min Dry Air Flow for y

~5 Air Exchanges per Hour●Data Measurement & Logging

H d i t t & l ti h idit• Headspace air temperature & relative humidity• Oil temperature & water saturation

Hydraulic Press Installation

Breathers

FlowMeter

Air T & RHPressure SwingAdsorption Dryer

Sensor

Oil Saturation Sensor

60

Dry Air ON Dry Air OFF Dry Air ON50

(%) a

nd

atio

n)y y y

40

Hum

idity

%

Sat

ura

30

Rel

ativ

e H

onte

nt (%

20

ace

Air

Roi

stur

e C

10

Hea

d Sp

aO

il M

o

06/16 6/26 7/6 7/16 7/26 8/5 8/15 8/25 9/4

H

Hydraulic Press Summary

Dry Air BlanketON

Dry Air BlanketOFFON OFF

Head Space AirRelative Humidity (%)

<10% 50% and Rising

Oil Moisture Content(% Saturation)

<10% 20% and Rising

Case 2: Bulk Fuel Storage

Bulk Fuel Storage Installation

●Location: Northern Iowa●Excavation company with history of

short fuel filter life.short fuel filter life.●Tanks cleaned during summer and

filter systems added for delivery andfilter systems added for delivery and off loading.Tank Si es 12 000 gallons filled ith●Tank Sizes: 12,000 gallons filled with Off Road Diesel in August, 2009. ●2 tanks used for test, one had dry air

blanket, one just a breather

Bulk Fuel Storage: Head Space Air

2 cfm 1 cfm

Bulk Fuel Storage

708090

onte

nt

n)Top Surface Water Content Versus Time

40506070

Moi

stur

e C

o%

Sat

urat

io

203040

10/14 10/24 11/3 11/13 11/23 12/3 12/13 12/23 1/2

Fuel

M (%

10010/14 10/24 11/3 11/13 11/23 12/3 12/13 12/23 1/2

80

90

100

Con

tent

io

n)

Average Water Content Versus Time

50

60

70

l Moi

stur

e C

(% S

atur

at

40

50

10/14 10/24 11/3 11/13 11/23 12/3 12/13 12/23 1/2

Fuel (

Bulk Fuel Storage Summary

Tank with Breather

Tank withDry Air BlanketBreather

OnlyDry Air Blanket

Avg Head Space Air R l ti H idit (%)

92% with f t

9%Relative Humidity (%) frequent

saturationAvg Fuel Moisture Content(% Saturation)

65% 50%(% Saturation)

Case 3: Paper MachineCrown Roll Press

Crown Roll Press Details

●Crown Roll Press Reservoir500 gallons oil 23 ft3 head space• 500 gallons oil, 23 ft3 head space

• Feeds press roll, gearbox, and some lube points.• Scavenge pump returns oil (and saturated air) from

himachine.• History of moisture problems with foggy oil• Vacuum dehydrator not successful in controlling water

●4 cfm dry air flow or 10 air exchanges/hour●Data Logging

• Headspace air temperature & relative humidity• Headspace air temperature & relative humidity• Oil temperature & water saturation

Crown Roll Press Installation

Fl M tFlow Meter

Pressure Swing

P R l t

Pressure SwingAdsorption Dryer

Pressure Regulator

Manifolded vents onManifolded vents on Machine up and away.

Oil

SensorIssues Oil

AirAir

Air

Crown Roll Press Summary

Before Dry Air Blanket

After Dry Air Blanket and BreatherBlanket and Breather

Manifold InstallationHead Space AirRelative Humidity (%)

Saturated air returned to tank by

<10% on average, maximum of 40%y ( ) y

scavenge pumpOil Moisture Content(% Saturation)

100% Saturated with free water. Even

42 % on average and still improving

vacuum dehydrator not able to keep up!

Payback Model: ARV™ vs DesiccantCumulative Dry Air Cost

$10,000C

ost

$5,000erat

ing

CTo

tal O

pe

ARV-3Desiccant every month

$-

T Desiccant every monthDesiccant every 2 weeksDesiccant every week

$year 1 year 2 year 3 year 4 year 5

ARV™ Ordering

● Order two parts1 ARV™ Vent Kit1. ARV Vent Kit

2. ARV System:Ult & M lUltrapac & Manual (Ultrapac set up

ARV™-3 & ARV™-10 Active Reservoir Vent™

Installation and Operation Manual

for 70 psi)

ARV™ Ordering

●ARV™ Vent Kit*: P568793●Std 3cfm Unit (2700 gal reservoir)

•Ultrapac & Manual: P568790Ultrapac & Manual: P568790

●Std 10cfm Unit (9000 gal reservoir)•Ultrapac & Manual: P568791•Ultrapac & Manual: P568791

●Up to 60cfm (54000 gal reservoir)

* ARV™ Vent Kit for flows up to 10 cfm and includes: TRAP, p ,0.5psi Pressure Relief Valve, 1” NPT Tee, and 1” Nipple

ARV™ Sizing Simplified●Q = ARV™ Flow (ft3/min)●E = Exchange Rate Per Hour

(usually target between 2 and 10)(usually target between 2 and 10)●Vhs = Head Space Volume

If Vhs is unknown, assume 25% of reservoir volume.

Vhs Vhs Vhs

reservoir volume.

(ft3) (gallons) (liters)

EV EVEV60

hsEVQ 2.1699hsEVQ

8.448hsEVQ

60 8.448

System SizingAir Exchange Rate●Air Exchange Rate, E, is the g

number of times the air in the head space is flushed per p phour.●Where

QE Where•Q = ARV Flow Rate•Vhs= Head Space Volume

hsVE

Vhs Head Space Volume

●“Static” Oil Volume: <3/hour“V i bl ” Oil V l 5/h●“Variable” Oil Volume: >5/hour

ARV™ Sizing Examples

●Example 1• E = 10: High moisture environment, g

variable oil volume• Vheadspace= 67 ft3

• Use 10 cfm unitcfmQ 1.11

60)67(10

• Use 10 cfm unit 60

●Example 2• E = 2: Normal moisture static oil volume• E = 2: Normal moisture, static oil volume• Vreservoir = 2000 gallons• Therefore, assume reservoir is 75% full or 25% head

space: V = 0 25(2000) = 500 gallonsspace: Vhs = 0.25(2000) = 500 gallons• Use 3 cfm unit

cfmQ 2.28448)500(2

● If in doubt, call your Donaldson District Manager

8.448

ARV™ Applications

●Hydraulic System Reservoirsy y●Gearboxes●Lube System Reservoirs●Lube System Reservoirs●Small Storage Tanks●Divide Flow to Protect Multiple

Reservoirs

ARV™ Installation

ARV™ Maintenance

Description Recommended Change Interval

Part NumberChange Interval

T.R.A.P.™ breather 6 Months P564669

Ultrapac 2000 Carepack (prefilter 1 Year ARV-3: P568796element, afterfilter element, desiccant cartridges, set of seals) for Ultrapac adsorption dryer.

ARV-10: P568797

* See Ultrapac 2000 Operation Manual for detailed description of replacement* See Ultrapac 2000 Operation Manual for detailed description of replacement procedure.

* See Ultrapac 2000 Operation Manual for additional replacement t if i dcomponents if required.

ARV™ Advantages

ARV™ Membrane DryersAir Dryness 1% Up to 30%Air Humidity

RangeConstant 1% Varies with inlet air

Durability Rugged molecular sieveDifficult to damage

Fragile membrane1 hole defeats membrane

Maintenance Annual change of sieveCannot be fouled

Can’t be maintained. Must be replaced

Easily fouledy

Questions?