V18 - Majka - Technology of Hydrodynamic Cleaning and High Velocity Oil Flushing of Turbo-Machinery Oil Systems

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
15.-16.5.2012
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
15.-16.5.2012
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
15.-16.5.2012
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
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
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 !!
15.-16.5.2012
Degradation and particle contamination?
source: Ecol, Siemens AG
15.-16.5.2012
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
Do you have such experience?
15.-16.5.2012
10
Critical turbine components sensitive to

oil contamination
Bearings
Control system, hydraulic

pumps
Generator shaft seals
Transmission gearbox
15.-16.5.2012
11
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.
15.-16.5.2012
12
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
=
15.-16.5.2012
precise and honored schedule of flushing
13
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.
15.-16.5.2012
Drying
Anticorrosive
turbine oil spray
14
Hydrodynamic cleaning some photos
15.-16.5.2012
15
Hydroblasting results - examples
before
after
before
before
after
after
15.-16.5.2012
16
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
15.-16.5.2012
17
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.
15.-16.5.2012
18
Flushing some photos
15.-16.5.2012
19
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).
15.-16.5.2012
20
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
15.-16.5.2012
21
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
15.-16.5.2012
22

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

2. Problem of contaminated oil systems in turbines

5. Selected case studies

Ecol Sp. z o.o. is based in Rybnik, Poland

hydrodynamic cleaning and flushing of oil systems

industrial lubrication management and maintenance

dust removing and vacuum cleaning

Core business - turbine technologies

our references range from size TG 1,5 MW up to TG 1000 MW

20 years of Ecol experience

Foam cleaning of turbines

Aquiex Hyrdochem of USA, deliverying chemical foam cleaning

Introduction to problem of contaminated oil

oil is considered as a key component of the machinery

tribology societies estimated that 82% of machine wear

VARNISH is nowadays well recognized problem

even small particles may cause damages od lubricated

there are situations when normal

Degradation and particle contamination?

source: Ecol, Siemens AG

Oil system condition

full flow filtration 5 40 m

All that above doesnt stop :

oil degradation or Varnish formation

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

Do you have such experience?

Critical turbine components sensitive to

Control system, hydraulic

Do not alow your turbine

Sludge presence in the oil system or varnish on machinery surfaces? Inaccurate

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

high flow rate oil flushing of oil system

external flushing skid; turbulent flow in pipeline

system prepared for easy start-up

precise and honored schedule of flushing

Step 1. Hydrodynamic cleaning - hydroblasting

Hydrodynamic cleaning consists of 4 operations:

High-pressure water spraying (up to 150 MPa)

Hydrodynamic cleaning some photos

Hydroblasting results - examples

Step 2. - High velocity oil flushing turbulent flushing

external flushing skid (capacity 800 1200 m3/h)

flushing is performed with new oil

Flushing parameters and criteria

Flow rates at all pipeline sections should be sufficient to invoke turbulence

Oil cleanliness class in various locations of the system should be better

No solid particles greater then 150 microns deposited on 100 mesh

Flushing some photos

Step 3. Offline filtration (post assembly)

most effective technology comparing to other methods,

hydroblasting shortens future flushing process,

new assembled turbine oil system

Thank you for your attention!

Please visit us at our stand

ul. Podmiejska 71A

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