Prezentace aplikace PowerPoint
Technology of hydrodynamic cleaning and
high velocity oil flushing of turbo-machinery
oil systems as a repair tool for power plants
review and practical applications
Wojciech Majka President of the Board, CEO
[email protected]
Tomas Klima Head of International Sales [email protected]
VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg, May 2012 r.
Overview
1. Introduction to Ecol company
2. Problem of contaminated oil systems in turbines
3. Cleaning and flushing - technology description
4. Photos from jobs execution
5. Selected case studies
6. Summary
15.-16.5.2012 VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg
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About us
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Ecol Sp. z o.o. is based in Rybnik, Poland established in 12.12.1991 current number of employees - 175 4 individual divisions located on customer site our subsidiaries:
Czech Republic
Ukraine
Kuwait (agency only)
Main activity :
hydrodynamic cleaning and flushing of oil systems
turbine foam cleaning for removing blading deposits
industrial lubrication management and maintenance
ultra high-pressure water cleaning (3000 bar)
dust removing and vacuum cleaning
VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg
Core business - turbine technologies
advanced technology of hydrodynamic cleaning and high velocity oil flushing of turbine oil systems
suitable either for old turbines or new build turbines
Experiences with:
turbogenerators, turbopumps, turboblowers, turbocompressors, etc.
emergency diesel engines in nuclear pp.; bio-gas engines
huge hydraulic systems in steel mills etc.
our references range from size TG 1,5 MW up to TG 1000 MW
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20 years of Ecol experience
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Over 450 turbo units have been serviced by Ecol
since Year 1994 acc. to presented technology.
Largest unit: 1000MW turbo-generator in
nuclear power plant.
Turbines serviced: Alstom Power, Siemens, Ansaldo, Skoda Power, Solar, Nuovo Pignone, MAN Turbo, Ekol Brno, CKD, LMZ, GE, Sulzer, KSB, Voith Turbo and many other OEMs and components producers
VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg
Foam cleaning of turbines
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Ecol since 2011 is the sole representative and service company of
Aquiex Hyrdochem of USA, deliverying chemical foam cleaning
technology in order to remove carious deposits from turbine steam
path without opening the casings.
VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg
Introduction to problem of contaminated oil system in turbomachinery
oil is considered as a key component of the machinery
tribology societies estimated that 82% of machine wear is particle induced
VARNISH is nowadays well recognized problem
even small particles may cause damages od lubricated components
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there are situations when normal filtration (oil care) isnt enough to keep proper cleanliness of oil and oil system !!
VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg
Degradation and particle contamination?
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source: Ecol, Siemens AG
VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg
Oil system condition
Standard conditions:
full flow filtration 5 40 m
water amount in the oil within limit ( 200 ppm)
pipeline material carbon/stainless steel
controlled oil properties by performing oil analyses
All that above doesnt stop :
- oil degradation or Varnish formation
- pipeline or other elements corrosion
- dirt entering during overhauls, revisions or modernizations
- the oil system is less or more contaminated and oil filtration has limits
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The most critical is start-up during commissioning. Standard flushing might not bring expected result in cleanlines class or time duration!!!
VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg
Do you have such experience?
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Critical turbine components sensitive to oil contamination
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Bearings
Control system, hydraulic pumps
Generator shaft seals
Transmission gearbox
VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg
We have solution
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Sludge presence in the oil system or varnish on machinery surfaces? Inaccurate function of hydraulic/control system? Troubles during turbine start-up? When this happens, the oil system require thorough cleaning and high flow rate oil flushing.
Do not alow your turbine fail or stop!!
VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg
Technology basics
1.
high pressure water cleaning (up to 1500 Bar) to remove corrosion, sludge, Varnish, welding slug or conservants like Tectyl
minimal disassembly; cleaning of the entire oil system
2.
high flow rate oil flushing of oil system external flushing skid; turbulent flow in pipeline
high efficiency full flow filters (size 3 m)
= system prepared for easy start-up precise and honored schedule of flushing
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Step 1. Hydrodynamic cleaning - hydroblasting
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Hydrodynamic cleaning consists of 4 operations:
High-pressure water spraying (up to 150 MPa)
(hydroblasting) of internal surfaces of
pipelines with flexible lances and nozzles,
Drying with compressed and filtered air,
Anticorrosive protection of cleaned surfaces,
Protection of stub pipes and openings against
secondary contaminants.
In this operation, high-pressure water is sprayed onto inner system surfaces to loosen soft deposits (oil ageing products, sludge, resins, asphalts) and hard deposits (corrosion, welding cinders).
Hydroblasting
Drying
Anticorrosive turbine oil spray
VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg
Hydrodynamic cleaning some photos
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Hydroblasting results - examples
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before
before
after
after
before
after
VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg
Step 2. - High velocity oil flushing - turbulent flushing
external flushing skid (capacity 800 1200 m3/h) full flow 3 m filters with high efficiency =1000 by-pass of bearings, servo-motors, system pumps variety of flushing hoses, manifolds, flow distributors control filters on strategic places
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flushing is performed with new oil and later used for operation
oil temperature is systematically changed
flow is deliberately disrupted by changing the sequence
VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg
Flushing parameters and criteria
Effective flushing of turbo-set oil system is based on the following three important criteria: Flow rates at all pipeline sections should be sufficient to invoke turbulence
(Reynolds number for the pipeline Re>4000) (in-pipeline flow velocities are measured using ultrasound flow rate meters ).
Oil cleanliness class in various locations of the system should be better than required by turbine manufacturer (e.g. 17/15/13 acc. to ISO 4406) (measurement of oil purity is done during the flushing process using appropriate instruments, according to a predetermined schedule). Cleanliness requirements can be also set higher (upon specific customers requirements).
No solid particles greater then 150 microns deposited on 100 mesh
strainers installed in strategic locations in the system (inlets to friction nodes lubricated elements). Other than 150 microns (smaller) sizes can also be warranted if agreed.
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Flushing some photos
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Step 3. Offline filtration (post assembly)
Off-line oil re-filtration in the reservoire during oil system start-up is done in order to remove post-assembly contaminants (introduced during overhaul after flushing).
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SUMMARY most effective technology comparing to other methods, mostly recommended for:
new assembled turbine oil system old, dirty, overhauled oil system
hydroblasting shortens fut
