Efficiently Eliminating Varnish from 23,500 Liters of Oil in Just 516 Hours

Mitigating a Potential Power Crisis in Western India through Varnish and Solid Contamination Removal

Synopsis
A Power Plant supplying a major 1967 MW of power to the Western

Efficiently Eliminating Varnish from 23,500 Liters of Oil in Just 516 Hours

Mitigating a Potential Power Crisis in Western India through Varnish and Solid Contamination Removal

Synopsis
A Power Plant supplying a major 1967 MW of power to the Western India, based in Dabhol, Maharashtra,and owned by one of the largest PSU’s, faced troubles with recurring turbine trip downs in two of its main turbines due to a sticky oil residue.Varnish and Solid Contaminants were identified with initial MPC values ΔE=38.6 and NAS 1638=Class 12, which needed reduction to ΔE≤15 and NAS 1638≤Class 6.Minimac's FS 500 machine, with a 3-stage system, achieved this in 516 hours, preventing frequent tripping, valve failures, erratic operations, extensive overhauls, and potential losses of ₹50 lakhs.

Initial Findings
Minimac's team conducted a site visit, analyzing the situation and taking an initial oil sample. Third-party lab testing revealed significant findings, with initial oil MPC values at ΔE=38.6 and NAS 1638 classification of Class 12.

Problems
The client encountered frequent turbine shutdowns in two of its primary turbines due to sticky oil residue within the Gas Turbines' (GTs) bearings and valves. A subsequent oil analysis confirmed the existence of varnish in the oil. As a result, Minimac was entrusted with the responsibility of removing the varnish from the main lube oil.

Client’s Requirements
To Purify 23,500 liters of Prime 32 oil.
To remove the varnish and solid contaminants.
To Achieve ΔE≤15 from its initial reading of 38.6.
To achieve NAS 1638≤Class 6 from its initial reading of Class 12.
Smooth & Timely Execution without any downtime.
Customized Solution.
No spillage.
Solutions
Deploying our customized machine at the site along with our trained and skilled engineers

FS 500: A miraculous 500-liter-per-minute machine featuring a 3-stage flushing and filtration system
It encapsulates varnish removal capacity and mechanical filters to effectively give the desired results.
It was connected to the main oil tank (MOT) of unit 3A, which contained 23,500 liters of Prime 32 oil.
Along with the equipment’s installation, our Service Engineer trained the client’s team on the functioning of the machine and the effective handling of the same.
Job executed 24/7, with continuous oil testing. Remarkably, set KPIs achieved in just 516 hours, showing significant improvement, reaching ΔE=7.2 and NAS 1638: Class 6.

Benefits
Prevented the environment from harm by averting the emission of 2,82,000 kilograms of CO2e.
Extended Oil Life.
Elimination of Oil Replacement Costs.
An enormous quantity of oil was cleaned in a limited amount of time.
Increased Machine Reliability.
Cost Saving
This Plant managed to save:

Cost of Oil Replacement: ₹50 Lakhs Approx.

Cost of Downtime : ₹1 Cr. Approx.

CO2e Savings

Total Savings = 2,82,000 kg of CO2e/0.282 gigagrams of CO2e

Graph

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Oil Reclamation project for the largest oil refinery in WB, India

A critical oil reclamation project for the largest oil refinery with a capacity of 8 million tonnes per year in West Bengal, India.

Synopsis
The lube oil used in various industrial

Oil Reclamation project for the largest oil refinery in WB, India

A critical oil reclamation project for the largest oil refinery with a capacity of 8 million tonnes per year in West Bengal, India.

Synopsis
The lube oil used in various industrial equipment such as pumps, compressors, turbines, blowers, turbo generators, recycle gas compressors, wet gas compressors, and coke cutting pumps had critical contamination levels initially. The problem was caused by poor maintenance by a previous service vendor, resulting in the presence of moisture and impurities in the oil tank. To address the issue, Minimac Operations and Maintenance Service (MOMS) carried out a timely service operation to help the plant bring down the moisture count and remove impurities from the oil tank. Before oil purification, NAS ≥ 12, Moisture ≥ 650 PPM; after oil purification, NAS < 5 and Moisture < 200 PPM This helped to improve the quality of the oil used in the equipment and ensure the smooth operation of the plant.

Problems
The oil was contaminated with moisture and mechanical impurities due to insufficient maintenance, which could lead to equipment failure and downtime. The presence of these impurities in the oil could also cause damage to the equipment, reduce its lifespan, and decrease its efficiency. It was essential to address this problem by implementing proper maintenance practices, such as regular oil changes, filtration, and moisture control, to ensure that the industrial oil is clean and free from contaminants. Failure to address this issue could lead to increased costs as well as production losses due to downtime.

Client’s Requirement
The target moisture level must be below 200 PPM.
Target NAS class must be maintained better than NAS class 5.

Solutions
Minimac Systems examined the oil circulation system, which consisted of high impurities.

Machine used: FS 80 LPM - 2 units; FS 40 LPM - 1 unit; FS 20 LPM - 1 unit.

NAS class < 5 and < 200 PPM moisture level was achieved.

Cost Saving
This plant managed to save:

Immediate tangible benefit = ₹9 Cr.*/ $90 Million* * considering the base price of oil as ₹150/lts /$1.83/lts.

Intangible benefits = Equipment reliability - less breakdowns - minimum equipment outage - reduced downtime - minimum hamper to production line.
CO2 e Saving
72,00,000 kg of CO2 e / 7.2 gigagrams of CO2 e.

Benefits
The reliable operation of the system and trouble-free operation of machines.
Sustainable performance of the overall process.
Less Breakdown.
Elimination of new compressor cost.
Reduction in the possibility of product degradation due to lack of proper filtration.
Timely Execution.
Feedback
Minimac believes in delivering the best experience to the clients with result-oriented project execution, hence, as a result, the project was extended further.

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Oil reconditioning project for India’s largest coal-based power producer

Team Minimac successfully executed a critical project to recondition the control fluid (two tanks of capacity 16 kiloliter each) for India’s largest energy conglomerate and

Oil reconditioning project for India’s largest coal-based power producer

Team Minimac successfully executed a critical project to recondition the control fluid (two tanks of capacity 16 kiloliter each) for India’s largest energy conglomerate and coal-based power producer with a capacity of 4760 MW.

Synopsis
The plant was built and is in service as a thermal power generating station, in Vindhyachal. There was a problem with higher Total Acid Numbers (TAN), observed typically when moisture content exceeds the permissible range. They were facing difficulties in stable unit operation because of the sluggish and erratic behavior of the turbine governing system. It was a significant threat to unit outage and generation loss. The situation was examined by Minimac Operations and Maintenance Service (MOMS). Resin skid - Minimac- FS-20-TRIX- 8-25 ltr-1S-FRF-DOL was deployed to address the issue.

Before Oil purification, the TAN value was≥ 0.62 mgKOH/gm, NAS ≥ 8, and Moisture ≥ 1471 PPM. After Oil purification, the recorded parameters were TAN value = 0.08 mgKOH/gm, NAS ≤ 4, and Moisture ≤ 260 PPM. The major challenge faced during the execution was if we charged resin, TAN would reduce, but moisture would increase. So, an analysis was done and implemented to control the moisture first, then charged the second resin cycle. Minimac gave a 100% customized and balanced solution within time.

Problems
The tank capacity was 16 kiloliters, which is huge. The biggest challenge was to execute the project while the system was in operation. Water contamination bubbles were forming, leading to the fluctuation in NAS - as for moisture control, it was necessary to turn off the system. Resin charge in Ion exchange was done intermittently to control moisture increase, and our motto was to hold moisture below 500 PPM so we could plan for the next cycle of resin charge.

Client’s Requirement
To purify the control fluid.
To reduce the TAN value from 0.62 to < 0.10 mgKOH/gm.
To bring down the moisture level < 500 PPM.
To achieve NAS < 5.
Smooth and timely execution without any downtime.
Tailor-made solution.
No oil loss because of processing or spillage.

Solutions
Resin skid - Minimac- FS-20-TRIX- 8-25 ltr-1S-FRF-DOL for NAS & moisture reduction was installed.

Before the oil conditioning process, the TAN ≥ 0.62 mgKOH/gm, which was reduced after oil purification to TAN ≤ 0.08 mgKOH/gm.

The Nitrogen generation unit (TMR 100) was deployed and installed at the client’s site.

For further improvement in TAN, the oil vapor extraction fan (OVEF) was throttled in the range of 70%, with the support of the user.

Minimac provided trained manpower and other consumables under the MOMS (Minimac Operations and Maintenance Service) offering. Minimac had given results far better than the KPIs.

Cost Saving
This plant managed to save:

Cost of oil replacement: ₹ 3.2Cr. approx/ $ 32 Million approx
Cost of downtime: ₹ 3.15 Cr. approx/ $ 31.5 Million approx
By investing ₹ 21 lakh approx/ $ 25.65k approx only.

CO2 e Saving
1,92,000 kg of CO2 e / 0.192 gigagrams of CO2 e

Benefits
Extended in-service oil life.
The smooth functioning of the machines.
Elimination of new oil replacement cost.
Avoiding the risk of fire and explosion.
Reduction in the possibility of product degradation due to blanketing.

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Saved the plant from a major breakdown

The Minimac team successfully completed a critical flushing project in a big fertilizer company with a capacity of 4000 tonnes in Jharkhand.

Synopsis
An installation project was ongoing at the fertilizer

Saved the plant from a major breakdown

The Minimac team successfully completed a critical flushing project in a big fertilizer company with a capacity of 4000 tonnes in Jharkhand.

Synopsis
An installation project was ongoing at the fertilizer plant’s premises. Newly built lube pipelines and tanks were to be flushed to remove the welding debris and other components left inside while fabricating the pipelines. The entire project was delayed due to a very slow flushing process. Minimac Operations and Maintenance Service (MOMS) team evaluated the situation and came out with a solution to expedite the flushing process. The project required flushing their two main compressors, i.e., PSE processed air compressor and carbon dioxide compressor

Problems
Proper flushing had to be done as the pipeline was newly fabricated; otherwise, it would have led to a major breakdown of the compressor, as the impurities would choke the blades and erode/damage the compressor. Other issues were to ensure proper calculation for variable pipe diameters, and if the oil goes to the rundown tank and overflows, 60-65 degree oil will fall, causing a huge mishap.

Client’s Requirement
Fast completion of the job to meet the project timeline.

Solutions
Minimac Systems examined the pipeline, which consisted of a low-pressure pipeline, high-pressure pipeline, and run-down tank.

A proper calculation was done as the work was a bit critical; any negligence could become a mishap

All parameters must be considered, including segment-wise flushing, hammering, thermal showering, etc.

At the end of the flushing, a mesh was installed to check if any impurities were present

Completing the flushing project was ensured as per ISO 18/15/12

Cost Saving
This plant managed to save:

Cost of import caused due to deficit of fertilizer.

CO2 e Saving
1,44,000 kg of CO2 e / 0.144 gigagrams of CO2 e

Benefits
The reliable operation of the system and trouble-free operation of machines.
Sustainable performance of manufacturing process.
Elimination of new compressor cost.
Avoiding the risk of fire and explosion.
Reduction in the possibility of product degradation due to lack of proper flushing
Timely execution.

Feedback
As a result of Minimac's excellent work, another assignment of a similar nature was assigned to them. Minimac achieved the OEM's request for no debris in the mesh.

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Reduction of the TAN value of the control fluid from 0.23 to 0.08 mgKOH/gm

Team Minimac successfully executed a critical project to re-condition the control fluid (tank capacity 16 KL) for a 2*600 MW coal-based thermal power plant in

Reduction of the TAN value of the control fluid from 0.23 to 0.08 mgKOH/gm

Team Minimac successfully executed a critical project to re-condition the control fluid (tank capacity 16 KL) for a 2*600 MW coal-based thermal power plant in Chhattisgarh.

Synopsis
The plant establishes, operates, and maintains a thermal power generating station in Chhattisgarh. There was a problem with higher Total Acid Numbers (TAN), observed typically when moisture content exceeds the permissible range. They were facing difficulties in stable unit operation because of the sluggish and erratic behavior of the turbine governing system. It was a significant threat to generation loss and unit outage. The situation was examined by Minimac Operations and Maintenance Service (MOMS). Three machines - Nitrogen Blanketing TMR unit (100 LPM), Oil purification MLC-LVDH-TRIX (50 LPM), and TAN reduction— Resin filter modified in cartilage format were deployed to address the issue.

Oil Purification TAN Value NAS Value Moisture
Before Oil Purification 0.23 mg KOH/gm 10 678 PPM
After Oil Purification 0.07 mg KOH/gm 6 250 PPM

The major challenge faced during the execution was if we charged resin, TAN will reduce, but moisture would increase. So, an analysis was done and implemented to control the moisture first, then charged the second resin cycle. Minimac gave a 100% customized solution within time.

Problems
The tank capacity was 16k liters, which was huge. The biggest challenge was to execute the project during running operations. Because for moisture control, it was necessary to turn off the system. Water bubbles were forming, leading to the fluctuation in NAS. Resin charge means moisture increase, and our motto was to bring moisture below 500 ppm so we can plan for the next cycle of resin charge.

Client’s Requirement
To purify the control fluid.
To reduce the TAN value from 0.23 to 0.08 mgKOH/gm.
To reduce the moisture levels.
To achieve NAS 6.
Smooth and timely execution without any downtime
Customized solution
No spillage

Solutions
The Nitrogen Generation Unit (TMR) was deployed and installed at the client's site. The salient features of the TMR unit are - 99.9% pure nitrogen, a dew point less than -15 degree celsius, and a dedicated moisture condensing unit.

For Nitrogen Blanketing, TMR – 100 LPM had a flow regulator of 0-150 LPM

Oil purification machine MLC-LVDH-TRIX-50 for NAS & moisture reduction was installed.

Installed 12 new resin filters for TAN reduction in existing recirculation units

Before the oil conditioning process, the TAN >= 0.210 mg KOH/gm (Electronic method) and 0.246 mg KOH/gm (manual titration), which was reduced after oil purification to TAN <= 0.097 mg KOH/gm (Electronic method) and 0.124 mg KOH/gm (manual titration)

For further improvement in TAN, the oil vapor extraction fan(OVEF) was throttled in the range of 50-55%, with the support of the user

They had an LVDH machine, and the NAS standard to be maintained as per the PO was 10+. We gave a better result without the replacement of the NAS filter

Minimac provided trained manpower and other consumables under the MOMS (Minimac Operations and Maintenance Service) offering. Minimac has charged resin in an 8-cycle with 3 hrs intervals. 24hrs resin charge KPI was 0.074 mgKOH/gm.

Cost Saving
This plant managed to save:

Cost of oil replacement: ₹3.2 Cr approx.
Cost of downtime: ₹3.15 Cr approx.
By investing ₹9 lakh only

CO2 e Saving
1,92,000 kg of CO2 e / 0.192 gigagrams of CO2 e

Benefits
Extended in-service oil life.
The smooth functioning of the machines
Elimination of new oil replacement cost.
Avoiding the risk of fire and explosion.
Reduction in the possibility of product degradation due to blanketing

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Lube Oil Reclamation from NAS 12 to NAS 3

Critical project successfully executed for ISO 9001 Certified - Millenium's shipbuilding yard under the Ministry of Ports, Shipping, and Waterways (Defence Sector).

Synopsis
The maritime-related facilities in

Lube Oil Reclamation from NAS 12 to NAS 3

Critical project successfully executed for ISO 9001 Certified - Millenium's shipbuilding yard under the Ministry of Ports, Shipping, and Waterways (Defence Sector).

Synopsis
The maritime-related facilities in the port city, the first enormous greenfield shipbuilding yard located in the state of Kerala, faced significant oil degradation issues affecting the overall functioning of the India's first Indigenous Aircraft Carrier (IAC), which led to the abrasion of the machines. 49k liters of oil were required to be purified and stored in two different tanks; the leading service tank had 22k liters of oil, followed by 27k liters of oil in another.

Due to the contamination and degradation of the oil, the plant faced issues in wear and tearing of the machines that would lead them to machine breakdowns.

Minimac provided FS225 and FS150 Oil Filtration Systems, which helped infiltrate the gearbox lubeoil. Also, testing the oil transparency was equally crucial so that no particles left could harm the mechanism

Problems
Due to high NAS level, the oil had degraded, resulting in increased friction and wear. There was frictional power loss aggravating the surface roughness. The NAS value 12 indicated the contamination of the oil, stating the risk factor the plant was having. They were facing frequent breakdowns and massive losses. The oil had solid contamination.

Client’s Requirements
To achieve NAS level < 5
To filter the gearbox lube oil.
To test the transparency of oil
To perform flushing activities
Smooth and timely execution of the tasks.
No spillage.
Solutions
Oil was present in separate tanks of stages 1 and 2, where 27k liters of oil were bifurcated again into reserved and storage tanks.

Filtering the oil and balancing the NAS level simultaneously was an arduous task.While performing tasks, continuous obstructions occurred due to various naval activities, engineers faced language issues, and the negative pressure created on the machines was quite challenging. Minimac provided FS225 and FS150 LPM Oil Filtration Machines, Trained Manpower and other consumables under the MOMS (Minimac Operations and Maintenance Service) offering.

The filtration process helped the oil to reach its standard value considering the contamination and transparency.

Our team achieved ISO19994460 18,15,12 standards. Before filtration, the initial NAS value was 12; after filtration, NAS 3 in tank 1 and NAS 5 in tank 2 was achieved successfully.

The team achieved this goal by dissembling the pieces of equipment, fabricating them, and re-assembling the equipment in the time and space given. No spillage occured during the service job.
Benefits
Extended oil life.
Smooth functioning of the machines.
Elimination of oil replacement costs.
Improved machine’s life.
Successful on time commissioning of the first IAC.

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