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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 Majka
President of the Board, CEO
wojciech.majka@ecol.com.pl

Tomas Klima
Head of International Sales
tomas.klima@ecol.com.pl

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

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VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg

About us

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

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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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VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg

20 years of Ecol experience


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
15.-16.5.2012

VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg

Foam cleaning of turbines


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.

15.-16.5.2012

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

there are situations when normal


filtration (oil care) isnt enough to keep
proper cleanliness of oil and oil system !!

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VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg

Degradation and particle contamination?

source: Ecol, Siemens AG

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zdroj: Siemens
AG Turbines and Operation of Steam Turbines 2012 - Hamburg
VGB Conference
"Steam

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

The most critical is start-up during commissioning. Standard flushing might


not bring expected result in cleanlines class or time duration!!!
15.-16.5.2012

VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg

Do you have such experience?

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VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg

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Critical turbine components sensitive to


oil contamination
Bearings

Control system, hydraulic


pumps
Generator shaft seals

Transmission gearbox

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VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg

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We have solution

Do not alow your turbine


fail or stop!!

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.

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VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg

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Technology basics
high pressure water cleaning (up to 1500 Bar)

1.

to remove corrosion, sludge, Varnish, welding slug or conservants like Tectyl


minimal disassembly; cleaning of the entire oil system

high flow rate oil flushing of oil system

2.

external flushing skid; turbulent flow in pipeline


high efficiency full flow filters (size 3 m)

system prepared for easy start-up

=
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precise and honored schedule of flushing

VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg

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Step 1. Hydrodynamic cleaning - hydroblasting


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

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.

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Drying

VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg

Anticorrosive
turbine oil spray

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Hydrodynamic cleaning some photos

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VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg

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Hydroblasting results - examples

before

after
before

before

after
after

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VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg

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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

flushing is performed with new oil


and later used for operation
oil temperature is systematically
changed
flow is deliberately disrupted by
changing the sequence

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VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg

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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 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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VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg

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Flushing some photos

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VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg

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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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VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg

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SUMMARY

most effective technology comparing to other methods,


mostly recommended for:

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.

new assembled turbine oil system


old, dirty, overhauled oil system

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VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg

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Thank you for your attention!


Questions and discussion?
Ecol Sp. z o.o.

Please visit us at our stand

ul. Podmiejska 71A


PL 44-207 Rybnik
tel.: +48 32 739 1830
fax: +48 32 739 1829
email: biuro@ecol.com.pl

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VGB Conference "Steam Turbines and Operation of Steam Turbines 2012 - Hamburg