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

1. Extending oil life.
2. Eliminate oil Replacement cost.
3. Protect Turbine against hunting.
4. 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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