This website uses cookies to ensure you get the best experience on our website.
To learn more about our privacy policy Click hereCan all contaminants be seen with naked eyes?
As a part 2 of #knowyouroil series, we will discuss about Particle Contamination. Whenever we talk about contamination the first thing that comes to our mind is solid particles that we can see or feel. But
Can all contaminants be seen with naked eyes?
As a part 2 of #knowyouroil series, we will discuss about Particle Contamination. Whenever we talk about contamination the first thing that comes to our mind is solid particles that we can see or feel. But what we do not understand is how big a particle can really cause wear and tear to your machines, can all contaminants be seen with naked eyes? Is it too late to wait until then?
To answer the above questions we must first understand the actual clearance size of the different types of lubrication film formed between rolling> and rotating components which is essential for providing proper lubrication. Oil film thickness in machinery is measured in microns (µm), or one-millionth of a meter.
For queries related to Oil Testing, follow:
https://www.linkedin.com/company/minimacsystemsprivatetlimited
Below are the finest tolerance found in different types of components.
When small particles, which cannot be seen through human eyes, pass through the critical machine parts under load, they create small microtears which get transformed into cracks over a period of time due to continuous stress and strain conditions leading to the more fine generation and hence increase contamination.
The contaminants that are considered to be most damaged are from size 2 to 20 µm and avoiding these are key to keeping your machinery breakdown free.>
But it is also important to understand when to call the oil clean and when dirty, as it is understood that changing oil very frequently and maintenance every time is not feasible.
Below chart shows us what particle levels are admissible and what harms our system.
But knowing this is not enough if we donât know when to get oil sampling and testing done. Below chart provides an estimation for testing and the type of test to be conducted.
Get your machine's oil check today with our technical expert call +91 7030901266. Ask for a brochure today.
We at Minimac System Pvt. Ltd. not only design a maintenance schedule for your lubrication oil but also provide OIL TESTING and FILTRATION services and the filtered oil complies to the ISO standard of Super Clean oil as we stand for MINImum MAChinery Maintenance.
Share this on
Common properties that are must haves in the turbine oil.
Oxidation Stability: Oxidation stability is a chemical reaction that occurs with a combination of the lubricant and oxygen. The rate of oxidation is accelerated by high temperatures, water,
Common properties that are must haves in the turbine oil.
Oxidation Stability: Oxidation stability is a chemical reaction that occurs with a combination of the lubricant and oxygen. The rate of oxidation is accelerated by high temperatures, water, acids, and catalysts such as copper. The service life of a lubricant reduces with an increase in temperature.
Viscosity Index: The viscosity index (VI) is an arbitrary, unit-less measure of a fluids change in viscosity relative to temperature change. It is mostly used to characterise the viscosity-temperature behaviour of lubricating oils. The higher the VI, the more stable the viscosity remains over temperature fluctuations.
Filterability: Capable of being filtered or separated by filtering.
Low Sludging Formation Tendency: Having low sludge formation tendency.
To know more about sludging, read: https://www.linkedin.com/pulse/what-varnish-its-effects-anshuman-agrawal
We at Minimac study your maintenance needs and provide the best solution. We believe in Discern, Design & Deliver.
Call +91 7030901266 for Mechanical Maintenance & Oil Check.
Steps to achieve perfect oil lubrication
It is a well-known fact that lubricantâs key responsibility is surface separation and protection. It reduces friction and saves a lot of costs that a company incurs in events of premature failure. One of the
Steps to achieve perfect oil lubrication
It is a well-known fact that lubricantâs key responsibility is surface separation and protection. It reduces friction and saves a lot of costs that a company incurs in events of premature failure. One of the things that people talk about very seldom is when to lubricate and how much to lubricate. Does over lubrication saves or increases the maintenance expense? Is there a sweet spot or optimum point for lubrication?
In this article, we will discuss how to work around your lubrication schedule to save on operational costs and simultaneously reduce energy consumption? To get answers ping us: +91 7030901266
As presented in a report by Dr. H. Peter Jostâs Projected Economic Benefits Associated With Improved Lubrication Design and Practice, âA large percentage of lubrication programs operate inefficiently and on auto-pilotâ.
Some of the properties where too little or excess consumes too much energy:
Viscosity
Grease Consistency
Grease Load
Oil Volume
Filtration
Grease Bleed
Summability: greaseâs ability to relax in its reservoir under gravity and be fed into the pump
4 steps of the Oil Lubrication to save costs and conserve energy are:
1. Calculate the machine lubrication schedule on the basis of the machineâs operating environment and characteristics. It is often observed that the lubrication schedule of the slow-moving machines is scheduled very frequently and that of fast-moving machines very seldom. This irregularity in relubrication leads to either excess lubrication and thus wasting the product or insufficient lubrication leading to friction between surfaces, higher wear, and tear and premature failure. Contact Minimac, to schedule maintenance and for filter audit drive, follow: https://www.linkedin.com/company/minimacsystemsprivatetlimited
2. Machinery Operators should conduct a basis pre-trip each day to check for the physical properties of the lubrication of oil. In this way, early contamination conditions could be detected.
3. Cleaning of lubricant sump should become a schedule to extend on the intervals to change sump oil to save new lubricant cost. This activity also saves varnish and sludge appearance in tanks.
4. Skip all 3 steps and call Minimac +91 7030901266
We at Minimac Systems Pvt Ltd. not only design a maintenance schedule for the lubrication oil but also provide a range of OIL PURIFICATION SYSTEMS & OIL TESTING KITS. Minimac stands for MINImum MAChinery Maintenance.
Professional Blood Draw Services at Your Doorstep in Cape Coral
In today's fast-paced world, convenience without compromising on quality is key. At our Cape Coral clinic, we offer Professional Blood Draw Services right at your doorstep, ensuring you
Professional Blood Draw Services at Your Doorstep in Cape Coral
In today's fast-paced world, convenience without compromising on quality is key. At our Cape Coral clinic, we offer Professional Blood Draw Services right at your doorstep, ensuring you get the healthcare you need without the hassle.
Our team of expert phlebotomists brings years of experience and precision to every blood draw. Whether you're managing chronic conditions, undergoing routine tests, or simply need diagnostics done at home, we've got you covered.
Why choose us? Our commitment to excellence means you receive accurate results in the comfort of your own space. No more waiting in long clinic queues or dealing with unnecessary travel. We understand that your time is valuable, so we make sure your blood draw experience is efficient, reliable, and stress-free.
From the moment you schedule your appointment to the final delivery of results, we prioritize your convenience and confidentiality. Rest assured, your health is in capable hands.
Experience the difference with Professional Blood Draw Services at our Cape Coral clinic.
Let us come to you. Book your appointment today and take the first step towards hassle-free healthcare in Cape Coral.
Visit https://getthinfl.com/in-house-blood-drawing/
How to manage the cost of Lubricant Filtration
The cost of removing dirt from oil is substantial, mainly when plants and fleets operate in dusty environments. We are aware of the fact that contamination control is optional but an important maintenance
How to manage the cost of Lubricant Filtration
The cost of removing dirt from oil is substantial, mainly when plants and fleets operate in dusty environments. We are aware of the fact that contamination control is optional but an important maintenance strategy. You may find it surprising, but most oils purchased these days are not filtered before being sold. It may look transparent, but it has particles that are not expected to be in new oil. The existing contaminants of lubricants must be addressed first before putting into service. Achieving cleanliness of oil at economical rates should be taken care of by smart maintenance professionals.
As already mentioned, many new lubricants may have impurities that contribute to premature filter plugging. An oil change can be more economical than filtration (in some cases). In simple words, filters last if they donât plug in particles/impurities. A careful inspection must be done in this case. If you change filters very often, it will be a waste of resources. The additional cost includes inventory, labour cost, disposal of used filter and waste oil, scheduling cost, etc. If you change a filter too late, then it can be a danger for the oil and machine. Many technologies like bypass indicators, delta-P indicators, online particle counting, and alerts are available to improve the filter change intervals. Itâs very important to remove the particles at the same rate they enter into the oil.
To learn about the latest technologies, Join our Community
Following are the factors which improve filters and their economy:
Filter with the right micron â Filters must have the right micron size to ensure the proper flow of lubricant. The appropriate micron should be checked before selecting a filter.
Temperature â A lubricant may have difficulty passing through a filter in cold temperatures compared to warm temperatures.
Viscosity â Lubricant viscosity is an important aspect too. For Low viscosity lubricant, a low micron rating filter should be considered and vice versa. This is due to the machine tolerance.
Moisture â If there is less moisture, then a spin-on or drop-in filter can be used to remove water from a machine. If the water is in a large amount, then a vacuum dehydrator can be the best option to remove water from a lubricant, as in this case, heat and suction are used to remove moisture.
Thus, it is important to select filters considering size, media type, capacity, filter design, dirt-holding, location of usage, pressure, flow, etc.
Connect with Minimac Experts: Click here
Are you buying the right oil filter?
Have you ever thought when you raise a requirement for a particular filter letâs say a 10-micron filter you get a range of prices some being ridiculously low and some being higher than most, and all claim to give
Are you buying the right oil filter?
Have you ever thought when you raise a requirement for a particular filter letâs say a 10-micron filter you get a range of prices some being ridiculously low and some being higher than most, and all claim to give the best 10-micron filter? We get tricked at this point and without looking at differences we think that the only differentiator is the profit margin and procure the filter with the least price. For filter check contact - +91 7030901266.
Letâs try to understand the real reason for the price difference. There are two types of filter ratings:
Absolute: Filter Rating meaning 99.9% of the particles larger than a specified micron rating will be trapped on or within the filter.
Nominal: Filter Rating indicating the approximate size particle, the majority of which will not pass through the filter. It is generally interpreted as meaning that 85% of the particles of the size equal to the nominal filter rating will be retained by the filter.
So, a vendor quoting for an Absolute 10-micron filter will have higher prices than the one quoting for a 10-micron nominal filter. So, the key is to always look for the datasheets of these filters and compare them basis the Beta Factor.
Also read: https://www.linkedin.com/pulse/can-all-contaminants-seen-naked-eyes-anshuman-agrawal/
We at Minimac Systems Pvt Ltd. provide services of Total Lubrication Management and Lubrication Consulting that help you optimize your Lubrication needs. Minimac stands for MINImum MAChinery Maintenance.
Control System Of Turbine - Failure & Maintenance
Control System
The turbine control system describes the control over the opening of control valves corresponding to demand signals, and steam flows into the turbine with the help of a governing system
Control System Of Turbine - Failure & Maintenance
Control System
The turbine control system describes the control over the opening of control valves corresponding to demand signals, and steam flows into the turbine with the help of a governing system that facilitates the operation of the turbo set in an interconnected grid system.
Governing system is responsible for various function such as speed & load control functions, the start-up/shut-down controls, the over-speed control, turbine stress calculation, to control the initial run-up and synchronization of the Unit, to assists in matching the power generated to that demanded by responding to system frequency changes, to regulate the steam control valves position (and hence the load generated)in response to signal from the operator or from the load dispatch Centre, to restrict the speed rise within acceptable limits should the unit get disconnected (islanding) from the lgridoad and some protective trip functions.
With continuous research and developments in modern turbine technology, the following three types of governing system are mainly available nowadays in power plants:
1. Hydraulic: Hydraulic governors have only a speed controller loop. Machine speed is measured and indicated as a primary oil measure. Speed transducer is a centrifugal pump whose discharge pressure is a function of machine speed. This signal is sent to a hydraulic converter, to generate a high-power hydraulic signal for the operation of different control valves. The range of speed control is 2790-3210 rpm. Its speed regulation range (droop)is 7%. HG (typically) cannot be isolated mechanically like EHG.
2. Electrohydraulic: This consists of three control loop speed, load, and pressure. Speed Electronic Transducer is used for measuring the machine speed. This signal is processed electronically and then sent to an Electrohydraulic converter (E-H) for converting the electronic signals into proportional hydraulic signals (I-P converter) for the operation of control valves. It gives a faster response and precise frequency control. The range of speed control is wider (0 †3210 rpm). Its speed regulation(droop) is 5%.EHG can be mechanically isolated by closing the secondary oil line from the local.
Major devices/component of the above Governing system are:
Remote trip solenoid
Turbine trip gear (main trip valve)
Starting and load limiting devices
Speeder gear
Auxiliary follow-up piston
Follow up piston
Hydraulic amplifier
Electro-Hydraulic convertor
Sequence trimming device
Solenoid for load shedding relay
Block Diagram of EH Governing system
Follow our page and stay updated about Lubrication Reliability - Minimac Systems Pvt Ltd
Oil Lube Flow In The Circuit:
Control Oil: Oil is taken from the AOP/MOP discharge header for the governing system.
Trip/Aux Trip Oil: These two oil circuits are established through main trip valves under reset condition.
Start-Up/Aux Start-Up Oil: These two oil circuits are established to peak pressure through starting device at 0% position and pressure started reducing when the position of the starting device is raised.
Aux Secondary Oil: This oil circuit is the output of the hydraulic governor and input to the hydraulic converter.
Secondary Oil: Output to Hydraulic and Electrohydraulic converter.
Test Oil: This oil circuit is established to test over speed trip device when the turbine is running at rated speed.
Remote trip Solenoid Valves: These are two in nos. and when any turbine trip gets initiated, the solenoids get energized& control oil gets drained through the valves and trips the MTV.
Main Trip Valve: These are two in nos. and called the main trip gear. All the turbine tripping take place through this device under non-trip condition establishes trip & aux trip oil and used for resetting/opening the stop valves and producing HP/IP secondary oil.
Starting device: this device is used for resetting and opening the stop valves and, main trip valves &hydraulic trip devices. this device either be operated manually by handwheel or from remote (MCR) through a motorized actuator.
Speeder gear: This device in combination with starting device forms a hydraulic governor and provides an input hydraulic signal to the hydraulic converter. this device either be operated manually by hand wheel or from remote (MCR) through a motorized actuator.
Hydraulic/Electro-hydraulic converter: amplifies & converts hydraulic /electrical signals to hydraulic signals (HP/IP secondary oil) for the operation of the HP/IP control valve.
Hydraulic trip devices: These devices provide mandatory protections of the turbine by draining aux trip oil. these devices are reset by aux start-up oil.
3.Digital Electrohydraulic: The main function of the DEH control system is to control before starting up (auto judging very hot, hot, warm or cold state), auto-adjusting servo system static relation, turbine latching, speed and load control, protection, supervising and communication. It consists of electronic parts and EH system which controls the speed/load through controlling the openness of all valves. The feature of special controlling on IP start-up mode (HP casing switchover and isolating of HP casing) can perform quick start-up and stable running for a long time with low load at all phases.
This is a modern high-pressure (110 to 180 bar) governing system.
Letâs know how it works. The electrical measuring and processing of signals offer advantages such as flexibility, dynamic stability and simple representation of the complicated functional relationship. The processed electrical signal is introduced at a suitable point in the hydraulic circuit through the electro-hydraulic converter. The hydraulic controls provide the advantages of continuous control of large positioning forces for control valves. The integration of electrical and hydraulic system offers the following advantages:
Exact load frequency droop with high sensitivity
Reliable operation in case of isolation from power grids
Dependable control during load rejection
Low transient and low steady-state speed deviations under all operational conditions
Excellent operational reliability and dependability
Safe operation of the turbo-set in conjunction with the Turbine Stress Evaluator (TSE)/Controller (TSC)
Operating Method Of DEH Governing:
The stop valve for HP/IP will open by the HP fire-resistant oil when the dump valve is closed
The dump valve will close when the trip oil is under pressure
The trip oil is under pressure when the trip solenoid (5,6,7,8 YV placed on the trip block) valve is in a de-energized position and the HP Trip oil header is under pressure
The oil will enter the bottom of the piston through the isolating valve (Supply sol.). Thus, the stop valve opens slowly against the spring force.
In case of a trip, the trip solenoid valves are energized and AST valves de-energize and HP trip oil header is de-pressurized and thus dump valve open to connect the bottom and top ports to drain the oil to LP accumulators
The valve quickly closes due to spring force
After the unit is reset and HP trip oil is formed
The trip solenoid valve is de-energized conditions will give pressurized oil to the dump valve to keep it closed
Pressurized Oil is up to the EH servo valve
The EH Servo valve based on the DEH valve command signal and valve position feedback signal from LVDT will connect the HP Fire resistant oil to the lower part of the piston or lower port to the drain till the matching is achieved
In the case of Trip, the dump valve opens due to energization of the trip solenoid or depressurization of the HP trip fluid header. The dump valve opening leads to the control valve quick closing due to spring force.
Access more articles, join our network! Click Here
Type Of Control System Loops:
The EHG function consists of mainly following control loops:
1.Speed control loop: In this loop, the speed controller essentially compares the speed reference generated by the speed reference limiter circuit and the actual speed of the turbine and accordingly provides an output for the valve lift controller. This loop only determines the control valve position to adjust turbine speed at setting value before the generator is paralleled to the power system. 2.Power control loop: The task performed in the speed control loop is then transferred to the power control loop or the MSP control loop after synchronization with the system. The steam turbine shall be controlled on this MW-control mode normally. In the event of a drop of grid frequency, the governor valves shall open instantaneously to provide frequency support in the form of additional MW. When the main steam pressure (MSP) control mode is an operation, this MW-controller is tracking to the main steam pressure (MSP) controller. 3.Turbine inlet steam pressure (MSP) control loop: MSP mode (Turbine Follow mode) of operation results in the governing system modulating the steam flow to regulate the steam pressure at a fixed value. The control system shall switch automatically to this mode when faults occur which prevent normal control of the boiler. MSP mode will take over following a drop-in steam pressure of 10% or an increase in pressure of 3%. It shall be possible to manually switch to this mode. When the power control mode is an operation, this steam pressure controller is tracking to the power controller. 4.Steam pressure Limiter control loop: The pressure limiter shall override the governor and progressively reduce the steam flow to the turbine as the steam pressure before the HP steam turbine governing valves drops below a predetermined value in order to limit serve drops in steam temperature. 5.Condenser Vacuum Limiter control loop: This limiting controller shall override the governor and progressively reduce the steam flow to the turbine as the condenser vacuum falls over a predetermined range in an effort to maintain the condenser vacuum at this value. The setting shall be adjustable. It shall be possible to override the device during vacuum raising and it shall not come into operation below 1000 rpm. 6.Control valve (CV) position control loop: An output from the above loops is given to the CV position control loop as its setting. Consequently, it adjusts the CV position in accordance with its characteristic curves respectively. This portion outputs the opening command to the Electro-hydraulic (E/H) converter mounted on each CV separately. Due to each E/H converter having two magnet coils, two separate signal (±10V) lines are connected to them.
Valve Comprised In The EHG Circuit:
Turbine speed control, load control, load shedding relay control and emergency control are carried out by open and close action of each:
Main Steam Stop Valve (MSSV)
Main Steam Control Valve (MSCV)
Reheat Steam Stop Valve (RSSV)
Reheat Steam Control Valve (RSCV)
Most of the failure-to-trip conditions can be attributed to five basic problems.
Steam deposits on the valve stem (or stems)
Lubrication deposits (i.e., soaps, dirt, detergents, etc.) in the top works of the valve exposed to the elements
Mechanical failures of the valve resulting from bent stems, either in the valve proper or the upper works, damaged split couplings, etc., all within about a 6" area near the centre of the valve mechanism
Galling of the piston in the hydraulic latch cylinder
Jamming of the screw spindle in the larger cylinder-type valve design due to forcing by operations personnel
Connect with our experts for Oil Analysis & Condition Monitoring - Click Here
Servo And Proportional Control Valves:
Failures of control valves have resulted in a very expensive loss of production and downtime to many energy generation companies. This led to the increasing use of servo and proportional control valves in modern hydraulic control systems. These devices are inherently at the critical stage of controlling the generating process and quality of the end product.
The most critical factor of their failures is the contamination of the hydraulic fluid with regard to cleanliness and chemical composition like water content and various forms of break down that can occur due to chemical contamination, excessive heat or working of the fluid, inappropriate filters for the valve etc.
To achieve high reliability and asset life for a longer time, it is important to closely evaluate the design of filtration and its effects, components included and circuit layout to achieve the optimum solution. The key system elements are Servo valves and proportional valves, Pumps and motors and Ancillary valves and components.
The types of failure on the basis of contamination can be broadly classified into:
Short term failure: This type of failure comes with no warning which results in an unplanned shutdown of the plant, catastrophic for equipment, production loss. The main causes are jamming of the spool or plugging of the orifice.
Particle Jamming: In this mechanism, contaminant gets lodge in the fine clearances between the spool and body, the particles became wedged in the spool blocking control orifices to cause a âhard overâ condition or loss of control pressure. To solve this type of problems by filtration, the size of clearances and driving forces to overcome particles should be considered. This causes permanent damage to control lands of the valve which means expensive repair or replacement with a new one
Silting: Silting refer to a phenomenon where a spool is being held in a fixed position with high pressure across the lands which results in a gradual build-up of fine âsiltâ particles that can lock the spool within 5-10 minutes. poppet type solenoid valves are used in safety circuits where long stand times can be involved. A conventional solenoid (or the return spring) will not move the spool after 3-5 minutes
Long term failure: This type of failure directly impacts system accuracy and repeatability. It results from the gradual build-up of other âvarnishâ or silt type contaminant that degrades the control qualities of the valve such as threshold and hysteresis, wear/erosion of valve parts. Long term effects cannot be eliminated, however, by proper design, it is possible to maximise the useful life of the valve before service or repair is required. This requires the effective application of silt level filtration.
Valve Design:
Control system performance, the filtration requirements and likely contamination sensitivity are dependent on how the best valve design is selected. Design goals should be balanced with component details, component costs and overall system costs. A good understanding of how and why the valve works will provide maximum benefits to the overall design solution. There are three principal areas to be considered for the best designing of a valve:
Internal forces: Understanding the forces within the valve that provide for correct operation and those that resist operation, is most valuable for understanding optimal filtration requirements. Forces determine both short term and long-term performance for contamination sensitivity and threshold/resolution.
Spool position control: For both servo valves and proportional valves the spool is capable of being positioned anywhere over its total designed stroke. How the spool is moved and held in that position will have a direct influence on the cost of manufacture, system accuracy and contamination sensitivity. Three methods used are
Open-loop or non-feedback
Mechanical feedback (MFB)
Electrical feedback (EFB)
Design tolerances: Finer tolerances will be more susceptible to wear and the potential for particle jamming. They will be an important factor for the evaluation of either servo valves or proportional valves with regard to filtration design. For both short and long term functionalities below are few manufacturing objectives such as:
Nozzle diameters and exit clearances
Spool diametral clearance
Spool travel - from 0.250mm for high-performance servo valves to 5-10mm for proportional valves. A shorter stroke means faster response, but finer manufacturing tolerances.
Spool control land overlap - which ranges from 10-20% overlap proportional valves to âaxis cutâ (zero overlaps) servo valves which require special protection of the lands to maintain performance. Zero overlap valves are used in the pilot section of some proportional valves so that protection requirements can be similar for parts of servo valves and proportional valves.
Control Oil - Fire Resistant Fluid (FRF):
A fire-resistant control fluid (FRF) is used in control and governing systems. The use of fire-resistant control fluid for turbine control and protection systems reduces the risk of fire. This is due to the higher ignition temperature (compared to mineral oil) in case of leaks.
It shall not cause corrosion to Steel, Copper and its alloys, Zinc, Tin or Aluminium (compatibility to be checked)
It shall be continuously regenerated with Fullerâs earth, ICB resins or an equivalent regeneration agent
It must not cause any erosion or corrosion on the edges of the control elements
It must be shear-stable. It should not contain any viscosity index improver
FRF leaking from the system, if any, must not ignite or burn in contact with hot surfaces (up to 550 degrees C)
It must be capable of withstanding continuous operating temperatures of 75 °C without physical or chemical degradation
It must be miscible with traces (max. 3 % by vol.) of TXP of another brand (without deterioration)
The air release of the FRF should not deteriorate in presence of Fluoroelastomer seals and packing used in the FRF system
It must be free of ortho-cresol compounds
It must not pose a safety or health hazard to the persons working with it, provided that the requisite hygiene regulations are observed
Contamination In FRF/Degradation Of Phosphate Ester
Though Phosphate ester fluid is designed for the long life of service of around 20 years if maintained properly, However, contamination or abuse in the oil because of poorly lubrication practices can degrade the oil life and reliability of the machine. Fluid degradation results in sticking valves, eroded servo valves, plugged filters and/or blocked servo valve strainers. The major contaminant or factor of oil degradation are described below:
Water Contamination
This is the most common and dangerous contaminant which frequently dictates the service life of FRF fluid. Phosphate ester has the tendency to hydrolyze which means breaking down into acid and alcohol and this process accelerates with increasing temperature and is catalyzed by the presence of strong acids and some metals.
Acid formation
Uncontrolled generation of acidic products is harmful to the life and performance of phosphate esters. strong acids are also chemically reactive and can form metal soaps or salts which adversely affect foaming and volume resistivity, the latter being used to assess the potential for servo-valve erosion. This soaps precipitates in servo valves and cause stickiness.
Lowering of Resistivity
Resistivity is a critical performance indicator for phosphate ester fluid quality. Low resistivity values are associated with electrokinetic wear, a very common failure mechanism of servo (MOOG) valves.
Solid Contamination
This particulate contamination is responsible for fluid darkening and is generally produced from micro-dieseling, which is a type of high-temperature fluid breakdown caused by air release issues. Solid contaminants of more than (>4) micron are measured by ISO4460 but less than (4) microns are not being detected. On investigation, 90% of total solid contamination in EHC fluids is below 4 microns which results in plugged filters, blocked servo valve strainers.
Oxidation degradation
Oxidation the most dangerous process which occurs due to contamination gives output in the form of heat. Oxidative degradation results in the production of a range of strong and weak acids and from very low molecular weight hydrocarbons that may plate out as varnish to higher molecular weight hydrocarbons or polyphosphates present as sludge that can increase fluid viscosity and reduce resistivity while blocking filters and causing valve sticking. External sources such as a steam line, hot/molten metal or a welding torch located close to the hydraulic line provide heat to the fluid. The difference between internal âhot spotsâ is that it occurs when the fluid is in circulation (except for the fluid being heated up in the tank) and external heat sources occur when the fluid is static.
Aeration (Thermal Stability and Pyrolysis)
The presence of a small amount of dissolved oxygen will result in degradation at lower temperatures - particularly in the presence of metals - and apparent changes in the physical/chemical properties of the fluid may be due to oxidation rather than pure thermal breakdown.
Maintenance Of FRF Fluid:
The fluid is pressurized, subjected to elevated temperatures, flows through fine clearances and is exposed to contaminants including water, dirt and air. Its maintenance should be focused on Keeping the fluid dry, clean and purified, checking material compatibility issues and employ regular fluid condition monitoring, following the guidelines for handling control fluid and for treatment of control fluid systems, Preservative Agents in Control Fluid System, precautions to Ensure Compatibility of the Control Fluid with other Materials, the procedure for sampling and analysis programs. Below is a chart summing up the maintenance properties:
Purification:
Ion Exchange System
Ion exchange resins have become a preferred form of treatment for fire-resistant fluids used in EHC systems. This treatment has overcome the practice of the fullerâs earth to control acidity generation in a "synthetic" fluid. Weak Base Anionic (WBA) resin in the hydroxide form could quickly reduce the acidity while a strong acid cationic resin (SAC) would, surprisingly, reduce the metal soap content. In order to reduce the amount of water released by the resins, they were dried at 80°C to a level of ~5% before use as a mixture in the existing filter housing. Over a period of about 1-2 months, the properties of the fluid returned to close to those of the new fluid. The below table shows function of commercially available type resin:
The followings points should be considered for the sampling of FRF oil:
Always perform sampling at the same location directly from the system
Recirculate the fire-resistant fluid long enough prior to sampling to avoid settling and give a homogeneous sample
Always perform sampling while the FRF system is in operation
Flush the sampling point prior to sampling by draining about 10 litres of fire-resistant fluid into a clean receptacle; return this into the system after sampling
Allow about 10 litres of fire-resistant fluid to pass through the sampling point before performing sampling by filling the fire-resistant fluid directly into the cleaned ground-glass flask
Do not use aids such as syringes or beakers
Always put identification-mark on the specimens uniquely and durably
Complete the sampling records and send them to the analyzing laboratory together with the FRF sample
Now we are showcasing our solutions and how they helped companies to achieve reliability in turbine maintenance, uptime in maintenance goals and uninterrupted power generation:
Check out the FRF Reconditioning System: Click Here
Minimac's Case Studies Of Reconditioning Of FRF
Case Study 1: A power plant in Northern India using Indo-Japanese Technology Turbine EHC System. The Power plant shows their awareness towards Lubrication Reliability through Reclamation of oil and with their proactiveness, managed to save the downtime values of 1.05 CR approx. Below the graph is a trend analysis of tracked parameter:
Case Study 2: India's first and largest supercritical coal-fired power plant in the private sector. This company avoided the breakdown of the Power Plant by following practices of reconditioning of oil. The below graphs show the trend analysis of TAN and NAS values tracked during the recondition of EH oil at Unit #1 and Unit #2 where Moisture level was also tracked & kept within the permissible limit.
Read in detail - Article
Case Study 3: A power plant in the coastal region of India was facing a high increase in the TAN, Moisture and ISO/ NAS due to which the plant has also faced breakdown and loss in power generation. To control the values in the permissible limits, an external Reconditioning system was equipped followed by a proper oil analysis program.
The below chart is showing the trend of a decrease in the values with continuous cycling of EH Oil.
Read the full Article
Conclusion:
The performance of Hydraulic system plays a vital role in the power generation and for its high-performance many factors must be considered importantly like understanding the valve design, setting & maintaining cleanliness objective, regular monitoring, the adaption of effective purification or filtration methods, monitoring of filter quality and replacement elements etc. Good filtration will always give the lowest machine running cost and greatest reliability for the end-user of hydraulic systems. Below are the major benefits of reconditioning of oil:
Extend oil life
Increased machine reliability
Reduced environmental contamination
Cost-saving on oils replacement
Time and effort saved for oil change out
Decreased waste disposal cost
Low carbon emission
Sustainable development
Call +91 7030901267 & speak to our Technical Experts and save Maintenance Cost.
Author: Mr Yogesh Kumar is a Mechanical Engineer with vast working experience of 11 years in Power plants. He has completed PGDC in Thermal Power Plant Engineering from NPTI. He is a certified Machinery Lubrication Analysis (MLA II) from the International Council of Machinery Lubrication (ICML), Vibration Analyst Level II from MOBIUS Australia, ISNT certified NDT Level II professional in RT, UT, DPT, MPI, BOE (Boiler Operation Engineer) Certification.
Co-Author: Ms Preeti Prasad is a Chemical Engineer with working experience in Refinery and various other sectors in connection with Lubrication Consultancy. She is a certified Machinery Lubrication Technician (MTL I) from the International Council of Machinery Lubrication (ICML).
Reference Taken:
Contamination Control - A Hydraulic OEM Perspective: Workshop on Total Contamination Control Centre for Machine Condition Monitoring Monash University, August 1997.
ASTM Paper on IX treatment, Whitepapers on Phosphate Ester from EPT clean
National Power Training Institute
Other documents from Scribd.com
Are you experiencing sub-optimal results even after changing filters?
TEAM MINIMAC
Feb 24, 2022 · 2 min read
We have talked about how to procure filters and what specifications to look for, but selecting the filter according to the specifications
Are you experiencing sub-optimal results even after changing filters?
TEAM MINIMAC
Feb 24, 2022 · 2 min read
We have talked about how to procure filters and what specifications to look for, but selecting the filter according to the specifications doesnât ensure the best results if a filter is not employed properly. In this article, we will discuss a few factors which can impair a filter's performance.
I hope you have read these 2 articles:
http://bit.ly/35J0Vuy
http://bit.ly/2QInSKi
Whenever you are experiencing sub-optimal results even after changing filters, below are some possibilities which should be checked for:
Collapsed center tube
Inconsistent media quality
Damaged or burst filter media â fatigue
Bypass at filter media seam
Bypass due to adhesive failure
Damaged gasket or O-ring seal
Bypass valve jammed in open/closed position
Installation error, installing a filter in the opposite flow direction
Bypass valve leakage
Misaligned filter and seal
If none of the above factors contribute to the sub-optimal functioning of your filters we suggest you contact the Minimac Consulting team for required filter calculations and further investigations.
Get your filter check today, Call +91 7030901266
We at Minimac Systems Pvt Ltd. provide services of Total Lubrication Management and Lubrication Consulting that helps you optimize your Lubrication needs. Minimac stands for MINImum MAChinery Maintenance.
Power sectors in india
After China and the United States of America (USA), India is the world's 3rd largest power producer currently producing 373,029.35MW of power. Catering to the huge population of India. Letâs take a glance at the power
Power sectors in india
After China and the United States of America (USA), India is the world's 3rd largest power producer currently producing 373,029.35MW of power. Catering to the huge population of India. Letâs take a glance at the power generation sector in India.
62% of the total production of power is generated by thermal energy sources.
23.9% is produced from Renewable Energy Sources such as wind and solar.
12.3% is produced from Hydro Energy & 1.8% is produced from Nuclear Energy.
In order to match the ever-increasing demand of the market, power production is increasing every passing day. India's electricity consumption has increased by approximately 2 folds in the last decade from 199,877 MW at the end of the 11th Five-Year Plan (2012) to 373,029 MW in 2020.
Sustainable development is very necessary for an industry that operates 24/7.
To fulfill the demand of the market it is necessary to keep the machinery healthy and for healthy machinery selection of the right lubricants is a must
Government vs Private... Power Generation Battle!
The majority of the power generation is held by the Government companies in India. Companies such as National Thermal Power Corporation Limited (NTPC), National Hydropower Generation Company (NHPC), and North Eastern Electric Power Corporation Limited (NEEPCO) constitute the majority of both Central as well as State owned government plants. With 47% to the Private Sector, Government-Owned Plants hold a 53% share.
On the other hand, private companies such as Adani Power, Tata Power, JSW energy hold the majority share in the sector of power generation.
Are government companies better than private sector companies or private sector companies are better than government companies in the power generation sector? This is still a debatable question. The amalgamation of the private and government sector in power generation helps provide sufficient power to back up India.
Visit https://www.minimacsystems.com/market-served to know about our clients in the power sector.
How do power plants generate Power?
Some of the common sources are Coal, Gas, Solar Energy, Hydro Energy & Nuclear Energy.
Thermal Power Plants hold 62% of power plants in India, constituting 53.6%, 1.7%, 6.7% and 0.1% of Coal, Lignite, Gas-based, and Oil-based respectively.
36.2% are Hydroelectric and Renewable Energy Power Plants. Renewable Energy is a sustainable and non-polluting source of power generation. Solar, being renewable is gaining popularity in the Power Sector with the Government investing majorly in Solar fields across the nation.
Nuclear power plants hold a mere 1.8% of total Power Plants in India, whereas it is the second-largest source of low-carbon electricity production globally after hydropower.
Do check https://www.minimacsystems.com/blog
Is solar becoming the new dawn of power generation in India?
India having the Summer season in the Majority of parts, Solar energy has a huge potential in Power Generation. Solar is also the cleanest source of energy hence can be sustained for the future.
Solar power capacity has increased by more than 11 times in the last five years from 2.6 GW to 28.18 GW in March 2019.
Do you think Solar will be the new era in Power Generation? Always remember Clean Oil = Healthy Machine.
Pollution is the enemy of sustainable development of power generation. Controlling harmful emission of greenhouse and disposal of waste is an important concern today.
Shifting to a cleaner source of power generation such as wind or solar energy sources will only solve half the issues. Application of 3R i.e Recycle, Reduce and Reuse are equally important in an operation and maintenance activities. Not only will it reduce the pollution but also will decrease the cost of operation and maintenance of the power plant.
Oil purification and reuse of lubricants is acceptable as per the ISO standard and is becoming essential part of power plant maintenance. Once you filter the oil it can be easily reused for a couple of years which will ultimately provide less harm to the environment.
Let's reuse the oil with proper and timely filtration and save our natural resources.
We at Minimac study your maintenance needs and provide the best solution accordingly. We believe in Discern, Design and Deliver.
Call +91 7030901266 for Mechanical Maintenance and Oil check.
Understanding the root cause of the symptoms that are observed on your machinery?
It is observed across the spectrum that whenever we see issues/symptoms like:
Oxidized oil
Destructive pitting
Excessive vibration
Abrasive wear
Cavitation
Machinery
Understanding the root cause of the symptoms that are observed on your machinery?
It is observed across the spectrum that whenever we see issues/symptoms like:
Oxidized oil
Destructive pitting
Excessive vibration
Abrasive wear
Cavitation
Machinery abnormal noise
Wear debris generation
High running temperature
We usually believe in either Repairing, Replacing, Rebuilding and Removing the affected component. However, it only subsides the symptoms temporarily. This approach is called the 4-R approach and it weeds out the issue from the surface and not at the root level and hence the problem reoccurs. Call +91 7030901266 for Mechanical Maintenance & Oil Check.
However, we should aim at studying these symptoms and work on the root causes. Some of the very frequent root causes that cause the above-mentioned symptoms are:
Misalignment
Wrong oil usage
Moisture
Machinery part imbalance
Particle contamination
Air contamination
Hence, we should aim at 5I approach i.e. Itâs clean, Itâs Cool, Itâs dry, Itâs aligned and balanced, Itâs well oiled. This approach keeps the machine healthy and eliminates the problem.
In case you are unable to understand the root cause of the symptoms that are observed on your machinery contact Minimac Systems Pvt. Ltd.
Untitled A
Untitled A
Wall Photo
Cover Phot
The site administrator will act on your review and you will receive an email correspondingly.
0 All | 0 Updates | 0 Check-ins | 0 Photos | 0 Events Attended |