Performance Improvements for

Turbomachinery

Anti-Fouling & On-line Washing

Fouling

Refers to solid substances, usually

polymers and/or salts, which
adhere to the internal aerodynamic
surfaces
Reducing efficiency
Causes unbalance
Vibrations (rubbing)
Blocks passageways

Charge Gas Compressor

Charge Gas Compressor

Hydrogen Recycle Compressor

Original Anti-Fouling Coating

Pos- -Coat

Multi-layer system

Fluoropolymer organic top coat

Pos-Coat
Advantages

Applications
Centrifugal compressor rotors & diaphragms and axial
compressor rotors & stator blades and LP turbine components
Typical applications include:
Cracked gas compressors at ethylene plants
Natural gas compressors
Gas turbine compressor sections
Industrial air compressors
Steam turbine LP stage blades and disk below 500oF
Properties
Typical thickness
0.004-0.006 in. (0.10-0.15 mm)
Typical surface finish
Ra~50 micro in. (0.001 mm)
Max temperature
500F (260C) continuous
600F (315C) < 1 hour
Safe pH range
4 to 9

Retard fouling process and prolong runtimes of compressors

Minimize fouling related vibration
Enhance rotor reliability and improve efficiency
Reduce cleaning and turnaround costs
Prevent corrosion related damage, which is a frequent cause of
catastrophic failure

Next Generation Coatings

Pos- -Coat Plus

Multi or Single layer system

Teflon Type Organic top coat (non-stick)

Galvanic Sacrificial basecoat (corrosion)

Pos- -Coat Plus

Advantages

Applications

Retard fouling process and prolong runtimes of compressors

Minimize fouling related vibration
Enhance rotor reliability and improve efficiency
Reduce cleaning and turnaround costs
Prevent corrosion related damage, which is a frequent cause of
catastrophic failure
Centrifugal compressor rotors & diaphragms and axial
compressor rotors & stator blades
Typical applications include:
o Cracked gas compressors at ethylene plants
o Natural gas compressors
o Gas turbine compressor sections
o Industrial air compressors

Properties

Typical thickness (M-layer)

Typical thickness (S-layer)
Typical surface finish
Max temperature
Safe pH range

0.003 in. (0.08 mm)

0.001 in. (0.03 mm)
Ra~50 micro in. (0.001 mm)
300F (150C) continuous
4 to 9

Next Generation Coatings

Pos

-523

Heavy-duty metallic coating

Nickel-Phosphorous alloy
Less susceptible to Stress Corrosion Cracking

Pos- -Coat 523

Advantages

Applications

Retard fouling process and prolong runtime of compressors

Minimize fouling related vibration
Enhance rotor reliability and improve efficiency
Reduce cleaning and turnaround costs
Prevent corrosion related damage, which is a frequent cause of
catastrophic failure
Prevent corrosion related damage to maintain material integrity
Allow in-line injection cleaning w/o deteriorating coating system
Centrifugal compressor rotors & diaphragms
Typical applications include:
Chlorine gas compressors
Cracked gas compressors at ethylene plants
Hydrogen recycle compressors at refinery plants
Natural gas compressors

Properties

Typical thickness 0.002 - 0.003 in. (0.05 - 0.08 mm)

Typical surface finish
Ra~45 micro in. (0.001 mm)
Max temperature 550F (290C) continuous
Safe pH range
2 to 12

Comparison - Coatings vs. Bare Steel

Foul Weight [mg]

80

60

Bare Steel
EL-Ni (550F)
3P
EL-Ni
M3P

40
20
0
0

200

400

600

800 1000 1200 1400

Scrub Cycles

SUMMARY

523

A HIGHLY SUCCESSFUL
COATING SYSTEM OVER
THE YEARS FOR ANTIFOULING & CORROSION
PROTECTION

A NEW COATING SYSTEM

WITH SUPERIOR ANTIFOULING PERFORMANCE

A MORE DURABLE
METALLIC ANTI-FOULING
& CORROSION RESISTANT
COATING SYSTEM

INTENDED FOR THOSE

APPLICATIONS REQUIRING
AGGRESSIVE IN-LINE
INJECTIONS

Cleaning Philosophy
Preventive Maintenance
Impact the Degradation Curve
Start Clean, Keep it Clean

Cleaning Mechanisms

Mechanical
Use of abrasives
By-Hand (Mechanical)
Washing (Chemical / Water)
Solvent Washing
System Treatments
Boiler

feed water for example

Washing Techniques
On-line (Ingested in Process)
Water
Oil
Detergent
Off-line (Crank Soak)
Water
Detergent

Centrifugal Compressor Cleaning

Systems

Water provides cooling which retards the

rate of polymerization but offers little in
cleaning capability. Water cannot be used
in some closed system processes

Wash oil solvents provide some cleaning

by dissolving some organic contaminants
but do little to retard and in fact may
contribute tothe polymerization
problem. Inorganic contaminants are not
soluble in petroleum distillates.

Cleaning Capabilities
Chemical Cleaners
Nozzle Assemblies
Skid Packages

System Design

Injection Systems can have the

following sub-systems:
Nozzle array or manifold
nozzle-ring.
Fluid delivery system
Control system

Fluid Delivery Systems

REQUIRED COMPONENTS
PRESSURE GAGE

VALVE
FILTER

PUMP

AIR

R-MC
TANK/RESERVOIR

COMPRESSOR
INLET

Nozzle Assemblies
Cleaning
>On-line
>Off-line
Fogging
Mass Flow (< 3% total)

Centrifugal Compressor Cleaning

Systems
Typical Multistage Centrifugal Compressor
Driven End
Impellers
Rotor
Case
Discharge

Suction

Centrifugal Compressor Cleaning

Systems
Typical Cooling Injection System
Temperature/Pressure
+

_
Water or
solvents
injected into
suction port
from external
skid

Contaminants
exit into
discharge port
separators.

Spray Nozzles

Note: < 3% of total mass flow

through the unit (including
nozzles).

Types of Skids
Basic Skids
Custom Skids
Upgrades and modifications
to installed/existing skids

Basic Skid

Constant flow at constant pressure

Many rates available
All SS wetted surfaces
Safety shutoff (flow or temp)
Meets most OEM flowrates

Basic Skid

Custom Skids

Capabilities:
> PLC
> Heated SS tanks
> API compliant or Explosion proof
> Trailer mounting
> Touch pad controls
> VFD: Multi-function
online
offline

Custom Skids

System Design

Control Systems

Range from the simple to the

complex.
Constant volume systems need
only provide the requisite quantity
of fluid at the appropriate pressure.
This is essentially an On-Off
system, manually operated and
monitored.

Centrifugal Compressor Cleaning

System
Experience has shown that cookie
cutter solutions are seldom effective.
Recognizing the difficulty of devising a
single solution for a complex and dynamic
problem, takes an approach which utilizes
the appropriate technology for the site
specific problem.

Chemical Cleaners

Non-Flammable
Non-Toxic
Biodegradable
Meets All OEM Specifications

Any Questions?