Engineering / Consultancy
We offer our services to chemical cleaning & EPC companies all around the world.
We believe that each of our clients faces a unique set of challenges and that their needs can be best met by providing innovative engineering solutions to these challenges. We carry out all the backroom services like evaluating a job, preparing a basis for firm techno-commercial proposals, write method statements, markup P&ID's, prepare risk assessments and also provide on-site services for execution, supervision and inspection of all pre & post operational chemical cleaning, hydrojetting and decontamination activities
We provide expertise in numerous areas of engineering and procedure writing, including:
- Pre-commissioning cleaning
- Commissioning cleaning and testing
- Unit shutdown cleaning and inerting
- Hydrojetting limits
Steam lines are blown prior to starting up a new unit to remove any debris, sand, oil, rust etc. that may be remaining in the equipments prior to plant start-up.
Our steam blowing systems are backed by best quality engineering and quality equipment.
During steam blowing, the piping is blown with enough velocity to ensure it will experience sufficient cleaning force for adequate removal of debris and scale. Thus, any potentially damaging particles will be blown out of the piping prior to plant operation. Excellent coordination and logistics, as well as close involvement with other workers, can prevent space and equipment conflicts and the potential need for re-work. Determining pipe sizing and design, pipe routing, steam conditions, noise level, thermal cycling, water quenching, and condensate generation are all factors that - with our proper planning - will ensure a successful steam blow operation.
Why steam blowing?
During any plant start up, there's a possibility that particles left in the pipe from the construction phase could break loose and travel downstream. These particles can damange instrumentation and impede other plant operations. During a steam blow, the piping is blown with sufficient boiler pressure to ensure that enough dynamic pressure will be experienced in the pipe to provide adequate cleaning.
Ecomaxx® Low Noise Steam Blow Technology
Ecomaxx® LN Steam blows allows power station customers to ensure that during normal operation no adhering material in the superheaters, reheaters and steam pipelines will get dislodged reach turbine blades and damage them.
During the maximum continuous rating load of the turbine the drag force in the pipe line can dislodge particles loosely adhering to the tubes internal surface, causing great damage to the turbine blades. The Ecomaxx® LN steam blowing operation cleans all the debris in the superheater, reheater and the steam pipe line connecting the turbine.
Ecomaxx® LN Steam Blows follows the European Standard VGB R513e to effectively carry out this operation and focuses on creating a drag force created on the inside surface of tubes or pipes which is much higher than that occurring during the maximum continuous rating load of the turbine.
The ratio of the drag created during steam blowing to the drag occurring during the maximum continuous rating load is called the disturbance factor usually limited to a factor of 1.6
In comparison to the normal Huff & Puff Techniques Ecomaxx® makes use of the sliding pressure method the salient features of which are -
- The boiler is operated at 20-40% load as against 40 - 60% for the Huff & Puff Method
- As against the quick release of accumulated pressure as in Huff & Blow Methods that puts huge stresses on the temporary piping the Ecomaxx® LN steam blow makes use of the sliding pressure technique that results in lower operating pressures but significantly higher cleaning velocities
- The Ecomaxx® LN steam blow offers a controlled K-value that extends for minutes as compared to the H & P method that has an uncontrolled K-Value lasting a few seconds.
- The piping that is being steam blown can be completely insulated thus leading to a safer work environment.
- The lower operating pressure of the boiler and the lesser time needed to achieve a clean target plate, normally 7 to 10 blows reduces fuel costs by up to 5 times on account of short blowing durations from 20 to 60 minutes, hence achieving maximum economic efficiency (Ecomaxx®) for plant owners.
- Taking into environmental considerations the Ecomaxx® LN Steam Blows are effectively muzzled to reduce noise levels to < 90 db in a 10 m radius
- Finally a simpler temporary piping design for the steam blow saves on manpower and erection costs.
Chemical Cleaning > De scaling
Span Chem Technologies efficiently removes fouling deposits from heat transfer equipment, boilers, and other industrial equipment by circulating chemical solvents under controlled temperature, pressure and time conditions.
Span Chem Technologies leads the industry in pre-operational and operational chemical cleaning with over 15 years of experience. This plays a vital role in assuring that the plant and product specifications will be met at the very outset of facility start-up and throughout the operational cycle. The facility will operate smoothly, efficiently, and on schedule. Troublesome and costly start-up difficulties due to undesirable deposits are eliminated.
We custom engineer each individual chemical cleaning job to provide a complete, high quality cleaning service. We analyze your equipment, processes, and deposits to design a cleaning process to fit your individual plant needs and select the optimal cleaning solvent system.
A series of chemical cleaning centrifugal pumps, specialized chemical hoses, heating units, filters and chemical mixing tanks are typically used to establish optimal circulation loops.
Each chemical cleaning project is custom engineered to deliver optimal treatment, taking into account:
- Deposit Sample Analyses
- Solvent/Metallurgy Compatibility
- Process Loop Geometry
- Fluid Flow Velocities
- • Pressure Drop Considerations
- Process and Chemical Handling Safety
- Waste Minimization and Disposal
We combine a wide variety of chemicals, including proprietary blends, with techniques such as circulation, fill-and-soak, cascading, foaming, rotating spray systems, and vapor phase cleaning to achieve superior performance and results.
Our services cater to a wide range of heat transfer equipment including: Marine Boilers, Lube Oil Coolers, Condensers, Evaporators, Compressor Jackets, Intercoolers/Aftercoolers, Pump Jackets, Chilled Water Cooling System, VHP Systems, Air Handling & Fan Coil Units, Shell & Tube Heat Exchangers, Double Pipe Heat Exchangers, Plate Type Heat Exchanges, Waste Heat Boilers
The chemical cleaning services include:
Gamma Jet Cleaning
Chemical Cleaning > De scaling >> Pre-Commissioning
Each year millions of rupees are spent by corporations in setting up process plants for oil, gas, chemicals and downstream processing. A major part of this money goes into piping & machinery. To ensure that this equipment and piping perform at its peak it is necessary to start operations on them in a clean condition.
When new equipment is fabricated, erected, or installed, engineers and plant management must concern themselves with deposits that have accumulated on the metal surfaces during construction or with deposits that have been applied in the manner of protective coatings at the mill. These deposits may appear in the form of dirt, weld splatter, iron oxide, paint, lacquer, or oil coatings.
The removal of these deposits from a newly fabricated process system is referred to as pre-commissioning cleaning, because thorough surface cleaning should be performed prior to initial equipment start-up.
Pre-Commissioning cleaning is desirable for several reasons. The most notable is that on the process side deposits can contaminate the product, reduce efficiency through restricting heat transfer, damage delicate or sensitive instrumentation and valves, and aid in accelerating corrosion. Since the unwanted deposits may be of an organic or inorganic nature, the application of a multistep cleaning procedure may be required to ensure removal of all unwanted deposits. Sometimes pre-commissioning cleaning is performed on exterior surfaces strictly for cosmetic purposes.
Steam Generation System, Amine System, Compressor Suction Circuits & Cooling Water systems that include both piping & equipment are normally cleaned before start up.
Spanchem Technologies ensures that the various factors namely the metallurgy being cleaned, type of deposits, mechanical design of the equipment, time & temperature constraints along with safety & disposal considerations are taken into account while formulating cleaning procedures.
We make use of a variety of techniques like dynamic circulation, fill & soak ,cascade cleaning, immersion cleaning, swab cleaning & foaming are used to meet the cleanliness targets set by the end user
Chemical Cleaning > De scaling >> Post-Commissioning
Today, the high cost of energy and downtime (nonproduction hours) is an important factor in considering post-commissioning chemical cleaning of systems or equipment. To minimize operating costs while maintaining high operating efficiency the removal of deposit buildup is essential to equipment life and product quality.
Consequently, the use of post-commissiong chemical cleaning techniques to remove unwanted deposits from the process-side and water-side segments of industrial process equipment are widely employed.
Neglect in removing organic or inorganic deposits on the process or water sides of industrial equipment may result in irrevocable damage to the equipment, leading to costly repairs and premature replacement of portions or the entire unit.
Spanchem Technologies has the ability to deliver customized solutions based on scale type, metallurgy and equipment geometry. The objective being that the customer's equipment is subject to the minimum downtime required for cleaning and restored to maximum possible efficiencies.
Over the years we have cleaned a wide variety of equipment like Shell & Tube heat exchangers, Double pipe heat exchangers, Plate type heat exchangers, Compabloc heat exchangers, Jacketed Vessels, Glass Lined Reactors, Utility boilers, Power Station Boilers, Marine Boilers, Condenser, Intercoolers, Knock out Drums, DG Set Cooling Circuits and have handled a wide range of metallurgies from Carbon Steels to Austenitic Steels, Martensitic Steels, Duplex Steels, Cast Iron, Admiralty Brass, Copper, Zirconium & Titanium.
We also specialize in the cleaning of refinery specific equipment like Packinox Exchangers, Helitowers, Split Feed Exchangers & Breech Lock Exchangers essentially working towards removing process contamination to reduce fouling.
Chemical Cleaning / De scaling >> Foam Cleaning
Foam Cleaning services from Span Chem Technologies clean dirty fin fans/tubes in air fin coolers & air pre heaters that can reduce the cooling efficiency of heat exchangers.
The traditional cleaning method of hydrojetting damages delicate fin fans and collates the debris into the center of the tube stack. With a chemical process, complete removal of dirt, debris and corrosive elements is possible without any damage to the equipment. Our low pressure, high volume cleaning process removes dirt and debris safely and thoroughly. We use environmentally friendly chemical foam that saturates and expands into every crevice of the gaps between the cooler tubes. A low pressure rinse minimizes over-spray and is safe for both workforce and the equipment.
Chemical Cleaning / De scaling >>Gamma Jet Cleaning
Gamma Jet’s rotary impingement tank cleaning machines combine pressure and flow to create high impact cleaning jets clean large tanks and pressure vessels.
Cleaning occurs at the point in which the concentrated stream impacts the surface of the tank. It is this impact and the tangential force that radiates from that point which blasts contaminants from the surface, scouring the tank interior. In conjunction with this impact, the Gamma Jet is engineered to rotate in a precise, repeatable and reliable, 360-degree pattern. This full-coverage, global indexing pattern ensures the entire tank interior is cleaned, every time.
The combination of high pressure and 360 degree coverage of the jets up to a 30 m radius gives us an edge in this business and the use of special chemistries enable us to clean tanks containing pyrophoric deposits as well.
Degassing & De-contamination
Reducing vessel entry time, providing cleaner systems and operational safety is our goal in decontamination services.
Most elements of refineries and petrochemical plants (columns, vessels, heat exchangers, etc.) build up hydrocarbon deposits over time. The cleaning of these is often less than straightforward requiring decontamination to eliminate hydrogen sulphide, benzene, explosive gases (LEL) and pyrophoric iron sulphides. Whether as part of scheduled maintenance or break fix works, Span Chen Technologies has experience in the chemical cleaning and decontamination of such elements and ensures that maintenance teams are swiftly provided with safe access to the plant for the required maintenance operations.
Span Chem Technologies uses chemical products for decontamination that are highly effective, fast-acting and safe for personnel, plant and the environment.
The chemicals themselves have near neutral pH, are non toxic and biodegradable. They have no VOCs and are not flammable, with an MSDS hazard rating of 0-0-0. The process drastically improves entry time to 12 hours or less and eliminates safety concerns associated with cleaning, degassing and environmental compliance.
We deliver our decontamination chemistry HYDROSOL both in the liquid and the vapor phase into vessels, columns and exchangers of refineries to reduce LELs, Benzene, H2S while emulsifying all oil into solution and finally neutralizing pyrophoric irons using OXONIA. Oil recovery is possible in this process and the chemistry is biodegradable.
Degassing & De-contamination >>Vapor phase
The vapor phase (decontamination) is a process that reduces the steam-out time needed prior to entering the equipment during a turnaround. In Vapor Phase Decontamination the HYDROSOL is entrained into the plant steam and onwards into the equipment. The steam ensures that the HYDROSOL reaches all the locations in the vessel or column and as it condenses the HYDROSOL brings the hydrocarbon into solution and carries away the gases in an action similar to stripping.Vapor Phase Decontamination techniques are appropriate for: fractionation columns in CDU, vacuum units, FCCU, visbreakers, HDS, LC finer, lube units, amine units, heat exchangers, separators drums, etc. They offer the advantage of low water requirement, lower lead times to set up in comparison to liquid phase decontamination and generate very little effluent while deliver very clean systems and are particularly useful in dense packed columns.
Degassing & De-contamination >>Liquid phase
The liquid phase decontamination is performed when vapor phasing alone is not sufficient to remove fouling or deposits. The liquid phase removes organic substances with medium and high molecular weight and muds. It is commonly used in CDU, vacuum units, visbreakers, FCC slurry, storage tanks, etc. and is also preferred in hydrocarbon processing units where the precipitation of asphaltenes, waxes, and coke particles may have caused fouling during the operation.
The liquid phase also removes light hydrocarbons such as benzene, toluene, xylene, light gasoline, etc., from the equipment and can also used for the removal of hydrogen sulphide and inorganic volatile salts (i.e., ammonium salts).
The liquid phase is capable of delivering extremely clean exchangers in the Crude Preheat Trains with no need to do any further hydrojetting, bundle pulling after liquid phase decontamination is a simple affair.
We offer complete customized solutions for chemical cleaning and take on turnkey jobs to carry our chemical cleaning at client locations.
We clean everything from simple condensers to complex Amine, Steam, Compressor and HRSG systems. Besides this we also offer lube oil flushing services to achieve required NAS values in Hydraulic and Turbine Oil Systems.
Span Chem Technologies carries out Oil Flushing with its own Oil Flushing Skids consisting of external pumps (gear/ centrifugal), beta-rated cartridge filters, heated break tanks and NAS value counters. Oil flushes to the piping system at 3 to 6 times its normal flow rate. This high volume of oil removes scale and particulate from the piping that is trapped in the filter. Thermal shocks greatly enhance the process and achieve NAS values quicker than normal flushing equipment. In most cases a pre-operational pickling of the piping is carried out to ensure cleaner systems.
Hydro-Jetting / HydroMilling
We specialize in providing hydro jetting services using high pressure jetting units to supplement our chemical cleaning services.
Hydro milling has been widely used in industrial cleaning and pre-commissioning applications for the removal of hard deposits from steam, lube oil, compressor, and process line systems, as well as tube bundles and vessels. It is recommended especially in the case of large diameter piping (>24") offering significant savings in utilities and waste disposal as compared to chemical cleaning. In order to help preserve the long-term integrity of these process piping systems, hydro-milling can be used to remove all undesirable foreign contaminants and particulate matter.
The nozzle head, fixed on the end of the high pressure hose is static, the entire length of HP hose itself is then rotated using a Rotating Hose Device (RDR unit). The RDR unit is either hydraulically operated or pneumatically operating rotary device. The RDR unit (a wheeled rotary joint) sits externally from the pipe being cleaned, in such a manner that the rotary device can travel the cleaning distances with the rotating hose length which is inserted into the pipeline opening.
The high pressure swivel installed on the RDR unit allows rotational speeds from as low as 10 rpm up to 300rpm thus cleaning the internal pipe wall in its circumference. The High pressure nozzle head and water jets are specially configured to ensure the nozzle stand-off distance from the pipe internal wall surfaces is kept constant, and the hose rotational speed is set to ensure the optimum water jet dwell time is achieved to clean the hardest scales and debris requiring removal from the pipe surface.
We employ automated, non-man entry tank cleaning and oil recovery solutions designed for optimum health, safety and environmental performance. Our systems clean above ground oil storage tanks and recover waste oil in a safe and efficient way.
Whether it's outine maintenance to remove solids and sludge, decontamination measures, tank renovation, or the demolition and decommissioning of a tank, trained personnel perform the storage tank cleaning. It covers :
- Chemical cleaning on industrial process systems to remove residual oils, corrosion products, chemical build-up and other contaminants
- Hydroblasting to help decontaminate and remove excess waste build-up from tanks, boilers, drum storage areas, plant floors, parking lots, machinery and a variety of other locations
- Vacuum cleaning to remove heavy sludges and solids that are not broken down by ordinary vacuum units. These units are able to replace previous methods using manual labor.
- Storing, transporting and disposing of hazardous and non-hazardous chemicals and or product during each tank cleaning
- Less exposure to safety risk
- Lower project costs
- Recovered hydrocarbons
- Less environmental harm
Our chemical tank cleaning methodology doesn't require personnel to enter the tank; all work is performed in a closed loop system. Our chemicals are the only thing that works inside. Plus, all of the hazardous materials are flushed out of the tank without people being exposed to them.
Air blowing is a varied process by which compressed air is utilized as a cleaning medium to remove construction debris, loose rust, liquids, and other contaminants from process piping.
Span Chem Technologies utilizes specializes equipment necessary to correctly perform air blows of various plant piping systems as well as air blowing of steam generating equipment. Piping systems which do not require high levels of cleanliness typically associated with steam blowing and chemical cleaning can effectively be cleaned by air blowing processes. Gross construction debris, sand and dirt are able to be transported out of the system and safely into one of our silencers/debris separators while causing minimal disruption to ongoing work activities.
Decompression air blowing involves pressurizing the system or an additional volume to a predetermined and engineered pressure so that operational forces during the process will be exceeded. Once the predetermined pressure has been reached, the pressurized portion of the system is decompressed into a specialized collection and noise reducing receiver. For continuous air blowing, the system is subjected to a continuous stream of air at a predetermined and engineered flow rate until the client’s desired cleanliness specifications have been met.