Cleaning Air-Cooled Condensers Case Studies

Transcription

1 Cleaning Air-Cooled Condensers Case Studies ACC Users Group October 4-6, 2016 Mr. Willis Shook Conco Services Corp Conco Services Corp.

2 Case 1: Leaking Tubes Yellowstone Power Plant Air Cooled Condenser 2

3 Case 1: Leaking Tubes ACC Specifics Each module contains 1 fan 6 finned tube bundles ACC has 10 module consisting of 8 condensing cells 2 reflux cells Finned tube bundles have 211 galvanized coated carbon steel oval tubes in a 3 tube arrangement 3

4 Case 1: Leaking Tubes The ACC has 10 fans 26 foot 10 bladed 2 speed gear reduced motor Fans turn at 125 RPM fast mode 63 RPM slow mode Fan motors have reverse contacts Reverse fans in severe winter 4

5 Case 1: Leaking Tubes Center of ACC 5

6 Case 1: Leaking Tubes Tubes Frozen and Degraded from Debris Trapped Behind Support Beams 6

7 Case 1: Leaking Tubes Frozen Burst Tube 7

8 Case 1: Leaking Tubes Holes in Top of Tube Connections to Steam Header 8

9 Case 1: Leaking Tubes Removal of Outer Tubes Gain Access to Inner Row Tube Leaks 9

10 Case 1: Leaking Tubes Leaks in Tubes at Lower Condensate Header Connections 10

11 Case 1: Leaking Tubes Environmental problems Wind Debris Cotton from cottonwood trees Ash Coke dust Other debris Cold weather Hot weather 11

12 Case 1: Leaking Tubes YPP s Solutions Use of underground cable shrink wrap and aluminum duct tape Patch major leaks in tubes Use of sleeve inserts and outer sleeves Fix tube to header connection leaks Sandblasting and pressure washing of tubes Remove debris from finned areas 12

13 Case 1: Leaking Tubes YPP s Solutions Continued Use of epoxy paints Help preserve and close pin hole leaks Steam header connections Condensate headers Wind Fence Wind Wall 13

14 Case 1: Leaking Tubes Cable Shrink Wrap Repair Major Holes in Tubes 14

15 Case 1: Leaking Tubes Tube Sleeve Inserts and Outer Couplers 15

16 Case 1: Leaking Tubes Epoxy Paint Holes in Tube Headers Holes Repaired and Epoxy Painted 16

17 Case 1: Leaking Tubes Wind Fence 17

18 Case 1: Leaking Tubes Wind Wall 18

19 Case 2: Cleaning with Biodegradable Degreaser Plant Conditions Plant burns coker gas from refinery Steam produced sent back to refinery Harsh winter partially froze coker gas line Created blockage in the line High pressure behind the blockage 19

20 Case 2: Cleaning with Biodegradable Degreaser Problem When blockage broke free Pressurized oil leaked through the Loop Seal Stack Oil covered Outside surface of the ACC unit Surrounding areas 20

21 Case 2: Cleaning with Biodegradable Degreaser Oil on Surface of Unit 21

22 Case 2: Cleaning with Biodegradable Degreaser Oil Covers Unit 22

23 Case 2: Cleaning with Biodegradable Degreaser Additional Problem Truck spilled fly ash near the ACC unit Ash sucked into the ACC fans Under side of fins coated with oil and ash Oil acted like a glue 23

24 Case 2: Cleaning with Biodegradable Degreaser Ash Covers Fins Underneath Unit 24

25 Case 2: Cleaning with Biodegradable Degreaser Initial Attempt to Clean Plant attempted to clean unit using: Cleaning system installed with unit High pressure water Cleaning was unsuccessful 25

26 Case 2: Cleaning with Biodegradable Degreaser Cleaning using De-Greaser ACC cleaning system brought to plant Capable of higher pressure adjustable Bundles presoaked with bio-degradable degreaser Unit cleaned using a higher pressure with ACC cleaning system 26

27 Case 2: Cleaning with Biodegradable Degreaser ACC Cleaning System 27

28 Case 2: Cleaning with Biodegradable Degreaser ACC Cleaning System: Riding the Rails 28

29 Case 2: Cleaning with Biodegradable Degreaser View from Inside Unit 29

30 Case 2: Cleaning with Biodegradable Degreaser Results 30

31 Case 2: Cleaning with Biodegradable Degreaser Results 31

32 Case 2: Cleaning with Biodegradable Degreaser Results 32

33 Case 3: ACC Vertical Unit Cleaning Solution Haverhill Issue unable to effectively clean unit Standard ACC cleaning system did not fit Had to modify entire unit Cleaning system had to fit between fans and unit 33

34 Case 3: ACC Vertical Unit Cleaning Solution Vertical ACC unit Consists of 78 fans Rectangular structure Fans on each of the 4 sides Fans are 2 high on each side ACC structure on the top of Main Building 34

35 Case 3: ACC Vertical Unit Cleaning Solution 35

36 Case 3: ACC Vertical Unit Cleaning Solution 36

37 Case 3: ACC Vertical Unit Cleaning Solution 37

38 Case 3: ACC Vertical Unit Cleaning Solution 38

39 Case 3: ACC Vertical Unit Cleaning Solution 39

40 Case 3: ACC Vertical Unit Cleaning Solution 40

41 Standard ACC Cleaning Equipment 41

42 Case 3: ACC Vertical Unit Cleaning Solution ACC System Modifications 42

43 Case 3: ACC Vertical Unit Cleaning Solution ACC System Installation 43

44 Case 3: ACC Vertical Unit Cleaning Solution ACC System Installation 44

45 Case 3: ACC Vertical Unit Cleaning Solution ACC System Installation 45

46 Questions 46