Turbine Lubricant Varnish Removal Case Studies using SVR

As of May 2014 there are over 400 SVR installations on turbine lubricant reservoirs operating throughout the world. These systems have gained an industry leading reputation for reducing and maintaining low varnish potential including many sites where competing systems have failed.

Each SVR installation is supported by a team of experts who will ensure that results are achieved and documented at your facility. This support is included with the purchase of each SVR.

Attached are 20 case studies that demonstrate typical results. Once an SVR is installed, the lubricant enters a “Restoration phase” that last 3-4 months on average. During this phase, previously deposited varnish dissolves back into the purified lubricant where it is removed by SVR. During this clean-up period, the MPC values fluctuate as the varnish content of the fluid varies. Once varnish deposits are removed, varnish is continually removed as it forms and the lubricant enters a “Stability phase” where MPC values are maintained at <15 (ASTM 7843). Because varnish is continually removed as it forms during the stability phase, varnish does not accumulate in the lubricant reducing the risk of varnish formation to nil. For privacy, all customer specific information has been removed.

For additional information, and a complimentary turbine lubricant assessment with lab scale demonstration please contact us at: http://www.cleanoil.com/contact/distributors.html

For additional information contact: [email protected]

Case StudiesTurbine Lubricant Varnish Removal Using SVR

10/15

When Results Matter

EPT 4772-50th Ave. S.E. Calgary, AB, Canada T2B-3R4T 403.246.3044 F 403.249.8096 [email protected]

Case Study #1Location: MD, USA

MW: 350 MW

Turbine Type: ST, GE

Oil Type: Mobil DTE 732

Volume: 8,000 Gallons/30,283 Litres

BACKGROUND:This site was experiencing a build-up of varnish on mechanical components. An SVR was installed and initial results described a three-month stabilization period as varnish deposits were adsorbed back into the lubricant. A significant decreasing trend began after four months of operation, which means that varnished mechanical components had been completely cleaned. SVR treatment reduced the fluid varnish potential value to below 10 over the subsequent three months. Varnish potential values are now stable and at historically low values.

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MPC ∆E Reduction Using SVR Mobil DTE 732


10/15

When Results Matter


Case Study #2Location: MD, USA

MW: 685MW

Turbine Type: ST GE



BACKGROUND:This site had a history of varnish problems; the customer consistently experienced build-up of varnish on mechanical components. Once SVR was installed, varnish potential numbers fluctuated over a two month period while varnish deposits were adsorbed into the lubricant. Notable reductions were achieved by month three. Consistent reductions continued over the next six months. Permanent use of SVR has been able to reduce varnish potential values by another 60% and to be maintained at 15 or below. Varnish potential values are now stable and at historical low values.

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10/15

When Results Matter


Case Study #3Location: PA, USA

MW: 190MW

Turbine Type: GE 7FA

Oil Type: Shell Turbo CC 32


BACKGROUND:This site had a history of varnish problems with QSA® varnish potential values at 75 or higher. Previous efforts on the part of maintenance staff were unable to control varnish potential values, which was a significant concern for the turbine owner. Upon installation of SVR, varnish potential values were quickly reduced. MPC varnish potential values are now at 10 or lower.

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MPC ∆E Reduction Using SVR Shell Turbo CC 32


10/15

When Results Matter


Case Study #4Location: CA, USA

MW: 40MW

Turbine Type: GT, GE 6FB

Oil Type: Shell Turbo TX 32


BACKGROUND:This turbine is used as the primary generator at an oil and gas production facility. High varnish potential values were of concern due to the critical nature of the turbine and the potential loss in production associated with any turbine outage. SVR was installed and quickly reduced varnish potential values by >50%. Further decreases were observed with continued SVR use. Varnish potential values are now less than 5.0 and stable.

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MPC ∆E Reduction Using SVR Shell Turbo TX 32


10/15

When Results Matter



MW: 210MW

Turbine Type: GT, GE 7FA

Oil Type: Mixture Mobile DTE 832/Shell Turbo CC 32


BACKGROUND:This unit had a history of varnish problems with multiple unit TRIPS and fail-to-start conditions. SVR systems were installed on all turbines and quickly reduced varnish potential by over 50% with no further turbine failures occurring. Continued long term use of SVR has been able to reduce varnish potential values by another 40% with values now at <15. Varnish potential values are now stable and at historical low values.

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MPC ∆E Reduction Using SVR Mobil DTE 832/Shell Turbo CC 32

Mix


10/15

When Results Matter



MW: 185MW

Turbine Type: GT, GE 7FA CC

Oil Type: Mixture Mobile DTE 832/Shell Turbo CC 32


BACKGROUND:Unit had a history with multiple trips and fail-to-start conditions. SVR system was installed on this unit and within six months had produced downward trending MPC results. No turbine failures occurred after the SVR system was installed. The length of time prior to decreasing MPC is based on the amount of varnish on system components. The varnish potential is now below 15 and continues to decrease.

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MPC ∆E Reduction Using SVR Mobil DTE 832/Shell Turbo CC 32

Mix


10/15

When Results Matter


Case Study #7Location: AB, Canada

MW: 100MW

Turbine Type: GT, GE 7EA

Oil Type: Teresso GTC 32


BACKGROUND:An electrostatic oil cleaner was operational on this system full-time since turbine commissioning in 2009. Within 18 months of initial operation, varnish potential values had increased above 40 to critical levels. SVR was installed February 2011 and reduced varnish potential, which then increased as system deposits were adsorbed back into the lubricant. Subsequent element changes performed annually have achieved stable and historically low varnish potential values.

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MPC ∆E Reduction Using SVR Teresso GTC 32


10/15

When Results Matter



MW: 520MW

Turbine Type: ST



BACKGROUND:When initially contacted, this site had extreme varnish potential values. SVR was installed and immediately reduced varnish potential values by >60%. Existing system deposits were then adsorbed back into the lubricant which increased varnish potential values. Based on the level of increase, the results suggest that existing system varnish deposits were above average. Secondary decreases followed by increases also suggest above average levels of varnish deposits were present. The system stabilized after eight months of SVR treatment. No additional operational problems have been experienced and varnish potential values remain at historically low levels.

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MPC ∆E Trending Using SVR Shell Turbo CC 32


10/15

When Results Matter


Case Study #9Location: LA, USA

MW: Base load—185MW



Reservoir Size: 6,200 Gallons/23,470 Litres

BACKGROUND:At this facility, three GE7FA Gas turbines provide the primary power and steam for the chemical plant. Plant reliability was negatively impacted from elevated varnish potential numbers in the gas turbine. To reduce the risk of outage maintenance staff tried a number of varnish removal systems without success. SVR was installed and had an immediate impact, reducing varnish potential numbers and within three months, values had been reduced by 80% to a varnish potential value of <5. Based on these successful results, SVR has been installed on all three gas turbines at this site.

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MPC ∆E Trending Using SVR Mobil DTE 724


10/15

When Results Matter


Case Study #10Location: TX, USA

MW: 160 MW

Turbine Type: GT, GE 7EA

Oil Type: Chevron GST 32


No specific site notes recorded.

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MPC ∆E Reduction Using SVR Chevron GST 32


10/15

When Results Matter


Case Study #11Location: GA, USA

MW: 185 MW

Turbine Type: GT

Oil Type: Chevron GST 32



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MPC ∆E Reduction Using SVR Chevron GST 32


10/15

When Results Matter



MW: 550 MW

Turbine Type: ST




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10/15

When Results Matter



Turbine Type: GT, Westinghouse




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10/15

When Results Matter


Case Study #14Location: VA, USA

MW: 151 MW


Oil Type: Texaco Regal R&O 32



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MPC ∆E Reduction Using SVR Texaco Regal R&O 32


10/15

When Results Matter


Case Study #15Location: SK, Canada

MW: 300 MW

Turbine Type: GT, Hitatchi

Oil Type: Esso Teresso GTC 32



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MPC ∆E Reduction Using SVR Esso Teresso GTC 32


10/15

When Results Matter




Oil Type: ConocoPhillips Hydroclear 32



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MPC ∆E and AN Reduction Using SVR ConocoPhillips Hydroclear 32


10/15

When Results Matter




Oil Type: ConocoPhillips Hydroclear 32



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MPC ∆E and AN Reduction Using SVR ConocoPhillips Hydroclear 32


10/15

When Results Matter


Case Study #18Location: WI, USA

MW: 250 MW





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When Results Matter


Case Study #19Location: WI, USA

MW: 185 MW





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When Results Matter


Case Study #20Location: WV, USA





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10/15

When Results Matter


Turbine Lubricant Varnish Removal Case Studies using SVR · PDF fileTurbine Type: GE 7FA Oil...

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