CX501KB7

TRAINING GAS TURBINES

COMPRESSOR WASH SYSTEM

MLN BLOCK 405, ALGERIA

OPERATOR TRAINING

CX501KB7
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COLD WEATHER WASHING

ALWAYS FOLLOW THE WASH FLUID MANUFACTURER'S

INSTRUCTIONS FOR MIXING - ADD ANTI FREEZE AT AMBIENT
TEMPERATURES BELOW +8°C
TURBINE DAMAGE MAY OCCUR IF THESE INSTRUCTIONS ARE
NOT FOLLOWED.

WASH SECTION 13 PAGE 1-2

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Compressor Wash System Description

In order to maintain the efficiency of the turbine, the compressor

must be washed periodically.
A build up of contaminants on the compressor will result in
reduced power and increased fuel consumption whilst maintaining
a constant turbine temperature.
Compressor cleaning should be carried out as part of the routine
maintenance schedule by the operator and frequency is dictated
by local conditions and rate of power loss over time.

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TYPICAL EFFECTS OF COMPRESSOR FOULING GAS TURBINES
AND CLEANING CYCLES

100%
POWER OUTPUT %

95%
TIME

CLEAN RUNNING RUNNING MOTORING

ENGINE WASH WASH WASH
* Each % point drop in performance is equivalent to about 50kW .
* Running washes are normally carried out after a 1½% drop. Full power may not be recovered.
* Motoring washes are carried out when the total power output has fallen by up to 5%. If correctly
performed, a Motoring Wash should return output to full rating. Power loss of >5% is unlikely
to be recovered by a Motoring wash
* Motoring / Running wash cycles are dictated by experience of local conditions and will vary
from site to site.
* Typical frequencies: Running wash - twice weekly; Motoring wash - Weekly
* Running wash = Online Wash; Hot Wash * Motoring Wash = Crank Wash; Cold Wash

WASH SECTION 13 PAGE 3-4

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Methods of Cleaning

There are 2 methods of cleaning the compressor:

1. Running Wash - where the cleaning agent is drawn through the
compressor whilst the turbine is running. This should be carried
out at least twice a week.
2. Motoring or Crank Wash - where the cleaning agent is drawn
through the compressor whilst the turbine is cranked during a
shutdown. This is the most thorough cleaning method and is
recommended on a weekly basis. This method uses a solvent type
cleaning agent and must be carried out on a cool engine.

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Monitoring Wash

The operator must keep a daily/shift change log of performance

parameters.
With the turbine running at normal power and temperature, the
following data should be noted before and after each compressor
wash:
1. Turbine Speed
2. Turbine Temperatures (CIT,CT & TOT)
3. Generator Power
4. Compressor Discharge Pressure
5. Ambient Pressure
This will enable the operator to ascertain the frequency and type of
cleaning required.

WASH SECTION 13 PAGE 5-6

 THIS DRAWING IS CONFIDENTIAL AND THE
COPYRIGHT OF CENTRAX LIMITED. IT MUST
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NOT BE COPIED OR COMMUNICATED WITH A
THIRD PARTY WITHOUT WRITTEN CONSENT GAS TURBINES
FROM CENTRAX LIMITED  2000

WASH SYSTEM

INSTRUMENT AIR

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TRAINING GAS TURBINES

Wash System Principal Items

1. Wash Tank Assembly

2. Air Driven Wash Pump (P104)
3. Pump Air Supply Solenoid Valve (EV110)
4. Filter (F106)
5. Plenum Wash Solenoid Valve (EV107)
6. Core Compressor Wash Solenoid Valve (EV109)

WASH SECTION 13 PAGE 7-8

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Running Wash
With the turbine running at normal load and temperature, record:
Turbine Speed,
Turbine Temperatures (CIT,CT & TOT)
Generator Power,
Compressor Discharge Pressure and
Ambient Pressure

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Mix a total of 20 litres of the cleaning fluid

and demineralised water in the wash tank.

Include anti-freeze
if the ambient
temperature is
below 8°C
40
38
36
34
32
30
28
26
24
20
18
16
14
12
10

WASH SECTION 13 PAGE 9-10

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Connect the tank to the nozzle

40
38
36
34
32
30
28
26
24
20
18
16
14
12
10

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At the HMI panel select the WASH system window from the
Overview page

WASH SECTION 13 PAGE 11-12

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Press the "Antifreeze Accept" pushbutton if antifreeze

has been added; and press wash;

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System Logic

If the ambient temperature is above +8°C ( or above +3°C with

antifreeze added) half the cleaning fluid passes through the plenum
nozzles. The solenoid valves then switch over and the remaining
fluid passes into the core compressor.

If the ambient temperature is between +8°C and +3°C and the

Antifreeze select button has not been operated the cleaning fluid will
only pass into the core compressor. Only half the cleaning fluid will
be injected. If the temperature is below 3°C and the Antifreeze select
button has not been operated the system will not operate.

If the ambient temperature is between -4°C and -7°C and the

Antifreeze select button has been operated the cleaning fluid will
only pass into the core compressor. If the temperature is below -7°C
and the Antifreeze select button has been operated the system will
not operate.

WASH SECTION 13 PAGE 13-14

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The wash pump will start...

the solenoid valve will open....

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half the mixture will be automatically injected into the

engine through the plenum nozzles

WASH SECTION 13 PAGE 15-16

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the remaining fluid is injected through the core compressor

nozzles..the complete process takes approximately six
minutes

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On completion of the cycle refill the tank

with 20 litres of de-mineralised water (add anti-freeze at
temperatures below +8°C) and press wash

After washing with any cleaning

fluid it is important to rinse the
fluid and residue from the
engine .
40
38
36
34
32
30
28
26
24
20
18
16
14
12
10

WASH SECTION 13 PAGE 17-18

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On completion...
Allow the turbine to stabilise and record the
performance and compare with the previous readings.:
Turbine Speed,
Turbine Temperatures (CIT,CT & TOT)
Generator Power,
Compressor Discharge Pressure and
Ambient Pressure

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Motoring/Crank Wash

With the turbine running at normal load and

temperature, record Turbine Speed, Turbine
Temperatures (CIT,CT & TOT) Generator Power,
Compressor Discharge Pressure and Ambient
Pressure;
Press the turbine Stop pushbutton. The turbine will go
into its normal stopping sequence with the 5 minute
cooldown period, at no load, followed by shutdown.
Before carrying out a Cold Wash the turbine Control
Temperature must be below 120°C - this is indicated on
the Wash window of the HMI.
If the temperature is above 120°C a "crank" may be
carried out to cool the engine ...select the "Control"
window on the menu bar at the bottom of the screen
and then press CRANK to accelerate cooling.

WASH SECTION 13 PAGE 19-20

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While the turbine is stopping ...

mix a total of 40litres of the cleaning fluid and potable water in
the wash tank...

Include anti-freeze
if the ambient
temperature is
40
38
below 8°C
36
34
32
30
28
26
24
20
18
16
14
12
10

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Connect the tank to the nozzle...

40
38
36
34
32
30
28
26
24
20
18
16
14
12
10

WASH SECTION 13 PAGE 21-22

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At the HMI panel select the WASH system window using the from
the Overview page

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If the Control Temperature is above 120°C a "crank" may be

carried out to cool the engine ...select the Overview window
on the menu bar at the bottom of the screen and then press
CRANK to accelerate cooling.

crank button

WASH SECTION 13 PAGE 23-24

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the priming oil pump runs...

...the BOVs close...

GEARBOX

Electric
...the start system Motor

is engaged... Hydraulic Hydraulic

Pump Motor

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...cooling intake air is drawn through the

engine for a one minute crank cycle..

60,59,58,57,56...

WASH SECTION 13 PAGE 25-26

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When the turbine is cool ...

Open the exhaust duct drain valve (if fitted)...

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Press the "Antifreeze Accept" pushbutton if antifreeze

has been added; and press wash;

WASH SECTION 13 PAGE 27-28

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the priming oil pump runs...

...the BOVs close...

GEARBOX

Electric
...the start system Motor

is engaged... Hydraulic Hydraulic

Pump Motor

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The wash pump will start...

the solenoid valve will open....

WASH SECTION 13 PAGE 29-30

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half the mixture will be automatically injected into the

engine through the plenum nozzles

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the remaining fluid is injected through the core compressor

nozzles..the complete process takes approximately six
minutes

WASH SECTION 13 PAGE 31-32

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leave the solvent inside the engine to soak the components

for a minimum of 20 minutes...

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On completion of the soaking cycle refill the tank

with 40 litres of potable water (add anti-freeze at
temperatures below +8°C) and press wash...
repeat the process with a second 40 litres of water...

After washing with any cleaning

fluid it is important to rinse the
fluid and residue from the
engine . AFTER A MOTORING
WASH THE RINSE SHOULD BE
40
38
36
34
32
30
28
26
CARRIED OUT TWICE
24
20
18
16
14
12
10

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On completion of the wash Motoring wash cycle...

Drain the intake plenum

Close the exhaust duct drain (where fitted)
Clean up any spillage within the enclosure
Restart the turbine within 30 minutes and run for a
minimum of 15 minutes to thoroughly dry out the
turbine.
Centrax recommend that all wash fluids are disposed
of safely in an environmentally friendly way.

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On completion...

On completion of the shutdown period and when

restored to normal operating conditions, record
performance and compare with the previous readings:
Turbine Speed,
Turbine Temperatures (CIT,CT & TOT)
Generator Power,
Compressor Discharge Pressure and
Ambient Pressure
IT IS ESSENTIAL TO COMPARE THE READINGS AS
THIS WILL DICTATE THE FREQUENCY OF CLEANING.

WASH SECTION 13 PAGE 35-36

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MIXING CLEANING FLUIDS GAS TURBINES

FLUID SERVICE DILUTION above 8°C DILUTION below 8°C RINSE

Fluid + Water Fluid+Water + Antifreeze required¹

B&B (solvent base) Motoring ² Only 8ltrs + 32ltrs Motoring 8ltrs fluid + 16ltrs Yes
methanol + 16ltrs water
RMC Powerback Motoring ² 3.5ltrs + 36.5ltrs Motoring 3.5ltrs fluid + 10 ltrs Yes
isopropyl + 26.5 ltrs water.
RMC Powerguard Run 4ltrs + 16ltrs Run 4ltrs fluid + 4ltrs isopropyl Yes
+12 ltrs water.

Rochem F1 (solvent Motoring ² Run Motoring 8ltrs+ 32ltrs Motoring 8ltrs fluid + 11ltrs Yes
base) methanol + 21ltrs water
Rochem F2 (natural Motoring ² Run Run 4ltrs + 16ltrs Run 4ltrs fluid + 6ltrs Yes
solvent base) methanol + 10ltrs water
Rochem F3 Motoring ² Run
Turbotect T927 (solvent Motoring ² Run Motoring 8ltrs+ 32ltrs Motoring Use only Turbotect Yes
base) premixed fluid
Turbotect 950 Motoring ² Run Run 4ltrs + 16ltrs Run Use only Turbotect Yes
premixed fluid
Zok 27 Motoring² Run Motoring 8ltrs+ 32ltrs Motoring 8ltrs fluid 11ltrs Yes
methanol + 21ltrs water Yes
Run 4ltrs + 16ltrs Run 4ltrs fluid + 6ltrs
methanol + 10ltrs water
Zok 27 Motoring for Storage Motoring 8ltrs+ 32ltrs Motoring 8ltrs fluid 11ltrs No
Run for Storage methanol + 21ltrs water No
Run 4ltrs + 16ltrs Run 4ltrs fluid + 6ltrs
methanol + 10ltrs water

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Notes on compressor cleaning fluids

¹ Centrax recommend that a rinse with water is carried out after

every wash, to purge the wash system and compressor of cleaning
fluid, preventing gumming of the spray nozzles and removing any
residues of fluid from the compressor, add antifreeze as required.
² Use potable water when Motoring wash both to dilute the fluid
and rinse.
Use de-mineralised water for Run washes and rinses as the high
temperatures within the compressor will bake any impurities in the
water onto the compressor.
SOLVENT BASE CLEANING FLUIDS ARE RECOMMENDED FOR
MOTORING WASHES.
ALWAYS CONSULT MANUFACTURER'S INSTRUCTIONS FOR
COLD WEATHER USE, RECOMMENDED ANTIFREEZE AND
DILUTION.

WASH SECTION 13 PAGE 37-38