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Acknowledgment

Internship at Ammonia II, Field Maintenance, Engro Fertilizers Limited has been a great learning experience for me. Not only did I get to learn about the fertilizer industry as whole machineries like Gas Turbine, Steam Turbines, Compressors, Pumps etc in particular, I was taught about the importance of safety and its practical implementation; about professionalism and work ethic, about achieving international standards. Id like to take this opportunity to thank everyone at maintenance office and shack, which supported and facilitated me throughout my stay. I owe special gratitude to Mr. Abbas Shahani, Mr. Adil Mushtaq , Mr. Hamid Masood, Mr. Umed Ali Mallah Mr. Ashraf Anjum, Umed Ali, Jamil Ahmed for guiding me through the course of the internship. Also, Im grateful to Mr. Mohsin Atta, Mr. Usman Raza, and all other technicians and apprentices who took me to plant rounds and answered my torrent of questions during their maintenance jobs. It has been an honor for me to be a part of such a fine organization, if only for six week. Thank you.

SYED ZIA ALI GHAZI


Mehran University Of Engineering & Technology

EXECUTIVE SUMMARY
KGT 2501 is the Gas Turbine coupled to Air Compressors at Ammonia II. It has a long history of problems notable of which is high exhaust temperature, lube oil leakages, oil and dirt fouling. The purpose of this report is to study operation and maintenance of GAS TURBINE KGT 2501 to propose ONLINE CHEMICAL CLEANING SYSTEM and also an improved suction filter house design to resolve high exhaust temperature issue/compressor fouling. This report aims at exploring the root causes of the problem and proposing adequate immediate and long term solutions. High exhaust temperature cause thermal distortion of gas turbine blades and cause damage to the hot gas path and many metallurgical failures can occur which decrease the overall efficiency of the turbine. Other factors such as axial compressor fouling because of the dirt and the lube oil leakages decrease turbine efficiency and increase high exhaust temperature for resolving this issue we perform carboblasting which is not so effective at oil leakages, cleaning is the only method by which we can decrease compressor fouling. There are two method of cleaning ONLINE & OFFLINE CLEANING. KGT 2501 plays a vital role on the production of ammonia; performing offline cleaning will affect output process so online cleaning is more preferable. Purpose of this report is to suggest a vendor for online cleaning at KGT-2501. Properly conditioned intake air is vital for top operation performance of a turbine. A good filtration system is much more necessary for the turbine working and a good filter house can protect the compressor form the dirt which causes the fouling in the compressor. And it is directly effect on the performance of the turbine. This report contains the design modification of the filter house. There are two basic problems one is the high ambient temperature issue and other is the proper filtrations of air. Air inlet chillers can decrease the high ambient temperature issue

PROCESS OF MAKING UREA


The main type of process equipments which are installed in accordance with process requirements at the ammonia -2 plant are as follows: Desulfurization Pre-reformer Primary reformer Secondary reformer High temperature shift converter Low temperature shift converter CO2 Absorber CO2 Stripper Methanator NH3 converter Knock out drums

DESCRIPTION Desulfurization D-2503 A / B


Purpose:
Desulfurization drums have been installed for the removal of sulfur compounds from the feed gas (natural gas) because these sulfur compounds are poisonous for the reforming catalyst. C4H4S (Thiophene).

ZnO + H2 S

ZnS

+ H2 O

C4 H4 S +

4H2

C4 H10

H2 S

Working & construction:


The feed gas enters from the top and flows downward by passing over the catalyst bed and the sulfur free gaseous mixture leaves from the bottom.

Pre-Reformer R-2501
Purpose:
This has been installed at the plant site for the initial reforming of the feed gas in order to least 10% duty of primary reformer. It removes all of the remaining sulfur compounds coming from desulfurizer due to which the life and efficiency of primary reformer increases. It also reduces the fuel consumption of primary reformer.

1. 2. 3. 4.

C2 H6 CH4 CO CH4

+ + + +

2H2 O H2 O H2 O 2H2 O

2CO CO

+ +

5H2 3H2 H2 4H2

CO2 + CO2 +

Working & construction:


The feed gas enters into it from the top together with the process steam and passes through catalyst bed of NiO at which the reforming process is taking place. After reforming the product gases leave from the bottom and are delivered to primary reformer. Pre-reformer is a fixed bed catalytic reactor in which a bed of NiO catalyst supported by the alumina balls at the bottom.

Primary Reformer F-2501 Purpose:


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It has two purposes as it provides the required amount of heat to feed gas ( in connective section ) in order to attain the desired temperature for the reaction and most of the reforming process completes in it.

Working & construction:


F-2501 is a gas fired Foster Wheeler Furnace with induced draft fans designed to use the exhaust from KGT-2501 as combustion air. It has two main sections.

CONNECTIVE SECTION:
No reforming process is taking place in this section and it is used only to provide a considerable amount of heat in the different passes of the feed gas in order the attain the desired temperature necessary for reforming process. The hot combustion gases from the radiant sections combine to flow through the convection section. The gas temperature is reduced to approximately 375 of at the inlet to the fans from the 2000 of at the arch

RADIANT SECTION:
The radiant section is divided into two cells or fireboxes. This section contains the 392 reforming catalyst tubes (196 per cell) through which the combined primary steam and natural gas flow. There are 120 burners per cell, in two terraces of 60 burners each. The entire fire box is refractory lined. Reforming process is actually taking place in this section in the catalyst filled vertical tubes. These vertical tubes are heated by the high temperature flue gases produced by the combustion of the feed gas with air.

Secondary Reformer D-2504

Purpose:
Secondary reformer has been installed in order to complete the reforming process. It also provides nitrogen for the ammonia synthesis reaction. 1. 2H2 2. CH4 3. CH4 4. 2CO + + + + O2 H2O 2H2O O2 2H2O CO + 3H2 CO2 + 4H2 2CO2

Working & construction:


Secondary reformer is also a fixed bed catalytic reactor in which the gaseous stream enters from the top with a small quantity of CH4 and leaves with at least no CH4 from the bottom. Process air is also supplied in order to provide N2 gas for synthesis reaction. The O2 present in the air is completely consumed by combining with the combustible components like CH4, CO, H2. The catalyst in it is 9? Below the burner. The 12? combined steam and air line enter from the top of secondary reformer combustion chamber through internal nozzles and the 34? Refractory lined gas line primary reformer enters from the side of secondary reformer.

High Temperature Shift Converter D-2510


Purpose:
The main purpose of the high temperature shift converter is reducing the quantity of CO present in the synthesis gas therefore by converting it into CO2.

Working & construction:


This is an exothermic process. Gas is cooled to some low temperature before entering into the HTSC b/c shift conversion reactions usually precede efficiently at low temperatures. Much of the CO converts to CO2 in HTSC and only 2.1 % of CO remain in the gaseous mixture leaving HTSC.

Low Temperature Shift Converter D-2513


Purpose:
The main purpose of this equipment is to complete the conversion process of CO to CO2 so as to remove the entire CO present in the synthesis gas mixture.

Working & construction:

Low temperature shift converter operates at a lower temperature as compared to HTSC and for this purpose the temperature of the gaseous mixture leaving HTSC is reduced by passing it through steam generator in order to produce low pressure steam at 585 psig. This is also a fixed bed catalytic reactor in which the gaseous mixture enters from the top and after the conversion process taking place at the surface of the catalyst, the product gas with only less than 0.17% CO remaining leaves from the bottom of the vessel.

CO2 Absorber C-2519 Purpose:


The basic purpose of the CO2 absorber is the absorption of CO 2 gas from the synthesis gas mixture in the Catacarb solution (K2CO3) in order to remove CO2 b/c this gas is poisonous for the ammonia conversion process catalyst.

Working & construction:


CO2 absorber is packed bed column. It operates at low temperature and high pressure. It is divided into two sections. It is just like a shape of a bottle.

CO2stripper C-2515
Purpose:
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CO2 stripper is installed to strip out CO2 gas from the catacarb solution with the help of steam (stripper media). This results in the regeneration of the catacarb solution.

Working & construction:


CO2 stripper is a packing bed column. It operates at a high temperature and low pressure. It is divided into two sections.

Methanator D - 2520
The purpose of the Methanator is to convert the entire remaining CO & CO2 into

Purpose:
CH4 b/c these oxides of carbon are poisonous for the ammonia synthesis catalyst. The reaction takes place in it is: CO + H 20 CO2 + H2

Working & construction:

Methanator is a fixed bed catalytic reactor in which the feed gas (effluent of absorber) ensures after being heated in different exchangers from the top and passes through the bed of catalyst at the surface of which the reaction takes place. The final product gases mixture leaves with only a minute concentration of CO & CO2 leaves from the bottom.

Ammonia Converter D - 2525 Purpose:


The basic and the main reaction of the ammonia plant is the reaction of H2 & N2 to produce NH3 and this reaction takes place in the ammonia converter ( in some industries it is also called ammonia reactor ) in the presence of promoted iron oxide catalyst. The reaction takes place is

3H2

N2

NH3

Heat
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Working & construction:


Ammonia converter is a fixed bed catalytic reactor in which the syn gas enters at a high pressure. The feed gas enters from the top and passes through the annular space b / w inside and outside wall of the converter. Major part of this gas enters through the internal exchanger and the feed gases are heated through the effluent of the second bed of catalyst. Feed gas then flows through the upward internal tube to the top of the first catalytic bed. The temperature of the first catalyst bed is controlled by some gas (which bypasses the internal exchanger) which is mixed with the feed gas stream at the outlet of the internal exchanger. This bypass so called cool shot. The feed flows horizontally on the first catalyst bed and then enters in the tube side of another internal exchanger where it exchanger heat with the quench gas to control the temperature of the 2nd catalyst bed. Feed gas after passing through the surface of the 2nd catalyst bed and exchanging heat with the incoming feed leaves from the bottom of the reactor.

Knock Out Drums Purpose:


Knock out drums are designed in order to separate the moisture content present in the gas stream by deminstering them.

Working & construction:


The gas stream enters into the K.O drum through a side opening from the upper periphery. Internally a demister pad is installed at the top. When the gas enters it, moves upward and passes through the demister pad in which the droplets of the moisture are captured and the water flows downward while gas free of moisture leaves from the top of
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drum. A certain level of the water is maintained in the drum. A level alarm is also attached to the drum which gives the indication in the control room when the level of the water in the drum exceeds the limits.

Product:
Anhydrous ammonia is pumped from the plant to two urea plants, Urea-I and Urea-II. Any surplus ammonia can be sent to storage tank TK-200, from where, it can be again sent to either of the urea plants depending upon need. The product is pure ammonia with 0.2% 0.25% water content. The ammonia is analyzed once per week for percent ammonia, percent water and oil/grease content.

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FLOW DIAGRAM OF UREA.

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KGT - 2501
Gas turbine obeys joules cycle or Brayton's cycle. Its working principle is that it converts chemical energy into pressure energy (by combustion process) then pressure energy is converted into velocity energy (with the help of nozzles) which rotates the turbine to produce mechanical energy. The axial flow compressor taken atmospheric air compresses it and routes it to the combustion section, where it is mix fuel gas and used a combustion air. The high temperature combustion gases expand through a two stage turbine which supplies power to drive the axial flow compressor and the air compressor train. The exhaust gases from the turbine are routed to primary reformer furnace, F-2501 or to the atmosphere.

KGT-2501 is a process air train that runs two centrifugal compressors for the secondary reformer it consists on a helping steam turbine (TK-2501) and having two gear boxes (XK2501/A) and (XK-2501/B). There are two centrifugal compressors one is LP case (K-2501/A) and other is HP case (K-2501/B). KGT-2501 is a very important gas turbine who plays a vital role in the production of ammonia, any issue at KGT-2501 can affect the production.

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HELPING STEAM TURBINE TK-2501


The purpose of the starting or General electric helper turbine is to slow roll Make the gas turbine train on startup Stages 2 and shutdown to allow the 5050 RPM various parts to cool down or Speed (RPM) heat evenly. When the gas Suction 585 PSIG turbine train is shutdown, it 5670 RPM should be slow rolled at 500 O/S Trip RPM rpms until the exhaust Mass of steam flow 37,000 lb/hr temperature is below 125 oF. This is to allow sufficient rotor cool down to prevent the shaft from bowing. It is also necessary to rotate the turbine to approximately 1500 RPM so that the proper mixture of fuel and air can be obtained for combustion during startup. The turbine is powered by 585 psig steam, which flows through a steam demand control valve (99 SD). The steam turbine KT-2501 rated power is 1625 HP and uses 37,000 lb/hr steam, & exhaust to the atmosphere. 99 SD control valve is operated thru Mark-V control system by 20SC during startup and shutdown. It can also be operated with a local panel mounted air regulator by switching the control to manual from the auto manual knob available at the same local panel. When the gas turbine is fired off and has attained normal operating speed, the starting turbine is no longer needed so Steam inlet control valve is closed by Mark-V control system. The exhaust temperature of the gas turbine can be lowered by the use of the steam turbine. As stated above, the turbine is not normally in service, that is, it is not supplying power to help roll the train. If the steam valve is opened to allow 585 psig steams to be admitted to the turbine, this would tend to increase the speed of the train. This speed increase would cause the speed control system to reduce the fuel gas thru FSR to slow the train. This reduction of fuel gas would result in a reduced exhaust temperature. This method of lowering the exhaust temperature is used when the temperature cut back causes a reduction in the fuel gas and speed of the train and will enable the operator to run, the train at maximum even on hot days. The steam control valve can be opened by Control room operator from Mark-V system.

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KGT 2501
Specifications KGT-2501 Speed (RPM) Make Power (BHP) Load Axial compressor stages Air flow in axial compressor Air inlet pressure Air inlet temperature Turbine exhaust temperature Turbine exhaust pressure Combustion chamber temperature No. of fire cans No. of spark plugs Wheel space thermocouple Ultra violate flame detector Operating values 5100 RPM General electric 17,000 12.92 MW 16 598,000 lbs/hours 14.4 PSIA 115 oF 1000 oF max 14.7 PSIA 1700 oF 10 2 ( 8th & 9th cans) 8 (control by Mark V) 2 (control by Mark V)

KGT-2501 consist on the


Axial Compressor Combustion chamber Turbine section

Axial compressor
It consists of a large circular bulkhead with a barrel-like casing on the forward side, containing the last seven stages of compressor stator blades and a smaller cylindrical section on the aft side which support both the inner barrel and the firststage nozzle assembly. The combustion 14

chambers are mounted on the forward side of the bulkhead. The forward end of the assembly is bolted to the compressor casing. The turbine shell is bolted to the aft side of the bulkhead. Provision for extracting air from the tenth stage of the compressor is made at the casing where it joins the compressor casing. The inner barrel and the aft end of the casing form the annular air path through which the high pressure air is guided into the combustion section. This area is so designed as to decelerate the air flow and increase the static pressure of the air supply to the combustion chamber.

COMBUSTION CHAMBER
The purpose of the gas turbine combustion section is to supply the heat necessary to expand the gases and drive the gas turbine. The fuel nozzles feed the fuel into combustion chambers. There are ten combustion chambers which are arranged concentrically around the axial-flow compressor and assembled to the axial compressor discharge and turbine frame bulk head.

Each combustion chamber has within it, a fuel nozzle, a combustion liner a long cylindrical part having a cap at the fuel nozzle end and an opening on the other end where the hot gases exit to the transition piece

. The air flow through the combustion chambers has three functions: oxidize the fuel, cool the metal parts, and adjust the extremely hot combustion products to the designed turbine inlet temperature.

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Transitional piece
The transition pieces is hot gas path link between the combustion liners and the first stage nozzle assembly is sealed at both its outer and inner periphery to prevent leakage of hot gases. There are 10 transitional pieces at KGT-2501

Fuel nozzle
Each combustion chamber is equipped with a fuel nozzle that introduces fuel into the combustion liner. Gaseous fuel is admitted directly into each chamber through metering holes located at the outer edge of the nozzle swirl plate. When liquid fuel is used, it is atomized in the nozzle swirl chamber by means of high pressure air. The atomized fuel / air mixture is then sprayed into the combustion zone. Action of the swirl tip imparts a swirl to the combustion air with the result of more complete combustion and control of emissions.

CROSSFIRE TUBES
The ten combustion chambers are interconnected by means of crossfire tubes enable flame from the fired chambers containing spark plugs to propagate to the unfired chambers during start-up.

Turbine section
The turbine section converts the high temperature gases discharged from the combustion section to use full shaft horsepower to drive the process air compressor, K-2501, and to compress the combustion air. It does this by expanding the hot gases through the turbine wheel blades. The turbine has a two stage rotor. The first stage (high pressure) wheel and the second stage (low pressure) wheel are bolted together to form a single operating unit. The first and second stage nozzles direct the flow of gas through this unit. The forward section of the shell acts as a casing for the aft end of the compressor discharge and combustion section. The aft section contains the first and second stage nozzles and shrouds for the first and second stage turbine rotors. The first stage nozzle assembly is sealed at its outer and inner edge to prevent leakage of the hot exhaust gases. The nozzle directs the hot exhaust gases against the first turbine wheel blades to gain the maximum power. The gases are cooled some what as they expand across the first wheel and are routed into the second stage nozzle assembly which directs the hot exhaust gases into the second turbine wheel blades and to the exhaust plenum.

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Brg # 01
(Undersized Journal Dia 7.980) Std. Journal Dia 8.00

1st stage wheel

Brg # 02
Journal Dia 7.9975 Std. Journal Dia 8.00

2nd stage wheel part #

Oil Deflector Size 7.994 / 9.014 / 10.012

No of holes 24 BCD 14.625 Hole size 0.627

No of holes 12 BCD 8.00 Hole size 0.501

16 stage Axial Air compressor Turbine Barrel / Distance piece

1st stage Turbine wheel

2nd stage
Turbine wheel
Dia 45.800

1st stage comp wheel

FIRST STAGE NOZZLES


The first stage nozzle assembly consists of air foil-shaped partitions contained between an inner and outer side wall. This assembly is divided into segments held in a retaining ring assembly supported by a clamping arrangement in the turbine shell.

SECOND STAGE NOZZLE AND DIAPHRAGM


The second stage nozzle and diaphragm assembly is supported between the first and second stage turbine wheels by a clamping arrangement in the turbine shell. Air foils shaped partitions contained the inner and outer side wall direct the gas flow into buckets of the second stage turbine

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COOLING / SEALING AND CONTROL AIR SYSTEM


When the turbine is operating, air is extracted from appropriate stages of the gas turbines axial flow compressor and is used to cool the turbine parts, to seal the turbine bearings and to provide an operating air supply for the control system of the gas turbine.

COOLING AIR
In addition to supplying combustion air, the axial flow compressor supplies cooling and sealing air for various parts of the turbine unit. 4TH STAGE AIR Air from the fourth stage of the compressor through two taps; on the upper left hand side of the unit and other on the lower right. It is piped externally to the turbine compartment ventilation educators and to the turbine shell. The cooling air passes through holes in the exhaust frame and is directed to the aft (back) side of the second stage turbine wheel space and exhausts to the exhaust plenum. 10TH STAGE AIR Air from the 10th stage of the compressor through two taps, one on the upper left hand side of the unit and other on the lower right side. This air is piped externally and is used for sealing air on the turbine bearings. Tenth stage cooling air is also mixed with forth stage cooling air at the aft side of the second stage turbine, after cooling exhausts to the exhaust plenum. 16TH STAGE AIR A slipstream of the sixteenth stage discharge passes through the opening formed by the clearance between the axial-flow compressor discharge casing and the (back) side of the compressor rotor ahead of the guide vanes. The air then passes into the first stage turbine wheel space. The air provides a seal between the axial-flow compressor discharge and the turbine and cools the forward face of the first stage turbine wheel. Another stream of the sixteenth stage routed to the forward side of 2nd stage nozzles and turbine wheel, cools the 2nd stage turbine nozzle and blades.

MAIN BEARINGS
Two main bearing assemblies support the unit rotor. The No.1 bearing assembly is located in the inlet casing, and the No.2 bearing assembly in the exhaust hood. The No.1 bearing

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assembly contains a journal bearing, two thrust bearings, oil deflectors, oil seals, and a housing in which the components are installed.

Gear box XK-2501 (A)


Make Size/ type Philadelphia USA 18 HS (HS= High speed single helical gear unit) 5100 RPM 6120 RPM 1 ---- 1.2 1.5 17.075 inches 20.424 inches

Input Speed (RPM) Output speed (RPM) Ratio Service factor Pitch diameter ( Pinion ) Pitch diameter ( Gear )

Gear box is attached after the turbine shaft and which is connected to the LP case centrifugal compressor.

CENTRIFUGAL COMPRESSOR K-2501(A) LP Case


Make Model Suction Discharge No. of stages Speed (RPM) Dresser Rand 4M8-6 1st stage 14.15 PSIA 2nd stage 33.03 PSIA 1st stage 36.93 PSIA 2nd stage 89.33 PSIA 6 5924 RPM

Centrifugal compressor are connected with the air suction and after that it transfer the air to the heat exchanger E-2502 then D-2507 and again return to the 2nd part of the air compressor.

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Gear Box XK-2501(B)


Make Western gear corporation limited. USA 6114 RPM 10675 RPM 1 ---- 1.7 1.5

Input Speed (RPM) Output speed (RPM) Ratio Service factor

Centrifugal compressor K-2501(B) HP Case

Make Model Suction Discharge No. of stages Speed (RPM)

Dresser Rand 2M8-6 3rd stage 80.43 PSIA 4th stage 207.1 PSIA 3rd stage 210.1 PSIA 2nd stage 526.5 PSIA 6 5924 RPM

The air coming form E-2503 and D-2508 is coming to the centrifugal compressor after that it compress and then it is transfer to the secondary reformer and utility 1.

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Problem at KGT 2501


High Exhaust Temperature Issue
Lube oil consumption High vibration at bearing #1 & bearing # 2

Report from Vulnerabilities List 2010-2011

KGT 2501 Sr. Vulnerability No 1 LO console level drop due to suspected oil leakage from bearing no. 1 Description LO Oil console level drop issue in KGT 2501 was reported by OPS in Sept 10 and on average 01 oil drum per day is being used. Initially it was being suspected that its LO coolers are leaking, causing this level drop as oil pressure is higher than that of CWS. CWR samples were sent to lab for analysis but no oil traces were found.1. LO leakages from the compressor casing joint 2. Oil is leaking from casing sealing air pipes and eccentric pin location 3. Oil leakage is also evident from several other locations Current Status/Remark In progress- The key performance parameters like PCD, exhaust temperature, wheel space temperature, spread, oil makeup rate are being monitored vigilantly and all are3 under preferred range. External sealing air at 45 psig is being supplied. All S/D preps are complete with respect to spares and bar chart. This activity will take 84 hours mechanical time. Action Plan Short term: 1. Routine close surveillance all key parameters and external sealing air supply provision 2. Monitoring of oil leakage trend Long term: Inspect/Replace the bearing no.1 and its deflector assembly in FAO Target 31-Mar11

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2 Scored bearing no.2 journal of KGT 2501

Scoring marks at bearing no. 2 journal, causing high vibrations at V108/109. Machine rpm is also limited to 5060 due to scored journal

3 Refurbishment of KGT 2501 First and Second stage nozzles

These nozzles were removed in April '09 turnaround. During initial inspection, minor and major cracks were found along with excessive ovality especially in the first stage nozzle. Most of the wheel space thermocouples were also damaged and were giving erratic readings. The nozzles need refurbishment

In ProgressCurrent rotor health is OK and vibrations are in acceptable range. No immediate threat. Spare rotor, bearings and buckets are available and rotor replacement activity is planned in TA 2012 In progressAmount of 6,564 KRs is solicited in One Time 2011. Fresh quote has been taken.

Rotor replacement is planned in TA-2012

15-Apr12

Therefore, refurbishment of these nozzles has been proposed in One Time Expense 2011 as part of the Critical Machinery Spare Philosophy of the site. It should be noted that this was a budgetary quote and actual repair scope quote will be received from MJB after inspection of diaphragms

31-Mar11

High Exhaust Temperature Issue


High exhaust temperature is quite dangerous for the Gas Turbine, which can become a cause of the lots of problems such as metallurgical failure, creep and detonation of the blade so for the temperature we should try to minimize the temperature as much as possible other thing is that losing the temperature in the atmosphere is also the loss of the of the energy which we should utilized for running the turbine. KGT-2501 due to its design and enormous amount of air consumed is sensitive to air quality. Its performance is changed by anything that affects density and / or mass flow of the air intake to the axial compressor. Ambient weather conditions are the most obvious changes from the reference conditions. During peak summer months, KGT-2501 load limit is not uncommon. This is due to the fact that with increase in ambient temperature, axial compressor intake air temperature increases. With increase in ambient temperature density of air decreases and hence volume increases. Since pressure and volume are inversely proportional, this increase in volume would cause decrease 22

in PCD and hence decreased pressure ratio. Decreased pressure ratio means less work with same heat input (as learnt above).

Reasons for high exhaust


1. High ambient temperature 2. Compressor fouling 3. Air and fuel improper mixture 4. Chocking of the cooling circuit. 5. Excessive load. 6. Turbine inefficient. 7. Turbine detonates 8. Damage diaphragm. 9. MARK-V system fails to maintain FSR. 10. Malfunction of speed governor valve 11. Malfunction of speed ratio valve 12. Malfunction of PRC-306 13. Malfunction PT-1 / PT-2 A/B/C transmitter 14. Improper burning of gas Graph shows the high exhaust temperature at KGT-2501

1000 980 960 940 920 900 880 860 21-Nov-10 00:00:00 21-Dec -10 00:00:00 21-J an-11 00:00:00

E X H-2501 Deg _F
E XH2501 Deg_F

21-F eb-11 00:00:00

21-Mar-11 00:00:00

21-A pr-11 00:00:00

21-May-11 00:00:00

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Recommendations (High Exhaust Temperature Issue) Short term proposals


Decrease the ambient temperature by spraying water.

Advantages
Decrease the ambient temperature.

Disadvantages
Cause corrosion in DYNAWANE filter house. Water carryover with air since mist is not forming. Raw water, if carryover may cause salt formation Housekeeping issue.

Opening of north door of filter house to provide fresh air and partially blind south side of filer house Abrasive Cleaning (Carboblasting)

Minimize hot air intake

Air quantity decrease. Difficult to allow same amount of air form only one door. Axial compressor may surge. Any foreign material may go inside through north side door hence chocking CWMs.

Decrease temperature up to 650F Increase PCD

Increase compressor fouling Not recommended for lube oil leakages Temperature increase after a week

Install Evaporated inlet chiller

Lowest capital cost Lowest O&M cost Can operate on raw water Can be install online

Limitation on capacity improvement. Do not decrease to much ambient temperature

Online cleaning

Online cleaning is the process of injecting cleaning solution into the compressor while running at full speed. No need to shut down the system No effect on the production. Good for the continuously running machine which cannot be off. Less time consume as compare to off-line. Remove some quantity of fouling without stopping

Can have a limited effect if not performed regularly Possibility of fouling being washed back in compressor and/or turbine. Do not remove efficient amount of fouling. Do not have long lasting effect Do not remove complete fouling Detergent solution will reduce the dirt, but also seem to

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process Over hauling time increase.

impact the effectiveness of the surfactant coating

Recommendation (high exhaust temperature issue)


Long term proposals
Mechanical inlet chiller attached

Advantages
Can increase gas turbine performance better than evaporative cooling, and fog system

Disadvantages
High initial capital cost High O&M cost Longer delivery and installation time Expertise is needed to operate and maintain the plant shutdown required Hazards of ammonia handling Increased maintenance and operational hazards. High installation cost.

Relocation of filter house

Will help in improving High inlet air temperatures.

High investment involved in relocating.

Offline cleaning / detergent cleaning Offline / online cleaning system install

To improve compressor PCD and hence elimination of issues due to low PCD Offline cleaning is much more efficient then the online. Every part of the compressor is properly clean. Maximum amount of fouling removed. Increase the life of machine

Shut downing is necessary for offline cleaning Time consuming as compare to online cleaning. Stop the process and required much more time

Internal filter house coating Replace blades of axial compressor to achieve designed PCD, if problematic/ eroded

Save compressor form corrode particles of filter house

Save compressor from corroded particles Increase filter house life

Gain design parameters

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Modify filter house to accommodate high efficiency bag type filters in place of CWMs

FILTER HOUSE
Air filters equipments selection recommendation for all climate condition.
Properly conditioned intake air is vital for top operation performance of a turbine. A good filtration system is much more necessary for the turbine working and a good filter house can protect the compressor form the dirt which causes the fouling in the compressor. And it is directly effect on the performance of the turbine. Environmental condition of intake air for gas turbine is required for several reasons, Prevention of erosion and fouling of axial blades Reduction of corrosion of the compressor air path and on its blades. Reduction of corrosion in hot gas area For weather protection For cooling For sound attenuation

Inlet weather protection (weather hood) The best protection against the rain snow sleet and hail, is a large weather hood so design that the air entre vertically upward The more usual protection however is by weather louvers. To be effective against have vertical blades of least 2 pass design and generous drainage point.

Housing design The intake filter housing design depends upon many factors such as. 26

Volume of air and types filter Wind load Snow load Negative pressure inside housing Installation weather ground level or above ground level Acceptable dimension for transportation to the job site. Protective finish against corrosion Location of blow-in doors Location of one or more air outlet connection of gas turbine combustion air and possible additional air required for other purpose such as alternator cooling etc Will filters be installed in one side two sides, three side or all four sides of the housing. Will space be required for possible installation of additional filter stages at some future time? Unfiltered air by-pass door It is considered absolutely essential that an unfiltered by pass door be provided on all gas turbine for the removal of the unfiltered air if it is packet there so the flow of the air will be effected. Evaporative cooler Due to the design of the filter turbine output is affected by the temperature of air entering the compressor when the temperature goes above the design point international rating condition of 59 0F and 14.7 Pisa there is the loss in horse power correspondingly when the temperature goes above the design point there is a gain rated above horse power. When customers specify a horse power requirement at an elevated temperature, the turbine manufactures re-compute as correspondingly higher horse power requirement for the standard design temperature point. Where this encroaches on the maximum rating of the turbine then it is worthwhile to consider the use of an evaporative cooler as an in expensive device to assist the turbine to produce more power. Silencer Silence is also an important component of the filter house in because of the noise pollution. Damages Damage that filters house can occur are the erosion and corrosion and fouling the filter house is directly content with the compressor for if the compressor do not received a clean and moist free air it will damage the blades of the compressor. The damages in the compressor can cause the increase in the exhaust temperature and the decrease in the overall efficiency of the system. Increase in the temperature is very dangerous for the Gas Turbine; it may cause the metallurgical failure in the system. Fouling Erosion Corrosion

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Axial compressor is very sensitive to erosion or deposits on their blades. Similarly Gas Turbine fuel nozzles, Its/2nd stage nozzles and buckets are to be kept clean and prevented from erosion. For best gas turbine performance, it is essential that air entering the compressor should be clean and free from dust. Any material in the incoming air that has a tendency to erode or adhere to internals of the gas turbine and the compressor must be removed by use of filters to maintain high efficiency. There are two basic separate we used: DYNAWANE & CWM

Fouling and erosion


Compressor fouling is normally due to one of two elements. The first is solid particulate minerals and/ or plant matter and other is in turbine with carbon smoke or hydrocarbon fumes which creates a sticky fly paper substance when deposit on the turbine blades. One contributing source of carbon smoke and hydrocarbon fumes is the gas turbine itself with its exhaust combustion gases and lube-oil tank vent vapors, however this is but a portion of the total problem considering the vast number of sources of the air pollution in evidence today. While coarse minerals dust may erode the rotor and stator blades, a fine sticky dust would create deposits on the blades in both cases is changed from its ideal design shape with cause continuous drop in the efficiency of the compressor. What is the difference both cases, is the in the former the damages in permanent and the parts must be replaced while in the letter the dirty parts can be cleaned. This fundamental difference in the mature of damage cause, determines the choice of a suitable intake air filter.

TYPES OF FILTER HOUSES

TYPES OF FILTER HOUSE

STATIC FILTER HOUSE

SELF CLEANING FILTER HOUSE

Filters type (KGT-2501)


Commonly the dust particles becomes a cause of fouling but in the moisture in the air may cause appreciable corrosion of the axial compressor as well as the hot gas power turbine.

DYNAVANE inertial dust separator Crinkle Wire Mesh Panel Filters (CWM).

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DYNAVANE
Two banks of inertial dust separators are provided on north and south sides of the filter house. Each bank of separators has a dust blower through a common duct to blow out dust particles. Dirty air enters the large opening of the wedge-shaped cell of the inertial separators. As the air carrying dust flows down the cell most of the air passes through the vanes in an "S" curve and the dirt particles get separated. Approximately 90% of the clean air passes through the vanes. The dirt and dust particles continue in a straight line along with the remaining 10% air into the blower duct and are thrown out. Approximately 88% micron size is removed. Pressure drop across separators is 2cm (0.8") WG. There are 42 separators in two sections on each north and south side of filter house.

WIRE MESH PANEL FILTERS (CWM's)


To ensure complete removal of dust particles, wire mesh panel filters are provided after the inertial separators. Wire mesh filters are coated with adhesive oil. Fine dust particles which are carried over with air from the inertial separators are removed by these filters. The panel filters have a fine wire mesh formed in alternate layers, flat and herring bone crimp, to form triangular openings facing the air stream. Air passes through these filters at high velocity, changing direction frequently and impinging dirt particles on the wires of the mesh. The dirt particles cling to the wires coated with adhesive oil. As dirt loading increases, pressure drop across these filters starts increasing. Before excessive pressure drop 1.3cm (0.5") is reached, filter panels are removed. After cleaning with hot condensate or with a solvent to remove dirt and re-coating with adhesive oil, panels are reinstalled. Almost 95% of dust particles in range of 0-5 micron size are removed and clean air passes to compressor suction thru silencers.

SPECIFICATIONS No. of panels Size of a panel Wire mesh thickness Maximum pressure drop 96 panels in each filter house. 48 panels each side (north/south) side 61 x 61 cm (24" x 24") 5.1cm (2") 0.4cm (0.15") WG for clean filters
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Maximum air flow Wire mesh size Wire mesh size

4046 NMCH (2380 CFM) each filter panel 2312 NMCH (1360 CFM) each filter panel 35.6cm (14") WC

GT 601(filter house)
Filter house has two banks of inertial separators (Dynavane filters) on north and south sides. Each bank of inertial separators has a dust blower. A bird screen is also installed before dyna vane filters. Total pressure drop across separators & panel filters is10.2-12.7 cm (4.0"-5.0") WC depending upon dust loading on the filters. Alarm value of GT 601 is 15.2 cm (6.0) WC, If total pressure drop down stream of panel filters reaches 17.8 cm (7.0") WC, the door starts opening to nullify negative pressure created due to high pressure drop. The filter house has a pressurizing air fan on its roof. Pressurizing fan supplies clean air from downstream of wire-mesh panel filters. Two electric motor driven dust blower fans, one on each north & south banks of inertial separators are installed.

GT 602 (filter house)


Filter house of the GT 602 is modified because of the climatically condition of the DAHARKI.

Reasons of modification
The filter houses installed originally in 1967 were single stage inertial only. Design was based on Arizona road sand analysis which comprises of more than 75% of coarse sand greater than 10 micron. Based on the Arizona road sand analysis the design filtration efficiency of the inertial filters was more than 93%. First re-evaluation of filter house design and performance was made in 1976-79 by EXXON. DAHARKI air borne soil contains more than 96% fine dust less than 10 micron and high sodium content. Filter house is inefficient for the DAHARKI climate.

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Filter house is modified by adding the second coded wire mash filter with that the efficiency increase about 21%. The efficiency of the filter at that time is to low less than 25%. But still the filter is not that much efficient that to stop the dust particles. Dust holding capacity of the filter elements was very low 0.5-0.6 kg (500-600 gm) that caused the filter panels to choke.

MODIFICATION
Storms buster weather louvers.
It is used for the protection against the rain, vertical vanes are there design for the passage of the air but the droplet is separated to the vane surface and drain out.

Pre-filter bags (stage # 1)

Design is made to increase the life of the second stage filter and minimize the pressure drop. The key features of these filters are: Low pressure loss even in wet and humid conditions. Large dust retention capacity 2.8kg (2800 gm). The filter house can be rapidly change by which it reduce the maintenance manpower. There are 48 stage 2 secondary air filters. These are in 4 sets of compact units.

High efficiency bag filters (stage # 2)


Bag filters are specially design for the land based gas turbine, effective against particles 2 micron and smaller in size. Key features are: Very high filtration efficiency .Low pressure loss even in wet and humid conditions .Large dust retention capacity 5kg (> 5000 gm). Clean air pressure loss will be 6 cm (2.36 inch) WC. In case total pressure drop increases to 15.2 cm (6.0) WC, an alarm for high delta P is sounded. If total pressure drop down stream of panel filters reaches 18cm (7.0) WC, the weight balance door starts opening to nullify negative pressure created due to high pressure drop. Filter house have the pressurized air fan at the top. Pressurizing fan supplies clean air from downstream of stage 2 panel filters to pressurize accessory compartment combustion compartment and static exciter cubical.

GT 603 (Filter House)


The filter house has two stage filtration systems with bird screen before first stage filter. The first stage filters are the Wall-cell-HV2 type. The filtering media of HV2 filters consists of corrugated tapered strips of screen wire.

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Air flow capacity thru a 61x61x5.2 cm (24x24x2) filter is 3400 m3/hr. 95% of dust particles in range of 0-5 micron size are removed in the first stage. The second stage filter is the Multi-V-Form type. Both the filters can be washable. Pressure drop across fresh filters is approximately 2.5 mm of W.C. and over a period it increase to about 12 mm W.C. A vacuum cum pressure relief door is installed which will open to the inside at a low pressure of 100 mm W.C. A bird screen is also installed.

GT 604 (filter house)


GT 604 air inlet system consist of an integrated system of high efficiency self cleaning filter house supported structure inlet ducting system with acoustical silencer, the elevated ducting and filter house arrangement provides a compact system and minimize pickup of dust concentrations found near the ground. Air filtration in GT 604 is being carried out in two stages, Through droplet cleaning catchers Through self cleaning filtration system Droplet catchers remove large moisture droplets from the incoming air flow and it will be drain out through the S shaped channels in the opposite direction of to air flow. Droplet catcher plays an important role in the protection and the operation of the high efficiency filters. Consist on numerous single stage high efficiency moisture resistant element pairs mounted on vertical guide plates Light gauge steel metal made Design for proper air flow Weather protection Internal & external surface protection with zinc primer with epoxy overcoat

The major difference between a static (barrier) and pulse (self cleaning) air filtration system is that a self cleaning systemic capable of automatically clean the filter elements via reverse pulse of air. Life increase the filter Dust is trapped cellulose, synthetic or combination cellulose/ synthetic filter paper

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The quality of the filter media is based on criteria of efficiency pressure drop and dust holding capacity

Filter efficiency Normal filter difference pressure Cleaning cycle start / stop Alarm value Trip value

98 % 50 mm H2O 55 / 45 mm H2O 120 mm H2O 180 mm H2O

PUGH MATRIX OF FILTER HOUSES


Filter house
Arrestance Weather protection Moisture control Self cleaning system Dust holding capacity Frequency of cleaning Pressure drop Filter efficiency Ease of cleaning Total

KGT 2501 1 0 0 0 2 2 2 1 3 16 2 5 0 0 2 2 2 2 3 18

GT 601 3 5 0 0 3 2 3 2 3 21

GT 602 3 5 0 0 3 2 3 3 3 22

GT 603 4 5 5 5 4 2 4 4 4 36

GT 604

Score given on scale of 1-5, with 5 being the highest 33

Very Easy

Spray water
Evaporated chiller
Fogging system / internal coating

Easy

Mechanical Chiller

EASE
Less Difficult

Pre-filter

Very Difficult

No Benefit

Less Benefit

Good Benefit

Excellent Benefit

BENEFIT

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Cleaning system of KGT-2501


INTRODUCTION
The loss of gas turbine performance is indicated by a decrease in power output and increase in heat rate. Often a loss of performance is a direct result of fouling of axial flow compressor. Fouled compressors result in reduces air flow, lower compressor efficiency and a lower compressor pressure ratio. Cleaning of the compressor can reduce the fouling and increase in the performance, compressor cleaning may also slow corrosion, thereby increasing the blade life and reducing the contribution of corrosion products to the formation of fouling deposits.

Method of Compressor Cleaning

ON-LINE Cleaning Method


ON-LINE Cleaning Method

OFF-LINE Cleaning Method

On-line cleaning is the process of injecting cleaning solution into the compressor while running at full speed and some percentage of loads. The advantage of on-line washing is that washing can be done without having a shutdown the machine.

OFF-LINE Cleaning Method


Off-line cleaning is the process of injecting cleaning solution into the compressor while it is being turned at cranking speed.
TYPES of Compressor Cleaning

SOLID-COMPOUND Cleaning

LIQUID-COMPOUND Cleaning

ORGANIC Substance

INERT CATALYST

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FOULING
The type the rate of the fouling is depends on the environment in which the compressor is operating and the experience has shown that fouling deposit consist of varying amount of moisture, oil , soot ,water soluble constituent insoluble dirt and corrosion product of the compressor balding material . Fouling deposits are probably held together by moisture and oil. If corrosion of the balding is occurring, the corrosion product will promote and stabilize the deposit. The good filtration system may greatly reduce the fouling problem. Moisture formation cannot be reduced in humid environment. The moisture is formed in compressor inlet when humid air is cooled below its dew point.

Fouling Detection
Usually based on combination of load and exhaust gas temperature Monitor compressor discharge pressure (pressure ratio) and compressor efficiency Trending graphically parameters Visual inspection Drop in compressor mass flow rate Drop in compressor efficiency and pressure ratio Thermodynamic / Aerodynamic effects - observed in drop in thermal efficiency and drop in power output. Fouling causes alteration in the shape of the blading which reduces air flow rate, pressure ratio and compressor efficiency Air flow distortion and compressor surge - fouling causes drop in mass flow in first stage effecting performance of latter stages Lading integrity effects Associated problems - (erosion, corrosion, cooling air passage Blockage, foreign object damage) - erosion caused by hard particles >10 micron

LIQUID COMPOUND CLEANING


WATER + DETERGENT = LIQUID COMPOUND CLEANING Liquid cleaning involved the washing the compressor with water and detergents. This can be accomplished while the turbine is on line or off line. As the on line washing practices has been found to be most effective when carried out daily, the specification on the liquid must be more restrictive for on-line washing then off-line washing. The water specification tables are given below.

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OFF-LINE CLEANING METHOD TOTAL SOLIDS (dissolved and undissolved) TOTAL ALKALI METAL OTHER METALS WHICH MAY PROMOTE HOT CORROSION (i.e. LEAD, VANADIUM) pH (determined by glass electrode)

100 ppm 25 ppm 1.0 ppm 6.5 to 7.5 * GE recommendation for Gas Turbine

ON-LINE CLEANING METHOD TOTAL SOLIDS (dissolved and undissolved) TOTAL ALKALI METAL OTHER METALS WHICH MAY PROMOTE HOT CORROSION (i.e. LEAD, VANADIUM) pH (determined by glass electrode)

5 0.5

ppm ppm

6.5 to 7.5
*GE recommendation for Gas Turbine

Except for the pH, the restrictions in this specification are concerned with deposits and corrosion of the hot gas path. The pH restriction is concerned with the corrosion in the water handling system. High purity dematerialized water after contact with air will have a pH in range of 5.0 to 6.0 thus allowance has been made in pH provided this is the reason for the low pH. The deposits are also having water soluble material and oils. The latter material will be more amenable to remove by detergent, but the deposits may be removed by the water washing alone, depending in the amount of water soluble material present. Hot water at 150 to 200 F (66 93 C) is generally more effective than cold water. G E recommends following three detergents cleaners. 1. B&B 3100 2. PENETONE 19 3. TURCO 4217

SOLID COMPOUND CLEANING


There are two types of the solid compound ORGANIC and INERT. In the solid compound cleaning was mostly used the nutshell and rice where as in the place of inert catalyst supports spent catalyst and polished powder combustible compound are preferred to inert compounds. The organics will also burn up in the combustion process while inert may not and cause erosion. SOLID CLEANING COMPOUND Particle Size Stone Content 40 to 200 microns 10 ppm (weight part) max

*GE recommendation for Gas Turbine

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The recent experience in the use of rice for cleaning compressor suggest that solid compound cleaning can be detrimental to compressor blade coatings and to compressor blade surface finish. Shallow impact craters of several miles in diameter and tenth of mils in depth have been found on cleaning number 1 rotor blading upon inspection immediately after solid compound cleaning, further more an increase of surface roughness from 20 micro inches to 100 micro inches has been observed on blade.

CARBOBLASTING
Carbo-blasting is a cleaning method for gas turbines with natural media like walnut shells, rice husks, spent catalyst, apricot pits etc. This cleaning method uses the solid cleaning media and is quite effective in de-fouling the turbine and compressor blades. Media is commercially available which a mixture of walnut shells with other agents is normally. It should be carefully selected considering the hardness of media and the metals along with their protective coatings.It is an alternative to chemical cleaning when downtime not available.
Natural media like walnut shells, rice husks, spent catalyst, apricot pits. Carboblasting is an online mode of cleaning.

Burn in combustion process. This is recommended for dry deposits and would not be adequate for oily deposits
Reference by Memorandum GE correspondence file

Carboblasting done at KGT

28, Jan, 2010

* Reference by Correspondence file 2008

First lube oil leakage reported October , 2010 Carboblasting again done 9th March , 2011

Carboblasting is not recommended for KGT-2501. Carboblasting increase fouling.

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Following carboblasting activity was performed at 9th March, 2011 Exhaust temperature drop about 65 F

Temperature drop after carboblasting

Temperature again increase after the two weeks

Exhust Temp: KGT 2501 March-11


970 960 950 940 930 920 910 900 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 Exhust Temp: KGT 2501 March-11

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CARBO-BLASTING PROCEDURE.
1. Turbine is prepared for cleaning by removing internal instrumentation equipment, or fittings that may become plugged by impingement of the media. 2. All open fittings, tubing, arid air bleed ports must be effectively closed with a cap or tape. 3. For injection of media, small fittings are installed in the inlet injection nozzle. An impingement cone is usually placed to provide more uniform distribution of the media. 4. Approximately 200-250 lbs. of media should be uniformly injected over a period of 3040minutes while the turbine is being operated at lower speeds. 5. The turbine should be run for an additional 5 minutes at idle, and shut down. 6. All temporary caps and enclosures should then be removed and the turbine operated again for 5 minutes to blow out the media residues that may have accumulated in the fittings. 7. Reinstall all instrumentation equipment and fittings that were removed prior to the cleaning operation.
* Procedure recommended by PETROSTREET

REASONS FOR CLEANING


Restore Engine Performance Reduced air compressor efficiency results in reduced output power and increased fuel consumption Maintain Time between overhaul life Fouled engine requires higher firing temperature for given load Maintain Start reliability Compressor fouling increases the possibility of a stagnated start Reduced air compressor efficiency raises turbines self-sustaining speed so more starting power is needed

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WHEN TO CLEAN

Exhust temprature increase by 5%

compressor discharge decrease by 5%

GE recommended cleaning System

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Method of cleaning

Advantages
Online cleaning is the process of injecting cleaning solution into the compressor while running at full speed. No need to shut down the system No effect on the production. Good for the continuously running machine which cannot be off. Less time consume as compare to off-line. Remove some quantity of fouling without stopping process May increase the time of over hauling.

Disadvantages
Can have a limited effect if not performed regularly Possibility of fouling being washed back in compressor and/or turbine. Do not remove efficient amount of fouling. Do not have long lasting effect Do not remove complete fouling Detergent solution will reduce the dirt, but also seem to impact the effectiveness of the surfactant coating

On-Line Cleaning

Off-Line Cleaning

Off-line water washing refers to washing the unit while it is in an unfired state. Offline cleaning is much more efficient then the online.

Shut downing is necessary for offline cleaning Time consuming as compare to online cleaning. Stop the process and required much more time

Every part of the compressor is properly clean. Maximum amount fouling removed. of

Solid Compound Cleaning

Increase the life of machine. There are two types of solid compound cleaning 1. Organic 2. Catalyst Solid compound cleaning is performed at full speed. For dry, hard deposits

Inert catalyst may cause erosion or blocked cooling holes Catalyst does not burn properly in the combustion chamber which cause problem.

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were present solid cleaning is preferable. In case where blading is corroded over time and surface roughness are well above 25 micro inches, solid compound cleaning should be preferable.

Increase in the surface roughness may harmful for the compressor. The moisture will not be removed by solid cleaning. Some damages can be occur

Liquid Compound Cleaning

Liquid cleaning involves washing the compressor with water and/ or detergents. It can be used for online and offline cleaning method, but at KGT 2501 we do chemical cleaning which is offline. It is much more effective on the moisture in the compressor. The specification of the liquid is more restrictive for online washing then off line washing. Carboblasting is the one of the online cleaning method. Carboblasting is good for the online cleaning in only dirt fouling. Carboblasting reduce exhaust temperature about 65 0F. Carboblasting can decrease the wheel space temperature.

If the detergent is used, additional restriction is required to ensure no harm will result to turbine component. It may be dangerous in online cleaning because of deposit and corrosion of the hot gas path.

Carboblasting

Unaffected at oil and dirt fouling Abrasive in nature

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