Minimac Systems Pvt. Ltd.

  A critical oil reclamation project for the largest oil refinery with a capacity of 8 million tonnes per year in West Bengal, India. Synopsis The lube oil used in various industrial equipment such as pumps, compressors, turbines, blowers, turbo generators, recycle gas compressors, wet gas compressors, and coke cutting pumps had critical contamination levels initially. The problem was caused by poor maintenance by a previous service vendor, resulting in the presence of moisture and impurities in the oil tank. To address the issue, Minimac Operations and Maintenance Service (MOMS) carried out a timely service operation to help the plant bring down the moisture count and remove impurities from the oil tank. Before oil purification, NAS ≥ 12, Moisture ≥ 650 PPM; after oil purification, NAS < 5 and Moisture < 200 PPM This helped to improve the quality of the oil used in the equipment and ensure the smooth operation of the plant. Problems The oil was contaminated with moisture and...

  Team Minimac successfully executed a critical project to recondition the control fluid (two tanks of capacity 16 kiloliter each) for India’s largest energy conglomerate and coal-based power producer with a capacity of 4760 MW. Synopsis The plant was built and is in service as a thermal power generating station, in Vindhyachal. There was a problem with higher Total Acid Numbers (TAN), observed typically when moisture content exceeds the permissible range. They were facing difficulties in stable unit operation because of the sluggish and erratic behavior of the turbine governing system. It was a significant threat to unit outage and generation loss. The situation was examined by Minimac Operations and Maintenance Service (MOMS). Resin skid - Minimac- FS-20-TRIX- 8-25 ltr-1S-FRF-DOL was deployed to address the issue. Before Oil purification , the TAN value was≥ 0.62 mgKOH/gm, NAS ≥ 8, and Moisture ≥ 1471 PPM. After Oil purification, the recorded parameters were TAN value = 0.08 mgKO...

  The Minimac team successfully completed a critical flushing project in a big fertilizer company with a capacity of 4000 tonnes in Jharkhand. Synopsis An installation project was ongoing at the fertilizer plant’s premises. Newly built lube pipelines and tanks were to be flushed to remove the welding debris and other components left inside while fabricating the pipelines. The entire project was delayed due to a very slow flushing process.  Minimac Operations and Maintenance Service (MOMS)  team evaluated the situation and came out with a solution to expedite the flushing process. The project required flushing their two main compressors, i.e., PSE processed air compressor and carbon dioxide compressor Problems Proper flushing had to be done as the pipeline was newly fabricated; otherwise, it would have led to a major breakdown of the compressor, as the impurities would choke the blades and erode/damage the compressor. Other issues were to ensure proper calculation for vari...

  Team Minimac successfully executed a critical project to re-condition the control fluid (tank capacity 16 KL) for a 2*600 MW coal-based thermal power plant in Chhattisgarh. Synopsis The plant establishes, operates, and maintains a thermal power generating station in Chhattisgarh. There was a problem with higher Total Acid Numbers (TAN), observed typically when moisture content exceeds the permissible range. They were facing difficulties in stable unit operation because of the sluggish and erratic behavior of the turbine governing system. It was a significant threat to generation loss and unit outage. The situation was examined by Minimac Operations and Maintenance Service (MOMS). Three machines - Nitrogen Blanketing TMR unit (100 LPM), Oil purification MLC-LVDH-TRIX (50 LPM), and TAN reduction— Resin filter modified in cartilage format were deployed to address the issue. Oil Purification TAN Value NAS Value Moisture Before Oil Purification 0.23 mg KOH/gm 10 678 PPM After Oil Puri...

Critical project successfully executed for ISO 9001 Certified - Millenium's shipbuilding yard under the Ministry of Ports, Shipping, and Waterways (Defence Sector). Synopsis The maritime-related facilities in the port city, the first enormous greenfield shipbuilding yard located in the state of Kerala, faced significant oil degradation issues affecting the overall functioning of the India's first Indigenous Aircraft Carrier (IAC), which led to the abrasion of the machines. 49k liters of oil were required to be purified and stored in two different tanks; the leading service tank had 22k liters of oil, followed by 27k liters of oil in another. Due to the contamination and degradation of the oil, the plant faced issues in wear and tearing of the machines that would lead them to machine breakdowns. Minimac provided FS225 and FS150 Oil Filtration Systems , which helped infiltrate the gearbox lubeoil. Also, testing the oil transparency was equally crucial so that no particles left co...

  A 1200 MW coal-fired thermal power plant using Indo-Chinese Turbine EHC System in Southern India Synopsis The Power plant was suffering from loss in electricity generation for a few days as per the desired target. The O&M team has identified that the turbine command is not functioning properly and was tripping frequently. On further investigation, it was found that the Servo Valve (Moog valve) has failed and showing hunting or sluggish behavior. Minimac’s EH oil reconditioning system “MLC LVDH TRIX 20” acted as a rescuer for the plant and saved the plant from an unexpected shutdown. If this system would have implemented earlier, a loss of more than 5 Cr could be saved. Problems Failure of Moog valve:  This was the main reason for the trip of the turbine and breakdown in the power plant. Poor Oil Analysis Program:  An oil analysis is supposed to be done monthly for Particle count & TAN (weekly if the trend is negative) and weekly test for water content but the cu...

  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...

  A 1,320 MW (2 x 660 MW), one of the first and largest supercritical coal-fired power plants using Indo-Chinese turbine EHC system in northern India Synopsis The plant was struggling with the rapid increase in TAN values in the EH oil of the governing system of the turbine. Moisture content was also 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”  acted as a savior for the plant and as a result the unexpected shutdown of the turbine worth ₹1.4 Cr per day was saved. Problems Degradation of EH oil properties at both the units of the plant. The installed regeneration system for each EHGC tank of unit #1 and #2 was failing to control neutralization number (TAN value) and showing a rapid increase in the same The company was unaware of the consequences of increased TAN values like possibilities of failure of servo valve, hunting...