EPIC HRSG Off-line Cleaning Case Study
In the spring of 2020, Thompson Industrial Services deployed the cutting-edge EPIC™ Extraction Pressure Impulse Cleaner on a Nooter/Eriksen HRSG (Heat Recovery Steam Generator) in a large combined cycle plant in Central Florida. This massive unit consists of six separate finned tube bundles 65 feet high by 32 feet across.
The combustion turbine backpressure was reduced by 4 inches of water column, resulting in a 41-day payback for the client due to increased efficiency and reduced fuel costs.
How Does It Work?
The revolutionary EPIC Extraction Pressure Impulse Cleaner derives its power from its ability to give a highly targeted 360° deep cleaning of only those tubes that have the kind of deposits that severely interfere with operational effectiveness.
The EPIC technology is so precisely focused, it doesn’t affect parts that don’t need to be cleaned. This minimizes mechanical fatigue, making components last significantly longer.
The technology involves generating IMPULSE® pressure waves within a 3-inch system chamber. Then, it directs these waves into areas of the HRSG where deposits have collected so that they can be removed. These shockwaves create a deep and encompassing cleaning energy, dislodging deposits with impressive effectiveness.
This improves combustion turbine backpressure, which in turn restores heat transfer efficiency. The process is done remotely to ensure the safety of technicians. Real-time observation of the work is done using six system cameras monitored within the command center. This monitoring is enhanced with borescopes so that backpressure reduction can be continuously assessed.
Workers can watch the work on a large screen that gives them real-time feedback on how well the pressure waves carry out their intended job.
If a company wants to get the most comprehensive view of the results, they can opt to have a drone fly through the unit to look at the cleaning’s overall effectiveness.
The Thompson Industrial Services team was tasked with removing deposits from the harp tubes on the inlet side of the HP Economizer #2 to the downstream side of the FW Heater #1 bundle. These deposits restrict gas flow and prevent heat transfer in areas where it’s needed.
The EPIC Extraction Pressure Impulse Cleaner successfully dislodged the deposits on the finned tubes of the HRSG. The crew worked tirelessly for five days to complete the work. This included setting up the equipment, vacuuming up the enormous amounts of debris the HRSG had accumulated, and dismantling the system once everything was done.
The plant managers and personnel were ecstatic once they pored over the data. That’s because the intensive cleaning of the HRSG resulted in massive improvements in operational performance. Backpressure was reduced by 4 inches, which decreased the heat rate by 0.5 MMBtu/MWh.
The Operations Manager even said:
“EPIC is the way to go to clean our HRSGs, and we’ll use it again in the spring for our next one.”
If you use EPIC Extraction Pressure Impulse Cleaner in your own facility, you could see similar results. What’s more, you don’t have to put scaffolding up, saving you time and money.
Read the full case study here to learn more about how these impressive results were achieved safely.
What We Can Do for You
Thompson Industrial Services has been providing safe and reliable industrial cleaning services for almost three decades. You can count on us for all your industrial cleaning needs. Here are a few things we offer:
- Automated Hydroblasting
- Dry Ice Blasting
- Chemical Cleaning
- In-Situ SCR Catalyst Cleaning
- Pneumatic and Hydrovacuum Excavation
Our technicians are highly trained, consummate professionals. They have what it takes to carry out a job at the highest possible level.
We’ll be with you every step of the way, ensuring that every cleaning project—from initial conception through scheduling and completion—is done to your complete satisfaction. We go beyond conventional cleaning to offer industry-leading solutions for your specific challenges. So, our services can be as unique as your business is.
Call us today at 800-849-8040 to see how our EPIC™ HRSG Off-line Cleaning can increase your business’s operational efficiency!