Reclamation of FRF

A 1200 MW coal-fired thermal power plant using Indo-Chinese Turbine EHC - System in Southern India.


SYNOPSIS

The power plant was suffering from a loss in electricity generation for a few days as per the desired target. The O&M team identified that the turbine command was not functioning properly and was tripping frequently. On further investigation, it was found that the Servo Valve (Moog Valve) had failed and showed hunting or sluggish behavior.

Minimac’s EH Oil Reconditioning System “MLC LVDH TRIX 20” acted as a rescuer and saved the plant from an unexpected shutdown.

If this system would have been implemented earlier, a loss of more than ₹5 Cr could have been saved.


PROBLEMS

Failure of Moog Valve: This was the main reason for the turbine trip and breakdown in the power plant.

Poor Oil Analysis Program: Oil analysis should be done monthly for Particle Count & TAN (weekly if the trend is negative). For moisture contamination, weekly test is suggested but the customer failed to perform the tests as per the schedule.

Inadequate Operation Practices: The solenoid valve of the LVDH (oil purification machine) vacuum line was only 20% closed which failed to generate vacuum.


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 Technology.

• 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.

Total Consumable Details:


  • Filter - 01 qty of 10 - microns
  • Filter - 01 qty of 3 - microns to achieve NAS 5 cleanliness
  • Total Resin - 36 liters

BENEFITS:


1) Extended oil life

2) Elimination of oil replacement cost

3) Protection of turbine against hunting

4) Increased turbine reliability



The below graph is showing the trend of decrease in the values with continuous cycling of EH Oil and total running hours of equipment being 698 hrs.

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