Reconditioning of EH oil

A 1200 MW coal-fired thermal power plant using Indo-Chinese turbine EHC system in southern India.

Synopsis
The plant was struggling with the rapid increase in TAN values in the EH oil of the governing system of the turbine.

Reconditioning of EH oil

A 1200 MW coal-fired thermal power plant using Indo-Chinese turbine EHC system in southern India.

Synopsis
The plant was struggling with the rapid increase in TAN values in the EH oil of the governing system of the turbine. Also, the moisture content was more than permissible limits. Degradation of the oil was due to contamination ingression into the system resulting in by-product formation.

Minimac’s EH oil reconditioning system “MLC LVDH TRIX 20” proved to be the savior and an unexpected shutdown of the turbine worth ₹1.05 Cr per day was saved.

Problems
A rapid increase in the Total Acid Number (TAN) could degrade the EH oil and lead to the possibilities of failure of servo valve, hunting, power generation loss, unplanned shutdown, etc

Oil analysis was done to check the properties of EH oil like moisture, NAS value, total acid number.

Solutions
Installation of Minimac’s EH oil reconditioning system “MLC LVDH TRIX 20” comprehensively designed with 4 major technologies to:

Remove solid contamination from oil by Superfine filtration

Remove moisture from oil by vacuum Dehydration technology

Reduce Total Acid Number (TAN) by Ion exchange technique.

EHC system tank moisture removal and ingress prevention by Inert Gas blanketing technique.

Along with equipment installation, our service engineer trained the customer’s team on the functions of the EH oil re-conditioner, FRF maintenance, contamination control, and importance of the oil analysis program.

Cost Saving
This plant managed to save:

Cost of oil replacement: ₹60 Lakh approx.
Cost of downtime: ₹4.2 Cr approx
CO2 e Saving
14,400 kg of CO2 e / 0.0144 gigagrams of CO2 e

Benefits
Extending oil life.
Eliminate oil Replacement cost.
Protect Turbine against hunting.
Increased Turbine reliability.

The below graph shows the trend analysis of tracked values during the reconditioning of EH oil at Unit #2

Total Consumable Details
Filter - 01 qty of 10 - microns
Filter - 01 qty of 3 - microns to achieve NAS 5 cleanliness
Total resin - 60 liters

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PE fluid reconditioning in turbine EHC system

A 1,320 MW (2 x 660 MW), one of the first and largest supercritical coal-fired power plants using Indo-Chinese turbine EHC system in northern India

Synopsis
The plant was struggling with the rapid increase

PE fluid reconditioning in turbine EHC system

A 1,320 MW (2 x 660 MW), one of the first and largest supercritical coal-fired power plants using Indo-Chinese turbine EHC system in northern India

Synopsis
The plant was struggling with the rapid increase in TAN values in the EH oil of the governing system of the turbine. Moisture content was also more than permissible limits. Degradation of the oil was due to contamination ingression into the system resulting in by-product formation.

Minimac’s EH oil reconditioning system “MLC LVDH TRIX 20” acted as a savior for the plant and as a result the unexpected shutdown of the turbine worth ₹1.4 Cr per day was saved.

Problems
Degradation of EH oil properties at both the units of the plant.

The installed regeneration system for each EHGC tank of unit #1 and #2 was failing to control neutralization number (TAN value) and showing a rapid increase in the same

The company was unaware of the consequences of increased TAN values like possibilities of failure of servo valve, hunting, power generation loss, unplanned shutdown, etc

Solutions
Installation of Minimac’s EH oil reconditioning system “MLC LVDH TRIX 20” comprehensively designed with 4 major technologies to:

Remove solid contamination from oil by Superfine filtration

Remove moisture from oil by vacuum Dehydration technology

Reduce Total Acid Number (TAN) by Ion exchange technique.

EHC system tank moisture removal and ingress prevention by Inert Gas blanketing technique.

Along with equipment installation, our service engineer trained the customer’s team on the functions of the EH oil re-conditioner, FRF maintenance, contamination control, and importance of the oil analysis program.

Cost Saving
This plant managed to save:

Cost of oil replacement: ₹78 Lakh approx.
Cost of downtime: ₹5.6 Cr approx

CO2 e Saving
14,400 kg of CO2 e / 0.0144 gigagrams of CO2 e.

Benefits
Extending oil life.
Eliminate oil Replacement cost.
Protect Turbine against hunting.
Increased Turbine reliability.

for more information check our website - www.minimacsystems.com

Reconditioning of EH oil

A power plant in Northern India using Indo- Japanese technology turbine EHC system saved 1.5 Cr approx. with MLC LVDH TRIX-20 EH Oil Filtration

Synopsis
A Power plant (2 x 600 MW) in the Northern region of India was struggling

Reconditioning of EH oil

A power plant in Northern India using Indo- Japanese technology turbine EHC system saved 1.5 Cr approx. with MLC LVDH TRIX-20 EH Oil Filtration

Synopsis
A Power plant (2 x 600 MW) in the Northern region of India was struggling with the rapid increase in TAN values in the EH oil of the governing system of the turbine and moisture content was also more than permissible limits. Degradation of the oil was due to contamination ingression into the system and resulting in the formation of by-products.

Minimac’s EH oil Reconditioning system “MLC LVDH TRIX 20 “acted as a savior for the plant which has escaped the unexpected shutdown of the turbine worth 1.05 Cr per day (approx. 15 hours downtime) and cost & effort for Replacement of oil worth 44 lakhs.

In total, the company has saved around 1.5 Crore by installing external Reconditioning system at their site

The above graph shows the trend analysis of NAS 1638, Moisture and TAN value during one-month installation of the reconditioning of EH oil at customer site.

Consumable required to complete the reconditioning of EH oil having quantity of 1200 liters are:

01 quantity of 10 microns and 03-micron filter element Total consumption of resin was 36 liters

Cost Saving
This Plant managed to save:

Cost of Oil Replacement: ₹44 Lakh approx.
Cost of Downtime: ₹1.05 Cr approx.
Benefits
Extending oil life.
Reduced TAN value.
Eliminate oil Replacement cost.
Protect Turbine against hunting.
Increased Turbine availability & reliability.

Problems
Failure of Servo valve, Hunting and Sluggish behavior of the turbine, Unplanned Shutdown, Presence of varnish & Silt in the clearance of the spool, High TAN value leading to electrokinetic erosion of line and accessories of EHC system, Ingression of particle & moisture contamination……Ultimately all resulting to GENERATION LOSS & REVENUE LOSS

Solutions
Installation of Minimac’s EH oil reconditioning system “MLC LVDH TRIX 20” comprehensively designed with 4 major technologies to:

Remove solid contamination from oil by Superfine filtration

Remove moisture from oil by vacuum Dehydration technology

Remove Total Acid Number (TAN) by Ion exchange technique.

EHC system tank moisture removal and ingress prevention by Inert Gas blanketing technique.

Along with equipment installation, our service engineer has trained the customer’s team on the function of the EH oil Re-Conditioner, FRF maintenance and contamination control, Importance of Oil Analysis Program.

Subscribe to our website And be a part of our Journey - Minimacsystems.com

Reconditioning of EH oil

A 1200 MW coal-fired thermal power plant using Indo-Chinese turbine EHC system in southern India.

Synopsis
The plant was struggling with the rapid increase in TAN values in the EH oil of the governing system of the turbine.

Reconditioning of EH oil

A 1200 MW coal-fired thermal power plant using Indo-Chinese turbine EHC system in southern India.

Synopsis
The plant was struggling with the rapid increase in TAN values in the EH oil of the governing system of the turbine. Also, the moisture content was more than permissible limits. Degradation of the oil was due to contamination ingression into the system resulting in by-product formation.

Minimac’s EH oil reconditioning system “MLC LVDH TRIX 20” proved to be the savior and an unexpected shutdown of the turbine worth ₹1.05 Cr per day was saved.

Problems
A rapid increase in the Total Acid Number (TAN) could degrade the EH oil and lead to the possibilities of failure of servo valve, hunting, power generation loss, unplanned shutdown, etc

Oil analysis was done to check the properties of EH oil like moisture, NAS value, total acid number.

Solutions
Installation of Minimac’s EH oil reconditioning system “MLC LVDH TRIX 20” comprehensively designed with 4 major technologies to:

Remove solid contamination from oil by Superfine filtration

Remove moisture from oil by vacuum Dehydration technology

Reduce Total Acid Number (TAN) by Ion exchange technique.

EHC system tank moisture removal and ingress prevention by Inert Gas blanketing technique.

Along with equipment installation, our service engineer trained the customer’s team on the functions of the EH oil re-conditioner, FRF maintenance, contamination control, and importance of the oil analysis program.

Cost Saving
This plant managed to save:

Cost of oil replacement: ₹60 Lakh approx.
Cost of downtime: ₹4.2 Cr approx
CO2 e Saving
14,400 kg of CO2 e / 0.0144 gigagrams of CO2 e

Benefits
Extending oil life.
Eliminate oil Replacement cost.
Protect Turbine against hunting.
Increased Turbine reliability.

The below graph shows the trend analysis of tracked values during the reconditioning of EH oil at Unit #2

Total Consumable Details
Filter - 01 qty of 10 - microns
Filter - 01 qty of 3 - microns to achieve NAS 5 cleanliness
Total resin - 60 liters

Visit our website - minimacsystems.com

Success Story: A small change can bring a Big Difference

Do you agree that the little things, if done consistently, add to the big things? The same applies to every field of life, whether it is personal or professional. The very recent example recites

Success Story: A small change can bring a Big Difference

Do you agree that the little things, if done consistently, add to the big things? The same applies to every field of life, whether it is personal or professional. The very recent example recites it very true. The whole story begins with an opportunity to supply and commission 8 numbers of Oil Quality Testing Equipment for a sector that is crucial regarding the nation's safety. It was a great experience to work with the best brains and brave hearts.

We started our journey from Pune to a remote location in Odisha, Koraput. When we landed at the nearest airport, we knew it was more than a 5-hour journey by road, crossing many hills, valleys, forests, and ghats. During our travel, we encountered many wild animals and, surprisingly, snakes like pythons crossing the road. Probably, high wind and rain were making it more scary and adventurous. We arrived at our stay very late at night. After such a long day, we were excited to hit the bull’s eye the next day.

We couldn’t resist the enthusiasm and reached the plant before the time the next morning. We were very happy to see the grand welcome following intense security protocols. The industry can be classified as Defense & Space. A division regularly conducted workshops for the customers to better understand and utilize the products.

We showed our advanced Oil Testing Equipment, LPA3, but a few officers were not confident enough about the deliverables. The technology they used then was outdated and failed to meet the latest standard. We had to install, commission, and demonstrate 8 particle counters at different locations and in different machines. We did it within 10 working hours, which was an achievement in every sense. Along with the demonstration, we made them understand the minimum human intervention and the impossibility of tampering with our oil quality testing equipment results. As they were following traditional practices, this technological advancement was much needed in their plant, and it was about to bring a big difference. We did our best in the least time. The company officials were really happy & fulfilled and so were we. It was a great experience, and a perfect example of a small change can bring a big difference.

Best practices for maintenance of FRF in turbine EHC systemWhat is a Turbine EH System ?
Electro-Hydraulic Control system (EHC system) of a turbine is the most critical equipment of a power plant. It’s the heart of a turbine which controls steam flow

Best practices for maintenance of FRF in turbine EHC systemWhat is a Turbine EH System ?
Electro-Hydraulic Control system (EHC system) of a turbine is the most critical equipment of a power plant. It’s the heart of a turbine which controls steam flow into the turbine. A malfunctioning EHC system can lead to turbine stoppage and thereafter create a dominoes effect on the synchronized processes of the power plant. Breakdown-free and reliable operation of the EHC system is the biggest challenge of an Operation & Maintenance Manager. To learn more follow:
https://www.linkedin.com/company/minimacsystemsprivatetlimited

Due to high steam pressure & temperature in the vicinity of a steam turbine, as safety compliance, it is a mandate to use Fire Resistant Fluids (FRF) for hydraulic control of the EHC system. A specially designed synthetic fluid called tri-xylenyl phosphate ester demonstrates best fire resistant properties for the application.

Phosphate esters are polar fluids with excellent lubricating properties that can operate under extreme conditions.
However, phosphate esters require strict control in order to extend their useful lifespan.

Water and Acids de-grade FRF
Phosphate esters (which are being used as FRF in EHC systems) are manufactured under controlled environment through the esterification of phosphoric acid, where water is a by-product.

Phosphoric Acid + Alcohol → Phosphate Ester + Water

Unfortunately, phosphate esters are highly hygroscopic (tendency to absorb water) in nature and the esterification process is reversible when phosphate esters come in contact with water. This is referred to as hydrolysis. The higher the water content and temperature, the faster the ester will break down by hydrolysis.

Phosphate Ester + Water → Phosphoric Acid or Acid Phosphates + Alcohol

Thereby it is recommended to control the water level, temperature, and acidity in FRF of the EHC systems. If uncontrolled, the acidity accelerates rapidly.

TAN value or Total Acid Number (measured in unit mgKOH/gm) is a parameter to denote acid content accumulation in FRF. A high TAN value degrades the fluid rapidly, decreases its viscosity and resistivity. Thereby causing acid corrosion of sensitive servo-valves and other system components of an EH System.

FRF de-gradation due to particles
Water and acid are not the only contaminants which can degrade the FRF.

Since the dynamic oil film and fine clearances in servo-valves are less than 5 micron, even the finest silt particles and sludge/varnish deposits from fluid degradation can hinder proper operation. Fine particles get trapped in clearances between the valve plunger and housing. This abrasive wear is known as seizing or grinding. This can result in wear rates that are a thousand times greater than anticipated by the valve manufacturer.
Therefore, it only makes sense to use very fine filtration (3-5 micron) for maintaining the EHC fluid. For any Technical Consultancy Call - +91 89751 50700

Consequences of FRF de-gradation

Acid, gel and sludge/varnish formation
Valve sticking or blocking
Reduced lubricity and film strength
Corrosion, erosion and abrasion wear
Reduced fluid resistivity
Soot generation (entrained air)
Short fluid life
The result is poor EHC system reliability and reduced turbine availability.
Condition based monitoring of FRF
It is highly recommended to carry out regular fluid analysis of FRF and identify any abnormalities in the trend for further preventive actions. Recommended parameter values for FRF:

Parameter unit value
Appearance ASTM colour code clear, < 3
Water content ppm 500
Kinematic Viscosity (@40 0C) cSt 41-45
Acidity (TAN) mgKOH/gm < 0.15
Particle contamination code ISO 4406 15/12
Cleanliness code (NAS-1638) NAS 1638 5

To learn more follow https://www.linkedin.com/company/minimacsystemsprivatetlimited

The Minimac FRF Re-conditioning System comprises 4 major steps, all packaged carefully in 1 single skid.

Solid contamination Super-fine Filtration
Moisture in oil separation by Vacuum Dehydration technology
TAN reduction by Ion Exchange technique
EHC system tank moisture removal by Inert Gas Blanketing technique
Would love to have your feedback, experience, query.. Got any question? Ask away!!

Is Overgreasing Dangerous?

Greasing is an important process that ensures the smooth functioning of machines. Let’s understand these two aspects first - Overgreasing and Undergreasing. To determine which of these is more problematic could be difficult

Is Overgreasing Dangerous?

Greasing is an important process that ensures the smooth functioning of machines. Let’s understand these two aspects first - Overgreasing and Undergreasing. To determine which of these is more problematic could be difficult but we can definitely decide which one is more damaging. Too much grease can generate excessive heat in the bearing and may result in seal failure. When the lip seals rupture because of over greasing, it allows the harmful contaminants to enter the bearing housing. This would create excessive pressure and may collapse the bearing race. On the other hand, not putting enough grease may cause damage to the rotating parts. Undergreasing allows contaminants to enter the load zones. We can say that it's better to avoid both aspects of over and under greasing.

How to determine the amount of grease a bearing needs?
The factor responsible for determining the right amount of grease depends on the dimensions of the bearing or its housing. Greasing must be done based on proper calculations. A formula that is used commonly is as follows:

The outside diameter of the bearing is multiplied by the width (in inches), then multiply the answer by 0.114. This would give you the amount of grease in ounces required for that particular bearing.
For example -
If the outside diameter of a bearing is 3 inches and the width of a bearing is 0.5 inches, then
3 X 0.5 = 1.5
1.5 X 0.114 = 0.17
Thus, The amount of grease needed is 0.17 ounces or 4.8 grams.

Still not sure how? Connect with our experts: Click here

How to solve the problem of Overgreasing?
After having a grip on how much grease to put, try to master the frequency. Take help from various tables and charts available for determining the frequency. Calibrating the grease guns could be a simple and easy step to determine the correct volume of grease. It is very important to discontinue greasing when any abnormal pressure is encountered. Manual grease guns used in the industry have a few disadvantages. The poor control of grease guns may lead to over/under lubrication. Because they are low in cost, easy to use, and allow the technicians to inspect the equipment during the tasks, industries prefer using manual grease guns.

Setting up a maintenance program could be a game-changer. Keep a track of each grease point and schedule maintenance & inspections for the same. Initially, it may take some time and effort but the end result would be great and impactful.

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