How you can reduce malfunctions and failures with the right filtration strategy

Filtration in hydropower plants – the best solution: CJC® Water Turbine Filter

How you can reduce malfunctions and failures with the right filtration strategy

Filtration in hydropower plants – the best solution: CJC® Water Turbine Filter

Filtration in hydropower plants with CJC® is a must if you …

  • want to avoid unplanned downtime due to repairs and component replacements.

  • wish to ensure consistent electricity generation and minimize penalties for non-delivery.

  • recognizes that valves are repeatedly clogged, which disrupts the function, control and performance of the turbine.

  • diagnose that wear and corrosion are shortening the service life of mechanical components.

  • desire to extend the oil change intervals for your water turbine and reduce oil consumption.

Your solution: a CJC® Water Turbine Filter. Achieve the highest oil cleanliness for optimum protection of turbine oil and water turbines — quickly, efficiently and cost-effectively.

Challenge

Dry and clean lubrication and control systems in water turbines are crucial to prevent expensive repairs and downtime. The main problems are water ingress and wear particles from the gearbox, which lead to malfunctions in the lubrication and control system and accelerate oil degradation processes. With new water turbines, there are more particles in the oil right from the running-in period, which means that there is an increased risk of wear from the very first second. If power generation fails due to unplanned downtimes, this can result in high contractual penalties. A water turbine filter that efficiently removes water, particles and oil degradation products from the turbine oil is therefore your key to higher turbine availability and lower costs.

Damages and consequences of contaminated and prematurely ageing turbine oil

gearbox wear, filtration in hydropower plants, water turbine filter
corrosion on shaft, filtration in hydropower plants, water turbine filter
valve with varnish, filtration in hydropower plants, water turbine filter
bearings with varnish, filtration in hydropower plants, water turbine filter
inline filter clogged with varnish, water turbine filtration, gas turbine, lubrication and control oil system
tank with varnish, gas turbine filtration, gas turbine, lubrication and control oil system

In particular, due to the temperature differences between the temperature of the oil system and the water that drives the water turbine — usually cold river and lake water — the water content in the oil can increase due to condensation. Moist ambient air enters the oil system via leaks and tank ventilation.

An increased water content in the oil leads to corrosion and cavitation, which simultaneously increases the number of particles in the oil. This is because the metal surfaces damaged by cavitation and corrosion have sharp, brittle edges. If particles hit these corroded surfaces, highly abrasive rust particles enter the oil circuit and further increase wear (chain reaction). In gearboxes, hydrogen embrittlement can lead to cracking with material erosion.

Turbine oil should be kept as dry as possible, regardless of whether it is mineral oil or synthetic fluid.

In particular, abrasive wear particles from the gearbox put a strain on the lubrication system of the water turbine. If lubrication is carried out via a central lubricating oil supply, all mechanical and hydraulic components are at risk. Even the smallest particles lead to heavy wear due to the tight tolerances. Bearings (axial, track, radial and guide bearings) and the hydraulic system for control and adjustment devices are affected. There is a permanently high risk of wear with intensive and intermittent loading.

Wear particles, especially metallic abrasion, also accelerate oil ageing processes (high additive consumption, decomposition of the base oil), which lead to varnish deposits. If varnish has already formed in bearing shells, for example, particles adhere to the sticky layer – an emery effect is created that rapidly accelerates wear processes (altered lubrication gap geometry).

With new water turbines, there are more particles in the oil right from the running-in period, which means that an efficient water turbine filter should be installed from the very first second to efficiently remove particles from the turbine oil. Also recommended, as freshly filled turbine oil often does not have the oil purity required for lubrication systems and control systems of water turbines.

Water turbines run at slower speeds and lower operating temperatures than gas and steam turbines. Nevertheless, temperature peaks are possible, which accelerate oxidation processes. Degradation products such as varnish, oil sludge and acids are formed and the viscosity increases. Metal particles from component wear and water further increase the speed of the processes taking place. Oxidation, wear and corrosion protection additives are used up prematurely, washed out or lose their function. The remaining service life of the oil is shortened rapidly – regardless of whether it is mineral oil or synthetic fluid.

Degradation products precipitate particularly in load zones, stagnant areas or narrow passages in the lubricating and control oil system. Easily recognizable as a solid, sticky layer on metal surfaces of e.g. bearings, valves, pumps or sludge-like deposits in pipes and tanks. Unplanned turbine stops and breakdowns are the result.

The MPC value for measuring the Varnish tilt should be below 10. With a CJC® water turbine filter, an MPC value of < 5 is achieved quickly and easily.

An increase in viscosity caused by impurities and oil oxidation leads to higher tensile forces. Increased energy consumption and tearing of the lubricating film are possible consequences.

Emulsified water also leads to an increase in viscosity, but results in a loss of resistance to shear forces.
Water is present as an emulsion in water as soon as the oil molecules can no longer hold the water components in solution (depending on the type of oil and the specific saturation limit). If the turbine oil only has a poor water separation capacity due to impurities, suspended matter, oil oxidation and additive consumption, the emulsified water remains in the oil for longer and thus in the oil system between the components.

Even a change in viscosity of +/- 5-10 % is critical for turbine oil, as thinner or thicker oil can cause metal surfaces to come into contact and wear.

In the case of impurities, oxidation products and increased viscosity, the air separation capacity deteriorates. Air bubbles in the turbine oil rise less easily and the risk of foaming increases, resulting in insufficient lubrication.

Your solution: efficient water turbine filters

Efficient filtration in hydropower plants means that particles, water and oxidation products are continuously removed from the turbine oil. Fact is, only with permanently clean and dry turbine oil you …

  • extend the service life of your water turbine and accelerate your return on investment.

  • reduce the risk of unplanned outages and penalties if you do not feed in electricity.

  • ensure optimum controllability and reduce maintenance costs.

  • reduce oil consumption andCO2 emissions for more sustainable operation of your water turbine.

  • protect existing inline filters, which clog less frequently and require fewer filter changes.

lower oil consumption, filtration in hydropower plants

Less turbine oil consumption

less maintenance, filtration in hydropower plants

Less maintenance

Higher reliability, filtration in hydropower plants

Higher reliability

higher resource protection, filtration in hydropower plants

Higher resource protection

CJC® water turbine filters for efficient filtration in hydropower plants

Oil analyses show a high water content and degree of contamination in your turbine oil? Do you have to replace gearboxes, bearings, valves and hydraulic components frequently due to wear? Then the CJC® water turbine filter is exactly the right solution for your hydropower plant. It ensures maximum oil cleanliness in the shortest possible time – optionally documentable via one of our CJC® Condition Monitoring Systems. Extremely high filter capacities and separation performance make it an efficient and cost-optimized solution.

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The separate pump unit enables installation in a separate circuit (offline) and thus continuous depth filtration and maintenance of the turbine oil (24/7). The gear pump draws in the turbine oil from the lowest point of the tank. The return line is depressurized near the suction pump so that the lubrication and control oil system is always supplied with clean oil.

The CJC® water turbine filter removes all impurities:

Water – free, emulsified and dissolved

Reduce water content to well below the saturation limit.

Particles

Achieve cleanliness classes up to ISO 12 (ISO 4406).

Oxidation products (varnish, sludge)

Permanently reduce the MPC value < 5 and achieve a long-lasting stable oxidation rate.

Acids

Absorb / neutralize and prevent acids for a permanently stable acid number (TAN).

CJC® Fine Filter Inserts are depth filters with a filtration degree of 3 µm absolute and a retention rate of < 1 µm. The whole volume of the insert is made of finely ramified fibres that offer an outer and, in addtion, an inner surface — from 120 to 150 m² per gram. That enables the extremely high dirt holding capacity — the higher, the longer the lifetime of the filter insert.

Fact is, our dirt holding capacities is the market leader.

CJC® water turbine filters can be optionally equipped with sensors for automatic online monitoring of the filter and oil condition. Depending on the selected system, you can choose up to nine sensors — whether for oil moisture, oil temperature, particles (4-250 µm), wear particles (40-1,000 µm), oxidation rate, filter pressure and/or oil system utilization. Limit values and warning messages can be configured so that you can counteract deviations from the normal state at an early stage.
Our oil condition sensors provide detailed real-time data and enable conclusions to be drawn about the condition of the oil and turbines thanks to the high data density.
Our intuitive operable cloud applications have a clearly arranged dashboard to visualise the sensor data. In the premium version, highly developed algorithms help you with automated data evaluation and interpretation. Ideal for critical water turbines where a failure can quickly have cost-intensive consequences. Optionally, the sensor data can be transferred to your own system via various interfaces.

CJC® water turbine filters: for lubricating oils & hydraulic fluids

water turbine filters, filtration in hydropower plants

Contact your regional contact now

Let’s talk about your water turbines, your lubrication systems, the oil you use and the specific challenges you face. We filter each oil. Whether you use mineral oils, synthetic fluids or fire-resistant hydraulic fluids. We work with you to maximize the service life of your lubricants and oil-lubricated components.

Receive a personal consultation and a non-binding offer for a CJC® water turbine filter for efficient oil maintenance.

Write or call us.

oil samplels without and with cjc, oil dewatering, desorber
oil samples before and with water turbine filter, lubricating oil, control fluid
oil samples before and with water turbine filter, lubricating oil, control fluid
oil samples before and with water turbine filter, lubricating oil, control fluid
oil samples before and with water turbine filter, lubricating oil, control fluid
oil samples before and with water turbine filter, lubricating oil, control fluid

That say our customers

Wasserkraft-Talsperre, Frankreich

„The laboratory reports have confirmed our first-hand impression after the visual inspection: From day one, the effect was evident (see photos of the oil samples). Our control valves work precisely and reliable again, and the oil quality meet the requirements. In a month, we treated the hydraulic oil in 2 tanks with the CJC® Filter and reached the same results. Components such as flow-blocks and pumps are now preserved more effectively against wear.“

Go to customer case

Maintenance Manager of the dam, Hydroelectric dam
wasserkraftwerk, turbinenöl-filtration, steuerkreislauf wasserturbine

“The CJC® Filter Separator is not only very easy to operate and extremely low-maintenance, it also allows us to completely dispense with the use of the centrifuge. I am more than satisfied with the results.”

Go to customer case

Mechanical Department Manager, Hydro power plant
getriebeöl-filtration, wasserturbine, kegelradgetriebe, steuerkreislauf

„I am very pleased with the results, we have obtained with the new CJC® Oil Care Systems. The approach of analysing the results for G3 before purchasing for the other eight units, made the decision easy for our controller.“

Go to customer case

Operation Manager, Energy generation plant

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Find out which advantages our customers benefit from and how easily and quickly you can achieve them with CJC®.