Optimization of online compressor washing frequency for enhanced performance and profitability of industrial gas turbines

This study investigates the optimization of online compressor washing frequency for enhanced performance and profitability of industrial gas turbines. Two representative engines: an aero-derivative LM2500 and a heavy-duty V94.3A (also designated SGT5-4000F) were simulated in GasTurb software under varying washing intervals of one day and ten days. Experimental data were applied to model reductions in compressor isentropic efficiency and mass-flow capacity due to fouling. The results indicate that extending the washing interval from daily to every ten days for one year causes significant performance deterioration. For the LM2500, power output decreased from 7 % to 16 %, thermal efficiency from 2.6 % to 6 %, and heat rate rose from 2.7 % to 6.6 %. Corresponding changes for the V94.3A were smaller, confirming that the aero-derivative turbine is more sensitive to fouling than the heavy-duty unit. Economic evaluation showed that while more frequent washing increased wash fluid consumption and operational costs, it provides substantial financial benefits. Daily washing produced additional annual net profits of approximately £11.69 million for the V94.3A and £4.6 million for the LM2500 compared with ten-day intervals. Overall, the findings demonstrate that optimizing compressor washing frequency is essential to sustain turbine performance, improve fuel efficiency, and maximize profitability. Frequent online washing mitigates the adverse effects of fouling and ensures cost-effective, reliable, and energy-efficient gas-turbine operation.