Diagnostics, Measurement, and Optimisation of Energy Systems

By analysing technical data on equipment condition, we can optimise production processes and identify bottlenecks that may hinder improvements in operational efficiency.

Using calibrated control instruments from ORGREZ, or by utilising operational measurements followed by analysis, we are able to verify the technical condition of equipment, identify operational bottlenecks, and contribute to improving operational efficiency. With our expertise in measurement and balancing, we also assist customers in identifying potential causes of malfunctions and comparing the effectiveness of implemented operational measures.

One of our highly specialised services is diagnosing the tightness of vacuum systems in turbogenerators and analysing condensation performance. A properly functioning condensation process has a critical impact on the operational efficiency of turbogenerators and can also influence their achievable output. To ensure optimal turbine performance, it is essential to maintain its tightness. ORGREZ provides comprehensive solutions for identifying the causes of leakage or deviations in exhaust steam temperature from design values. We conduct cause analysis primarily through thermal performance calculations of the condenser, vacuum system leakage diagnostics during operation using helium, and by measuring the performance characteristics of vacuum pumps.

Our team consists of measurement specialists and engineers with expertise in various technologies. While we typically perform measurements using our own equipment, we also provide supervision of third-party measurements when required for a specific project. Our in-house measuring equipment primarily includes devices for temperature, pressure, differential pressure, and flow measurement, such as clamp-on ultrasonic flow meters and systems for ultrasonic flow measurement in open channels. All equipment is regularly calibrated according to ORGREZ’s calibration protocol or specific project requirements, primarily in our own temperature and pressure calibration laboratory.

We perform diagnostics and optimisation of the following assets:

• Power plant boilers, heating plants, district heating systems, and waste-to-energy plants
• Renewable energy production facilities
• Steam turbines and combustion turbines
• Cooling towers
• Pumps, heat exchangers, and other thermal energy equipment

Our services for diagnosing and optimising thermal equipment include:

• Development of a warranty/verification measurement procedure
• Preparation of measuring equipment, including calibration, and execution of the measurement
• Evaluation and preparation of a technical report with measurement results
• Condenser thermal calculations in compliance with HEI standards
• Ultrasonic measurement of cooling water flow or flow balance calculations using operational data
• Inspection of the shutoff point and the ejector cooling system
• Measurement of ejector characteristics using critical nozzles under operational conditions with dry air
• Additional activities, such as visual inspection with a fiberscope and subcontracted laboratory analysis of deposits