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Kaydon Filtration understands that downtime is the ultimate enemy of power plant equipment and as a
result has developed application specific filtration technologies to minimize downtime and maximize
Every phase of your plant’s operation has specific needs that Kaydon Filtration understands. From
super-clean turbine oil and varnish free components, to ultra-dry transformer oils, Kaydon Filtration
can provide a solution to meet your demanding and varied oil and fluid conditioning needs. In the end,
we offer more than long-term, predictable and profitable performance for your plant equipment; we offer
R E C I R C U LATI ON
F I LT R ATI ON
DIESEL FUEL
BACKUP POWER
• Cleanliness ISO 16/14/11
• Water ≤ 500 ppm DIESEL
FUEL TANK
• FCS™ Technology GEAR OIL
• Cleanliness ISO 17/15/12
• Kaymax™ Technology
DIESEL OFFLOA D HYDRAULIC OIL
DIESEL ENGINE • Cleanliness ISO 16/14/11
F U E L TA N K
• Water ≤ 100 ppm
• Smart-Vac™ Technology COAL
PU LVE R I Z E R
COAL
HY D R AU LI C CR U S H E R
FR ON T- E N D COAL D U M PE R
LOAD E R
O F F LOA D
C OA L YA R D
PR I MARY AI R FAN
Our optimized turbine oil conditioning Our primary oil condition systems combine
systems with Kaydon Filtration’s patented particulate and water removal into a single skid
Turbo-TOC® coalescing technology are mounted, completely automatic solution with
specifically geared to protect the: processing rates exceeding 100 GPM (380
• Main turbine system LPM) with total water removal to less than 100
• Boiler feed pump ppm and an ISO cleanliness level to 15/13/11
• Primary, forced draft, and induced fans or better. These systems continuously condition
• Fluid drive turbine oil reservoirs during turbine operation
and during scheduled down times.
The technologies Kaydon Filtration has
developed for steam power plant oil, fluid, Not only does proper oil condition keep
and fuel conditioning applications include: your turbine systems up and running, it
Kaydon Filtration specializes in keeping oils
• Turbo-TOC® Technology for single pass2, also ensures your turbines and equipment
and fluids in your steam turbine plant clean
high flow water removal in turbine oil come back online easily and in the shortest
and dry. We have technologies to support oil
• Smart-Vac™ Technology for electro-hydraulic time after shutdown.
and fluid conditioning in steam turbine units
control fluid, hydraulic oil, and transformer oil
ranging from 1 to 1,000 MW. Kaydon Filtration technologies are used around
• Kaymax™ Technology for maximum
cleanliness levels in lubricating fluids the world to help power plants to:
• BCA™ Technology for sub-micron (varnish) • Keep steam turbines on-line longer
particulate removal • Make downtime scheduling more predictable
• FCS™ Technology for conditioning diesel • Meet peak demand requirements
fuels during off-load, storage, and fueling • Reduce maintenance and replacement costs
• Extend lubricant life
KAYDON FILTRATION • 5 • POWER GENERATION
TURBINE OIL
ELECTROHYDRAULIC
• Cleanliness ISO 15/13/11
CONTROL FLUID
• Water ≤ 100 ppm
• Cleanliness ISO 16/14/11
• Turbo-TOC® Technology
• Water ≤ 1,000 ppm
• BCATM Technology* STA C K
• Acid ≤ 0.09
• Smart-Vac™ Technology
SEAL OIL
• Cleanliness ISO 15/13/10
TRANSFORMER OIL • Kaymax™ Technology
• Cleanliness ISO 16/14/11
• Water ≤ 25 ppm
• Acid ≤ 0.09 TURBINE OIL
• Smart-Vac™ Technology • Cleanliness ISO 15/13/11
• Water ≤ 100 ppm
BOI LE R • Turbo-TOC® Technology
• BCATM Technology*
E L E CT R O STAT I C
R P R E CI PI TATO R
R E CT I F I E R
TRAN S FOR M E R TU R B I N E
G E N E RATOR
I N D UCE D
D RAFT
FA N
TRAN S F OR M E R
FORCE D CON D E N S E R
D RAF T FAN C OOLI N G
TOWE R
BOI LE R FLU I D D R I VE
FE E D PU M P
Kaydon Filtration also offers fluid Maintaining these utility system oils, Diesel engines with high pressure
conditioning systems to effectively lubricants, and fluids in top condition not injection systems3 can have on-
purify other fluids and lubricating oils only increases their useful life but it also board filters easily overwhelmed by
used in your power plant: reduces unscheduled maintenance and contaminated fuel resulting in:
t
• Hydraulic oil pre-mature equipment failure. • Unscheduled maintenance
st
• Gear oil • Power loss
• Seal oil In addition to turbine and lubrication oils,
• Decreased fuel efficiency
nd • Transformer oil Kaydon Filtration offers conditioning
• EHC fluids technologies and systems to protect • Injector and high-pressure pump failure
your diesel fuel during offload, storage, • Expensive down time
e and distribution. Diesel engines used in
modern heavy equipment, backup power Kaydon Filtration has the experience and
generators, and other diesel powered technology to keep critical application
s
operations require clean, dry fuel more diesel powered equipment up and running.
than ever.
COMBUSTION TURBINES
Power plants using combustion turbines face unique challenges for oil and fluid
contamination. Beyond the traditional turbine oil contaminates of dirt and water,
sub-micron particles (varnish) can adversely affect the operation of servo valves and
other internal metal components causing unscheduled downtime. Kaydon Filtration
TURBINE OIL
technologies can remove these varnish components suspended in your lubrication
• Cleanliness ISO 15/13/11
oils and over time can clean those lubricated surfaces experiencing varnish build up. • Water ≤ 100 ppm
• Turbo-TOC® Technology
R E C I R C U L AT I O N • BCATM Technology*
F I LT R AT I O N
BACKUP POWER
DIESEL DIESEL FUEL
FUEL TANK
• Cleanliness ISO 16/14/11 AI R
• Water ≤ 500 ppm I NTAK E
• FCS™ Technology
DIESEL
O F F LOA D DIESEL FU E L TAN K
ENGINE
TU R B I N E
O F F LOA D
CO
C
FI LTE R
S E PARATOR
TRANSFORMER OIL
• Cleanliness ISO 16/14/11
• Water ≤ 25 ppm
/11
• Acid ≤ 0.09
• Smart-Vac™ Technology
y
H E AT
SEAL OIL
E X H AU S T • Cleanliness ISO 15/13/10
• Kaymax™ Technology
TRAN S F OR M E R
RBINE G E N E R ATOR
C O M B U S TI O N
CHAM B E R
Kaydon Filtration also offers fluid Maintaining these utility system oils, Diesel engines with high pressure
se conditioning systems to effectively lubricants, and fluids in peak condition injection systems3 can have on-
purify other fluids and lubricating oils not only increases their useful life but it board filters easily overwhelmed by
used in your power plant: also reduces unscheduled maintenance contaminated fuel resulting in:
• Seal oil and pre-mature equipment failure. • Unscheduled maintenance
• Transformer oil • Power loss
In addition to turbine and lubrication oils,
n • Hydraulic oil • Decreased fuel efficiency
Kaydon Filtration offers conditioning
• Gear oil technologies and systems to protect • Injector and high-pressure pump failure
your diesel fuel during offload, storage, • Expensive down time
and distribution. Diesel engines used in
modern heavy equipment, backup power Kaydon Filtration has the experience and
generators, and other diesel powered technology to keep critical application
operations require clean, dry fuel more diesel powered equipment up and running.
than ever.
HYDROELECTRIC TURBINES
Failures of the wicket gate mechanism, turbine governor, and
turbine bearings are among the top 25 causes of forced outages4
within a hydroelectric facility. Through improved fluid management
and conditioning these failures can be significantly reduced.
TRANSFORMER OIL
• Cleanliness ISO 16/14/11 DIESEL FUEL
TURBINE OIL • Water ≤ 25 ppm • Cleanliness ISO 16/14/11
• Cleanliness ISO 15/13/11 • Acid ≤ 0.09 • Water ≤ 500 ppm
• Water ≤ 100 ppm • Smart-Vac™ Technology • FCS™ Technology
• Turbo-TOC® Technology
• BCATM Technology*
BACKUP POWER
R E S E R VO I R
R E CI R CU LATI ON
POWE R HOUS E FI LTRATI ON
TRAN S M I S S I ON
LI N E S
DIESEL
G E N E RATOR FU E L TAN K
OFFLOAD DIESEL
I N TA K E PE N ENGINE
STO
CK
S P H E R I CA L TH R U ST
VA LV E S B EAR I N G S
TURBINE OIL
TU R B I N E GUIDE TU R B I N E • Cleanliness ISO 15/13/11
G OV E R N O R B EA R I N G S • Water ≤ 100 ppm
• Turbo-TOC® Technology
• BCATM Technology*
Whether you use reaction or impulse turbines, Our solutions can be used to protect: In addition to turbine and lubrication oils,
keeping your oils and lubricants clean and dry • Turbine governors Kaydon Filtration offers conditioning
is critical to your uptime, ability to schedule • Spherical valves technologies and systems to protect your
maintenance, and protection of expensive diesel fuel during offload, storage, and
• Guide bearings
equipment. Kaydon Filtration technologies and distribution. Diesel engines used in modern
solutions can be sized to support hydroelectric • Thrust bearings heavy equipment, backup power generators,
units from 1 to over 1000 megawatts. • Lift pumps and other diesel powered operations require
• Transformers clean, dry fuel more than ever.
Our patented technologies effectively:
The technologies Kaydon Filtration
Diesel engines with high pressure
• EXTEND the service life of lubricating fluids has developed for hydroelectric power
injection systems3 can have on-
• PROTECT expensive equipment plant oil, fluid, and fuel conditioning
board filters easily overwhelmed by
• REDUCE premature failures applications include:
contaminated fuel resulting in:
• Turbo-TOC® Technology for single pass,
• Unscheduled maintenance
The elimination of water, particulates, high flow water removal in turbine oil
• Power loss
varnish, and other harmful contaminates • Kaymax™ Technology for maximum • Decreased fuel efficiency
from lubricating oils and fluids is Kaydon cleanliness levels in lubricating fluids • Injector and high-pressure pump failure
Filtration’s expertise and we have been helping
• BCA™ Technology for sub-micron (varnish) • Expensive down time
hydroelectric power plants worldwide in
particulate removal
protecting their equipment investments. Kaydon Filtration has the experience and
• Smart-Vac™ Technology for hydraulic oil
technology to keep critical application diesel
and transformer oil
powered equipment up and running.
• FCS™ Technology for conditioning diesel fuels
during off-load, storage, and fueling
KAYDON FILTRATION • 9 • POWER GENERATION
Separator Element
The final component of the technology is the separator stage. The separator provides a hydrophobic screen that acts as a
water barrier to prevent smaller water droplets from flowing downstream. In addition, the separator element includes a
micro-fiber component that acts as a final polishing filtration stage for particulates. This polishing affect eliminates the need
for the expensive final filter stage found in traditional oil conditioning systems.
The combination of the coalescer and separator stages delivers water removal in oil to less than 100 ppm
esel and polishing to <5 microns.
When it comes to turbine oil particulate removal, look no
further than Kaydon Filtration.
Smart-Vac™ Technology Kaymax ™ Technology
Many fluids require water removal to well below 100 ppm Kaymax™ technology provides exceptional particulate filtration for
or because of their chemical composition render coalescing oils, fluids, and fuels. Kay-Max™ technology combines meticulous
ineffective in removing water. Separation of water from oil by filter media selection and filter element construction methods to
removing it in the form of water vapor, rather than removing it produce proven and repeatable filtration performance. Kaymax™
in the liquid state, is the principle used in Kaydon Filtration’s technology uses specially formulated multi-layered, micro-
Smart-Vac™ technology. In this way, water can be removed from fiberglass fibers to deliver exceptional particle retention and high
oil without regard to the degree of emulsification. Even the most particle holding capacity. Kaymax™ construction helps maintain
stubborn, stable oil/water emulsions can be separated. pleat integrity under high flow and high viscosity conditions, and
with supporting materials, pleat bunching or collapse during high
The vacuum distillation used in Smart-Vac™ technology is different
flow, high dirt loading or cold start-ups is eliminated. Construction
than other dehydration processes. It uses an integrated three
materials are selected for proper fluid compatibility and are
stage process of low-temperature dehydration, disperser assisted
corrosion resistant. Kaymax™ technology performance meets or
distillation, and rapid condensing. Kaydon Filtration Smart-Vac™
exceeds ISO 15/13/11 cleanliness level.
systems performance delivers less than 25 ppm water content
with an ISO 16/14/11 cleanliness level. Turbine Oil
Kaymax™ technology is utilized with Turbo-TOC® turbine
Smart-Vac™ technology allows for water removal in
conditioning systems. The technology is a vital component of
a number of liquids and applications that cannot be
addressed through coalescing: the conditioning process, and its use is instituted in the pre-
filtration and polishing filtration stages of the Turbo-TOC® system.
Electrohydraulic Control Fluid (EHC) The benefits of Kaymax™ technology in the pre-filtration stage
Smart-Vac™ technology removes water from phosphate ester fluid is its ability to capture larger particles and extend the life of the
used with EHC systems. Combining this technology with acid coalescer element. Polishing filtration removes the smaller particles
removal and Kaymax™ particulate removal technology, a complete and provides turbine oil cleanliness of less than ISO 15/13/11.
purification system is created. Acid number (AN), water content
(ppm) and particulate cleanliness levels (ISO Cleanliness Code) Gear Oil
are all three maintained within fluid manufacturer and OEM Kaymax™ technology removes particulate contamination from gear
equipment specifications. oil, therefore protecting gearbox operation. Gear oil is susceptible
to invasion of particulate contamination and the abrasive action of
Hydraulic Oil
particulate creates mechanical wear of gearbox bearing and gear
Water contamination in hydraulic systems causes oil degradation,
surfaces. Prevention of mechanical wear can be attained through
reduction of oil film thickness, viscosity changes, component
the use of Kaymax™ technology equipment. The benefits of
surface damage and corrosion. Smart-Vac™ technology provides
removing mechanical wear producing particulates are a reduction
continuous protection from water contamination in hydraulic oil,
of bearing and gear failures, prevention of downtime and a
therefore safeguarding sensitive hydraulic power unit components.
decrease in maintenance costs.
Transformer Oil
Seal Oil
Excessive water in transformer oil causes accelerated
Kaymax™ technology protects seal oil from particulate
degradation of transformer insulation materials and reduction of
contamination. Particulate contamination in the seal oil system
oil dielectric strength. Because transformers depend on oil for
causes abrasive wear that may require shaft repair or
cooling, insulation, and protection from corrosion, the removal
replacement of seal rings. Gland seal wear caused by particulate
of water in transformer oil is an essential part of transformer
contamination can cause shaft sealing failure, which will permit
maintenance. Smart-Vac™ technology removes water from
hydrogen to escape from the generator. Prevention of seal oil
transformer oil to acceptable levels to protect transformers from
system failure can be attained through the use of Kaymax™
being adversely affected by water contamination.
technology equipment. The benefits of removing particulates
from seal oil are prevention of shaft and seal wear and prohibits
hydrogen leakage.
KAYDON FILTRATION • 11 • POWER GENERATION
+ VDC Electrodes
• Transfer and distribution
• Equipment refueling
• Backup power
• Combustion turbines
e Smaller “Agglomerated”
particles larger particle *BCATM Technology is a registered trademark of ISOPUR Fluid Technologies.
clusters 1
The Effect of Water in Lubricating Oil on Bearing Fatigue Life, Richard E. Cantley
- VDC Electrodes The Timken Company, Asle Transactions, Volume 20, 3 244-248
2
Nominal results with influent at <=5000 ppm and <=18/16/13 cleanliness.
Actual results may vary.
3
The Benefits of Diesel Fuel Filtration ©Kaydon Filtration 2008
4
s Statistical information from the North American Reliability Council
Kaydon Filtration specifications are subject to change without notice.
When all is said and done – lubricants, fluids,
and diesel fuel are the core of your power plant
equipment. Kaydon Filtration is here to keep
them in peak condition.
To make sure you arrive at the solutions that are best for your application, Kaydon Filtration offers a variety
of value-added services from design and testing to manufacturing, service and consulting. Whether your
requirements revolve around protecting a single piece of equipment or for an entire facility, Kaydon Filtration
is ready to respond with the expertise and answers you can trust.
We regularly partner with customers to tackle specialized filtration challenges. Our team of applications
engineers draws on extensive knowledge in the areas of mechanical engineering and chemistry to expertly
craft engineered solutions that address your particular situation both now and in the years to come. We invite
you to learn more about how we are EXTENDING YOUR ENERGY!