Executive Summary

Overview

A major power plant in Chhattisgarh faced a real reliability crisis from dirty lube oil and EH systems. Moisture, degradation, high TAN levels, and debris were putting bearings, valves, and startup timelines at serious risk.

Minimac Systems implemented targeted filtration, purification, and TAN reduction, bringing the oil back to spec and boosting overall system dependability.

Key Metrics

Introduction

Background Information

Minimac Systems is a trusted provider of advanced oil flushing, filtration, and contamination control solutions for critical industrial equipment. For this project, Minimac Systems deployed specialized filtration and TAN reduction systems to address severe oil contamination in power plant lubrication and electro-hydraulic systems.

Client Profile

• Location: Chhattisgarh, India
• Sector: Power Generation

Systems Involved:

• Main Lube Oil System (50 KL MOT)
• Electro-Hydraulic (EH) Oil System (600 liters)

The Challenge

Problem Statement

The power plant was experiencing high contamination levels, excessive moisture, and degraded oil conditions across both lube oil and EH oil systems. These conditions posed a direct threat to turbine bearings, servo valves, and overall system stability.

Impact of the Problem

• Oil cleanliness levels are far above acceptable limits.
• Elevated TAN indicates oxidation and varnish risk.
• Presence of mechanical impurities and installation debris.

Increased risk of:

• Bearing damage
• Valve malfunction
• Sludge and varnish formation
• Filter choking
• Reduced system reliability
• Delays in commissioning and startup

Detailed Analysis

Based on site inspection and oil testing reports, Minimac engineers identified:

• Lube Oil Cleanliness: NAS 12–8 (Required: NAS 6)
• EH Oil Cleanliness: Above NAS 8 (Required: NAS 5)
• TAN Level: 0.52 mg KOH/g (Limit ≤ 0.25 mg KOH/g)
• High Moisture Content: Indicating advanced oil degradation and oxidation

Both the 50 KL Main Oil Tank (MOT) and EH oil tank contained suspended particles, mechanical impurities, and debris, significantly increasing the risk of premature equipment failure and operational instability.

The Solution

Implementation of Minimac Systems

To address contamination, moisture, and oil degradation, Minimac Systems implemented a multi-stage oil filtration and purification program in line with the work order requirements.

Key Solutions Deployed

1) MLC-LVDH-TRIX-20

• Applied to the EH oil system.
• Effective TAN reduction, moisture removal, and NAS improvement.

2) FS-150-2S-H-V Filtration Skid

• Deployed for the 50 KL Main Oil Tank (MOT).
• Achieved targeted NAS cleanliness levels.

Process Highlights

• Multi-pass high-efficiency filtration.
• Removal of mechanical impurities, suspended particles, and installation debris.
• TAN reduction treatment to control oxidation and varnish formation.
• Continuous oil circulation with online monitoring.
• Filtration continued until stable NAS, TAN, and moisture levels were consistently achieved.

Results

Quantitative Outcomes

1) Main Oil Tank (MOT – 50 KL)

2) EH Oil Systems (600 Litres)

Qualitative Outcomes:

• Improved turbine and hydraulic systems reliability.
• Reduced risks of varnish, sludge, and filter choking.
• Enhanced protection of bearings and servo valves.
• Stable oil condition enabling smooth commissioning.
• Increased confidence in long-term equipment performance.

Conclusion

Summary of Benefits

By implementing Minimac Systems' advanced oil filtration and TAN reduction solutions, the power plant successfully restored oil health, achieved required cleanliness standards, and safeguarded its operations.

The Intervention:

• Longer oil usability.
• Safeguarded turbines and valves.
• Cut unplanned outages.
• Reliable, safe operations.

Dealing with dirty oil, moisture, or varnish in your setup?

Reach out to Minimac Systems, and we'll show you how our solutions can boost reliability, stretch equipment life, and keep things running smoothly.

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