Power Plant Oil Filtration
The need for clean, dry oils and fluids is essential for the long-term reliability of power plant equipment. Recognizing that downtime is the ultimate enemy of power plant facilities, Kaydon Filtration has developed application-specific oil filtration technologies to minimize downtime and maximize performance for steam, combustion, and hydroelectric power generation plants. Turbine manufacturers worldwide trust Kaydon Filtration to keep their turbines operating properly, a testament to their experience and expertise. Kaydon Filtration understands the specific needs of every phase of your power plant’s operation.
From super-clean turbine oil to varnish-free components, Separator Spares & Equipment, LLC provides turbine oil filtration solutions to meet your demanding and varied oil and fluid conditioning needs. For the power generation industry, advanced turbine oil filtration systems provide assurance that your critical equipment stays online. We offer oil filter systems that provide long-term, predictable, and profitable performance for your power generation facility.
Steam Turbine Oil Conditioning: Mitigating Water Contamination
Operating in high-temperature and high-humidity environments, steam turbine equipment is at risk of rapid water contamination of lubricant oils. Recent studies have shown that water content above 200 ppm can reduce bearing life by as much as 50%. Kaydon’s oil filtration technologies offer solutions that can reduce water content to less than 100 ppm in a single-pass filtration process. This ensures maximum bearing and journal life for your steam-powered turbines.
Kaydon Filtration specializes in keeping oils and fluids in your steam turbine plant clean and dry. Kaydon has technologies to support oil and fluid conditioning in steam turbine units ranging from 1 to 1,000 MW. Utilizing Kaydon’s optimized turbine oil conditioning systems, featuring the patented Turbo-TOC coalescing technology, ensures comprehensive protection for crucial components, including the main turbine system, boiler feed pump, primary, forced draft, and induced fans, and fluid drive.
Kaydon’s advanced technologies for oil, fluid, and fuel conditioning in steam-powered plants include:
– Turbo-TOC Technology: For single-pass, high-flow water removal in turbine oil
– Kaymax Technology: Ensures maximum cleanliness levels in lubricating fluids
– FCS Technology: Designed for conditioning diesel fuels during offload, storage, and fueling
Kaydon’s primary oil condition systems offer a seamless solution, combining particulate and water removal into a single skid-mounted, fully automatic setup. With processing rates exceeding 100 GPM (380 LPM), these filter systems achieve total water removal below 100 ppm and an ISO cleanliness level of 15/13/11 or better. They continuously condition turbine oil reservoirs during power plant operation and scheduled downtimes.
Turbine Oil Conditioning: Achieving ISO 15/13/11 in Power Plants
Maintaining proper oil condition not only keeps turbine systems operational but also facilitates quick and efficient restarts after shutdowns. Kaydon Filtration technologies are globally recognized for their ability to extend steam turbines’ online availability, improve the predictability of downtime scheduling, meet peak demand requirements, reduce maintenance and replacement costs, and extend lubricant life.
In addition to turbine and lubrication oils, Kaydon Filtration offers fluid conditioning systems to effectively purify other fluids used in power plants, including hydraulic oil (ISO Cleanliness Code 16/14/11), gear oil (ISO Cleanliness Code 17/15/12), seal oil (ISO Cleanliness Code 15/13/10), and transformer oil (ISO Cleanliness Code 16/14/11). Preserving the condition of these utility system oils and fluids not only extends their useful life but also minimizes unscheduled maintenance and equipment failures. With our experience and advanced technology, Kaydon’s power plant oil filtration systems ensure that critical application diesel-powered equipment remains operational.
Diesel Engine Protection: Kaydon Filtration provides conditioning technologies and systems to safeguard diesel fuel (ISO Cleanliness Code 16/14/11) during offload, storage, and distribution. Modern diesel engines, especially those equipped with high-pressure injection systems, are vulnerable to contaminated fuel, which can lead to unscheduled maintenance, power loss, decreased fuel efficiency, injector and high-pressure pump failure, and expensive downtime.
Combustion Turbine Filtration: Removing Varnish and Sub-Micron Particles
Power plants using combustion turbines face unique challenges for oil and fluid contamination. Beyond the traditional turbine oil contamination of dirt and water ingression, sub-micron particles (varnish) can adversely affect the operation of servo valves and other internal metal components, causing unscheduled downtime. Kaydon Filtration technologies can remove these varnish components suspended in your lubrication oils and, over time, clean the lubricated surfaces experiencing varnish build-up.
Kaydon Filtration specializes in ensuring the reliability and longevity of combustion turbine systems by minimizing failure rates, extending time between repairs, and facilitating successful lube oil system inspections. With extensive experience in this field, Kaydon’s oil filtration technologies are designed to keep turbine systems operating reliably and free from damaging lubrication contaminants.
Kaydon Filtration’s innovative technologies for combustion turbines’ power generation include:
– Kaymax Technology: Ensures maximum cleanliness levels in lubricating fluids
– Turbo-TOC Technology: Facilitates single-pass, high-flow water removal in turbine oil
– FCS Technology: Conditions diesel fuels during offload, storage, and fueling
Turbine Oil Conditioning: Achieving ISO 15/13/11 in Power Plants
Kaydon Filtration’s solutions achieve cleanliness levels to ISO 15/13/11 or better for turbine oil and maintain water contaminants to 100 PPM or less. Specifically geared to protect the main turbine systems, servo valves, heat exchangers, and bearing surfaces, Kaydon oil filtration technologies optimize turbine oil conditions. Kaydon Filtration offers fluid conditioning systems for other utility fluids, such as seal oil (ISO Cleanliness Code 15/13/10), transformer oil (ISO Cleanliness Code 16/14/11), hydraulic oil (ISO Cleanliness Code 16/14/11), and gear oil (ISO Cleanliness Code 17/15/12). Maintaining these fluids in peak condition increases their useful life and reduces unscheduled maintenance and premature equipment failure.
Diesel Engine Protection: Kaydon Filtration provides oil-conditioning technologies to protect diesel fuel (ISO Cleanliness Code 16/14/11) during offloading, storage, and distribution. Diesel engines with high-pressure injection systems require clean, dry fuel to prevent unscheduled maintenance, power loss, decreased fuel efficiency, and component failure. We have the experience and technology to keep critical diesel-powered equipment operational, ensuring minimal downtime and optimal performance.
Hydroelectric Power Plants: Fluid Management for Wicket Gates and Bearings
Failures of the wicket gate mechanism, turbine governor, and turbine bearings are among the top 25 causes of forced outages in hydroelectric power generation facilities. Through improved fluid management and conditioning, these failures can be significantly reduced. Kaydon Filtration’s power plant oil filtration systems effectively extend oil service life, protect expensive equipment, and reduce premature failures.
The elimination of water ingression, particulates, varnish, and other harmful contaminants from lubricating oils and fluids is Kaydon Filtration’s expertise. Kaydon’s oil filtration solutions safeguard various components in hydroelectric power plants, including turbine governors, valves, bearings, and pumps.
Kaydon’s advanced technologies for oil, fluid, and fuel conditioning in hydroelectric power generation include:
– Turbo-TOC Technology: Provides single-pass, high-flow water removal in turbine oil
– Kaymax Technology: Ensures maximum cleanliness levels in lubricating fluids
– FCS Technology: Conditions diesel fuels during offload, storage, and fueling
Diesel Engine Protection: Diesel engines are used in modern heavy equipment, backup power generators, and other diesel-powered operations, which require clean, dry fuel more than ever. Kaydon Filtration has solutions to prevent issues such as power loss and reduced efficiency in diesel-powered equipment, ensuring uninterrupted operation.
Power Plant Oil Filtration: Advanced Turbine Reliability
Kaydon Turbo-Toc Technology
Kaydon Filtration’s patented Turbo-TOC coalescing technology protects turbine rotating components by providing quick and efficient water removal from turbine oil. Studies have shown that bearing life can be reduced by 50% with water contamination of 200 ppm when compared to oils conditioned to 100 ppm. As a result, our Kaydon Turbo-TOC technology was developed to remove water to less than 100 ppm in a single pass at process rates exceeding 100 GPM (380 LPM).
Coalescer / Separator Design and Technology
Coalescer Element: The core component of the oil filtration technology is the patented coalescer element. The coalescer element utilizes three (3) stages to coalesce (grow together) droplets of water from turbine oil.
Separator Element: The final component of the technology is the separator stage. The separator provides a hydrophobic screen that acts as a water barrier, preventing smaller water droplets from flowing downstream. In addition, the separator element includes a micro-fiber component that acts as a final polishing filtration stage for particulates. This polishing effect eliminates the need for the expensive final filter stage found in traditional oil conditioning systems.
The Turbo-TOC Series 1 turbine lube oil conditioning system is the evolution of turbine oil filtration, replacing the earlier Bowser 832P oil conditioning system. The Bowser 832P, introduced in 1938, was adequate for mineral-based turbine oils; however, the Turbo-TOC, introduced in 1987, offered superior design and performance, leading to the discontinuation of the Bowser 832P.
Thinking of upgrading your current Kaydon Turbo-TOC Series 1 system? If your turbine oil purification unit is over 25 years old, you are risking costly downtime, hard-to-find parts, and reduced efficiency. The Turbo-TOC Series 2 offers an unstoppable solution with modern controls, higher heater output, smart diagnostics, and guaranteed parts availability. Do not wait for a turbine-related oil failure to occur. Discover why plants worldwide are switching to the most advanced turbine oil conditioning system on the market. To learn more, visit Reasons to replace old Turbo-TOC units with a Kaydon Turbo-TOC Series 2!
When it comes to removing turbine oil particulates, look no further than Kaydon Filtration!
Kaydon Kaymax Technology
Kaydon Kaymax provides exceptional particulate filtration for oils, fluids, and fuels. It combines meticulous filter media selection and filter element construction methods to produce proven and repeatable oil filtration performance. It utilizes specially formulated, multi-layered micro-fiberglass fibers to deliver exceptional particle retention and high particle-holding capacity. Kaydon Kaymax construction maintains pleat integrity under high-flow and high-viscosity conditions, eliminating pleat bunching or collapse during high flow, high dirt loading, or cold start-ups. Materials are selected for fluid compatibility and corrosion resistance. Performance meets or exceeds ISO 15/13/11 cleanliness level.
Turbine Oil: Kaydon Kaymax technology plays a vital role in Turbo-TOC systems, used for pre-filtration and polishing. It effectively captures larger particles during pre-filtration, extending the coalescer element’s lifespan. Furthermore, polishing filtration ensures turbine oil cleanliness levels below ISO 15/13/11 standards.
Gear Oil: Kaydon Kaymax technology effectively removes particulate contamination from gear oil, safeguarding gearbox operation. Gear oil’s susceptibility to contamination, which can cause abrasive action and mechanical wear on bearings and surfaces, is mitigated. Using Kaydon Kaymax technology equipment reduces failures, prevents downtime, and lowers maintenance costs.
Seal Oil: Kaydon Kaymaxtechnology protects seal oil from particulate contamination, preventing abrasive wear that could lead to shaft repair or seal ring replacement. Contaminants causing gland seal wear may result in shaft sealing failure and hydrogen leakage. By employing Kaydon Kaymax technology equipment, seal oil system failure is prevented, preserving shaft integrity and preventing hydrogen leakage.
Kaydon Fuel Conditioning Series (FCS)
The Kaydon Filtration Fuel Conditioning Series of products gives you the assurance that the diesel fuels you are using in your diesel engine applications are clean, water-free, and exceed the latest ASTM D975 Diesel Fuel Specification. Diesel fuel becomes contaminated with water and particulates during transportation and storage from the refinery. This contamination worsens with each transfer and storage, leading to fuel deterioration. It’s particularly problematic for occasional-use fuel tanks such as emergency power generators, where condensation, microbiological growth, and oxidation can occur. Eventually, this contamination reaches the fuel tank of vehicles or diesel-powered equipment, causing filter overload, power loss, decreased efficiency, and equipment failure.
Kaydon Fuel Conditioning Series (FCS) technology offers an effective and economical solution by removing water to levels acceptable by diesel engine manufacturers. It operates through four (4) stages: (1) Pre-conditioning, (2) Coalescing, (3) Drain layer, and (4) Barrier layer, reducing water content to less than 500 ppm with a cleanliness code better than 16/14/11. This technology is available in two (2) system configurations: (1) in-line for single-pass filtration during fuel distribution or transfer, and (2) recirculation for fuel storage tanks.
Kaydon Filtration’s power plant oil filtration systems help decrease unwanted downtime by extending equipment life.
Separator Spares & Equipment, LLC is an Authorized Kaydon Filtration Distributor. We are committed to providing cost-effective oil filtration systems for critical systems that will positively impact your business. Kaydon Filtration is a global leader in advanced hydraulic and lubrication oil and fuel conditioning solutions. Are you looking to improve your ISO oil cleanliness levels? We can assist with oil purification systems, a broad range of custom flow rate solutions, and expertise.
Separator Spares & Equipment offers a broad range of power plant oil filtration systems designed to remove particles, water, varnish, and other contaminants. Our cost-effective power plant oil filtration systems (filter systems) will lower maintenance costs (lowering the total cost of ownership), increase reliability, and reduce energy consumption. At Separator Spares & Equipment, our reputation is built on our dedication to outstanding service and efficient power plant oil filtration systems.
Power Plant Oil Filtration Systems | Solutions, Service, and Expertise