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GEK 111898a Revised, January 2011

GE Energy

F Class Gas Turbine Compressor Water Wash System

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser's purposes the matter should be referred to the GE Company.
General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

GEK 111898a

F Class Gas Turbine Compressor Water Wash System

The below will be found throughout this publication. It is important that the significance of each is thoroughly understood by those using this document. The definitions are as follows: NOTE Highlights an essential element of a procedure to assure correctness. CAUTION Indicates a potentially hazardous situation, which, if not avoided, could result in minor or moderate injury or equipment damage.

WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION, WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY

***DANGER*** INDICATES AN IMMINENTLY HAZARDOUS SITUATION, WHICH, IF NOT AVOIDED WILL RESULT IN DEATH OR SERIOUS INJURY.

General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

F Class Gas Turbine Compressor Water Wash System

GEK 111898a

TABLE OF CONTENTS
GENERAL .................................................................................................................................................... 4 A. OnBase Supplied Equipment ................................................................................................................ 4 B. OffBase Equipment............................................................................................................................... 4 C. Functional Description ............................................................................................................................ 4 D. System Operation.................................................................................................................................... 5 II. FALSE START DRAIN SYSTEM (APPLIES TO DUAL FUEL UNITS ONLY)................................. 8 I.

General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

GEK 111898a

F Class Gas Turbine Compressor Water Wash System

I. GENERAL Gas turbines can experience a loss of performance during operation as result of deposits of contaminants on internal components. This loss is indicated by a decrease in power output and an increase in heat rate. The deposits of atmospheric contaminants on compressor parts occurs with the ingestion of air. The ingested air may contain dirt, dust, insects, and hydrocarbon fumes. A large portion of these can be removed before they get to the compressor by inlet air filtration. The dry contaminants that pass through the filters as well as wet contaminants, such as hydrocarbon fumes, have to be removed from the compressor by washing with a waterdetergent solution followed by a water rinse. A. OnBase Supplied Equipment The onbase turbine equipment supplied with this compressor wash system consists of piping from the purchaser's connection on the base, air operated water injection valve(s), and the appropriate spray manifold(s). Drains from the inlet plenum, combustion area, exhaust frame, and the exhaust plenum are also provided. In addition, there are purchaser connections in these drain lines. Refer to the Water Wash Skid schematic for this on-base equipment. B. OffBase Equipment The off-base portion of the water wash system, known as the water wash skid, contains both a watertank and a detergent tank. The water tank is equipped with temperature sensors and electric heaters to maintain proper water temperatures. The skid is equipped with a centrifugal water pump motor (88TW-1) and a venturi used with the water pump to mix detergent solution. Also included on the skid are the various control panels to initiate wash and to manually start/stop the appropriate devices. All equipment is made of corrosion resistant material. Refer to the Water Wash Skid schematic for this on-base equipment. All devices are set to give proper temperature, pressure, and flow. The settings for these devices can be found in the device summary for the corresponding system. C. Functional Description During the washing operation, water or wash solution is delivered through customer piping to the gas turbine in the proper mix ratio. The wash water solution is delivered to the turbine unit at the proper pressure, temperature, and flow rate to wash the gas turbine compressor. Refer to the system schematic for proper pressure(s), temperature(s), and flow rate(s) for this gas turbine. 1. System Requirements Water used for washing turbine parts should be reasonably clean so that it does not cause fouling or corrosion in itself. Distilled or deionized water is recommended. Water quality requirements are listed in Table 1 of GEK-111895 (Latest Revision). Oily or varnished oil deposits on internal gas turbine parts require that a detergent solution be used during the washing operation. The detergent shall meet the requirements of GEK-111895 (Latest Revision), Appendix 1.

General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

F Class Gas Turbine Compressor Water Wash System

GEK 111898a

2. Compressor Washing Frequency The frequency of compressor washing depends upon the severity and type of atmospheric contamination that fouls the compressor and reduces performance. The recommended method for establishing the frequency is to monitor gas turbine performance, comparing the routine performance with the baseline performance to observe the performance trends. If the performance has fallen significantly, and compressor fouling is suspected, it must be verified by visual inspection. This visual inspection should include the compressor inlet, bellmouth, inlet guide vanes and the first and, possibly, the second stage of the compressor blades. NOTE Inspection should be made for the source of the oily deposits. If possible, corrective action should be taken. D. System Operation 1. General a. Off-line Water Wash Off-line water washing should be scheduled during a normal shutdown, if possible. This will allow enough time for the internal machine temperature to drop to the required levels for the washing. The time required to cool the machine can be shortened by maintaining the unit at crank speed. During this cooling of the turbine, the wash water may be heated to the proper level. Off-line wash water flow control is accomplished through a manual tuning valve installed in the off-line supply line, and a local pressure gauge to allow the operator to set the specified manifold supply pressure. Refer to the system (MLI 0442) schematic for off-line wash operating parameters. Refer to GEK-111895 (Latest Revision) for gas turbine compressor liquid washing recommendations b. On-line Water Wash (Only if applicable) The period between off-line water washes can be extended via frequent on-line washing. When the compressor is suspected of being heavily fouled, an off-line wash should be performed. The online compressor wash system allows an operator to water wash the turbine compressor without having to shut down the turbine. The method of washing is similar in many ways to the offline system. Both systems use the same pump, 88TW-1, and piping to supply high quality wash solution to the compressor. When the supply pipe reaches the vicinity of the turbine base, it splits into two branches, one for the offline system and one for the online system. Each branch contains a stop valve, flow control orifice, manifold(s) and spray nozzles.

General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

GEK 111898a

F Class Gas Turbine Compressor Water Wash System

There are significant differences, though, between the two systems. GE recommends against the use of detergents during on-line washing, while the use of detergents during off-line washing are encouraged. The online wash water requirements differ from that of offline wash solution and must meet the requirements of Table 1 of GEK-111895 (Latest Revision) for online washing. Finally, the online system proceeds automatically after it is manually initiated; whereas, the offline system requires operator intervention before and after the wash. Per the latest on-line wash design improvements, the forward on-line wash manifold has been removed to minimize the risk of blade root erosion. Therefore, only the outer, aft, manifold is used during an on-line wash. Also, the on-line flow control orifice plate has been replaced with a pressure regulator (VPR74-1). A local pressure gauge is installed on the on-line circuit to make it easy for the operator to set the specified manifold supply pressure for improved flow control. In addition, a pressure transducer (96WW-3) is installed on the on-line aft manifold to measure wash water pressure relative to ambient pressure. This transducer is wired to the control system to monitor on-line wash water supply pressure. Refer to the system (MLI 0442) schematic and the device summary for on-line wash operating parameters and instrument settings and ratings. NOTE When using a detergent solution for online washing, it is recommended that the wash be followed by enough rinse water to remove the detergent residue from the wash nozzles at the spray manifold. This will prevent the detergent solutions from drying and clogging the nozzles. c. Grid Frequency Control (Applies to units with GFC requirements only) Provides water wash injection hardware and control software designed to increase gas turbine power for grid frequency control (GFC) by spraying water into the compressor inlet. A GFC circuit is installed parallel to the on-line wash circuit so that both circuits are supplied simultaneously by the water wash skid. During an extreme under frequency event, two control valves are commanded open and water flows through both the on-line wash circuit and GFC circuit for a specified time duration. The total flow rate is the same as the maximum flow capacity of a standard GE water skid, which requires no modification for a GFC application. To maximize system reliability, a self-test of the GFC circuit is performed for a few seconds every time that on-line compressor wash is initiated. Several grid codes specify that at specific frequencies below normal, such as 50 Hz, power delivered to the grid must meet or exceed a minimum power level. At very low grid frequencies, water wash injection is used to reduce the net over firing of the gas turbine to conserve hot section life. For a GFC installation, the following components are added to on base piping (MLI 0953): GFC control valve (VA16-4), manual tuning valve, GFC supply line pressure transducer (96WW-4), GFC water manifold and nozzles with injection on inner cone of inlet plenum (MLI 1612).

General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

F Class Gas Turbine Compressor Water Wash System

GEK 111898a

The turbine control includes GFC software (MLI 210) to actuate control valves during an under frequency event and perform a periodic self-test to verify that supply pressure to the GFC nozzles exceeds the minimum allowable water pressure. Refer to the system (MLI 0442) schematic and the device summary for GFC operating parameters and instrument settings and ratings. 2. Mandatory Precautions Before water washing of the compressor begins, the turbine blading temperature must be low enough so that the water does not cause thermal shock. CAUTION The differential temperature between the washwater and the interstage wheelspace temperature must not be greater than 120F (67C) to prevent thermal shock to the hot gas parts. The maximum wheelspace temperature as per TIL 1196-1 must be no greater than 150F (65.5C) as measured by the digital thermocouple readout system on the turbine control panel. To reduce this difference, the wash water may be heated and the turbine kept on crank until the wheelspace temperatures drop to an acceptable level. The wheelspace temperatures are read in the control room. CAUTION If, during operation, there has been an increase in exhaust temperature spread above the normal 15F to 30F (8.3C to 16.6C), the thermocouples in the exhaust plenum should be examined. If they are coated with ash, the ash should be removed. Radiation shields should also be checked. If they are not radially oriented relative to the turbine, they should be repositioned per the appropriate drawing. If the thermocouples are coated with ash, or if the radiation shields are not properly oriented, a correct temperature reading will not be obtained. If neither of the above conditions exists and there is no other explanation for the temperature spread, consult the General Electric Service Engineering representative.

WARNING THE WATER WASH OPERATION INVOLVES WATER UNDER HIGH PRESSURE. CAUTION MUST BE EXERCISED TO ENSURE THE PROPER POSITIONING OF ALL VALVES DURING THIS OPERATION. SINCE THE WATER MAY ALSO BE HOT, NECESSARY PRECAUTIONS SHOULD BE TAKEN IN HANDLING VALVES, PIPES, AND POTENTIALLY HOT SURFACES.

General Electric Company, 2011. GE Proprietary Information. All Rights Reserved.

GEK 111898a

F Class Gas Turbine Compressor Water Wash System

NOTE Before water washing the compressor, inspect the inlet plenum and gas turbine bellmouth for large accumulations of atmospheric contaminants that could be washed into the compressor. The deposits can be removed by washing with a garden hose. II. FALSE START DRAIN SYSTEM (APPLIES TO DUAL FUEL UNITS ONLY) The purpose of the False Start Drain System (FSD) is to remove fuel oil or other liquids from the combustion, compressor discharge, turbine, and exhaust sections while the unit is shutdown and during startup sequence. The False Start Drain valves are instrument air operated with open and closed limit switches. The liquid fuel from the combustion cans will drain from a common header for the lower combustion cans through the False Start Drain valve (VA17-1). The position of this valve is controlled by a solenoid valve (20TFD-1). The limit switches (33TFD-1 and 33TFD-2) are used to verify valve position. The other False Start Drain valves (VA17-1B, VA17-2, VA17-6A, VA17-6B, &VA17-7) are controlled by a single solenoid (20TFD-2). Open and closed limit switches on each of these valves (33TFD-5, 33TFD-6, 33TFD-7, 33TFD-8, 33TFD-9, 33TFD-10, 33TFD-12, 33TFD-13, & 33TFD-14) are used to verify valve position. Refer to TIL 1575-R1 for operational parameters and recommended checks.

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