Power Gen Middle EastDoha, Qatar

Tuesday, 5 October 2010

Robert Burke – Application Engineering ManagerPer Andersson – Business Development Leader – Dubai

Pravin Lohar - Nama Development – Abu Dhabi

Application of Multi-Stage Compressor Cleaning System on Large Frame DLN Combustion Turbines

Agenda

1. Water Wash Technology and Design Process

2. Water Wash Performance Observations

3. Case Studies1. GTE WW vs. Annual Cleaning2. GTE WW vs. OEM Offline WW3. GTE WW vs. OEM Offline & Online WW(Multi-staged Compressor Cleaning System)

4. Summary & Conclusions

2

Compressor Efficiency – An Operational Imperative

General Gas Turbine Energy Balance

3

Increases in Compressor Efficiency = Increases to Available Power

Water Wash Design Objectives

1. Highly Atomized Spray, with Proper Momentum to Scrub Blade

- Mass Adequate to Reach Blade Surface- Mass in-Adequate to Erode Blade- Velocity Adequate to Avoid Break up enroute to Blade

2. Spray Injection Controlled to Enter and Cover Compressor Core

3. Water Quality Controlled, Ion Starved

- Absorbs Free Ions on Blade Surface- Avoids Corrosion of Blade, HGP

4. Duration and Flow Optimized to Minimize Water Usage

5. Automated Operation / Digital Plant Interface

4

Water Wash Technology

5

Key Design Features– Gas Turbine Specific Nozzle and Pressure Selection

• 60 to 80 bar, produce droplets 80 to 250 microns D43• Mean droplet size of 156 microns D43• Avoid droplets > 500 microns• Water temperature 60°C for fouling stability

– Nozzle Placement Optimizes Wash Coverage• One position for both Online and Offline Wash• CFD model prediction of specific gas turbine inlet

– Wash Process Minimizes Water and Detergent Volume• Wash duration 3 to 5 minuites, flow at 5 to 250 l/min• Air/Water ratio of 0.33• No detergent, no rinse for Online• Reduction of detergent need by 80% for Offline

– Automated PLC interface to Plant Control

Optimized droplets delivered at optimum momentum

Patent 5,868,860 Key Claims– Supply Pressure 50 to 80 bars– Mean Droplet range 120 to 250 microns

Water Wash Design Process: Nozzle Selection

• Laser Test measuring of water droplet size and velocity from nozzle(PDA-Phase Doppler Anemometer)

• Each Nozzle Class characterized: Size distribution Velocity distribution

SIZE COUNTS VOLUME4 9 0

21 25941 71138 33251 534355 19890 959873 10565 1142790 5123 10423

107 2484 8540124 1103 5911141 553 4369158 268 2982175 150 2267192 106 2130209 112 2897226 107 3506243 70 2834260 63 3152277 42 2511294 30 2194311 26 2258328 19 1926345 21 2430362 18 2375379 18 2851396 14 2404414 0 0431 10 2173448 0 0465 0 0482 1 254499 7 2534

100000 100000

INSTRUMENT: Dantec PDA D[10] = 48.7DATE : 2005-12-05 D[20] = 57.6NOZZLE : P/N 20508 D[30] = 70.6BEAM AIM : off-axis D[32] = 106.1DISTANCE : 30 cm D[43] = 176.8PRESSURE: 50.5 bar Dv10 = 46.9FLOW RATE : 14.50 l/min Dv50 = 115.1WAT. TEMP: 15 C Dv90 = 370.9

1 microns

FLOW THROUGH

OVERSIZE500 microns

EVAPORATION &

PREFERRED

6

• Droplet Size Distribution- Mean Droplet Diameter- D43 Mean Volume Mass- D42 Mean Sauter Diameter

• D43 diameter of 80-250 µm gives the best optimization of washing results, penetration and low impact during wash

Water Wash Design Process: CFD and Nozzle Placement

7

The gas turbine inlet geometry is entered intoa GTE developed CFD-code. Air flow issimulated in a k-epsilon model.

In a second step numerous particles withthe same size, mass, speed and angle asthe washing droplets are injected into theair flow field by a MATLAB code thusenabling studying the droplet trajectories.

Water Wash Design Process: Evaluation Coverage

Simplicity & Functonality in an MS7001 example:

• 9 nozzles each located midspan between each strut

• Optimized nozzle placement

• WW nozzle inserted through bellmouth

• Single position for both wash cycles- Offline WW- Online WW

• Obsolete OEM nozzles & positions

8

Water Wash Design Process: CFD Optimization

• Air Flow: 289 kg/sec

• Wash Fluid 90-100 l/min

• Offline WW:70% by volume @ 25% Span

• Online WW:55% by volume @ 54% Span

20-60%span

Offline WWOnline WW

Modeled and confirmed by CFD Analysis

9

Performance Observations: Comparative View

10

Low Pressure Wash System Penetration Limitation High Atomizing Offline Wash

OEM GTE

11

Case Studies

GTE References for different as-is configurations:

1. Paka, TNB, Malaysia, 6- off GE Frame 9E –GTE Water Wash System & Process vs. Annual Abrasive or Hand CleaningCustomer also reporting benefits of GTE vs. other systems

2. Laem Chabang, Thailand 2- off GE Frame 6B –GTE Water Wash System & Process vs. OEM Offline Only WW System

3. Evangeline, USA, 2-off Siemens 501F – GTE vs. OEM Online WW systemGTE Multi-Stage Water Wash System vs. OEM Online & Offline WW System

12

Heat Rate Improvement: ~ 4-5%

Gross Power Improvement: ~ 8-10%

6xMS9001E GT Units Operating w/ 3 GTE 600i WW Systems

Case 1: GE MS9001E Paka Malaysia

Case 1: GE MS9001E Paka Malaysia

Operational Experience & Feedback • GT model: 6 off MS9001E, originally equipped with carbo-

blasting system for compressor blades cleaning

• Reported problems with oily contaminants, clogging of “instrumentation lines”, erosion of atomising air cooler tubes and risk of blocking the turbine blade cooling holes

• #6 GTE 600i-110 WW systems installation: May ’07 - June ‘08

• WW schedule: Offline every opportunity shutdowns with chemicalsOnline every day with Demi Water, no detergent

Feedback from customer• 45 MW recovery from all 6 GTs from the first offline wash

• Thermal efficiency has increased by 0.4% - 1.4%

• Average drop in the gross power output < 1 MW/month

• Improved gross HR can still be maintained up to 10 months

• Evaluation of gross power output recovery from subsequent offline washes for GT2A and GT2B indicates the recovery of approximately 1.5 MW and 2.0 MW respectively.

13

BEFORE AFTER

Stage 1 & 2

Stage 17

Customer technical paper

14

GTE performance recovery sustainable for up to 10 months vs. 3 with other systems

Case 1: GE MS9001E Paka Malaysia

Case 2: GE MS6001B Fortum Thailand

32

33

34

35

36

37

38

15.2. 2.3. 17.3. 1.4. 16.4. 1.5. 16.5. 31.5. 15.6. 30.6. 15.7. 30.7. 14.8. 29.8. 13.9. 28.9. 13.10.

28.10.

12.11.

Gas T

urbin

e cor

recte

d out

put (

MW)

Installation of new GTE-400 system - Daily Online Water Wash +1.0% GT output deterioration without Online Washing System

Offline washes with OEM system Outage + Offline wash Offline wash

• Results +2.1% versus initial Offline with detergent 45 to 180 day Offline cycle +3% availability

52,000 hrs of service TD Online water providing +1.0% Production Output

15

16

Application of Multi-Stage Compressor Cleaning System on Large Frame DLN Combustion Turbines

•GTE HP Bellmouth Nozzle & Manifold Install•GTE HP Cone Nozzle Install•Piping Upgrade

• HP Flanges•Zone manifold with valves• Water Cessation

Siemens Installation vs. GTE Installation

Siemens System

•Electrical Wiring•On-line CWW automation through WDPF•Logic Changes

• IGV’s• Fuel Fraction

GTE System

Installation Scope Summary

Siemens Water Wash Skid and GTE Module

GTE 1600iSiemens Skid

GTE System providing increased Radial & Circumferential Coverage

GTE Multi-Stage Nozzle Kit: Patent Pending

•GTE HP Cone Nozzle utilizing OEM Positions• OEM Manifold remains in place • GTE Nozzle direct replacement for OEM Nozzle

• Increased Flow Rate• Increased Radial Coverage • Characterized Droplet Size

•GTE HP Bellmouth Nozzle & Manifold Install•GTE Nozzle Placement in Velocity Field

• Increaded Flow Rate• Increased Radial Coverage • Characterized Droplet Size

• GTE Manifold for Bellmouth Nozzles • GTE Supply & Drain Valve Control

GTE Bellmouth Nozzle Installation

Bellmouth Nozzle Manifold SystemAlignment Procedure

GTE Coverage is Greatly Improved Over OEM

Siemens Online

Siemens On-crank GTE 2 Stage Offline

GTE 2 Stage Online

Coverage Comparison: Siemens vs. GTE

21

GTE Coverage is Greatly Improved Over OEM

Coverage Comparison: Siemens vs. GTE

22

GTE 3 Stage OnlineSiemens Online

GTE 3 Stage OfflineSiemens Offline

Siemens Water Wash GTE Water Wash

Droplet Size D[90] 250 microns D[90] = 150 micron

System Operating Pressure 200 psi 900 psi

Nozzle Pattern Full Cone Flat FanHeated Water No 140 °FTotal Flow Rate 24 GPM 42 GPM

Number of Nozzles 12 Cone12 Cone – Zone 18 Bellmouth – Zone 28 Bellmouth – Zone 3

System Differences: Siemens vs. GTE

Siemens SGT Water Wash

Daily Losses/ Degradation Rate: -.0317 MW/day

Start: 164.5 MW

Stop: 160.6 MW

ISO Corrected Power – Base Load Data

Case 3: Siemens 501F Cleco Evangeline US

Avg. Daily Degradation.0317 MW/day

24

GTE Highly Atomized Water Wash System

Daily Losses/ Degradation Rate: -.01585 MW/day

Start: 162.0 MW

Stop: 160.6 MW

Avg. Daily Degradation.01585 MW/day

Corrected Power Summary

Exh Temp Unit 7-2 Unit 7-1 Net PercentRange Pwr Degr. Pwr Degr. Improvement Improvement

Temp Control -0.0317 -0.01585 0.0159 50.00%

ISO Corrected Power Daily Degredation Rates

Exh Temp Unit 7-2 Gross Pwr Unit 7-1 Gross PwrRange Start/Stop Loss Start/Stop Loss

Temp Control 164.5 162160.696 3.804 160.098 1.902 1.18%

Annual Benefit 3.59%

ISO Corrected Power Interpolated Losses

Percent Power Benefit

Case 3: Siemens 501F Cleco Evangeline US

25

Siemens OEM Water Wash

Daily Losses/ Degradation Rate: +.5407 Btu/kWh/day

Start: 9080 Btu/kW-hr

Stop: 9144 Btu/kW-hr

ISO Corrected Heat Rate – Base Load Data

Case 3: Siemens 501F Cleco Evangeline US

Avg. Daily Degradation.5407 Btu/kw-hr

26

GTE Water Wash

Daily Losses/ Degradation Rate: +.3164 Btu/kW-hr

Start: 9110 Btu/kW-hr

Stop: 9130 Btu/kW-hrAvg. Daily Degradation

.3164 Btu/kw-hr

Corrected Heat Rate Summary

Case 3: Siemens 501F Cleco Evangeline US

Exh Temp Unit 7-2 Unit 7-1 Net PercentRange HR Degr. HR Degr. Improvement Improvement

Temp Control 0.5407 0.3164 0.2243 41.48%

ISO Corrected Heat Rate Daily Degredation Rates

Exh Temp Unit 7-2 Gross Hr Unit 7-1 Gross HRRange Start/Stop Loss Start/Stop Loss

Temp Control 9080 91109144.884 -64.884 9136.916 -26.916 0.42%

Annual Benefit 1.27%

ISO Corrected Heat Rate Daily Degredation RatesPercent

HR Benefit

27

Water Wash Product Offering

28

Range (Mw)Up to 10 10 to 14 14 to 35 20 to 40 35 to 55 55 to 120 120 &

above Above 200

WW Product 50hz 30i 80i 160i 200i 400i 600i 1200i 1200i

WW Product 60hz 100i 200i 200i 400i 1000i 1600i 2200i

Specifications:• Stainless Steel Tank• Stainless or Carbon Steel Skid • PLC Control• Fully Automated Online CWW• Positive Displacement Delivery Pump • Adjustable Discharge Pressure• Automated Heater Control & Protection• Automated Level Control & Protection• Discharge Fluid Filtration

Eco Value ™Water Wash

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)

Track Record• > 1000 Turbines• > 30M Operating Hours• Validated Results

Benefits/Demonstrated Improvement• Availability: ~ 2 % • Performance/Output: ~ 3 % • Heat Rate: ~ 1 %• Payback < 6

Months

Long Term OEM Agreements• Siemens• Caterpillar / Solar• Rolls Royce• GE Aero

Business Overview and History

29

Conclusions: GTE Overall Product Portfolio

30

Eco Value™Water Wash

Fluid Systems

Control Panels

Aux Skids

Advanced FuelSkids

Power Aug

CombustionProducts

ECOMAX™ DLN Tuning Products

Dynamics Monitoring and Services

Combustion DLN 2 Repair & New

Combustion DLN 1 Repair & New

Developing Integrated Product & Service Solutions

Turbine Services

Business Overview and History

31

• Gas Turbine Efficiency PLC – Established in 1989– Aviation and Industrial Water Wash

– Eastern Hemisphere HQ in Sweden

• IPO on London AIM Exchange in December 05– Strengthened Leadership Team - Industrial

• Established Manufacturing Capabilities in US– Control Center LLC in Orlando, FL Western Hemisphere HQ since 2007

• Established Combustion Repair Capability and Facilities in US– Duncan, SC Combustion Repair acquired in June 2007

• Enhanced Combustion and Fuel Systems Capabilities– Addition of Combustion Design team in Troy, NY

• Establishing Sales and Service Capabilities Worldwide – Recent addition of North Lincolnshire, UK and Florence, Italy

– Business Development & Sales Office, Dubai & Abu Dhabi UAE

32

GTE… in Summary

Thank you!

World Class Leadership Team

Proven Technical Expertise

Responsive, Agile, Accessible

Extensive Knowledge of CombustionTurbines and Oil & Gas Industry

– Specializing in Combustion, Fuel Management and Auxiliary systems