hydroblasting

lubrication excellence in powergeneration
Ecol Sp. z o.o.
Company presentation
Solutions for turbine oil systems
Wojciech Majka – CEO
Andrzej Grudzieo – Director for Services
Rybnik, 09.11.2015
Copyrights 1991-2015 Ecol Sp. z o.o. Distribution in any form beyond Centrenergo use - without
knowledge and permission of Ecol - is prohibited. 1 z 87
lubrication excellence in powergeneration
Ecol Sp. z o.o. of Rybnik, PL, is the largest european independent
specialist service company providing lubrication engineering
solutions supporting pro-active maintenance of poweplants.
Core business is focused on supplying unique service of cleaning
and flushing of oil systems in turbo-sets and big pumps, industrial
cleaning, supplying turbine oils and tribo-diagnostics & industial oil
service during pre-commisioning and operation of plants.
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General information
lubrication excellence in powergeneration
Date of establishment:
12.12.1991
Employees (June 2015)
220 including >40 engineers
Divisions:
Rybnik (headquaters + overhaul service workshops)
Rybnik (Division) – EDF Group Rybnik Power Plant Maintenenance Division
Płock (Division) - BasellOrlen Polyolefins Maintenance Division
Włocławek (Division) – PKN Orlen PTA Maintenance Division
Łagisza (Division) – PKE, Łagisza II (460 MW) Maintenance Division
Nowe Czarnowo – PGE GiEK SA ZEDO PP Maintenance Division
Lublin - PGE GiEK CHP Lublin Wrotków Maintenance Division
Gliwice – NGK Ceramics Polska – Maintenance Division
Affilates/Sales offices:
Czech Republic
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Certified integrated management system based on:
lubrication excellence in powergeneration
•
ISO 9001 (quality)
•
ISO 14001 (environment)
•
OHSAS 18001 (health and safety)
•
ISO 17025 (oil laboratory accreditation)
•
SCC Petrochemical (health and safety)
•
WHG Industrie Service (water consumption and waste management)
•
As sole in Poland (June 2015) -one of total c.a. 1200 persons in the world Ecol’s posesses CLS certificate (Certified Lubrication Specialist)
issued by STLE (Society of Tribologists and Lubrication Engineers)
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Important customers – OEMs, EPC’s , service companies, other industry
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Important International Refences (energy)
CEZ Nuclear PP Temelin (Czech Rep.)
CEZ Nuclear PP Dukovany (Czech Rep.)
CEZ Nuclear PP Bohunice (Slovakia)
Energoatom Nucelar PP Zaporozska (Ukraine)
Rosenergoatom Nuclear PP Balakovo (Russia)
Rosenergoatom Nuclear PP Kalininsk (Russia)
Energai CGGT PP (Lithuania)
Petrochemical Industry Company (Kuwejt)
CEZ Detmarovice PP (Czech Rep.)
CEZ Prunerov PP (Czech Rep.)
CEZ Ledvice PP (Czech Rep.)
CEZ Tusimice PP (Czech Rep.)
Kosovo A PP (Kosovo)
Tuzla PP (B-H)
El. Maritza III (Bulgaria)
Plzneńska Energetika (Czech Rep.)
Energertika Trinec (Czech Rep.)
Biocel Paskov (Czech Rep.)
WTE CHP Accera (Italy)
Odesky Priportovy Azot (Ukraine)
Nova Hut Ostrava (Czech Rep.)
Trinecke Żelezarny (Czech Rep.)(Czechy)
Delenii Gas St. (Rumunia)
Fettrafinerie Brake (Germany)
Vantaa PP (Finland)
lubrication excellence in powergeneration
Voest Alpine CHP (Austria)
Smurfit Kappa Herzberg (Germany)
Papierfabrik Hamburger (Austria)
OMV Burghausen Refinery (Germany)
Gardane PP (France)
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Range of activity
Specialist services addressed to new built/modernised PP
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Hydrodynamic cleaning and flushing of oil systems of
turbines and large equipment (e.g. boiler feed pumps)
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Lubrication commisioning of equipment (management,
execution, lubrication systems preparation for 1st start up)
•
•
Lubricants care (filtration, dehydration, handling)
•
specialized industrial cleaning for powerplants – ultra high pressure water
cleaning; chemical cleaning, vacuum cleaning (steam pipelines, boiler surfaces,
exchangers, other piping and equipmnent)
Lubricants supplies (turbine oils and other lubricants – turnkey
deliveries (filters etc.), waste collection)
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Overhaul and commisioning services
Ecol Sp. z o.o. offers service for overhauls of powerplants – in
operation and commisioning services for new-built blocks.
All large projects of commisioning of new turbines in utility
poweplants and CHPs in Poland and Czech have been serviced
with specialist cleaning and flushing service and key lubricants
supplies.
Hydrodynamic cleaning and high velocity oil flushing of turbine
oil systems (C&HVOF)
Over 600 turbo units have been serviced by Ecol since Year
1994 acc. to unique Ecol’s cleaning and high velocity oil flushing
technology.
C&HVOF Services are delivered to both, NEW-BUILT and
OVERHAULED power plants and chp’s.
Largest unit: 1000MW turbo-generator in nuclear power plant.
Experience of serviced
turbines, pumps and
compressors (major OEMs):
(graphics: Ecol)
Alstom Power, Siemens,
MAN Turbo, Doosan Skoda,
GE, Ansaldo, LMZ, Solar,
Nuovo Pignone, Thomasen,
Ekol Brno, CKD, Sulzer, KSB,
Voith Turbo, Ingersoll Rand,
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and many other OEMs and
components producers
Cleaning and flushing of oil systems – recent references for NEW blocks
Recent experience (2010+) at major NEW built power blocks – hydrodynamic cleaning
and flushing service )
• CEZ Nuclear PP Temelin 1000MW (DoosanSkoda turbine& turbopumps)
• CEZ Nuclear PP Dukovany 4x460MW (DoosanSkoda turbines& turbopumps)
• Bełchatów 858MW (AP turbogenerator, turbopump, electro-pumps)
• Łagisza 460MW (AP turbogenerator, turbopump, electro-pumps)
• Pątnów 480MW (AP turbogenerator, turbopump, electro-pumps)
• Vattenfall Heat Poland (Polimex-M., 4xSiemens 100MW turbogenerator)
• Tauron BielskoBiała CHP (Polimex-M., 1xSiemens TG)
• CEZ Ledvice PP 460MW (DoosanSkoda TG, turbopump)
• CEZ Tusimice PP 200MW (DoosanSkoda TG, turbopump)
• CEZ Prunerov PP 200MW (DoosanSkoda TG, turbopump)
• PKN Orlen Włocławek CHP (SNC – Lavalin, GE CGGT 460MW unit)
• PKN Orlen PTA 35MW MAN Turbo (PKN for Mitsubishi H-I, turbocompressor,
refinery)
• CHP Plana &CHP EC Rzeszów (Rolls-Royce gas engines).
Oil analysis laboratory and lubrication manintenance
advisory service and industrial lubrication at pre-commisioning
and operation phase
Ecol is a leading provider of oil analysis, tribo-advisory and consulting in Poland
On a daily basis Ecol lubricates and monitors thousands units of various
machinery, Including many turbogenerators (6 business units for lubrication
maintanance outsourcing for power and chemical plants in Poland).
Ecol is experienced in turnkey care of ousourced lubrication service during new
builds in power generation and refining (whole plant lubrication and lubrication
start-up)
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State of the art. oil laboratory (accredited ISO 17025)
Oil laboratory 24h/7d services
Specialist Industrial cleaning by hydroblast, vacuum and chemicals
Technology of hydrodynamic
cleaning and flushing of
oil systems in turbines
- key concepts
- discussion and clarification
Tomas Klima – OilDoc Conference 2013
Introduction to a problem of contaminated oil systems in turbomachinery
•
oil is a key component of the machinery
•
the need of appropriate oil care in turbines is commonly
recognized and accepted
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experts estimated that 82 percent of machine wear is particleinduced
•
however the purity of the oil system itself is underestimated
• system cleanliness after production and
assembly IS CRUCIAL issue for 1st start up and
might limit effective commisioning process.
(photos - Ecol)
Post production and post-assembly dirt accumulates and waits for
occasion to get released (rust, sand, welding products, grinding and
machining products, oils, greases, coatings, tools and other
unwellcome stuff)
Impurities stick to oil system elements and hide in dead zones. Vibrations, oil temperature
changes, flow distortions release them and they start to circulate in the oil system.
Pipelines
(especially return lines)
Oil tanks and reservoirs,
housings
Oil coolers
(schematics: Ecol)
Critical turbine typical components sensitive to oil contamination
Bearings
Control system,
hydraulic pumps, lift oil
Generator shaft seals
Transmission
gearbox
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How to clean the oil system?
mechanically - with brushes, ramrods
Ecol technology
by steam – blowing pipes with steam
hydroblasting – 100% mechanically using
by chemicals – pickling with acids
high pressure water to remove all kind of
deposits from the inner surface
by detergents – flushing with detergents
mixed with lube oil some days before
outage
No cleaning – standard flushing only
(by system pumps)
........... standard methods
turbulent oil flushing – high
developed flushing procedure
with external flushing
skid
(photos & schematics - Ecol)
ECOL Technology basics
1.
• high pressure water cleaning (up to 1500 Bar) – decontaminates the system
• to remove dust, corrosion, sludge, welding slag or conservants like Tectyl etc.
• minimal disassembly; cleaning of the entire oil system
2.
• high flow rate oil flushing of oil system – bringing fine cleanliness of the system
• external flushing skid; turbulent flow in pipelines
• high efficiency full flow filters (size 3 µm)
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• system prepared for safe&easy start-up and commissioning process
• precise and honored schedule of flushing end
ECOL’s technology is based on own experience, requirements
of OEMs, EPRI, ASTM and VGB reccommendations
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Step 1. Hydrodynamic cleaning hydroblasting
In this operation, high-pressure water is sprayed (jetted) onto inner system surfaces
to loosen soft deposits (oil ageing products, sludge, resins, asphalts) and hard
deposits (dust, corrosion, welding cinders, slag, temporary coatings).
Hydroblasting
Hydrodynamic cleaning consists of 4 operations:
• High-pressure water cleaning (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.
Drying
Anticorrosive
turbine oil
spray
Hydroblasting (water cleaning) is not water flushing. Piping is not fully
filled with water and is not circulated. Water hydroblasting is detaching
contaminants from surfaces and then evacuating them out to waste
collection tanks.
(schematics: Ecol)
Hydroblasting – in action
(photos - Ecol)
Hydroblasting results – example effects.
before
after
before
before
after
after
After hydroblasting on cleaned surfaces no attached contaminants remain.
Hydroblasting – waste water collection and
working nozzle princip
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Hydroblasting
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Hydroblasting
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Inspection after cleaning (visual, videoendoscopy)
Cleaning proces is properly
checked:
• Hydroblast plan
• Cleaning criteria (state of
surfaces)
• Inspection before and after
cleaning
• Scheduled ispection with
customer
• Documentation for customer
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Step 2. High Velocity Oil Flushing (turbulent
flushing). [24hrs/day proces]
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installing set of by-passes and flow distributors
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using external flushing skid
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control filters on each bearing and all servomotors
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oil stream filtered in full flow
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absolute fine full flow filters ß3 = 1000
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oil temperature and flow is systematically
changed
Contionous monitoring when HVOF is in progress:
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Flow rates and flow direction (USG, thermovision)
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Cleanliness class (ISO/NAS) by microscope and
automatic partilce counter
ISO 4406
12/9
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Contaminants size and shape
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Temperatures
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Sampling for future tests of oil
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Sample archive
(schematics: Ecol)
Flushing parameters and criteria
Effective flushing of turbo-set oil system is based on the following three
important criteria:
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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 ).
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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
customer’s requirements).
•
No solid particles greater then 150 microns in oil and deposited on steel strainers
installed in strategic locations in the system (inlets to friction nodes – lubricated
components)
Flushing is performed with operating oil (no flushing batch) – significant
savings of costs for avoided additional oil batch and its handling.
Special absolute PALL filter elements are used by Ecol for oil
flushing service
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By-pass& pipe conections for HVOF (example)
Detailed HVOF plan is
prepared:
• Logistics and feasibility
study for on-site works
• H&S plan – fire hazards,
environmental issues
• Quality measures
• Oil handling
• Flow directions
• Flow rates
• Flow & temp. control
• Control points (sampling)
High velocity oil flushing – some photos
(photos - Ecol)
HVOF, example flushing skid;
oil delivery and handling
Oil is delivered in appropriate quantity
and quality just in time. No need to long on-site
storeage and handling by cutomer.
All equipment is environmental and safety friendly.
Cisterns and tanks are low temperatures operartionsready (heated).
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By-pass ložisek a čerpadel
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Flushing connection acc. to flushing project
Upstream the
bearings, servomotors, seals etc.
additional
strainer filters
with steel sieves
and magnets are
installed. This is
also check point
for flushing
proces quality
and sampling
point.
Flushing connection acc. to flushing project
Flushing skids
Ecol posesses variuos flushing skids
with pumps of different kind and flow
rate/pressure and compatible filters
Temporary HVOF connections
Temporary HVOF connections
Temporary HVOF connections
Big attention is paid on
surface&area protection
against oil spills and safety.
All connections are checked
and sampling places are
additionallly equiped with
catch-plates.
On-site oil cleanliness class and water content measure
Turbulent Oil Flushing process runs until the required cleanliness creteria of
oil is reached (ISO/NAS code + particles size/distribution)
.
After
HVOF oil sample for full-oil analysis is taken. Oil is removed from the
system for disassemblies and ultimate turbine set-up.
Step 3. Off-line fine 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
assemblies after flushing).
After final filtration oil sample for full-oil analysis is taken. Oil remains for 1st start up
and for future operation.
(photos & schematics - Ecol)
Project management at Ecol
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Based on PRINCE method elements
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Project leader, manager and site management highly experienced in power plant
commisioning projects
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Turn-key project available (service+oil supply+condition monitoring after service)
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No subcontractors hired by Ecol – optimal quality and responsibility
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Full support within Ecol organisation (e.g. oil delivery, oil lab., engineering)
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Full English documented and spoken projects
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Experience with all major OEM wo
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Known to investors (Power Plants). Fits for future cooperation in operation of PP.
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Insurence for responsibility for €2.2 mln. in HVOF business.
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SUMMARY
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100% of engineering, staff, equipment & oil handling =>> Ecol =>> no investment for customer.
Clear responsibility and warranty.
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outstanding quality and expertise by Ecol professionals (over 600 cleaned turbines)
most effective technology comparing to other methods,
mostly recommended for:
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new assembled turbine oil systems (also for other large oil systems)
–
old, dirty, overhauled oil systems
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fully schedualable – multi-stage proces possible to transparent management and verify. KPIs&milestones applied,
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reduced quantities of flushing oil batch in the process,
hydroblasting EFFECTIVELY shortens future flushing process,
hydroblasting eliminates risk of damage of oil – therefore no additional oil batch for flushing is required
process independent on other contractors on-site and not stopping other works,
no need for automation readiness (system pumps steering; power supply) since external flushing skid is used,
the only way of achieving truly turbulent flows in whole cirquit of oil system thanks to special high capacity flushing skids
oil analyses results without misleading information,
trouble free operation, start-up on time (NO EFFECT OF DEAD ZONES SECONDARY CONTAMINATION),
long-term oil system and oil purity,
oil system will retain natural protective oxides layer on the inner walls of the pipeline system. No pickling and passivation required (if
carbon steel used),
reduced wear of lubricated parts and extended MTBR,
significant increase in oil durability (reduced quantities of replacement oil),
higher equipment availability,
significant reduction of filter inserts consumption in maintenance,
no turbine outages due to dirt in the oil system , reduced total operation cost.
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lubrication excellence in powergeneration
Thank you for your attention!
Ecol Sp. z o.o. - Headquaters
Podmiejska 71 A
44 207 Rybnik, Poland
Tel.: +48 32 739 18 30
Fax: +48 32 739 18 29
E-Mail: [email protected]
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