Poltava Drilling Company LLC, Ukraine’s largest private drilling company, approached TWEKO with the task of modernizing its painting section to enhance the efficiency and safety of processing welded steel structures for drilling equipment. The company’s production facility in Poltava required innovative solutions for applying protective coatings and surface cleaning that comply with international standards and environmental regulations, particularly in harsh conditions (saltwater, gas condensates).
TWEKO delivered a comprehensive solution: a KASO series abrasive blasting chamber and a IKFS Diagonal series painting and drying chamber (KFS). Despite logistical challenges during the martial law period of 2022–2023, the project was successfully completed: processing time was reduced, coating quality improved, and safe working conditions were ensured for operators.
About the Client
Poltava Drilling Company LLC is a recognized leader in Ukraine’s drilling industry with extensive experience, ranking among the top oil and gas operators in Eastern Europe. The company specializes in drilling, well repair, and geological consulting, utilizing advanced technologies such as LWD telemetry and rotary steerable systems for complex conditions. Its products and services are exported to Europe and Asia, and its Poltava production facility is equipped with modern capabilities and engineering teams. To enhance the quality and durability of steel structures prone to corrosion and oil deposits, the company required equipment to prepare surfaces to SA 2.5 (ISO 8501-1) and apply protective coatings with a thickness of 75–125 µm.
Project Objectives
Poltava Drilling Company LLC tasked TWEKO with modernizing the painting section for processing large-scale steel structures of drilling equipment (up to 13,000×3,000×3,000 mm, weighing up to 20,000 kg). The goal was to create a dead-end technological line integrating surface cleaning to SA 2.5 (ISO 8501-1), application of protective coatings with a thickness of 75–125 µm, and drying at temperatures up to 60°C. Per the technical specifications, the complex had to ensure automated abrasive recycling, efficient air filtration, energy efficiency (up to 50 kW for cleaning, 30 kW + 310 kW diesel burner for KFS), and production safety and environmental compliance. The dead-end layout with rail transport optimized the movement of parts within a 40×10×6 m hangar, minimizing downtime and ensuring an efficient workflow.
Solution
TWEKO implemented a comprehensive solution: a KASO-15 abrasive blasting chamber and a IKFS-D painting and drying chamber (model KFS000.00.00-ENERGY “D”) with a working zone of 15,000×5,500×5,000 mm. Both systems were integrated into a unified production cycle via rail carts RTK-20-6 (2 units, 20-ton capacity, speed 0.5–1.5 m/min), enabling seamless part movement between chambers. The abrasive recycling system (KASO), diagonal ventilation (up to 30,000 m³/h in IKFS-D), diesel burner (310 kW), and multi-stage filtration create a closed, energy-efficient cycle compliant with international and environmental standards. Equipment was manufactured at TWEKO’s Kyiv plant, delivered in stages under DDP terms (Incoterms 2010). Installation began in late January 2023 after the client prepared foundations and utilities and was completed in June 2023 with commissioning and operator training (2 operators per shift, working in PPE, 8-hour cycle).
- KASO-15 Abrasive Blasting Chamber:
- Cleaning of steel structures from rust, scale, and old coatings to SA 2.5 per ISO 8501-1 (productivity up to 15 m²/h, 6 bar pressure).
- Automated recycling system for G25–G40 steel shot in a closed cycle (scraper floor, conveyor, separator).
- Ventilation with 10,000 m³/h capacity, operating temperature +15…25°C.
- Integration with RTK-20-6 rail cart (20-ton capacity, speed 0.5–1.5 m/min).
- Safety for two operators: “STOP” buttons, protective barriers, maximum power consumption up to 50 kW.
- IKFS-D Painting and Drying Chamber (Model KFS000.00.00-ENERGY “D”):
- Application of 1–2 layers of protective coatings (epoxy, epoxy-polyurethane, dry residue ≤65%) via airless spraying, layer thickness 75–125 µm.
- Automated drying at up to 60°C with an Italian-made 310 kW diesel burner (fuel consumption 8.6–26 kg/h) and diagonal airflow up to 30,000 m³/h.
- Dry filtration system for exhaust air, gas detector, and automatic fire suppression system with regulatory approval.
- Operating temperature +15…25°C, maximum power consumption up to 30 kW.
- Safe operation for two operators in a shared hangar (15,000×5,500×5,000 mm) with 3-leaf gates (3,600×4,000 mm).
Technical Specifications
| Parameter | KASO | KFS IKFS-D |
|---|---|---|
| Dimensions | ||
| Internal Dimensions | 15,000 × 5,500 × 5,000 mm | 15,000 × 5,500 × 5,000 mm |
| Service Access | ||
| Hermetic Gates | 2 sets, 3,600 × 4,000 mm | 2 sets, 3,600 × 4,000 mm |
| Service Doors | For personnel | For personnel |
| Processing | ||
| Type | Cleaning to SA 2.5 | Painting 75–125 µm |
| Abrasive/Coating | G25–G40 Steel Shot | Epoxy, Polyurethane |
| Systems | ||
| Recycling | Scraper floor, separator | Ventilation 30,000 m³/h |
| Heating | Not applicable | 310 kW burner, 60°C |
| Ventilation | 10,000 m³/h | 30,000 m³/h |
| Maximum Power Consumption | Up to 50 kW | Up to 30 kW |
| Safety | ||
| Systems | “STOP” buttons | Gas detector, fire suppression |
The complex reduced part processing time, improved coating quality, and ensured safe working conditions, optimizing energy costs even during wartime challenges.
Key Components of KASO Abrasive Blasting and KFS IKFS-D Painting and Drying Chambers
| Component | KASO (Abrasive Blasting) | KFS (Painting and Drying IKFS-D) |
|---|---|---|
| Chamber | Steel structure with hermetic end gates (2 sets, 3-leaf, 3,600×4,000 mm), service doors, lighting system, and abrasion-resistant rubber coating. | Steel structure with hermetic end gates (2 sets, 3-leaf, 3,600×4,000 mm), service doors, lighting system, and chemical-resistant protective coating. |
| Recycling System | Collection, cleaning, and reuse of G25–G40 steel shot with scraper floor, conveyor, separator, and storage bunker. | Automated air recycling system with fans for diagonal airflow (up to 30,000 m³/h), filters, and recuperator. |
| Filtration and Ventilation System | Dust-laden air removal system with 10,000 m³/h capacity for a clean working zone. | Supply and exhaust ventilation with dry filtration of exhaust air, up to 30,000 m³/h capacity. |
| Transport System | Integration with rail cart (model RTK-20-6) with 20-ton capacity and cable drive, equipped with “STOP” buttons, 2 units, plus 4 painter carts (suspended platforms for operators in KFS during painting). | |
| Heating/Drying System | Not applicable (cleaning only). | Diesel burner (up to 310 kW, consumption 8.6–26 kg/h) for drying at up to 60°C. |
| Control System | Control panel with status indicators and emergency stop buttons. | Control panel with painting and drying regulation, gas detector, and emergency stop buttons. |
Project Implementation
- Design: The design of the chambers began with an analysis of the technical specifications, considering dimensions (15,000×5,500×5,000 mm), productivity, and safety, with a commercial proposal (dead-end type). Documentation (foundations, electrical, compressed air, gas) was adapted to a 40,000×10,000×6,000 mm hangar and delivered to the client in January 2023.
- Manufacturing: Production was completed at TWEKO’s Kyiv plant using durable materials (corrosion-resistant steel, pneumatic cylinders) suited for oil and gas conditions. Martial law in 2022 complicated logistics, but deadlines were met, with manufacturing completed in 2023.
- Delivery: Equipment was delivered in stages (January–March 2023) under DDP terms (Incoterms 2010) to Poltava in disassembled form for transport convenience, including 2 rail carts and 4 painter carts.
- Installation: Work began in late January 2023 after the client prepared the hangar (foundation, rails, utilities). Under TWEKO’s supervision, installation continued until late June 2023, concluding with commissioning and testing for hermetic sealing, along with operator training.
- Training: Personnel underwent training on operation and safety, emphasizing PPE (suit, gloves, helmet) and pre-operation hermetic checks, per instructions.
Operating Principle
The complex operates in a closed cycle, covering surface cleaning and painting per the technical specifications. The KASO chamber uses an abrasive blasting unit with steel shot to remove contaminants to SA 2.5, while IKFS-D applies 1–2 coating layers via airless spraying. Parts (up to 20,000 kg) are moved by rail cart (0.5–1.5 m/min), allowing 2 operators to process complex areas. “STOP” buttons ensure safety. In IKFS-D, coatings are dried at 60°C with a diagonal airflow of 30,000 m³/h, while KASO recycles abrasive. Both systems filter air (10,000 m³/h for KASO, 30,000 m³/h for IKFS-D), maintaining a temperature of +15–25°C and cleanliness, with one 8-hour shift.
Maintenance, Safety, and Warranty Obligations
To ensure long-term, safe, and stable operation, TWEKO developed structured procedures:
- Maintenance: Daily inspections, abrasive recycling (KASO) and ventilation (KFS) checks, weekly air pressure checks (6 bar), monthly filter assessments, quarterly conveyor/burner diagnostics, and semi-annual electrical inspections.
- Safety: Prohibition of opening doors/gates during operation, electrical connections only with power off, mandatory PPE (suit, gloves, helmet). “STOP” buttons, interlocks, and a ban on flammable materials eliminate risks. Malfunctions halt equipment with supervisor notification.
- Warranty: 12 months from commissioning (with manufacturer-supervised installation) or 15 months from delivery per invoice, provided rules are followed. Repairs by TWEKO, parts delivery at the client’s expense.
Results
- Efficiency: KASO increases cleaning productivity to 15 m²/h, and IKFS-D enables coating application and drying at 60°C, both with rail transport for large parts, reducing cycle time.
- Processing Quality: KASO achieves SA 2.5, and IKFS-D ensures 75–125 µm coatings, protecting against corrosion.
- Environmental Compliance: Filtration (10,000 m³/h for KASO, 30,000 m³/h for IKFS-D) and recycling reduce waste, meeting standards.
- Reliability: The design ensures long-term operation with a 12/15-month warranty.
- Safety: “STOP” buttons, gas detector, and PPE protect 2 operators.
Conclusion
TWEKO’s comprehensive production line—KASO abrasive blasting chamber, IKFS Diagonal painting and drying chamber, and rail carts with a traction winch—proved to be an optimal solution for Poltava Drilling Company LLC. It delivered high cleaning and drying productivity, reliable coating protection, operator safety, and environmental compliance through recycling and filtration systems. Even under wartime conditions, the project reduced processing time, lowered energy costs, and enhanced the durability of drilling structures. This underscores TWEKO’s expertise in delivering tailored solutions per technical specifications and contracts—from design to commissioning.
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