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T-22 turbine oil is a mineral oil produced from sweet crude by the acid purification method.  Since the oil does not contain additives, T-22 turbine oil is a relatively inexpensive product making it very popular with industrial buyers.

One of the ways to purify T-22 turbine oil is to remove accumulated contaminants by the use of the “Gravity Settling” method.  The idea is that all solid particles or water micro-droplets are under the influence of two forces, gravity and buoyancy in opposite directions.  The total of the two forces defines volume force which causes the suspended particles to settle.  This is what is referred to as sedimentation or settling.

Oil is a usually made up of weakly concentrated suspensions containing a small amounts of particulate matter.  Settling of particles therefore, occurs without interaction of the particles and this is what is known as free settling.  Another force acting on particles moving downward through the liquid is friction.  It will hinder the movement of the particles.  This force is directed upwards vertically.

Laminar flow around a particle is common for small particles and the significant viscosity of T-22 oil.  If particle size increases, or the oil’s viscosity decreases, the flow becomes turbulent.

The final efficiency of turbine oil reclamation with this method depends on the density of the contaminant materials, the density and viscosity of the oil, and the contaminant particle size and concentration.  For the settling of water droplets, not only their density, but also viscosity of the oil should be considered.

Settling tanks should be insulated and protected against direct sunlight.  One of the most efficient methods of creating a thermally static environment is to place the settling tank into the ground.

The gravity acting on water droplets emulsified with the oil, is based on their coagulation and settling into a water-removal device.  The velocity of settling of these larger particles is defined not only by their size, but also by the difference of the densities of water and turbine oil.  For example, 15-20 micron droplets can settle one meter in ten hours.  If the size of the particles is 10-15 microns, settling may take 24 hours.

It is the long time requirements of settling and the removal of only relatively large particles that is the main drawback of gravity purification.

To resolve the existing problems with oil purification, we recommend using complete oil treatment units from GlobeCore’s CMM-0.2MR line of equipment.  The GlobeCore units combine vacuum processing and sorbent purification into one easy to use unit.  The sorbent type used in these oil purification units is Fuller’s earth.  This product can be reactivated in the unit without stopping to process to remove and replace the sorbent material.  This is an obvious advantage since there is no need to stop the process to replace or replenish the sorbent.

Purification and regeneration using GlobeCore’s CMM-MR units allows the equipment operator to completely restore all physical and chemical parameters of the oil (turbine, electrical insulation and industrial oil) by removing acids, alkali and other contaminants and aging products.

After regeneration using the GlobeCore CMM-MR units, all specifications of turbine oil are as good as new allowing the reuse of oil in industrial equipment.

GlobeCore offers an efficient working solution to extend the oil’s service life and the service life of the industrial equipment.

Shell Omala is an industrial oil made specifically for use as a lubricant in heavy duty industrial gearboxes. This oil contains no lead and is designated as an “unleaded” oil.  Shell Omala also has good Extreme Pressue (EP) performance characteristics. Due to its performance, Shell Omala can be used in gear boxes, steel gear transmissions, bearings, circulation systems, spray systems, and industrial drives requiring oils with high EP performance.

This oil is made by deep purification of the base oil stock with high viscosity and the introduction of additives with high sulfur and phosphorus content.  The phosphorus is what gives the oil its extreme pressure qualities.

Water, solids and oxidation products may enter the oil during operation of your equipment.  These undesireable contaninants can have a significant negative influence on the oil’s performance.  The manufacturer recommends to use the oil responsibly in terms of environmental protection and to submit used oil to special disposal facilities.  There are however, several problems with the disposal of used oil.  Of course, oil must be disposed of correctly to prevent environmental hazard. On the other hand, the long distance shipping of oil to disposal facilities creates unwanted costs and the potential for oil loss and spills.  (such facilities are often located in remote locations)

If the oil is rto be disposed of, then new oil will have to replace the used oil.  Buying new oil can be quite costly especially when there are several pieces of equipment that require a large volume of oil.  There are however, solutions in the market that can help resolve the above issues.

GlobeCore is a leading manufacturer and supplier of oil purification and regeneration equipment for industrial oil, turbine oil, dielectric insulating oil and other types of indutrial oil.

Oils produced and sold by Shell can be purified and regenerated using GlobeCore’s CMM-CM mobile oil purification unit or  CFU-M oil filter carts.  The CMM-CM mobile oil units are equipped with zeolite for removal of water from the industrial oils.  These units feature reactivation of the sorbent materials in the unit without having to remove and replace during processing jobs.  Using these units for regeneration and purification of industrial oil allows the equipment operator to significantly extend the service life of the industrial equipment.  The units come in noth mobile or stationary versions.

The CFU-M filter carts purify industrial oil by removing ash, free and some solved water, solid particles, as well as water soluble acids and alkali.  Equipment of this type uses a thermovacuum purification process and restores oil in one cycle.  After regeneration, the oil can be used again since it will be restored to new like condition. GloeCore’s CFU-M units are mobile, simple to operate and easy to service.

Successful purification of industrial oil requires knowledge of its composition.  In practical terms, samples of industrial oil in use allows the equipment operator to determine its quality and the need to purify it or not.

Knowing the oil’s content level of each contaminant, one can select the most efficient methods of oil regeneration.  Let’s first consider the general composition of used industrial oil and then the possible methods of removal of the various contaminants.

Used industrial oil is chemically similar to motor oil.  The approximate composition of oil after being used in lubricating systems of machinery is as follows:

• oil – 78%;
• degradation products – 8%;
• water/moisture – 4%;
• particulate matter – 3%;
• additives – 1%; and
• fuel – up to 6%.

The main chracteristics also change especially in comparison with fresh oil specifications: Viscosity at 50ºС/122ºF – 23-43 mm2/second, acid number – 0.07-0.37 mg KOH/g, ash content – 0.019-1.288%.

A common property of used industrial oil is poor water solubility (below 5%), fire hazard (flashpoint in the range of 135-214ºС), and chemical inactivity in storage.

Used industrial oil is stored temporarily in special closed vessels.  Physical purification methods are used to remove particulate matter, microscopic water droplets and some coke and tar from the oil.  Volatile substances are removed by an evaporation method.

Oil can be treated by the application of centrifugal, gravity or other forces such as electric, magnetic, and vibration forces.  Physical methods of treatment also include heat and weight exchange processes to remove oxidation products, water, volatile fractions and hydrocarbons.

The simplest method of treatment is settling.  This occurs through the natural settling of particulate matter under the force of gravity.  The amount and kind of contamination of the oil defines the actual role of settling.  It may be a separate process or preparation for filtration or centrifugal purification.  The main disadvantage of settling is the duration of particle separation from the oil and the ability to only remove the largest particles from 50 to 100 microns.

Filtration is the removal of solid particles and tar from the oil by passing the oil through special porous or mesh filters.  The most commonly used filter media are plastic and metal meshes, fabric, felt, paper and ceramics.  There are also systems with two stages of filtration where coarse filters are followed by fine filters of the corresponding type.

Centrifugal purification of industrial oil is considered the most efficient and high performance method for removal of water and solid particles. The fractions separate under the influence of centrifugal force.

Combined physical and chemical methods of industrial oil reclamation are adsorption, coagulation and selective purification.  One kind of adsorption purification is ion exchange purification.

Obviously, the chemical composition of used industrial oil can be very different, with numerous contaminants in varying quantities.  It is therefore, impossible to practically remove all contaminants equally well by using just one method.  It is recommended to use a combination of several methods for purification.

GlobeCore produces mobile oil purification units in its CMM-5CM line.  These units are designed for removal of water and solid particles from oil with viscosity of no more than 70 cSt at 50ºС/122ºF. The GlobeCore СММ-5CM offers complete sorbent purification of oil with subsequent reactivation of the sorbent in the unit.

Using the CMM-5CM unit for regeneration of industrial oil significantly extends the service life of the oil and the industrial equipment. These units are easy to transport and simple to operate and service.

Turbine oils are used for lubrication and cooling of bearings in steam and water turbines and generators. The importance of this type of oil has increased since they are also used in regulation systems of modern equipment.

Until recently, turbine oil was mostly made from distillates of light oil (predominantly from Apsheronian and Embine oil fields).  Today over htree quarters of all turbine oil is produced from eastern sweet crude.

At this time, the oil industry produces the following turbine oils: Т-22, Тp-22, Тp-22С, Тp-22Su, Тp-30, Т-46 and Тp-46.

When compared to industrial oils, it should be noted that turbine oils are more highly purified.  Hence turbine oil’s higher oxidation stability in high temperature extremes (45°C – 60°C).

Turbine oils have the capability of quick and complete separation from water. Additionally, the initial acid levels and ash content are quite low.  Fresh turbine oil must be free from any contaminants.

If maintained and moitored properly, turbine oil can operate in the system for up to eight years.  In fact, even a longer service life of transformer oil has been recorded.  So what does “proper maintenance” mean in terms of turbine oil?  First and foremost it means constant purity control and periodic monitoring .  This is what really defines the “health” of the entire system.  If the oil contains no harmful contaminants, both the oil and the equipment will function well without failures and/or service interruptions.

The reality however, is that oil becomes contaminated during the operation of the oil filled equipment.  Contaminants may enter turbine oil not only when they are used directly in the oil filled equipment, but also when the system is filled with oil or when the oil is transported.

If the purity of the oil is not compliant with equipment specifications, the oil must be purified immediately before operating the equipment.  Such purification may be performed by the CMM-MT line of units made by GlobeCore.  These modern and indutry leading oil processing units do an excellent job of removing particulate matter, water and gases from the oil.

GlobeCore’s line of mobile units designed for turbine oil purification can operate in four modes: (1) filtration; (2) filtration and heating; (3) thermal vacuum purification; and (4) degassing.

Turbine oils are purified by GlobeCore units using a one cycle thermal vacuum method that results in significantly increasing the service life of the oil and oil filled equipment.

Despite being new and unused, fresh and newly delivered oils must also be controlled in terms of purity, specifications, and performance characteristics. When the oil is delivered, some of the parameters to monitor are:

• kinetic viscosity;
• flashpoint;
• acid number;
• water extract reaction;
• deemulsification ability;
• water and particulate matter content;
• sodium content; and in some cases;
• cloud point.

If water or particulate matter is detected, they must be removed by using the GlobeCore equipment described above featuring the GlobeCore Process.

Sampling of turbine oil in operation should be performed by the operator once per shift.  The first thing is to check the oil visually for the presence of water, sludge and particulate matter.  A more detailed analysis is performed by testing the oil for its “acid number.” Additional testing should be performed at least once for the following: water extract reaction, viscosity, flashpoint, water and solid particle content.  If the acid number exceeds 0.6 mh KOH and water is present in the oil, the analysis will be performed every two weeks.  A rapid degradation of the oil’s quality requires an unscheduled analysis.

Why purification of turbine oil is profitable?

The cost of oil varies but can be quite high depending on the actual oil grade.  The prices of a large amount of oil may is quite a significant factor in the cost of maintaining your oil filled equipment.  Additionally, used oil must be properly disposed of in accordance with environmental laws and regulations further increaing your eqipment maintenance costs.  Purification of your oil filled equipment using GlobeCore’s CMM-MT unit, featuring the GlobeCore Process, saves money and eliminates oil disposal costs.   The oil purified with the GlobeCore Process, can be used in the system over and over again many times.  Utilizing the GlobeCore Process will extend the service life of turbine oils and dielectric insulating oils indefinetly.  The oils will far outlast the equipment itself.

It’s time to get with the Process.  The GlobeCore Process!

Many industrialized cities do not have enough space to build additional high-voltage lines to serve the electric power needs of their communities.  Growing demand for electricity has  increased the amount of power equipment being used to service that increased demand.  In order to meet this growing demand, the service and security capabilities of electric grids and the oil-filled equipment also need to grow.

One of the ways electric power companies are meeting the increased demand for electricity in the “space constrained” industrialized cities is through the use of “Oil-Filled” cables.  Oil-filled cables are bulky substitutes for high-voltage networks that are constantly visible.  Oil-filled cables remain hidden from view and are laid out in trenches 3 meters deep on special fixed brackets.  Essentially, the cables are placed in an underground cable pipeline that normally has a diameter of between 70 to 80 millimeters.  A transmission cable consists of a copper conductor wrapped in insulating paper that is placed inside the cable pipeline.  The cable is filled with insulating oil and then it is sealed.

Liquid insulation, or cable oil, is used in all oil-filled cables of 110 kV and above.  As with any other type of oil used in the energy industry, the cable oil must meet certain requirements and standards. The failure to comply with the required standards and specifications will most likely result in equipment failures and can lead serious accidents.

Requirements for cable oil are actually much higher than for electric power transformer insulating oil.  Cable oil therefore, is usually made ​​from a more highly refined base oil.  The oil is usually enriched with performance enhancing additives that increase resistance to oxidation.  Key indicators and standards for cable oils differ depending on their classification.

The cable type of insulating oil is exposed to various contaminates that impair its properties and performance characteristics that lead to aging, degradation, and malfunction of the cable system. In order to prevent these cable system enemies from disrupting electric service, an oil cleaning system is used to purify the cable oil.  It is done in a batch fashion and ultimately, the cleaning system will be used to introduce the oil under high pressure into the tank that is used to supply and service the oil-filled cable.

Most often, purification equipment for cable oil is of the dehydration type where the primary task is the removal of moisture from the oil while also performing other cleaning functions.  The purification unit consists of a vacuum column (degasser), a coarse filter, two fine filters and two fore-pumps to increase the productivity of the purification process.

In one cycle, a dehydration type unit can normally process up to 800 liters (800L) of cable oil in an eight (8) hour period.  After a full cycle of processing, the oil is re-directed to the pressure tanks. For the refilling process, lead tubes are used.  Each pressure tank has two valves, one for removing the cable oil, and one for refilling the tank with cable oil.

The demand for cable oil cleaning equipment is quite large both in our country and throughout  the entire industrialized world.  Energy companies must use every opportunity to prevent accidents, breakdowns, and  power outages due to contaminated liquid and solid insulation.  Cable oil therefore, must be properly cleaned and maintained.

Installing new high voltage power lines in congested and industrialized cities with limited space has become increasingly impractical.  The laying of underground cables however, is a reasonable solution for the ever growing demands for electricity.  Cleaning equipment for cable oil has therefore, not lost its relevance.  Cable oil cleaning equipment may not be as versatile as the new systems for comprehensive cleaning and regeneration of industrial oil but, it does a very good job of maintaining the purity of the cable’s solid and liquid insulation.  This helps to prevent cable failures and electric service interruptions.