Grease Quality Issues on Middle Voltage Switchgear: Corrosivity, Resistivity, Safety and Ageing

Grease products recommended by OEM for conventional 11kV switchgears are generally trusted. Some disadvantages might however exist among them or their supply could be insufficient and lead to use of non-OEM-recommended grease. This paper reports analysis methods to evaluate both types of grease that were recently used in the switchgears at local electrical distribution stations owned by Tenaga Nasional Berhad. Hardened, greenish and severely irritating greases probably caused by incompatible compounding, electrochemical reaction, and hazardous components, respectively, were among common problems faced by workers. Eight physical tests and four chemical tests were conducted on 10 grease samples using thermogravimetry, switchgear rig, gas chromatography and infrared spectroscopy besides other equipment and standard methods. Grease stability, oil bleeding, flammability of grease droplet and dropping point were among the characteristics determined in the analyses. The results reveal copper corrosion, chemical change, instable and inconsistent grease, and toxics in grease, which surprisingly included the OEM-recommended one. ABSTRAK: Produk gris yang disyorkan oleh Pengeluar Peralatan Asal (OEM) bagi gear-suis konvensional 11 kV secara umumnya dipercayai ramai. Kemungkinan terdapat kekurangan pada produk-produk tersebut ataupun bekalan gris mereka yang tidak mencukupi telah mendorong kepada penggunaan gris yang tidak disyorkan oleh OEM. Kaedah analisis kajian ini melaporkan tentang kedua-dua jenis gris yang kebelakangan ini digunakan oleh Tenaga Nasional Berhad pada gear-suis di stesen pencawang elektrik. Gris mengeras, berlumut dan menjengkelkan mungkin disebabkan oleh sebatian bahan yang tidak sesuai, tindak balas elektrokimia dan komponen yang tidak selamat, masing-masing adalah antara masalah yang dihadapi oleh para pekerja. Lapan ujian fizikal dan empat ujian kimia telah dijalankan pada 10 sampel gris menggunakan termogravimetri, pemakai gear-suis, kromatografi gas dan spektroskopi inframerah selain alatan lain dan kaedah-kaedah piawai. Antara ciri-ciri yang dikaji dalam analisis ini adalah kestabilan gris, sifat lelehan minyak, sifat mudah terbakar titisan gris dan takat rendah gris. Hasil kajian mendapati gris ini menyebabkan tembaga terhakis, sifat kimia berubah, sifat gris yang tidak stabil dan mudah berubah, dan juga beracun memberi kejutan kerana pihak OEM tetap mengesyorkan gris jenis ini

Comparison of natural adsorbent for emulsified wastewater treatment

Oil emulsion is often generated from machining industries, such as computer numerically controlled (CNC) machines and palm oil mill effluent (POME). The current study presents the adsorption strategy in treating the waste emulsion from CNC machines and POME using activated carbon, corncob, and rice husk. To evaluate the adsorbent performance, a jar test apparatus was used with the addition of the adsorbents for treating waste emulsion at the mixing rate of 100 rpm, mixing time of 30 min, and room temperature. The collected wastewater samples were characterised and analysed for chemical oxygen demand (COD), biological oxygen demand (BOD), oil and grease (O&G), and total suspended solids (TSS). Five dosages of activated carbon, corncob, and rice husk were used in the study (i.e., 2, 4, 6, 8, and 10 wt. %) with the control (0 wt. %). The study showed that rice husk and activated carbon managed to reduce pollutants in the emulsified wastewater. Thus, rice husk and activated carbon are suitable for treating industrial waste emulsion

Characterization of industrial wastes as raw materials for emulsified modified bitumen (EMB) formulation

This study was conducted to characterize industrial wastes for the formulation of emulsified modified bitumen (EMB), in relation to their physical characteristics and elemental compositions. The aim was to determine which raw materials from industrial wastes could be used for EMB formulation. Bitumen is produced from crude oil extracted from the ground, which categorizes crude oil as one of the non-renewable fossil fuels. Various environmental issues that have risen in Malaysia are caused by the excessive manufacturing activities and the miss-management of industrial wastes. In an effort to mitigate these issues, industrial wastes are being used in various EMB formulations. Industrial wastes, such as polystyrene, polyethylene, and used automotive oil can be used as alternatives to formulate bitumen. Normally, a suitable emulsifier is needed to produce the final product, which is EMB. The emulsifier will yield a charge, depending on its properties, to bind the oily bitumen with water. In this current study, physical characteristic studies were performed using thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), flash point test, density test, and moisture content test. Fourier Transform Infrared Spectroscopy (FTIR) analysis was also performed to determine the material’s molecular composition and structure

Synergistic effect of molybdenum disulphide and butylated hydroxytoluene in lithium complex grease

Lubricating grease is vital as a sealant and provides extra protection for automotive parts, such as bearings. Bearings are subjected to friction and sliding wear, which results in the degradation of automotive or machinery performance. The present article analysed the effect of molybdenum disulphide (MoS2) and butylated hydroxytoluene (BHT) as grease additives in reducing the frictional and wear behaviour of steel ball bearings. The experiment was conducted by preparing two formulated lithium complex-based grease with a different blending of additives of BHT only (LCG 01/18) and MoS2 + BHT (LCG 01/5). The formulated greases were compared with two industrial greases as the controlled parameters. Next, the physical characterization of formulated and industrial greases was conducted which includes dropping point test (ASTM D2265-00), cone penetration test (ASTM D217-02) and oil separation test (ASTM D6184-17). Then, the four-ball test (ASTM D2266-01) was performed to identify the effect of additives on the wear and frictional coefficient behaviour. The blending of MoS2 and BHT improves the physical characterization of grease in terms of dropping point and oil separation. The blending of MoS2 and BHT also helps to decrease the wear diameter and frictional coefficient. Nonetheless, further study is desired to gain a thorough understanding of the processes so that an optimal system can be developed for the industry

Optimization of amylase reaction through design of experiments(DOE)

The use of starchy biomass as an industrial raw material bring commercial success of amylases, which have potential industrial applications due to the ability to hydrolyze starch to glucose.The implementations of conventioanl method that employ sreening using one factor at a time usually give inaccurate optimum condition. Moreover,this method is time consuming.Thus,this paper aims to apply design of experiment as a tool to optimize reaction.In this work,the two-level full factorial design and response surface methodology with central composite design was used to identify and optimize the significant parameters.The experiments were conducted with the aid of Design Expert Software 7.1.6.The effect of pH, temperature,substrate concentration and enzyme concentration were studied.The result concluded that the optimized value for pH,temperature and substrate concentration were 8.90, 40.76'C and 5.46% (w/v), respectively;with R2 of 81.86%.The experimental design was proven to be tool for optimization process with less number of experiments and more accurate optimum value

Formulation of Bitumen from Industrial Waste

Bitumen is a mixture of organic liquids which is black, high viscosity and it is sticky materials where it can be applied in several of application. Waste sludge can be used as another alternative to formulate the bitumen by manipulating ratio needed. Waste sludge consists of mineral oil solid waste, which includes oily sand, tank bottoms and other three kinds of sludge from refineries such as dissolved air flotation scum, excessively activated oily sludge and bottom sludge of oil from pools. Waste sludge is the major source of pollution produced in the process of oilfield production and development. In order to formulate the bitumen, other material that is needed include mineral oil, waste sludge and crumb rubber. The form of crumb rubber is form from discarded tyre. Generally, the tyre rubber is ground to a particulate or crumb prior to adding it to bitumen. This form of the tyre rubber is called Crumb Rubber and the mineral oil is used as the medium to heat up the crumb rubber until it is melt and dissolved. The main objective in this experiment is to formulate and identify the best ratio of the bitumen produced. The method that is used to formulate is heating and mixing process which is being conducted inside the fume hood. So that it can absorb the fume released when the process is conducted. The key parameter during the process is weight of the sample, temperature, time and the speed of the mixer (rpm). Once it is produced, then the sample need to analyse based on the density 15°C using ASTM D70 method, viscosity test by using ASTM D2170, penetration @ 25°C test which by using ASTM 5 method and softening point test which is by using ASTM D36 method. The best ratio by far is (1:2:1.2) formulation by having viscosity of 93 centipoise, density of 1.0398 Kg/L, softening point which is at 62°C and penetration which is at >40 mm of penetration. The sample that is formulated were then being compared with the actual bitumen sampl

Bio-coagulant and smart system for sustainable water treatment

Waste emulsion is one of the major toxic wastes that are generated from the metal processing industry. Emulsions are commonly used in the metal processing production as emulsified coolant and in power plant as lubricating oil. This paper presents a research to suggest the best coagulant in treating waste emulsion from manufacturing plant via coagulation method. Chitosan and bio-solvent will represent the natural coagulants, alum and polyaluminium chloride (PAC) will represent the industrial coagulant. Jar Test apparatus was used to treat the waste emulsion. It will be conducted in a batch test with a row of six beakers. One jar will be used as a control and the other five will be of different dosages of coagulant at 150 rpm of mixing rate, 30 minutes of mixing time and at room temperature. From the results, PAC showed to be the best coagulant with 82.29%, 95.45%, 99.95%, 96.4%, and 53% removal of COD, BOD O&G, TSS, and Turbidity, respectively, at a pH of 3.7 and minimum dosage of 2wt%. In conclusion, the PAC managed to break the oil and water bonding from the waste emulsion. Thus, it was suitable to treat the industrial waste emulsion

Formulation of modified bitumen emulsions from polymer wastes and used motor oil

Wastes made from used high density polyethylene (HDPE), scrap tyres, and waste oil imparted to a significant number of total waste disposal into environment. The materials exhibit detrimental effects on local environment if not properly disposed or repurposed. The study was conducted to formulate these wastes into a modifier and compatibilising agent for the modified bitumen. The process involved heating and mixing of a predetermined ratio of the wastes, neat bitumen and crude oil. About 20 wt. % of neat bitumen, and pre-determined ratios of HDPE waste, crumb rubber, crude oil, and used motor oil were used in the study for the formulation. The modified bitumen was further tested for the softening point and the penetration tests to evaluate the properties of the formulated bitumen. The modified bitumen was further processed into emulsified bitumen with the addition of polyethylenimine, 80% ethoxylated solution which is the novelty of this work. The result shows that the modified bitumen has the softening point of 33.85 and 41.70 ℃, and the penetration value of 386.8 and 383 (1/10 mm) for Formulation 1 and Formulation 2, respectively. The best ratio of 20:2:39:39 (bitumen: HDPE: crude oil: used oil) was used for the emulsification process

Remediation of oil and gas sewage effluents using physical treatments

The industrial effluents from the oil and gas industry contain harmful contaminants that bring detrimental effects to the aquatic life and human population. The primary concerns are the high value of Chemical Oxygen Demand (COD), Total Suspended Solids (TSS), turbidity and heavy metal content such as ferum and copper in the effluents, which did not comply with the Environmental Quality Act (1974) Industrial Effluent (Regulations) 2009 of Malaysian Department of Environment (DOE). This research aims to study the efficiency of natural bio-coagulants in treating the industrial effluent from the oil and gas industry. The industrial effluent sample was treated by using two natural biocoagulants F.A and F.B and three commercial treatment agents (bio-solvent, alum, and poly aluminium chloride (PAC)). Different beakers consisting of 7.5 wt% of each agent were added into 1.5 L of wastewater sample and left for a week without mechanical assistance. For the second stage, only F.A and alum were used during the experiment. By using five different weight percentages: 2.5%, 5.0%, 7.5%, 10.0%, and 12.5%, the treatment agents were added into 100 ml of wastewater and left for a week without any mechanical assistance. Then, the samples were analyzed for each of the five parameters. The results showed F.A is the best agent in COD treatment, with 41% reduction; followed by alum with 36%, PAC with 26% and bio-solvent with 22% reduction, respectively. The obtained results also showed that F.A and alum are at optimum performances at 7.5 wt%. The F.A and alum efficiency are deteriorating when the dosage is below and above 7.5 wt%

Grease quality issues on middle voltage switchgear: corrosivity resistivity safety and ageing.

Grease products recommended by OEM for conventional 11kV switchgears are generally trusted. Some disadvantages might however exist among them or their supply could be insufficient and lead to use of non-OEM-recommended grease. This paper reports analysis methods to evaluate both types of grease that were recently used in the switchgears at local electrical distribution stations owned by Tenaga Nasional Berhad. Hardened, greenish and severely irritating greases probably caused by incompatible compounding, electrochemical reaction, and hazardous components, respectively, were among common problems faced by workers. Eight physical tests and four chemical tests were conducted on 10 grease samples using thermogravimetry, switchgear rig, gas chromatography and infrared spectroscopy besides other equipment and standard methods. Grease stability, oil bleeding, flammability of grease droplet and dropping point were among the characteristics determined in the analyses. The results reveal copper corrosion, chemical change, instable and inconsistent grease, and toxics in grease, which surprisingly included the OEM-recommended one