Ultrasonic cleaning and testing –
for better performance and greater efficiency
Additional offering available for your SGT5-4000F and SGT6-4000F premix and pilot gas burners
siemens.com/energy/field-service-fossil
Answers for energy.
Seal of quality
After cleaning, the burner
components are stored,
ready for reassembly
The Siemens Field Service Seal
This seal, signifies that your burners have been
expertly cleaned at Siemens according to our
technical and quality assurance requirements.
Our process for the chemical cleaning of burner
components – designed to avoid damaging
their surfaces – is described in detail in our procedures, which are regularly updated to reflect
our latest technical knowledge.
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Flow measurement
2
Thermal pre-treatment
3
Blow-out
4
Immersion cleaning
Immersion cleaning
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Rinsing
Rinsing
6
Passivation
Passivation
7
Blow-out
Blow-out
8
Drying
9
Flow measurement
Yes
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Visual inspection
11
Conservation
End of cleaning
OK?
No
Ideal burner cleaning sequence
with dual-flow measurement
After the cleaning one machine
showed improved operation
Burner cleaning for SGT5-4000F and SGT6-4000F
What are the benefits of ultrasonic
cleaning for premix and pilot gas
burners?
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Combustion chamber instability
Experience with our fleet of turbines
with annular combustion chambers
has shown that deposits can form on
burners over time during operation
depending on the fuel used and the
ambient conditions. It can affect
operating behavior in many ways,
including:
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Power loss
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Increased trips
(emergency shutdowns).
arbonization and sulfur deposits
C
(hot/cold spots)
We offer ultrasonic cleaning of the
premix and pilot gas burners in combination with dual-flow measurement.
You can see what benefits the cleaning
provides, and we can verify the success
of this key service.
„The benefits of Siemens
burner cleaning?
That’s easy – potential for
fewer trips and improved
operation.“
Werner Brödner
Siemens Project Manager
Burner cleaning
On the left, the still
uncleaned burner; on the
right, the cleaned burner
looking almost like new
Burner cleaning and
flow measurement go
hand in hand
For reliable results
1
9
Flow measurement for proven results
In our work process, considerable attention is paid to flow measurement
before and after cleaning, because this
is a key indicator of the effectiveness
of the cleaning. It also provides a verification that the cleaning process did
not affect operation of your gas turbine.
Our internal specifications define in
detail the procedure for performing
flow measurement.
Using flow measurement, we calculate
the effective through flows and the
deviation from the mean value of
the entire burner set. This allows the
cleaning process to be controlled to
help prevent damage to the burner.
Documentation of the measured
values before and after the cleaning
provides Siemens Service Engineering
with important information for assessing the complex burner system as well
as any service measures that may be
recommended. Or would you rather
rely solely on a visual inspection of
the burners?
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23
300
1
2
290
3
280
22
4
270
260
21
5
250
240
230
20
6
220
210
200
19
Photos below:
The endoscopic inspection
prior to cleaning reveals
deposits that necessitate
a qualified cleaning process
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17
10
16
15
11
14
13
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“Our customers have reported
high satisfaction with the results
of burner cleaning. Flow measurements before and after cleaning
demonstrate the effectiveness
of the process.”
Thomas Wänger
Flow Measurement Specialist
Flow measurement
Graph:
The flow measurement
diagram showing the
measurement before cleaning
7
An ideal way to prepare
the burner for cleaning
Heat treatment followed by blow-out
2
3
Thermal pre-treatment
Blow-out
Siemens’ experience with burner cleaning
without thermal pretreatment is that it can
in many cases yield less than desirable
results. Siemens’ process for thermal pretreatment for burner cleaning is designed
to remove organic residues, especially
from inside the components to be cleaned.
These include residues of, for example,
grease, oil, cooling lubricants, and conservation agents as well as combustion
residues – and elemental sulfur, which
are often difficult or impossible to
remove. The components are heated in
a furnace and then, after a prescribed
dwell time, they are cooled in a controlled
process that can take several hours.
Especially in the case of operationally
stressed components, loose particles may
be present inside the components after
thermal treatment has been performed.
We remove these particles by blowing
them out with compressed air in order to
achieve faster results with the citric acid
cleaning process described below.
3
“With the thermal pre-treatment of
burners, we strive to optimize results
in the subsequent cleaning process.”
Herbert Fandel
Burner Cleaning Specialist
Thermal pre-treatment and blow-out
2
The burners are cleaned and
rinsed in multiple cycles
Immersion cleaning in the ultrasonic bath followed by rinsing
4
5
Immersion cleaning in citric-acid bath
Rinsing
The components are placed in the heated
citric-acid bath. The cleaning effect of this
bath is accelerated and intensified by means
of ultrasonic waves of a particular frequency.
We can vary the cleaning time according
to the thickness and type of contamination.
The citric-acid cleaning process can take
up to several hours. On the basis of past
experience, Siemens typically performs two
cleaning cycles on operationally stressed
components for maximum effectiveness.
Results are also confirmed by post-cleaning
flow measurement.
Following the citric-acid bath, the parts are
rinsed wet-on-wet inside and out with water.
4
5
5
“Immersion cleaning supported by
ultrasound is essential for optimal
burner cleaning.”
Marcus Goetze
Burner Cleaning Specialist
Immersion cleaning and rinsing
After immersion in the
citric-acid bath, the burners
must be spray-washed
in order to rinse off any
remaining acid
A clean solution
for outstanding quality
Subsequent passivation, blow-out, and drying
6
7
8
Passivation
Blow-out
Drying
In order to help prevent rust,
non-rustproof components are
briefly passivated by immersion
in a degreasing bath for a short
time after rinsing.
Partially dissolved particle layers
can still remain inside the components after the acid treatment.
These can then later detach in
operation and impair the function
of the components. For this reason,
we perform another blow out with
a compressed air device.
Blowing out with compressed air helps remove
remaining particles and dries
the components, especially
inside, to remove residual
humidity which can affect
the conservation process.
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6
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“The sight of a clean burner –
almost like new and ready for
installation – gives me a feeling
of accomplishment every time!”
Karsten Wegener
Site Manager
Passivation and drying
Detailed photos show
the burners in the
degreasing bath and
during subsequent drying
Final quality controls
to optimize effectiveness
Testing and handover for installation
10
11
Visual inspection
Conservation
We visually inspect the burner components for
contamination externally and also internally
using an endoscope and follow a rigorous
process to disposition findings. If we ascertain
that there are any large, loose particles still inside,
we can draw on further treatment processes
which have been approved by Siemens Service
Engineering.
Finally, we coat components made of non-rustproof material by immersion in or spraying with
a universal corrosion resistance agent.
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30
1
2
3
29.5
29
22
4
28.5
28
21
5
27.5
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26.5
20
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26
25.5
25
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Photos on the right:
The endoscopic inspection
after cleaning can
verify the success of the
cleaning process
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15
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“Our cleaned burners have elicited
positive responses: many customers
have stated that the gas turbines ran
more quietly with fewer trips and
better performance.”
Carsten Schmidt
IBS Engineer
Quality control
Graph:
Uniform distribution of the
flow values is a sign of an
excellent cleaning result
7
Our goal:
shortest outage times for the highest
availability of your power plant
Siemens Field Service worldwide
Qualified, committed, on-site –
wherever you need us!
Profit from the expertise and experience
of an industry leader:
Siemens Field Service offers comprehensive services
for complete power plant installations, gas power
plants, steam turbine power plants, and generators.
We work with state-of-the-art plant diagnosis and
fault-detection systems as well as Siemens Service
Engineering in order to improve efficiency, reduce
emissions, and guarantee availability over the entire
lifecycle of the power plants. With our strategically
positioned branches in many countries of the world,
we are always close to our customers so that we
can implement project- and customer-specific field
service solutions at any time.
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anufacturer and specialist knowledge based
M
on over 165 years of experience
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Products and services from the OEM
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onstruction and commissioning of
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more than 50 new power plants annually
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Inspections and maintenance annually
– 200 gas power plants
– 150 steam power plants
– 50 conventional islands
Global presence
Expert knowledge and know-how
through continuous qualification
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Locally in more than 190 countries
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90 production sites and factories
2
in more than 40 countries
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9 field service branches world1
wide close to our customers
ver 1,500 qualified field service
O
engineers and technicians worldwide
High quality standards
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Fast, confidential, flexible:
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24/7 telephone hotline for
emergencies or issue resolution
with your plant
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Over 2,000 field service employees
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ver 100 subcontractors
O
worldwide
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00 customer training courses
1
annually
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repared more than 200 project
P
plans annually
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I ntegrated quality management
system, certified to DIN IS0 9001
Siemens Field Service worldwide
Our Field Service worldwide
works intensively together
with specialists, subsuppliers
and customers – back to grid
as soon as possible
Published by and copyright © 2013:
Siemens AG
Energy Sector
Freyeslebenstrasse 1
91058 Erlangen, Germany
Siemens Energy, Inc.
4400 Alafaya Trail
Orlando, FL 32826-2399, USA
Energy Service Division
Service Fossil
Field Service Marketing Region Europe
Huttenstr. 12
10553 Berlin, Germany
E-mail: field-service-marketing.energy@siemens.com
For more information, please contact
our Customer Support Center.
Phone: +49 180/524 70 00
Fax:
+49 180/524 24 71
(Charges depending on provider)
E-mail:support.energy@siemens.com
Energy Service Division
Order No. E50001-G520-A481-X-4A00 | Printed in Germany |
Dispo 34805 | c4bs No. 7816 |
TH 258-130138 | BR | 461500 | WS | 07131.5
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Subject to change without prior notice.
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Trademarks mentioned in this document
are the property of Siemens AG, its affiliates,
or their respective owners.
The information in this document contains general
descriptions of the technical options available, which
may not apply in all cases. The required technical
options should therefore be specified in the contract.