Varnish Removal Unit

Solution for removal of dissolved and suspended

soft contaminants from oil in
Gas & Steam Turbines

Avoid varnish related

turbine trips and
expensive oil changes
 Your Challenges
turbine trips | oil aging | valve sticking | inline filter blocking

When varnish strikes, the costs associated When soft contaminants are dissolved in oil,
Get with a production outage are often very high.
The precursors to varnish, the so-called soft
typically at temperatures above 40ºC (100 ºF),
they cannot be removed through standard
Your First contaminants, are created in the hot spots in mechanical filters or electrostatic filters. The
MPC Test the oil system, e.g. bearings, pumps and high soft contaminants are polar in na-
flow in-line filters. Recent studies have ture and adsorb onto dipolar,
- for Free! found that the soft contaminants exist in colder metallic surfaces in
both dissolved and suspended phases “cold spots”, e.g. valves
and should be removed in order and coolers. They
to avoid varnish formation. Once will also settle
- send us your formed, varnish can seize and out when the oil
oil sample clog valves, filters and temperature
- contact other small passages decreases during
your nearest
CJC Distributor and reduce the oil l outages. The soft
ife considerably. contaminants
also have lower
thermal stabil-
ity than the oil
so they are more
likely to bake onto
cold and hot surfaces,
e.g. journal bearings.

Varnish coated in-line filter of

IGV servo valve hydraulics

Varnish on plate heat exchanger Varnish on valve spool Varnish on journal bearing, gas turbine

Consequences of Varnish
• Valve sticking  loss of control, which results in turbine trips or
fail-to-start
• Filter blockage  restriction of oil flow, which increases oil tem-
perature and wear
• Sandpaper surface  increases component wear
• Ineffective heat exchangers  increases oil temperature
• Lacquer baked onto bearings  flow restriction, increased wear
and temperature
• Frequent oil changes and system flushing
2
Our Solution
high efficiency | low maintenance | reliable | easy to install

3usein 1 Solution
the CJC™ VRU and remove
Varnish, Particles & Water - in one single pass

C.C.JENSEN A/S introduces the

CJC™ Varnish Removal Unit with
a revolutionary high efficiency Oil System
for removing soft contaminants  Turbine lube and control oil
from oil – dissolved and sus-  Hydraulic oil
pended – even from hot opera-  Compressor oil Contamination
ting gas and steam turbines. now under Control!

The CJC™ VRU is designed to 3 in 1 Solution

remove dissolved and suspen- The optimized filtration and
ded soft contaminants by polar treatment in the CJC™ VRU
attraction in the optimized, captures the soft contaminants,
cellulose based CJC™ Varnish which can then be removed
Removal inserts, VRi. It does this from the system completely
without any additional power, In-line by replacing the CJC™ Varnish
chemicals or beads which may Filter Removal insert, VRi
be harmful to the oil’s additive
package. Clean Oil
System
Pump
The hot oil is drawn from the Varnish
lowest point of the system tank Oil degradation products
to the CJC™ Varnish Removal – dissolved and suspended –
Unit by means of the transfer are removed from the oil and
system components.
pump on the unit. The process
inside the unit includes pass-
ing the oil through the efficient Particles & Water
CJC™ Varnish Removal insert, Not only varnish is
VRi 27/27 specially designed for removed, also particles
varnish removal in combination and water is retained in the
with the CJC™ Varnish Removal inserts and removed from
Unit. After cleaning, the oil is the oil.
returned to your system. CJC™ Varnish
Removal Unit
The varnish free oil will start
cleaning all system components
it comes in contact with, ulti- Clean Oil
mately resulting in a completely
varnish free system. The varnish
level in the oil will typically be
cut in half within a few weeks of
operating the CJC™ VRU.

The specially designed CJC™ Varnish Removal inserts VRi, used in

the CJC™ Varnish Removal Unit make it possible to remove oil deg-
radation products from oil in gas and steam turbines, up to 45,000
L (11,900 gal) – dissolved and in suspension

– even from high temperature

operating turbines!
3
Our Result
no turbine trips | no oil aging | no valve sticking | no inline filter blocking

Before and After installation of CJC™ VRU

MPC Safe Level

0-
Turbine oil BEFORE
filtration with the VRU
Turbine oil AFTER just
a few weeks of filtration
with the VRU
5-
10 -
{ < 15 = normal

15 -
20 -
25 -
{ 15-30 = monitor

30 - > 30= critcal

Millipore membrane Millipore membrane 35 -
MPC>50 AFTER filtration with
40 -
the VRU, MPC <10
45 -
50 -
55 -
60 -
Ultra Centrifuge test, Ultra Centrifuge test, 65 -
initial sample before sample after a single 70 -
the VRU (inlet) pass through the
75 -
VRU (outlet)
80 -
85 -
90 -

Clearly visible varnish at No more varnish at

the metal surface BEFORE the metal surface
startup the VRU AFTER startup
the VRU

6 months WITHOUT VRU: 6 months WITH VRU:

Varnish on the inline filter No varnish on the
inline filter

Varnish Removal insert, Varnish Removal insert,

VRi before startup VRi, after filtration

Customer
A 95 MW Combined Cycle Power Plant in Spain. The savings obtained from
Two base loaded gas turbines each containing reduced oil purchases,
6,500 L (1,700 gal) of Mobil DTE 832 oil. Varnish flushing and oil handling,
level measured with Membrane Patch Colorimetric add up to approximately
was reduced from MPC 55 to MPC 15 within two
weeks of operating the CJC™ VRU. By using the $ 35,000
CJC™ VRU, a pending oil change and flushing were per gas turbine.
not necessary anymore, and turbine trips due to
varnish were avoided!
4
Your Benefits
no expensive turbine trips | no uncontrolled shut downs

Benefits No u
ion e se of
Increased system reliability and availability
No turbine trips or sticking valves due to varnish
xchan
resin ge
Prevent uncontrolled shut downs and reduces maintenance costs
Extends the lifetime of both oil, additives and components,
e.g. bearings, valves, seals etc. !
No need for system flushing and tank cleaning
MPC values at extreme low levels
Improved lifting oil pressure
More stable bearing temperature

Savings (average)
Avoiding a turbine trip and prolonging oil life can result
in huge savings – a real example:
$ 40,000 saved by avoiding a turbine trip (not including lost revenue)
$ 35,000 saved on oil, flushing and disposal costs
$ 4,600 per hour penalty for not supplying energy
Total cost for a turbine trip can easily exceed $ 100,000 including
down-time penalties

Environment
With the CJC™ VRU the oil life time can be extended to 10-20 years
in operation without compromising its properties
Extend the lifetime of components
Prolonged oil and addivitive lifetime
No use of ion exchange resin

Less Maintenance
No need for system flushing and tank cleaning
Avoid malfunction of hydraulic valves e.g. inlet guide vane valves
Reduced consumption of in-line filters
Avoid sludge and varnish build-up in heat exchangers
Minimal maintenance and supervision of the CJC™ VRU
Maintenance of the CJC™ VRU does not require shutting down the main oil system
Less vibrations due to varnish in bearings

5
 C.C.JENSEN
- contact us today!

Manufacturing & headquarters

C.C.JENSEN A/S
Løvholmen 13 | DK - 5700 Svendborg | Denmark
Tel. +45 6321 2014 | Fax: +45 6222 4615
[email protected] | www.cjc.dk

C.C.JENSEN subsidiaries and sales offices

Belgium France Italy United Kingdom
C.C.JENSEN Belgium C.C.JENSEN France KARBERG & HENNEMANN srl C.C.JENSEN Ltd.
Tel.: +32 484 25 36 96 Tel: +33 3 59 56 16 58 Tel: +39 059 29 29 498 Tel.: +44 1 388 420 721
[email protected] [email protected] [email protected] [email protected]
www.ccjensen.dk www.ccjensen.fr www.cjc.it www.ccjensen.co.uk

Benelux Germany Poland USA

C.C.JENSEN Benelux B.V. KARBERG & HENNEMANN C.C.JENSEN Polska Sp. z o.o. C.C.JENSEN Inc.
Tel.: +31 182 37 90 29 GmbH & Co. KG Tel.: +48 22 648 83 43 Tel.: +1 770 692 6001
[email protected] Tel: +49 (0)40 855 04 79 0 [email protected] [email protected]
www.ccjensen.nl [email protected] www.ccjensen.pl www.ccjensen.com
www.cjc.de
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Tel.: +56 2 739 2910 C.C.JENSEN Greece Ltd. Tel.: +34 93 590 63 31
[email protected] Tel.: +30 210 42 81 260 [email protected]
www.ccjensen.cl [email protected] www.cjc.dk
www.ccjensen.gr
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C.C.JENSEN Filtration India C.C.JENSEN AB
Equipment (Tianjin) Co. Ltd. C.C.JENSEN India Tel.: +46 8 755 4411
Tel: +86 10 6436 4838 Tel.: +91 4426241364 [email protected]
[email protected] [email protected] www.ccjensen.se
www.ccjensen.cn www.ccjensen.in
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Denmark Ireland C.C.JENSEN Middle East
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Tel: +45 7228 2222 Tel.: +353 86 82 71 508 [email protected]
[email protected] [email protected] www.cjc.ae
www.cjc.dk www.ccjensen.ie

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