COMPRESSOR WATER WASH SYSTEM GENERAL Gas turbines can experience a loss of performance during operation as the result of deposits of contaminants on internal components. 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 water-detergent solution followed by a water rinse. ON BASE SUPPLIED EQUIPMENT The on-base gas turbine equipment supplied with this compressor wash system consists of piping from a purchaser's connection on the base, a motor-operated water injection valve 20TW-1 and local pushbutton control station, a compressor water manifold and eight spray nozzles in the compressor inlet bellmouth. In addition there are purchaser connections in the drain lines from the inlet plenum, combustion area, turbine shell and the exhaust plenum. OFF-BASE EQUIPMENT (BY CUSTOMER) Itis the responsibility of the customer to provide a water storage tank, and a detergent storage tank of adequate capacity and a system for injecting the detergent solution into the water at the proper mix ratio, Also required is a system to deliver the water to the turbine at the required temperature, pressure and flow rate. Heaters and heat tracing should be supplied if considered necessary. All equipment should be of corrosion-resistant material. The customer also is to provide a waste water tank and the necessary piping to drain water from the gas turbine drains and the exhaust plenum to this tank. FUNCTIONAL DESCRIPTION Wash water is supplied from a customer provided supply system including storage tanks, water and detergent pumps, related valves and controls. 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. For this gas turbine unit they are: Off-Line On-Line Pressure (psig) 5 100 Temperature (F) 160-180 65-180 Flow rate (gpm) 42 10 Wash solution from the customer's supply flows from the customer's connection through the water injection valve and on- base piping to the compressor spray manifold, This water injection valve is motor driven and is manually opened from a local pushbutton switch. It is closed automatically when the Wash Selector Switeh is in the OFF position. During compressor washing, water injection valve 20TW-1 allows the wash solution to flow into the compressor spray manifold and through the spray nozzles into the compressor bellmouth to accomplish the washing. SYSTEM REQUIREMENTS Potable water is to be used for all washing. Water used for washing turbine parts should be reasonably clean so that it does not cause fouling or corrosion in itself. 4M-1Distilled or de-ionized water is excellent although tap or drinking water may be acceptable provided it is low in sodium and meets the requirements of Table 1. Oily or varnished oil deposits on internal gas turbine parts require a detergent solution be used during the washing operation. A list of approved detergents is given in Table 2. Any cleaning agent not listed herein must be approved by the Gas Turbine Division before being used. COMPRESSOR WASHING FREQUENCY The frequency of compressor washing depends upon the severity and type of atmospheric contamination which fouls the compressor and reduces performance. The recommended method for establishing the frequency is to monitor gas turbine performance, comparing the routine per- formance with base line performance to observe the trends. The unit is run at a steady BASE Load while the power output, exhaust temper ature, inlet air temperature, barometric pressure, compressor discharge temperature and pressure, and fuel consumption is measured and recorded. An analysis of the compressor ratio and efficiency can be made when the output and heat rate is corrected to a standard condition, utilizing the performance curves. Current "performance levels are then compared to baseline data. The analysis and comparison will show performance trends. If the performance has fallen significantly, and compressor fouling is suspected, it must be verified by visual inspection. | This visual inspection should inelude inspection of the compressor inlet, bellmouth, inlet guide vanes and the first and possibly the second stage of the ‘compressor blades. If the fouling is caused by “dry" contaminants, abrasive cleaning would probably be sufficient to restore lost performance. If the deposits are oily, the water/detergent wash and water rinse should be performed followed by abrasive cleaning. 4M-2 NOTE Inspection should be made” for the source of the oily deposits. If possible, corrective action should be taken. WASHING SYSTEM OPERATION GENERAL Since the customer is providing the water supply system, including storage tanks, pumps, valves and controls, the procedure references control elements by functional names and not by actual device nomenclature. For this reason it is recommended that the following procedure be reviewed by the customer and rewritten to adapt the instructions to his particular equipment and system requirements. 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 is to be heated to the proper level. MANDATORY PRECAUTIONS Before water washing of the compressor begins, the. turbine blading temperature must be low enough so that the wash water does not cause thermal shock. CAUTION The differential temperature between the wash water and the interstage wheelspace temper- ature must not be greater than 120F to prevent thermal shock to the hot gas parts. For wash water of 180F, the maximum wheelspace temperature must be no greater than 300F as measured by the digital thermo- couple readout system on the turbine control panel. “or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 15 to 30F the thermo- couples in the exhaust plenum should be examined. If they are coated with ash, this should be removed, Also, the radiation shields should be checked. If they are not radially oriented relative to the turbine, they should be reposi- tioned’ 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 exist and there is no other explanation for the temperature spread, consult the General Electric Installation and Service Engineering representative. ** WARNING ** The water wash operation in- volves 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. 4M-3 NOTE Before water washing the compressor, inspect the inlet plenum and gas turbine bell- mouth for large accumulations of atmospheric contaminants which could be washed into the compressor. These deposits can be removed by washing with a garden hose. WATER WASHING PROCEDURES The next sections set forth procedures for performing the following types of cleaning: 1 Off-line compressor wash only I On-line compressor wash To perform the type of cleaning designed for this particular unit, refer to the system schematic in the Reference Drawings Section of Volume I and the device summery to verify the wash system equipment furnished. Follow the steps outlined in the appropriate section(s) below. I, OFF-LINE PROCEDURE COMPRESSOR WASH 1, Make certain the turbine is shut down, 2, Select the Water Wash control display on the turbine contro! panel CRT and press the Off-Line Water Wash On softswiteh. At this time, the turbine is prohibited from firing.3 4. 5. 6 Place the Master Operation Selector Switch in the CRANK position. Initiate a turbine START signal. NOTE At this time, the following sequence of events will occur automatically a, Cooling water will flow. (When customer supplies cooling water, insure that water is flowing.) b. If on-base cooling water system auxiliary cooling water pump will start (if supplied) and radiator fan will start. ec. If off-base cooling water system cooling water skid will start. 4, Inlet guide vanes will go to the full open position. The turbine will accelerate to full continuous crank speed. The cranking motor will maintain the unit on crank for the cooldown cycle until the stop signal is given. The cooldown procedure must be continued until the wheelspace temperatures are within 120F of the wash water temperature, NOTE The turbine may be allowed to cool down on turning gear, if time permits, 4M-4 During the crank cycle, manually place the following in the positions indicated and in the order listed: a. The flow through the false start drain valves (VA17) must be diverted from the sludge tank to a wash water effluent tank. NOTE ‘The false start drain flow or any flow that goes normally to the sludge tank must be diverted from its “normal” path into the sludge tank, into the wash water effluent drain to prevent an overflow of the sludge tank. In addition, the false start drain effluent should be visible to evaluate the effectiveness of the wash eycle. b. Close the hand valves on both flame detectors. e. Arrange any valves in the exhaust plenum drain piping to divert effluent from the sludge tank to the waste water tank. Open the main wash water drain valve at the bottom of the exhaust plenum. Close the valve located in the atomizing air line between the atomizing air system and the turbine such as the supply at the compressor discharge casing and the discharge at the atomizing air manifold. fe. Open all the low point drain valves in the atomizing air lines. f. Open the atomizing air separator drain valves and the inlet plenum drain valve if provided.a (Continued) g- Open the valve at the inlet of atomizing air compressor, CA2 and the discharge of atomizing air compressor CA1. h, Open the switch at the motor control center for 88AB, the drive motor for the atomizing air compressor, CA2. i, If a valve is installed in the line supplying compressor discharge air to the false start drain valve, close it. Switeh the motor controller for the turbine exhaust frame cooling fan motors, 88TK-1 and 88TK-2, in the manual "ON" position. NOTE This step is necessary to prevent water wash from entering the exhaust frame cooling system during the wash cycle. ‘The cooling and sealing air cireuitry is insulated in the following manner: k, Close AE-5 block valve. 1. Close AD-1, AD-2, AD-4, AD-6 and AD-T7 valves, m, Open the separator drains on the line coming from the AE-5 valve, n, Close valve in sealing air AE-II lines, the bearing supply line from ©. If the turbine has a self cleaning inlet filter, close the block valve and open the drain valve on the self cleaning inlet filter air line. 4M: 5 8. 9. 10. ua 12, 13. 14 The water wash skid should now be checked for operational readiness. Determine if the following condi tions exist: a, The water tank is full. b. The detergent tank is full. €. The water temperature is at the required level. d. The valve on the main wash pump suction side is open. The operator must verify that all turbine wheelspace temperatures have cooled to within 120F (300F maximum) of the wash water temperature. This is to minimize thermal shock to the hot gas path parts, This is accomplished by monitoring the temperature indi- ator on the turbine panel, For the proper detergent/wash ratio, refer to the detergent manufacturer's instructions or the compressor cleaning information in the Maintenance volume of this service manual. Open the water wash valve at the compressor using the pushbutton 20TW-1/PB. This pushbutton is located near the 20TW-1 valve. Allow the turbine to reach crank speed. Start the main wash pump. Start the detergent metering pump. a. Wash/detergent solution should run approximately 3 minutes (about 120 gallons) into the compressor.14 15. 16. i 18, 19, a, (Continued) Allow enough flow time to displace water in the lines between the wash skid and the compressor wash manifold nozzles. b. Initiate the turbine STOP signal and close 20TW-1 using the pushbutton station. c. Shut off the detergent pump. 4. Shut off the main wash pump. During the coastdown and immedi- ately afterward, allow the turbine to soak for approximately 20 minutes. After the soak time is complete initiate a turbine START signal. Open the water wash shutoff valve, 20TW-1, using the pushbutton station 20TW-1/PB at the turbine. Allow the turbine to reach full continuous crank speed. Start the water pump (88TW-1) on the skid. Rinse the compressor by pumping clear water from the skid with the main wash pump. Rinse the compressor for 15-20 minutes. NOTE Experience will determine the proper time intervals for the various wash operations or whether repetition of the above procedure is necessary to restore lost performance. 20. After washing is complete, initiate a turbine STOP signal and shut off Allow the turbine to dry for aber 20 minutes the main wash pump. while coasting down, 4M-6 21. Close off all valves on the skid and close solenoid valve, 20TW-1, using the pushbutton station. 22. After the turbine has stopped, initiate a turbine START’ signal with the ion selector the CRANK 23. Allow the turbine to accelerate to crank speed. 24, Allow the turbine to dry for 20 minutes at crank speed. 25, Initiate a turbine STOP signal. 26, Press the Off Line Water Wash OFF softswitch on the water wash control display. NOTE When the off line water wash OFF is selected, the permissive is in place to allow the turbine to fire and the permissive is removed to allow the 20TW-1 valve to be opened. 27, Return the following manual valves to their previous position in the order listed: a. Return the three-way false start drain combustion system and turbine shell valves from water drain to fuel drain (if installed). b. Restore all false start drains to their normal drain paths to the sludge tank. oF21, (Continued) CAUTION It is important that the line that allows waste fuel to drain to the sludge tank be kept open after water washing and during normal turbine startup and operation, so that fuel or water which may accumulate in the exhaust plenum can continuously drain out of the ~—plenum.. Accumulation of waste fuel in the exhaust plenum is potentially hazardous. e. Open the hand valves on both flame detectors. d. Rearrange any valves installed in the exhaust plenum drain piping to divert effluent from the wash water tank to the sludge tank. e. Open the valves located in the atomizing air line between the atomizing air system and the turbine; such as the supply at the compressor discharge casing and at the discharge of the atomizing air manifold. f. Close all low point drain valves in the atomizing air lines. Close the atomizing air separa— tor drain valves. Close the inlet plenum drain valve. NOTE This is important to prevent intake of dirt ete. into the compressor. h. Close the valves at the inlet to atomizing air compressor, CA2 and at the discharge | from compressor, CAL. 4M-T 27. (Continued) i. Close the switch at the motor control center for motor 884B; the drive motor for atomizing air compressor, CA2. j. If valve is installed in the line supplying compressor discharge air to the false start drain valves, open the valve. k. Switeh the motor controller for the turbine exhaust frame cooling fan motors 88TK-1 and 88TK-2, into the "AUTO" mode. NOTE Allow the water to drain from the lines while the above restorations are being per- formed. ‘The cooling and sealing air circuitry is re-engaged in the following order: 1 Open both AE-5 block valves. m. Open the AD-1, AD: AD-6 and AD-7 valves. » AD=4, n. Close the separator drains on the line coming from the AE-5 valve. Open valve on bearing sealing air supply line (from AE-11 lines). p. If the turbine has a self cleaning inlet filter, open the block valve and close the drain valve on the self cleaning filter on line. NOTE Allow the water to drain from the lines while the above restorations are being per formed.28. Place the Master Operation Switch in the AUTO or REMOTE mode. 29, Initiate a turbine START signal within 24 hours after completion of the DRY cycle and allow it to accelerate to, and remain at, full speed for a minimum of five minutes. 30, After the compressor and turbine washing is completed, the com- pressor and turbine’ should be cleaned with a solid compound, if provided. cleaning 31. The gas turbine is now available for commercial service and may be loaded. NOTE Check for air leakage from all drains. Il. ON-LINE COMPRESSOR WATER WASH The on-line compressor wash system allows an operator to wash the turbine 4M-8 compressor without having to shut down the turbine. On-line wash is initiated from the turbine control panel. The operator selects WATER WASH at the control display on the panel CRT and then presses the ON LINE WATER WASH ON softswitch. From this point the water wash cycle is automatic. In order to perform an on-line wash certain permissives must be satisfied: 1, The turbine must be operating at full speed and not in the process of shutting down, 2 The compressor inlet temperature must be greater than 50°F, 3. Permissives incorporated by the customer must be met. When all permissives are met, motorized valve (20TW-3) will oper wash will begin, Wash duration is initially set at 30 minutes. The operator should measure the effectiveness of the wash at various time settings and adjust it accordingly. When wash is complete, the valve (20TW-3) will then close.TABLE 1 Water Quality, Total Dissolved Solids 100 ppm (max.) Total Sodium + Potassium + Lead + Vanadium (Na + K + Pb + Y) 25 ppm (max.) pH 6.0 (min,) 8.0 (max.) TABLE 2 Detergent Cleaners Product Vendor Application B&B 3100 B&B Chemical Co. 1 part detergent Miami, Florida to 4 parts water Turco 5884 Turco Product 1 part detergent Division of Purex Corp. to 4 parts water Erie, PA These products are considered acceptable by General Electric. While other products may be satisfactory, General Electric must be consulted before they are used. aM-9