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Research Papers

Predictive Compressor Wash Optimization for Economic Operation of Gas Turbine

[+] Author and Article Information
Houman Hanachi

National Research Base of
Intelligent Manufacturing Service,
Chongqing Technology and
Business University,
Chongqing 400067, China;
Department of Mechanical and
Materials Engineering,
Queen's University,
Kingston, ON K7 L 3N6, Canada
e-mail: hanachih@lifepredictiontech.com

Jie Liu

National Research Base of
Intelligent Manufacturing Service,
Chongqing Technology and
Business University,
Chongqing 400067, China;
Department of Mechanical and
Aerospace Engineering,
Carleton University,
Ottawa, ON K1S 5B6, Canada
e-mail: jie.liu@carleton.ca

Ping Ding

National Research Base of
Intelligent Manufacturing Service,
Chongqing Technology and
Business University,
Chongqing 400067, China;
Department of Mechanical and
Aerospace Engineering,
Carleton University,
Ottawa, ON K1S 5B6, Canada
e-mail: ping.ding@carleton.ca

Il Yong Kim

Department of Mechanical and
Materials Engineering,
Queen's University,
Kingston, ON K7 L 3N6, Canada
e-mail: kimiy@queensu.ca

Chris K. Mechefske

Department of Mechanical and
Materials Engineering,
Queen's University,
Kingston, ON K7 L 3N6, Canada
e-mail: chris.mechefske@queensu.ca

1Present address: Life Prediction Technologies Inc., Ottawa, ON K1J 9J1, Canada.

2Corresponding author.

Manuscript received March 6, 2018; final manuscript received July 25, 2018; published online October 8, 2018. Assoc. Editor: Haixin Chen.

J. Eng. Gas Turbines Power 140(12), 121006 (Oct 08, 2018) (11 pages) Paper No: GTP-18-1117; doi: 10.1115/1.4041168 History: Received March 06, 2018; Revised July 25, 2018

Gas turbine engines (GTEs) are widely used for power generation, ranging from stationary power plants to airplane propulsion systems. Compressor fouling is the dominant degradation mode in gas turbines that leads to economic losses due to power deficit and extra fuel consumption. Washing of the compressor removes the fouling matter and retrieves the performance, while causing a variety of costs including loss of production during service time. In this paper, the effect of fouling and washing on the revenue of the power plant is studied, and a general solution for the optimum time between washes of the compressor under variable fouling rates and demand power is presented and analyzed. The framework calculates the savings achievable with optimization of time between washes during a service period. The methodology is utilized to optimize total costs of fouling and washing and analyze the effects and sensitivities to different technical and economic factors. As a case study, it is applied to a sample set of cumulative gas turbine operating data for a time-between-overhauls and the potential saving has been estimated. The results show considerable saving potential through optimization of time between washes.

Copyright © 2018 by ASME
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References

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Figures

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Fig. 1

Variation of power and fuel consumption with time: (a) demand power, clean capacity, and actual power, (b) power deficit percentage, and (c) extra fuel consumption rate

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Fig. 2

Effects of fouling on power deficit (ΔPW) and fuel consumption increase (ΔWF) at different (a) ambient temperatures and (b) turbine degradation levels

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Fig. 3

Effects of fouling on fuel consumption increase (ΔWF) at different loads

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Fig. 4

Compressor fouling at 16.5 kg/s compressor flow under different humidity condensation rates

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Fig. 5

Variation of the cost and availability with different washing times: (a) total annual costs, and (b) specific cost per unit of energy and the average available power

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Fig. 6

Effects of the fouling rate on the cost of fouling and washing: (a) total annual costs and (b) specific cost per unit of energy

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Fig. 7

Effects of the turbine degradation level on the cost of fouling and washing: (a) total annual cost and (b) specific cost per unit of energy

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Fig. 8

Effect of the total cost of washing per service on the total annual costs

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Fig. 9

Increase of optimum washing period due to longer duration of washing

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Fig. 10

Effect of the fuel price on the annual cost of fouling and washing

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Fig. 11

Rise of electricity sales price calls for shorter washing periods

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Fig. 12

Effects of small and large deviations of the demand power on the annual cost of fouling and washing

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Fig. 13

Operating condition: (a) ambient temperature, (b) ambient pressure, and (c) GTE power under degradation

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Fig. 14

The process flow to calculate the total cost and the average cost rate for fouling and washing in each washing period

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Fig. 15

Power generation results: (a) actual power and expected power with clean compressor, (b) power deficit, and (c) cumulative energy production deficit

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Fig. 16

Fuel consumption results: (a) actual fuel flow and expected fuel flow with clean compressor, (b) extra fuel consumption, and (c) cumulative extra fuel consumed

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Fig. 17

Cumulative fouling and washing costs

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Fig. 18

Variation of average rate of fouling and washing cost for different durations of washing periods in: (a) four-year operation and (b) the first washing period

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Fig. 19

Actual and optimum durations of washing periods

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