A waste-to-energy power plant in Germany faced servo valve sticking, bearing deposits, rising varnish, depleted antioxidants below ten percent, and failing air release. Manual cleaning restored operation short term. One year later, oil condition fell again. Legacy ESP was installed three months before the oil change to clean the system. MPC dropped from 58 to 11. After the oil change, MPC stabilized at 5 to 6. The same ESP process was deployed on two additional turbines with the same results. The project improved efficiency, restored ISO cleanliness, stabilized temperatures, and delivered an 800 percent ROI.
Problem
Fluitec’s ESP was installed three months before the oil change and dropped MPC from 58 to 11. After the oil was changed, the ESP stayed in service and MPC stabilized at 5 to 6. Based on this success, the ESP was moved to two additional turbines with similar varnish and temperature issues. Both units saw cleaner oil, restored ISO levels, lower temperatures, and improved efficiency.
Solution
After installation of the ESP system on the first turbine, a decline in the MPC values from 58 to 11 was seen. After the new oil change, the ESP unit remained in service on this turbine and the MPC values remained within the normal range (below 15) for the next three years. The ISO cleanliness levels were also maintained and fell between the ranges of 16/14/13 and 19/18/15.
Results
After the installation of the Legacy ESP & addition of Boost AO to the gearbox, there was a significant decrease in MPC levels from 38 to a maintained level of 12. The ISO cleanliness rate also greatly improved from 23/20/13 to 18/15/14 & 15/14/12. The system did not experience any unplanned downtime and the plant was able to successfully deliver its products to all of its customers.
