AXIAL COMPRESSOR ON/OFF-LINE
Us
WASHING
DECLINE OF AXIAL COMPRESSOR
PERFORMANCES CAUSED BY FOULING
Gas turbine installations have inlet air filtration sys-
tems to reduce or eliminate contaminants which can
damage the axial compressor or affect its performance.
Irrespective of filter efficiency, axial compressor
fouling is unavoidable and depends on environmental
conditions. Excessive fouling on compressor blades
results in lower compressor efficiency and conse-
quently a loss of gas turbine performance.
Axial compressor fouling can be caused by several
types of contaminants.
Dust, sand, insects
Like all other solid contaminants, they cannot be
completely eliminated by the intake filter system.
They generally cause erosion and can lead to foul-
ing when combined with other constituents such as
oily vapors.
Salt water
Also if specific filter medias are used to remove it,
some salt percentage is ingested in any case. Salt
gives rise to blades corrosion and must be promptly
removed. As a rule, salt and dissolved constituents
deposit on blades when the water containing them
evaporates.
GE Power Systems
Oil & Gas
Nuovo Pignone
CM&
Hydrocarbons and chemicals
TURBINES
GAS TURBINES
The worst fouling problems are caused by mixtures
of liquids, oils or generally hydrocarbons, which
deposit on the blading and form an oily film which
catches dry particulate matter. Oily vapors may
come from breaches in number 1 bearing seals or
from the lube oil tank vent system.
In general, erosion or buildup of material on blades
alters airfoils causing lower compressor performance.
Part of the loss is due to fouling and can therefore
be recovered by cleaning; the rest is due to aging of
the machine or component wear and performance
can be restored only by bringing worn components
up to as-new condition.
Performance loss as the result of axial compressor
fouling occurs during normal compressor operation
producing an increase of gas turbine fuel consump-
tion as well as dangerous fluid-dynamic phenomena
GAS
(axial compressor surge).
The turbines at greatest risk of performance loss
operate in plants in humid environments contami-
nated by vapors generated by industrial processes.
CM&Us TU/GA07-9/2002
 For good gas turbine efficiency, it is therefore necessary
to verify compressor performance on a routine basis
and clean when efficiency loss reaches critical levels.
PERFORMANCE RECOVERY WITH AXIAL
COMPRESSOR WASHING
There are two methods used for axial compressor
cleaning:
ON-LINE WASHING with the machine running
at full speed and loaded
OFF-LINE WASHING with the machine on crank.
Cleaning consists in injecting detergents in the axial
compressor inlet following set procedures.
Fig.1 shows a graph representing decline in output
against running hours. As can be noted, each set of on-
line washes alternates with an off-line wash. Correct
application of this procedure allows turbine perfor-
mance loss to be kept near the minimum due to aging
of the machine, indicated as non recoverable degrada-
tion. The graph also shows that off-line cleaning is defi-
nitely more effective than on-line cleaning thus explain-
ing why the off-line system is an indispensable tool for
proper operating of gas turbines.
Consequently, on-line washing is used in conjunction
with off-line washing in order to extend time between
shutdowns as much as possible.The Nuovo Pignone
specification ITN07831 gives a detailed description of
the washing operating procedure to be followed. This
specification is available upon request.
The type of detergent to be selected from the range of
liquid detergents available depends on the type of foul-
ing to be removed: the choice is made on site after
checking how the agents respond to the type of foul-
OUTPUT PERFORMANCE LOSS
WASHING
OFF-LINE
WASHING
ON-LINE
AFTER INSPECTION &
COMPRESSOR SCOUR
24.000
GAS TURBINE FIRED HOURS
Figure 1 - Expected gas performance loss vs. fired hours
ing. Also cleaning frequency and the quantities to be
used in washes must be established during operation.
These should be determined by analyzing axial com-
pressor performance and monitoring efficiencies before
and after cleaning. Nuovo Pignone can supply a sin-
gle system to carry-out both the on-line and the off-
line washing. A dedicated kit is available for each one
of the following heavy duty gas turbines:
PGT2 - PGT5 - PGT10 - MS3002 - MS5002
MS5001 - MS6001 - MS7001 - MS9001
Off-line washing
Off-line cleaning is carried out with the machine turning
at cranking speed. The procedure is performed in two
steps. The first consists in injecting a sufficient quantity
of detergent to completely soak the deposits. After a
period in which the detergent is allowed to soak and be
absorbed by the deposits, the compressor should be
rinsed with water. The detergent and rinsing water are
injected through a series of nozzles mounted in the air
inlet casing. Before starting the cleaning procedure,
all turbine components that must be kept dry must be
protected and all drains opened.
On-line cleaning
The on-line system allows the turbine to be cleaned
while running at full speed and loaded and has to be
used to supplement the off-line system. It is less
effective than the off line and has to be used increase
the time between each off-line washing. To perform an
on-line compressor wash, is normally required to have
the compressor inlet air temperature and the
water/detergent temperature greater than 10 C (50 F).
Actual output
loss with washing
Non recoverable
degradation
Average output loss
during operation
with washing
output loss
without washing
48.000
 THE KIT
In the schematic are shown the components of the kit. Detergent
Inlet Detergent
The kit consists of a skid, with three instrumented Tank
tanks. The upper tank contains the detergent. The
other two tanks contain the water and/or the
water/detergent mixture depending on the type of
washing which is active. The washing sequences are
Water
controlled by a local panel. A pump delivers the liquid Inlet
to the proper manifold. Both the on-line and the off-line
have their own manifold. Several nozzles are connected
to each ring. The exact number depends upon the tur- Tank 1 Tank 2
bine model. The nozzles of the off-line system are
mounted on the inlet casing. The nozzles of the on-line
system are mounted on the inlet plenum or on the inlet Heater
casing. The on-line system has a greater number of
nozzles in order to provide a better nebulization of the
detergent and to direct it uniformly into the axial com- M
pressor inlet.

The following example shows the economic impact of Gas

Turbine
running the gas turbine with the axial compressor Package
fouled. Consider an MS5002C running at full speed full
load for 8000 hours/year. If we assume a 2% average
decrement of gas turbine efficiency, this will cause an On-Line Off-Line
extra fuel consumption of ~8.2x1010 kJ/year.
Considering a fuel gas having a LHV of 33500
kJ/Nm3 and assuming a cost of 0.15 $/Nm3, we find a
cost of ~370.000 $/year due to loss of performance. Figure 2 - On/off - line wash system schematic
This evaluation can be done for each turbine model
scaling on the output power.The result confirms also
the economic convenience of installing a washing
system.

OFF-LINE WASHING
TANK 1: Water/Detergent mixture
TANK 2: Rinse with water
Detergent
Tank ON-LINE WASHING
TANK 1: Water/Detergent mixture

Water Detergent
Inlet Inlet

Tank 1 &
Tank 2
To
On-Line
& Delivery
Off-Line Pump
Electric
Motor

Figure 3- On/off - line wash system layout

AXIAL COMPRESSOR ON/OFF-LINE
WASHING
SCOPE OF SUPPLY The on-line washing system can be controlled by the
The on/off-line washing system comprises the following gas turbine control panel upon client request.
main components The on-line and the off-line systems are available also
separately upon request of the client.
COMPONENT QUANTITY
tank for detergent 1 BENEFITS
tank for off-line 1 Restoration of lost performance as a result of axial
tank for on/off-line 1 compressor fouling
delivery pump 1 Reduced turbine operating costs
electric motor 1 Reduction of gas turbine fuel consumption
on-line wash manifold 1 (2 for MS9001)
off-line wash manifold 1 NOTES
on-line set of nozzles 1 (2 for MS9001) Nuovo Pignone has developed an automatic system
off-line set of nozzles 1 for monitoring compressor performance which signals
local control panel when cleaning is necessary (see the kit -TU/GA SYS-
instrumentation TEM FOR MONITORING AXIAL COMPRESSOR
valves & control devices PERFORMANCE) that is strongly suggested to be
used in conjunction with the washing system.
The size of the components depends upon the turbine
model.

COMK/MARK 667/I I- Studio Tre Fasi - 9-2002 2002 Nuovo Pignone S.p.A. all rights reserved

Nuovo Pignone S.p.A.

via F. Matteucci, 2 - 50127 Florence (Italy)
Tel. +39/055 423211- Fax +39/055 4232800
E-mail: info.service@np.ge.com
www.gepower.com