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  • 200812 现场给压气机涂层可省大笔美金

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    gas turbine compressor blade coating

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    200812-现场给压气机涂层可省大笔美金

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    gas turbine compressor blade coating

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    3 views4 pages

    200812 现场给压气机涂层可省大笔美金

    Uploaded by

    wangchao821
    gas turbine compressor blade coating

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 4
    iin 7S TNT Field application of compressor coatings saves big dollars Over time, turbine compressors and other driven compressors suffer from cor- rosion, oxidation, and, in many cases, severe fouling, which in turn can cause in-service breakdown and premature overhaul. Today’s innovative protective coatings can be applied on-site to rotors and individual compo- nents to replicate the surface finish, corrosion resistance, and antifouling properties of new components. By Mark F. Mosser and Paul Brooks, Sermatech International Inc. Coating conundrums The goal of any coating ata low surface rougl eliminate cor- rosion and fouling. But choosing a coating is a complex decision, because turbines operate in environments that often combine high hu rmidity, high salinity, severely acidic or alka- line pollution (in chemical plants), and sand erosion. On the other hand, many turbi ‘operate in low-humidity conditions without any extreme environmental influences. Because of these many variables, the OEM may apply protective coatings suitable for “average” or “typical” conditions, Such coatings may perform well in some environ ‘ments and fail prematurely in others, but the OEM cannot economically provide for coat ing protection in every different application, In fact, driven centrifugal compressors (any that aren’t integral to a gas turbine) are often not coated at all and are therefore more sub- ject to corrosion and fouling, In addition, the time between overhauls of all gas turbine compressors has increased, Which means that compressors must function efficiently for significantly longer periods of time. That makes the quality of compressor ‘even more important. coatin Coating failure can quickly lead to blade failure due to stress corrosion, pitting, and catastfophic failure (Figure 1). Fatigue fail- ures invariably originate with corrosion pits forming a stress riser from which a crack propagates—ultimately resulting in blade failure (Figure 2) Though fatigue failure is a serious issue, there are other consequences of coating fail- ture. Any inerease in surface roughness results in a decrease in compressor eff increased fuel consumption, crating costs. In addition, aerodynami in the compressor may increase exhaust gas {temperatures and increase wear and hot cor- 1. Gone but not forgotten. stress corrosion at the blade base caused this blade failure. Courtesy: Sermatech International 2. Trickle-down theory. Many dow stream blades are damaged by a single liber. ated aol. Courtesy: Sermatech International rosion, further increasing costs and decreas- ing time between overhauls. Fouling is a drag Al compressors need a surface coating that cen eliminate of mitigate fouling because the aerodynamic drag in a compressor increases with the roughness of the airfoil surfaces. Fouling consists of any deposit on a surface that contacts @ moving fluid (such as air the ease ofa gas turbine), disturbs the laminar flow ofthat fluid, and consequently decreas- ethe erossectional area ofthe gas path. De posits on airfoils will disturb fluid flow and increase drag even when the accumulation is not suf area of the flow path in an axial compressor Fouling can occur in a turbine engine Lough a variety of mechanisms, For exam. ple, materials dissolved in moisture, which is present in the intake air, ean condense and dry on blade surfaces. Additionally, fine par ticles in the air can be attracted and held on surfaces by electrostatic forces The most prevalent source of fouling on nt to decrease the crosssectional foils is corrosion, Corrosion results from the reaction of the metal surface with its operating environment. Corrosion is natural. All engineering metals—ineluding iron, nickel, and aluminum—are found as compounds of oxy ture, These compounds must be refined to produce eng natural process by which these refined metals return to their natural state as compounds of either oxygen or sulfur. In extreme cases, corrosion consumes load-bearing metal and weakens engi neering structures. Corrosion pits localize ‘mechanical stresses and can lead to cata trophic mechanical failure. Even before pitting or loss of metal present significant ‘mechanical problems in a turbine, rough sn-and/or sulfur in na {neering metals. Corrosion is the corrosion deposits on airfoil surfaces will 3. Rough air. Piting and corosion prod- Uucts deposited on blade surfaces disrupt the smooth airflow required for efficient opere- tion. Source: Sermatech international In. Turbulent fow and structural damage Laminar flow Corrosion products Pts disturb laminar flow and diminish perfor- mance. Figure 3 presents the two types of flow with the clearly visible result of sur- face deposition: turbulent flow and ineffi ciency. Deposits lead to prolonged surface wetness; prolonged surface wetness leads to corrosion and specifically to pitting, which will preferentially occur under the deposit. Causes of corrosion Aqueous corrosion of metals is caused by ‘moisture that is contaminated with ions, es- pecially chloride and sulfate ions. The rate of corrosion is determined by: ‘= The length of time that the surface remains wet 1 The acidity or alkalinity of the solution on the surface. ‘= The exact ions present in the solution, ‘= The concentration of the ions in the solu- tion (such as conductivity ofthe solution). Extremes of pH—highly acidic or highly alkaline—may be more corrosive than neu: tral (pH = 7) solutions. For example, the low pH of rain in northern Europe, which can be 3.0 t0 4.5, accelerates corrosion in industrial turbines there, Chloride and sulfate ions also tend to aggravate corrosion, For example, steel will not corrode at high pH unless chlo- ride is present. ‘A gas turbine vacuums contaminants from its surroundings and concentrates them. within the compressor’s intake air. These ‘contaminants precipitate and deposit on air- foils as intake air is compressed and heated. AC shutdown, these deposits absorb moisture from the air. When the deposits first begin to dissolve in water condensing on a fouled airfoil, the concentration of ions in the drop- lets is very high and the solution is extremely corrosive. As this cycle is repeated, gas tur- bines suffer aggressive corrosion and gas path surfaces roughen, Limit fouling by treating the surface One way of changing the response ofan i foiltoits operating environments to teat the surface with a coating. Coatings have been ug 2018 POWER Table 1. Proper Inc. Note: Ra = surface roughness. used for many years to manage and limit the corrosion of airfoils and entre compressor. Coatings are often the only practical alterna- tive t contol corrosion and fouling of tur bine hardware ‘Aluminum-flled overlay coatings are usually used in turbine applications. These ‘coatings begin as water-based slurries of alu- minum powder (

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