Reducing High Varnish Levels in a Hydropower Dam in Thailand
Customer Challenge
A major hydropower dam in Thailand experienced severe varnish contamination in its turbine lubrication system. The customer reported that the Membrane Patch Colorimetry (MPC) value had reached a critical level of 55, posing risks to equipment reliability and efficiency. The high varnish levels were leading to increased operational risks, such as:
- Reduced Lubrication Efficiency – Varnish buildup compromised oil flow and heat dissipation.
- Increased Maintenance Costs – Frequent maintenance was required to remove deposits manually.
- Potential Equipment Failures – Varnish deposits in control valves and bearings could lead to unplanned shutdowns.
To prevent equipment damage and meet operational reliability standards, the customer sought an effective solution to rapidly reduce varnish levels and bring the MPC value within an acceptable range.
Lubefix Solution
To address the varnish contamination issue, Lubefix proposed installing a Dept Media Varnish Removal System. The high-efficiency filtration system was strategically integrated into the lubrication circuit to:
- ✅ Continuously remove soluble and insoluble varnish from the oil.
- ✅ Prevent new varnish formation by stabilizing oil chemistry.
- ✅ Extend lubricant life and enhance overall system reliability.
Results & Impact
The installation of the Dept Media varnish filter delivered outstanding results in just two days:
| Parameter | Before Installation | After 2 Days |
|---|---|---|
| MPC Value | 55 | 12.3 |
- 🔹 78% Reduction in MPC Value – Achieved rapid varnish removal, bringing the lubricant condition within an acceptable range.
- 🔹 Improved Equipment Reliability – Lower varnish content reduced risks of valve sticking and bearing failures.
- 🔹 Extended Lubricant Service Life – The solution minimized the need for frequent oil changes, lowering maintenance costs.
Customer Feedback
The customer was highly satisfied with the performance of Lubefix’s Dept Media solution, noting its quick effectiveness and long-term varnish control benefits. The success of this project reinforced the importance of proactive varnish removal strategies in hydropower lubrication systems.
Conclusion
By implementing the Lubefix Dept Media Varnish Removal System, the dam successfully reduced its MPC value from 55 to 12.3 within 48 hours, significantly enhancing lubrication reliability. This case highlights the importance of effective varnish management in critical industrial applications, ensuring long-term asset protection and operational efficiency.
📞 Contact Us
For more information or consultation on varnish removal solutions, contact Lubefix today! 😊