7F Compressor Fouling

Progress Energy - Richmond County Plant 7FA.03 DLN 2.6 Presented by: Ben Meissner

Background Unit 8

7FA.03, Donaldson Inlet Conical/Cylindrical No On-line water washes performed Semi-annual off-line water wash (borescope) Last inlet filter replacement Fall 2007

Replacement was based on failure to meet burst test criteria (not DP)

Current Filter - Donaldson Spiderweb

Discovery

On the morning of Oct 31, 2010 (@0300) it was noted that Gas Turbine Unit 8 on the combined cycle block was performing 27 MW lower than the adjacent unit (Unit 7). Units were on base load control with IGVs open at 87. Cooling tower plume was drifting into Unit 8s inlet CPD for Unit 8 was 22 psig lower than Unit 7 Troubleshooting was performed and Unit 8 was shut down to perform compressor inspections

Trouble Shooting Unit 8

AFPCS (compressor inlet pressure)- 4.74 inH2O vs. 2.34 inH2O on unit 7. AFPBD (bell mouth pressure)- 12 inH2O lower than unit 7. While inline Points above were forced at current values, Transducer tubing was removed and any moisture was removed resulted in minor change in instrument value. Inlet filters were inspected and recorded as wet from cooling tower plume but no filters were damaged The #2 bearing vibration showed a 0.8 in/sec increase during the event but returned to normal a few hours later.

MW and #2 Bearing Data

Unit 8 Compressor Efficiency Data

It was noted that there were several inlet DP events prior to this event

Unit 8 Compressor Inspection

Conducted inspections of the compressor inlet and aft end. Stator blades were found to have significant build up of sludge Aft compressor blades were covered with a white powder substance (smoldered deposits)

Unit 8 Inlet Inspection

Inlet duct (clean side) was inspected and puddles of black water were discovered Pools of water (2 deep) found behind inlet filters It is believed that this water carried over to the compressor and deposited on the compressor blades (sludge)

Unit 8 Inlet Filter Inspection

Two filter sets were removed for inspection. One filter was removed and sectioned using a band saw-mass amounts of dust/pollen fell out of the filter media The other was sent out for flow/pressure testing No results yet. Clean side corrugated web was rusty/corroded (water is passing though filters) Water puddle marks were found on the clean side of the filters at the seal.

Corrective Actions

No compressor blade damage was found Performed 2 off-line water washes to clean compressor Inlet was cleaned and standing water was removed

Future project created to install clean side drains

Inlet filters were left as is for time being (waiting materials and window of opportunity) Unit was put back on-line

Summary

It is believed the spike in vibration was caused by sludge falling off the compressor stator blades and impacting rotating blades Compressor efficiency and MW output were restored and exceeded Unit 7 output by 7 MW after water wash cleanings

Unit 7 was inspected soon after and was found to have some fouling as well

Gore Inlet filters Gore H12 3-layer conical/cylindrical filters will be installed this spring DRB Industry CF80Max drift eliminators will be installed in the hoods to knock down heavy moisture from cooling tower drift.

Thank You

Questions?