Power Plant Service (BKS) - Brochure

INDUSTRIAL SERVICE FOR CONVENTIONAL POWER PLANTS AND INCINERATORS www.kraftwerk-service.deBuchen ... at the heart of industry2THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORSKraftwerKService THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORSBUcHeN KraftwerKService – tHe SPecia- LiSt fOr iNDUStriaL Service iN cONveNtiO- NaL POwer PLaNtS aND iNciNeratOrSBuchen KraftwerkService offers services to the operators of conventional power plants, thermal waste treatment plants and industrial incinerators and steam boiler plants throughout Europe, which range from consulting for the cleaning and decontamination of systems and system components up to waste management. We create indi-vidual service packages customized to your needs; this helps minimize your coordination and work expenses and simplifies your process procedures during revisions. For disruptions and emergencies, our 24-hour service is available day and night under the national hotline 0800-7177-111.where we work for you: Feed hoppers Container/steam generators Turbines Condensers Ash removal Primary air preheater (LUVO) Gas preheater (GAVO) Exhaust denitrification systems (DeNOx) Dust extraction plants (E-filter) DESOX plant (REA) Coolant systems and towers Piping and canals Tanks Instruments and containers Heat exchangers Chimneys And a lot moreSCHWEDT(Ausbildungszentrum)COTTBUSINGOLSTADTBURGHAUSENSTADEBRUNSBÜTTELHAMBURGROSTOCKMERSEBURGKÖLNDUISBURG/BOCHUMVOERDEMARLBRAMSCHEKARLSRUHEGRENZACHLUDWIGSHAFENVOHBURGBERLINABOUT THE BUCHEN GROUPThe Buchen Group is an internationally active service provider, who sets standards in the industrial service, waste and decontamination markets. We invest our full effort every day at over 60 locations in Germany, Eu-rope and the Middle East in order to offer our customers professional industrial service. We know that our 2,300 employees are the greatest capital of the Buchen Group. That is why we keep their technical knowledge and abili-ties up to date through regular training and education programs in our certified training centre. All areas of the Buchen Group are certified throughout Europe in regards to quality, safety, health and environment management. Furthermore, all locations in Germany in which we offer waste management services are certified as specialists. The companies from our Group combine basic values that help our customers become more successful and pre-serve the environment.THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORS3THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORSIn order to provide good technical availability and reli-ability, the operators count on competent partners for the on-time execution of required repairs and cleaning work. This is the only way that their delivery and acceptance ob-ligations can be maintained. The basis for operation and maintenance is the constant cleaning of the system.Waste incineration does not occur without residues. Due to the chemical and physical properties of the combustibles, caking, waste and incrustation form on the heating areas of the steam generator. These hinder the transfer of heat, lead to an increase in the system’s power needs due to the increased flow resistance and in extreme cases, this may even result in total failure. For these reasons, regular clean-ing of the system is indispensable.Good planning and its implementation in combination with an operating team and external partners is the requirement for a quick cleaning and rapid restart of the system.Our procedures: Sandblast procedure Dry ice blasting technique(CO2- lasting) Vacuum stream procedureareas of application: Mechanical basic cleaning of all heating surfaces Removal of ramming mass Blooming of surfaces Descaling Removing rust Surface preparation for coating work Preparation of measuring points Fire damage restoration Turbine/machine cleaningUNDerPreSSUriZatiON/ SUctiON Draft rePLaceMeNtIf the suction draft is out of order during a revision, we are able to provide for an adequate replacement with our mobile high-power vacuum dust extracting systems. Of course, we also offer this service for unplanned dis-ruptions. Your benefits at a glance: Extraction and filtering of dust in order to protect the direct environment from contamination Replacement of the facility’s suction drafts if needed Depending on the requirements, provision of devices with different power classes and volume capacities Filtering either through a bag or cartridge filter Filling of the dust into the bunker or big-bagsBOILER CLEANING4THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORSKraftwerKService THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORSOur mobile suction vehicles and high-performance air conveyors are approved according to GGVSE/TRbF and develop a suction power of up to 8,100 m3/h. This enormous amount of power and an operating radius of around 300 m without changing the location allows for the extraction of dusty, dry, pasty or liquid materials. For dangerous dusts, we have filters with the dust pro-tection class “H”. The removal occurs through dumping, filling in big bags or blowing – depending on the local circumstances.the procedure is ideal for: Dusty goods Dry material Pasty products Liquid goods Hazardous goodsEXTRACTION THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORS5THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORSResidue is created in all production systems. Everywhere where a smooth work process depends on the optimal throughput in systems or pipes, our automated or manual water-jet high-pressure cleaning can be used. It is envi-ronment-friendly and conserves the materials. Because the cleaning process does not occur with the help of chemicals, but rather purely mechanically – through pure water power. We have the required techni-cal know-how and corresponding equipment for all areas of application: The drive powers of our high pressure pumps reach up to 600 kW. Depending on the degree of contamination, we use pressures of up to 2,500 bar.we achieve optimal cleaning results for the fol-lowing areas of application: Stubborn deposits on heat exchangers Algae and copper rust residues in the interior of ce-ment and wood cooling towers Incrustation in pipes Removal of coating and lining Cleaning of tanks, containers and systemsHIGH PRESSURE WATER CLEANING6THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORSKraftwerKService THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORSAir coolers and air condensers in power plants are sub-ject to the recondensation of water that drives the turbines when it is in a steam form. These are heat exchangers with finned pipes for cooling the medium through ex-changing heat with the surrounding atmosphere.Through contamination and deposits, the heat exchange is lowered in the air cooler, the condensation process is hindered and the efficiency of the power plant decreas-es.Buchen KraftwerkService developed an automated high pressure cleaning procedure specializing on the proper-ties of air coolers and air condensers in order to clean these sensitive systems in a preserving and efficient man-ner. With a combined ladder and slide system, it is pos-sible to clean large surfaces of the air cooler in a short amount of time. The semi-automated procedure is used for fine work where the cleaning sleds are controlled by qualified spe-cialists by remote control. Your benefits at a glance: Clear increase in efficiency Optimal degree of cleaning Shortened cleaning time Directed beam control Increase in the degree of efficiency Material-preserving The large number of jets allows for the simultaneous cleaning of a larger area Increased work safetyAIR COOLER CLEANINGTHE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORS7THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORSContaminations on the heating surfaces of primary air preheaters lead to problems during operation. The heat transfer is dramatically reduced through this and the back-pressure in the system increases. The consequenc-es: Forced draft fans and suction draft fans are hindered. The efficiency of the system decreases considerably. Buchen KraftwerkService has developed a fully automat-ed, computer-controlled system for water high-pressure cleaning of primary air and gas preheaters. This mature procedure is mobile, works in a self-sufficient manner and only requires electricity and water. It allows you to clean heating surfaces of primary air preheaters with a very high degree of cleaning using the water high pressure procedure – faster and more efficient than ever.Your benefits at a glance: Highest degree of cleaning Shortened cleaning times Longer system availability Shortening of downtime Considerably improved heat transfer Considerable reduction of the ?p (differential pressure) Directed beam control Either electrical or diesel operation Optional: Takeover of sewage managementLUVO CLEANING8THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORSKraftwerKService THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORSWith chemical cleaning, we can remove stubborn attach-ments on and in system parts. Here we determine the selection and dosing of the solvent individually for each case. We use this procedure wherever the constellation of material and contamination makes it necessary or if we can obtain better cleaning results with this procedure. For example, in hard to reach system areas. We pro-fessionally treat and minimize the accrued residue. On request, we can also take care of the disposal.we achieve optimal cleaning results for the fol-lowing areas of application: Combustion chambers Heat exchangers Superheaters Convection zones Primary air preheaters Containers Pipes FixturesThe object of chemical circulation cleaning in fluid sys-tems is to restore bare, metallic surfaces in heat exchang-ers, condensers and coolers. Coatings of scale, iron, magnetite or biofilm are removed from pipes. Losses dur-ing heat transfer are reduced in the devices, energy costs decrease and the life cycle of a system or of the system parts is extended dramatically.Your benefits at a glance: Saving of assembly times (dis- and reassembly) Cost benefits: No scaffolding and lifting equipment required Decrease in energy costs Restoration of the performance values to a new device level Extension of the system run timesBefore afterCHEMICAL CLEANINGCLEANING IN PLACE (CIP)THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORS9THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORSperature camera for this purpose, which allows us to execute a boiler or system inspection during operation. The situation in the system can be precisely analyzed through a monitor. The conditions found have a direct influence on the planning of the most effective way to take care of the disruption. Thus, for example, with an intended explosive cleaning, the detonation process and required dosing can be calculated in advance. The recordings can also be documented on video.the camera can be used for the localization and evaluation of: Damaged areas (rips in the pipes, etc.) Caking (which hinders an optimal operating state) Leaks (heating surfaces, pipes, canals, etc.) Flame patterns Flow conditions For the removal of dust, dirt and product deposits in combustion chambers from giant boilers and in modern fluidised bed boilers or in downstream systems for ex-haust gas treatment, detonation cleaning is used within the scope of planned downtime in the offline procedure and during the running operation in the online proce-dure. While cleaning the deactivated systems, the first safety cleaning through detonation cleaning can occur during the cooling phase and large amounts of deposits can be quickly reduced to conveyable, small pieces. We use industrial climbers for hard to reach areas. Det-onation cleaning technologies can be combined with conventional cleaning procedures. Your benefits at a glance: Reduction of the planned downtime Decrease in costs through savings on equipment High personal safety during the preparatory work for the downtimeFor cleaning while in operation, the system safety is guaranteed by maintaining the temperature of the load under 70 °C. The increase in the operating times, high personal safety, saving of equipment and avoidance of residues from conventional cleaning materials are all important benefits of detonation cleaning. A special camera guarantees the visual state detection before and after the cleaning is done in the system.HiGH teMPeratUre caMeraIt is often the case that contamination cannot be pre-cisely located in large combustion plants. Even if a de-viation from the normal values is determined through the system sensors, this says nothing about the size and quality of the cause. For effective cleaning and the de-termination of the ideal cleaning process, it is important to precisely determine the type, scope and position of the contamination or disruption. We use a high tem-DETONATION CLEANING10THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORSKraftwerKService THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORSStrong adhesive contaminations, also on hard to reach areas of the respective system parts, can be removed effectively with the industrial canon aimed directly at the problem. With the manually operated industrial canon, you shoot plastic balls filled with water at high speeds against the walls in the boiler or industrial systems, which are encrusted with deposits. The energy released upon impact causes the immediate dissipation, removal and breaking of deposits. You can also use plastic balls filled with sand or metal scrap. The accuracy of the industrial canon is 1 square meter with a range of 100 meters. Due to the good accessibil-ity of nearly inaccessible areas, potential safety hazards in systems caused by deposits can already be repaired from a safe distance, before entering the facility.A functional fire-proof system is an important factor for effi-cient incineration in a lot of combustion plants. Connectors between the boiler tube and fire-proof coating are metallic anchoring elements (studs). These are primarily attached through the stud welding process.Your benefits at a glance: Removal of old studs, for example, boiler boats, well anchors, plate holders Face grinding of old anchoring elements Delivery and proper welding of different anchor types according to individual customer requests Consulting services about material qualities and anchor typesINDUSTRIAL CANONuntil 100 mContaminationLaser-aim-deviceImpulse-shoot-cannon80 mm projectileDepending on use optinal filled with water, sand etc.STUD WELDING/STUD REMOVALTHE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORS11THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORSAt hard to reach areas, conventional scaffolding meets its technical and economical limits. This is where the rope-supported elevated work is used for cleaning, testing and inspecting and for maintenance work. Specialized elevated workers provide for proper and ef-ficient operation.Your benefits at a glance: Safe services at hard to reach areas Rope-supported industrial climbers Safety cleaning Tests and inspections Flexible and fastest possible use No or low downtime through dis- and assembly times Cost benefits through no scaffolding and lifting equip- ment Innovative rope-guided and supported industrial cleaning through dry and wet blasting processes as well as weld-ing work and wall thickness gauging have proven to be economical alternatives in many projects.ELEVATED WORK12THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORSKraftwerKService THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORSFURTHER SPECIAL SERVICES waLL tHicKNeSS GaUGiNGA test of the pipe wall thicknesses is frequently executed after the cleaning of boiler systems from fossil-fuel pow-er plants or waste burning plants. We use the newest measuring technology to measure the wall thickness. The measuring devices have a high performance probe so that it is possible to perform optimal measurements, even at higher object temperatures... The recording oc-curs through an integrated measurement data memory, which supports grid formats and is designed for up to 50,000 values. Furthermore, min. and max. values and alarms and differential measurements can be executed in order to allow for an immediate comparison between the measured and nominal wall thicknesses. The files are transported to a PC through a Mini USB Com Port and then imported in Microsoft Excel. caNaL-tv-iNSPectiONWith the most modern camera systems, we inspect systems, pipes and canals. Here, we cover all uses in non-accessible and accessible areas up to ex-areas. The inspection vehicles used for the TV canal inspections are state-of-the-art. caNaL cLeaNiNGWe reliably clean canals and lines up to DN 2,000 with combined suction and cleaning vehicles, which are used to extract and transport the residues. All vehicles are approved according to GGVSE/TRbF.THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORS13THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORS SLUDGe treatMeNtWe treat sludge and suspensions and drain them so that the amounts of waste are reduced. We use power-ful decanters, centrifuges or chamber filter presses for this. We would be happy to dispose of the residue on request. MaNUaL cLeaNiNGDespite all mechanical equipment and progressive au-tomation, manual work is still indispensable in certain areas. Our trained personnel execute this quickly and professionally. DecONtaMiNatiONIn regards to decontamination, we execute decommis-sioning, dismantling and decontamination projects. Here we use our know-how from our different areas of expertise and bundle it with individual complete pack-ages from one source. The concentrations here are in the decontamination of contaminated land and build-ings and system dismantling. waSte MaNaGeMeNtCleaning work is normally connected with waste tasks. On the basis of legal regulations, we work on integrat-ed concepts for the management and removal of waste. Our offer reaches from the collection to the storage, classification and declaration up to the transportation and treatment of all types of waste in our own waste management facilities.Now it’s your turn: what can we do for you?FURTHER SPECIAL SERVICES14THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORSKraftwerKService THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORSOUR EMPLOYEES Training as a breathing apparatus wearer HD-training (theoretical and practice) SCC training and test Trained fork lift operators (50%), first aid workers (30 %) and Safety officers (15 %) Own safety officers Own breathing protection apparatus workshops* Safety instructions are documented in the safety passThe abilities of our employees are the basis for our suc-cess. Continual training and education guarantee a wide standard of qualifications among our skilled workers.KraftwerkService skilled workers DEKRA-certified basic training “skilled workers for sandblast work” Systematic guarantee of general and activity-related instructions (SAP-monitoring)* Medical screening according to G 1.4 / 2 / 8 / 20 / 25 / 26.3 / 30 / 32 / 40 / 41 Confident knowledge of GermanTHE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORS15THE SPECIALIST FOR INDUSTRIAL SERVICE IN CONVENTIONAL POWER PLANTS AND INCINERATORSOUR CERTIFICATES Quality management ISO 9001 Safety management SCC** Specialist Company in accordance with German Water Act § 19 l WHG VGB SeSaM Qualification DEKRA evidence of conformityOur qualifications Personnel qualification for activities as an industrial cleaner HD-cleaning specialist HD-machine operatorBuchen KraftwerkService GmbH Emdener Straße 278 D-50735 KölnPhone: +49 (2 21) 71 77-0 Fax: +49 (2 21) 71 77-111Buchen KraftwerkService GmbH Stadtring 3 D-03042 CottbusPhone: +49 (3 55) 7 35-490 Fax: +49 (3 55) 7 35-491Buchen KraftwerkService GmbH Industriestraße 953 D-50345 HürthPhone: +49 (22 33) 94 60-54 Fax: +49 (22 33) 94 60-55Buchen KraftwerkService GmbH An den Rohrackern 2 D-06217 MerseburgPhone: +49 (34 61) 5 56-151 Fax: +49 (34 61) 5 56-444vertrieb.bks@buchen.net www.kraftwerk-service.dewww.buchen.netBuchen KraftwerkService GmbH Freiheit 24-25 D-13597 BerlinPhone: +49 (30) 3513 03-42 Fax: +49 (30) 3513 03-41Biermann Hochdruck-Strahltechnik GmbH Wiescherstraße 92 D-44805 BochumPhone: +49 (2 34) 8 91 85-0 Fax: +49 (2 34) 8 91 85-20Buchen KraftwerkService GmbH Hohe-Schaar-Kamp 9 21107 HamburgPhone: +49 (40) 74 20 00-101 Fax: +49 (40) 74 20 00-100Buchen KraftwerkService GmbH Kreuzholzstraße 3 67069 LudwigshafenPhone: +49 (621) 6 68 85-25 Fax: +49 (621) 6 68 85-23