cleanblade_presentation
TRANSCRIPT
CleanBlade GTC1000 Treatment Program*For Gas Turbine Compressors
*Patent Pending
2 /GE /
GE Gas Turbine Portfolio – our start target market
Aeroderivatives: 13 –47 MW
• LM1600
• LM2000
• LM2500 / LM2500+
• LM6000
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LM1600 Gas Turbine
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LM2500 Gas Turbine
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Aeroderivative Market
6 /GE /
GE Gas Turbine Portfolio
Heavy Duty Gas Turbines
• Frame 6: 42 –76 MW–6B: ~ 1000 units globally
• Frame 9: 126 –255 MW
• Advancements as FA / FB / H series
• F/FA: ~ 60 units for 50 Hz market (7FA 180 units for 60 Hz market)
–9H: Baglan Bay, Wales 480 MW
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Table of Contents
• Gas Turbine Compressor Fouling - Problem Description
• CleanBlade Product Description & Lab Test Data
• GT Compressor Cleaning Process
• US Field Trial Experience
• GT Compressor Performance Monitoring
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Gas Turbine Compressor Fouling
Compressor sections of Power Plant gas turbines ingest large quantities of outside air for the combustion process, that can contain:• Particulate matter• Aerosols of hydrocarbons• Other organic compounds• Industrial production gases (i.e. nitrogen, chlorine,
sulfur…)
Compressor
Generator
Combustors
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Gas Turbine Compressor Fouling
Ingested compounds and fine particulate matter can deposit on compressor blades, altering the aerodynamics of the blades, decreasing the efficiency of the compressor and resulting in:• Power losses• Higher operating temperatures• Increased fuel consumption• Shorter component life
Some turbines are more prone to fouling than others (i.e. those operating in contaminated air)• However all GT compressors foul to some extent.
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Routine off-line washing of compressors with an approved cleaning solution will remove the deposited fouling, restoring the aerodynamics and compressor efficiency, helping to ensure:• Maximum available power output• Improved fuel efficiency• Reduced wear and tear on machine components
(bearings, blades …)
On-line washing is not as efficient as off-line washing:• The purpose of on-line washing is to extend the
period between off-line washes by regaining some of the lost power.
Gas Turbine Compressor Fouling
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Depending on the amount of deposits on the blades, off-line washing (using the correct cleaner) can result in efficiency gains of 2-3%.• For a typical Power Plant gas turbine, this can
translate into savings of hundreds of thousands of dollars a year.
The time between off-line washes will be dictated by:• Site operations• Degree of air pollution• Amount of fine particulate matter in the air• Acceptable power loss by the operator• Use of on-line washes
Gas Turbine Compressor Fouling
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To monitor the effectiveness of off-line cleanings, the following compressor parameters can be monitored:• Compressor inlet and discharge pressures and
temperatures• Exhaust gas temperature (EGT)
– Measuring the EGT at a specific power setting before and after a wash will indicate the efficiency gained through the washing.
– A more efficient (i.e. cleaner) compressor will show a decrease in the EGT.
Gas Turbine Compressor Fouling
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CleanBlade GTC1000• CleanBlade GTC1000 is…a concentrated
high performance, non-flammable, biodegradable, low foaming aqueous-based cleaner for cleaning Gas Turbine compressors.
• CleanBlade GTC1000’s unique chemistry (surfactants, emulsifiers, …) is specifically designed to remove deposits found on gas turbine compressor blades.
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• Water based clear solution with a mild pleasant odor
• Excellent cleaning performance:– Attains cleaning efficiencies similar to solvent-
based products.• Low foaming, easy rising off.• Low alkali metals and ash levels (<0.004%)
– Specifically formulated to ensure that no incremental trace elements can contribute to corrosion
– Contains a unique blend of corrosion inhibitors
CleanBlade GTC1000 Product Features:
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• Environmentally friendly, biodegradable– Where permitted, the cleaning solution can be
discharged into the local sewer system, eliminating the need to collect the solution for disposal.
• Safe to use– Contains no solvents (w/aromatic hydrocarbons)
reducing the amount of protective clothing required during cleaning
• Approved for use by GE Power Systems– Confirms fully with following GE Turbine
specifications: GEK103623B, GEK107122B, GEK107518A, GEK110529, GEI41042
CleanBlade GTC1000 Product Features:
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Laboratory Cleaning Efficiency Test Apparatus
MIL-PRF-85704C (1998)
GE Proprietary
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99.4 99.6 99.8 100.0 100.2 100.4 100.6
95% Confidence Interval for Mu
99.85 99.95 100.05 100.15 100.25
95% Confidence Interval for Median
Variable: 2595-122-1
A-Squared:P-Value:
MeanStDevVarianceSkewnessKurtosisN
Minimum1st QuartileMedian3rd QuartileMaximum
99.860
0.186
100.000
1.1070.004
100.039 0.266
7.07E-02-1.027094.22461
11
99.390100.000100.000100.100100.510
100.218
0.467
100.113
Anderson-Darling Normality Test
95% Confidence Interval for Mu
95% Confidence Interval for Sigma
95% Confidence Interval for Median
Descriptive Statistics
CleanBlade Lab Performance Capability
GE Proprietary
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Actual (LT)
Potential (ST)
99 100 101
Process Performance
LSL
Actual (LT) Potential (ST)
1
10
100
1000
10,000
100,000
1,000,000
0 5 10
Actual (LT) Potential (ST)
PPM
Sigma(Z.Bench)
Process Benchmarks
6.31
1.56E-06
6.97
1.37E-04
Process Demographics
Date:
Reported by:
Project:
Department:
Process:
Characteristic:
Units:
Upper Spec:
Lower Spec:
Nominal:
Opportunity:
06/16/03
Laibin Yan
GT Cleaner NPI
Cooling Technology
Cleaning Efficiency
%
98.36
100
1
Report 1: Executive Summary
CleanBlade Lab Performance Capability
GE Proprietary
19 /GE /
Steam Cleaning Efficiency TestingMIL-PRF-85704C
Solutions heated at 80oC
GTC1000
GTC1000
Solutions at room temp (35oC)
Benchmark*
Benchmark*
Benchmark*
Benchmark*
Solutions heated at 80oC
Solutions at room temp (35oC)
GTC1000
GTC1000
Soil on the panel was baked at 232oC for 15 min
testing with 77oC Stream
Soil being applied onto the panel testing with 54oC Stream
GE Proprietary
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Accelerated Storage Stability Test
Steel (SAE-AMS5046)
CleanBlade GTC1000 passed the
Accelerated Storage Stability Test
(MIL-PRF-85704C)
GE Proprietary
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• The local GE Water & Process Technologies representative will work with the plant team to develop a specific cleaning procedure (frequency, dosage, flow rates …) utilizing GTC1000 for the on-site gas turbines
• The procedure will following the turbine manufacturers instructions
• What follows is a brief overview of the cleaning process
Cleaning Process
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GTC1000 Cleaning Process
Step 1: Prepare cleaning solution:
Mix GTC1000 (1 part) w/demineralized water (4 parts) in day tank.
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Step 2: Apply cleaning solution to GT compressor:
• Pump dilute GTC1000 cleaning solution according to cleaning procedure while GT is operating at crank speed for specified time
• Continue pumping dilute GTC1000 cleaning solution during coastdown until day tank solution contents are empty.
• Allow cleaning solution to soak for specified time
• Depending on the level of fouling, repeat cleaning procedure as required
GTC1000 Cleaning Process
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Step 3: Rinse GT compressor:• Pump rinse water according to specified cleaning
procedure while GT is operating at crank speed for specified time
• Continue pumping rinse water • Repeat rinse cycle as specified by cleaning
procedure as required
GTC1000 Cleaning Process
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Step 4: Drain and Dry GT compressor:
Allow gas turbine to drain and dry for specified time or until low point drains are dry at crank speed
GTC1000 Cleaning Process
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• Six trials completed: Five 7FAs and one 7EZ– 7FA trials General (9FA trials will probably be similar)– Have pulsed wash system (1 min pulses of wash/rinse
water; 3 min spins without water– Not much rinse water used: foaming and rinsing are issues– 20 to 60 liter of detergent normally used– Sometimes there is a long distance from detergent tank to
turbine (150-200 meters) Hence, must carefully monitor/plan timing of detergent additions
• Results of cleanings have been positive. No negative comments from customers. Customer comments: “less foam and better rinsing”
• Have detailed performance data at one site (cleaning impact). Data from other sites available soon.
• Want comparisons with competitive water-based cleaners at differing settings (industrial vs. rural vs. seacoast, etc.)
CleanBlade US Field Trials
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Average Decrease in Heat Rate = 47.3 BTU/KWhrAnnual Savings ~ $246,500/year @ $3.5/MMBTUAnnual Savings ~ $317,000/year @$4.5/MMBTU
CleanBlade Cleaning Impact
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Information/Data Needed from CleanBlade GTC1000 Applications• Turbine model• Amount of actual employed detergent used• Temperature and amount of wash water used• How much is the actual product diluted• Ambient temperature• Site location: Industrial? Rural? Suburban? Seashore?• When was the turbine cleaned last?• Was the spent cleaning solution…trucked away? Discharged to a
sanitary sewer system? Directly discharged?• Performance/efficiency data, before and after cleaning• Performance/efficiency data of a competitive product, before and
ater cleaning• Was the foaming that was observed during cleaning excessive?• How did the customer rate the cleaning compared to competitive
products?
CleanBlade Application Data
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Air temperature
Gas Turbine Performance Influencers
Effect of ambient temperature
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• Air humidity
• Inlet and exhaust losses
• Fuels
• Fuel heating
• Diluent injection
• Air extraction
GT Performance Influencers