European Turbine Network A.I.S.B.L.

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Position Paper Fouling Preventive Coatings

Author: Jose Miguel Berrio Soler - Iberdrola

INTRODUCTION. On a deregulated electricity market, manufacturers must keep competitive offering turbines with increasing hot gas temperature that leads to an increase of the power output and thermal efficiency. At the same time, owners have to stay alert and must take care of their maintenance investments over the entire life cycle. Air entering the compressor can contain particles which form deposits on the blades that contribute to compressor fouling. This phenomenon disturbs the flow field and reduces the mass flow decreasing the turbine performance. Therefore, in order to compensate this disruption and maintain a constant power output, the firing temperature must be increased. [1] To restore the performance of the compressor, washing is required and can be done either on-line or off-line. Fouling is a phenomenon that is specific for each turbine and depends on several factors, such as washing characteristics and frequency, type of environment (coast, industrial, etc.) and filtration systems and their maintenance. Washing water droplets and particles in air also have a detrimental effect on compressor blades. As they increase the erosion rate of the leading edge, which can lead to a blade rupture and a catastrophic failure. The application of anti-fouling coatings on compressor blades would reduce the performance degradation, costs and operational risks associated with compressor washing and filtering. PROJECT JUSTIFICATION. The objective of this project is to investigate the feasibility of reducing the rate of compressor fouling degradation and associated rate of specific fuel consumption (SFC) increase through the application of anti-fouling coatings. A successful anti-fouling coating can reduce compressor fouling preventing the performance decrease with their associate costs as fuel consumption. Additionally, fouling prevention through coatings would reduce maintenance costs of washing and filtering, as well as the risk of a blade failure due to detrimental effects of washing water droplets and particles in air on compressor blade mechanical integrity. STATE OF ART. The anti-fouling coatings are intended to substantially decrease blade surface roughness. They normally have inert top layers and contain an anti-corrosive aluminum-ceramic base coat. SermaLon coating (Sermatech) consists of an aluminum-filled chromate/phosphate bond coat, an intermediate high temperature polymeric inhibitive coating and a PTFE impregnated topcoat that provides a barrier against corrosion and resistance to fouling [2].

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PX-2000 coating (Praxair) inhibits compressor-section corrosion and increases stage efficiency by reducing surface roughness [3]. EEC-A2 coating (Dresser Rand) is a multi-layer metallic-ceramic-polymeric system that includes a galvanic sacrificial base as a second line defensive layer to protect equipment from corrosive attack. This base coating is sealed with an anti-stick polymer-impregnated top layer [4]. Available information of physical properties and performance data for some commercial coatings are shown in Table 1.

Physical Properties Typical Thickness Range Max. Continuous Oper. Temperature Peak Oper. Temperature/Time 3-6 mils (75-150 ) 500F (260C) 600F (315C)/ 1 hour 3-9

Performance Data Salt spray (ASTM B117) on 410 Stainless steel Adhesion 5B (ASTM D3359) 100% Humidity (ASTM D2247) Surface Finish (On new machined external surfaces) >3000 hours with no red rust No pickoff, Excellent 3000 hours-no effect

<40 microinches Ra at .030 cutoff pH Operating Range <1.0 microns 2-9.5 Ra at 0.8 mm cutoff. Table 1. Physical properties and performance data of a typical anti-fouling coating [2] [4].

Typical coating tests consist of injecting a known amount of salt solution into the gas turbine inlet while gathering compressor performance degradation and fuel economy data for different generator load levels. The collected data for turbine inlet temperature, compressor efficiency and fuel consumption are plotted as a percentage of the baseline conditions for each compressor. According to the literature consulted, the results show a decrease in the rates of compressor degradation and SFC for the coated compressor compared to the uncoated compressor [5]. PROJECT OBJECTIVES. The objectives of this project are: Selection, study and testing of anti-fouling coating systems. Comparison of results between coated and uncoated compressor blades. Study the performance indicators and relationship between: o Anti-fouling coating systems and washing o Filtering characteristics and systems.

REFERENCES. [1] Variations in Gas-Turbine Blade Life and Cost due to Compressor Fouling. A Thermoeconomic Approach. Int.J. Applied Thermodynamics, Vol.5, (No.1), pp.37-47, March-2002.
http://www.icatweb.org/vol5/Vol_5.1/jordal030602.pdf

[2] SermaLon Coating for Turbomachinery.

http://www.sermatech.com/documents/Datasheet%20STS-12%20SermaLon.pdf

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[3] Praxair Surface Technologies brochure.

http://www.praxair.com/praxair.nsf/0/A30422DBB9FCD89185256F3F005B12DA/$file/PXA_IGT_Bro_Fin al.pdf

[4] EEC-A2 Engineered Anti-foulant Coating for Turbomachinery.

http://www.dresser-rand.com/services2/coatings/2017-EEC-A2.pdf

http://scitation.aip.org/getabs/servlet/GetabsServlet?prog=normal&id=JOTUEI00012500000300048200 0001&idtype=cvips&gifs=yes

[5] Rolls Royce/Allison 501-K Gas Turbine Antifouling Compressor Coatings Evaluation. J. Turbomach. July 2003 Volume 125, Issue 3, 482 (7 pages) DOI:10.1115/1.1573665