This
summarized study has been produced by rb bertomeu S.L., with the
objective of summarizing and publicizing the activities carried out in
power plants equipped with Deutz Diesel engines, with regard to the
ongoing monitoring of corrosion detected on the exhaust valves in engines
installed in power plants, as well as its significant reduction with
the use of “rb bertomeu” beco F1/ASF additive for heavy fuel oil.
The
monitoring activities were all carried out in collaboration with our clients
and DEUTZ IBERIA, mainly through DEUTZ SERVICE VIGO, who received a copy of
all documentation and reports produced.
This
report should be read in conjunction with the following documentation, on
which it is based.
- RB DOC-013E Study of the
maintenance history of exhaust valves in Deutz engines at MINERA DE SANTA
MARTA S.A.
- DOC-014E Study
of the maintenance history of exhaust valves in Deutz engines at UFEFYS S.L.
- DOC-011E Study
of the maintenance history of exhaust valves in Deutz engines at MYTA S.A.
- RB-13 Tests to
extend the operational life of exhaust valves to reach 6,000 Hours in motor
no. 1 at CALVO ENERGIA (EnergyWorks-Carballo).
Since
1995, rb bertomeu S.L. has treated the fuel oil used in several
power plants, largely equipped with Deutz Diesel engines, with
several aims, but most importantly to reduce the significant levels of
corrosion that exhaust valves suffered, in order to achieve the following
main objectives:
a)
To reduce the financial cost of replacing the valves discarded due to
corrosion, by means of increasing their operational life.
b)
To reduce both stoppage times and loss of production due to unscheduled
stoppages caused by severe corrosion (blowouts).
c)
To increase the T.B.O. for exhaust valve overhauls, exceeding original
TBOs of 2,500 hours , which was difficult to overcome because of corrosion
levels.
As
is well known in the power generation industry, the main cause of corrosion on
valves is the corrosive action of sodium vanadates at high temperatures,
arising from the presence of vanadium and sodium in fuel oil. The combustion
of fuel oil produces sodium vanadates in liquid form, which produce corrosion
and incrusted residues (mainly a mixture of vanadates and sulphates) not only
on exhaust valves, but also on turbochargers as was later discovered with the
benefit of many years’ experience.
Our
company, with the consent of Deutz Iberia and our clients operating
power plants, initiated a series of programmes to monitor engine
overhauls, in order to verify the efficacy of the additive treatment applied
to the fuel oil. This was a long and arduous task, but it helped all concerned
to analyse the problem of corrosion in greater depth, and moreover, to solve
it to a large extent. Thus, in terms of round figures, it is possible both
to double the operational life of exhaust valves and to double the TBO for
valve overhauls in relation to normal values obtained without using “rb
bertomeu” additives.
The
main monitoring processes carried out during stoppages for valve overhauls
were as follows (see annex Official Authorisation Procedure RB-001):
1-
Compiling photographic reports on all valves inspected (valve and valve seat,
to provide a graphic record of all anomalies detected (corrosion, blowouts,
compacting, etc.).
2-
Weighing of incrustation accumulated on each valve.
3-
Maintaining a record of all components replaced (valves and valve sleeves)
including reasons for replacement.
Numerous
plants have undergone this type of monitoring, and those of greatest
interest, i.e., with longer monitoring periods, are included in the Annexes
MINERA DE SANTA MARTA, UFEFYS and MYTA. Nevertheless, monitoring was
carried out, whether for longer or shorter periods, at the following plants
with Deutz engines.
-
Cogeneración Bañeres
-
Cogeman
-
Cere A.I.E.
-
Boinersa
- Calvo
Energía S.A.U.
-
Intasa
-
Paquito
-
Artabra
Each
plant has demonstrated the effectiveness in preventing corrosion and
incrustation of the “rb bertomeu” additive treatment. The
following examples, though by no means exhaustive, demonstrate the principal
achievements and are supported and certified by letters from the owners
of the plants (see letters of reference for full details).
THE
PLANT AT MINERA SANTA MARTA:
The
systematic valve overhaul consisted of dismantling, rectifying and re-installing
all the valves, i.e., valves were not replaced unless they were rejected due
to severe corrosion, thermal fatigue or failure to conform to size. This
system made it easy to carry out monitoring of the operational life of the
valves.
The plant consumed Fuel BIA during the first twelve months
approximately, and thereafter used Fuel No. 1, which presents greater
corrosion problems, as it contains more impurities. However, this did
not affect the efficacy of the additive treatment.
The operational life of the valves increased from a
theoretical value of 10,000-12,000 hours to an actual value of 25,000-30,000
hours, whereby the theoretical value is at least doubled.
The average saving produced by this increase in the
operational life equalled 70-80% in consumption of valves.
The plant achieved, without difficulty, the TBO of
3,000 hours, which prior to treatment it was unable to attain. The TBO
was not exceeded for technical reasons.
As a test, the plant operated with a TBO of 4,500
hours, which it completed successfully, although this TBO was not implemented
on a regular basis for technical reasons.
Next you can find letters of reference fom some of our customers that ratify the effectiveness of the additive "rb bertomeu" beco F1/ASF in order to prevent corrosion (Letters in Spanish).
- Carta Minera Santa Marta 01/08/1998
- Carta Minera Santa Marta 18/09/1996
THE PLANT AT UFEFYS
The plant achieved, without difficulty, the TBO of
3,000 hours, which prior to treatment it was unable to attain. The TBO
was not exceeded for technical reasons.
As a test, the plant was subjected to a TBO of
4,500 hours, which it completed successfully, although this TBO was not
implemented on a regular basis for technical reasons.
Next you can find letters of reference fom some of our customers that ratify the effectiveness of the additive "rb bertomeu" beco F1/ASF in order to prevent corrosion (Letters in Spanish).
- Carta UFEFYS 26/06/2015
- Carta UFEFYS 30/01/2001
- Carta UFEFYS 24/10/1996
THE PLANT AT MYTA
This plant was affected by numerous problems
originating in the design of the engines, which had to be modified. Once
these problems had been solved, corrosion on valves was the main problem.
The problem of corrosion was notably reduced, which
allowed the plant to achieve the TBO of 3,000 hours.
Next you can find letters of reference fom some of our customers that ratify the effectiveness of the additive "rb bertomeu" beco F1/ASF in order to prevent corrosion (Letters in Spanish).
- Carta MYTA 17/06/2015
- Carta MYTA 25/01/1999
THE PLANT AT INTASA
The TBO was doubled with respect to the TBO used
prior to treatment with “beco F1/ASF”, increasing from 2,000–3,000 hours to
5,000 hours in certain cases.
All corrosion that had previously formed on
Turbochargres was eliminated.
Next you can find letters of reference fom some of our customers that ratify the effectiveness of the additive "rb bertomeu" beco F1/ASF in order to prevent corrosion (Letters in Spanish).
- Carta Intasa 20/01/2001
THE PLANT AT ARTABRA
The TBO for exhaust valves and turbochargres was
systematically increased by almost 50% in relation to the normal values given
by Deutz (the TBO was increased from 3,000 hours to 4,300 hours).
Valve blowouts occurring between overhauls have been
virtually eliminated.
Operational life has been extended for components
in the housing of the first turbos installed, and subsequently
replaced. Their new operational life remains to be defined, as they
have not yet been replaced.
Next you can find letters of reference fom some of our customers that ratify the effectiveness of the additive "rb bertomeu" beco F1/ASF in order to prevent corrosion (Letters in Spanish).
- Carta Artabra 15/02/2001
THE PLANT AT BOINERSA
The great reduction in corrosion on exhaust valves
and turbcharger components has led to an increase in their operational life
(which cannot yet be quantified), allowing the plant to operate
systematically with periods between maintenance of 25% longer than previously
scheduled.
Next you can find letters of reference fom some of our customers that ratify the effectiveness of the additive "rb bertomeu" beco F1/ASF in order to prevent corrosion (Letters in Spanish).
- Carta Boinersa 10/01/2001
In
view of the positive results obtained with our additive treatment for fuel
oil, we considered applying for recognition from DEUTZ in the form of
official authorisation of the product, in view of the fact that DEUTZ
IBERIA had participated in the monitoring process.
A
large part of the information compiled was submitted to DEUTZ MWM AG
in a meeting with the Department AE-UB, held in Mannheim in March 1998,
attended by Deutz Service Vigo and rb bertomeu S.L. as well as
Messrs Haury (Manager of Large Engine Development), Koll (Manager of Project
Management, Diesel Energy Systems) and Helms, (Manager of Customer Service
Medium and Large Engines), in representation of Deutz MWM AG.
As
a consequence of this meeting and the reports of Deutz Iberia, in
December 1999 we were granted official authorisation: the only brand of fuel
additives to achieve such recognition. It should be emphasised that
both Deutz Iberia and Deutz Service Vigo have collaborated in
all the verification checks carried out, and that they also have experience
of the positive results obtained.
Finally,
in 2001, Deutz Iberia proposed that a new control test of TBO increase to be
carried out in the power plant at CALVO ENERGIA (currently ENERGYWORKS-
Carballo) with the objective of reaching 6,000 hours instead of the usual
3,000 hours. At the end of this test, the propose objectives had been met: duplicating the TBO. In the next link you can find more information: "Bulletin Num. 16: Exhaust valves in large engines operated with heavy fuel oil. Doubling the TBO for general overhauls."
It is important to underline that from then till now, end of 2015, the company EWCAR-EnergyWorks-Carballo has been continuously using the additive as can be read here, having increased the valves TBO up to 7,200 hours (140%!)
In "RB-13 EnergyWorks-Carballo extension of the useful life of exhaust valves up to doubling TBO" you can read the complete study and its updates.
CONCLUSION
All
parties involved in this question, owners of power plants
and Deutz Iberia – Deutz Service, have for many years
concurred in that the application of the fuel oil additive treatment “rb
bertomeu” beco F1/ASF provides improved operation in power plants
with Deutz diesel engines. Similarly, they recognise that among the
many great benefits obtained that we will not mention here (see RB-28 Actions and benefits of "rb bertomeu" heavy fuel oil additives) there is the significant direct saving in maintenance (the cost of
replacing valves and turbos) and a potential saving that is only obtained in
certain cases, but could be obtained generally if so desired (increase in TBO
for valve overhauls from the present 3,000 hours to the 5,000-6,000
is possible).
In
short, if fuel oil is treated with the “rb bertomeu” beco F1/ASF additive,
the overall maintenance cost for the engines is REDUCED, while the overall
availability of the plant is INCREASED, thus improving the profitability of
the power plant.
Our
company, in collaboration with Deutz Iberia, conducted several
profitability studies in order to quantify these maintenance savings, on the
basis of prices quoted by Deutz Iberia and the percentages of
improvement recorded in monitored plants (equipped with Deutz engines).
These studies carried out on the Deutz engine models BV 16M 640 and
TBD 645 L9 demonstrate the high cost-effectiveness of our additives, and
the results are applied in the “RB-1 Profitability study in power plants after using additive “rb bertomeu” beco F1/ASF in diesel engines running on heavy fuel oil”
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