CJC™ in the Power Sector

C l e a n O i l - B r i g h t I d e a s

Power Plant Applications

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Power supply depends upon maximum machinery per-formance, which depends upon clean oil

Have 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 varnish

Turbine Control SystemsRemoval of varnish, particlesand reduction of acids

Feed PumpsRemoval of water, particles and varnish

Baltzer Grafik • Power Segment • UK • 07.2010

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Coal Mill Gear BoxesRemoval of varnish and particles

Boiler BlowersRemoval of water, varnish and particles

Crane Hydraulic SystemsRemoval of particles, water and varnish

Further Applications in Power Plants• Cooling towers

• Tap changers

• Conveyor belts

Reliable Power SupplyStarts with Clean Oil

The Most Common Types of Wear

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80% of all machinery repair and maintenance costs arerelated to contaminated oil

Particles

Water

Varnish/resin

“Sandblasting” When particles are transported with the oil flow, the particles col-lide with metal parts, destroyingthe metal surface and formingnew particles.

GrindingWhen clearance sized hard particles are wedged betweenmovable metal parts, they destroy the metal surface further and can result in additional wear.

CavitationCavitation occurs in areas where 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.

Oil DegradationOxygen, water and high tempera-ture lead to oil degradation whichis the precursor of varnish/resin.The result of these deposits is a “sandpaper-like” surface onmachine parts.

Oil care is a must because up to 80% of all machinery repair and maintenan-ce costs 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 degra-dation products - which are not retained effectively by most inline filters.

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Particles

Water

Varnish/resin

Removal of ParticlesParticles down to 0.8 μmare retained in the uniqueCJC™ Filter Insert.

Removal of WaterThe CJC™ Filters can either absorb or separate the water according to oil system requirements.

Removal of Degradation ProductsResin in the oil will be attracted to the polar fibres in the CJC™ Filter Inserts.

One Filter - Three SolutionsCJC™ Offline Filters remove particles, absorb waterand retain oil degradation products round-the-clock

CJC™ Offline Filters do not only remove solid particles and water. They alsoretain oil degradation products - “soft contaminants” - which are the pre-cursors to the sticky varnish, that deposits on metal surfaces. Varnish cannotbe removed by traditional filtration, but with the CJC™ Filter Insert, it can.

Traditional Inline Filtration

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In most applications the inline filter alone, cannot keepan oil system clean

Inline filters are usually of very compact design but must still cope with highflow rates. This affects their minimum pore size, and consequently, the opti-mum oil cleanliness can rarely be achieved. Oil degradation products, waterand microparticles will accumulate in the oil.

Millipore membrane

Sample taken before installation of CJC™Offline Filter

External EnvironmentWater from the external environ-ment enters the system via thesurroundings, high-pressure water cleaner, washing etc.

Wear Particles Wear particles are generated inside the oil system.

Air VentParticles and water enterthrough the air vent.

Internal EnvironmentWater condensation in the oil reservoir, due to temperature variations.

Acid Produced by OxidationHigh temperature + contaminatedoil = acid and resin.

Rust /CorrosionWater initiates the formation of rust particles which are very hard and abrasive particles.

Cooler Leaking WaterA leaking cooler results in wateringress to the oil reservoir.

Varnish/ResinOil degradation products,microparticles and water are accumulated in the bottom of the oil reservoir.

Contamination Sources:

Oil systemHydraulic, gear,lube, etc.

Inline filter

System pump

InlineFiltration

Principle drawing of inline filtration

Round-the-clock removal of particles, water, and oildegradation products, all in the same operation

The CJC™ Offline Solution

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CJC™ Offline Filters are easy to install and the depth filter insert has a verylarge dirt holding capacity. CJC™ Filters have low operation costs and arealmost maintenance free. All CJC™ Fine Filter Inserts have a 3 μm absolutefiltration ratio and will remove particles, water, and oil degradation pro-ducts, all in the same operation.

External EnvironmentWater ingress from the environmentis continuously removed from thesystem with CJC™ Filters.

Wear Particles Wear particles are still being created, but are removed by the CJC™ Filter.

Air VentContamination can be reduced byadding an airborne silica gel filter.

Internal EnvironmentWater still condensates in the oilreservoir, but with the CJC™ Filtersinstalled, the water is removed before it reaches the oil system.

Acid Produced by OxidationThe risk of developing acids and oxidation by-products has been considerably reduced.

Rust /CorrosionContamination is still being createdbut is removed by the CJC™ Filter.

Cooler Leaking WaterThe leaking cooler can be repaired at scheduled overhauls as the CJC™ Filters continuously removewater in large volumes.

Varnish/ResinOil degradation products and micro particles have now practically disap-peared from the bottom of the oilreservoir.

Contamination Sourcesare now under Control:

Oil systemHydraulic, gear,lube, etc.

Inline filter

System pump

OfflineFiltration

The CJC™ FilterSeparator

Clean oilis returned

to the oilreservoir

Clean oil

CJC™ Filter Insert after use

Principle drawing

of offline filtration

Millipore membrane

Sample taken afterinstallation of CJC™Offline Filter

CJC™ Filter Insert before use

The Power of CJC™ Oil Filtration

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Each application performs specific tasks - so do CJC™Offline filters in order to ensure high oil cleanliness

The 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 turbi-ne, with steam and oil working oneach side of the labyrinth seal, moi-sture enters into the oil is a constantthreat. The leading suppliers of turbi-nes specify maximum water contentin the oil of 300 ppm.

For turbine lube oils we recommendthe use of a CJC™ Offline FilterSeparator, type PTU3.

Gas 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 mal-functioning of the system.

For gas turbines we recommendthe use of the CJC™ Offline FineFilter (HDU series) .

CJC™ HDU 27/54

CJC™ PTU3 2x27/108

CJC™ PTU3 27/081

CJC™ HDU 2x27/108

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CJC™ Offline Filters for All Power Plant Applications

Coal Mill GearsTypically the main problem for oilin a coal mill gear is the high con-tent of small particles as well asresin caused by high temperatures.

The result is that some of the smal-lest particles (approx. 2 micron) willenter the bearing and gears andcause damage. This again leads tofurther particles and wear on allcomponents.

To solve the contamination problemwe recommend the use of the CJC™Offline Fine Filter (HDU series)

Hydraulic 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 reversi-ble when ester is exposed to water.As little as 100 ppm water is enoughto start a reaction (hydrolysis) wereester fluid degrades and acid com-pounds are generated. To remove water and acids from ester-based fluids we recommend the useof a CJC™ Ion Exchange / Acid Re-moval Filter

CJC™ HDU 27/54

CJC™ HDU 27/108

CJC™ HDU 27/27

CJC™ Ion Exchange /Acid Removal Filter

HDUSeries

PTUSeries

CJC™ Series of Solutions

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All CJC™ Series are of uncomplicated design, easy toinstall and almost maintenance free

Using CJC™ Offline Filters will have a positive effect on your maintenancebudget and will increase your productivity and reduce your energy consump-tion - all advantages in terms of total economy!

C l e a n O i l - B r i g h t I d e a s

CJC™ HDU SeriesThe CJC™ Fine Filters remove particles, water, and oil degradation products fromhydraulic and lubrication oils and have flow rates from 45 to 20,000 L/h.

CJC™ Filter Inserts before use and after use, showing thelarge dirt holding capacity.

CJC™ PTU SeriesThe CJC™ Filter Separatorscombine depth filtration withwater separation and are usedfor water contaminated diesel,hydraulic and lubrication oils.

The CJC™ PTU Series continuously removes water from oil in large volumes.

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AcidityRemoval

FilterInserts

Optimal Oil Performance WithCJC™ Offline Filters

CJC™ Ion Exchange / AcidRemoval FilterProblems with phosphate esters areoften associated with development of oxidation caused by acidity

CJC™ Filter Units neutralize andabsorb the acid from the fluid - alongwith sludge, particles and moisture

The CJC™ Filter Insert SystemThe unique modular build-up of the CJC™ Filter Inserts means thata CJC™ Filter can be sized to fitany applications and requirements.

Furthermore, they can be equippedwith a neutralizing media for removal of acids from oil.

CASESProblem solving and preventive maintenance are keywords in the power sector

A CJC™ Filter Separator

operating at Vattenfall A/S,

Helsingør Kraft-varmeværk,

Denmark

HelsingørKraftvarmeværk

is a combined heat- and

power station

Cases and Statements from Our Customers in Power

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Vattenfall A/S

SolutionA CJC™ Filter Separator was installed on the steam tur-bine and CJC™ Fine Filters were installed on the gas tur-bine and 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 correspon-ding to 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.

C l e a n O i l - B r i g h t I d e a s

Oil sample before filtration

- and after filtration

Bjarne 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 unac-ceptably high 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.

Application:Steam Turbine

Niedzica S.A. Application:Water Turbine Control System

Elsam A/S Application:Coal Mill Gear

North American Electric Power Plant Application:Gas Turbine

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ProblemMechanical 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 pro-blems with 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.

Mr. 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.”

ProblemOil analyses showed a high content of metal particles and resin,indicating wear on the components. The very small particles ente-red the 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.

Mr. Jørgen Brix AndersenElsam A/S:

“As the oil analyses show, we have achievedcleaner oil, after we have installed CJC™Filters on our 8 coal mills. The need for oilchanges is gone, and the risk of breakdown inthe bearings has been extremely reduced”.

ProblemExcessive varnish formation causing sticking valves. Varnish conta-mination leads 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 Decem-ber through 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.

Acc. 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.”

Hydro PowerPlants GroupNiedzica S.A,Poland

Elsam A/S,Studstrupværket,Denmark

Major Electric Power Plant,USA

Clean Oil Clean Oil - Bright Ideas

At C.C.JENSEN, our mission is unmistakable - CO2 emissions must be redu-ced to help the global environment.

The company contributes to this target through the development of BRIGHTIDEAS and by making them accessible to the rest of the world.

We are fully aware of the importance of CLEAN OIL, both for the environ-ment and the economy. Offering our customers CLEAN OIL is the aim of allinitiatives and development programmes within the company.

C.C.JENSEN is respected as a company that offers values such as quality,traditions, reliability, credibility and stability. C.C.JENSEN is actively workingtogether with customers, promoting "green" solutions to benefit for the glo-bal environment.

At C.C.JENSEN, we are firmly committed to assisting in the global target toreduce emissions, and this is why we believe that CLEAN OIL - BRIGHTIDEAS makes sense.

C l e a n O i l - B r i g h t I d e a s14

- Bright Ideas

CJC™ Filter Inserts are made of 100%

organic material

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C l e a n O i l - B r i g h t I d e a s

C.C.JENSEN All Over the WorldThe CJC™ Offline Filters are distributed by our own inter-national sales organisations and designated distributors

Your Local CJCTM Distributor We are represented globally by distributors.

Find your nearest distributor on our website: www.cjc.dk

- or give us a call.

Manufacturer & Headquarters

C.C.JENSEN A/SLøvholmen 13 • DK 5700 Svendborg • Denmark Tel. +45 6321 2014 • Fax: +45 6222 4615filter@cjc.dk • www.cjc.dk

Benelux C.C.JENSEN Benelux B.V.Tel.: +31 182 37 90 29ccjensen.nl@cjc.dkwww.ccjensen.nl

Chile C.C.JENSEN S.L. LimitadaTel.: +56 2 739 2910 ccjensen.cl@cjc.dk www.ccjensen.cl

ChinaC.C.JENSEN A/S ChinaTel: +86 10 6436 4838ccjensen.cn@cjc.dkwww.ccjensen.cn

DenmarkC.C.JENSEN DanmarkTel: +45 72 28 22 22ccjensen.dk@cjc.dkwww.cjc.dk

FranceC.C.JENSEN FranceTel: +33 3 59 56 16 58ccjensen.fr@cjc.dkwww.ccjensen.fr

GermanyKARBERG & HENNEMANN GmbH & Co. KGTel: +49 (0)40 855 04 79 0kontakt@cjc.dewww.cjc.de

Greece C.C.JENSEN Greece LTD.Tel.: +30 210 42 81 260ccjensen.gr@cjc.dkwww.ccjensen.gr

Ireland C.C.JENSEN IrelandTel.: +353 61 374 943ccjensen.ie@cjc.dkwww.ccjensen.ie

ItalyKARBERG & HENNEMANN srlTel: +39 059 29 29 498info@cjc.itwww.cjc.it

Poland C.C.JENSEN Polska Sp. z o.o.Tel.: +48 22 648 83 43ccjensen@ccjensen.com.plwww.ccjensen.pl

Spain C.C.JENSEN Ibérica, S. L.Tel.: +34 93 590 63 31ccjensen.es@cjc.dkwww.cjc.dk

United Arab Emirates C.C.JENSEN Middle EastTel: +971 4 447 2886ccjensen.uae@cjc.dkwww.cjc.ae

United Kingdom C.C.JENSEN LTD.Tel.: +44 1 388 420 721filtration@cjcuk.co.ukwww.ccjensen.co.uk

USA C.C.JENSEN INC.Tel.: +1 770 692 6001ccjensen@ccjensen.comwww.ccjensen.com