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Rochem has been designing and manufacturing gas turbine performance recovery equipment for over 40 years. Our multi-disciplinary team provide industry-leading compressor wash systems to sites of all sizes around the globe.
Process compressors are at the heart of every thriving power plant and ensuring that they run efficiently and reliably is essential to operations. We're confident that we can provide a cost-effective solution to regain lost power at your plant.
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What kind of fouling affects my gas turbine compressor?
The kind of fouling you'll suffer from varies site-to-site depending on the environment. However, you're likely to notice:
Why is fouling a problem?
Fouling of your gas turbine compressor; reduces efficiency; increases the risk of unscheduled shutdowns; can damage equipment; and can cost you millions of pounds in losses over a year.
Can I clean the gas turbine compressor?
Yes, and we strongly recommend it! However, it’s important to use the right equipment and products.
Do I need special equipment for on-line cleaning?
Yes. Rochem design and manufactures specialist nozzles.
These nozzles produce optimum droplet size distribution and wetting of the compressor inlet to provide effective cleaning of the compressor blades while eliminating potential blade surface erosion.
We use Computational Fluid Dynamics and 3D modeling techniques, together with field testing to continually develop and improve our system efficiency. Our wash delivery systems are designed for ease of use and minimum maintenance whilst providing control of fluid delivery to the on-line and off-line nozzles.
The short answer is likely to be yes. In most cases, Rochem equipment can be retrofitted to gas turbine compressors.
Standard nozzles use NPT or 1-1/2" ANSI/DIN flange connections rated to suit the process application. However, we can manufacture parts for any application.
Do I need to use special compressor cleaning detergents?
Many common foulants will be cleansed away with pure water. However, it's worth using a specially designed detergent for a thorough clean. Our range of FYREWASH® chemicals have been made especially for gas turbine compressors and can be used for both on-line and off-line cleaning.
Is gas turbine compressor cleaning cost effective?
The short answer is 'yes'. At countless sites around the world customers note an increase is power output and a decrease in unscheduled shutdowns. The combined increase in revenue and decrease in costs significantly outweighs the expense of equipment and detergents used for cleaning.
Why is CHP more efficient?
A CHP (or cogeneration) unit generates the electricity where it is needed and additionally gives the opportunity to use the excess heat for heating and hot water. This can make CHP more than twice as efficient as conventional power stations - giving you cost savings, reducing emissions and carbon footprint.
Whilst there are a range of different forms of CHP, typically, a gas-powered turbine or reciprocating engine is used to produce electricity, and the heat recovered is used for local water or space heating, or to support an industrial process.
The principle aim of any CHP is to maximize efficiency to support the process.
Rochem's cleaning technology can assist any CHP provide maximum electrical and heat energy using our gas turbine compressor cleaning systems and chemicals ensuring that your gas turbine operates as efficiently as possible while providing minimal impact on our environment.
How do compressors foul?
In spite of the highly sophisticated air cleaning systems available today, ingression of air borne particles into the gas turbine compressor is inevitable.
As a result, fouling of air-path surfaces in the turbines compressor occurs., leading to performance loss and increased fuel consumption.
Worldwide field experience has clearly demonstrated that axial flow compressor deterioration during operation accounts for the major portion of gas turbine-related performance loss.
Of the total gas turbine performance loss approximately 70% can usually be attributed to compressor deterioration due to blade fouling.
Fouling of axial flow compressor blade is generally attributed to airborne particulate in the sub-micron to 10 micron size range and this will the major source of fouling. Another possible source of compressor fouling is oil leakage from the compressor rotor inlet bearing.
Why does this fouling affect my engine's performance?
Axial flow compressor blading creates smooth airfoil shapes similar to an airplane wing. Consequently, blade performance may deteriorate due to increases in surface roughness or due to shape changes brought by blade deposits.
Blade deposits or fouling reduces both compressor airflow and overall thermal efficiency. In addition to compressor discharge, pressure drops due to the reduced air mass flow rate through the turbine nozzle.
Fouling will therefore be recognized by a drop in turbine output for a given exhaust gas temperature, accompanied by a lower compressor discharge pressure and an increase in heat rate resulting in higher fuel consumption.
How do you clean your process compressor?