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CLEAN OIL 
BRIGHT IDEAS 
www.cjc.dk © CC JENSEN A/S – IPS, Cannes- 20 -22th Feb 2013 
CJC Off-line Oil Filtration Systems 
Power Industry 
Carl Christian Jensen 
1906-1972 
Carl Aage Jensen 
 
Henrik Søren Christian 
CLEAN OIL 
BRIGHT IDEAS C.C. Jensen A/S, a Danish family owned company 
PRODUCTS APPLICATIONS WHY CJC COMPANY VARNISH VRU 
www.cjc.dk 
CLEAN OIL 
BRIGHT IDEAS 
PRODUCTS APPLICATIONS WHY CJC COMPANY VARNISH VRU 
© CC JENSEN A/S – IPS, Cannes- 20 -22th Feb 2013 
HDU Fine Filter w. BG, B or A filter inserts for particle, sludge 
and limited water removal, 3 micron fine filtration 
HDU 27/27 
Flow: 120 – 250 l/h 
Gear oil: 100 – 1000 l 
Hydraulic: 500 – 3000 l 
 
•Gears oil 
•Compressor oil 
•Hydraulic oil 
•Turbine control oil 
•Engine lube oil 
•Generator lube oil 
•Gas turbine lube oil 
•Tap changer 
•Cooling tower gears 
 
Price: 3.000 – 6.000 € 
HDU 27/54 
Flow: 200 – 600 l/h 
Gear oil: 300 – 2000 l 
Hydraulic: 1000 – 6000 l 
 
•Gears oil 
•Compressor oil 
•Hydraulic oil 
•Engine lube oil 
•Generator lube oil 
•Gas turbine lube oil 
•Coal mill gears 
 
Price: 3.500 – 7.500 € 
HDU 27/108 
Flow: 400 – 1250 l/h 
Gear oil: 600 – 4000 l 
Hydraulic: 2000 – 10000 l 
 
•Gears oil 
•Compressor oil 
•Hydraulic oil 
•Engine lube oil 
•Generator lube oil 
•Gas turbine lube oil 
 
Price: 4.500 – 10.500 € 
HDU 2x27/108 
Flow: 800 – 2600 l/h 
Gear oil: 2000 – 8000 l 
Hydraulic: 4000 – 20000 l 
 
•Hydraulic oil 
•Lubrication systems 
•Gas turbine lube oil 
•Heat transfer oil 
 
Price: 13.000 – 25.000 € 
HDU 427/108 
Flow: 800 – 5200 l/h 
Gear oil: 4000 – 15000 l 
Hydraulic: 10000 – 40000 l 
 
•Engine & Generator lube oil 
•Gas turbine lube oil 
•Quench oil 
•Biodiesel (in comb. w. Desorber) 
•Transfer diesel filtration 
 
Price: 9.000 – 25.000 € 
CLEAN OIL 
BRIGHT IDEAS 
PRODUCTS APPLICATIONS WHY CJC COMPANY VARNISH VRU 
PTU2 27/27 
Flow: 120 – 250 l/h 
Gear oil: 100 – 1000 l 
Hydraulic oil: 500 – 3000l 
 
•Thrusters 
•Stern Tubes 
•Gear oil 
•Steam turbine lube oil 
•Deck hydraulics of cranes 
and winches 
•Feed pumps 
 
Price: 4.500 – 12.000 € 
PTU3 27/108 
Flow: 400 – 1250 l/h 
Gear oil: 600 – 4000 l 
Hydraulic oil: 2000 – 10000 l 
Diesel: 1250 l/h 
 
•Hydraulic oil 
•Feed pumps 
•Steam turbine lube oil 
•Diesel filtration 
•Marine MGO/MDO - PTU1 
 
Price: 10.000 – 17.500 € 
PTU3 2x27/108 
Flow: 800 – 2600 l/h 
Gear oil: 2000 – 8000 l 
Hydraulic oil: 4000 – 20000 l 
Diesel: 2600 l/h 
 
•Hydraulic oil 
•Steam turbine lube oil 
•Single shaft ST+GT lube oil 
•Diesel filtration (Storage tanks) 
 
Price: 20.000 – 27.500 € 
PTU3 4x27/108 
Flow: 2600 – 7500 l/h 
Gear oil: 4000 – 16000 l 
Hydraulic oil: 20000 – 60000 l 
Diesel: 7500 l/h 
 
•Hydraulic oil 
•Steam turbine lube oil 
•Single shaft ST+GT lube oil 
•Diesel filtration (Storage tanks) 
 
Price: 32.500 - 47.500 € 
 
CLEAN OIL 
BRIGHT IDEAS PTU Filter Separators w. BLAT, BLA or F filter inserts for particle, sludge, bacteria 
and water removal, 3 micron fine filtration and water removal 
PRODUCTS APPLICATIONS WHY CJC COMPANY VARNISH VRU 
Desorbers to remove water from emulsions, synthetic ester 
based oils, biodegradable oils and high viscosity oils . 
Desorber D10 
 
•Thrusters 
•Stern Tubes 
•Ester based synthetic fluids 
•Biodegradable oil 
•Smaller gears 
•Hydraulic oil 
 
Water removal: 0.2 L/h 
Volume: < 2000 L 
 
Price: 15.000€ 
Desorber D30 
 
•Lube oil in Paper Mills 
•Lube oil in Steel Mills 
•Hydraulic applications 
•Ester based synthetic fluids 
•Waste Oil Applications 
•Bio-diesel 
 
Water removal: 2 L/h 
Volume: < 5000 L 
 
Price: 25.000€ 
Desorber D40 
 
•Lube oil in Paper Mills 
•Lube oil in Steel Mills 
•Hydraulic applications 
•Ester based synthetic fluids 
•Waste Oil Applications 
•Bio-diesel 
 
Water removal: 8 L/h 
Volume: < 25000 L 
 
Price: 48.000€ 
Desorber D88 
 
•Lube oil in Paper Mills 
•Lube oil in Steel Mills 
•Hydraulic applications 
•Ester based synthetic fluids 
•Waste Oil Applications 
•Bio-diesel 
 
Water removal: 15 L/h 
Volume: < 50000 L 
 
Price: 80.000€ 
CLEAN OIL 
BRIGHT IDEAS 
PRODUCTS APPLICATIONS WHY CJC COMPANY VARNISH VRU 
Special Filter units for specific applications 
HPS 27/27 
High Pressure HDU 15/12 
Low volume 
HD HDU 15/25 
Heavy duty 
HDU 15/25 
by-pass 
HTO 2x27/108 
Heat transfer oil 
VRU – Varnish Removal Unit 
for gas and steam turbine oil 
GFU – Gear Flushing 
Unit for gear lube oil 
CLEAN OIL 
BRIGHT IDEAS 
PRODUCTS APPLICATIONS WHY CJC COMPANY VARNISH VRU 
Siemens Wind Energy – Brande 
 
• Siemens Bonus 600 – HDU 15/25 
• Siemens Bonus 1300 – HDU 27/27 
• SWT 2.3 - HDU 27/27 
• SWT 3.6 – HDU 27/54 
CLEAN OIL 
BRIGHT IDEAS 
VARNISH PRODUCTS APPLICATIONS WHY CJC VRU COMPANY 
CJC HDU Off-line Fine Filter HDU on Siemens Wind turbines 
Siemens Industrial Turbomachinery, 
Finspång 
 
• Siemens SST 500 – PTU3 27/108 GP – EPW 
• Siemens SST 700 - PTU3 2 x 27/108 GP - EPW 
• Siemens SST 800 - PTU3 2 x 27/108 GP - EPW 
• Siemens SGT 500 - HDU 27/108 
Siemens Industrial Turbomachinery, Finspång 
CJC Filter Separator PTU3 2x27/27 GP-EPW on Siemens SST 800 at CSP – Extresol, Spain 
12 
Thermal Power Plants 
CJC HDU 427/108 GP – EPT and PTU1 27/108 P - EPW 
Flushing a Steam Turbine at EDP Aboño 
C.C.JENSEN 
IBÉRICA, S.L. - 
14 
Hydro Power Plants 
CJC Fine Filter HDU 15/25 PV 
on hydraulic control of hydro turbine 
CJC Filter Separator PTU3 27/108 GP – EH1PW 
on hydro turbine lubrication 
Nuclear Power Plants 
CJC Filter Separator PTU3 5x27/108 N - EPWT 
on Steam Turbine at Nuclear Power Plant Vandellos 
C.C.JENSEN 
IBÉRICA, S.L. - 
19 
Combined Cycle Power Plants 
CJC Desorber D30 
on EHC – Electro hydraulic control with servo valves 
for control of GE D11 steam turbine at Gas Natural 
Aceca 
CJC VRU – Varnish Removal Unit 
on Siemens 501F Gas Turbine 
at Calpine Delta Energy Center, Pittsburg, CA 
www.cjc.dk 
Oil contamination – the mayor bearing failure root cause 
CLEAN OIL 
BRIGHT IDEAS 
VARNISH PRODUCTS APPLICATIONS WHY CJC VRU COMPANY 
© CC JENSEN A/S – IPS, Cannes- 20 -22th Feb 2013 
www.cjc.dk 
Premature bearing failure root cause – by SKF 
 
16 % Improper fitting 
 
36% Inadequate lubrication 
 
14% Lubricant contamination 
 
34% Abuse in service 
 
 
 
No gearbox survives without an adequate lubrication system 
in which it is essential to have the oil clean, dry and cold. 
 
CLEAN OIL 
BRIGHT IDEAS 
Oil contamination – the mayor bearing failure root cause 
VARNISH PRODUCTS APPLICATIONS WHY CJC VRU COMPANY 
© CC JENSEN A/S – IPS, Cannes- 20 -22th Feb 2013 
Oil contamination – OEM specifications 
 Double click on the MOOG manual, Pages 20. 
 
– Use a 3 to 5 micron low pressure filter in an off-line 
filtration loop. 
 
– Recirculate oil in reservoir more than 5 times per hour. 
This is justified on the bias that: 
 
(ii) It is neither practical nor economical to try to clean 
the oil with a small, relatively expensive, high pressure 
element. The cheaper, low pressure element is many 
times larger and has the potential to filter continually 
and under more ideal conditions. (Steady flow and 
lower velocities increase filtration efficiency.) 
CLEAN OIL 
BRIGHT IDEAS 
VARNISH PRODUCTS APPLICATIONS WHY CJC VRU COMPANY 
 Double click on the MOOG recommendation 
letter: 
 
MOOG recommends CJC to ensure maximum 
valve life time and to avoid down time due to oil 
contamination 
 
 
CLEAN OIL 
BRIGHT IDEAS 
Oil contamination– OEM recommendations 
VARNISH PRODUCTS APPLICATIONS WHY CJC VRU COMPANY 
www.cjc.dk 
Transmission (Convert energy) 
 
Lubrication (Reduce friction) 
 
Refrigeration (Transport heat) 
 
Dispersion (Transport contamination) 
 
Conservation (Prevent corrosion) 
CLEAN OIL 
BRIGHT IDEAS 
Oil contamination – deterioration of oil functions 
© CC JENSEN A/S – Power Presentation - 8th Feb 2013 
VARNISH PRODUCTS APPLICATIONS WHY CJC VRU COMPANY 
www.cjc.dk 
14 
micron 
6 micron 
4 
micron 
Resins, sludge and varnish Humidity - Water 
Solid particles 
Temperature C º 
CLEAN OIL 
BRIGHT IDEAS 
Oil contamination – Particles, Water, Varnish, etc. 
VARNISH PRODUCTS APPLICATIONS WHY CJC VRU COMPANY 
© CC JENSEN A/S – IPS, Cannes- 20 -22th Feb 2013 
www.cjc.dk 
VARNISH PRODUCTS APPLICATIONS WHY CJC VRU COMPANY 
© CC JENSEN A/S – IPS, Cannes- 20 -22th Feb 2013 
Oil degradation - Oxidation 
www.cjc.dk 
VARNISH PRODUCTS APPLICATIONS WHY CJC VRU COMPANY 
© CC JENSEN A/S – IPS, Cannes- 20 -22th Feb 2013 
Oil degradation - Oxidation 
www.cjc.dk 
VARNISH PRODUCTS APPLICATIONS WHY CJC VRU COMPANY 
© CC JENSEN A/S – IPS, Cannes- 20 -22th Feb 2013 
Oil degradation - Oxidation 
C 
H 
H 
H C 
H 
H 
+ O2 1/2 C 
H 
H 
H C 
H 
H 
OH + O2 C 
H 
H 
H C 
H 
O + H2O 
C 
H 
H 
H C 
H 
O + O2 1/2 C 
H 
H 
H C 
O 
OH 
+ C 
H 
H 
H C 
H 
H 
OH H2O + 
C 
H 
H 
H C 
O 
O C C 
H 
H 
H 
H 
H 
RESINE / SLUDGE / VARNISH 
Catalysts 
CLEAN OIL 
BRIGHT IDEAS Oil degradation - Oxidation 
VARNISH PRODUCTS APPLICATIONS WHY CJC VRU COMPANY 
www.cjc.dk 
CLEAN OIL 
BRIGHT IDEAS Oil oxidation – The anti oxidant mechanism 
VARNISH PRODUCTS APPLICATIONS WHY CJC VRU COMPANY 
© CC JENSEN A/S – IPS, Cannes- 20 -22th Feb 2013 
www.cjc.dk 
CLEAN OIL 
BRIGHT IDEAS 
© CC JENSEN A/S – Power Presentation - 8th Feb 2013 
Oil degradation process 
Oxidation Polymerization Solubility Precipitation Agglomeration 
Settling & Deposition of 
Varnish on system surfaces 
VARNISH PRODUCTS APPLICATIONS WHY CJC VRU COMPANY 
CLEAN OIL 
BRIGHT IDEAS 
Varnish 
VARNISH PRODUCTS APPLICATIONS WHY CJC VRU COMPANY 
CLEAN OIL 
BRIGHT IDEAS 
Varnish 
VARNISH PRODUCTS APPLICATIONS WHY CJC VRU COMPANY 
Varnish depositions on bearings and/or gears cause increase surface 
roughness, lead to “Sandpaper Effect” and poor lubrication film 
thickness / quality. 
 
Varnish sticking to servo-valves diminish their operation accuracy, lead 
to total failure and valve blockage. 
 
Heat exchanger covered by Varnish lose efficiency and cooling capacity. 
In-line oil filters are blocked and/or have to be changed very frequently. 
 
The oil itself looses its properties, antioxidant additives are depleted. 
Hydraulic control 
Turbine bearing Plate heat exchanger 
CLEAN OIL 
BRIGHT IDEAS 
Varnish 
VARNISH PRODUCTS APPLICATIONS WHY CJC VRU COMPANY 
Consequences: 
Wear of components, temperature 
increase, efficiency loss, high risk of 
failure of critical components such as 
servo –valves, which may lead to 
turbine trips and downtime. 
CLEAN OIL 
BRIGHT IDEAS 
VARNISH PRODUCTS APPLICATIONS WHY CJC VRU COMPANY 
Oil degradation products – How to monitor ? 
• Ultracentrifuge Test (UC) 
 
• Membrane Patch Colorimetric 
(MPC) /Varnish Rating (QSA) 
 
• RULER (ASTM D6971) 
 
• Gravimetric Analysis 
 
• Infrared Spectroscopy (FT-IR) 
 
• Rotating Pressure Vessel 
Oxidation Test (RPVOT) 
 
• Viscosity Test (indicator) 
 
• Acid number (indicator) 
VRU - Varnish Removal Unit 
Development, installations & field experiences 
CLEAN OIL 
BRIGHT IDEAS 
www.cjc.dk © CC JENSEN A/S – IPS, Cannes- 20 -22th Feb 2013 
VRU prototype on GE 6B gas turbine 
at Son Reus, Mallorca, Spain 
VRU 
HISTORY 
www.cjc.dk 
CLEAN OIL 
BRIGHT IDEAS 
VARNISH PRODUCTS APPLICATIONS WHY CJC VRU COMPANY 
Oil degradation process 
Oxidation Polymerization Solubility Precipitation Agglomeration 
Settling & Deposition of 
Varnish on system surfaces 
Precipitation Agglomeration 
Settling & Deposition of 
Varnish on system surfaces 
© CC JENSEN A/S – IPS, Cannes- 20 -22th Feb 2013 
VRU on Siemens gas turbine at combined cycle 
cogeneration power plant at Hillerød, Denmark 
SIEMENS gas turbine V 64.3 (53.9 MW) 
 
Oil type: Mobil DTE 832 
 
Oil volume: 9.800 l, since 31/5-2005 
Operational hours - 36.000 hrs. 
 
Reservoir oil temperature : 62 ˚C 
VRU on Siemens gas turbine at combined cycle 
cogeneration power plant at Göteborg Energi, Sweden 
VRU 
TODAY 
SIEMENS gas turbine SGT-800 (GTX100) 
Oil type: Shell Turbo CC 46 
Oil volume: 12.000 l 
Reservoir oil temperature : 72 ˚C 
Operation type: base load 
Remote dP control for on time filter insert change. 
The graph shows the increasing filter insert change 
interval for the first three filter inserts changes. 
55 
Calpine Delta Energy Center, Pittsburg, CA 
 
Siemens 501F Gas Turbine (185 MW) 
Oil volumen: 21.000 l 
Oil Type: Shell Turbo T 32 
Operating Temperature 
Reservoir oil temperature : 78 ˚C 
Operation type: base load 
Problem: 
Varnish on bearings surfaces and on heat 
exchanger, caused efficiency reduction of 
the overall turbine operation. 
Solution: 
VRU – Varnish Removal Unit, 
outdoor version 
Results: 
Immediate drop (inlet vs. outlet) from 
UC 6 to 1 
MPC 41 to 6 
VRU - Varnish Removal Unit on 
GE 9FA (250 MW) – 26.000 liters Shell Turbo CC 32 at 
Iberdrola Tarragona Power, (BASF), Tarragona, Spain 
The problem: 
High risk of turbine trips due to varnish. 
Oil analysis showed MPC of 62 ΔE indicating high 
varnish level caused by oil degradation. 
Conventional filter systems were not able to remove varnish as it is 
dissolved in the oil at operating temperature. At Tarragona Power 
several filters were used but none was able to remove varnish. 
Another filter system 
that did not work and 
had been disposed 
The Solution: 
VRU - Varnish Removal Unit 
Efficient varnish removal. The VRU first treats the oil, making the varnish precipitate 
and come out of solution to be then adsorbed by the cellulose fibers of the 
VRi - Varnish Removal insert 
67 
In one single pass the VRU removes 70% of the varnish in the oil. 
The Result: 
Within 3 month the MPC dropped from critically high 
value of 64 down to safe value of 19 ΔE 
 
VRi´s - after 5 days operation 
New VRi´s before use 
The Result: 
Within 3 month the MPC dropped from critically high value of 64 
ΔE down to a safe value of 19 ΔE 
M0 vs. M5 
after 1 month operating VRU 
A happy CJC guy 
An even happier 
VRU - Varnish Removal Unit on 
GE 6B (42MW) gas turbine – 6.500 litres Mobil DTE 832 at 
Iberdrola Energyworks Cartagena, (SABIC) Spain 
74 
The oil is lubricating turbine bearings, reduction gear and 
generator bearings. The same oil is also used for the hydraulic 
control incorporating servo valves. 
75 
Oil operating temperatures: 
Tank: 66ºC 
Thrust bearing: 66ºC 
Turbine bearing: 80ºC 
Gearbox: 85ºC 
Generator bearing: 64ºC 
76 
Plugged IGV inline filter 
causing turbine trips 
The Problem: 
High oil operating temperatures caused 
premature oil oxidation and formation of varnish 
resulting in: 
High MPC = 64 ∆E 
77 
The Solution: 
VRU – Varnish Removal Unit 
Outdoor version 
78 
VRU – Varnish Removal Unit 
Installed at Energyworks Cartagena 
79 
VRU – Varnish Removal Unit in operationTotally PLC controlled with integrated 
safety and alarm function 
80 
The result: 
VRi – Varnish Removal inserts 
after 5 days of VRU operation. 
The result: 
 
MPC membranes (0,45 μm) 
of samples taken during first month of 
VRU operation. 
 
Starting MPC: 55 ∆E 
After 1 month MPC: 15 ∆E 
Oil samples taken at the VRU 
inlet vs. outlet 
82 
The result: 
IGV inline filter 
before VRU operation vs. after 6 month VRU operation 
VRU - Varnish Removal Unit on 
GE 9FB (250 MW) – 17.000 liters Repsol Turbo CC 32 at 
Iberdrola Arcos de la Frontera, Cadiz, Spain 
At completion, this was the largest power plant ever built by 
Iberdrola as well as the largest combined cycle power plant in 
Spain. Block III was the launch plant for the GE 9001FB gas turbine. 
85 
The problem: 
MOOG servo valve sticking and mal function due to varnish 
The solution: 
CJC VRU – Varnish Removal Unit 
87 
VRU – Varnish Removal Unit in operation 
totally PLC controlled with integrated safety and alarm function 
The results: 
MPC reduction from 37 to 15 within 40 days 
VRU - Varnish Removal Unit on 
GE 6FA (75 MW) – 30.000 liters Repsol Turbo CC 32 at 
Endesa Granadilla, Tenerife, Spain 
Before installing the VRU - 
Granadilla tried 
unsuccessfully to remove 
varnish from the lube oil of 
TG3 using: 
• Hydac IXU, ion exchange 
filter (originally intended 
to use on phosphate ester 
oil of EHC - electro- 
hydraulic control systems) 
• Kleentek EOC, 
electrostatic filter 
Both systems failed and 
were not able to reduce 
and maintain the varnish 
below critical level MPC 20 
The CJC VRU does work ! 
92 
VRi – Varnish Removal Inserts 
The VRU works off-line 
The suction line shall be installed at the lowest possible point of the oil reservoir (drain valve) and the return 
line to the top of the reservoir on the opposite. The VRU is designed to work 24/7. For efficient varnish 
removal, it is important to operate the VRU during turbine operation with hot oil in order to extract oil with 
high concentration of dissolved varnish. The VRU shall also be operated when the turbine is off in order the 
remove contamination the may have deposit on the bottom of the tank. Thus the turbine will be started up 
on clean oil. 
HOW DOES 
VRU WORK 
The VRU does a non chemical oil treatment to make dissolved contaminants precipitate and come out of 
solution. It incorporates a 3 micron low flow multi-pass filtration, whereby the varnish is permanently 
(definitely) removed (adsorbed) by the VRi – Varnish Removal Insert. 
 
Simple and intelligent equipment control for totally safe and reliable operation. 
HOW DOES 
VRU WORK 
The VRi insert is made of superabsorbent sub-micron cellulose fibers with extreme affinity for varnish. 
Its design offers high filter media surface and volume. 
The VRi filtration is a non chemical process, with no impact on additives or chemical oil properties. 
 
Long term anti oxidative properties 
HOW DOES 
VRU WORK 
HOW DOES 
VRU WORK 
CLEAN OIL 
BRIGHT IDEAS 
www.cjc.dk 
 
Development, installations & field experiences 
© CC JENSEN A/S – IPS, Cannes- 20 -22th Feb 2013