Condenser Tube Cleaning

Client Testimonial

Background

With the supply of electricity, a key issue in Nigeria. Tube Tech International worked to demanding deadlines and in extreme conditions to effectively clean and integrity inspect 12,000 condenser tubes, at the Egbin thermal power plant.

The Problem

Condenser cleaning at the power plant had previously been performed by the plant operator – National Electric Power Authority (NEPA) – but there had never been any quantifiable means of checking cleanliness or integrity of the tube walls. Fouling had accumulated in the condenser tubes over time, this made the deposits harder and increasingly more difficult to remove, a gradual reduction in heat transfer and diminished condenser performance demonstrated that improved cleaning was required.

The Problem

Condenser cleaning at the power plant had previously been performed by the plant operator – National Electric Power Authority (NEPA) – but there had never been any quantifiable means of checking cleanliness or integrity of the tube walls. Fouling had accumulated in the condenser tubes over time, this made the deposits harder and increasingly more difficult to remove, a gradual reduction in heat transfer and diminished condenser performance demonstrated that improved cleaning was required.

The Solution and Benefits

With the power plant supplying 35% of Nigeria’s electrical needs it is of vital importance to ensure supply is available when required. Recognising this, NEPA’s Technical Board/Committee invited Tube Tech to present on how an innovative approach could provide higher standards of cleanliness and measure the condition of the tubes.

Tube Tech’s approach, to achieve NEPA’s request, required employing several innovative technologies, including RotaFlex and WysperFlex systems to unblock and descale the most severely restricted tubes and DarTT technology to remove any remaining scale quickly and cost effectively, which returned all tubes back to bare metal and the condenser to optimum performance.

Tube Tech’s subsequent Eddy Current (ECT) and IRIS inspection confirmed the integrity of all tubes cleaned to the highest possible standard, enabling the condenser to return to maximum efficiency, with the confidence that there was no imminent tube corrosion or erosion. Tube Tech also provided the client with sufficient information to establish a planned maintenance schedule.

To carry out this condensed timescale cleaning and inspection operation, in temperatures of 38-40°C and 70 per cent humidity, Tube Tech’s team members rotated roles and worked extended shifts. Despite having to manoeuvre in air-cooled suits for certain aspects of the work, the Tube Tech team continued worked efficiently and effectively involving site managers and engineers.

The General Manager, Lagos Thermal Station, Egbin said “Supplying power/electricity is a key issue in Nigeria and Tube Tech International was able to carry out the cleaning and inspection in a very restricted time frame. We now have substantially improved condenser performance and knowledge regarding the integrity of the tubes.”

Happy To Help

For more information or to arrange, call or email us at +44 1268 ­786999 or info@rotaflex.com

Rotaflex Industrial Cleaning System