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Advanced Compressor Water Wash Technologies 진보된 압축기 수세정 기술

Advanced Compressor Water Wash Technologies 진보된 압축기 수세정 기술. Presented By: Robert Burke Applications Engineering Manager Monday, May 18 th 2009 HURECO CO., LTD 서울특별시 금천구 가산동 345-9 SK 트윈타워 ㅁ -707 Tel . 02-864-8100. Fax. 02-865-4335 E-mail : hojoongkim@hureco.co.kr.

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Advanced Compressor Water Wash Technologies 진보된 압축기 수세정 기술

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  1. Advanced Compressor Water Wash Technologies진보된 압축기 수세정 기술 Presented By: Robert Burke Applications Engineering Manager Monday, May 18th 2009 HURECO CO., LTD 서울특별시 금천구 가산동 345-9 SK트윈타워 ㅁ-707 Tel . 02-864-8100. Fax. 02-865-4335 E-mail : hojoongkim@hureco.co.kr

  2. Compressor Efficiency- An Operational Imperative압축기 효율 – 운전상의 불가피성 General Gas Turbine Energy Balance (전형적인 가스터빈 에너지 균형) 출력 의 60%가 압축기 운전

  3. Typical Compressor Contaminants대표적인 압축기 오염물질 • Stage 2 압축기 • 연질의 침전물 과 공기에 의한 오염 • 카본 침착 • 먼지, 실리카 • 기타 주위 공기 오염물 • 베어링에서 누출 되는 기름 • Stage 17 압축기 • 단단한 침전물 • 날게 표면에 붙어 굳어짐 • 입구 cooling water로 부터의 광물질 • 성능/운전에 주는 영향 • 날개표면을 거칠게 함 • 공기흐름을 방해 • 압축기 효율 손실 • 압축기에서 나오는 압력 손실 • 압축기 방출온도 상승 • 터빈의 출력 저하 • SPFC 증가, 열비(Heat Rate) 저하

  4. Typical Installed Base System Performance Practices전형적인 기존 시스템의 성능사례 • 전형적인 GT 기능저하 • 45일 주기 OFF-LINE세척 • 1일 가동정지/OFF-LINE • 년간 8일 • 수익 감소 • 일일 출력 손실 • 정비 비용 • 부대 경비 ONLINE 세척 안했을때 GT 출력 하락표 • OEM 세척기의 단점 • 가동정지 후 세척 • 저압 세척 • 많은 세척 수 사용, 1000 겔론 • 시간이 오래 걸림 연마제 세척: • MAJOR OVERHAUL 필요함 • WALLNUT SHELL – COOLING HOLE이 막힘 Off-line wash

  5. Improved Design/ Application Process개선된 설계/ 프로세스적용 • 최적의 세척 성능을 내기 위한 방안 : • 최적화된 비말(작은 물방울)은 최적의 운동량을 만듬 • 노즐과 압력 선택 • 60 TO 80 BAR,80-250 microns D43 물방울 생성 • 부착물 용해를 위한 세정 수의 온도 60 deg. C • 중심부를 커버하기 위한 노즐 위치선정 • CFD MODEL 예측 • 0.33의 공기, 세정수 비율을 얻기 위한 세정시간과 물량 • 세정시간 3-5분, 세정물량 분당 5-250 리터 • Plant Control과 PLC를 연결을 통하여 자동화된 운전 • 물방울 분사를 위한 기하학 및 압력 • 속도 부분과 조화를 맞춘 물방울 분사 • 공기의 흐르는 방향으로 압축기 내부로 들어가도록 틈과 위치 선정 • 정밀하고 독특한 기계적 결합구조의 제품

  6. Droplet Characterization물방울 특성은 각 터빈마다 각기 다른 물방울 사이즈를 사용. -- 노즐이 다름. LASER로 물방울 사이즈 측정 및노즐에서 분사 속도 측정 (PDA-PHASE DOPPLER 측정법) • 각 노즐별특성화 • 크기 분배 • 속도 분배

  7. Wind Tunnel Testing풍동 시험 • 목적 • Base Load 동작 모의 시험 • 물방울 특성 • 물방울 크기 분배 • 물방울 속도 • CFD 모델과 비교 • SPECIFICATION • Base Load 조건 • 15KW 송풍기 5KG/S 풍동생성 • 속도 마하 0.5 • LASER에 의한 물방울크기 측정 • 여러 위치와 속도에서 물방울 측정 • 결과 • CFD 모델이 전형적 모델임을 확인 • 물방울 분배 확인 • 물방울 사이즈 • 물방울 속도 • 물방울 깨짐 • 목 적: • 날개의 습분 상태 이해 • 고정날개 물을 흘림 • 부식가능성 이해 • Specifications: • FLOW RATE의 변화 • 속도의 변화 • Laser SPECTROMETER로 물방울 싸이즈 측정 • 여러 위치와 속도로 물방울 측정 • 결 과: • 많은 물방울이 작은 리벳 머리모양의 흔적을 남김 • 밑으로 흐르는 물방울은 부식을 일으키지 않음

  8. CFD Tool & Nozzle Placement Definition GT입구 기하학적 체계를 GTE에서 개발한 CFD CODE에 넣고, 공기흐름을 K-EPSILON MODEL로 SIMULATE함 다음단계로 많은 량의 물분자를 – 같은 크기, 량, 속도, 각도를 가진--MATLAB을 사용하여 물방을을 공기흐름속으로 분사하여 물방울 의 궤도를 살핌. Water Mass at 60% Compressor Inlet

  9. Erosion Study- Typical Drop Strike Pressure Side- Tangential Velocity 물방울이 날게에 부딭치는 속도와 분포

  10. Erosion Model • 많은 종류의 시험기계와 물질을 가지고 시험함. • 상관관계가 아직 새로운 환경하에서 오랜 기간 예측함에 미약함. • -VOL:METAL 부식량 • -Flux: 물이 표면에 닿는 량 (M3/M2/SEC) • -NER: METAL의 일반 부식 저항력 (=4 FOR 400 SSL) • -V: 보통 충격 속도 (M/SEC) • -D: 물방울 지름(mm) • -T: 총 세척 시간 (SEC) • 충격속도에 대단히 민감함 • 120000시간 운전시 5mm 정도 마모 • Example Calculation: • V=350 m/sec, D=180 MICRONS, NER: 4 (410 S니) • T=3min/day * 365/YR * 30YR*60s/min=3.942*106 sec • WATER FLUX: .549 * 10-3m/sec • FOR THE BEST STELLITE, NER=50, VOLUME ERODE=1.6mm 5 mm of wear in 120000 operating hours

  11. Reverse Flow Bellmouth Installation (제작사) • Cone Mounted Design • Wash ports usually built in • Good performance for offline wash • Poor performance for online wash • Water builds on hub • (STRUT에 물방울이 부딪쳐 HUB에 물이 생김) Start Animation

  12. GTE Bellmouth Installation • Bellmouth Mounted Line of Site Design • GTE preferred design • Nozzle aimed with air stream Acceptable online performance • Approximately 30-50% R0 • 만족할 수있는 ONLINE성능시 R0에 30-50%의 물이 뿌려짐 • Good offline performance • Approximately 20-25% R0 • 최적의 OFF LINE 성능시에는 R0에 20-25% 뿌려짐 Start Animation

  13. Design Evaluation Coverage- 7EA • Simplicity & Functonality: • 7 Nozzles; each located midspan between each strut (각 지주 중앙에 위치한다) • Nozzle은Bellmouth를 통해 삽입한다. • Optimized Nozzle Placement (최적의 노즐배치) • Single Position for both wash cycles • Offline WW • Online WW • Obsolete OEM Nozzles & Positions(기존노즐없앰)

  14. Design Objectives: Droplet Size • Offline WW • 70% by volume @ 20% span • Online WW • 55% by volume @ 60% span • Air Flow • 289 kg/sec • Wash Fluid • 95-110 l/min • 물방울 크기, 분사 압력, 노즐등 모두 ONLINE시나 OFF LINE시 같이 쓰임. • 단지 다른것은 엔징 속도임- OFF LINE 시에는 800 RPM, ON LINE 시에는 3600RPM • 그러므로 AIR 속도가 달라짐-- 그래서 물방울이 그림에서 보는것 같이 OFF LINE에는 밑으로 20% 흐르고, ONLINE시에는 물이 날려서 60%선에 흐름. • OFF LINE 시 20% 선에서 70%물이 흐르고, ON LINE시에는 60% 선에서 55%의 물이 흐름. GE 7EA 의 경우임. 20-60% span Offline WW Online WW

  15. Typical Standard Nozzle Systems vs. GTE System • Standard System Nozzles • GTE System Nozzles

  16. Offline CWW Performance; Stage 2 Before & After GTE CWW Heavy coverage of soft deposits removed by Offline CWW

  17. Offline CWW Performance; Stage 17 Compressor Before & After CWW Heavy Crystalline deposits removed by Offline CWW

  18. GTE 400i-42 2xMS6001B CC GT output deterioration without online washing system Installation of new GTE-400 system • Results • +2.1% versus initial offline with detergent • 45 to 180 day offline cycle +3% availability • 52,000 hrs of service TD • Online water only wash Offline washes Outage + Offline wash Offline wash

  19. GTE 600i-110 6xMS9001E SC • Wash Benefits • ~8-12% Power Recovery • ~4-6% Heat Rate • TNB Fleet Standard • 2 more systems on 4 units

  20. GTE 1000i-110 3xMS7001E CC • Single System Serving 3 Engines • DCS Controlled / Scheduled • Online Water Only Wash • Improved Offline Cycle • From 30 to 75 days • +2% Availability • Additional Benefits: • >3% Power • >1.0 % Heat Rate

  21. Benefits Calculator- Power Gen Click on Blue Fields, and enter specific values, to use benefits calculator

  22. Water Wash Delivery- GTE1000i-95 • Specifications: • Stainless Steel Tank • Carbon Steel Skid - Painted • PLC Control • Fully Automated Online CWW • Positive Displacement Delivery Pump • Adjustable Discharge Pressure • Automated Heater Control & Protection • Automated Level Control & Protection • Discharge Fluid Filtration • Automated Detergent Injection • Adjustable Detergent Flow Control • User Interface Panel (HMI), touch-screen • Options: • Stainless Steel Skid • Electric Detergent Drum Pump • Total Dissolved Solids feedback & control • Remote Operation (Optional) • Data Logging (Optional)

  23. Developing Integrated and Service Solutions • Specifications: • Stainless Steel Tank • Stainless or Carbon Steel Skid • PLC Control • Fully Automated ON-Line CWW • Positive Displacement Delivery Pump • Adjustable Discharge Pressure • Automated Heater Control & Protection • Automated Level Control & Protection • Discharge Fluid Filtration • Options • Adjustable Detergent Flow Control • User Interface Panel (HMI), touch-screen • Electric Detergent Drum Pump • Total Dissolved Solids feedback & control • Automated Detergent Injection (Optional) • Remote Operation (Optional) • Data Logging (Optional) Water Wash

  24. GTE Fleet: > 800 Units; 20M Operating Hours

  25. Why GTE? Technology & Value Solutions • Boeing 747 • Fuel Savings $ 164 K • Wash Cost: ~ $ 36 K • Payback: ~ 3 Months • Additional Benefits • CO2 Reduced: 800 Tonnes • EGT Recovery:: ~ 9 o C • Time-on-Wing: + 4000 Hr • Foundation from Aviation/Jet Engines • In excess of 15000 Engine Washes • Major Air Carriers • Foreign and Domestic Military • Industrial Gas Turbine Water Wash • 800+ Unit Installed Base • 20 MM+ Operating Hours • Benefits • Power Recovery 2-3 % • Heat Rate Improvement 0.3 - 1 % • Availability Improvement 2 – 3 % • Payback ~ 3 - 6 Months

  26. Why GTE? Technology and Value Solutions • The GTE technology team is unique in experience, capability and breadth • The top 10 technology leaders have over 250 years experience in the energy industry and bring a wealth of systems physics knowledge, familiarity with advanced modeling tools, tough problem solving, practical, and hands-on field experience • GTE’s capabilities complement OEMs and are recognized as ‘expert’ in key product lines • GTE’s aero-modeling, controls and fluid systems integrated with manufacturing, supply chain, and life cycle cost elements -- positions us to develop advanced, cost effective solutions more rapidly • ‘Scientists’ with proven track records and practical tech application offers rapid design at low cost

  27. Proven Track Record with Blue Chip Clients Validated Results: • Track Record • > 800 Turbines • > 20MM Operating Hours • Long Term OEM Agreements • Siemens • Caterpillar / Solar • Rolls-Royce • Large Global OEMs

  28. Patented Water Wash Technology • Patent 5,868,860 Key Claims • Supply Pressure 50 to 80 bars • Mean Droplet range 120 to 250 microns • Key Design Features • Nozzle Selection to: • Produce Mean Droplet 120 to 250 microns • Avoid Droplets > 500 microns • Nozzle Placement Optimizes Wash Coverage • One position for both Online and Offline Wash • Wash Process Minimizes Water Volume • No Detergent, No Rinse for Online • Wash Process Minimizes Detergent Need for Offline • Reduction of Detergent Need by 80% for Offline

  29. Patented Methods & Wash Nozzle Placement • Patent 7,428,906 Key Claims • System for Wash during Operation • Method with mean drops less then 150 microns • Slip ratio of minimum 0.8 at compressor inlet • One or more Nozzles in acceleration duct • Key Design Features • Nozzle Selection & Discharge Pressure to: • Produce Mean Droplet less than 150 microns • Provide velocity at Nozzle Tip 40% of final at Compressor Inlet • Nozzle Placement Optimizes Wash Coverage • Injection relatively parrallel to air stream • Online Wash Process Claims • No Online Wetting of Stationary Components • Spray velocity 100-200 m/s

  30. Our Clients have the BEST Aviation & Industrial Turbines in the world. We make them PERFORM BETTER. Cleaner. More Output. More Reliable. More Available. More EFFICIENT.

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