Executive Summary

A 2 x 600 MW power plant in Western India, utilizing a Chinese technology turbine, Electro-Hydraulic Control System (EHC) or the Digital Electro-Hydraulic System (DEH) was struggling with increasing Total Acid Number (TAN) and high moisture content in its Electro-Hydraulic (EH) oil. These issues led to severe operational challenges, including servo valve failure, unplanned shutdowns, and turbine hunting.

Minimac Systems implemented its MLC LVDH TRIX-20 EH Oil Reconditioning System, a comprehensive solution designed to eliminate solid contaminants and moisture and reduce TAN effectively. This intervention prevented a potential turbine shutdown worth ₹2.8 Crore and avoided oil replacement costs of ₹21 Lakh, resulting in total savings of ₹3.01 Crore.

Key Metrics:

• TAN Reduced:Restored EH oil quality using ion exchange purification.
• NAS 5 Achieved: Removed solid contaminants with superfine filtration.
• ₹₹3.01 Crore Saved:Prevented turbine shutdowns and oil replacement costs.
• Turbine Performance Improved:Eliminated hunting and valve failures.

Introduction

Minimac Systems is a leading provider of EH Oil Reconditioning Systems designed to enhance the performance and longevity of industrial lubricants. Our flagship product, the MLC LVDH TRIX-20 EH Oil Filtration System, offers cutting-edge solutions for contamination control, TAN reduction, and moisture removal.

Client Profile:

• Industry: Power Generation (Thermal Power Plant)
• Plant Capacity:2 x 600 MW
• Location: Western India
• Technology Used: Chinese Technology Turbine EHC System

The Challenge

Problem Statement: The power plant faced rapidly increasing TAN values and excessive moisture content in the EH oil of the turbine governing system. Contamination ingress and by-product formation severely degraded the oil quality, impacting the plant’s operational efficiency.

Impact of the Problem:

• Frequent Servo Valve Failures Hlead to turbine hunting and sluggishness.
• High TAN Valuecausing electro-kinetic erosion of EHC system components.
• Presence of Varnish & Silt obstructing spool clearance.
• Unplanned Shutdownsresult in generation loss and revenue loss.

The Solution

Implementation of Minimac Systems:

To address these issues, the MLC LVDH TRIX-20 EH Oil Reconditioning System was deployed. The system is specially designed to tackle EH oil degradation through a combination of advanced technologies.

Features Utilized:

1. Superfine Filtration:Effective removal of solid contaminants.
2. Vacuum Dehydration Technology:Comprehensive moisture removal.
3. Ion Exchange Technique: Significant reduction of Total Acid Number (TAN).
4. Inert Gas Blanketing:Prevention of moisture ingress in the EHC system tank.

Consumables Used

• EH Oil Quantity Processed: 1200 liters.
• Filter Elements Required: 10-micron (1 qty), 3-micron (3 qty)
• Resin Consumption: 36 liters

Minimac Systems' service engineers also provided training to the plant’s team on Fire Resistant Fluid - FRF, maintenance, contamination control, and the importance of a robust oil analysis program.

Results

Quantitative Outcomes:

• Cost of Oil Replacement Avoided: ₹21 Lakh
• Cost of Downtime Avoided:₹2.8 Crore (48 hours downtime prevention)
• Total Savings Achieved:₹3.01 Crore
• CO2 Emission Reduction: 14,400 kg of CO2 e / 0.0144 gigagrams of CO2 e.

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

Qualitative Outcomes:

• Enhanced Turbine Availability & Reliability.
• Extended Oil Life through effective contamination control.
• Prevention of turbine hunting and sluggishness.
• Improved understanding of Fire Resistant Fluid - FRF maintenance and oil analysis through expert training.

Conclusion

By implementing Minimac Systems’ MLC LVDH TRIX-20 EH Oil Reconditioning System, the power plant achieved:

• Significant cost savings of ₹3.01 Crore.
• Enhanced operational maintenance reliability and efficiency.
• Reduced environmental impact through CO2 emission reduction.

Minimac Systems' solution effectively addressed the client’s challenges, enhancing turbine reliability and extending EH oil life.

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