FOR POWER PLANT MAINTENANCE

(Repair for equipments and various parts, summary of POWER PLANT MAINTENANCE )
1. Shell & tube type HEAT EXCHANGER
General method

NEW METHOD (Chemical cleaning)

Open shell cover

Connect chemical circulation line

Cleaning tubes by drilling, high press water wash, hydrofracturing

Apply chemical(repeat circulation & holdup) for scale dissolution

Close shell cover

After chemical cleaning, rinse with fresh water

Drilling

Chemical flow in TUBE SIDE

Water jet

Chemical flow in SHELL SIDE

Air Vent

hydrofracturing

Chemical
circulation
line

Pump
Chemical
Tank

1) CCW (Cross Cooling Water Exchanger)

This equipment is to decrease water temperature which it used as cooling fresh water and it flows the sea water to reduce the shell side temperature
through tube side to shell side. Under processing lots of sea shell, oyster shells and larva cling are grow up in the tube inside wall and with tube
clogging. So it must remove all to free from sea biota. The tube outer wall of shell side is formed film scale by Hydrazine(N2H4) and it do deteriorate the
heat exchanger capacity. To increase effect of heat exchanger, It must remove the all scale in the shell side and tube side.
* Application example 1. (CCW of BORYEONG thermal power plant in Korea)
Details : Cooler for main cooling fresh water, Cooling fresh water flow shell side and cooling sea water flow tube side. (tube material is copper) shell
side scale cleaning is never have been before and tube side scale cleaning takes time 3 weeks by using drilling.
Using new method only takes 4 days of working time to clean both shell side and tube side.
Reduce cleaning time.(Capacity 30ton, number of tubes 4,000EA)
Methods
Small CCW(Capacity 1ton) : ST-407S(50% Solution) chemical circulation for shell & tube side takes 6hrs and rinse by fresh water.

[Before TUBE SIDE]

[After TUBE SIDE]

Large CCW (Capacity 30ton) : ST-407S(50% Solution), chemical circulation for shell side takes 48hrs, tube side takes 48hrs.
* The large equipment takes longer time to clean, the actual circulation has little effect.

-1) Application equipment

C.W Exchangers

Sea water scales in tube side

(shells, oyster larvae)

Sea water inlet & outlet

Plugged tubes.
Physical cleaning(drilling) cause leakage
in tube.

-2) Sample Test (shells, oyster larvae dissolution test)

40, 60min

Before: 2.90g
After: completely
dissolved

50, 60min

Before 4.87g
After: completely
dissolved

40, 90min

50, 90min

Before 1.59g

Before 1.59g

Barnacle shell(Ca) is
completely dissolved but
only flesh remain.

Oyster larvae (ST-407S, 50%)

After 0.03g

After 0.02g

Barnacle (ST-407S, 50% )

-3) Application method

i) Diagram of CCW chemical circulation cleaning

First, shell side

(Cooling Water side clean)
Second, tube side
(Sea water side clean)

ii) Preparation and performed

Chemical preparation, tool box meeting

Dilution, Circulation, Steam heating

Chemical circulation cleaning

-4) Before and after

i) Outside tube (Shell side)

Before cleaning
(Film scale cause of coolant additives)

After cleaning

ii) Inside tube (Tube side)

Various kinds of sea scales in tube channel

** Remark : ST-407 (15% solution) solution can replace ST-407S

After cleaning

2) Condenser
This is an equipment to exchange from used steam for turbine operating to water with condensation. It material made from Titanium for
seawater and stainless steel for fresh water. The scale formed on the inner wall of the tube makes decreases heat transfer efficiency,
To maintain the efficiency clean the tubes periodically. But scale removal takes a lot of cost and time because the scale is various ingredients
buildup with high heat. The time of this equipments maintenance takes is affect on the time it takes the entire power plant maintenance. * *
* General size of condenser

Related equipments

- Total capacity : 70~150ton

- Tube length : Within 10m
- Number of tube : 6,000 ~15,000 EA

Condenser

Desalination (MED Process)

Evaporator

2-1) General method

High press water jet : Each pipes cleaning with high press water wash
* Problems 1) Require a lot of time to work.
2) The surface on the soft scale can be removed but cannot
be removed the strongly adhered scale.

After cleaning

Before cleaning

Scale diagram

Hydrofracturing : Inserting the high-pressure water spray nozzle to remove the scale.
* Problems 1) Require a lot of time to work.
2) Require expensive equipment and highly skilled worker.
3) It is very difficult to do cleaning work on site, Move the equipment to work place.
4) Impossible to remove the scale perfectly.

Hydrofracturing diagram

Drilling : Drilling each pipes.

* Problems 1) Require a lot of time to work.
2) Impossible to use long pipes..

[6]

2-2) New method (Shorten the maintenance time)

Small condenser : Circulation chemical until dissolve the scale completely.
Large condenser : To prevent to overdoes the chemical, Chemical cleaning with minimal amount and after chemical treatment washed out
scale by high press water jet over 1000bar.
[Application suggest 1.]
i) Accessory : To prevent overdoes the chemical attach below device(red line) to condenser.
Air vent

Chemical
inlet
Heater
(steam pipe)

Chemical
tub

Chemical
outlet

** Use a device made of steel or aluminum designed to fit into the condenser can be assembled by bolts, nuts. The device has chemical inlet, outlet
and air vent for emission gas.
ii) Application procedure
a. Attach the save chemical device.(assembly)
b. Input chemical into upper chemical inlet line. (Chemical must be slowly inject due to scale melting gas emission)
c. Use lower drain line discharge chemical into chemical tub.
- Repeat b, c depending on site conditions.(Chemical cleaning 3~5 days, high pressure water jet 3~5 days)
- Increasing the higher chemical temperature can save chemical dosage amount. (Higher temperature increases chemical scale solubility)
- Chemical : ST-407 (5~15%)
- Chemical temperature : 60 ~ 80

[Application suggest 2.]

To save dosage of chemical use below pictures device. Connect each condenser tube with tube connecter and hose to melt scale.
After melt down the scale use high press water jet to remove remaining.
O-ring

Tube 10mm fitter

Tank

Pump
Chemical circulation each tubes

i) Application : Indonesia power

* Use chemical make scale solubility and
wipe out scale by high press water jet spray

[ Condenser tube side]

ii) Application device : Connect chemical circulation hose to each tubes(ST-407, 10%
solution 3 times exchange, chemical temperature 50) high press water jet

[ Front]

[ Rear ]

[ After high press water jet]

2. Pin tube (Heat exchanger)

Pin tube type heat exchanger for power plant is mainly used to increase the temperature of the air supply in the fuel combustion process.
Aluminum oxide film and air dust deposited on pin tube decrease heat transfer efficiency is degraded whole power plant efficiency. Oxide film
and deposited material should be removed periodically, but most of cleaning company do not have appropriate cleaning chemical only remove
dust.
** Pin tube heat exchanger cleaning process

Pin side

Before

Tube side

Water wash(Existing method)

After chemical cleaning

** Application examples 1. Listrindo(Indonesia) Gas, coal Power Plant AFC (Air Fan Cooler)
Application method: Spray the chemical (RR-101B, 30%) and prepare vinyl at the bottom of AFC to correct chemical drain for circulation.

Picture of AFC

AFC

Prepare vinyl or tarpaulin cloth at the

bottom of unit to circulation of chemical

AFC cleaning

Before

After

After (close up)

** Application examples 2. PLN(Indonesia) Gas, diesel Power Plant AFC (Air Fan Cooler)

Picture of AFC

Chemical Application Test

Bottom of device

Close up

3. PHE (Plate type Heat Exchanger)

[New method]

Total Cost saving by chemical circulation

[General method]

Connecting
pump

Disassemble

Maintain maximum efficiency of machineries

- Saving energy cost

Chemical input

Maximize Heat Exchanger life cycle

Dipping 30 min
into inhibitor
remover

- Minimize the metal damage

Brushing

Saving cost & time for disassembling &

Circulating

reassembling

Drying and
rubber gasket
reassembling

Rinse

Assembling

Heat exchanger

Chemical bath
PUMP

Test operation

Problems of current method

Be shorten Heat exchanger life by Acid chemicals cleaning
Brushing causes the mechanical damage and requires additional labor cost
Damaged rubber gasket must be replaced additional cost and working time.

** Application examples 1. (PLN)-(Indonesia)

- Suggest method : ST-407(15% Solution), 8~12hr Circulation.
- Below pictures plate HE total capacity : 1.5ton/ea
- Remarks : Suggested chemical cleaning method is Circulation Hold up Reverse circulation due to scale clogged between plate to plate.

Target heat exchanger

Cleaning two devices at one time

Chemical Bath

After cleaning

** Application examples 2. Steel company(BNG Steel ) Rolling oil cooler

Picture of
Cooling water side scale
& Rolling oil side scale

Target
heat
exchanger

After cleaning both side

are perfectly clean up

Connect
chemical
circulation hose
MSR-100, 50, 5hr

ST-100L, 50, 5hr

** Each Scale Each Solution

Water based scale, Water slime, (Plate : SUS)

Mud, Seawater based scale (Plate: Titanium)

Carbonized oil/lubricant sludge (Plate: Titanium)

Phosphate coating process scale (Plate : SUS)

4. Chlorination
: By using electric power with generating chlorine to use cooling water which It will be used to remove sea shell and oyster shells and the
inner side is titanium material.
i) General method : Disassemble each unit and removing the scale at electrode by hand.
ii) Suggest method : ST-407 15% solution, for 8~12hr circulation.
iii) Below pictures chlorination total capacity : The quantity of chemical circulation (water+chemical) : about 7ton(1,850 gallon)
iv) Remarks : It occur much of air bubble in processing the chemical and scale reaction and because of air bubble if the chemical and scale do
not contact fully, the scale may not dissolve easily. So please remove the air bubble by circulation and reverse circulation processing repeatedly.
** Application examples : PLN - Indonesia

5. CPP Filter (Tae-an power plant) -Korea

: This filter is using to remove impurity materials in the boiler water.
General method : Disassemble Hydrochloric acid treatment Ultrasonic wave Brushing Re-assemble(Maintenance time takes 30days)
Suggest method : MSR-100 30%, normal temperature, for 4hr circulation

Filter bundle

Filter Element

Filter bundle close up

[Methane ]

Before Filter Element

MSR-100
Picture of reverse cleaning

After Filter Element

6. For remove grease from new turbine blade (Boryeong power plant)
** After manufacturing the turbine, it use rust inhibitor(or grease) on the turbine surface and before installation the turbine, the rust inhibitor
would be remove by using incombustible chemical(M.C) but this is poisonous and contained carcinogenic agent. So it can substitute water
soluble chemical as below.
** Suggest method : Mclean-100 30% solution spraying (10~30minute staying) High pressure water washing Drying

Chemical spray

High pressure water wash

7. Remove copper oxide of various heat exchanger

* Application examples : Inter Cooler cleaning (PLTD - Indonesia)
- Suggest method : MSR-100, 30% Solution, 40
- Pin side : Dipping into chemical - Water wash
- Tube side : Circulate chemical - Circulate water

Before Inter Cooler (Pin)

After Inter Cooler cleaning

Before (tube side)

After

Dipping into chemical

After dipping, water wash

Chemical circulation

Bath for chemical circulation

8. Remove rust and scale of various heat exchanger

: Generally using acid basis chemical or wire brush or sand blaster to remove rust or scale. But working condition is very bad and productivity
decreased.
1) Small parts enough to dipping
* Suggest method
i) Chemical : RR-101B 30% solution
ii) Temperature : Room temperature ~ 50
iii) Procedure : Dipping Water wash Drying
* If the temperature of washing water 80, it may dry
naturally when it pull out.
* To increase the productivity it need big size bath for
one batch dipping.

2) For small size parts fouled lightly

: It use the RR-101B 100% making wet to fabric and scour rust and then do wash it with water or alcohol.

3) Wide area parts with allowing water wet(No have electric wire)
i) It use the RR-101B 100% by spraying evenly on the surface of parts.
ii) Do high pressure water wash 10~30 minute lately
iii) Dry naturally or with high pressure air wind

4) Wide area parts but not allowed water wet (it have electric wire)
i) Cover with highly hygroscopic fabric on the parts surface.
ii) Do spay the RR-101B 100% on the fabric enough.
** Incase thick rust and scale, if need to remove rapidly with raise up reaction time, you can use high temperature air wind or steam to reduce
the processing time.
iii) Take off the fabric and scour with watered fabric or alcohol.

5) Thin inner diameter pipes inside : chemical circulation (Yeong kwang Nuclear power plant)
i) Chemical : Iron oxide scale : RR-101B 30% Solution
: Seawater based scale, Calcium(Ca) based scale : ST-407 15% Solution
: Silica(SiO2) based scale : ST-205 30% Solution
ii) Temperature : Room temperature ~60
iii) Application : Do connect with flange and chemical circulation for 30 min to 4 hours and then water washing.

9. Cooling tower (Listrindo-Indonesia)

** Chemical spray to remove the scale deposited on cooling tower filler surface. (Without disassemble or replace )
** Suggest method : ST-407, 20% Solution Spray & circulate Water wash

Cooling tower diagram

Cooling tower filler

Before

After

10. Dust collect filter

: This filter are using for gas, coal and diesel fuel power plant and there are kinds of ash filter and imperfect combustion carbon filter. Standard
type is 20cm diameter with cylindrical shape and many of air mesh made from fiber materials.
The collected ash and imperfect combustion carbon is removed by vibration or feeding the high pressure air into the filter and if it fill up
impurities, the filter would be replace as new ones. The filter price is U$1,000 per piece and one turbine have thousands of this filter and
commonly after using it would be waste. Not only power plant but also factory, incinerator using coal and gas fuel are many of filter.
** recommendation method : Roll up the filter and put in the washing machine with ST-407 10%, normal temperature for 10~30 minute
dissolving impurities and then water washing dehydration Drying.
Ash filter

Ash filter before treatment

Ash filter before treatment

Methane incomplete combustion

carbon filter before treatment

Methane incomplete combustion

carbon filter after treatment

Methane incomplete combustion

carbon filter

 Reference
Fig excerpt from www.babcock.com

Filter cage

Picture of filter

Place the filter

General method of filter cleaning

(Limited effect)

Device schematic view

Reference - Boryeong Thermal Power Plant, Taean Thermal Power Plant, Yeong kwang Nuclear power plant => Korea Power plant.
- PLN, Indonesia Power, PLTD => Indonesia Public Power plant.
- Listrindo : Indonesia Private Power plant.

T. R&I company
Ura, Yunhee Lee
Ura,
Business Organizer
M : +82 10 3630 6042
E : trnisales@gmail.com
Joey Kim
Business Operator
M : +82 10 3890 6338
E : trnichemical@gmail.com
Office: +82 70 4225 0068
Fax: +82 2 400 0068