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ABSTRACT - All gas turbines deteriorate in performance during operation. The most common contributing factor to the
loss of performance in operation is a direct result of fouling of compressor. Compressor fouling is best controlled by a
combination of two methods i.e employing high quality air filtration system, and periodic on-line and/or off-line
compressor washing. However, as fouling will inevitably occur, compressor washing is be used to control its impact.
1.0: INTRODUCTION
Tenaga Nasional Berhad (TNB) operates 29 units of
gas turbines of various models and capacities
throughout 6 different power stations i.e 1) Sultan
Ismail Power Station (SIPS), Paka (***), 2) Sultan
Iskandar Power Station (SIPS), PG (**), 3) Connaught
Bridge Power Station (CBPS), Klang (**), 4) Gelugor
Power Station (GPS), Penang (***), 5) Tunku Jaafar
Power Station (TJPS), PD (***) and 6) Putrajaya
Power Station (PPS), Putrajaya (*).
The earliest units were installed in the early 1980s with Fig. 1: Typical GT Performance Deterioration (Source:
rated capacity of 100MW (Siemens V94.2 at CBPS), to Cranfield Univ, 05)
the recent ones in 2005 with rated capacity of 250MW
(MHI 701F3 at TJPS). The power plants are either The Online washing is normally used as a means to
fully combined cycle (CC) (***) or open cycle (OC) control fouling by avoiding the problem from
(*), or combination of combined cycle and open cycle developing. The primary objective is to extend the
units (**). operating period between the Offline washes by
minimising the build-up of deposits in the compressor
All gas turbines deteriorate in performance during and thereby reducing the ongoing rate of incremental
operation. Even operated under the best possible power losses. Online washing is performed with unit in
conditions, the deterioration in the performance of gas full operation (Ref 1). Demineralised water quality is
turbines is unavoidable due to several degradation always specified for On-line washing, to avoid the
mechanisms. The impact of performance deterioration possibility of introducing harmful trace metal
results in loss in power output and increases fuel contaminants into the combustion turbine.
consumption, and later affects the revenue and
operating costs respectively. Both these factors Complete performance recovery can only be achieved
increase equipment life cycle cost. by an Off-line compressor washing where distilled
water mixed with a special detergent is sprayed into the
The most common contributing factor to the loss of gas turbine while being rotated by the starter at the
performance in operation is a direct result of fouling of crank speed. Under extreme fouling condition, hand
compressor (see Fig. 1). Compressor fouling is washing of Inlet Guide Vanes (IGV) may be required.
typically caused by the adherence of particles (smaller During overhaul, hand cleaning of the full axial
than 2µm) to airfoils and annulus surfaces. The compressor is the most effective option.
adherence is caused by oil or water mists and results a
build-up of material that causes increased surface There is also concern regarding the regular and
roughness and to some degree changes the shape of the aggressive compressor water washing may lead to
airfoil. Fouled compressors result in reduced air flow, compressor blade erosion. This is mainly true in the
lower compressor efficiency and a lower compressor case of On-line wash in which the high velocity of the
ratio. compressor blade during operation has the potential to
initiate and drive compressor blade erosion.
Compressor fouling is best controlled by a combination
of two methods i.e employing high quality air filtration This paper describes the effectiveness of practices
system, and periodic on-line and/or off-line compressor adopted by TNB through “wet cleaning” as part of
washing. However, as fouling will inevitably occur, performance loss recovery effort in most of its
compressor washing is used to control its impact. combined cycle plants. Mitigation measures
1
undertaken in reducing the risk of compressor blade Similarly, GPS consists of 1 block CC with 2x2x1
erosion due to On-line washing are also discussed. configuration, and located near the sea. However, the
station only practices Offline washing at every 3
2.0: PRACTICES BY TNB - CCP months interval.
The rate at which a compressor fouls or an inlet filter
clogs is highly dependent on the site conditions as well For the rest of CC plants, most of the systems are of the
as on current weather and climate. As such no low pressure type, and capable of conducting Off-line
standardized guideline has been set by TNB in and On-line washes. The plants practice either weekly
determining the type of compressor water washing (CBPS, TJPS) or daily (SIPS_PG) On-line washing by
system. using demineralised water. The duration for the On-
line spray varies from 10 – 30 minutes depending on
Most of TNB’s CC power plants have installed GT the type of system installed. The Off-line wash is
Compressor Washing system either through the carried during any plant maintenance shutdown
Original Equipment Manufacturers (OEM) or third opportunity.
party system, and summarized as below:
3.0: PERFORMANCE RECOVERY
Power Plant Practice 3.1: SIPS_Paka: Boroscope Inspection
On-Line Off-Line Boroscope Inspections were carried out during the first
SIPS_Paka Daily During Minor Offline washing for SIPS_Paka (GT2A) in May 2007.
(GT: GE 9E) (3 mins) Inspection In general, the condition of inlet guide vane (IGV) and
[3rd Party] compressor blades were heavily fouled prior to the first
CBPS Weekly (Frid) During Minor Offline wash. Fig. 2a shows the initial condition of the
(GT: V94.2) ~ ½ hour Inspection compressor stage 17 before the first wash.
[OEM] Subsequently, during the first wash the IGV required
TJPS Weekly (Mon) 3-Monthly heavy manual cleaning as well as the Offline wash had
(GT: MHI701F3) ~ 3 mins/spray to be repeated for at least 3 times. Fig 2b shows the
[OEM] image of the same stage after the first Off-line wash
GPS Facility 3-Monthly with obvious removal of hard deposits as far back as
(GT: GE 9E) Available the last stage of the compressor.
[3rd Party]
SIPS_PG Daily Every
(GT: 13DM) (10 mins) Inspection
[OEM & 3rd Party]
Table 1: Summary of TNB’s practices
As a replacement, SIPS_Paka commissioned a high During the second Offline wash (October 2007), IGV
pressure compressor water washing system in May required light manual cleaning and the plant only
2007 for the Block 2 (GT2A & GT2B). The system is carried out the Offline wash for 1 time only. This could
capable of providing the Off-line and On-line washing be due to the fact that the daily On-line wash has
for both GTs. Since commissioning, the plant has been minimised the build up of deposits in the compressor.
adopting daily On-line wash ever since with the spray
duration not exceeding 3 minutes while the keeping the 3.2: SIPS_Paka: Power Output & Efficiency
load at 5% lower than the baseload. The Off-line wash The overall gas turbine performance and output depend
is carried during any plant maintenance shutdown strongly on the axial compressor performance. GT2A’s
opportunity. compressor efficiency before first Offline wash was
about 84.6%. As a direct result of performing the
2
Offline wash, the compressor efficiency increases to GPS, in particular, can only maintain the improved
89.6%, which is the result of the increased mass flow performance by at most 3 weeks. This is as expected
rate along with lower discharge temperature (reduced since the plant does not practice the On-line wash to
by 7oC) and higher discharge pressure (raised by 0.7 minimise the build-up of deposits in the compressor
bar). For the case of GT2A, there is an increase of 5% and thereby to reduce the ongoing rate of incremental
compressor efficiency, directly responsible for an power losses.
increase in gross power output and gross thermal
efficiency (lower gross heat rate). Power Average Performance Recovery (Offline)
Plant & Sustainability
In general, the Off-line wash for Block 2 of SIPS_Paka CBPS • Load: Limited by HRSG capacity
has resulted in a gross power recovery of • Efficiency: 0.7%
approximately 6-10MW (7% - 13%) (See Fig. 3a) and • Sustainability: 2-3 months
improvement in gross thermal efficiency of at least 1% TJPS • Load: 3-5MW (< 2%)
- 1.5% (See Fig. 3b). Evaluation of the 1-year data
• Efficiency: 1-2%
(May 07 – May 08), indicates the combination of the
• Sustainability: ~ 3 months
Off-line and daily On-line washes is able to maintain
GPS • Load: 1 MW (< 1%)
the improved gross power output for a period of more
than 10 months. The sustainability of the improved • Efficiency: < 0.5%
gross heat rate, however, is slightly shorter duration i.e • Sustainability: ~ 1-3 weeks
approximately 6-7 months (Ref 2, Ref 3). SIPS_PG • Load: 2-3 MW (< 3%)
• Efficiency: 0.7%
Block 2 - Average Monthly Gross Baseload at 32 Deg C
• Sustainability: 2-3 months
Table 2: Average Performance Recovery (Offline) &
Average Monthly Gross Baseload
Sustainability
100
93 93 92 93
95 91 91 92 91 91 91 91
90
88 88 87 The frequencies of on-line and off-line compressor
(MW)
85
88 88 87
89 88 87
89 89 88 washing are also a widely debated issue. As a general
86 86
80
GT2A (MW) rule of thumb, for the Offline wash, the determination
75
70
78 GT2B (MW)
of the washing interval shall satisfy the requirement for
the washing (cost of washing) and the lost in revenue
May-07
May-08
Aug-07
Nov-07
Mar-08
Apr-08
Jun-07
Jul-07
Sep-07
Oct-07
Dec-07
Jan-08
Feb-08
Jun-08
34.30 35.01
34.71
34.0
33.73 33.79 34.67 34.68 34.56 33.63 33.60 describes the erosion volume is:
Average Monthly
34.31 33.41
34.01
33.61 33.52
33.0 32.64
32.79
33.11 33.02 32.89 Vol = (Flux / 2 x NER ) [ V/2500]4.8 d0.67 t
32.0
Average GT2A Eff (%)
Average GT2B Eff (%)
31.0 Where:
30.0 • Vol - Volume Eroded
May-07
Jun-07
Jul-07
Nov-07
Jan-08
M ar-08
May-08
Apr-07
Aug-07
Sep-07
Oct-07
Dec-07
Feb-08
Apr-08
4.0: CONCLUSIONS
Compressor efficiency defines the performance of the
compressor section of a gas turbine. The overall gas
turbine performance and output depend strongly on the
axial compressor performance.