2 of 23

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

Varnish in Turbine Oil Systems

Varnish is a well-known problem in the power industry, clogging inline filters and creating restriction in valves, resulting in turbine trip-outs

But the solution is here !

Hydraulic pilot valve spools covered in varnish

Varnish clogged inline filter

Turbine trip-outs can easily cost $100,000

CJC Varnish Removal Unit

www.cjc.dk

3 of 23

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

Varnish Removal with C.C.Jensen

All CJC filters remove varnish

VRU takes it to a whole new level...

CJC offline filters have been removing varnish for 60 years

Standard “HDU” vs “VRU” filter systems on the same oil tank for the same period

CJC Varnish Removal Unit

www.cjc.dk

4 of 23

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

VRU – Varnish Removal Unit

Photo of VRU 27/108

The VRU is incorporating all the best practice in oil filtration and extensive knowledge gathered through 60 years by C.C.JENSEN.�The VRU is removing oil degradation products from oil – dissolved and in suspension – even from high temperature operating turbines.

The varnish level in the oil typically goes from MPC 60 to MPC 10 in four to six weeks, but results are improved in a few hours !

MPC 60 to MPC 10 in a few weeks

CJC Varnish Removal Unit

www.cjc.dk

5 of 23

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

Varnish Removal Results

This is what you can expect when installing a CJC^TM VRU on a gas turbine lube & control oil.�From sample 1 to sample 4 only 10 days have past, but dramatic differences of up to 80% can be seen between the VRU inlet and outlet.

VRU Inlet VRU outlet

Oil after a single pass�through the VRU

Oil improvements can be seen within 2 hours

CJC Varnish Removal Unit

www.cjc.dk

6 of 23

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

This is how the inserts look

after removing the varnish from

gas turbine lube and control oils

VRU Varnish Removal Unit

The secret behind the high efficiency of the VRU is a combination of extensive cooling, multi-pass offline-to-offline and the optimized VRi 27/27 inserts

The VRU utilizes polar attraction to capture varnish like all other CJC filters, but the VRU can also retain dissolved soft contaminants which are precursors to varnish formation

CJC Varnish Removal Unit

www.cjc.dk

7 of 23

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

Typical applications where varnish problems are difficult to solve with standard the HDU Fine Filters or PTU Filter Separators:

VRU Applications

Gas turbines with combined lube and control system fluid e.g. GE frame 7�
Base loaded gas or steam turbines operating with high oil temperature �(above 60 ̊C / 140 ̊ F)�
Highly stressed and hot running lube or� hydraulic systems

CJC Varnish Removal Unit

www.cjc.dk

8 of 23

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

The benefits of varnish free oil and system components are:

Increased turbine reliability and availability
No turbine trips due to varnish (save min. $40,000 plus loss of revenue)
Full control of governor system – no sticking fuel or IGV valves
No need for tank cleaning and system flushing
Longer lifetime of oil and components
MPC values continuously within safe levels (MPC < 10)
Reduced varnish levels can be seen after only 2 hours

(typically 50% - 80% reduction in MPC value from VRU inlet to outlet)

Easy maintenance of the VRU, which does not require stopping the turbine

Customer Benefits

Varnish can be removed

CJC Varnish Removal Unit

www.cjc.dk

9 of 23

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

VRU Reference List

Turbine	Oil volume	Oil type	Result
GE base loaded	6,500 L	Mobil DTE 832	MPC 64 to MPC 24 in ten days
Siemens base loaded	9,800 L	Mobil DTE 832	MPC 24 to MPC 7 in eight weeks
Alstom base loaded	22,000 L	Mobil DTE 846	MPC 28 to MPC 7 in one week
More available upon request

The VRU 27/108 is designed to clean up to 35,000 L (9200 gal) oil in 3 months

CJC Varnish Removal Unit

www.cjc.dk

10 of 23

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

Oil analysis for detecting varnish

Used oil analysis tests for varnish detection are important tools.�For best repeatability and easy understandable result use:

Ultra Centrifuge test (UC)

Best below 3

Critical above 7 �

Membrane Patch Colorimetric test (MPC)

Best below MPC 15 Critical above MPC 40

Explanation to MPC and UC can be found in the VRU compendium

CJC Varnish Removal Unit

www.cjc.dk

11 of 23

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

Oil Analysis

Take oil sample from both VRU inlet and outlet

�First time after 3 hours of operation

Then after 1 week, 3 weeks, and 6 weeks…

Labs capable of performing

MPC or UC tests:

Insight Services, USA
R&G Laboratories, Florida, USA
Spectro, labs in the UK, USA & Switzerland
Filtrex, the Netherlands
Tekniker, Spain
C.C.JENSEN lab in Svendborg

CJC Varnish Removal Unit

www.cjc.dk

12 of 23

The VRU incorporates air cooling, heat exchanger and chiller (no water supply needed) as well as a “multi-pass” arrangement known as “offline to offline”.
It also utilizes special designed inserts which are optimized for varnish removal (VRi 27/27).
The warm oil is drawn from the system tank to the VRU by means of the transfer pump. The oil is first passing an air cooler to lower the oil temperature in the cheapest possible way. Secondly it passes a cross-flow heat exchanger where the outgoing oil from the VRU cools the incoming oil down.
Now the oil enters the offline-to-offline circuit where the second pump circulates the oil over a chiller (a set of coils dipped in refrigerated water), which gradually lowers the oil temperature to 10°C (50°F).
The cold oil is circulated over the inserts and the chiller five times before being re-heated through the cross-flow heat exchanger and sent back to the system tank as varnish free oil.

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

The function of the VRU

MPC value reduction 50 – 80 % in a single VRU pass

CJC Varnish Removal Unit

www.cjc.dk

13 of 23

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

The additives in the now varnish free oil will start cleaning all system components in contact with oil, resulting in a complete varnish free system after some weeks up to a few months depending on system age.

Effects of the VRU

CJC Varnish Removal Unit

www.cjc.dk

14 of 23

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

The graph shows

a typical

varnish removal trend

using the

CJC™ VRU 27/108

Varnish Removal Trend

CJC Varnish Removal Unit

www.cjc.dk

15 of 23

VRU Selection

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

One VRU size fits all gas and steam turbines

Selection is easy since the VRU27/108 will remove varnish from turbine sizes to 35,000 L

Optimized inserts, offline-to-offline and extensive cooling does the trick (<10ºC/50ºF)

The VRU is optimized for varnish removal, so in applications with severe particle or water contamination please add another HDU or PTU in a separate offline loop

To convince customers of the new technology and efficiency the VRU

can be sold as “no cure – no pay”

CJC Varnish Removal Unit

www.cjc.dk

16 of 23

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

Filter replacement intervals (VRi 27/27)	Time
First time	After 4 weeks of operation
Second time	After an additional 8 week of operation
Third time	After an additional 12 week of operation
Periodically	Every 4 to 6 months of operation

The VRi 27/27 utilizes polar attraction to retain soft contaminants being dissolved or in suspension in the oil

CJC Varnish Removal Unit

www.cjc.dk

17 of 23

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

Gas Turbine, 53,000L Chevron GT32

CJC Varnish Removal Unit

www.cjc.dk

18 of 23

FAQ for the VRU

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

Question	Answer
Which results can be expected when installing the VRU on a gas turbine lube & control oil?	Typically the varnish level measured with MPC goes from ΔE 60 to ΔE 10 in 4 - 6 weeks
Is the VRU incorporating chemical beads which could alter the oils additive package?	No, the VRU only uses offline cellulose depth media and cooling to retain varnish
Does the VRU require external water supply to operate?	No, the cooling consist of air fan and a chiller which is a stand alone unit. Only power supply is needed.
Is the VRU also capable of removing particles?	Yes, particle filtration is 3 micron absolute like all other CJC filters, but the main benefit of the VRU is removal of dissolved varnish/soft contaminants from the oil
Why is the oil temperature so low in the VRU	Soft contaminants being precursors to varnish are dissolved in turbine oil at temperatures above 40°C (100°F) .To be able to remove it all you’ll need oil temperatures around 10°C (50°F)
How do you size the VRU?	One size fits all gas and steam turbine sizes - the VRU 27/108. Please state available power supply and in- or outdoor installation.

CJC Varnish Removal Unit

www.cjc.dk

19 of 23

VRU case 1 – Denmark

Base loaded V64.3 Siemens gas turbine (53.9 MW).

9800 L (2600 gal) Mobil DTE 832. Mineral based 32 cSt turbine oil, 6 years in operation.

Oil operation temperature: 62 ˚C (144 °F)

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

MPC 24 to MPC 7 �within 8 weeks

MPC down to safe levels within 1 week

CJC Varnish Removal Unit

www.cjc.dk

20 of 23

VRU case 2 - Mallorca

Peak loaded GE frame 6 gas turbine in Spain.

6500 L (1700 gal) Repsol Aries 32. Mineral based 32 cSt turbine oil

Oil operation temperature: up to 85˚C (185 °F)

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

The varnish level went from MPC 64 to safe levels and remained there

Varnish levels down to MPC8 within 24 hours with the VRU

This good result in 24 h means a single stay VRU 27/108 can easily do the job

CJC Varnish Removal Unit

www.cjc.dk

21 of 23

VRU case 3 - Spain

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

Base loaded gas turbines 2 x GE 42 MW in Spain

6500 L (1700 gal) on each turbine, Mobil DTE 832 mineral oil, 4 years in operation

Oil temperature 66 – 85°C (150 – 185°F)

Varnish level from MPC 64 to MPC 24 in 10 days with the VRU

CJC Varnish Removal Unit

www.cjc.dk

22 of 23

VRU case 4 - Malaysia

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

Keeping the varnish continuously within safe levels

Base loaded Alstom GT-11E gas turbine (176 MW).

22,000 L (5800 gal) Mobil DTE 846. Mineral based 46 cSt turbine oil.

Varnish level from

MPC 28 to MPC 7 in one week with the VRU

CJC Varnish Removal Unit

www.cjc.dk

23 of 23

VRU case 5 - USA

C.C.JENSEN A/S, Varnish Removal Unit intro & results, SDN, Aug 31, 2011

Page *

Base loaded gas turbine, GE 7FA 150MW

Conoco Diamond Class ISO32, 22,700 L, operating temperature 54°C

Varnish level from MPC 22 to MPC 5 in three weeks with the VRU

CJC Varnish Removal Unit