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