A power plant in western India using chinese technology turbine EHC system saved 3.01 Cr approx. with MLC LVDH TRIX-20 EH oil filtration

Synopsis

A power plant (2 x 600 MW) in western 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 into formation of by-products.

Minimac’s EH oil reconditioning system “MLC LVDH TRIX 20 “act as saviour for the plant which has escaped the unexpected shutdown of the turbine worth 2.8 Cr (approx. 48 hours downtime) and cost & effort for replacement of oil worth 21 lakhs.

In total, the company has saved around 3.01 Crore by installing external reconditioning system at their site.

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 electro kinetic 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.

Benefits

1. Extending oil life.
2. Reduced TAN value.
3. Eliminate oil Replacement cost.
4. Protect Turbine against hunting.
5. Increased Turbine availability & reliability.

Cost Saving

This plant managed to save:

• Cost of oil replacement: ₹21 Lakh approx.
• Cost of downtime: ₹2.8 Cr approx

CO2 e Saving

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

Above graph shows the trend analysis of NAS 1638, moisture and TAN value around one-month installation of the reconditioning of EH oil at customer site.

Consumable required to finish this reconditioning of EH oil having quantity of 1200 liters are: 01 quantity of 10 micron and 03-micron filter element. Total consumption of resin was 36 liters

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