Power Sector Brochure - Cjc.dk

CJC in the Power SectorC l e a nO il -B ri g h tI d e a s

Power Plant ApplicationsPower supply depends upon maximum machinery performance,which depends upon clean oilHave You Ever Experienced..?Oil analyses exceeding condemning limits?Oil contaminated with water?Unforeseen breakdowns?Excessive wear on components?Sticking valves due to oil oxidation?- all can be avoided by offline oil filtration!Turbine Lubrication SystemsRemoval of water, particles and varnishTurbine Control SystemsRemoval of varnish, particlesand reduction of acidsFeed PumpsRemoval of water,particles and varnish2Baltzer Grafik • Power Segment • UK • 07.2010

Reliable Power SupplyStarts with Clean OilCoal Mill Gear BoxesRemoval of varnishand particlesBoiler BlowersRemoval of water,varnish and particlesCrane HydraulicSystemsRemoval of particles,water and varnishFurther Applicationsin Power Plants• Cooling towers• Tap changers• Conveyor belts3

The Most Common Types of Wear80% of all machinery repair and maintenance costs arerelated to contaminated oilOil care is a must because up to 80% of all machinery repair and maintenancecosts can be traced back to contaminated system oils and fluids. This hasbeen substanciated by several independant analyses. The main cause iswear induced by contamination through solid particles, water and oil degradationproducts - which are not retained effectively by most inline filters.Particles“Sandblasting”When particles are transportedwith the oil flow, the particles collidewith metal parts, destroyingthe metal surface and formingnew particles.GrindingWhen clearance sized hardparticles are wedged betweenmovable metal parts, they destroythe metal surface further andcan result in additional wear.WaterCavitationCavitation occurs in areaswhere water is present and oil iscompressed. The water implodesand blows particles off the metalsurface, which then cracks.CorrosionWater or chemical contaminentsin the oil cause rust or chemicalreactions, which deteriorate thecomponent surfaces.Varnish/resinOil DegradationOxygen, water and high temperaturelead to oil degradation whichis the precursor of varnish/resin.The result of these deposits isa “sandpaper-like” surface onmachine parts.4

One Filter - Three SolutionsCJC Offline Filters remove particles, absorb waterand retain oil degradation products round-the-clockCJC Offline Filters do not only remove solid particles and water. They alsoretain oil degradation products - “soft contaminants” - which are the precursorsto the sticky varnish, that deposits on metal surfaces. Varnish cannotbe removed by traditional filtration, but with the CJC Filter Insert, it can.ParticlesRemoval of ParticlesParticles down to 0.8 µmare retained in the uniqueCJC Filter Insert.WaterRemoval of WaterThe CJC Filters caneither absorb or separatethe water according to oilsystem requirements.Varnish/resinRemoval ofDegradation ProductsResin in the oil will beattracted to the polar fibresin the CJC Filter Inserts.5

The Power of CJC Oil FiltrationEach application performs specific tasks - so do CJCOffline filters in order to ensure high oil cleanlinessThe most effective and economical way to maintain oil in the many systemsfound in power plants is the use of CJC Products. Equipment reliabilityand lifetime can be dramatically increased by installing a CJC Oil FiltrationSystem.Steam Turbine Lube SystemsWater is the greatest threat to thelube oil system in a steam turbine.Owing to the construction of a turbine,with steam and oil working oneach side of the labyrinth seal, moistureenters into the oil is a constantthreat. The leading suppliers of turbinesspecify maximum water contentin the oil of 300 ppm.CJC PTU3 27/081For turbine lube oils we recommendthe use of a CJC Offline FilterSeparator, type PTU3.CJC PTU3 2x27/108Gas Turbine Lube SystemsDue to high operating temperaturesthe oil in a gas turbine will sufferfrom an oxidation process whichproduces among others “resin”-likesubstances in the oil system. If notremoved, this will lead to malfunctioningof the system.CJC HDU 27/54For gas turbines we recommendthe use of the CJC Offline FineFilter (HDU series) .CJC HDU 2x27/1088

CJC Offline Filters forAll Power Plant ApplicationsCoal Mill GearsTypically the main problem for oilin a coal mill gear is the high contentof small particles as well asresin caused by high temperatures.The result is that some of the smallestparticles (approx. 2 micron) willenter the bearing and gears andcause damage. This again leads tofurther particles and wear on allcomponents.CJC HDU 27/54To solve the contamination problemwe recommend the use of the CJCOffline Fine Filter (HDU series)CJC HDU 27/108Hydraulic Control SystemsThe power transmitting fluid in ahydraulic control system can eitherbe hydraulic oil or phosphate ester.Hydraulic OilHydraulic oil will often show a highcontent of wear particles as well asoil degradation products. To removethe contamination we recommendthe use of CJC Offline Fine Filter(HDU Series)Phosphate EsterEster-based fluids are produced bythe chemical reaction between acidand alcohol (esterification).Unfortunately this reaction is reversiblewhen ester is exposed to water.As little as 100 ppm water is enoughto start a reaction (hydrolysis) wereester fluid degrades and acid compoundsare generated.To remove water and acids from esterbasedfluids we recommend the useof a CJC Ion Exchange / Acid RemovalFilterCJC HDU 27/27CJC Ion Exchange /Acid Removal Filter9

CJC Series of SolutionsAll CJC Series are of uncomplicated design, easy toinstall and almost maintenance freeUsing CJC Offline Filters will have a positive effect on your maintenancebudget and will increase your productivity and reduce your energy consumption- all advantages in terms of total economy!HDUSeriesCJC HDU SeriesThe CJC Fine Filtersremove particles, water, andoil degradation products fromhydraulic and lubrication oilsand have flow rates from45 to 20,000 L/h.CJC Filter Inserts beforeuse and after use, showing thelarge dirt holding capacity.PTUSeriesCJC PTU SeriesThe CJC Filter Separatorscombine depth filtration withwater separation and are usedfor water contaminated diesel,hydraulic and lubrication oils.The CJC PTU Seriescontinuously removeswater fromoil in largevolumes.Cl e a nO il -B r i g h t I d e a s10

CASESProblem solving and preventive maintenance are keyCases and Statements fromOur Customers in Powerwords in the power sectorVattenfall A/SApplication:Steam TurbineA CJCFilter Separatoroperating atVattenfall A/S,Helsingør Kraftvarmeværk,DenmarkHelsingørKraftvarmeværkis a combinedheat- andpower stationOil samplebefore filtration- and afterfiltrationBjarne Karlsen, Operations Manager at Vattenfall A/S:“After installation of the CJC Fine Filters andthe CJC Filter Separator on our lubrication oilsystems, we quickly solved the problem of unacceptablyhigh water content on the steam turbine’slubrication oil.An HDU Fine Filter installation on our gas turbine’slubrication oil tank was also a great success”ProblemOil samples from all oil systems at the combined heatand power station were submitted for oil analyses. Theoil samples from the steam turbine revealed a very highwater content as well as high particle contamination,rust and oil degradation products.SolutionA CJC Filter Separator was installed on the steam turbineand CJC Fine Filters were installed on the gas turbineand the hydraulic power unit at the same time.Prioer to installation, the oil sample showed a watercontent of 31,400 ppm and a particle content correspondingto ISO code 20/19/14.One month after the installation of the filters, watercontent was reduced to 60 ppm and the ISO code wasreduced to 16/14/10. After an additional two months offiltration, water content was reduced to 24 ppm and theISO code to 13/11/6.Cl e a nO il -B r i g h t I d e a s12

Niedzica S.A.Hydro PowerPlants GroupNiedzica S.A,PolandMr. Eugeniusz KiełtykaMechanical Department Manager:“The CJC Filter Separator is not only verysimple to operate, but it also allows us tofully eliminate the usage of a centrifuge.Moreover I am very satisfied with theresults.”Application:Water Turbine Control SystemProblemMechanical contamination of oil, oil degradation products, risk ofexcessive water content, the necessity of periodical cleaning anddrying the oil with a centrifuge.SolutionA CJC Filter Separator was installed in order to solve the problemswith particles and oil degradation products. Additionally,the CJC Filter Separator removes the free water from the system.During the test period of three months the contamination levelwas reduced from 15/13/8 to 13/12/7 according to ISO standard,while at the same time water content was maintained on a stable,low level.A significant prolongation of the oil life time was achieved.Elsam A/SMr. Jørgen Brix AndersenElsam A/S:Elsam A/S,Studstrupværket,Denmark“As the oil analyses show, we have achievedcleaner oil, after we have installed CJCFilters on our 8 coal mills. The need for oilchanges is gone, and the risk of breakdown inthe bearings has been extremely reduced”.Application:Coal Mill GearProblemOil analyses showed a high content of metal particles and resin,indicating wear on the components. The very small particles enteredthe bearings and caused damage.SolutionA CJC Fine Filter was installed and after a test period of threemonths the results were clear. The first sample taken had an ISOcode 21/17/13.After one month with the CJC Filter installed the ISO code wasreduced to 16/15/12. After three months the cleanliness levelwas further reduced to an ISO code 15/13/7.1,304,472 of > 2 microns particles were reduced to 18,195,meaning the CJC Filter had removed 98% of those particles.Furthermore, the resin was totally removed.North American Electric Power PlantApplication:Gas TurbineMajor ElectricPower Plant,USAAcc. to the Maintenance Manager:“Finally got a dispatch of several of our filters.Unit 3 (the one the CJC Filter is on) workedbeautifully. When we checked Unit 3 the IGVservo looked completely free of varnish andthe last change of filter inserts had absolutelyno evidence of varnishing.”ProblemExcessive varnish formation causing sticking valves. Varnish contaminationleads to unit trips that cost from $ 25,000 to $ 250,000in lost production, downtime, and repairs.SolutionA CJC Fine Filter was installed in the test period from Decemberthrough May, operating 9 hours a day. The minimal run timeallowed the CJC Fine Filter to clean the oil in the reservoirmany times over, polishing the oil. During the month of June theturbine run time increased by 250 hours, allowing the ultra cleanoil in the reservoir to circulate through the turbine lube oilsystem.As a result, the varnish level was reduced and the entire lubesystem was cleaned. More importantly, a reduction in unit tripswas observed and recorded.13

C.C.JENSEN All Over the WorldThe CJC Offline Filters are distributed by our own internationalsales organisations and designated distributorsManufacturer & HeadquartersC.C.JENSEN A/SLøvholmen 13 • DK 5700 Svendborg • DenmarkTel. +45 6321 2014 • Fax: +45 6222 4615filter@cjc.dk • www.cjc.dkBeneluxC.C.JENSEN Benelux B.V.Tel.: +31 182 37 90 29ccjensen.nl@cjc.dkwww.ccjensen.nlFranceC.C.JENSEN FranceTel: +33 3 59 56 16 58ccjensen.fr@cjc.dkwww.ccjensen.frItalyKARBERG & HENNEMANN srlTel: +39 059 29 29 498info@cjc.itwww.cjc.itUnited KingdomC.C.JENSEN LTD.Tel.: +44 1 388 420 721filtration@cjcuk.co.ukwww.ccjensen.co.ukChileC.C.JENSEN S.L. LimitadaTel.: +56 2 739 2910ccjensen.cl@cjc.dkwww.ccjensen.clChinaC.C.JENSEN A/S ChinaTel: +86 10 6436 4838ccjensen.cn@cjc.dkwww.ccjensen.cnDenmarkC.C.JENSEN DanmarkTel: +45 72 28 22 22ccjensen.dk@cjc.dkwww.cjc.dkGermanyKARBERG & HENNEMANNGmbH & Co. KGTel: +49 (0)40 855 04 79 0kontakt@cjc.dewww.cjc.deGreeceC.C.JENSEN Greece LTD.Tel.: +30 210 42 81 260ccjensen.gr@cjc.dkwww.ccjensen.grIrelandC.C.JENSEN IrelandTel.: +353 61 374 943ccjensen.ie@cjc.dkwww.ccjensen.iePolandC.C.JENSEN Polska Sp. z o.o.Tel.: +48 22 648 83 43ccjensen@ccjensen.com.plwww.ccjensen.plSpainC.C.JENSEN Ibérica, S. L.Tel.: +34 93 590 63 31ccjensen.es@cjc.dkwww.cjc.dkUnited Arab EmiratesC.C.JENSEN Middle EastTel: +971 4 447 2886ccjensen.uae@cjc.dkwww.cjc.aeUSAC.C.JENSEN INC.Tel.: +1 770 692 6001ccjensen@ccjensen.comwww.ccjensen.comYour Local CJC TM DistributorWe are representedglobally by distributors.Find your nearestdistributor on ourwebsite: www.cjc.dkCl e a nO il -- or give us a call.B r i g h t I d e a s