GE 9FA Water Wash PROCEDURE Final

EGYPTIAN ELECTRICITY HOLDING COMPANY ‫اﻟﺸﺮﻛـﺔ اﻟﻘﺎﺑﻀـﺔ ﻟﻜﮭﺮﺑﺎء ﻣﺼـﺮ‬
MIDDLE DELTA ELECTRICITY PRODUCTION COMPANY ‫ﺷﺮﻛﺔ وﺳـﻂ اﻟﺪﻟﺘـﺎ ﻹﻧﺘـــﺎج اﻟﻜﮭﺮﺑﺎء‬
NUBARIA POWER STATION COMBINED CYCLE ‫ﻣﺤﻄﺔ ﺗﻮﻟﯿﺪ ﻛﮭﺮﺑﺎء اﻟﻨﻮﺑﺎرﯾﺔ اﻟﻤﺮﻛﺒﺔ‬
Module III ‫اﻟﻤﻮدﯾﻮل اﻟﺜﺎﻟﺚ‬
Gas Turbine Compressor Off-Line Washing Procedure

F-Class
Nubaria Power Station
Prepared by Eng\ Abdelaziz Mohamed Eldeeb
Operation General Manager Nubaria Power Station Head of sector

Eng \ Islam Abdelmenam Khalil Eng \ Fathy Mohamed Mousa
1
Abdelaziz Eldeeb NUBARIA POWER STATION [email protected]
Index
1 - Introduction ………………………………………………………………………………………. 3
2 - Water Wash system major components…………………………………….………. 5
3 - Water wash flow chart ……………………………………………………………….…..… 7
4 - A - Field Preparation ………………………………………………………….….………….11
4 - B. Manual Isolation Valves Positions ……………………………………….……….12
4 - C. Transmitters Isolation ………………………………………………………………….. 13
4 - D- WW SKID and HMI Preparation …………………………………………………….. 14
4 - D – 1. PREWASH PULSE (Water Only) ………………………………………………… 14
4 – D – 2. WASH 8-PULSE (detergent)………………………………………………..…….15
4 - D – 3. 20-Min SOAKING …………………………………………………………………….. 16
4 - D – 4. RINSE 30-PULSE (Water Only) …………………………………………………. 16
4 - D – 5. RINSE 5-EXTRA PULSE (Water Only) ………………………………………… 17
4 - D – 6. END WATER WASH …………………………………………………………………….17
4 - D – 7. DRYING …………………………………………………………………………………….17
4 – D – 8. END OF DRYING …………………………………………………………………………18
5 - NORMAL POSITION ……………………………………………………………………….…….19
6 - P&ID AND Figures…….………………………………………………………………….………20
7 - Water wash control logic explanation ……………………………………………….26
8 - SOME IMPORTANT SIGNALS ……………………………………………………….….…..34
9 – Trends .….………………………………………………………………………………………….35
10 – References ………………………………………………………………………………….……38
11- Water Wash Field Checklist…………………………………..……………….………….39
2
Introduction:
 The loss of performance is a direct result of fouling of the axial flow compressor.
 Fouled compressors result in reduced airflow, lower compressor efficiency and a lower
compressor pressure ratio.
 A loss in gas turbine performance is detected by a decrease in power output and an increase in
both heat rate and fuel consumption.
 The performance data is obtained by running the unit at steady-state BASE load and
recording output, exhaust temperature, inlet air temperature, barometric pressure,
compressor discharge pressure and temperature, and fuel consumption.
 Compressor washing will assist in removing the fouling deposits and restoring performance.
 Compressor washing may also slow the progress of corrosion, thereby increasing blade life.
 If corrosion of the blading is occurring, the corrosion products will promote and stabilize the
deposit.
 Fouling deposits consist of varying amounts of moisture, oil, soot, water-soluble constituents,
insoluble dirt, and corrosion products of the compressor blading material.
 Good filtration may greatly reduce fouling
 Filtration can remove most, but not all, of these substances. Particles or vapors that are
aqueous can pass through the filters via deliquescence and deposit on the compressor blades.
Other contaminants may originate from air bypass locations around the filters (missing
gaskets, open hatches, etc.) into the clean air path.
 It is recommended that the customer perform an off-line water wash when the loss in gas
turbine performance attributable to the compressor reaches the 2-3 % level between off-line
washes.
 GE recommends that the compressor flow rate be monitored over time and the compressor be
subjected to an off-line wash to prevent the flow rate from decreasing more than 5% relative to
new and clean levels.
 In general, each 1% loss in flow or efficiency is equivalent to approximately 1% loss in turbine
power.
 An increase in BASE load power of 5 % is common following an off-line wash.
 GE experience has indicated a strong correlation between fouling rate and the season of the
year, with little to no losses during the winter season and heavy fouling rates in spring and
summer
 During this cooling of the turbine, the wash water may be heated to the proper level.
 High purity demineralized water after contact with air will have a pH in the range of 5.0 to
6.0.
3
 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 time required to cool the machine can be shortened by maintaining the unit at crank
speed.
 To reduce this difference in temperature, the wash water may be heated and the turbine is
kept on crank until the wheelspace temperatures drop to an acceptable level.
The differential temperature between the wash water and the average of the three
turbine wheelspace temperatures must not be greater than 120°F (67°C) to prevent
thermal shock to the hot gas parts. To support this requirement the maximum
average turbine wheelspace temperature must be no greater than 150ºF (65.5ºC) as
calculated within the turbine control system.
Danger
Gas turbine rotors are potentially sensitive to rapid local cooldown. Rapid local
cooldown associated with incorrect offline compressor water wash can result in
reduced interference at critical rotor rabbet interfaces. The reduced interference may
result in changes in unit vibration performance or localized cyclic stress if the unit is
operated at elevated cooldown speed in this condition.
4
Water Wash system major components

• Water wash and water tank.
• Water wash detergent tank.
• Motor driven water wash pump.
• Detergent addition and recirculation line with detergent injection venture.
• Main recirculation line with solenoid valve.
• Main supply line from the pump to the on-line & off line control valves.
• On-line supply line with control valves, manifold, and eighteen spray nozzles.
• Off-Line supply line with control valves, manifold, and nine spray nozzles.
• Two sets of gas turbine drain lines consisting of six automatic false start
drain valves, and eleven manual drain valves, which drain the water
wash supply system and various turbine components. Six of the manual
valves are three way valves that will allow shifting of drain outflow to
either the water wash drain tank if a off line water wash is in progress,
or to the oily waste drain tank for normal turbine operation.
5
6
7
8
9
Water Wash Preparation

HEATER Permissives Hand cleaning Ready to Start
Manual Isolation Valves

FSD Inlet Plenum Exhaust Plenum IBH Combustion Chamber
Cooling Lines for 9 and 13 AA and Gas purge APU
Transmitters Lines
96CD 96PL 96WP 96GN-1 96AA 96AT 96WW 96GN-2,3,4 96S2N-1
96S3N-1 96CS 96BD 96AP 96EP-2,-3
HMI / WW SKID Preparation:

Purge WW line start purge WW line Initiate Wash Purge WW line Initiate Rinse 5-EXTRA
RINSE STOP
Drying
CRANK START, purge speed 699 RPM for 20 Min drying + 10 Min FSL or 40 Min drying
STOP
END RINSE STOP PB OFF for Off-line Water Wash
WASH CYCLE
PREWASH(1 pulse) WASH1(1 pulse) WASH2(5 pulse) WASH3(1 pulse) WASH4(1 pulse)
RINSE CYCLE
30 RINSE 5 Extra-RINSE
10
Color Code
Number color Location
1 Green Field
2 Orange W.W SKID
3 Blue HMI
These steps are for F-class gas turbine (gas fuel)

A - Field Preparation:
Switch ON the HEATER to raise water temperature to 82ºC,

1.
hot water is more effective than cold water
2. Check Water tank and Detergent tank levels

3. WW valves positions are ready for washing
The max average of wheelspace temperature must be
4.
stabilized at 150ºF (65.5ºC) or lower.
First Steps In the Field
Prior to initiating the off-line water wash, the bell mouth,

struts, and IGV’s should first be hand cleaned to prevent
5. these deposits from being washed into the compressor during
the cleaning. These deposits can be removed by washing with
a garden hose.
If necessary, blank-off flame detector.
6. Water may foul the flame scanners and make start-up
difficult.
7. Excitation: Rack-IN and press ON.

8. LCI: Rack-IN and ready.
9. Open all manual isolation valves of the gas fuel line.
10. Unit at Turning Gear and Ready to Start.
11
B- Manually isolate systems, open drains of Manual Isolation Valves as follows:
The THREE VALVES of the False Start Drain must be

1.
diverted from the sludge tank to a water wash effluent tank
(From 120 to 0º near IBH) & (3-way valve & manual valve near
diffuser door).
Open the Inlet Plenum water wash drain VALVE at or near

2.
the bottom of the inlet plenum.
3. Close the manual Isolation VALVE of IBH
Turbine Compartment VALVES
Open the Exhaust Plenum water wash drain VALVE at or near

4.
the bottom of the exhaust plenum.
5. Open the manual drain TWO VALVES of IBH
Open the water wash drain VALVE in the Combustion
6.
Chamber water wash drain header.
Open water wash drain VALVE in the man way cover in the
7.
Combustion Chamber.
Close the manual isolation FOUR VALVES of Cooling Lines for
8.
9 and 13 stages
Open the manual drain EIGHT VALVES

9.
(TWO VALVES for each Cooling Line for 9, 13)
10. Close the manual isolation VALVE for AA and Gas purge.
11. Open the manual drain TWO VALVES for AA and Gas purge.
12. Close the manual isolation VALVE for APU.
 Fuel manifold low point drains are to remain closed during the pulse mode wash
cycle. Open at the end of the rinse cycle, prior to the start of the drying cycle to
ensure that no water is present in the manifold(s).
12
C- Manually isolate systems, open drains of Transmitters Lines as follows:

Close THREE VALVES in compressor discharge pressure transducer supply lines
1.
96CD-1,-1B,-1C
Close THREE VALVES in Liquid Fuel Purge pressure transmitters supply lines
2.
96PL-1A,-1B,-1C
Close THREE VALVES in Water Injection Purge Differential pressure transmitters

3.
supply lines 96WP-2A,-2B,-2C
Close THREE VALVES in Gas Fuel Nozzle Pressure Ratio pressure transmitter
4.
supply lines 96GN-1,-2,-3
Turbine Compartment TRANSMITTERS
Close THREE VALVES in Atomizing Air Purge pressure transducer supply lines
5.
96AA-1A,-1B,-1C
6. Close the VALVE in Online Compressor Wash Manifold supply line 96WW-3
7.
supply lines 96GN-2A,-2B,-2C
8.
9.
10. Close THREE VALVES of Cavity Pressure Transmitter S2N supply lines 96S2N-1,-2,-3
11. Close THREE VALVES of Cavity Pressure Transmitter S3N supply lines 96S3N-1,-2,-3
Divert FOUR VALVES to the vent for

96CS-1 COMPRESSOR INLET TOTAL PRESSURE
96BD-1 BELLMOUTH STATIC PRESSURE
12.
96EP-1 EXHAUST PRESSURE
96AP-1A / 1B / 1C BAROMETRIC PRESSURE
Close THREE VALVES for 96AP-1A-1B-1C
Close TWO VALVES of the exhaust duct pressure transmitter and Divert ONE
13.
VALVE to the vent of 96EP-2,-3
13
D- WW SKID and HMI Preparation:
PREWASH PULSE (Water Only)
1. Divert the 3-way valve of WW line to drain any old dirty water for 3A and 3B
2. Close Detergent valve and open min-flow water valve

W.W SKID Step1
Run WW pump manually to purge any dirty water to the drain for 1-3
3.
minutes
4. Divert the 3-way valve of WW line to normal position for 3A and 3B
5. Run WW pump manually to fill WW line

Adjust the manual tuning valve at WW skid to the required pressure ( +7 bar)
6.
(Pump discharge pressure low @ 6.44 bar and suction pressure low trip @0.13 bar).
7. Put WW pump at Auto
1. Select SP/SS to prevent Diverter Damper from Opening.

2. Select GAS
3. Select CRANK
HMI Step 1
4. Select Offline-WW ON
5. Unit must be Ready to Start, Press Master Rest PB.
6. Make a trend for L83WWOFLZ and TNH_V
Select START
7.
(This will make the first PREWASH PULSE for 60 second at 300 RPM )
 A pre-wash cycle will be initiated in order to flush all the loose contaminates
such as dust and dirt from the compressor prior to applying detergent during
the detergent cycle. This is a water only application, which reduces the
amount of dirt particles that may become entrained in the detergent foam.
14
 If Water Wash is selected, unit reached cranking speed L14HW, and no

flame detection signals are detected, IGV’s will go to full open position.
The IGV’s will remain in the full open position throughout the wash
cycle.
After the PREWASH PULSE close min-flow water valve and Open the
1.
detergent valve
W.W SKID
2. Divert the 3-way valve to the drain

Run the WW pump manually to purge and replace the water by the
3.
water/detergent to the drain about 5 min or by visual inspection
4. Divert the 3-way valve of WW line to normal position
Step 2
5. Run WW pump manually to fill WW line

6. Put WW pump at Auto it will run at pulses only
7. Observe the operation of the pump as it may take TRIP each time
WASH 8-PULSE (detergent)
After Mixing water and detergent Select Initiate Wash

HMI Step 2
Observe the 8- WASH PULSES each for 60 second at 360 RPM

1.
Each cycle injection time will be 1 min and soaking time will be 4
min (1st ~ 6th cycle). After 6th injection, turbine speed will start to
come down and soaking time will be 3 min.
WW SKID
Adjust detergent flow to 6 GPM( Water : detergent Ration = 4 : 1)

Step 3
1.
 If more detergent is injected, long rising duration is required

 Maximum level drop in the tanks shall be about 40-45 mm
 The speed will be lowered to TG for 20 Minutes SOAKING
15
20-Min SOAKING
During Soaking Divert the 3-way valve of WW line to drain the

1.
water/detergent
W.W SKID
2. Close Detergent valve and open min-flow water valve

Run the WW pump manually to purge and replace the water/detergent
3.
by water only to the drain about 5 min or by visual inspection
4. Divert the 3-way valve of WW line to normal position
Step 4
5. Run WW pump manually to fill WW line and open min-flow water valve
6. Put WW pump at Auto it will run continuously throughout rinses
7. Observe the operation of the pump as it may take TRIP any time
 These steps are important in preventing detergent from entering the off-line
manifold during the rinse cycle(s).
 The object of the rinse cycle(s) is to remove detergent from the surface areas of the
compressor blades and to rinse the remainder of the unit.
RINSE 30-PULSE (Water Only)
After the +20 Minute Soaking Select Initiate Rinse

HMI Step 3
Observe 30-RINSE
1.
each for 60 second at 360 RPM each cycle injection time will be 1
min and interval time will be 3.5 min
(water
injection solenoid valve VA16-1 will open and water wash
pump 20 WDET-1 recirculation solenoid valve will close)
 If water injection solenoid valve VA16-1 and water wash pump 88TW-1
recirculation solenoid valve operation is not synchronized then pump may trip on
pump discharge pressure low or pump water flow low. In that case, throttle (50%)
pump recirculation isolation valve.
16
Measure the CONDUCTIVITY it must be 5-10 microSiemans/cm

WW SKID
Step 5
1. higher than Demi water
RINSE 5-EXTRA PULSE (Water Only)
1. Select 5-EXTRA RINSE to initiate extra 5 rinse

HMI Step 4
Select ANOTHER additional 5-EXTRA RINSE (up to total 50 rinse) to

2.
initiate extra until the difference in CONDUCTIVITY is 5 -10 microSi/cm
 It is suggested that a drain conductivity measurement be made at the drain (WW33).

 This method is an alternative to a visual observation of the amount of foam that is
present in the drain
 The difference in conductivity between supply demineralized water and drain shall
be less than 5-10 microSiemans/cm for an interval of 5 rinse cycles.
END WATER WASH
1. Select END RINSE

HMI Step 5
2. Select STOP PB to return the GT to Turning Gear
3. Select OFF for Off-line Water Wash
DRYING
FIELD 1
1. Open Gas Fuel manifold low point drains prior to the start of the drying
17
 All water wash low point drains should be open at this time including all low point
drains in the gas fuel, atomizing air system, inlet bleed heat and purge systems to
ensure that no water has entered these systems.
1. Select CRANK
HMI Step 6
2. MASTER RESET may be required before selecting START again.
Select START to run the unit at purge speed 714 RPM for 20 Min
3.
drying + 10 Min FSL or 40 Min drying
 The drying cycle is designed to remove any residual water left in the unit that has
yet to drain out
 It is preferred that the unit run at FSNL for a minimum of 10 minutes within 24
hours of conducting an off-line water wash to ensure any remaining water is
removed from within the unit.
 If firing the unit is not a viable option following an off-line water wash, it is
recommended that the crank speed drying cycle be extended to 40 minutes as an
alternative to ensure proper drying of the unit.
 Once it has been confirmed that no water is draining from the unit, the drying cycle
can be brought to a close by initializing a turbine STOP signal.
At the end of the 20+10 FSNL or 40 minute drying cycle, an operator will
FIELD 2
1. have to visually check the various offline water wash drain ports on the gas
turbine to ensure that no water wash effluent is flowing out of the unit.
END OF DRYING
Select STOP TURBINE

Step 7
1.
HMI
18
In the event of an aborted water wash, the unit shall not be

re–started until the full rinse and drying cycle is completed.
NORMAL POSITION
Return the previous items and manual valves to their previous
19
20
21
22
23
24
WW
SKID
TURBINE
DRAIN
ARM 1- Flow direction when the ARM is in Below

FLOW From WW skid to Turbine
2- Flow direction when the ARM is in Above
FLOW
From WW skid to Dr ain
3- Flow direction when the ARM is in Left

FLOW From Turbine to Drain
4- Flow direction when the ARM is in Right

FLOW From WW skid and Turbine to Dr ain
25
7-Water wash control logic
 Water wash selected L43BW is true when the operator select pushbutton
 Crank mode selection permissive L43C_PERM is true when

Flame detection control L28FDX is false
AND (gas fuel selected OR No ignition permissive l2tvx)
 Crank mode Selected L43C is true when

Crank mode selection permissive L43C_PERM is true
AND turbine /compressor water wash control L83BW is true
 Wheelspace temperature water wash permissive L69TWW is true when

The high selected of (the average of the two adjacent thermocouples of each
wheelspace (6 averages)) is < max of (CTIM OR 80 °f) + 70 °f at 30 rpm or less.
 ALARM, Water wash inhibit Wheelspace temp high L30TWW is true when
(wheelspace temp high WW inhibit L30TWW_ALM) when
Wheelspace temperature water wash permissive L69TWW is false
AND Water wash selected L43BW is true
 Inlet temp offline water wash perm logic L3WATID is true when CTIM is > 40 °f
 ALARM, Inlet temp offline water wash trouble L30WATID is true when
CTIM is ≤ 40 °f
AND Water wash selected L43BW is true
 Turbine /compressor water wash control L83BW is true when

Water wash selected L43BW is true
AND Crank mode Selected L43C is true
AND Inlet temp offline water wash perm logic L3WATID is true
AND Wheelspace temperature water wash permissive L69TWW
AND master control startup permissive L1X is true
AND speed is < L14HT (36 RPM)
26
 Aux to l4bw L83GVMAX is true when

Turbine /compressor water wash control L83BW is true
AND Turbine HP speed in % TNH is >10%
AND master protective signal is true
AND NO flame detection control
 Offline water wash IGV signal logic L4BW_IGV is true when

OR Minimum speed signal L14HM is true at 420 rpm
 IGV open enough for water wash LCSGV_WW is true when

IGV angle in degree (feedback) is > 81°
 Load commutated Inv (static start) ready to start L3SS_RS is true when
(Static starter 3A ready to start AND LS2100#1 selected to serve TCP G1)
OR (Static starter 3B ready to start AND LS2100#2 selected to serve TCP G1)
 Master start signal for static start WW mode L4SS_W_WASH is true when
Load commutated Inv (static start) ready to start L3SS_RS is true
AND Turbine /compressor water wash control L83BW is true
AND master protective signal is true
AND master control startup permissive is true
 Static starter connect sequence complete L3SS_CON is true when

Master control startup permissive is true
AND static starter connected to AC power
AND Exciter connected to static starter
AND static starter disconnect switch closed L89SSC
AND static starter disconnect switch NOT open L89SSO
AND static starter neutral gnd disconnect sw open L89NDO
AND static starter neutral gnd disconnect sw NOT closed L89NDC
 Initiate static starter water wash connect seq L83SS_WW_CON is true when
Master start signal for static start WW mode L4SS_W_WASH is true
AND Static starter connect sequence complete L3SS_CON is false
27
 Permissive to run steady state to water wash L83SS_WW_RUN is true when

Master start signal for static start WW mode L4SS_W_WASH is true
AND Static starter connect sequence complete L3SS_CON is true
 Select static starter fast cooldown speed ref L83SS_WWCOOL is true when
Permissive to run steady state to water wash L83SS_WW_RUN is true
AND Wheelspace temperature water wash permissive L69TWW is false
 Min speed relay for forced cooldown to water wash L14SS_WW_CD is true when
Turbine HP speed in % TNH ≥ 8 %
AND HP accelerating speed signal L14A is false < 46 %
 Max speed relay for forced cooldown to water wash L14SS_WW_CDSTP is true when
Turbine HP speed in % TNH ≥ 6 %
AND HP accelerating speed signal L14A is false < 46 %
 Select start water wash / cooldown contact L83SS_WW_CD is true when

Wheelspace temperature water wash permissive L69TWW is false
AND the output of
((L83SS_WW_CD AND NOT L14SS_WW_CDSTP ) OR (L83SS_WW_RUN AND
NOT L14SS_WW_CD) is true
 Select static starter water wash speed reference L83SS_WASH is true when
Permissive to run steady state to water wash L83SS_WW_RUN is true
AND Wheelspace temperature water wash permissive L69TWW is true
AND offline WW LCI torque disable cmd for soak is false
 Offline water prewash start LOFLPW_INJ is true when

IGV open enough for water wash LCSGV_WW is true
AND offline water wash prewash permissive L4OFLWW_PW is true
AND offline water prewash finished LOFLPW_FIN is false
 Offline water prewash finished LOFLPW_FIN is true when

{Offline water prewash start LOFLPW_INJ is true
OR (LOFLPW_FIN AND L83BW)} for 60 second
28
 Water wash continue with wash/det LOFLW_CON is true when

Operator select water wash continue to wash/det from HMI
AND Offline water prewash finished LOFLPW_FIN is true
AND Turbine /compressor water wash control L83BW is true
 Offline water wash 1 permissive L4OFLWW_W1 is true when

Water wash continue with wash/det LOFLW_CON is true
AND HP speed: Offline wash speed permissive L14HWW at 300 rpm
AND Offline water prewash finished LOFLPW_FIN is true
AND offline water wash 1 finish LOFLW1_FIN is false
AND Aux to water wash skid trip is false
 Offline water wash 1 start LOFLW1_INJ is true when

Offline water wash 1 permissive L4OFLWW_W1 is true
AND offline water wash 1 finish is false
 offline water wash 1 finish LOFLW1_FIN is true when

Offline water wash 1 start LOFLW1_INJ is true for 60 second

HP speed: Offline wash speed permissive L14HWW at 300 rpm
AND offline water wash 1 finish LOFLW1_FIN is true
AND offline water wash 2 finish LOFLW2_FIN is false
 Offline water wash 2 initiate pulse cycle LOFLW2_INJ is true when

{Offline water wash 2 permissive L4OFLWW_W2 is true
AND offline water wash 2 finish is false
AND offline water wash pulse LOFLW_PULSE is false} for 240 sec
 Offline water wash pulse LOFLW_PULSE is true when

Offline water wash 2 initiate pulse cycle LOFLW2_INJ is true for 60 second
 offline water wash 2 finish LOFLW2_FIN is true when

Offline water wash pulse LOFLW_PULSE is true for 5 counts
 Post wash 2 T.D. prior to cutting LCI L83OFL_SOAK is true when

Offline water wash 2 finish LOFLW2_FIN is true for 120 second
29

Offline water wash 2 finish LOFLW2_FIN is true
AND Offline water wash 3 finish LOFLW3_FIN is false

AND Offline water wash 3 finish LOFLW3_FIN is false} for 180 second
 Offline water wash 3 finish LOFLW3_FIN is true when


AND Offline water wash 4 finish LOFLW4_FIN is false

AND Offline water wash 4 finish LOFLW4_FIN is false} for 180 second
 Offline water wash 4 finish LOFLW4_FIN is true when

 Offline water wash prerinse permissive L4OFLWW_PRS is true when

AND cooldown slow roll start speed relay L14HT is false at 36 rpm
AND offline water wash prerinse soak finished LOFLPRS_FIN is false
 Offline water wash prerinse soak finished LOFLPRS_FIN is true when

Offline water wash prerinse permissive L4OFLWW_PRS is true for 20 minutes
 Offline water wash cont to rinse after deluge LOFLR_CONT is true when
Operator sel water wash continue to rinse pushbutton
AND Offline water wash prerinse soak finished LOFLPRS_FIN is true
30
 Offline WW LCI torque disable cmd for soak is true when

AND Post wash 2 T.D. prior to cutting LCI L83OFL_SOAK is true
AND Offline water wash cont to rinse after deluge LOFLR_CONT is false
 AGAIN , Select static starter water wash speed reference L83SS_WASH (360rpm)
is true when
Offline WW LCI torque disable cmd for soak is false
AND Wheelspace temperature water wash permissive L69TWW is true
AND Permissive to run steady state to water wash L83SS_WW_RUN is true
 Offline water prerinse permissive L40FLWW_PR is true when

Offline water wash prerinse soak finished LOFLPRS_FIN is true
AND HP speed: offline water speed permissive L14HWW AT 300 RPM
AND offline water prerinse finished LOFLPR_FIN is false
 Offline water prerinse start LOFLPR_INJ is true when

Offline water prerinse permissive L40FLWW_PR is true
AND offline water prerinse finished LOFLPR_FIN is false
 Offline water prerinse finished LOFLPR_FIN is true when

Offline water prerinse start LOFLPR_INJ is true for 60 second
 Signal to operate rinse recirculation valve L20WDET is true when

{Offline water rinse permissive L40FLWW_R is true OR Offline water additional 5
rinse pulses select LOFLR_OPT is true}
AND master control offline compressor water wash L20TW4 is false
 Offline water rinse permissive L40FLWW_R is true when

{Offline water optional additional 5 rinse pulses perm LOFLR_XTRA is true OR
Offline water additional 5 rinse pulses select LOFLR_OPTX is false}
AND Offline water prerinse finished LOFLPR_FIN is true
AND HP speed: offline water speed permissive L14HWW AT 300 RPM
AND Offline water rinse finished LOFLR_FIN is false
AND Offline water completed L83OFL_COMP is false
31
 Offline water rinse start LOFLR_INJ is true when

Offline water rinse permissive L40FLWW_R is true
AND Offline water wash rinse pulse LOFLR_PULSE is false
 Offline water wash rinse pulse LOFLR_PULSE is true when

Offline water rinse start LOFLR_INJ is true FOR 60 second
 Offline water optional additional 5-rinse pulses perm LOFLR_XTRA is true when
Operator select additional 5 rinse pulses PB LOFL_XTR is true
AND Offline water additional 5 rinse pulses select LOFLR_OPT is true
AND Offline water rinse finished W/opt 5 pulses LOFLR_FINX is false
 Offline water additional 5 rinse pulses select LOFLR_OPT is true when

{Offline water additional 5 rinse pulses select LOFLR_OPTX is true OR Offline
water rinse finished W/opt 5 pulses LOFLR_FINX is true }
AND Offline water optional additional 5-rinse pulses perm LOFLR_XTRA is false
 Master control offline water wash motor L4WW2 = L4WWX is true when
Offline water wash start pump permissive L4WW2X is true
AND Offline water completed L83OFL_COMP is false
 Offline water rinse finished W/opt 5 pulses LOFLR_FINX is true when

{Offline water wash rinse pulse LOFLR_PULSE is true
Offline water optional additional 5-rinse pulses perm LOFLR_XTRA is true}
For 5 counts
 Offline water completed L83OFL_COMP is true when

Offline water rinse finished LOFLR_FIN is true
32
 Offline valve 20TW_4 operate command L83WWOFLZ is true when

OR Offline water wash 1 start LOFLW1_INJ is true
OR Offline water wash 2 initiate pulse cycle LOFLW2_INJ is true
OR Offline water prerinse start LOFLPR_INJ is true
OR Offline water rinse start LOFLR_INJ is true}
For 5 second
 Master control offline compressor water wash L20TW4 = L20TW4X is true when
Offline valve 20TW_4 operate command L83WWOFLZ is true
AND Aux to l4bw L83GVMAX is true
 Offline water wash start pump permissive L4WW2X is true when

OR Offline water wash 2 initiate pulse cycle LOFLW2_INJ is true
OR Offline water prerinse start LOFLPR_INJ is true}
 Aux to water wash skid trip L86WWXX is true when

{Master control offline water wash motor L4WW2 = L4WWX is true
AND water wash skid control lockout trip L86WWX}
For 5 second
33
8- SOME IMPORTANT SIGNALS
1 L14HT Cooldown slow roll start speed relay
2 L14HWW HP speed: Offline wash speed permissive
3 TNH_V Voted speed signal
4 L83SS_WASH Select static starter water wash speed reference 360 RPM
5 L4 Master protective signal
6 L1X master control startup permissive
7 L20TVX1 Turbine Compressor Inlet Guide Vane Open Command
8 CSRGV IGV REFERENCE
9 CSGV IGV angle in deg
10 L43C Crank Mode Selected
11 L43BW Water Wash Selected
12 L83BW Turbine /compressor water wash control
13 LOFLW_CON Water wash continue with wash/det
14 LOFLR_CONT Offline water wash cont to rinse after deluge
15 LOFLR_OPT Offline water additional 5 rinse pulses select
16 L4WWX Master control offline water wash motor
17 L20WDET Signal to operate rinse recirculation valve
18 L20TW4X Master control offline compressor water wash
19 L83WWOFLZ Offline valve 20TW_4 operate command
20 LOFLPW_INJ Offline water prewash start
21 LOFLW1_INJ Offline water wash 1 start
22 LOFLW2_INJ Offline water wash 2 initiate pulse cycle
25 LOFLPR_INJ Offline water prerinse start
26 LOFLR_INJ Offline water rinse start
34
36 rpm
L14HT
csrgv
88°
[email protected]
35
100 rpm VALVE CLOSE L20TW4X = 0 PUMP STOP L4WWX= 0

55 se c
Pulse 9 WASH 4
~15 mi n
VALVE OPEN L20TW4X = 1

5 sec
120 rpm PUMP RUN L4WWX = 1

180
sec
220 rpm
VALVE CLOSE L20TW4X = 0 PUMP STOP L4WWX= 0
Pulse 8 WASH 3
55 se c

5 sec
270 rpm PUMP RUN L4WWX = 1

360 rpm LCI OFF
180
120
sec
sec

pulse 7 WASH 2 #5
55 se c

5 sec
PUMP RUN L4WWX = 1

240
SEC

Pulse 6 WASH 2 #4
55 se c
WASH CYCLE 1 + 8 PULSES

5 sec
PUMP RUN L4WWX = 1

240
SEC

Pulse 5 WASH 2 #3
55 se c

5 sec
PUMP RUN L4WWX = 1
NUBARIA POWER STATION

240
SEC
360 rpm

pulse 4 WASH 2 #2
55 se c

5 sec
PUMP RUN L4WWX = 1

240
SEC

Pulse 3 WASH 2 #1
55 se c

5 sec
PUMP RUN L4WWX = 1

240
SEC

pulse 2 WASH 1
55 se c

5 sec
Select initiate wash + L4WWX =1

60 se c
360 rpm Pulse 1 PREWASH

5 sec
320 rpm
csrgv
88°
305 rpm LOFLPW_INJ + PUMP RUN L4WWX = 1

L14HWW + CSRGV = 88
~1. 5 mi n
300 rpm
L14HT + L20TVX (IGV)
45 rpm
csgv =21°
csrg = 29°
Abdelaziz Eldeeb
30 se c
Unit start L1X +L4
Creank mode selected L43C
6 rpm Ww selected L43BW
36 rpm
L14HT
csrgv
29°
~15 mi n
[email protected]
36
Select STOP TURBINE + L4 =0 + L1X = 0

360 rpm Select E ND OFFLINE WW + L83BW =0
Select E ND RINSE + L4WWX =0 + L20WDET = 0
VALVE CLOSE L20TW4X = 0& MIN FLOW OPEN L20WDET= 1
Pulse 35 5-XTRA RINSE #5
55 se c
VALVE OPEN L20TW4X = 1& MIN FLOW CLOSE L20WDET= 0

5 sec
RINSE CYCLE 1 + 29 + (5 or more) PULSES

55 se c

5 sec
210
SEC

55 se c

5 sec
210
SEC
SELECT 5 EXTRA RINSE LOFLR_XTR

360 rpm

Pulse 30 RINSE #29
55 se c

5 sec
210

SEC

pulse 29 RINSE #28
55 se c

5 sec

55 se c
Pulse 3 RINSE #2
5 sec
210
SEC

pulse 2 RINSE #1
55 se c

5 sec
210
SEC
55 se c
360 rpm Pulse 1 PRERINSE

310 rpm VALVE OPEN L20TW4X = 1& MIN FLOW CLOSE L20WDET= 0
5 sec
300 rpm PUMP RUN UNTIL THE END OF WASH L4WWX = 1
~1. 5 mi n
INITIATE RINSE LOFLR_CONT
Abdelaziz Eldeeb
6 rpm
≥ 20 m in
Soaking
csrgv
88°
36 rpm L14HT
6 rpm
[email protected]
37
~30 mi n
csrgv
29°
714 rpm SELECT STOP UNIT

DRYING TIME = 40 MIN OR (20 MIN +10FSNL)
714 rpm

714 rpm CRANK SPEED
420 rpm L14HM
L14HT + L20TVX1 (IGV)
36 rpm
~30 SEC
SELECT START UNIT
Be sure to Select CRANK
csrgv
Be sure to Select STOP TURBINE

29°
Abdelaziz Eldeeb
Be sure to Select END OFFLINE
6 rpm
~10 mi n
36 rpm L14HT
10-REFERENCES
1. ML0461 - P&ID water wash unit 133E4815.
2. Water Wash System 146e4553.
3. Wash Water Specification gek111895.
4. Water Wash System 146e4553.
5. Water Wash System gek111898.
6. Kuwait Sabiya, GT Water Wash System GE-WW-117.
7. Gas turbine compressor offline water wash sabiya_op. 4.1.
8. TIL 1236-R2 30 OCTOBER 2012.
9. Georgia, Power Goat Rock Turbine Operator Training.
10. Nubaria III, ON & OFF line water wash system test N3-CT-9FA-WWT-CT3A.
11. Saudi 10th power plant, procedures: gas turbine water wash PP10-OPD2018-011.
12. Field experience, + 10 years.
13. GE toolbox/ST, MarkVI/e , Trend/er , HMI.
38
A - Field Preparation:
ITEM POSITION
ITEM LOCATION
DURING DURING NORMAL
WASH DRYING OPERATION
The HEATER to raise water temperature to 82ºC, hot water Water wash Switch
1. Switch ON Switch ON
is more effective than cold water skid OFF
Water wash Check Check Check

2. Check Water tank and Detergent tank levels skid levels levels levels
Water wash
3. WW valves positions are ready for washing skid
Checked Checked Checked
The stage 2 aft wheelspace temperature must be stabilized at 150 ºF 150 ºF 150 ºF
4. HMI
150 ºF (65.5ºC) or lower. (65.5ºC) (65.5ºC) (65.5ºC)
Prior to initiating the off-line water wash, the bell mouth, struts,
and IGV’s should first be hand cleaned to prevent these deposits IGV Hand Hand Hand
5.
from being washed into the compressor during the cleaning. These bell mouth Cleaned Cleaned Cleaned
deposits can be removed by washing with a garden hose.
If necessary, close flame detector valves or blank-off, based on both Turbine Close Close
6. the type of flame detector and gas turbine model. Water may foul If If Open
the flame scanners and make start-up difficult. Compartment necessary necessary
SWITCH Rack-IN Rack-IN Rack-IN
7. Excitation 6.3 K: Rack-IN and press ON. GEAR press ON press ON press ON
SWITCH
8. LCI 6.3 K: Rack-IN and ready. GEAR
Rack-IN Rack-IN Rack-IN
SWITCH
9. A.A Compressor 6.3 K : Rack-out GEAR
Rack-out Rack-out Rack-IN
10. Open all manual isolation valves of the gas fuel line. Gas fuel line Open Open Open
Switch Switch
11. Spark plug power supply in Mark Vie PEECC OFF OFF
Switch ON
Ready to Ready to Ready to

12. Unit at Turning Gear and Ready to Start. HMI
Start Start Start
39
B- Manually isolate systems, open drains of Manual Isolation Valves as follows:

ITEM POSITION
ITEM LOCATION DURING DURING NORMAL
Under the
1. Off line water wash line isolation valve inlet plenum
Open Open Close
Under the
2. ON line water wash line isolation valve inlet plenum
Close Close Open
Under the
3. the Inlet Plenum water wash drain valve inlet plenum
Open Open Close
Near turbine
4. the manual Isolation valve of IBH compartment Close Close Open
door
False Start Drain valves must be diverted from the sludge
Diverted Diverted Diverted
1 tank to a water wash effluent tank
120° to 0º 120° to 0º 0° to 120º
5. 3-way valve from 120° to 0º near IBH Near turbine
compartment Diverted Diverted Diverted
2 3-way valve near exhaust diffuser door door to water to water to sludge
3 Manual bypass valve near exhaust diffuser door. to water to water to sludge
Under
6. Open the Exhaust Plenum water wash drain valve Diverter Open Open Close
Damper
1 the manual drain valve #1 of IBH Open Open Close

Turbine
7.
Compartment
2 the manual drain valve #2 of IBH Open Open Close
Water wash drain valve for the FSD of Combustion Chamber Turbine
8. Open Open Close
water wash drain header. Compartment
Water wash drain valve for the FSD of man-way cover in the Turbine
9. Open Open Close
Combustion Chamber. Compartment
Turbine
10. Close the manual isolation valve for APU. Compartment
Close Close Open
40
ITEM POSITION
ITEM LOCATION DURING DURING NORMAL
1 manual isolation valve for Cooling Line for 9 stage left side Close Close Open
2 manual isolation valve for Cooling Line for 13 stage left side Close Close Open
Turbine
11.
Compartment
3 manual isolation valve for Cooling Line for 9 stage right side Close Close Open
4 manual isolation valve for Cooling Line for 13 stage right side Close Close Open
1 manual drain valve # 1 for Cooling Line for 9 stage left side Open Open Close
Turbine
12.
Compartment
5 manual drain valve # 1 for Cooling Line for 9 stage right side Open Open Close
Turbine
13. Manual isolation valve for AA and Gas purge. Compartment
Close Close Open
1 Manual drain valve # 1 for AA and Gas purge. Turbine

Open Open Close
14.
Compartment
2 Manual drain valve # 2 for AA and Gas purge. Open Open Close
1 Gas Fuel manifold low point drains PM1 Close Open Close
Turbine
15. 2 Gas Fuel manifold low point drains PM2 Compartment
Close Open Close
3 Gas Fuel manifold low point drains PM3 Close Open Close
41
C- Manually isolate systems, open drains of Transmitters Lines as follows:

ITEM POSITION
ITEM LOCATION
DURING DURING NORMAL
1. Close THREE VALVES for compressor discharge pressure transducer Turbine Close Close Open
supply lines 96CD-1,-1B,-1C Compartment
2. Close THREE VALVES for Liquid Fuel Purge pressure transmitters Turbine Close Close Open
supply lines 96PL-1A,-1B,-1C Compartment
3. Close THREE VALVES for Water Injection Purge Differential pressure Turbine Close Close Open
transmitters supply lines 96WP-2A,-2B,-2C Compartment
4. Close THREE VALVES for Gas Fuel Nozzle Pressure Ratio pressure Turbine Close Close Open
transmitter supply lines 96GN-1,-2,-3 Compartment
5. Close THREE VALVES for Atomizing Air Purge pressure transducer Turbine Close Close Open
supply lines 96AA-1A,-1B,-1C Compartment
6. Turbine Close Close
Close the VALVE for Online Compressor Wash Manifold supply line 96WW-3 Open
Compartment
7. Close THREE VALVES for Gas Fuel Nozzle Pressure Ratio pressure Above Turbine Close Close Open
transmitter supply lines 96GN-2A,-2B,-2C Compartment
10. Close THREE VALVES for Cavity Pressure Transmitter S2N supply lines Above Turbine Close Close Open
96S2N-1,-2,-3 Compartment
11. Close THREE VALVES for Cavity Pressure Transmitter S3N supply lines Above Turbine Close Close Open
96S3N-1,-2,-3 Compartment
12. Close TWO VALVES for EXHAUST DUCT PRESSURE Transmitter Above Turbine Close Close Open
96EP-2,-3 Compartment
Divert VALVES to the vent for Diverted Diverted Diverted
1 to normal
96CS-1 COMPRESSOR INLET TOTAL PRESSURE Transmitter to vent to vent operation
2 96AP-1,-2,-3 PAROMETRIC PRESSURE Transmitter Close Close Open
13. 3 96BD-1 BELLMOUTH STATIC PRESSURE Transmitter

Above Turbine Diverted Diverted Diverted
to normal
Compartment to vent to vent operation
4 96EP-1 EXHAUST PRESSURE Transmitter to vent to vent
to normal
operation
5 96EP-2,-3 EXHAUST PRESSURE Transmitter to vent to vent
to normal
operation
42
43

GE 9FA Water Wash PROCEDURE Final

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GE 9FA Water Wash PROCEDURE Final

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EGYPTIAN ELECTRICITY HOLDING COMPANY ‫اﻟﺸﺮﻛـﺔ اﻟﻘﺎﺑﻀـﺔ ﻟﻜﮭﺮﺑﺎء ﻣﺼـﺮ‬

Gas Turbine Compressor Off-Line Washing Procedure

Nubaria Power Station

Prepared by Eng\ Abdelaziz Mohamed Eldeeb

Operation General Manager Nubaria Power Station Head of sector

2 - Water Wash system major components…………………………………….………. 5

3 - Water wash flow chart ……………………………………………………………….…..… 7

4 - A - Field Preparation ………………………………………………………….….………….11

4 - B. Manual Isolation Valves Positions ……………………………………….……….12

4 - C. Transmitters Isolation ………………………………………………………………….. 13

4 - D- WW SKID and HMI Preparation …………………………………………………….. 14

4 - D – 1. PREWASH PULSE (Water Only) ………………………………………………… 14

4 – D – 2. WASH 8-PULSE (detergent)………………………………………………..…….15

4 - D – 3. 20-Min SOAKING …………………………………………………………………….. 16

4 - D – 4. RINSE 30-PULSE (Water Only) …………………………………………………. 16

4 - D – 5. RINSE 5-EXTRA PULSE (Water Only) ………………………………………… 17

4 - D – 6. END WATER WASH …………………………………………………………………….17

4 – D – 8. END OF DRYING …………………………………………………………………………18

5 - NORMAL POSITION ……………………………………………………………………….…….19

6 - P&ID AND Figures…….………………………………………………………………….………20

7 - Water wash control logic explanation ……………………………………………….26

8 - SOME IMPORTANT SIGNALS ……………………………………………………….….…..34

Water Wash system major components

Water Wash Preparation

Manual Isolation Valves

HMI / WW SKID Preparation:

These steps are for F-class gas turbine (gas fuel)

Switch ON the HEATER to raise water temperature to 82ºC,

2. Check Water tank and Detergent tank levels

Prior to initiating the off-line water wash, the bell mouth,

7. Excitation: Rack-IN and press ON.

B- Manually isolate systems, open drains of Manual Isolation Valves as follows:

The THREE VALVES of the False Start Drain must be

Open the Inlet Plenum water wash drain VALVE at or near

Open the Exhaust Plenum water wash drain VALVE at or near

Open the manual drain EIGHT VALVES

C- Manually isolate systems, open drains of Transmitters Lines as follows:

Close THREE VALVES in Water Injection Purge Differential pressure transmitters

Divert FOUR VALVES to the vent for

D- WW SKID and HMI Preparation:

PREWASH PULSE (Water Only)

2. Close Detergent valve and open min-flow water valve

4. Divert the 3-way valve of WW line to normal position for 3A and 3B

5. Run WW pump manually to fill WW line

7. Put WW pump at Auto

1. Select SP/SS to prevent Diverter Damper from Opening.

 If Water Wash is selected, unit reached cranking speed L14HW, and no

2. Divert the 3-way valve to the drain

5. Run WW pump manually to fill WW line

WASH 8-PULSE (detergent)

After Mixing water and detergent Select Initiate Wash

Observe the 8- WASH PULSES each for 60 second at 360 RPM

Adjust detergent flow to 6 GPM( Water : detergent Ration = 4 : 1)

 If more detergent is injected, long rising duration is required

During Soaking Divert the 3-way valve of WW line to drain the

2. Close Detergent valve and open min-flow water valve

RINSE 30-PULSE (Water Only)

After the +20 Minute Soaking Select Initiate Rinse

Measure the CONDUCTIVITY it must be 5-10 microSiemans/cm