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Application Story from Atlas Copco Rental
For further information please contact:
Olivia Gambin – Divisional Communications Manager
Phone: +32 (0)3 750 82 87 - e-mail: olivia.gambin@be.atlascopco.com
Targeted Airblow
Cogen Cleaning Uses 18 Atlas Copco compressors to make quick work out of the
Russell City power plant construction.
A new facility called Russell City Energy Center will be up to 40 percent more efficient
and significantly cleaner than older technology, using reclaimed water for cooling and
boiler makeup, and preventing nearly 4 million gallons of wastewater per day from being
discharged into San Francisco Bay as it generates electricity.
That tall order was started on May 22, 2001, when Calpine Corporation and Bechtel
Enterprises Holdings Inc., known as the Calpine/Bechtel Joint Development, filed an
Application for Certification with the California Energy Commission seeking approval to
construct and operate a 619 megawatt (MW) natural gas-fired, combined-cycle, electric
generating facility. Calpine is the owner of the facility and Bechtel is the general
contractor. Construction didn’t start until 2010 and by 2013, the pressure was on to
complete the job on time and on budget. Cogen Cleaning and Atlas Copco Rental
equipment stepped in during the final stages before startup—with oil-free air to clean the
pipes.
The 14.7-acre facility site, known as the Russell City Energy Center (RCEC), is located
in Hayward, Alameda County, Calif. The isolated location sits in the Industrial Corridor
directly south of Hayward's Water Pollution Control Facility.
The project consists of two "F-class" combustion turbine-generators (CTGs), two multipressure,
supplementary-fired heat recovery steam generators (HRSGs), a single threepressure,
reheat, condensing steam turbine-generator (STG), and a hybrid, wet/dry
plume-abated mechanical draft cooling tower. A facility of this type operates at 90
percent efficiency using natural gas to drive the F-class generators, while recycled steam
from those generators powers the secondary steam system.
Preparations for startup
The process of commissioning a startup requires cleaning the pipes throughout the
facility. That task was awarded to Cogen Cleaning Technology of San Leon, Texas, a
global company that specializes in all types of piped facilities cleaning.
Kevin Wakeem, the project manager on the RCEC project for Cogen, said, “Steam is the
preferred method for this type of work, but because of water availability and timing, the
next best alternative is oil-free air.”
The company chose Atlas Copco Rental to assist them with the compressors, boosters
and other components for the job. Chris Rhoades was Atlas Copco Rental’s sales
representative on this project. He said, “We needed 22 truckloads of equipment to supply
enough equipment for this project.”
Atlas Copco Compressor Technique - Specialty Rental Division
Visitors and mailing address: Telephone: +001 (281) 454 22 00
5810 Wilson Road Suite 100 Telefax: +001 (281) 454 22 11
Humble, Texas 77396, USA www.atlascopcorental.com

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Wakeem said he has completed dozens of chemical, targeted steam blow and targeted
airblow projects around the world, but only about 10 big airblows like this one. And the
size is significant, about 30 percent larger than the others he has managed. “Typically a
big airblow will be eight to 12 compressors. This project had a total of 18 Atlas Copco
PNS 1250 and XRVS high pressure compressors.” Wakeem said 16 were required at a
time, with the additional two compressors serving as backup.
“We scale a project with one booster for every two compressors for the high pressure
portion of this project,” Wakeem said. They rented nine Atlas Copco B7-41/1000
Hurricane boosters.
The air must be perfectly clean flowing into the plant, and because the boosters run on
oil-flooded screws, every booster had a coalescing filter pack inline following the
booster. These were also rented from Atlas Copco.
Although the Atlas Copco compressors used less diesel fuel due to the FuelXpert
feature, a constant and abundant fuel source was necessary. Atlas Copco rented 14, 800-
gallon auxiliary fuel tanks for this project. The job was running only 7 a.m. to 7 p.m., but
the compressors could have actually run a full day without having to stop for refueling.
The plan was originally to have two backup compressors, but because of their availably
and tight timeline to complete the project, the plan was changed. Having the additional
air volume of two XRVS high pressure compressors allowed Wakeem to reconfigure the
manifold so the high pressure and low pressure testing could be conducted at the same
time.
“The type of process we use is based on matching the build design specifications with the
air, steam or chemical methods for cleaning. Those are specified by the OEMs for the
components in the plant,” Wakeem said.
Every facility requires a chemical cleaning first. This is a combination of soaps and acids
to remove flux, slag and other residues left by the welding process. Wakeem said on this
job the chemical process was followed by a “hydrolaze” process. “That’s a high-pressure
spray that knocks out debris stuck to the walls of the pipes.”
It was at this point the compressors were brought into the job. In total it took a month for
this airblow project. “The idea is that the customer wanted us to do this on the fast track.
Each of the two high-pressure blows will take a week, the low-pressure systems two to
three days, and the intermediate pressure systems three to four days each. It’s about a
week per system, but we are combining the process to get it done faster,” Wakeem said.
Gregg Alper, President and CEO of Cogen Cleaning said, “CCT has been doing airblows
for years, unfortunately with companies professing to provide ‘oil-free air.’ It wasn’t until
our partnership with Atlas Copco Rental that we perfected the service and started to
provide our clients the continuity we feel separates us from other service companies.
Choosing Atlas Copco Rental as our partner in this project was a no-brainer. Our
previous business with Atlas Copco and particularly Chris Rhoades created the perfect
environment to win this project and serve our customer with the best equipment
available. Chris and his team were critical in securing this project, providing their
expertise all throughout the bid process.”
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Choosing a partner
Selecting the air solution was more than a choice of manufacturers. The extra time
usually associated with renting in a heavily regulated environment was reduced because
of the Atlas Copco Rental partnership. “There may be no other place more regulated than
California. Choosing Atlas Copco to work with is a great help. They have gone through
the certification process. They take care of recording and reporting. Atlas Copco handles
the regulatory problem that is California. If these machines can work in California, they
can work anywhere,” Wakeem said.
Finishing targeted airblows
The process of blowing air to clean the plant’s piping systems consisted of a systematic,
precisely timed routine. Air entered the system in a series of blows. The bank of
compressors produced 20,000 cfm while the boosters increased the 350 psi compressor
air to the required 900 psi.
Wakeem said, “It’s a process. The 900 psi air is released for about five seconds using one
of Cogen’s quick opening valves and the system needs about eight and a half minutes to
recharge. It’s the mass flow of air that pushes debris though the system.” The air was
released at varying pressures to create fluctuation in pressure from 900 to 675 psi.
After this routine, a target was inserted into the line. When sufficient time had passed, the
target was removed and checked for quality of air in the system.
Targets are polished carbon steel plates that have been shined to a mirror finish. After a
series of targets have been tested, the change is quite visible. Targets at first are pitted
and abrasive, eventually giving way to almost clean targets. Wakeem said, “This turbine
manufacturer allows a 0.5 mm tolerance. That’s a mark equal to the tip of a mechanical
pencil – almost indistinguishable. I just keep watching for impacts. When the targets
show repeatedly clean, the process is finished.”
For most projects there are 50 targets supplied. Wakeem said the target process is random
and he reinserts based on knowledge of the system and previous experience. The targets
are expensive and he doesn’t want to waste them either. “It doesn’t pay to put a target
right back in if I know the result won’t change for a day or two,” he said.
This process for the medium and low pressure piping in the plant was done much the
same way.
This project required 18 systems to be blown, each with different lengths of time. For
example, there were five low-pressure systems that took five days total. The first highpressure
system required six days to complete. Wakeem said that a high pressure system
was complete when he got two consecutive clean targets.
Wakeem said that with 27 large compressors and boosters operating over a long period of
time there are bound to be problems. “You go into a project this size knowing there will
be issues. It’s how you deal with those issues that makes for success. We received very
good support from Atlas Copco Rental that allowed us to continue to make progress for
our customer. That to me is a successful project.”
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All photos are available to download from the Atlas Copco Multimedia Gallery:
http://multimedia.atlascopco.com/sharesearchentry.jspx?q=russel+city+power+plant
Russel City Power Plant - 03
Russel City Power Plant - 01
Russel City Power Plant - 12
Russel City Power Plant - 04
Russel City Power Plant - 02
Russel City Power Plant - 05
Russel City Power Plant - 09
Russel City Power Plant - 06
Russel City Power Plant - 10
Russel City Power Plant - 11
The setup at Russell City required nine separate groups
of equipment to be piped into the common manifold. A
grouping of equipment included two Atlas Copco Rental
PNS compressors, an Atlas Copco B-41 Hurricane
booster, a coalescing filter pack and an 800 gallon fuel
tank.
Getting ready to blow, the power plant is covered in
plastic to protect it from debris and dust shooting from
the plants pipe system. In the lower center, the two
vertical pipes are exhaust vents, the larger vent is for
high and medium pressure air and the smaller for low
pressure. The plant has high, medium and low pressure
rated piping.
(2) Getting ready to blow, the power plant is covered in
plastic to protect it from debris and dust shooting from
the plants pipe system. In the lower center, the two
vertical pipes are exhaust vents, the larger vent is for
high and medium pressure air and the smaller for low
pressure. The plant has high, medium and low pressure
rated piping.
View of the high pressure exhaust
shows both exhausts and power plant but no compressors
On the left, Chris Rhoades is Atlas Copco Rental’s area
sales manager for California. At the right, Kevin Wakeem
is Cogen Cleaning Technology’s expert on location to
manage the setup and airblow.
To clean the pipes, high pressure air was sent through
the pipes. A polished steel bar called a target was
inserted into the line for the air—and debris—to pass by.
Debris in the line caused damage to a target. Multiple
targets were used over the month-long process to show
the debris was dissipating. Once the target showed no
more damage, the system was proven clean.
These pneumatic plungers insert the target into the
exhaust pipe just before the end of the discharge line.
An advantage of working with rental compressors from
Altas Copco Rental is the environmental protection
certification that is secured by Atlas Copco. Cogen can
focus on the project while Atlas Copco Rental focuses on
the equipment.
Steve Green is Atlas Copco Rental main field service
technician onsite. He ensures the equipment is operating
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Russel City Power Plant - 08
Russel City Power Plant - 07
to peak efficiency throughout the project.
L to R: Atlas Copco Rental field service technicians Steve
Green and Mark Burford, areas sales manager Chris
Rhoades, Gogen Cleaning site manager Kevin Wakeem,
Cogen Cleaning’s technicians Steve Scott and Kenneth
“Captain” Williams.
Cogen Cleaning Technology Site Manager Kevin
Wakeem
Atlas Copco is an industrial group with world-leading positions in compressors, expanders and air treatment
systems, construction and mining equipment, power tools and assembly systems. With innovative products
and services, Atlas Copco delivers solutions for sustainable productivity. The company was founded in 1873,
is based in Stockholm, Sweden, and has a global reach spanning more than 170 countries. In 2012, Atlas
Copco had 39 800 employees and revenues of BSEK 90.5 (BEUR 10.5).
Learn more at www.atlascopco.com.
Specialty Rental is a division within Atlas Copco’s Compressor Technique business area. It serves
customers in various industry segments around the world with temporary air, steam, nitrogen and power
rental solutions. The specialty rental services are offered under several brands. The divisional headquarter is
located in Houston, USA.
Learn more at www.atlascopcorental.com
130416_ASR_ApplStory_Russel Power City USA.docx