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LOAD OPTIMISATION BY BLADE &
STEAM WASHING-CASE STUDY
OLKARIA II
ARGEO-C6 CONFERENCE : 31ST OCTOBER-4TH NOVEMBER 2016
ADDIS ABABA (ETHIOPIA)
Presented by: BONFACE KIPKORIR
MECHANICAL ENGINEER (POWER PLANT)
Kenya Electricity Generating Company Ltd
31st October-4TH November, 2016
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GEOTHERMAL MAP IN KENYA
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Conclusion & Recommendation
Discussion
Experimental Data analysis
Objectives
Problem statement
Introduction
Contents
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INTRODUCTION
Olkaria II power station receives steam from olkaria North east field which
measures about 6km square.
The field has 20 production wells,4 hot re-injection wells and two cold re-
injection wells.
It has three shallow wells,M1,M2 and M3 which were drilled as monitoring
wells.
The steam field has further been divided into eastern and western fields
for better operation and management.
The well casing program consists of 20” diameter surface
casing;13.375”,anchor casing 9.55”,production casing, and 7” slotted
liners.
The production casing usually extends to between 600m and 900m while
the drilled well depth ranges from 1800m to 2500m.
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INTRODUCTION……
Scales are hard mineral coating and corrosion
deposits made up of solids and sediments that
collect in the distribution systems.
The reduction in power generated and increased
operating costs from scaling impacts a plants
financial outcome.
Geothermal fluids from different wells have differing
chemistry even within same field.
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OLKARIA II PROCESS FLOW DIAGRAM
CHF
IntermediateTemperature
Cold
Surface Water
Surface Rock
High TemperatureReservoir
SteamScrubber
Silencer
PRODUCTIONWELL
Gas Extraction System
Cooling Towers
CHF
Intermediate
Temperature
Cold Surface Water
Surface Rock
High Temperature
Reservoir
Gases
CONDENSER Re-injectionWell
Hot Condensate
Hot WellPumps
Re-injection Pump
TURBINEGENERATOR
SEPARATOR
Water
Steam
Main Steam Pipe
PressControlSystem
CooledCondensate
To BrineRe-injectionSystem
Sump
Steam fromother wells
Drain pot
Normallyclosed valve
NormallyOpen valve
Normallyclosed valve
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Generator load is the key focus of every power plant output.
The parameters of interest for this study were turbine inlet pressure, steam flow rate, steam chest pressure and Load.
After operating for two years, steam chest pressure increased from 3.5 bar-a to 4.1 bar-a and steam consumption increased to 82.2 kg/sec.
This led to decline in turbine overall rated capacity of 35 Mw and hence Efficiency.
INTRODUCTION
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After dismantling and inspecting for the purpose of this study, significant sulphur deposition and silica scaling deposits.
Significant scaling on the circulating water line, Turbine shroud and nozzles.
Real time data analysis of the de-scaling of turbine blade nozzles to improve on the Olkaria II power plant performance.
The study realized that steam and blade washing had an overall decrease of steam chest pressure.
The decrease in steam chest pressure improved turbine efficiency by up to 10%.
INTRODUCTION………
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PROBLEM STATEMENT
Geothermal fluids contain varying concentrations of
dissolved solids and gases.
The dissolved solids and gases often provide highly
acidic and corrosive fluids and may induce scaling
and corrosion.
Silica scaling is a major problem in most geothermal
fields in olkaria.
Therefore it is for this silica phenomena in
geothermal equipment that this paper has been
developed.
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OBJECTIVES
To explore blade washing and steam washing
procedures for de-scaling of turbine blades and
shroud.
Real time experimental data analysis from Olkaria II
Power station for load optimisation.
Improving the geothermal power plant efficiency by
way of silica de-scaling.
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GEOTHERMAL EQUIPMENT WITH SILICA
ATTACKS Main Condensers.
Inter-Condensers.
Hot well pumps and pits.
Turbine nozzles and blades.
Steam scrubbers and pipelines.
Brine separators.
Steam ejectors
Main stop valves and control valves.
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TURBINE BLADES & SHROUD
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DESCALING OF TURBINE BLADES DURING
AN OVERHAUL
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PRESSURE LET DOWN VALVES SCALING
SILICA SCALES
ON PLDS
SILICA
SCALES ON
THE VALVE
SHROUD
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SILICA ATTACKS
Turbine nozzle without
silica
Turbine nozzle with silica
CLEAR
TURBINE
BLADE Silica scale
(whitish
substance)
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DISCUSSION-TURBINE
The Turbine is the most important and costly
equipment in a geothermal power plant.
After steam is expanded through a turbine ,it is
exhausted into the condenser.
In binary plants, geothermal fluid heats a secondary
fluid in a heat exchanger and the secondary fluid is
expanded through a turbine (organic rankine cycle).
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TURBINE…….
Steam and Turbine
generator
Organic rankine cycle.
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TURBINE……
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TURBINE….
These changes can be calculated as the average fluid enthalpy is constant (adiabatic flashing).
The fraction to steam can be calculated by the equation:
𝐡𝟏𝐦 =hf𝐦 f +hg𝐦𝐠
X = (h1-hf)/ (hg-hf) = (h1-hf)/hfg
Where;
H5=H6=697 KJ/kg (Brine for hot re-injection)
H2=Enthalpy of steam to turbine blades (useful energy)
H1=Total heat flow from production wells.
𝒎 =Mass flow rate in Kg/seconds.
X =Dryness fraction of steam.
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WORK DONE AT THE TURBINE
Under isentropic expansion (constant entropy),
point 4 to 5s, the work extracted from a steam flow
rate of 1 kg/s is given as:
W = h4 − h5s
Where W = Work output from turbine (kJ/kg);
h4 = Steam inlet enthalpy (kJ/kg);
h5s = Steam exit enthalpy (kJ/kg).
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STEAM WASHING
Steam washing is a basic steam scrubbing technique of
injecting steam condensate into the steam flow up-stream of
a final scrubber.
This will collect unwanted substances entrained and
dissolved in the steam into the wash water.
This is followed by separation of the liquid fraction from the
flow.
Silica, boron, and arsenic can all be removed readily in this
manner.
Scrubbers can also be used to remove ammonia, however
other non-condensable gases such as carbon dioxide and
hydrogen sulfide cannot be removed readily by scrubbing.
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DATA ANALYSIS AND INTERPRETATION
Samples of two-phase brine-steam mixture, steam, scale
deposits, and condensate were taken for analysis in the
geochemistry laboratory.
Also, well production flow rates at 6 bar-a were compared
with separator design capacity to discover whether there was
brine carry-over to steam pipelines.
Four samples collected from inside the turbine shroud and
turbine blades were analysed using X-ray diffraction (XRD) in
Olkaria geochemistry laboratory.
X-ray fluorescence was also done for element composition
analysis in Japan by Mitsubishi Heavy Industries.
Other samples were analysed for calcite scaling, silica
scaling and corrosive components in the local laboratory.
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EXPERIMENTAL DATA ITEM TO BE MEASURED UNIT BEFORE DURING
BLADE WASH
1
AFTER
BLADE WASH
1
DURING
BLADE WASH
2
AFTER
BLADE
WASH 2
BL
AD
E W
aS
H
Time hours 1235 1635 2035 0035 0435
1 Generator load Mw 26.4 26.4 29.5 29.0 33.0
2 Blade wash water flow T/H 0 4.0 0 4.5 0
3 Main steam flow T/H 290.38 285.7 279.3 273.9 269.2
4 Main steam pressure interface Barg 4.42 4.35 4.31 4.28 4.24
LH 4.03 4.06 4.07 4.07 4.07
RH 4.01 4.04 4.05 4.05 4.06
5 Main steam temperature interface
C
151.34 151.5 151.6 151.7 152
LH 150.1 150.1 150 150 150.2
RH 150.16 150.4 150.1 151.1 151
6 Steam chest pressure Barg 3.638 3.642 3.534 3.509 3.47
7 Condenser vacuum Bara 0.077 0.079 0.077 0.075 0.07
8 Gv position LH % 61% 60.5 55.3 52.2 50.4
RH 59% 58.5 52.9 51.8 50.3
9 Bearing metal temperature #1 C 66.5 66.7 66.4 66.3 66.2
#2 63.5 63.6 63.4 63.2 63.1
#3 62 62.3 61.9 61.8 61.6
#4 60.8 60.9 60.6 60.5 60.3
10 Bearing
vibration
#1 X Micron P-P 18 17 14 14 14
y 19 18 15 14 14
#2 X 24 23 17 17 17
y 24 24 19 18 19
#3 X 32 32 31 31 33
y 20 21 20 20 21
#4 X 24 24 25 24 26
y 29 29 29 29 32
10 Rotor position Mm -0.09 -0.09 -0.11 -0.11 -0.11
12 Differencial expansion Mm 1.11 1.11 1.15 1.16 1.24
12 Thrust bearing metal temperature (gov side) C 58.2 58.3 57.6 57.4 57.3
13 Thrust bearing metal (gen side) C 44.1 44.2 43.9 43.8 43.6
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ANALYSIS OF RESULTS
Generator load.
0
5
10
15
20
25
30
35
40
1235 1635 2035 35 435
Load (Mw)-Time (Hrs) Graph
Load (Mw)-Time (Hrs) Graph
Lo
ad
in
Mw
Time in hrs
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MAIN STEAM FLOW
255
260
265
270
275
280
285
290
295
1235Hrs 1635Hrs 2035Hrs 35Hrs 0435Hrs
Steam Flow Rate in Ton per hour Against Time (Hrs)
Steam Flow Rate in Ton per hourAgainst Time (Hrs)
Flo
w R
ate
Time
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STEAM CHEST PRESSURE S
team
Pre
ssu
re
Period
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CONCLUSION
The scaling has been identified to be chemically
formed and this would also require chemical
inhibitors to clear.
The study has also realized that there is significant
load optimization through steam and blade washing.
The generator Loading in a geothermal power plant
is mainly affected by the steam chest pressure,
main steam flow rate as well as the Condenser
vacuum.
Steam washing should be regularized in every
power plant that exhibits silica scaling.
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RECOMMENDATIONS
Geothermal plants in Olkaria should establish a
comprehensive steam wash and blade wash system for
mitigation in its future plants.
A well designed steam washing and blade washing system
to be designed as a least cost mitigation measure to
augment on optimal generator loading design.
The steam wash system should be combined with other
chemical methods such as the use of chemical inhibitors to
minimise silica scaling right at the well head.
The use of pH variation as well as separation pressure
method to be be employed as well to maximise on the
benefits.
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