v18_majka_technology of hydrodynamic cleaning and high velocity oil flushing of turbo-machinery oil...

8/10/2019 V18_Majka_Technology of Hydrodynamic Cleaning and High Velocity Oil Flushing of Turbo-machinery Oil Systems

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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 MajkaPresident of the Board, CEO

[email protected]

Tomas KlimaHead of International Sales

[email protected]

VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg, May 2012 r.


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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 2


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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


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Core business - turbine technologies

advanced technology of hydrodynamic cleaning andhigh 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

15.-16.5.2012 4VGB Conference "Steam Turbines and Operation of Steam Turbines 2012- Hamburg


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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



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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


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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 !!



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Degradation and particle contamination?

15.-16.5.2012 8zdroj: Siemens AG

source: Ecol, Siemens AG



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Oil system condition

Standard conditions:

full flow filtration 540 m

water amount in the oil within limit ( 200 ppm)

pipeline materialcarbon/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!!!



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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



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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!!



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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 toloosen soft deposits (oil ageing products, sludge, resins, asphalts) and hard deposits

(corrosion, welding cinders).Hydroblasting

Drying

Anticorrosive

turbine oil spray



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Hydrodynamic cleaningsome photos



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Hydroblasting results - examples

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before

before

after

after

before

after



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Step 2. - High velocity oil flushing -

turbulent flushing

external flushing skid (capacity 8001200 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 bychanging the sequence



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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 velocitiesare measured using ultrasound flow rate meters ).

Oil cleanliness class in various locations of the system should be betterthan required by turbine manufacturer (e.g. 17/15/13 acc. to ISO 4406)(measurement of oil purity is done during the flushing process usingappropriate instruments, according to a predetermined schedule).Cleanliness requirements can be also set higher (upon specific customersrequirements).

No solid particles greater then 150 microns deposited on 100 meshstrainers installed in strategic locations in the system (inlets to frictionnodes lubricated elements). Other than 150 microns (smaller) sizes canalso be warranted if agreed.



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Flushingsome 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 toremove 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 future flushing process,

oil analyses results without misleading information,

Trouble free operation, start-up on time,

long-term oil system and oil purity, oil system will retain natural protective oxides layer on the inner walls of

the pipeline system,

reduced quantities of flushing oil batch in the process,

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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Thank you for your attention!

Questions and discussion?

Ecol Sp. z o.o.

ul. Podmiejska 71APL 44-207 Rybnik

tel.: +48 32 739 1830

fax: +48 32 739 1829

email: [email protected]

Please visit us at our stand

VGB C f "St T bi d O ti f St T bi 2012 H b

v18_majka_technology of hydrodynamic cleaning and high velocity oil flushing of turbo-machinery oil...

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