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Technology development in gas turbine compressor washing over the last 10 years and
todays state of the art technology is presented in this paper. Based on various long term
field tests and observations, correlation between rate of power degradation and atmospheric conditions can be established. Questions about compressor on line washing with
water alone against the use of detergents, as well as washing frequencies are also addressed in this paper. Performance degradation behavior between gas turbines of different sizes and models can be explained with an index of sensitivity to fouling. The implementation of an optimized regime of on line and off line washing in the preventive turbine
maintenance program is important. It will improve the plant profitability by reducing the
costs of energy production and contribute to a cleaner environment.
DOI: 10.1115/1.1361108
Introduction
Gas turbine GT cleaning was made in the early days by crank
soak washing and/or by injecting solid compounds such as nutshells or rice husks at full speed with the unit on line. This method
of on line cleaning by soft erosion has mainly been replaced by
wet cleaning since the introduction of coated compressor blades
for pitting corrosion protection. Further, unburnt solid cleaning
compounds and ashes may also cause blockage of sophisticated
turbine blade cooling systems if ingressed into the GT air cooling
stream. At the beginning of the introduction of compressor wet
cleaning in the 1980s, time intervals between on line washing
and the combination with off line washing had to be established.
Further, there was also a belief among many users that on line
washing could replace off line washing. Hoeft 1 quoted that an
airflow reduced by 5 percent due to fouled compressor blades will
reduce output by 13 percent and increase heat rate by 5.5 percent.
With todays large scale use of gas turbines in combined cycle
base load application as well as with their increase in nominal
output, gas turbine compressor washing has gained more and
more attention by their owners.
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Considerations on the Economical Profitability. The average power degradation over 4000 operating hours at the above
tested plant and when compressor cleaning is not performed is up
to 10 percent. By using similar criteria as presented by Diakunchak 3, the plant production profitability during above regime of
on line and off line compressor wet cleaning was improved by US
$1,175,000 over 8000 operating hours, representing a very substantial additional profit. An amount of approximately US $20,000
was spent for the chemical cleaner consumed during the program,
representing a very marginal cost as compared to the improved
profitability. Further, and without a regime of on line and off line
compressor wet cleaning, there will be an additional loss of profitability due to reduced steam production as a result of compressor
fouling in a combined cycle application. The reduction in mass
flow has a greater effect on the steam production than the increase
in exhaust temperature due to compressor fouling.
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Gas Turbine Compressor Design Parameters. Smaller engines have a higher sensitivity to fouling than larger engines.
Tarabrin et al. 419 concluded that the degree of the particles
deposition on blades increases with growing angle of attack. Further, that the sensitivity to fouling also increases with increasing
stage head. Multishaft engines are more sensitive to fouling than
single shaft engines. Design parameters such as air inlet velocity
at the inlet guide vanes IGV, compressor pressure ratio, aerodynamical and geometrical characteristics will determine the inherent sensitivity to fouling for a specific compressor design.
Site Location and Surrounding Environment. The geographical area, the climatic condition and the geological plant
location and its surrounding environment are major factors which
are influencing compressor fouling. These areas can be classified
in desert, tropical, rural, artic, off-shore, maritime, urban, or industrial site locations. The expected air borne contaminants dust,
aerosols and their nature salts, heavy metals, etc., their concentration, their particle sizes and weight distribution, as well as the
vegetation cycles and the seasonal impact are important parameters influencing the rate and type of deposition.
Plant Design and Layout. Predominant wind directions can
dramatically affect the compressor fouling type and rates. Orientation and elevation of air inlet suctions must be considered together with the location of air/water cooling towers in a combined
cycle plant, the possibility of exhaust gas recirculation into the air
inlet, orientation of exhaust pipes from lube oil tank vapor extractors, as well as with other local and specific sources of contaminants such as location of highways, industries, seashores, etc.
Other plant design parameters which affect the rate of compressor fouling are as follows.
The selection of the appropriate type of air inlet filtration
system self-cleaning, depth loading, cell, pocket, mat, pleat, oilbath filter, etc., the selection of filter media, the number of filtration stages, weather louvres inertial separators, mist separators,
coalescer, snow hoods, etc. Design parameters such as air velocity
through the filters, filter loading and their behavior under
high humidity, pressure drops, etc., are also factors of high
consideration.
In case inlet conditioning systems are used, to have appropriate mist eliminators installed downstream of evaporative coolers.
Inlet chilling in humid areas will result in continuous saturated
conditions downstream. Thus, the presence of dust contamination
in the air can combine with the moisture and additionally contribute to compressor fouling.
Plant Maintenance. Quality of air filtration system maintenance, frequency of compressor blade washing deposition leads
to higher surface blade roughness which in turn leads to faster rate
of degradation, prevention of potential bearing seal oil leaks into
air inlet stream, periodic water quality control in closed loop
evaporative cooling systems, etc., are all measures which can
positively influence compressor fouling and their rate of fouling.
Fig. 3 Power losses vs. total absolute humidity for 14 comparative operating periods
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Fouling Deposits. Most fouling deposits are mixtures of water wettable, water soluble, and water insoluble materials. Very
often pH 4 and lower can be measured in compressor blade deposits. This represents a risk of pitting corrosion. Furthermore,
Hot or Cold Water for Off Line Washing. Hot wash water
will soften the deposits better than cold water, further it will also
help to prevent thermal shocks and thus reduce the cooling time
period. However, hot water has also several disadvantages, it has
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Fig. 8 First stage guide vanes of the same compressor pictured in 13 vane length from the tip and from the root, washed
on line every four days with detergent during approx. a one
month continous operation period
On line injection mass flow. Gas turbine engine manufacturers are very much concerned with deposition of washed off dirt
from the front stages onto downstream compressor stages. Further, that washed off dirt may enter into sophisticated airfoil film
cooling systems of turbine blades with the potential to clog them,
resulting in temperature hot spots. In this respect, also a sound
isolation scheme to avoid run-off effluent water penetrating into
the internal engine piping systems during off line washing is of
prime importance. Low level of flame detector intensities during
on line cleaning on units with Dry Low NOx DLN combustors
are also claimed for potential tripping of the units e.g., fogging of
flame detector lenses, etc.. Some users also observe higher CO
emission levels during on line washing. Small quantity on line
cleaning injection mass flow combined with the optimum washing
regime will counteract against above claimed potential problems
in modern gas turbines. Therefore, a small injected quantity of on
line cleaning solution mass flow is preferable. For instance, Turbotects on line compressor cleaning system for a 120 MW heavy
duty engine comprises 30 injection nozzles, the total mass flow
applied is only a fraction of comparative on line washing systems.
This low mass flow has demonstrated that it does not impair the
cleaning efficiency and has further also the advantage to lower
significantly overall demineralized water and cleaner consumption. In addition it will also reduce the required size, volume, and
cost of the washing skids.
Wetting. A very effective wetting of the IGVs is reached by
a uniform and finely distributed atomized cleaning solution. Droplets are subject to gravity, they must be stable in size and small
enough that they do not cause blade erosion, and light enough that
they do not drop out of the air stream before they reach the compressor blade surface. A nonuniform wetting of the IGVs will
result in spot cleanings and heavier droplets will most likely fall
to the bottom, wasting some injected cleaning solution.
Equipment. The on line nozzle injection design is of prime
importance to achieve a high washing efficiency. The nozzles are
designed to inject a small quantity of fine atomized cleaning solution into the air stream where it will be thoroughly mixed and
carried uniformly into the compressor bellmouth. A relatively
high number of nozzles positioned in the air inlet casing on both
up-stream and down-stream sides of the bellmouth are ensuring a
better distribution of the injected fluid into the air stream and
consequently a better wetting.
The nozzle atomizer is integrated in a spherical body which can
be rotated in two dimensions to set the spray angle. The adjustment of the spray angle allows proportioning of atomized cleaning
solution massflow which shall penetrate into the air stream from
the mass flow which shall remain trapped in the boundary layer
for root and tip blade cleaning. The nozzle body is installed flush
mounted under the surface of the intake structure and penetration
of the nozzle into the air stream is minimal to avoid inducing
vibration into the air stream. Further, this design also prevents
misuse of the nozzles as climbing support during compressor intake inspection. Its design is ruling out loss of any parts into the
air stream see Fig. 9.
Off Line Cleaning Injection System Design Criteria. The
Transactions of the ASME
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signed such that an angle up to 5 deg can be adjusted for compensation. The off line washing soaking and rinsing method can
be considered as a mechanical erosion of deposit layer and soaking time will allow the cleaner to penetrate and soften the deposit
layers. For instance, systems with high atomization pressure will
have no impact pressure on the IGVs, this because the spray
pressure will have lapsed approx. 20 cm from the nozzle outlet
and the atomized droplets will need to be carried by the small air
stream produced at crank speed. These high pressure systems do
not show the same effectiveness in removing salts and insoluble
compounds on downstream stages.
Drainage. The effluent water collection system to drain the
dirty water outside the engine and the isolation scheme to hinder
run-off water to penetrate sensitive systems such as sealing and
cooling air systems, instrumentation air systems, etc., during
washing is of prime importance.
The physical location of the air systems taps on compressor
casing is also important. Taps on the bottom are likely to drain
run-off water, they should be preferably located in the upper part
of the casing. Drains in air inlet casing, in the compressor casing,
combustion chamber, and exhaust should be located at the lowest
point. The drain diameters should allow a good run-off, it can be
observed that sometimes they get plugged because of dirt being
not properly evacuated. A good isolation and drainage concept
will insure that no dirty water ingress into cooling, sealing-air, and
other systems during the off line washing procedure.
Paint and Corrosion Damage in Air Inlet Manifolds. Some
users are claiming that the corrosion protective paint applied
originally inside the air inlet casing gets softening and some detaching paint spots are depositing by the air stream on IGVs due
to frequent on line washings, this possibly because of the chemistry involved in the cleaner.
Chemistries involved in the formulation of compressor cleaners
are very soft. These cleaners have all been tested for e.g. immersion corrosion, sandwich corrosion, and hot corrosion on metals,
alloys, coatings, etc., used in the manufacture of compressors;
effect on polymeric materials, on rubber, silicone elastomers, on
epoxy adhesives, on painted surfaces, etc., according to existing
US MIL-C-85704B specification Cleaning Compound, Turbine
Engine Gas Path.
Fig. 10 Appendix A
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Conclusions
Fouling rates can vary very much and are very specific to each
plant. The gas turbine unit design parameters, the site location and
its surrounding environment, the climatic conditions, the plant
concept, design, and its layout are given once the plant has been
built. The site weather parameters are then having the largest impact on fouling rates and performance degradation. Therefore improvements on the plant profitability by reducing the impact of
compressor fouling can only be related to the plant maintenance,
monitoring of plant performance, the performance of the installed
washing system, the selection and quality of the detergent used
and the optimum chosen washing regime.
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