turbo-k® distributor sales training...
TRANSCRIPT
Turbo-K®
Distributor Sales Training Manual
Ver 1.0
Gas Turbine Compressors – Where are they used?
Power
• Power Plants
• Manufacturing
• DOD
Oil & Gas
• Onshore Refineries
• Offshore Rigs
• Pipelines
Marine
• Commercial
• DOD
Aviation
• Commercial
• DOD
Turbo-K® can be used in all types of GAS TURBINES in all industries
Gas Turbine Engines – Major Global Manufacturers
Alstom
France
Rolls Royce
UK
General Electric
USA
Solar Turbines (Caterpillar)
USA
MAN GHH
Borsig
Germany
SafranTurbomeca
France
Siemens
Germany
Pratt & Whitney
USA
Turbo-K® Is Approved By All Leading Gas Turbine Manufacturers – These Are A Few Examples
Turbo-K® - Gas Turbine Compressor Cleaner
Versatile Gas Turbine Compressor
Cleaner
Specially designed for on-line (hot wash) and off-line (cold wash) cleaning of gas turbine engines
Safety
Water-based, Non-toxic, Non-hazardous, Non-flammable, Non-
corrosive And Fully Biodegradable
Proven Performance in Online washing
Can fully restore turbine power to 100%
efficiency in a single wash
Revolutionary -“No Cloud Point”
proprietary formula means product functions at all
temperatures and pressures, unlike all
other cleaners globally
No Shipping Restrictions
(Air, Road & Sea)
Available in 1,000 liter IBC’s, 200 liter drums
and 20 liter containers
Turbo-K® is the all-in-one gas turbine compressor cleaner.
Turbo-K® Gas Turbine Compressor Cleaner – “No Cloud Point”
Turbo-K® provides 100% on-line cleaning
performance in a single pass
No other gas turbine compressor cleaner
can clean all the stages of the turbine while
online
Unlike all other gas turbine compressor cleaners there will be no redepositing of fouling removed from front stages
onto latter stages of the compressor
Stable at all working temperatures and
pressures, meaning 100% of fouling is carried directly to the combustion
chamber
Through the use of an innovative and complex, triple-
active formula of cationic, nonionic and amphoteric
surfactants., Turbo-K® has “no cloud
point”
+1 It ensures maximum available power output while lowering the working temperature.
+2 Increases fuel efficiency while decreasing exhaust gas temperatures and emissions
+3 Reduces wear and tear(fatigue) on machine components such as bearings & blades
+4Significantly extends period between necessary gas turbine shut-downs for off-line washing (crank-wash), thus reducing
costly down time and production losses.
+5Increases worker safety as it’s water-based, non-toxic, non-
hazardous, non-flammable, non-corrosive and fully biodegradable
Benefits Of Cleaning With Turbo-K®
Large Savings
$
$
Gas Turbine Compressor Cleaners – Some Global Competitors
BrandCountry of
OriginCompany Product
Cloud Point
Comments
UK Turbo-K® UK Ltd Turbo-K® No
Of all compressor cleaners on the
market only Turbo-K® has no cloud
point.
Cloud point is the most significant
barrier to online cleaning efficiency.
Only Turbo-K® can completely clean
while running the turbine online at
all normal working temperatures
and pressures.
Competitors products are not
meant for online cleaning due to
their cloud points failing well below
the 400-500C Celsius working
temperature of gas turbine
compressors
UKRochem Technical
ServicesFyrewash F4
Yes(80C)
Germany Chemtall ArdoxYes
(80C)
UKZok international
GroupZOK mx27 Gold
Yes(80C)
Switzerland Turbotect Ltd Turbotect 2020Yes
(80C)
Ardrox®
Sources of fouling (contamination)
Industrial & Urban
Pollution
• Hydrocarbons
• Fly ash
• Smog
MineralDeposits
• Limestone
• Coal dust
• Cement dust
Airborne Materials
• Soil, Dust, Sand
• Chemicals, Fertilizers, Insecticides
• Plant matter, Insects
• Salt
Additional Sources
• Oily vapors from lube oil tank
• Vapor plumes from adjacent cooling tower
• Bearing oil leakage from front bearing
Contaminants reduce the aerodynamic and thermal efficiency of the blades, resulting in deteriorating engine performance
Disadvantages Of Cleaning With Water
-1 Not effective against oily/greasy contaminants and lacquered or hard carbon deposits
-2 Evaporates by stages 5-6 moving deposits to hot section of engine significantly increasing fouling
-3 May directly cause corrosion if not inhibited
-4 May cause thermal shock / blade stress if not injected properly
-5 Not effective for off-line cleaning unless deposits are water soluble
Lost profits
$
$
-6 Higher frequency of shutdowns necessary for off-line cleaning
Disadvantages of cleaning with solvent-based products
-1 Solvents severely damage the seals, bearings and metals used in the engine
-2 Serious environmental concerns as they are not biodegradable
-3 Toxic posing serious safety concerns when handling by personnel
-4 Special storage due to flammability & fumes
-5 Do not work as efficiently on inorganic contamination sources like salt
Lost profits
$
$
Advantages Of Online Cleaning With Turbo-K®
Large Savings
$
$
+1Maintain maximum power output to avoid loss of
production revenue and unnecessary use of standby machines
+2Slow down the rate of compressor fouling while
gas turbine remains in operation, thus maintaining heat rate and saving large amounts
of money by avoiding additional fuel burn
+3 Eliminates disposal costs as all the fluids are flushed straight to the combustion chamber
+4No engine shutdown required therefore reducing
erosion, thermal shock, bearing damage and cooling system blockages
+5Extend total engine life through the reduction in thermal cycles as a result of avoiding frequent
shutdowns for off-line washing
+6 Reduce plant emissions through less fuel consumption and by maintaining heat rate
+7 Corrosion inhibitors prevent and reduce corrosion to all hot gas path components
+8 Saves on labor and management costs as the online cleaning requires minimal time
Advantages Of Online Cleaning With Turbo-K®
Large Savings
$
$
Advantages Of Online Cleaning
US MilitaryResearch
Proved that fouling accounts for 68% of lost efficiency in gas turbine engines. Some
plants experience gas turbine efficiency reduction or
degradation up to 10% every 2000 hours of operation.
On-line Cleaning Maximizes
Available power output, improves fuel efficiency and
reduces wear & tear on machine components such as
bearings and blades.
On-line Cleaning Reduces
Shut-downs for off-line cleaning thus reducing costly
downtime and production losses.
Gas Turbine Compressors – Normal Cleaning Practices
ON-LINE WASHING:
With the machine running at full speed and loaded(ON)
Usually done every 2 -10 days depending on location and level of contamination.
OFF-LINE WASHING:
With the machine on crank(OFF)
Usually done every 15-20 on-line washes
Both methods are used for axial gas turbine compressor cleaning in balance
** Frequency **
Depends on usage, location environment and model, but all must be cleaned
frequently(once per week average, could be daily if near salt water).
Savings Calculation Using Turbo-K®
Mechanical Power
(oil rig example) Mechanical Drive Assuming gas turbine power output reduces by 1% every week with a loss production of 1 MMSCF of natural gas.
If the cost of natural gas is $5.00/MSCF on-line cleaning of the gas turbine to restore power yields an annual saving of 52/1 X 1 X $5 X 1000 = $260,000.
Electricity GenerationA 100 MW power plant produces 2400 MWh of electricity per day or 16800 MWh per week.
If a KWh costs $0.08, a 1% weekly power output reduction means a loss of 168 X 1000 X $0.08 = $13,440 weekly or
$698,880 annually.
This is the saving that can be realized if on-line cleaning to restore gas turbine power is performed regularly.
Projecting Volume Usage Rates – See attached brief example list of manufacturers, models & recommended cleaning volumes
1 - Manufacturer
First always start with identifying the turbine manufacturer.
Then look up the official list of turbine models and cleaning volumes needed
i.e. GE turbine model list
2 - Turbine Model
Find the turbine model you have on the list.
i.e. GE LM5000
Note the volume needed for one cleaning
i.e. 34MW=140L per clean
3 - Location of Turbine
The frequency of cleaning will depend on usage but also heavily on the environment of the location.
If there is sea water close by or heavy air pollution cleaning will be much more frequent.
i.e. every 2 days instead of every 10 days
Projecting Volume Usage Rates – Simple Example Calculation
1A typical 35 MW gas turbine plant requires 150 liters(RTU) of gas turbine compressor cleaner per on-line wash as specified in the manufacturers manual.
35MW =
150L(RTU) / Clean
2In this analysis lets be the most conservative and say the on-line cleaning is performed every 10 days = 36 times a year
Online cleaning every 10 days =
36 times / year
3Conservative annual consumption of gas turbine compressor cleaner will be:
150 X 36 =
5,400 L(RTU) / year
5400/4
= 1,300L concentrate 1:4
1300 X CAD$10/L
= $13,000 / year / 35MW
Projecting Volume Usage Rates - Simple Example Calculation Continued
4An area that has a 1,500 MW capacity (Ontario has more then 16,000MW) will be able to sell a minimum of
1,500 / 35 X 1,300 =
55,714.29 liters(L 1:4) annually
= $557,143 annually
5Assuming they are able to penetrate 5% of the market then:
Sales will be
= $27,857 annually
Sales will be therefore
= $ 2,322 monthly
** NOTE**This is taking a very conservative position in terms of users cleaning scheduling, penetration and only basing numbers on 35 MW turbines as an example
Turbine machines greatly range in size and usage therefore much higher volumes are possible