Power Generation

(Combined Cycle)

COMBINED CYCLE

Precision Iceblast has supported the combined cycle industry for decades. We have worked for major power supplies all over the world including on six different continents. Our specialty is cleaning Heat Recovery Steam Generators (HRSGs) and providing massive efficiency gains for these power plants. In addition, we provide industrial cleaning and coating of various surfaces throughout the entire process. We provide MSA’s and LTSA’s to ensure long term reliability for company fleets.

HRSG DEEP CLEANINGTM

We offer our customers an exclusive and patented cleaning method, capable of performing a thorough cleaning of all rows of tubes totally safe and of incomparable quality with other existing methods on the market. We analyze HRSG projects and manufacture customized blasting and alignment devices for each application.

The deep cleaning method (HRSG DEEP CLEANING ™), patented by Precision Iceblast, safely guarantees a better functioning of your HRSG, reducing back pressure, improving the heat rate and increasing the performance of your power plant.

We bring the complete solution to you.

Benefits of HRSG Cleaning

Output Power Recovery
Higher Thermal Efficiency and Steam Production
Less Fuel Consumption for Gas Turbines
Avoids Corrosion and Breakage Problems
Increases The Service Life of HRSG Tubes

HRSG Fouling

During the operation of its combined cycle, your heat recovery system generator (HRSG) will become fouled due to deposits and corrosions produced by the process, causing loss of performance and operational savings for your power generation plant. Seeking to restore the performance of your HRSG and have greater reliability and availability is essential for the efficiency of your plant.

Types of HRSG Fouling

Ammonia
Sulfur
Iron oxide
Insulation

Each HRSG may have different fouling problems, depending on the process settings. Knowing how to identify the real problem and propose the right solution is our specialty. In addition to being the only company that has the patented HRSG DEEP CLEANING ™ method, we have developed special devices and applied qualified labor to promote the cleaning of your HRSG in an efficient, safe and incomparable quality.

Our HRSG Cleaning Process

Our solution consists of using carbon dioxide gas (CO²) in the form of small 3mm cylindrical high density blasting pellets, ultra-high pressure air, and Deep Cleaning Alignment Tools which collectively make up our Deep Cleaning™ technology.

Safe access by scaffolding for inspection and deep cleaning of the modules.
Deep tube cleaning with dry ice blasting using ultra high pressure compressed air.

Advantages of the HRSG Deep Cleaning™

We work with real results, not assumptions. Below is a comparison of our patented deep cleaning versus
conventional cleaning and explosive cleaning processes.

HRSG Deep Cleaning™

Cleans every surface of every tube resulting in 95% clean.
Allows access for visual inspection of deep tubes.
No harm done. Works with sublimation effect.
50 – 70% reduction in back pressure.

Conventional Cleaning

Cleans only the first two rows of tubes in the module.
Debris gets pushed into middle of module.
No harm done. Works with sublimation effect.
0-10% Reduction in backpressure.

Explosive Cleaning

Cleans only the first four rows in a module.
No access for visual inspection of tubes.
May cause damage to tubes and other parts.
30% Reduction in Back Pressure.

Debris Removed Comparison

Results

HRSG Deep Cleaning™ is able to remove any type of deposit from any type of HRSG.

HRSG Fouling Negative effects

Every 4 inches or (10 mbar)

(0,42%) Power output losses

(1,1℉) Exhaust Temperature Increase

(0,42%) Heat Rate Increase

Turnkey Solution

Case Studies

OTHER APPLICATIONS

Catalyst Cleaning

Catalyst are essential for running a clean operation at combined cycle plants. However, through general operations SCR and CO Catalyst get dirty and decrease the efficiency of the plant. Most fouling consists of dirt, dust, and insulation.

Precision Iceblast Corporation provides a successful technique of removing this fouling from Catalysts. Catalyst are cleaned with a combination of low pressure air (90 psi) and high volume low pressure vacuuming. The upstream and downstream faces are vacuumed first to remove any debris. The downstream face is air lanced blowing upstream. Air lancing the downstream face allows any lodged debris to work its way out to of the upstream side of the Catalyst. Once air lancing is completed the upstream face is vacuumed to remove any final debris that was forced out from the air lancing.

Generators

Ice blasting is a very safe process on generators. These surfaces can be cleaned without damaging the existing coating. If the coating needs to be replaced, Precision Iceblast can reapply a new coating with their expert NACE coating team.

Steam Turbine Blades

Steam turbine blades are more difficult to clean than compressor blades. Using ultra-high pressure is the key to the success of removing this debris. The non-abrasive quality of the dry ice continues to provide benefits with cleaning steam turbines.

Inlet Scrolls

Inlet Scrolls need to get recoated from time to time. The surface preparation is a very concerning process as the turbine is directly behind the scroll. Ice blasting is ideal as the media vaporizes and turns into a gas upon impact. Using any kind of grit media is far too risky. Precision Iceblast offers a great turnkey solution to safety ice blast (in preparation for recoating) and then recoat your inlet scroll with our NACE certified painters. With scores of inlet scrolls projects being completed, you can rest assure that this project will be done safely, professionally, and with the upmost quality.

Stacks

The inside of stacks in combined cycle plants are exposed to very harsh environments. There is massive heat from the flue gas going through them combined with open exposure to the elements. In almost all cases this leads to significant corrosion on the stack walls and stack bottom. Putting a protective coating on the stack walls and bottom is critical to preserving the life expectancy of the steel.

Precision Iceblast Corporation can help determine the extend of the work that needs to be performed. In many cases only the bottom 16 feet and stack bottom need to be coated. In other cases, a protective coating is needed from the stack bottom to the dampers. Precision Iceblast provides a turnkey solution to scaffold, blast, and coat with high temperature coatings to preserve the longevity of your stack.

AIG Grids

Running ammonia through the system will naturally cause build up over time. Ammonia grids become plugged and do not operate efficiently. Precision Iceblast has a proven system to clean the AIG system properly.

Precision Iceblast begins the process of cleaning by hooking up a vacuum truck at the flange downstream of the blower. This will create a suction on the system removing all debris out of the system. All valves are closed except the valve for the header that will be cleaned at that time. Once that header is cleaned the valve is closed and the next valve in sequence is opened and cleaned. AIG cleaning is performed by boring out the nozzles and tapping on the headers with a rubber mallet to loosen up the debris.

Compressor Blades

Traditionally, compressor blades have been removed from the compressor and shipped off to be sand blasted. Ultra-high pressure ice blasting has become a much better alternative. Compressor blades are now cleaned in the half shell and typically take only a shift to clean. This saves the power pant major downtime and costs. In addition, because dry ice is non-abrasive the blades can be cleaned over and over again and never change the surface of the blade. This has now become the preferred method for cleaning and recommended by most OEM’s.

Filter Houses

Over the years paint failures and corrosion will inevitably occur in your filter houses. Failure happens even sooner in environments closer to the ocean where salt in abundant in the air. Temperature fluctuations and the wetness on the steel further accelerate paint failures.

Traditional blasting methods such as sand or water blasting create enormous messes along with large quantities of waste that need to be disposed of properly. This also increases the cost of refurbishing the filter houses. Furthermore, introducing media anywhere into the combined cycle system creates significant risks that this media can get to the turbine. Damaging a turbine is extremely costly and plants will take all measures to ensure its safety.

Dry ice blasting your filter houses is the most safe and effective method of refurbishing them. Ultra-high pressure ice blasting will remove all of the loose and failed paint from the surfaces. Any remaining coating is solid and can be recoated over. Heavy corroded areas are hand tooled to remove the thick scale. All removed material is collected and put into small containers. The debris is minimal as all of the dry ice media vaporizes upon contact. Once blasting is completed, coatings are applied by our NACE certified coaters.

Outside of HRSG

The combined cycle industry is starting to age. With age comes degradation of steel. Plants are now trying to extend the life of their plants which includes putting a protective coating on the outside of their entire system (inlet – turbine house – boiler – stack). These surfaces are exposed to the elements and undergo paint failure and corrosion as they age.

Precision Iceblast Corporation has the solution! Ice blasting is a great method for surface preparation and best of all it can be performed while the plant is in operation. Therefore, no lengthy shutdown is needed to complete the work. Access to areas can be gained from boom lifts and scaffolding. As ice blasting is a dry process and does not leave behind blast residue, coatings can be applied immediately after blasting. Minimal waste is generated from the blasting and the finished result is a new looking plant that can now continue to operate for decades longer.

How can we help? Contact us today!
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