Reasons to replace old TURBO-TOC units with a Kaydon Turbo-TOC Series 2!
This applies to TURBO-TOC systems that are more than 25 years old.
Availability of Parts
Most parts, especially electrical parts, are no longer available. This is especially true of the older Kaydon KT100AH systems that use a PLC and frequency drive.
Continued Reliability
A combination of the age of the components, the availability of parts, and inactivity creates a potential for a once-reliable system to become unreliable suddenly. Instances have occurred with systems that are 25 years old or older, where they were shut down for element replacement, and upon return to operation, the system could not be restarted. Additionally, reliability issues become a concern after a system has been placed in storage and then urgently needed for operation again, or when the system has been moved to another plant and inactivity has caused it to become inoperable at the new location.
Larger Heater
When the TURBO-TOC systems were developed, the heaters installed on the Model KL10, KL30, and KL100 TURBO-TOC systems were undersized. Kaydon Filtration listened to the customer’s comments after understanding the need for additional supplemental heat to help raise the bulk oil temperature in the oil reservoirs. Kaydon responded with the design of the Series 2 TURBO-TOC systems by significantly raising the heater temperature kW ratings. The KL10 went from 2.5 kW to 7.5 kW, the KL30 went from 8 kW to 22.5 kW, and the KT100 was raised from 12 kW to 75 kW for the current Model KL100S3-N system.
Controls
The 25+ year old TURB0-TOC systems use pushbuttons and alarm lights on the control panel that are occasionally unclear in indicating their operating status, especially to a new operator, and less clear to remaining element life, level of pump pressure, and suction condition of the pump. The control panels of TURBO-TOCs that are over 25 years old lack a clear understanding of their operational status.
The new Series 2 TURBO-TOC systems feature a simple, easy-to-read, and intuitive graphical display that displays all necessary parameters on a single screen. The simplicity of this screen helps a new operator who has never seen the system understand how to operate (start and stop) the system, as well as easily view the critical operating parameters.
Strainer
The strainer on the 25+ year old TURBO-TOC systems is no longer available, and a replacement is not available. The lid of the strainer can easily be broken or cracked, and when this happens, Kaydon Filtration does not supply replacement parts or a replacement strainer.
Location of Gauges
All older TURBO-TOC systems use a “gauge panel” located underneath the control panel. The pump pressure gauge and filter differential pressure gauges/switches, which indicate the remaining life of the elements, are installed in this panel. The problem is that the panel is too low to view the gauges easily, and the gauge face sizes are too small to accurately determine the needle location. However, the worst part is that if a gauge needs to be replaced, gaining access to the wires, tubing, and fittings to replace a gauge through the back of the gauge panel is very tight; therefore, most systems that are 25 years or older operate without working gauges.
The process to replace a damaged gauge is cumbersome and difficult. To start, access is very tight and limited; the back cover must be removed. A single ½” rigid conduit supplies all of the wires to the multiple differential gauges /switches. This creates difficulty when installing a new gauge with multiple wires from a single conduit. In addition to the wiring jumble, removing a differential pressure/gauge switch requires drilling out the pop rivets very carefully. If not performed carefully, the drill will enter into the wiring. In addition, the copper tubing is cluttered in the panel. When a new gauge is installed, it must be rewired, new copper tubing must be installed, and new compression fittings must be installed. The task is long, complicated, and most end users do not attempt to replace damage gauges due to the tight and cramped working space in the panel.
Pumps and Motors
Availability of the pumps and motors for 25+ year old TURBO-TOCS is increasingly difficult, some parts are obsolete, and the delivery times for a replacement pump or motor over the last few years have turned from a few weeks to a few months. Additionally, it is unclear whether the pump or motor supplier will ultimately decide to discontinue. The new Series 2 TURBO-TOC systems utilize readily available pump/motor assemblies sourced from Kaydon’s pump supplier partner, which stocks all the pumps for the Series 2 TURBO-TOC systems. If not in stock, they can be delivered in just a few weeks.
Vacuum Switch, but no vacuum gauge
An oversight in the design of the older TURBO-TOC systems is the lack of a vacuum gauge to indicate the suction condition of the pump. A vacuum switch is installed, but there is no vacuum gauge, and no port is available on the suction side of the pump to install one. As any pump manufacturer would suggest, every pump requires both a vacuum gauge and a pressure gauge. Without these two simple yet very important instruments, determining a pump’s operating condition is difficult.
An easy-to-read and easy-to-see vacuum gauge and pressure gauge are installed on the new Series 2 TURBO-TOC systems along with a vacuum transducer and pressure transducers, which send the level of vacuum and pump pressure to the Touch Screen for easy viewing. An added benefit is that if the accuracy of the vacuum level or pressure level indicated on the Touch Screen is questioned, its accuracy can be verified by viewing the physical vacuum gauge and pump gauge.
Automatic Water Drain Assembly
The 25+ year old TURBO-TOC systems use an awkward mechanical float ball apparatus with a diaphragm valve to release accumulated water. Several problems arise with this assembly, with the majority of the problems occurring with the automatic water drain diaphragm valve. This valve opens after the float ball, which floats on water and not on oil, rises to a high level. The cross-sectional area opening of the diaphragm valve through which the water is released is extremely small, in a low micron range, and therefore becomes easily clogged, which disables the valve. Kaydon Filtration sells many replacement automatic water drain diaphragm valves, plus valve repair kits.
The Kaydon TURBO-TOC Series 2 utilizes a float switch with a water drain solenoid valve, eliminating any potential for a clogged valve or need for ongoing repair and maintenance.
How does the TURBO-TOC turbine oil conditioning system work?
Since introducing the TURBO-TOC oil conditioning system in the mid-1980s, Kaydon Filtration has continually worked to enhance and expand operational capabilities. The TURBO-TOC Series 1 turbine lube oil conditioning system is the evolution of turbine oil filtration, replacing the earlier Bowser 832P oil conditioning system. The Bowser 832P, introduced in 1938, was adequate for mineral-based turbine oils; however, the TURBO-TOC, introduced in 1987, offered superior design and performance, leading to the discontinuation of the Bowser 832P.
The Kaydon TURBO-TOC Series 2 turbine oil conditioning systems are the most efficient conditioning systems on the market. The Kaydon TURBO-TOC Series 2 system removes 100% of damaging water from turbine oil and reduces Total Water Content to 100 PPM (0 PPM Free Water, 0 PPM Emulsified Water, 100 PPM Dissolved Water). Kaydon TURBO-TOC systems achieve 99% removal of free and emulsified water in a single pass, reducing the total water content to below 100 ppm. Designed for continuous-duty operation, units provide variable flow rates, up to 125 gpm, enabling multiple reservoir turnovers per day depending on system size and oil temperature.
Engineered for high-efficiency turbine oil conditioning!
This high-frequency circulation supports rapid decontamination, especially after seal failures or water ingress events. Kaydon TURBO-TOC oil conditioning systems consistently achieve ISO 15/13/11 oil cleanliness levels, restoring turbine lube oil to a “clear and bright” condition that minimizes the risk of varnish formation, bearing wear, and fewer forced outages.
Do you need to upgrade your current TURBO-TOC oil conditioning system? Let’s Connect!
Separator Spares & Equipment, LLC is an Authorized Kaydon Filtration Distributor. We are committed to providing oil filtration systems that will have a positive impact on your business. We can assist with oil purification products, solutions, and expertise. We offer a range of oil filtration products designed to remove particulate contamination, water contamination, varnish, and other undesired particulate contaminants from oil. Our cost-effective oil filtration systems will help reduce maintenance costs, lower the total cost of ownership (TCO), increase reliability, improve ISO cleanliness codes, and decrease energy consumption.
To learn more about Kaydon TURBO-TOC’s cost-effective solution for improving oil cleanliness, visit www.kaydonfiltration.com or contact us.