Gulf Coast Cogen Facility
PROJECT SUMMARY REPORT
HIGH VELOCITY OIL FLUSH SERVICES ABB STAL VAX STEAM TURBINE
This report documents the High Velocity Oil Flush performed on the ABB STAL VAX Steam Turbine at Gulf Coast Cogen Facility.
Objective:
Provide a safe and efficient Flush of these systems, satisfying all customer requirements.
Results:
▪ 255 Man Hours worked with ZERO incidents or injuries o SFM Reliability Solutions (SFM RS) commitment to safety, demonstrated by its safety record, provides plant owners, construction companies, and OEM’s peace of mind and safety assurance.
▪ Mutually developed a comprehensive flush plan with all related parties and executed the Flush meeting or exceeding customer requirements
Comprehensive and properly developed flush plan provided peace of mind and assurance that all flush requirements were satisfied, including properly draining and purging all system piping
SFM RS executed the flush utilizing purpose-built equipment and superior technical expertise. This helped the customer avoid schedule extensions during the outage.
▪ Provided documentation of flush procedures confirming SFM RS guarantee that all customer criteria were met.
Filtration:
In addition to one-micron nominal “full flow” filtration used on the inlet side of the flush, mobile heater/ filter units were used to constantly control oil heat and cleanliness to OEM oil cleanliness.
Project Time-Line Overview:
DATE | MAN HOURS | ACTIVITY |
|---|---|---|
11/25 | 11.5 | Completed site safety requirements. Staged equipment and finalized jumper installation. Completed pre-flush walk down. |
11/26 | 38 | Staged generator; electrical hook-up, staged tanker, started heating oil on reservoir only; circulate on reservoir over night |
11/27 | 39 | Staged PVDOPS, started PVDOPS on reservoir-pulled 4 gallons of water; started filling system with Heater Unit @ 17:00 and HVOF @18:00; pulled screens @ 19:00; started coarse flush @ 20:00; monitored system all night and swapped filters/coolers every 2 hours |
11/28 | 37.5 | Continued coarse flushing. Dumped approx. 10 gallons of water from PVDOPS; swap coolers and filters every 2 hrs. |
11/29 | 36 | Continued course flush; thermal cycle system for 3 hrs; oil sample @ 18:00 – ISO 18/15/12; all water has been removed from system, will leave the PVDOPS on-line until morning |
11/30 | 34 | Continued flushing; installed inspection screens 0740-0940 (pass all screens); 2nd set of screens installed and ran 0950-1050 (Passed all screens) Final oil count was 14/12/7; removed oil from system and stored in tanker, completed @ 1400; started circulating on tanker with Heater Unit |
12/1 | 33 | Circulating on tanker with PVD-pulled 2 gallons of water; obtained CSE permit for reservoir clean out |
12/2 | 21 | Circulating on tanker with PVDOPS-pulled 5 gallons of water with PVDOPS |
12/3 | 5 | Loaded up all equipment not needed; took oil samples to ship to lab for testing |
12/4 | - | Stand-by waiting on sample results |
12/5 | - | Stand-by waiting on sample results |
12/6 | - | Stand-by waiting on sample results |
Total Days - 12 | Total Hours – 255 | |
The following pages detail and photo-document the project, including completion of objectives.
The engine piping and components were flushed to the required specification, cleanliness and acceptance criteria were verified, witnessed and documented. The “Final Flush Acceptance” documents for the system, detailed flushing logs, and photo documentation are included in this report. These documents indicate time duration during various phases of the project, along with the on-site cleanliness level, photo documentation of various aspects of the flush.
Equipment Setup:
Equipment Setup (Cont’d):
Vacuum Dehydrator Water Removal - VDOPS
Inspection Screen photos:
Tank photos:
Particle Count Photos:
Particle Count Photos (Cont’d);
