Change language
|
ROCHEM Fyrewash Ltd
5-6 Sun Valley Business Park
Winnall Close, Winchester
Hampshire
SO23 0LB
ROCHEM Fyrewash Inc
23707 West Hardy Road
Spring
Texas
77373
11.25.19
When it comes to process compressors, there is no ‘one size fits all’ solution. Unlike gas turbines, where the process medium is always air, process compressors have specific and different tasks. This must be taken into account when deciding how best to clean them.
Our four-step process makes sure we deliver a perfectly tailored system to achieve optimum results. This approach saves time and money and has a proven track record.
In one case study, after consulting Rochem and implementing our plan, the customer reported cost savings of USD $5m per event.
This equates to a potential saving of USD $15m in just two years.
To put that figure into perspective, our typical contract value is approximately £100k, which includes the feasibility study (step 2). This initial outlay is a tiny fraction of the money a could save you.
Through normal use, build up inside your compressor. Unfortunately, even if you do everything right, this buildup is inevitable.
Contaminants such as exhaust fumes, salt, and sand enter the system through the air supply while essential lubricants can also end up in the wrong place.
These and other foulants coat the compressor blades and interrupt the airflow, with a knock-on effect when it comes to efficiency.
The less aerodynamic system
Fortunately, there are four simple steps to cleaner compressors. Follow these steps and you will not only enjoy peace of mind that your equipment is being kept in good working order, but you will also ultimately save money that would have been wasted on excess fuel and unscheduled shutdowns.
We may have met you at a conference or exhibition, or you may have gotten in touch because of our reputation for results. However that first connection is made, we will send out a comprehensive questionnaire for you to fill in.
Data from your responses allows us to determine whether or not a system can be designed to suit your site. If ‘yes’ then we move on to the next step.
It is worth mentioning that at Rochem we design and install the hardware required for on line and off line washes as well as offering FYREWASH®: a range of specialised cleaning products.
We are on hand to offer guidance from what kind of equipment is best for your specific needs to advising on the right chemicals based on your individual priorities.
For example, if your foulant problems are predominantly water soluble, a detergent-based cleaner is best for you. Alternatively, to remove mineral oils you are better off choosing a solvent-based option.
This is an exciting step because we have established that we can help you, it is just a case of working out the best approach. We carry out a feasibility study for £10k - £20k.
The figure depends on the scope of the study and is paid for under the purchase order.
Once completed, the study provides the basis for design of your process compressor cleaning system. In turn, this enables you to gain capex for the project.
The basis for design enables us to put together a proposal for the cleaning system, including the chemicals required.
This is where you can really start to imagine the system in place and begin looking forward to the benefits.
With your ‘go-ahead’ and our receipt of the purchase order, we get started on the detailed engineering design. Once this is approved by you, we build the whole bespoke system.
Following thorough testing, we deliver your new to your site. This is always a very exciting day.
You can now install the as per the design. This is usually completed by the customer but Rochem can provide commissioning, training, and handover at the site under the purchase order if you prefer.
Your new process compressor cleaning system is up and running, ready to start improving efficiency and saving you money.
Now that your new process compressor cleaning system is up and running, it’s time to start improving efficiency and saving you money.
There are two kinds of compressor cleaning:
It is wise to implement a regular cleaning schedule which employs both methods to ensure your compressor is kept thoroughly clean and efficient.
This kind of compressor cleaning can be carried out during normal use. Detergent and/or water is injected into the system while it is running.
The foulants are broken down and rinsed away without having to reduce load or shut down the turbine.
As a rule of thumb, it is a good idea to conduct a water-only on line clean every day, and a water/chemical on line clean twice per week.
Off line cleans are really thorough and entail shutting down the gas turbine before draining the engine, injecting your chosen water and chemicals, allowing them to soak the compressor before rinsing and then restarting the engine.
Regular on line cleaning delays or even eliminates the need for the more thorough but more time-consuming off line alternative.
The same equipment and cleaning chemicals can be used for both kinds of cleaning but a combination of the two methods leads to the best results.
Looking at a case study conducted at an oil refinery, following the implementation of our four step plan with regards to a cracked gas compressor, the following improvements were noted:
This all contributes to huge , far more than the total cleaning costs, including initial equipment outlay.
The customer is extremely happy and added that no abnormalities (vibration, noise, etc.) have been observed during a clean. We continue to work closely with this customer, looking at ways to further optimise their online cleaning regime through cleaning quantity, frequency and sequence.
This is not an isolated case and we regularly enjoy the fantastic feedback from our customers as they observe the improvements and count the savings.
Find out how with our four step plan, you could also enjoy lucrative results. Get in touch with our friendly, knowledgeable team and request the no-obligation questionnaire today.
Post written by Martin Howarth
An extensive knowledge of mechanical and electrical engineering together with hands on experience with gas turbines provides a bedrock for his work at Rochem.
