THE PROVEN PERFORMANCE OF ENVIROLOGIC ENVIRONMENTALLY ACCEPTABLE LUBRICANTS IN THE OFFSHORE AND MARINE INDUSTRIES

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1 THE PROVEN PERFORMANCE OF ENVIROLOGIC ENVIRONMENTALLY ACCEPTABLE LUBRICANTS IN THE OFFSHORE AND MARINE INDUSTRIES Mark E. Miller, Lisa Owen, Dr. Bernard C. Roell, Jr. RSC Bio Solutions 600 Radiator Road Indian Trail, NC October 2014

2 Table of Contents Abstract... 3 Introduction... 3 Performance Testing... 4 Intertek Research... 4 Rotating Pressure Vessel Oxidation Test... 5 Demulsibility... 5 Hydrolytic Stability... 5 Pour Point... 5 Boiling Point Distillation... 5 Viscosity Index... 5 VDMA Elastomer Testing... 7 Comparative Field Performance... 8 HEPR Hydraulic Fluid Field Demonstration... 9 Viscosity Total Acid Number (TAN) Wear Metal Levels Conclusions Eighteen Years of Marine Industry Field Experience Financial Analysis Conclusion About the Authors Appendix A Tables: HEPR Hydraulic Fluid Field Demonstration Viscosity Appendix B Tables: HEPR Hydraulic Fluid Field Demonstration TAN Appendix C Tables: HEPR Hydraulic Fluid Field Demonstration Wear Metal Levels

3 Abstract The unique lubricant formulas developed by RSC Bio Solutions chemists and engineers are designed to meet or exceed the performance attributes of many conventional products. They will protect equipment under the most adverse operating conditions; extreme temperatures, high pressures, wet conditions. As a result, these environmentally preferable fluids reduce total cost of ownership by providing a long useful life and reducing downtime. This paper will review the extensive in-field experience and testing performed collaboratively with customers and independent laboratories and the validation it gives to the high performance of RSC Bio Solutions products in the offshore and marine industries. It will also compare relative performance to both petroleum based lubricants and other types of Environmentally Acceptable Lubricants (EALs). Introduction An increasing number of owners, operators, leaseholders and regulatory agencies are recognizing the benefits of environmentally acceptable fluids. Using these lubricants can potentially save an operator thousands of dollars in terms of fines, cleanup costs and down time. The U.S. Environmental Protection Agency (EPA) defines an EAL as a Lubricant that is readily biodegradable, exhibits low toxicity to aquatic organisms and has a low potential for bioaccumulation. (EPA 800-R , Publication U.S. Environmental Protection Agency, November 2011) In these emerging industries, companies are offering a variety of products that have a range of environmental benefits and performance attributes. The four main ISO classifications of EAL types are as follows: 1) Vegetable Oil Based (Hydraulic Environmental Triglyceride HETG) 2) Polyalkylene Glycol Based (Hydraulic Environmental Polyalkylene Glycol HEPG) 3) Synthetic Ester Based (Hydraulic Environmental Synthetic Ester HEES) 4) PAO (Polyalphaolefins) and Related Types (Hydraulic Environmental PAO and related others HEPR) There is a wide range of performance levels among both readily biodegradable and petroleum based lubricants. Customers have a wide array of options from less expensive, lower performance lubricants to high end, high performing fully synthetic products. While care must be taken in choosing the appropriate product for the specific application, readily biodegradable products also offer the full range of performance. It s important to know that some readily biodegradable products provide higher performance results than either some petroleum based or readily biodegradable ones. Additionally, there are two widely used designations for biodegradability: inherently biodegradable and readily biodegradable. Simply saying something is biodegradable still means it can persist in the 3

4 environment for years, continuing to cause substantial damage. This damage often will require longterm remediation with most petroleum based products. According to ASTM D 5864, inherent biodegradation is defined as degrading > 20 percent to < 60 percent within 28 days. Readily biodegradable materials, on the other hand, degrade by 60 percent or more within 28 days or less. For those products that degrade more rapidly, like those from RSC Bio Solutions, this means that the material will decompose to water and carbon dioxide more quickly than petroleum oil counterparts. Performance Testing Intertek Research Synthetic ester based EALs are the most commonly available, so a major multinational offshore drilling contractor wanted to compare the performance of these types of EALs against that of EnviroLogic 3046, which is a readily biodegradable* polyalpholefin HEPR. To do so, a series of tests was conducted, both in a laboratory and in the field. In late 2012, Intertek Automotive Research, an independent third-party test lab, was used to develop data and compare the performance of EnviroLogic 3046 with a leading, commercially available Synthetic Ester Based EAL HEES Competitor 1. Contained in the table below is a summary of Intertek Research Laboratory results: *As per OECD 301B or ASTM D7373 4

5 Rotating Pressure Vessel Oxidation Test (RPVOT) ASTM D 2272 measures the oxidation stability of lubricating oils. Oxidation is a typical weakness of some environmentally acceptable fluids. EnviroLogic 3046 has more than double the RPVOT value of the synthetic ester based product 376 minutes compared to 180 minutes demonstrating the superior oxidation stability of EnviroLogic 3046, which translates to a better ability to withstand high temperature and provide longer fluid life. Demulsibility ASTM D 1401 measures the rate at which a liquid (such as oil) separates from an emulsion. EnviroLogic 3046 rapidly breaks down an emulsion of 50% fluid and 50% water while the synthetic ester based product maintains the emulsion. Retaining water in a hydraulic fluid will increase acids, rust and wear and degrade seals. Hydrolytic Stability is the ability of a lubricant to resist chemical decomposition in the presence of water and is quantified by looking at acidity levels (Total Acid Number or TAN) within the fluid. EnviroLogic 3046 clearly outperforms the synthetic ester based product, as a lower number indicates that it holds up better against acid formation. This occurs because of key chemistry differences of base oil constituents in these formulations. Base stocks of synthetic ester products are produced by reacting fatty chain acids with alcohols and acid catalyst. In the presence of water and heat, the synthetic ester fluid reaction reverses forming acid, which can corrode systems and deteriorate seals. Hydrolytic instability is well known in the industry. In fact, another supplier of ester based fluids, ExxonMobil, writes in a case report that although water should be avoided where both natural and synthetic esters are used at high temperatures to minimize hydrolytic breakdown, modern, good, quality products are designed to have good demulsibility to minimize these effects. 1 EnviroLogic 3046 is based mainly on HEPR or readily biodegradable hydrocarbon and related types that do not contain the ester moiety that is susceptible to hydrolysis and breakdown to acid. Pour Point is the temperature at which a liquid no longer flows. EnviroLogic 3046 has a pour of - 42 C, while the synthetic ester product has a pour point of -27 C. Therefore, EnviroLogic 3046 will protect better in cold temperatures, such as operating in polar waters. Boiling Point Distillation EnviroLogic 3046 boils at 248 C while the synthetic ester based product boils at 195 C, a significantly lower point. The synthetic ester clearly has light ends that volatize relatively early, which will affect the viscosity and other characteristics of the fluid. Viscosity Index represents the change in viscosity relative to change in temperature. EnviroLogic 3046 has a viscosity index of 218 compared to the synthetic ester product s viscosity index of 146. This demonstrates the EnviroLogic fluid s ability to maintain design viscosity over a much broader temperature range. 1 Retrieved 27 August 2014 from 5

6 In summary, independent laboratory testing of EnviroLogic 3046 demonstrates superior oxidation stability, rapidly breaks down fluid from water, holds up better against acid formation, protects better in cold temperatures and has a wider temperature stability range. VDMA Conventional corrosion testing such as the DIN 51759/ASTM D 130 Copper Strip Corrosion Test or the ASTM D 2619 Hydrolytic Stability Test does not adequately demonstrate real-world performance of lubricants in marine environments. As such, the Verband Deutscher Maschinen- und Anlagenbau e.v. (VDMA), one of the largest industrial associations in Europe that represents all aspects of the engineering sector, developed a meaningful test for both mineral oils and biodegradable fluids. Together with Linde Pumps, they developed a screening method capable of establishing correlation between field experience and the results of an accelerated test. Test parameters include copper-alloy materials, temperature and different mixtures of biodegradable oils with mineral oils and water, as well as the simulation of mechanical activation of the "corroding" surfaces. It is suggested that the Linde test provides a simple, quick and low-cost laboratory method to determine the compatibility of biodegradable oils with copper alloys in hydraulic systems under conditions representative of realworld use in hydraulic applications. The procedure, although simple, is very severe. The fluid is contaminated with petroleum oil and water. It is then heated to 120 C (248 F) and copper alloy strips are added. The fluid and copper alloy strips are agitated with glass beads that work to grind the test samples. After 96 hours, the samples are weighed and the mass loss is determined. The samples are also evaluated for corrosion and are rated none, weak, strong or extreme. Typically brass (CuZn 35 Mn 2 Si), cast bronze (CuPb 15 Sn 8 ), sintered bronze (CuPb 10 Sn 8 ) and bearing steel 100 (Cr 6 ) are used. When comparing biodegradable products, this four metal test can help separate high-quality products from lesser quality products. EnviroLogic 3068 and another prominent synthetic ester, HEES Competitor 2, were both subjected to the VDMA test at the request of another major drilling contractor. The test results are summarized in the table on the next page. 6

7 The resulting data clearly shows that the synthetic ester product tested failed cast bronze and narrowly passed sintered bronze. It also caused a slight corrosion in bearing brass. As such, the overall test performance of the synthetic ester is a fail. In contrast, EnviroLogic 3068 passed all metal sample types with excellent results and outperformed the synthetic ester in every test. All weight loss parameters are within prescribed limits, and the corrosion effect was none in all but cast bronze, which was weak. It is clear that EnviroLogic 3068 is a better choice for many demanding applications including severe offshore applications. Elastomer Testing There is a misperception in the market that EALs are not compatible with seals and other lubricants. Testing and documentation, however, prove this claim to be unfounded and show that many types of EALs are compatible with many types of sealing materials. SKF Group, a leading global technology provider with expertise in bearings and units, seals, mechatronics, services and lubrication systems, conducted independent, third-party testing ASTM D (Standard Test Method for Rubber Property-Effect of Liquids) and ASTM D 2240 (Standard Test Method for Rubber Property-Durometer Hardness) on the four classes of EALs with some of the most common marine elastomers including NBR, HNBR, FKM and thermoplastics and elastomers. Based on the information published by SKF Group, and through independent laboratory testing, RSC Bio Solutions has also found that under certain situations with certain characteristics, all of the EAL 7

8 fluid types are compatible. Under heat, however, the HEPG hydraulic fluids can be stressed, which can lead to less than preferred performance. Water will stress these fluids even more, and RSC Bio Solutions has found that the glycols used with FKMs in high temperatures (higher than 100 C [212 F]) can cause significant problems and should not be utilized. Comparative Field Performance The performance of EnviroLogic 3046 and HEES Competitor 1 were also put to the test in a longterm field demonstration for a multinational offshore drilling contractor and then analyzed by an objective third-party laboratory. The fluids were monitored in similar applications on similar vessels both were used in topside rig hydraulics and in-service oil sampling and analysis were conducted routinely. One key element of oil analysis is the measurement of Total Acid Number (TAN), sometimes referred to simply as Acid Number (AN). This measures the buildup of acid in the system. As previously mentioned, acid can cause multiple problems in a system including accelerated rust, wear and seal degradation. In addition, the presence of acid shortens the life of the fluid, requiring premature oil change outs and equipment downtime. The industry standard for condemning oil limit is a TAN 8

9 measurement of 2.0 units for petroleum products. At RSC Bio Solutions, we have found that EALs can operate at above an absolute TAN measurement of 2.0 with no negative impact on the performance of the fluids. Therefore, with EALs, the condemning limit is a TAN greater than 4.0 and when the oil exceeds 2.0 TAN, a cautionary note is documented. The results from in-service oil analysis are plotted below. While some fluids offer excellent results in the laboratory under controlled laboratory conditions, the real proof of performance is how the fluid withstands the conditions seen during service duty. Looking at this field analysis, HEES Competitor 1 exceeds the cautionary limit of 2.0 at approximately 26,000 hours of service, while EnviroLogic 3046 maintains a fairly consistent level well below the standard TAN limits. The synthetic ester product then completely breaks down at 26,500, passing our condemning limit of 4.0 units. HEPR Hydraulic Fluid Field Demonstration RSC Bio Solutions was seeking original equipment manufacturer (OEM) approval for EnviroLogic 3046 in NOV s hydraulic power units (HPU) for a major multinational offshore drilling contractor. To do so, we examined the product performance in NOV s HPUs on several offshore drilling rigs and drill ships with service hours ranging from 15,000 to 47,000 hours. While a longer, more consistent 9

10 sampling program would be preferred, the testing was limited to the irregularities of working drilling rigs. We began by routinely collecting, testing and analyzing oil from the units. Routine sampling and oil analysis scientifically monitors the condition of the lubricant and enables objectivity in conclusions about the product s performance. Viscosity The kinematic viscosity of EnviroLogic 3046 at 40 C remains within ISO Grade over the course of the demonstrations for all the units no changes indicates no oxidation. Tables in Appendix A, page16, depict the kinematic viscosity of EnviroLogic 3046 at 40 C over time. Total Acid Number (TAN) Furthermore, TAN was measured to determine the buildup of acid in the system. The results show a minimal TAN increase the change well under condemning limits. Tables in Appendix B, page 19, depict the TAN of EnviroLogic 3046 over time. Wear Metal Levels Finally, we examined the levels of wear metals iron (Fe) and copper (Cu) present in the oil. The levels of wear metals never approached the caution threshold in all the measured hours of operation, which ranged from 15,000 hours to 47,000 hours depending on the unit. The consistently low levels of wear metals (<20 ppm) further demonstrate the hydrolytic stability, durability and lubricity of EnviroLogic 3046 in these applications. Tables in Appendix C, page 22, depict the wear metal concentration found in EnviroLogic 3046 over time. Conclusions RSC Bio Solutions is able to make the following conclusions about EnviroLogic 3046 based on the data gathered throughout the continuous oil analysis: EnviroLogic 3046 is a durable fluid, able to withstand harsh conditions Envirologic 3046 demonstrates excellent hydraulic protection and EP/antiwear characteristics over the life of the field trial with very little Fe and Cu wear metal detected EnviroLogic 3046 demonstrates excellent resistance to breakdown from water ingression as shown by small change in TAN 10

11 Eighteen Years of Marine Industry Field Experience Routine oil sampling and analysis is offered as a service to RSC Bio Solutions customers, and through the range of marine equipment the EnviroLogic products are used in and the extensive monitoring periods, this program has resulted in an expansive demonstration of the products performance in the marine industry. RSC Bio Solutions has oil analysis data from 203 systems on 42 vessels representing 14 OEMs totaling approximately 690 total combined years of service. Additionally, the use of 11 different EnviroLogic lubricants and gear oils is represented in this data. Since the start of the analysis in July 2004, there has never been an equipment failure related to EnviroLogic lubricant performance in any of these units or in any other application. Through the analysis of hours of real-world fluid performance, conclusions may be made about the RSC Bio Solutions products. The products provide excellent oxidative stability, meaning they are durable and can contribute to the extended life of equipment. Additionally, due to their stable viscosity and the low levels of wear metals, the products offer continuing system protection. 11

12 In summary, EnviroLogic readily biodegradable lubricants have been thoroughly evaluated in the field. The products have been widely proven across a range of applications and OEMs and demonstrate equal or superior performance to petroleum based products, making them an ideal choice for a variety of marine systems. Financial Analysis RSC Bio Solutions and our drilling rig customer also looked at the effect of converting to EnviroLogic 3046 from a traditional petroleum product in terms of four expense categories: Regulatory fines Maintenance, repair and operations (MRO) costs - mostly servo valve maintenance, downtime and replacement Fluid top-up costs post initial fill Fluid cost at initial fill Year zero represents the operation before conversion to EnviroLogic lubricant. In year one, the company began using EnviroLogic 3046 hydraulic fluid. Initially top-up and MRO costs remained consistent, but there was an additional cost for the initial fluid change out. The downtime costs are also reduced significantly, due to a cleaner overall system with the EAL 12

13 resulting in less servo valve sticking, which positively impacts the bottom line. In fact, on an average floating rig operation, one hour of downtime equates to a cost of more than $15, Post-conversion, the company s fines related to spills and leaks were eliminated completely. An operation converting to EnviroLogic 3046 today may experience even greater savings, as they could now incur additional fines from the U.S. EPA Vessel General Permit (VGP) that were not in place at the time of this conversion. The 2013 EPA VGP now requires that all vessels over 79 feet use an EAL in oil-to-water interfaces unless technically infeasible. Therefore, an EAL like HEPR EnviroLogic 3046 can ensure regulatory compliance and a reduced risk of fines, while meeting or exceeding the performance of petroleum based products. Coupled with less downtime and better operational efficiency, these benefits more than compensate for the initial fluid cost. CONCLUSION Based on extensive field testing performed by and with RSC Bio Solutions customers and independent laboratories, it can be concluded that the company s fluids perform as well or in many cases better than petroleum based alternatives and other EAL offerings in marine and offshore oil and gas markets. The performance benefits EnviroLogic products offer include: Reduced environmental impact (readily biodegradable, minimally toxic and not bioaccumulative) and U.S. EPA 2013 VGP compliant Equal or better lubricating performance relative to petro-chemical based fluids Equal or longer fluid change out intervals compared to incumbent petrochemical based fluids Improved hydraulic component wear protection Reduced workplace hazards and environmental risks associated with spills or leaks that can tarnish reputations and lead to remediation expenses involving clean up, potential fines and downtime 2 Floating Production, Maritime Reporter & Engineering News, June 2014, p

14 ABOUT THE AUTHORS Mark E. Miller is executive vice president of business development and was cofounder and CEO of Terresolve Technologies. He is responsible for new customer acquisition. Prior to joining RSC Bio Solutions and founding Terresolve Technologies, Miller was a global major account manager for The Lubrizol Corporation, a $5 billion NYSE chemical additive company, providing performance chemistry to major petroleum and marketing companies. Miller has a B.S. in chemical engineering from Tufts University and an M.B.A. from Manhattan College. He has engineered, sold and marketed lubricants and lubricant additives for more than 30 years. Lisa Owen is vice president of sales and marketing. Owen leads marine and land key account, sales teams, product management and company marketing initiatives. Owen brings more than 25 years of general management, marketing and industrial business to business commercial development experience including eight years with biobased solvents and renewable resourcebased plastics from her roles at NatureWorks, LLC. Most recently, Owen served as business director of aftermarket services for BAE Systems Global Combat Systems Vehicles business, the second largest aerospace, defense and security company headquartered in the U.K. Owen holds a B.S. degree in chemical engineering from the University of South Carolina and an M.B.A from the University of Richmond. Bernard C. Roell, Jr. Ph.D. is the vice president of technology for RSC Bio Solutions since Dr. Roell joined RSC Bio Solutions from a seven-year stint at Houghton International, where he was VP of technology and director of operational excellence. Dr. Roell s lubricant expertise and experience includes a combined 15 years at Ciba Specialty Chemicals and The Lubrizol Corporation. He has been intimately involved with developing products and managing business segments in industrial products and automotive transmission fluids. Dr. Roell has a Ph.D. in organic chemistry from Ohio University and a B.S. in chemistry and B.A. in mathematics from Lock Haven University. For more information about EnviroLogic products, field test results or environmental pedigree, please visit or call (800) Terresolve Technologies, Ltd. DBA RSC Bio Solutions. EnviroLogic is a registered trademark of Terresolve Technologies, Ltd. Copyright RSC Bio Solutions. All Rights Reserved. 14

15 APPENDIX A: HEPR Hydraulic Fluid Field Demonstration Viscosity 15

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18 APPENDIX B: HEPR Hydraulic Fluid Field Demonstration TAN 18

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21 APPENDIX C: HEPR Hydraulic Fluid Field Demonstration Wear Metal Levels 21

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