GAS TURBINE INGESTIVE CLEANING

Operation of the unit may be performed only when conditions indicate it is safe to proceed. Dangerously explosive natural gas accumulations, fuel fumes, oil tank vent leakage, and solvent fumes must be avoided. This is done by proper ventilation, elimination of Leaks, and by confining the use of solvents to appropriate maintenance facilities. The operator must understand gas turbine and driven equipment operation, function, and systems and know and understand all indicators, normal indications, controls, and operating limits. Operating and maintenance personnel must use fair hearing and eye protection near the operating gas turbine.

Purpose of Axial Compressors Cleaning

Contaminants such as dust, salt, and oil-laden air pass through the gas turbine air filters. They adhere to the engine compressor blades and decrease engine performance. Ingestive cleaning may eliminate the following engine performance-related problems:

• An increase in turbine temperature (T5) causes the topping machine occurs.
• General lack of acceleration.
• Failure to accelerate to full speed.
• Compressor surge.
• Inability to develop full output power.
• Loss of compressor discharge pressure.

Sometimes, the need for compressor on-crank cleaning is indicated when

contamination is visible at the air inlet and through the compressor borescope ports. When cleaning the engine axial compressor, ensure that any sources of contamination, including poor air filtration, the oily mist from the oil tank vent, and the exhaust of nearby equipment, have been eliminated.

Performance Evaluation on Saturn Gas Turbine

Evaluate engine performance to determine if the engine axial compressor should be cleaned on the crank. Cleaning should be performed if the trend of the per cent-of-change approaches 5 % (measured from the baseline or the final reading of the most recent cleaning). You must evaluate follows critical factors:

• Turbine gas temperatures (T5, T7)
• Compressor inlet temperature (Tl)
• Barometric pressure (or site elevation)
• Gas producer speed (Ngp)
• Compressor discharge pressure (PCD)
• Output power
• Inlet and exhaust duct pressure drop
• Water injection rate (if applicable)
• Fuel flow

Recording Pre/Post-Cleaning Performance Data

To accurately measure the performance of the compressor cleaning system and determine necessary changes to cleaning frequency and dosage, the essential engine operating parameters should be recorded before each cleaning and about 30 minutes after the water rinse. If this data is recorded carefully, a performance trend will soon be established to show how the cleaning system performs.

Cleaning Modes

The gas turbine axial compressor can be cleaned while the engine is cranking (on-crank mode) or while the engine is operating in the simple cycle mode (online mode).
On-crank and online compressor cleaning system is specifically designed to maintain the engine compressor. Its effectiveness will depend on the proper use and monitoring of engine performance parameters regularly. Monitoring engine performance can indicate the effectiveness of on-crank and online engine cleaning. However, degradation of engine output is not necessarily related to gas turbine compressor degradation only and, therefore, should not be the sole basis for evaluating the effectiveness of on-crank or online engine cleaning.

ON-CRANK MODE

In the on-crank mode, the engine operates at the maximum speed obtainable by the starter alone, with the fuel and ignition systems de-activated. On-crank cleaning is more effective than online cleaning. The waste stream produced during the on-crank cleaning procedure is discharged through the drain ports. Online cleaning may be used between on-crank cleaning cycles to extend the time between on-crank cleaning and to minimize further contamination of the gas turbine compressor.

ONLINE MODE

In the online mode, the engine operates at any power level ranging from idle (no load) to full-rated power with engine temperature stabilized at operating speed.
In online mode, an engine compressor can be cleaned with the gas turbine operating

normally within minutes. Cleaning does not affect engine operation and should be performed on a scheduled basis. This allows the operator to avoid engine downtime while preventing a fouled and inefficient gas turbine compressor.

The online cleaning system is based on the injection of finely atomized water and cleaning fluid, thus avoiding the many problems associated with abrasive cleaning methods, which can erode blades, damage special coatings and bearings, and block up turbine blade cooling holes.

 Online cleaning in a salt-laden environment is not recommended.

Adequate air treatment must be employed to remove the bulk of airborne constituents, such as dried salt particles. Airborne salts removed during the cleaning process can cause serious damage to the hot section of the turbineOn-line cleaning is intended as a supplement to on-crank cleaning, not a substitute. The compressor must be cleaned in the on-crank mode regularly.

 Cleaning Fluids

The two cleaning fluids are water and cleaning solutions. Either fluid may be used in either cleaning mode (on-crank or online). The concentrations will vary depending on the cleaning mode selected.

 WATER WASH

Water removes water-soluble contaminants such as salt, chemicals, dust, or other non-oily nonwaxy substances from the compressor air path. Standard ambient-temperature water wash and low ambient-temperature water wash are the two water washing methods. It is recommended that deionized water be used. A recommended method for measuring water purity would be a conductivity meter. Acceptable values should be four megohms resistance or 0.25 micromhos conductance.

CAUTION

Low-ambient temperature water wash may be done only in the on-crank mode.

 Standard Ambient-Temperature Water Wash

Standard ambient-temperature water wash is used at inlet plenum temperatures above +39F (+4C) and may be conducted in either the on-crank or online cleaning mode. If the inlet plenum is not easily accessible to verify the temperature, the water wash may be conducted at ambient temperatures above +50F (+10C)

Low Ambient-Temperature Water Wash

Low ambient-temperature water wash is used at inlet plenum temperatures from
+39F to -4F (+4C to -20C) and can be conducted only in the on-crank mode. The solution for low ambient-temperature water wash is a mixture of water with equal parts-by-volume ethylene glycol (per MIL-E-9500) or isopropyl alcohol (per ASTM M 70). The water used in the mixture must meet the requirements for water used in ingestive cleaning. It is recommended that deionized water be used.

CAUTION

Engine cleaning is not recommended when the ambient temperature is below -4 F (-20C)' Automotive or commercial antifreeze products are not acceptable. The use of such products may cause severe damage to engines.

Use of Antifreeze Materials in Cold Weather Operation recommends that the operator consider using antifreeze for on-crank washing when the inlet plenum temperature is at or below +39F (+4C) and ambient temperature below +50F (+10C).

CLEANING SOLUTIONS

Solar cleaning solutions should never be used for online cleaning unless a properly designed and installed injection system is fitted. Solar cleaning solutions can be used with any on-crank cleaning system. Solar Turbines recommended cleaning solutions may be used in the on-crank and online cleaning systems. Other cleaners may not work effectively.
Before use, mix the applicable concentrates with deionized water. Cleaning solutions will not chemically attack special blade coatings. For cold weather, refer to standard procedures and mix cleaning solutions with commercially available antifreeze agents such as isopropyl alcohol or methanol.

NOTE

The water and antifreeze must be pre-mixed before adding the concentrate, cover, on-crank washing, and on-crank rinsing.

The liquid detergent and antifreeze/water solution must be a homogenous mixture during the injection. If a mixture of concentrate, antifreeze, and deionized water is allowed to sit for an extended time, the solution should be constantly agitated to regain homogeneity.

Gas turbine cleaning

Gas turbine cleaning is a crucial maintenance task that helps ensure the optimal performance and longevity of gas turbines. Regular cleaning of gas turbines is essential to prevent the buildup of contaminants such as dust, salt, and oil-laden air on the compressor blades, which can lead to decreased engine efficiency and performance.

Proper cleaning of gas turbines involves the removal of contaminants that can adversely impact engine operation. Ingestive cleaning methods, such as water washing and the use of cleaning solutions, are commonly employed to remove deposits from the compressor blades and restore the engine's efficiency. By implementing a regular cleaning schedule, operators can mitigate the risk of compressor fouling and maintain peak turbine performance.

Regular maintenance and cleaning of gas turbines not only improve engine efficiency but also extend the operational life of the equipment. Removing contaminants and deposits from the compressor blades through effective cleaning methods can help prevent issues such as compressor surge, loss of power output, and excessive turbine temperatures, ensuring reliable and consistent turbine performance.

Ensuring the cleanliness of gas turbines is essential for safe and efficient operation. Contaminants that accumulate on the compressor blades can disrupt airflow, leading to decreased turbine efficiency and potential performance issues. By adhering to a comprehensive cleaning regimen, operators can safeguard the integrity and functionality of gas turbines, minimizing the risk of operational disruptions and costly repairs.

Online gas turbine compressor cleaning

Online gas turbine compressor cleaning involves operating the engine at any power level, from idle to full-rated power, with the engine temperature stabilized. This mode allows for the cleaning of the compressor while the turbine is running normally.

Cleaning is performed within minutes, ensuring minimal downtime for the gas turbine. The process is efficient and does not interfere with engine operation, providing a convenient way to maintain a clean and efficient compressor.

The system injects finely atomized water and cleaning fluid to remove contaminants from the compressor blades. This method avoids abrasive cleaning techniques that can damage the blades and other components of the turbine.

Online cleaning is recommended as a complement to on-crank cleaning, enhancing the overall maintenance strategy for the gas turbine compressor. It helps extend the time between on-crank cleanings and ensures optimal performance.

Adequate air treatment is essential to remove airborne particles during online cleaning. This precaution prevents damage to the turbine from salt particles and other contaminants present in the environment.

Clean gas turbine compressor blades

Cleaning the gas turbine compressor blades is crucial for maintaining optimal performance of the unit. Contaminants like dust, salt, and oil-laden air can accumulate on the blades, leading to reduced engine efficiency. Regular cleaning of the compressor blades helps prevent issues such as turbine temperature increases, compressor surge, and decreased power output.

Proper cleaning of the gas turbine compressor blades involves removing any visible contamination at the air inlet and compressor borescope ports. By eliminating potential sources of contamination, like poor air filtration and oily mist, the efficiency and longevity of the engine can be preserved.

Performance evaluation of the gas turbine is essential to determine when cleaning the compressor blades is necessary. Monitoring factors such as turbine temperatures, gas producer speed, and compressor discharge pressure can help in deciding the appropriate timing for maintenance.

Recording pre and post-cleaning performance data is a critical step in assessing the effectiveness of the compressor blade cleaning process. By documenting key engine parameters before and after cleaning, trends can be analyzed to optimize the cleaning frequency and dosage for maximum efficiency.

Utilizing water wash and cleaning solutions is a common method for cleaning gas turbine compressor blades. Water wash helps remove water-soluble contaminants, while cleaning solutions can target specific residues. Understanding the appropriate methods and concentrations is vital for a successful cleaning process of the compressor blades.

Gas turbine compressor washing

Gas turbine compressor washing is a crucial maintenance procedure that helps ensure optimal performance and efficiency of gas turbines. Regular cleaning of the compressor blades is essential to remove contaminants such as dust, salt, and oil-laden air that can accumulate and hinder engine performance. By keeping the compressor clean, the turbine can operate at peak efficiency, leading to improved power output and fuel efficiency.

Compressor washing can address various performance-related issues that may arise due to the build-up of contaminants. These issues include increased turbine temperature, compressor surge, loss of output power, and general lack of acceleration. By conducting regular compressor washing, operators can prevent these problems and extend the lifespan of the gas turbine.

There are two main modes of compressor cleaning: on-crank and online cleaning. On-crank cleaning is typically more effective as it allows for a thorough cleaning of the compressor blades while the engine operates at maximum speed. Online cleaning, on the other hand, can be performed while the engine is running and is useful for regular maintenance to prevent further contamination.

Water wash and cleaning solutions are commonly used in compressor cleaning to remove contaminants effectively. Water wash is suitable for removing water-soluble substances, while cleaning solutions can tackle more stubborn deposits. The choice of cleaning fluid and method depends on factors such as ambient temperature and the level of contamination present in the compressor.

Proper recording and analysis of performance data before and after compressor cleaning are essential for evaluating the effectiveness of the cleaning process. By monitoring key performance indicators such as gas temperatures, compressor inlet pressure, and power output, operators can determine the optimal cleaning frequency and ensure the gas turbine operates efficiently.

Gas turbine parts washing

Gas turbine parts washing is a critical maintenance procedure that involves cleaning various components of the gas turbine to ensure optimal performance and longevity. Proper cleaning of gas turbine parts is essential to remove contaminants such as dirt, oil, and debris that can accumulate over time and negatively impact the turbine's efficiency.

One of the key benefits of gas turbine parts washing is the prevention of corrosion and erosion, which can lead to costly repairs and downtime. By regularly cleaning the turbine components, operators can extend the lifespan of the equipment and maintain peak performance.

Effective gas turbine parts washing requires the use of specialized cleaning solutions and equipment designed to safely and thoroughly remove deposits without causing damage to the components. Proper cleaning techniques must be followed to ensure that all parts are thoroughly cleaned and inspected.

Regular maintenance schedules that include gas turbine parts washing help to identify any potential issues early on, allowing for prompt repairs and adjustments to be made. By incorporating thorough cleaning into routine maintenance practices, operators can optimize the efficiency and reliability of their gas turbine systems.

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