MAINTAINING ELECTRO-HYDRAULICCONTROL(EHC)
SYSTEMS FOR TURBINE GENERATOFIS USING
PHOSPHATE ESTER EHC FLUID
RAY CRANE
IEEE Member #7326135 (Sr. Member)
Weyerhaeuser Paper Company
Columbus Pulp and Paper Complex
P. 0. Box 1830
Columbus, MS 39703-1830
Abstract-The reliability of Electro-Hydraulic-Controlled
(EHC) turbine generators can be increased by properly
maintaining the hydraulic system and fluid. With
increasing cost of production downtime and energy, the
demand for reliable turbine generator operation
becomes more prevalent year after year. The purpose
of this paper is to describe the necessary requirements
for maintaining the electro-hydraulic system through
proper care of the phosphate ester fluid. Also it will
also address the expected results of operating a system
with contaminated fluid and the cleanup of a
contaminated system.
1. INTRODUCTION
Phosphate ester fluids are used on EHC turbine
generator controls due to their fire resistant
characteristics which reduces the risk of fires if a leak
were to occur. Properly maintained, phosphate ester
fluids will result in years of trouble-free operation of
turbine generators controlled by the electro-hydraulic
process.
Fig. 1. Hydraulic System for EHC Controlled Turbine Generator
183
Some of the key elements in maintaining the fluid are:
1. Cleanliness by proper maintenance and use of the
auxiliary filtering system.
2. Maintain moisture content below 0.10%.
3. Maintain the temperature of the fluid
between 110°F and 115°F.
4. Maintain resistivity of the fluid above 5,000
meg. ohms/cm.
5. Maintain acid neutralization number below 0.20, (mg
KOH/g) which is affected by all of the above.
II. CLEANLINESS
The EHC fluid cleanliness can be maintained free of
particulate by proper filtration. Maintaining cleanliness
can be done by the auxiliary recycle system where a
small (typically 0.5 GPM) amount of EHC fluid is
circulated from the reservoir through two filters back
into the reservoir. (See Fig. 1.) The first unit is the
large Selexsorb GT filter. The main purpose of the first
filter will be discussed under the moisture and acid
number paragraph. The second filter is a 1/2 micron
particulate element whose only purpose is particulate
CH3142-719210000-0183 $3.00 C 1992 IEEE
 Also, the main hydraulic pumps have an inline stainless
steel suction filter and a discharge filter made of dual
filter elements, 25 micron inside stainless steel element
with an outside element of 10 micron size. (See Fig. 1.)
It is vital to keep the particulate count to a minimum
due to very close tolerances in servo valves and
switching valves which can easily be plugged, stick or
operate sluggishly if particulate count rises beyond
specified recommendations.
Another element of concern in cleanliness of the fluid
is inadvertently contaminating it with a petroleum based
hydraulic oil. Adding additional EHC fluid should not be
necessary unless a leak occurs. If the need arises to
add fluid, make sure that only phosphate ester fluids of
the same manufacturer and grade that is in the unit are
used and that it is installed with utensils that have been
thoroughly cleaned with mineral spirits.
111. MOISTURECONTENT
Moisture content is the most vital element to control.
Unlike petroleum oil, phosphate ester fluid will combine
with water or hydrolyze to form acids. This is the
primary reason phosphate esters breakdown in service.
As moisture content rises and combines with the
phosphate ester fluids, a chemical reaction occurs
forming another product. Unfortunately, this product
being formed is acid. The usual concern is that when
weak acids come into contact with the mechanical
system, corrosion occurs and with phosphate ester
fluids deposits form. These deposits and corrosion
cause havoc in EHC control systems. Phosphorus acids
extract metal ions from such items as "fullers earth" filter
elements, servo valves, switching valves, pumps, rams,
etc. The tolerances in servo valves are very close and
when the metal is attached by the phosphorus acid, the
tolerances increase to the point where the leakage
across the servo valve becomes so great that the main
hydraulic pump motors become overloaded and will trip
out.
The hydraulic system reservoir is equipped with a
breather vent canister. Inside this canister is a number
of silica gel material packets used to absorb moisture
that may enter the reservoir and combine with the
phosphate ester fluid. These packets should be dried
out every quarter by placing them in a controlled
temperature oven at 250" F for 16-24 hours. This
should be done by placing 1/2 of the packets at a time
in the oven. When they are reinstalled, the other 1/2 of
the packets should be dried, then reinstalled. Also,
never use water or water-base materials around the
hydraulic unit. Any cleaning of cans, funnels, hoses or
the tank itself, should be done with a good quality
mineral spirit.
All General Electric EHC controlled turbine generators
sold since the fifties have had "fullers earth' elements
supplied in the auxiliary filtering system. It has been
proven that once the moisture content begins to rise
that the "fullers earth" element compounds the problem
increasing the acid number. This problem can be
eliminated by changing the "fullers earth' element to a
Selexsorb GT element. Using the Selexsorb GTR
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element in the auxiliary filtering system should help to
keep the acid number low. If, in testing, the acid
number begins to creep up or the resistivity creeps
down on an operating system, change the Selexsorb
GTR filter element and it should bring these values
back into specified ranges.
N. TEMPERATURE
Maintain the temperature of phosphate ester fluid
between 110°F and 115°F. It is recommended that
the hydraulic fluid temperature in the reservoir be
measured and maintained by water cooled heat
exchangers and a control valve that modulates the
water flow controlling the fluid temperature at the
desired setpoint. This system should be checked and
calibrated often.
Heat accelerates the hydrolysis process causing the
acid number to rise more rapidly, however, the
temperature should be higher than the ambient
temperature by 10" F or 15" F to keep down
condensation in the reservoir.
V. FLUID RESISTIVITY
Resistivity of the fluid should be maintained at 5,000
meg ohms/cm or greater. Resistivity is directly affected
by the moisture content, acid number and particulate
count. Pay close attention to the resistivity number
from the testing procedure and trend it. If the trend
starts down, it is a clear indication that trouble looms
around the corner.
VI. ACID NUMBER
As stated previously in this article, the key reason for
elevated acid numbers is moisture content. The acid
number should be maintained below 0.10.This value is
determined by a titration test of mg KOH/g of fluid.
This value can easily be maintained by the system
breathing through the silica gel packets and by using
the Selexsorb GT' filter element in the auxiliary filter
system.
VII. OPERATING A CONTAMINATED SYSTEM
As previously stated, the cleanliness of the phosphate
ester fluid is vital, as contaminated fluid will cause both
sludge deposits and will extract metal ions forming
phosphorus acids. This condition will very quickly result
in servo valve failures. Tolerances will increase in the
servo valve spool and body, causing larger GPM flows
from the high pressure main hydraulic pump that is in
service. Generally the motors driving these pumps are
sized for the normal GPM flow required to operate the
turbine valves. As the flow increases, the HP
requirements increase proportionately while maintaining
system pressure and overloads the motor causing it to
trip. When this occurs, the second motor/pump will
automatically start on low pressure and it too will be
overloaded due to the same large flow and trip out
taking the turbine generator off line. A good procedure
is to take and record motor load readings regularly. If
the load starts to increase, you can be sure that flows
are changing and very probably indicates changed
tolerances in the servo valve due to contaminated fluid.
VIII. CLEANING A CONTAMINATED SYSTEM
When a system has been operated contaminated for
long periods of time, follow the procedure listed below
to clean it up:
rn Remove the "fullers earth" filter and change the 1/2
micron backup element in the auxiliary filtering system.
(See Fig. 1.)
With unit operating, add 5% of 88050 Fyrquel
flushing fluid and run for 12 hours, watching for
foaming. If foaming occurs, add a small amount of
silicone defoamer. (88050 purchased from AKZO
Chemical, Inc., Gallipolis Ferry, WV, 25515).
Add an additional 5% of 88050 flushing fluid and
operate for another 12 hours watching for the foaming
possibility.
With the machine down, shut the hydraulic system
down and lock out the pumps. Drain all the EHC and
88050 fluid.
Clean the tank and auxiliary filter reservoirs
thoroughly using lint-free rags dampened with a good
quality mineral spirit and refill with Fyrquel EHC fluid.
Run for 24 to 48 hours and shut the system down, lock
the pumps out and drain the tank. This step removes
the sludge deposits that have been dislodged by the
88050 cleaning fluid. Once again, clean the tank and
filter reservoirs thoroughly.
rn Refill the tank with Fyrquel EHC fluid.
rn Install a Selexsorb GTR filter element in the Hilco-
Hiflo filter (P/N ST718-00-03WCO with gasket FB-811-
6).
Start the system back up and flush the servo valves
and rams. This can be done by disconnecting the drain
lines and connecting a hose to catch the fluid in a 5-
gallon container for proper disposal. Reconnect the
drain lines and put the turbine generator back into
operation. Run for 7 days and take a sample of the
fluid and send to AKZO Chemical, Inc., for testing.
DC SAF€W/ENVIRONMENTAL
USE CHEMICAL HANWNG GLOVES AT Au. TIMES
WHEN H A N W N G PHOSPHATE ESTER RUIDS.
ALWAYS F W O W MSDS PROCEDURES WHEN
HANWNG OR DISPOSING Of THE FLUID.
X TESTING PROCEDURES
Phosphate ester fluids, such as FyrquelR EHC supplied
by AKZO Chemical, Inc., are very different from
petroleum oils and should be tested only by the people
furnishing the fluid. The supplier of the fluid supply test
kit and will test the fluid quarterly free of charge and
furnish a d e t a i l e d test r e p o r t i n c l u d i n g
185
recommendations. With this process, any change in the
fluid quality can quickly be detected and the
appropriate steps taken to correct the problem.
Whereas with extended operation, the system will
become severelycontaminated and component damage
will occur.
X RECOMMENDATIONS
Test the fluid every three (3) months.
Replace the "fullers earth filter with a Selexsorb GTR
element in the auxiliary filtering system. Change this
element as needed or at least once a year.
Change the 5 micron filter element in the auxiliary
filtering system every six (6) months.
Dry the silica packets in the breathing compartment
of the hydraulic reservoir in a controlled temperature
oven at 250" F for 16-24 hours every 6 months.
Maintain temperature of the EHC fluid in the
reservoir between 110" F and 115"F.
Change the hydraulic supply pump in-line filter first-
stage element (outside 10 micron) and wash the second
stage stainless steel inside unit once a year on a clean
system. This can be done on the run by switching
pumps.
Make sure that the system is not inadvertently
contaminated with mineral oil by clearly posting a sign
"Fyrquel EHC Fluid Only" on the hydraulic reservoir.
Use a good quality mineral spirits to clean all
components that will come in contact with the
phosphate ester fluid. CAUTION!!! Never use any other
cleaning fluid.
rn Take hydraulic pump motor load readings and
record them watching for any increase from normal.
XI. SUMMARY
In order to keep your turbine hydraulic control system
operating trouble-free, maintain your phosphate ester
EHC fluid in top condition by keeping the system dry as
possible, particulate count low, temperature between
110" F and 115" F avoiding high temperature
conditions and of utmost importance, maintain a low
acid number. This can be done through a
comprehensive fluid maintenance program. This
program should include a quarterly monitoring and
testing program of the fluid by a qualified phosphate
ester testing laboratory.
NI. REFERENCE
The numbers and suppliers used above are for a
standard General Electric furnished hydraulic system for
turbine control of an EHC machine.