How you can effortlessly maximize the availability of your gas turbine and avoid contractual penalties

Gas turbine filtration with CJC®: Your #1 for turbine oil

How you can effortlessly maximize the availability of your gas turbine and avoid contractual penalties

Gas turbine filtration with CJC®: Your #1 for turbine oil

Gas turbine filtration with CJC® is a must if you …

want to avoid turbine stops due to component failure and malfunction to save costs.
desire to minimize resin and sludge deposits on valves, coolers , bearings and inline filters.
wish to avert premature wear and maximize the service life of your turbine components.
would like to extend the oil change intervals for your gas turbine and reduce oil consumption.

Your solution: CJC® Gas Turbine Filters. Achieve application-specific oil cleanliness for optimum protection of turbine oil and gas turbines — quickly, efficiently and cost-effectively.

Challenge

The lubricating oil system is one of the most critical systems in a gas turbine — faults here lead to some of the most serious damages and failures. High operating temperatures and speeds are the primary load factors for the turbine oil in the lubrication and control oil systems of the gas turbine.

With the central lubricating oil supply, all lubrication points and control elements are lubricated with the same lubricating oil or come into contact with it: Bearings (plain, axial, main and pinion bearings), cooling system, pump and the sensitive control and valve technology. Contamination and varnish therefore lead to a high risk of wear and failure, deposits on all oil-lubricated components, reduced turbine performance and frequent oil changes with possibly costly system flushing as a result (high expense due to the large oil fillings).

In separate control oil systems, fire-resistant hydraulic fluids (typically phosphoric acid esters) are often used, which quickly become unstable and acidify when exposed to water (increasing the risk of corrosion).

Damages and consequences of contaminated and prematurely ageing turbine oil

Deposits, varnish, oil oxidation and additive degradation

Due to the high temperatures (the peak oil temperature near the combustion chamber is up to 300 °C), oxidation processes are rapidly accelerated, resulting in degradation products that lead to varnish, oil sludge and acids as well as an increase in viscosity. Impurities such as metal particles and water further accelerate these processes. Oxidation, wear and corrosion protection additives are used up prematurely, washed out or rendered dysfunctional. As a result, the remaining service life of the oil automatically decreases.

Degradation products are deposited 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 and heat exchangers or as a sludge-like deposit in pipes and tanks. Unplanned turbine stops and breakdowns would be the result.

The MPC value for measuring the Varnish tilt should be below 10. With a CJC® Gas Turbine Filter, an MPC value below 5 can be achieved quickly and easily.

Wear due to solid contamination

In the highly sensitive and heavily stressed lubricating and control oil systems, bearings, valves and pumps wear out due to the tight tolerances caused by even the smallest particles. Particles are introduced from outside (dust via the tank ventilation, defective seals) or are caused by wear within the oil system. However, freshly filled turbine oil often does not have the oil cleanliness required for lubricating and control oil systems in gas turbines. Once particles circulate in the oil system, new particles are constantly being created, resulting in a chain reaction of wear.

If varnish has already formed, e.g. in bearing shells, particles adhere to the sticky layer — an emery effect occurs which rapidly accelerates wear (altered lubrication gap geometry).

An oil cleanliness class of 16/14/11 in accordance with ISO 4406 is therefore recommended. In addition to varnish, CJC® Gas Turbine Filters also remove particles, water and acids.

Lubrication effect & energy consumption

Impurities and oil oxidation lead to an increase in viscosity in the gas turbine oil, which results in higher tensile forces and higher energy consumption. If the lubricating film is torn off by excessively viscous oil, the metal surfaces of the components come into contact and wear increases. Even a change in viscosity of +/- 5-10 % is critical for gas turbines.

Special features of ester-based HFD fluids, e.g. phosphoric acid esters:

When water is introduced, the viscosity decreases and the fluid becomes thinner and loses its lubricating effect.
In the case of phosphoric acid esters, the base oil without additives already offers very good viscosity and oxidation stability, but water in combination with high operating temperatures / temperature peaks lead to the splitting of the ester molecules into their original alcohol and acid components (hydrolysis). The acid content in the fluid increases (TAN). The more advanced the hydrolysis, the faster the further decomposition of the ester takes place, which rapidly increases the acid number and thus the risk of acid corrosion.
As CJC® Gas Turbine Filters remove water and acids, hydrolytic decomposition can be significantly slowed down (extending service life), the lubricating effect kept stable and corrosion and sludge formation prevented.

Air release property and foam risk

Impurities, oxidation residues and an increased viscosity worsen the air separation capacity. Air bubbles in the turbine oil rise less easily and the risk of foaming increases, resulting in insufficient lubrication.

Corrosion, rust, cavitation and hydrogen embrittlement

Contamination with water typically only occurs with peak-load turbines.

If phosphoric acid ester is used as a hydraulic fluid in a separate lubricating and control oil system, water can lead to hydrolysis, especially in combination with thermal load. The resulting splitting of the ester into the original alcohol and acid components increases the risk of acid corrosion. Acids in combination with water are highly corrosive.

Both hydrogen and acid corrosion damage the metal surfaces. Sharp edges are created and hard, highly abrasive rust particles enter the oil circuit. If particles hit corroded surfaces, additional particles are released.

Turbine oil should be kept as dry as possible to prevent corrosion, cavitation and hydrogen embrittlement, regardless of whether it is mineral oil or synthetic fluid.

Contact your regional salesperson now

Your solution: efficient gas turbine filtration

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

protect your investment – extended gas turbine life, faster ROI.
minimize unplanned downtime, repairs, maintenance costs and penalties.
ensure reliably functioning valves and controllability at each time.
minimize oil consumption and CO₂ emissions for even more sustainability.
protect existing inline filters, which clog less frequently and require fewer filter changes.

lower oil consumption, lubrication and control oil system

Less oil consumption

Less maintenance

Higher reliability

Higher resource protection

Contact your regional salesperson now

CJC® Gas Turbine Filters for efficient maintenance of turbine oil

Does your oil quickly reach high oxidation rates and acid numbers, has poor purity classes or contains water? Do you have to change or clean bearings, valves and heat exchangers frequently due to resin-like and sticky deposits? Then the CJC® Gas Turbine Filter is exactly the right solution for your gas turbine. It ensures maximum oil cleanliness in the shortest possible time — optionally documentable via our CJC® Condition Monitoring Systems. Extremely high filter capacities and separation performance make it a safe and cost-optimized solution.

gas turbine filter for lubrication and control oil system, gas turbine

Installation in the offline circuit

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.

Sensational separation performance

The CJC® Gas Turbine Filter removes all impurities:

Oxidation products (varnish, sludge)

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

Particles

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

Water – free, emulsified and dissolved

Reduce water content to well below the saturation limit.

Acids

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

High dirt holding capacity and filtration degree

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 capacity is the market leader.

Condition Monitoring

CJC® Gas 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 gas 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® Gas Turbine Filters: Turbine oil filtration and maintenance

Contact your regional contact now

Let’s talk about your gas turbine, the turbine 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® Gas Turbine Filter for efficient oil maintenance.

Write or call us.

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oil samples before and with gas turbine filter, lubrication and control oil system

That say our customers

“The CJC® VRU has reduced the MPC value to low, stable and controlled levels, giving us peace of mind and the security of having clean, varnish-free oil. In addition, since the CJC® VRU Filter was put into operation, we have abserved fewer pressure filter changes and a reduction in system component failures, which has resulted in financial savings.”

Go to customer case

Maintenance Manager , Cardboard factory

“Before the installation of the CJC® Gas Turbine Filter,we were experiencing failed gas valve servo(s) just about every start. We tried other varnish removal units, but we were not getting the results we wanted. Within a short time after we installed the CJC® Gas Turbine Filter, the varnish problems we were experiencing, diminished. Our varnish levels dropped to very low levels and we have not experienced servo problems since. We are very satisfied with the results and now have again the confidence that the gas turbine will operate reliably as soon as the start button is pushed.”

Go to customer case

Operating and Maintenance Manager , Power plant

„In addition to the good advice that we have always received, I positively value the effectiveness of the treatment in the short term (6 months), allowing us to prolong the lifetime of the oil, with the corresponding cost savings and reduction of the waste generated.“

Go to customer case

Maintenance Manager, Naturgy CCC Aceca

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Our practical reports

Convincing practical reports from a user’s perspective waiting for you.

Find out which advantages our customers benefit from and how they have achieved them with CJC® — simply, quickly and cost-effectively.

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