Varnish Analysis, Mitigation and Removal Services

Segi Perkasa offers a comprehensive Varnish Analysis, Mitigation and Removal Services to ensure that any problem which is related to varnish and sludge occurance can be resolved and thus will ensure the optimum system effectiveness. 

Segi Perkasa uses a 3 stage approach to understand the problems in the mitigation process as follows;

1. Identification of the varnish problem through analysis, occurance of operational problems and visual observation. 

2. Understanding the root cause of the varnish problems by interpretation and analysis of data.

3. Selecting and proposing the various solutions for the mitigation process based on the findings from the analysis and the interpretation of the root cause analysis.

Turbine Problems Caused by Varnish

After formation of varnish in the system, these sticky deposits adhere to the metal surfaces of the oil loop — piping, valves, heat exchangers, strainers, filters and other sensitive equipment. In turn, this growing film catches other fine particulates on the sticky surface, which continues to build up around the particulates, forming an abrasive, destructive surface. Research has shown that deposits of polymerized oil oxidation products contribute to the deterioration of gaskets and mechanical seals.

Other potential problems caused by varnish in turbine systems include:

• Reliability problems with control valves,
• Performance problems with heat exchangers,
• Premature filter and strainer plugging,
• Advanced wear rates on bearings and valves,
• Reduced heat transfer, resulting in the lubricant’s inability to cool bearings because the varnish acts like an insulator, and
• Catalytic effects on the deterioration of the turbine oil.

The bottom line is: varnish build-up can significantly increase maintenance costs and may result in unplanned outages.

Thus by using the 3 stage approach, the objective is to provide the client with an extensive solution to the varnish issues and to offer a comprehensive solution which can be applied effectively to mitigate the varnish and related  issue.

 

MITIGATION AND REMOVAL STRATEGIES

• many different approach of solving varnish or oil degradation. 

• most important point though, is that   we can’t effectively go about solving the problem unless we understand what’s causing it to begin with. 

• Understanding the mode of degradation is critical.

• In many cases, such as spark discharge or micro dieseling, if we identify it as a contributing mode of degradation to the turbine oil, there are proven methods that can eliminate and reduce its occurrence. 

It is important to understand what is causing the fluid to degrade and then corrective action can be planned accordingly.

There are basically 3 categories of varnish control technology;-

• electrostatic oil cleaners or agglomerators,

•  depth media filters, and  

• chemical filtration.

 

the key strategy is applying the right technology at the right time….. 

- key difference between the three technologies;-

• chemical filtration will allow you to remove the soluble products when they are both in solution and suspension,

• depth media and agglomeration or electrostatics are removing these products when they are suspended in the oil.

So, there’s a difference when applying these technologies.

For example, if the oil is operating at 50-65 degrees C, all of these degradation products are in solution, so in a situation like that, it’s more effective to put a chemical filter on the system that can remove these degradation products while they’re soluble and while they’re in solution in the turbine oils.