Operational Safety in Power Stations

Project Sales Corp –Product Information Bulletin

An Important Contribution towards Operational Safety in Power Stations

MOLYKOTEP 37 Thread Paste Sets New Standards

With a view towards the greatest possible operational safety, particularly high standards have to be met by the materials used in power stations. These also include lubricants, particularly those for bolted connections.

Bolted connections are in some cases exposed to extreme temperatures, which can reach up to 330°C in plants operated using nuclear power and up to 950°C in gas turbines. Such bolts must therefore be made of heat-resisting and high-temperature steels, for example nickel-based alloys, in order to guarantee adequate strength even at such highoperating temperatures. The surfaces of these steels, as a rule, only develop a very thin oxide film. As a result, cold bonding tends to occur when the bolts are tightened or loosened, and so they must be protected with the help of a special lubricant to separate the surfaces. The coefficient of friction should be approx.0.12 to 0.14 order to permit the required uniform tightness of the bolted connections. This is particularly important with flanged connections in order to avoid leaks.

Bolted connections have to be dismantled during regular power station inspections. This, however, is often not possible if an unsuitable lubricant has been used during assembly. The bolts, or studs, then have to be sawn off and the stubs drilled out of the blind hole.This work can take up a lot of precious time. Even greater problems can arise through bolt fractures, for these can lead to leaks at the connected components; these are notifiable accidents in nuclear power stations. Such fractures may be caused not only by metal fatigue but also by the thread lubricant. If, for example, a lubricant containing low melting point metals like lead, tin or zinc, is used the molten metal can defuse into the grain boundaries of the fastener alloy eventually leading to stress fracture. The suspicion exists that even traces of sulphur can cause corrosion on bolts in presence of water or vapour. Halogens, such as chloride or fluoride, can also lead to corrosion of the bolt which may cause fracture.

For the reasons stated above SIEMENS, the power station construction company, stipulates that high temperature bolt lubricants for use in power stations must not contain lead, tin or zinc in their formulation. Any unavoidable contamination by these materials must not exceed 500 mg per kilogram of lubricant. In the past nickel based pastes were sometimes used in bolted connections exposed to high temperatures. Because of the carcinogenic effects of nickel powder, SIEMENS has removed these pastes from their list of approved products.

In nuclear power stations bolted connections are in some cases exposed to radiation and as a result specific ingredients in the lubricant, for example antimony, canthemselves be transformed into radioactive isotopes and begin to radiate. For this reason high temperature lubricants used for such applications should contain no elements, which can be activated at the reactor operation. For these reasons graphite lubricants have been used in the past mainly onscrews exposed to water or vapour. However, due to the lubricating properties typical for graphite,problems occurred after extended exposure to high temperatures. Sometimes bolts could not be loosened and so had to be drilled out.

In 1992 MOLYKOTE and SIEMENS agreed to a joint development programmeto produce and approve a high temperature thread lubricant for power stations which would overcome existing problems. Product development would be in the hands of MOLYKOTE while SIEMENS took over the responsibility for practical testing.

The following were the bolt materials selected for testing as these alloys were considered to be the most widely used in the industry.

•Nr. 1.7709 (21 CrMo NiV 57)

•Nr. 1.4913 (X19CrMoV Nb N III)

•Nr. 1.4986 (X8 Cr Ni Mo BNb 1616)

•Nr. 1.4952 (Ni Cr 20 Ti AI -Nimonic)

The breakaway torques were measured after high temperature exposure at 300, 600 and 850°C. Finally, within the framework of a complete quantitative analysis, the percentage purity of the paste was determined. After completion of the very thorough practical tests MOLYKOTEP 37 high temperature thread paste, which had been developed by this joint project, was approved by SIEMENS for all types of power stations, in accordance with their TLV9600 02/02, for the lubrication of bolted connections in a dry atmosphere.

At about the same time SIEMENS discovered in the course of extensive autoclave tests that MOLYKOTE P 37 was also suitable for threads which come into contact with water or steam. The new thread lubricant meets fully the requirements of power station manufacturers and operators. Its specification does not include any metals, or sulphur, fluoride or chloride. Any contamination from raw materials is far below laid down limits. This high degree of purity is achieved with the help of a special production plant which is solely used for this one lubricant. As an additional safeguard, each production batch is inspected and tested for purity not only on our own premises but also by an independent institute. A purity certificate is enclosed with each delivery. Despite the importance attached to purity, each batch is also checked for mechanical performance as a thread lubricant on a special bolt testing machine before release

.To sum up, it can be said that the new MOLYKOTEP 37 thread pastemakes an important contribution to operational safety in power stations. Due to its ingredients which are non-reactive with bolt alloys, together with its purity and Carefully adjusted coefficient of friction, it protects against seizure of bolts and allows connections to be dismantled easily, even after long periods at high temperature.

Technical advantages of MOLYKOTEP 37.

Good lubrication properties in bolted connections.

Solid lubricants stable up to temperatures of 1400°C.

Contains no metals whatsoever .

Less than 200ppm of sulphur, chloride and fluoride.

Coefficient of friction within the range of oiled bolts.

Purity certificate enclosed

Also approved by GE, P&W, Westinghouse, BHEL, Rolls Royce, Mitsubishi Heavy Industries Ltd, Daimler-Chrysler Aerospace, US Navy Ship Board Turbines, Nuovo Pignone, MTU, Electricity De France, Thai Petroleum Corporation Limited and many more power stations, refineries, and turbine and engine manufacturers around the world.

Now available in imported brush top tins of 500 grams. The packaging of the thread paste in tins with brushes helps to avoid contamination which could occur through brushes that have been used elsewhere.

Ships for Rs. 3250/-per tin plus taxes, with a purity certificate, off course ! Project Sales Corp, 28 Founta Plaza, Suryabagh, Visakhapatnam 530020, APCall +91-8912564393, Fax +91-891-2590482, Mob +91-98851 49412http://www.projectsalescorp.com

Marston Jointing Compound from Marston Domsel

Marston Universal Jointing Compound is a unique non-hardening sealant used extensively in the industry today for sealing metal-to-metal joints at high temperatures, in the presence of oils, fuels and gases.

It is a polyester urethane based viscous sealant blended with a solvent. The product is a non-setting sealant, it doesn't harden, even at 250oC.

It has a unique curtaining action. As flanges sealed with Marston are pulled apart, the material stretches, and then breaks cohesively, leaving sealant on both sides. When the flanges return together, the putty reseals, a self-healing mechanism. This makes Marston a particularly effective sealant on close fitting large flanges which are subject to extreme vibration, distorition, or joint movement, because while the seal may break for a microsecond, it reseals and the fluids remain contained.

Chemical Resistance Properties

Marston is resistant to a wide range of fluids, including all industrial fuels, oils, water and brine, air, turbine and piston engine combustion products, water, water/glycol and methanol mixtures, petroleum and synthetic diester lubricating oils, gasoline, lubricating oils, gasoline, kerosene fluids, and most fluorocarbon refrigerants. Marston can be used to seal joint faces or threaded parts. It is effective for sealing metal to metal joints in the presence of oils and high temperatures.

Marston is designed for industrial sealing applications. The application areas include:

Turbine pedestal bearing parting planes in thermal, gas and nuclear power stations

Oil joints in turbines
Engines
High temperature gear box flanges
As a gasket dressing product on pre-formed gaskets for better sealing in the presence of oils and fuels.
Diesel engines cylinder head gasket, inlet manifolds, oil sumps, etc
Thread sealing applications in drain plugs, etc.

Advantages of using Marston as a sealing product

Can be used as an aid to sealing with other compression gaskets.

Allows easier dismantling as components are not bonded together.

High temperature range of 250-300 deg c compared to others for gasketing applications.
Excellent thermal, mechanical and chemical resistance.
Completely resistant to oil, fuels, gases, water, air, antifreeze and many others.
Non-hardening - hence handles vibrations and lateral movements better.
Seals all asperities in metal-to- metal joints with one easy application.
Unlimited assembly time after application.

Marston is approved by all leading companies in the field of aviation, power generation, engine manufacturing, gear construction, etc. OEMS include Renk, Reinz, Rolls Royce, Thyssen, Deutz, MAN, Massey- Fergusson, Mercedes, Toyota, Shell, Texaco, AEG, Bosch, Siemens, Varta, Phillips, Caterpillar, Demag, Dynamit Nobel, SKF, Perkins, BASF, Bayer, Hapag Lloyd and many more machine, gear, seals and aircraft manufacturers.

Listed with Nato and German Federal Armed Forces, as well as many nuclear, gas and thermal power stations.

Available with:

Project Sales Corp

28 Founta Plaza

Suryabagh

Visakhapatnam

530020 AP

India

Call 0891 2564393

Fax 0891 2590482

satish@projectsalescorp.com

www.projectsalescorp.com

Birkosit Turbine Sealing Compound

Application area, metal-to-metal joints

BIRKOSIT - Dichtungskitt ^®

BIRKOSIT - Dichtungskitt ^® Sealing Compound has been used for 50 years on Siemens turbines (product development 1952 with Siemens). Without the additional sealing of individual pressure areas using BIRKOSIT - Dichtungskitt ^® the production imprecision or the distortion under loads are no longer evened out, which means that the turbine areas in the individual pressure areas become permeable under pressure. This means the turbine loses power, and can even lead to unplanned reconditioning.

BIRKOSIT - Dichtungskitt ^® is formulated to be practically inert in its standard applications in steam and gas turbines. It is, therefore, resistant to exposure to hot air, steam, water, light fuel oils and lubricants. By implication, it should be resistant to crude oil and natural gas.

For placing your orders, please contact

Project Sales Corporation, General Agency of A.I. Schulze, for marketing BIRKOSIT - Dichtungskitt ® in India
28 Founta Plaza, Suryabagh, Visakhapatnam 530 020, AP, India; phone: +918912564393; fax: +918912590482

http://india.birkosit.com

Ordering Instructions:
Product : BIRKOSIT DICHTUNGSKITT (SEALING COMPOUND)
Make : AI SCHULZE, GERMANY
Pack Size: 1 kg
Price: Rs.4250 per KG
Taxes: CST 2% extra against form C, else 14.5% extra
Delivery FOR Destination through First Flight Courier/GATI
MOQ: 10 kgs
India Distributors: Project Sales Corporation, Visakhapatnam
Country of Origin: Germany

Arexons Motorsil D

Nuovo Pignone/ BHEL recommended product

Arexons Motorsil D:

A high temperature oil and fuel resistant silicone RTV Sealant cures in the presence of moisture to form a reliable seal in flanges.

Properties
Acetic elastomer component type. Cures at room temperature. Good resistance to temperature, water, moisture.

Excellent oil resistance. Good dielectric properties. Excellent tear resistance. High degree of vibration absorption.

Good resistance to mechanical stress.

Temperature range: -70 ° C to +250 ° C with peaks of 300 ° C.

Does not harm catalytic converters

For more information, data sheet and other links:

http://www.facebook.com/pages/Aexons-Motorsil/105082426215183?ref=sgm

For ordering, please contact importers and distributors of the product in India
Project Sales Corp, 28 Founta Plaza, Suryabagh, Visakhapatnam 530020, AP

Call +91-891-2564393; Fax +91-891-2590482 sales@projectsalescorp.com

Birkosit application turbines

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Birkosit application turbines

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Turbine Maintenance Solutions from Project Sales Corp

No one services the turbine markets better than we do. From anti-seize compounds to torque wrenches, from high temperature gasketing products to testing and thread repair products, we are the only one-source supplier of Maintenance-Repair-Overhaul (MRO) consumables in your region. Lets take a look at what’s in store with us:

Anti-seize Compounds

Molykote® 1000, the industry standard anti-seize when you require uniform torque-tension even after repeated assemblies, to the ultra-pure all OEs recommended Molykote P 37, it’s all available with us. Press-fit of turbine blades or just to prevent fretting, assembly pastes from Molykote make sure you spend less money in wear related repairs.

Sealing Compounds

When you want 100% sealed, you trust Marston, a German non-hardening sealing compound. Unlimited shelf life as well as assembly time, this oil resistant high temperature gasketing compound ensure your pedestal bearing parting planes are sealed until your major overhauls. Available in 80 ml imported tubes from Marston Domsel, Germany.

Gasketing at 900 deg C

Metal-to-metal joints as in turbine parting planes, are best sealed with BIRKOSIT - Dichtungskitt ®. BIRKOSIT - Dichtungskitt ® Sealing Compound has been used for 50 years on Siemens turbines (product development 1952 with Siemens). Without the additional sealing of individual pressure areas using BIRKOSIT - Dichtungskitt ® the production imprecision or the distortion under loads are no longer evened out, which means that the turbine areas in the individual pressure areas become permeable under pressure. This means the turbine loses power, and can even lead to unplanned reconditioning. BIRKOSIT - Dichtungskitt ® is formulated to be practically inert in its standard applications in steam and gas turbines. It is, therefore, resistant to exposure to hot air, steam, water, light fuel oils and lubricants. By implication, it should be resistant to crude oil and natural gas.

Torque Products
Our torque range gives you more ways to turn fasteners than anyone else, and most importantly we give you all the option to tighten them correctly. Designed to build jet engines, but equally well suited for the ones on ground, Snap-On mechanical and digital torque wrenches ensure you get the right torque at your critical assemblies. What more, they are designed to withstand shock without failure and last you a life time.

NDT Products

We are a one-stop shopping for all your NDT needs. Be it visible or fluorescent dye penetrants, from large automated systems to small power packs, Magnaflux NDT products available from us for detection of surface discontinuities and cracks ensure the smallest and finest cracks get noticed. What more, the products are available with a technical back up from ITW India as reliability is critical to the inspection process.

Reliable Thread Repairs
We have the quickest and simplest method to repair stripped or damaged threads. That not only returns the thread to the original size, but is also stronger than the original female thread. Recoil Thread Repair Kits and inserts, available in all sizes and materials (304, 316, Inconel, etc) ensure you get a stronger assembly than conventional drilling and tapping.

Maintenance and Repair Epoxies
Precision maintenance and metal repair epoxies, allow fast, economical repairs to plant equipment, reducing downtime and returning it to service within hours. Devcon, the most trusted brand has a full service line of metal and maintenance repair epoxies for emergency repairs. What more, they are available from us with technical back-up for the right application, a very critical factor for their successful performance.

Quick Maintenance Sprays
Don’t break your head over a nut. Whether it’s a disassembly of heavily rusted stud, or ensuring moving parts move even at the highest of loads and temperatures, Project Sales Corp has one of the most exhaustive range of maintenance aerosols from world renowned companies like CRC, LPS, Dow Corning, Permatex, WD-40 to ensure your downtime is minimized and shutdown jobs are completed on-time.

Trust and Reliability
If you have a problem, we have a solution. This unique offering from Project Sales Corp has allowed us to service over 40 power plants and turbine overhaul service providers everytime they have a need. From captive power, to large thermal plants and O&M contractors, we provide the dependable and reliable service built on over 6 years of trust.

Explore your options with us.™

Write to us today at 28 Founta Plaza, Suryabagh, Visakhapatnam 530020, India
or mail us at sales@projectsalescorp.com. www.projectsalescorp.com
You can fax us at +91 891 2590482 or call us on +91 891 2564393; 5566482.