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

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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.

lubrication excellence in powergeneration

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General information

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:

• 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

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) 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

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Specialist services addressed to new built/modernised PP

• Hydrodynamic cleaning and flushing of oil systems of

turbines and large equipment (e.g. boiler feed pumps)

• Lubrication commisioning of equipment (management,

execution, lubrication systems preparation for 1st start up)

• Lubricants care (filtration, dehydration, handling)

• Lubricants supplies (turbine oils and other lubricants – turnkey

deliveries (filters etc.), waste collection)

• specialized industrial cleaning for powerplants – ultra high pressure water

cleaning; chemical cleaning, vacuum cleaning (steam pipelines, boiler surfaces,

exchangers, other piping and equipmnent)

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.

Overhaul and commisioning services

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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): Alstom Power, Siemens, MAN Turbo, Doosan Skoda, GE, Ansaldo, LMZ, Solar, Nuovo Pignone, Thomasen, Ekol Brno, CKD, Sulzer, KSB, Voith Turbo, Ingersoll Rand, and many other OEMs and components producers

(graphics: Ecol)

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).

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)

Oil analysis laboratory and lubrication manintenance advisory service and industrial lubrication at pre-commisioning and operation phase

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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 turbo-

machinery

• oil is a key component of the machinery

• the need of appropriate oil care in turbines is commonly

recognized and accepted

• experts estimated that 82 percent of machine wear is particle-

induced

• 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

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Bearings

Control system,

hydraulic pumps, lift oil

Generator shaft seals

Transmission

gearbox

How to clean the oil system?

........... standard methods

mechanically - with brushes, ramrods

by steam – blowing pipes with steam

by chemicals – pickling with acids

by detergents – flushing with detergents

mixed with lube oil some days before

outage

No cleaning – standard flushing only

(by system pumps)

Ecol technology

hydroblasting – 100% mechanically using

high pressure water to remove all kind of

deposits from the inner surface

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)

=

• system prepared for safe&easy start-up and commissioning process

• precise and honored schedule of flushing end

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ECOL’s technology is based on own experience, requirements of OEMs, EPRI, ASTM and VGB reccommendations

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.

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).

Step 1. Hydrodynamic cleaning -

hydroblasting

Hydroblasting

Drying

Anticorrosive

turbine oil

spray

(schematics: Ecol)

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.

Hydroblasting – in action

(photos - Ecol)

before

before

after

after

before

after

Hydroblasting results – example effects.

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)

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Cleaning proces is properly

checked:

• Hydroblast plan

• Cleaning criteria (state of

surfaces)

• Inspection before and after

cleaning

• Scheduled ispection with

customer

• Documentation for customer

Step 2. High Velocity Oil Flushing (turbulent

flushing). [24hrs/day proces]

(schematics: Ecol)

• installing set of by-passes and flow distributors

• using external flushing skid

• control filters on each bearing and all servo-

motors

• oil stream filtered in full flow

• absolute fine full flow filters ß3 = 1000

• oil temperature and flow is systematically

changed

ISO 4406

12/9

Contionous monitoring when HVOF is in progress:

• Flow rates and flow direction (USG, thermovision)

• Cleanliness class (ISO/NAS) by microscope and

automatic partilce counter

• Contaminants size and shape

• Temperatures

• Sampling for future tests of oil

• Sample archive

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 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.

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Special absolute PALL filter elements are used by Ecol for oil flushing service

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

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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 operartions-ready (heated).

By-pass ložisek a čerpadel

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Flushing connection acc. to flushing project

Upstream the bearings, servo-motors, 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.

Turbulent Oil Flushing process runs until the required cleanliness creteria of

oil is reached (ISO/NAS code + particles size/distribution)

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On-site oil cleanliness class and water content measure

After HVOF oil sample for full-oil analysis is taken. Oil is removed from the

system for disassemblies and ultimate turbine set-up.

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).

Step 3. Off-line fine filtration (post-assembly)

(photos & schematics - Ecol)

After final filtration oil sample for full-oil analysis is taken. Oil remains for 1st start up

and for future operation.

Project management at Ecol

• Based on PRINCE method elements

• Project leader, manager and site management highly experienced in power plant commisioning projects

• Turn-key project available (service+oil supply+condition monitoring after service)

• No subcontractors hired by Ecol – optimal quality and responsibility

• Full support within Ecol organisation (e.g. oil delivery, oil lab., engineering)

• Full English documented and spoken projects

• Experience with all major OEM wo

• Known to investors (Power Plants). Fits for future cooperation in operation of PP.

• Insurence for responsibility for €2.2 mln. in HVOF business.

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SUMMARY

• 100% of engineering, staff, equipment & oil handling =>> Ecol =>> no investment for customer. Clear responsibility and warranty.

• outstanding quality and expertise by Ecol professionals (over 600 cleaned turbines)

• most effective technology comparing to other methods,

• mostly recommended for: - new assembled turbine oil systems (also for other large oil systems)

– old, dirty, overhauled oil systems

• fully schedualable – multi-stage proces possible to transparent management and verify. KPIs&milestones applied,

• 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 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!

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: ecol@ecol.com.pl

lubrication excellence in powergeneration