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SmartSkidTM Technology--Nuclear Power turbine flush
Scenario: A nuclear power plant in a refueling outage sampled and analyzed the oil from the main turbine reservoir, which had been drained to the dirty oil tank. The particle count on the oil returned a value of 19/17 ISO Rating, well in excess of the required 15/13 rating required by the turbine OEM. The plant sent a work order to the mobile maintenance crew to filter the Dirty Lube Oil tank. After hooking up the new triple filter housing rig and recirculating at 60 gpm for 7 days, a followup sample was taken. The results for that sample were nearly identical to the original sample. After investigation, it was seen that there was less than 0.5 psid across the filters. This revealed that the filters had been in bypass from the time the rig was started. The situation was rectified, but not until threatening the scheduled restart of the unit, or the possibility of starting with dirty oil in the turbine reservoir.
Problem: Typical supplemental filtration operations rely on a blind assessment of the installation, and the hope that the filters are removing contaminants at the desired rate. Sampling is either performed frequently, which can be costly in lab fees and manpower requirement, or only at the end of a prolonged period of filtration. By waiting on the results of oil analysis, there is no way to know precisely when the filter has completed its task of reaching the target cleanliness levels. Optimizing the use of the filter elements requires dedicating a vigilant worker to continuously monitor the filter housing differential pressure. If not monitored, the efficiency of purification can grind to a halt.
Solution: With SmartSkidTM technology, the purification of the Dirty Oil Tank would have required only about 5 hours in the schedule, based on experience with similar contamination levels and the efficiency of the rig when properly set up. SmartSkidTM enables the monitoring of lube oil purification in real time, with the ability to indicate problems with filter installation, bypassing, or loss of filter efficiency. By monitoring pressure trends and comparing to target change-out DP, it projects the remaining time until filter change will be required. It can also determine the exact time when the cleanliness targets or criteria have been reached, in many cases allowing flushing operation times to be reduced, and shortening outage duration. |
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