HYDAC’s integrated fluid management and condition monitoring solutions for coal-fired power generation
Advanced fluid management for reliable coal‑power operations
HYDAC boosts coal‑power reliability with integrated fluid management, filtration, and condition monitoring for safer, more efficient plant operation.
A systems-based approach to power plant optimisation
Coal-fired power generation demands high system reliability, operational efficiency, and effective lifecycle cost management. HYDAC, a global specialist in fluid power solutions, offers an integrated portfolio tailored to the specific challenges of power plant operations—particularly those involving hydraulic, lubrication, and cooling systems.
When HYDAC approaches a coal power plant—or any power station—our objective is to deliver holistic, system-level solutions that improve safety, efficiency, and long-term sustainability, says HYDAC South Africa Technical Sales Support Duncan Angove.
This begins at the design phase, where HYDAC incorporates advanced system monitoring and filtration technologies to optimise reliability from the outset.
By leveraging condition monitoring and high-performance fluid care systems, HYDAC supports continuous operational excellence in both legacy infrastructure and new-build facilities.
Filtration and oil cleanliness: the foundation of system longevity
HYDAC’s filtration solutions remain central to its offering, designed to extend component life and reduce maintenance intervals.
Power plants reliant on critical hydraulic and lubrication systems benefit significantly from robust filtration solutions such as the RFLD, explains Duncan. Its primary advantage lies in the dual-filter design, which enables uninterrupted operation, even during filter replacement or maintenance, eliminating costly downtime. These filters are equipped with contamination sensors to ensure real-time fluid cleanliness, critical in preventing premature wear or catastrophic failure of turbines and auxiliary equipment.
South Africa's public electricity utility frequently engages HYDAC for its RFLD range, recognising its effectiveness in managing contamination loads efficiently.
Stat-free and STAT-X technology: eliminating electrostatic discharge
Oil degradation due to electrostatic discharge is a persistent problem in high-flow systems, Duncan notes.
HYDAC addresses this with its stat-free and STAT-X filter media technology elements—a proprietary solution that suppresses electrostatic charges within the filtration medium. This not only improves fluid integrity but also extends the service life of filters and system components, ultimately reducing the total cost of ownership.
Water contamination: detection, removal, and prevention
Water ingress remains one of the most destructive contaminants in lubrication systems, dramatically reducing oil effectiveness and accelerating corrosion and wear.
To address this challenge, HYDAC offers the FAM (Fluid Aqua Mobil). The latest Fluid Aqua Mobil 3000 series employs vacuum dewatering technology to effectively extract both free and dissolved water, as well as gases, from hydraulic and lubrication fluids.
This advanced range of dewatering units is available for both purchase and rental. By efficiently removing moisture and other contaminants, these systems often eliminate the need for complete oil replacement.
Using a FAM rental unit to remove water is far more cost-effective than oil disposal and replacement, especially for large-volume reservoirs common in power plants, says Duncan.
Condition monitoring and predictive diagnostics
HYDAC’s condition monitoring systems provide plant operators with detailed insights into system health, supporting proactive maintenance and reducing unplanned downtime. Key technologies include:
HYDAC South Africa's Laboratory
A compact multi-sensor module for online monitoring of contamination, temperature, and water saturation. It integrates seamlessly with PLC systems for comprehensive data management.
BIS (bladder information system)
A smart sensor mounted atop accumulators to monitor internal pressure and detect leaks or safety-critical failures.
Aqua sensors
Real-time monitoring solutions for water content are also available. “All sensor data can be integrated with a PLC, enabling real-time data analysis, trend monitoring, and system evaluation,” adds Duncan.
Thermal management: cooling system expertise
HYDAC also delivers tailored cooling system solutions—crucial for maintaining the thermal stability of oil and system components. These include:
- ACLN air coolers, including the AC-LN 1–14 series, designed for applications where oil or water-glycol must be cooled using air. These units feature axial fans and can be installed in both return and bypass flow circuits. A wide range of accessories and optional configurations allows flexible integration into diverse system requirements.
- Plate heat exchangers, including models from FUNKE, known for reliability and efficiency in public utility environments. These systems are engineered to support high-load operations and integrate easily into existing plant infrastructure.
Accumulator safety and monitoring
For hydraulic energy storage and pressure compensation, HYDAC supplies bladder-type accumulators, valued for their reliability under variable load conditions.
The BIS sensor system enhances these units by providing real-time leak detection and safety status—particularly important in high-pressure turbine control circuits.
Precision valves for turbine and safety functions
Turbine systems demand high-precision fluid control. HYDAC’s directional control and safety valves are engineered to deliver fast, accurate actuation of turbine doors and other critical elements. These valves ensure both safety compliance and long-term operational stability.
Sustainability and lifecycle cost efficiency
The new SN range of filters reflects HYDAC’s commitment to sustainable engineering,
says Duncan.
These eco-friendly filter elements offer extended service life, reduced resource consumption, and a lower CO₂ footprint. Incorporating Stat-Free technology as standard, they also reduce differential pressure by up to 30%. Their high dirt-holding capacity frequently results in fewer replacements compared to competitor products.
As a result, power plants benefit from lower filter consumption, reduced downtime, and substantial cost savings over time.
Conclusion: a total solution partner for power plants
From filtration and fluid conditioning to intelligent diagnostics and predictive maintenance, HYDAC delivers a complete system solution for coal-fired and conventional power stations.
In South Africa and globally, HYDAC is increasingly being approached directly by plant operators seeking advanced reliability, reduced operating costs, and sustainable system performance, Duncan concludes.
