AES operates WORLDWIDE, on call 24 hours a day. Call our toll free hotline at: 1-877-816-9081

American Efficiency Services FAQ's



Question: What does the AES safety program consist of?
Answer: All AES field employees are full time employees so that our safety program can be monitored and controlled.

Upon hire each employee completes a 30 hour OSHA safety course and is drug tested; a Federal Background check is conducted; and a Transportation Worker Identification Credential (TWIC) card is obtained. Annually each employee completes a 10 hour OSHA refresher course. Our employees average four random drug tests per year.

AES commits to a safe and drug free environment for its employees.

Tube Cleaning FAQ's

Question: What does your Tube Cleaning on-site crew consist of?
Answer: AES’ crews typically consist of 3 – 5 individuals depending on the scope of work. One of these individuals, no matter the size of the scope of work, is a dedicated safety / documentation supervisor. His primary role is to ensure the crews safety: that equipment is properly staged throughout the plant, all daily / mid-day safety briefings are conducted, safety equipment is within specifications, and all confined spaces are properly controlled.

Question: What types of cleaners are available?
Answer: AES primarily uses the Goodway line of tube cleaning products. This line of products consists of a wide variety of cleaners that range from metal tube scrapers, nylon bristle brush, hard polymer scrubber, plastic tube scrubber and rotary cleaners for smaller heat exchangers.

Question: Which cleaner is best for my condenser / heat exchanger?
Answer: Past experience is the best guide for future use if all conditions have remained consistent with cooling water and chemical treatment. If an unknown scenario exists AES crews can be equipped with multiple types of cleaners so adapting to the exact situation is possible.

While on site AES will obtain waterbox, tube sheet and internal before / after photographs.  This information will allow AES crews to work with the plant personnel to determine what is the best course of action for the next tube cleaning.

Question: Are there any unit size and / or time limitations?
Answer: AES has conducted cleaning on condensers / heat exchangers as small as 200 tubes and up to 60,000 tubes.

AES can work to the customers schedule regarding scope of work time constraints. Many times during a course of a year cleaning scopes of work will need AES to work around the clock to meet outage needs.

Question: Do your personnel understand plant operation?
Answer: Yes. Since all AES employees are full time we are able to keep our personnel in the plants year round. All of our personnel are crossed trained so a lot of their time is spent on job sites conducting helium inspections on the turbines, condenser and generators.

Most of our customers have commented on the comfort level of having individuals on both the inspection and tube cleaning job sites. If personnel have a working knowledge of a customer’s site they are typically assigned to a tube cleaning project to ensure all safety and operational procedures of that customer are understood.

Question: What are the needs of the crew while on-site?
Answer: The crews will need access to plant water and / or air depending on the mechanical cleaner used for the cleaning.

If the water pumps are used as the mode of force to push the cleaner down the length of the tube then 460 v 3 phase (50/60 Hz) 13 amps (per pump) would be required with a water supply of at least 35 gallons per minute at a pressure between 20 and 70 psi.

If the Quick Shot guns are used a combination of air and water are used as the mode of force to push the cleaner down the length of tube. Plant water such as a garden hose can be used coupled with plant air with a pressure between 80 – 100 psi. Air is the primary mode of force with the water used as a flush.

Question: How often should I clean?
Answer: Most owners take advantage of the annual outage to clean to ensure there are no limitations regarding heat rate during operation. In most cases this is to prevent a build up over and to “stay ahead”.

There are some stations that must clean more frequently due to their cooling water source and location.

Question: What do you do about stuck cleaners?
Answer: Stuck cleaners occur primarily due to foreign debris being lodged down the length of the tube. If a cleaner is not able to be passed with the normal means of water or air and water pressure then a fiberglass rod is passed through the tube in an effort to dislodge the obstruction and cleaner.

If the debris is lodged in such a way that it and the cleaner cannot be removed from the tube this tube(s) is identified to station personnel to be plugged. AES personnel can plug the tube or plant personnel opt to plug tubes on occasion.

If the debris and cleaner are removed from the tube and the Project Manager deems the removal to have been a difficult removal (excessive force needed and/or the debris removed is identified as being sharp) these tubes will also be recommended for plugging.

Helium Leak Detection FAQ's

Question: Is any manipulation of the Unit necessary for an inspection?
Answer: Most units have easy access to the discharge of the air removal system. AES crews insert a 3/8” sample line into the discharge opening. If the discharge is not easily accessible the air inleakage measurement system is valved open to provide the sample during the inspection. (Condenser Air Inleakage & Tube Inspections)

Question: Does the unit load matter?
Answer: AES crews prefer to have the unit operating at or greater than 10% turbine load but have conducted many inspections with less than 10% turbine load, and at times with the unit off-line with by-pass steam with success. Higher turbine loads provide for crisper leak responses. The steam flow through the steam space of the condenser assists with the air and non-condensables being forced to the air removal section of the tube bundle. An experienced inspection crew can interpret the more difficult responses at low or no turbine load.

When a unit is experiencing a problem at a certain load, AES recommends that the unit operates at that load during the inspection. (Condenser Air Inleakage & Tube Inspections)

Electrical Generator inspections can be conducted on or off-line.

Question: How long does the average inspection take?
Answer: 1-3 days depending on the size of the unit, the number of leaks identified and the response / clear-out time of the helium indications. (Condenser Air Inleakage & Tube Inspections)

Most electrical generator inspections can be conducted within one 8 – 12 hour shift.

Question: How much does an inspection cost?
Answer: On average the per unit inspection price including all labor, equipment, travel and expenses is between $4,500 – $10,000. The determining factors are unit size, number of leaks identified and the location of the power station in relationship to the AES home or satellite offices. AES has offices in Maryland, Florida, Missouri and Texas.

When multiple unit inspections are conducted within a powerhouse or utility, the per unit cost decreases because the mobilization and demobilization charges are amortized over the multiple units.

Question: Is helium safe?
Answer: Helium is an inert gas, which means exhibiting no chemical activity.

Although helium is “a safe tracer gas”, safety precautions must be adhered to at all times while handling pressurized cylinders.

Question: In the event of a leak that limits the unit load, what is the response time?
Answer: In most cases, AES crews can be mobilized within the first two hours of the initial telephone call. AES crews are prepared to arrive on-site and immediately initiate the inspection to identify the source of leakage.

If all AES inspection crews are assigned to other inspections and an emergency occurs at another facility, AES will attempt to reschedule or postpone a current routine inspection to address the emergency.

Question: How successful are the inspections?
Answer:

Our guarantee says it all, “if we don’t find your leak, you don’t pay”.

AES crews are trained to arrive on-site and efficiently identify the sources of leakage. AES wants the plant personnel to attend to their daily business while we conduct our inspections.

On occasion the cause of the problem is not a condenser air or tube leak. By having AES’s experience on-site, condenser air or tube leaks can be ruled out as a potential root cause and the AES crew can assist in evaluating the other potential causes until the problem is solved.


American Efficiency Services

American Efficiency Services

American Efficiency Services

American Efficiency Services

American Efficiency Services

American Efficiency Services