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GEK 116771
December 2010

GE Energy

GE Energy recommendations
Fuel Supply System Cleaning for Gas Turbines

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.
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GEK 116771 GE Energy recommendations

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 SITUA-
TION, WHICH, IF NOT AVOIDED WILL RESULT IN
DEATH OR SERIOUS INJURY.

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GE Energy recommendations GEK 116771

TABLE OF CONTENTS

I. INTRODUCTION.......................................................................................................................... 4

II. SCOPE ........................................................................................................................................... 4

III. BACKGROUND ........................................................................................................................... 4

IV. THE GE ENERGY POSITION.................................................................................................... 7

V. CONSIDERATIONS FOR ALTERNATIVE CLEANING METHODS .................................. 7

A. Pneumatic Blows, Air, Nitrogen and Steam ............................................................................ 7
B. Pipeline Pigging ....................................................................................................................... 9
C. High-pressure water jet flushing .............................................................................................. 9
D. Routing Gas to a Flare System ................................................................................................ 9

VI. START WITH CLEAN COMPONENTS TO REDUCE THE FIELD CLEANING EF-
FORT............................................................................................................................................... 10

VII. CLEAN AS YOU GO .................................................................................................................... 10

VIII. FINAL CLEANING AND VERIFICATION ............................................................................ 10

LIST OF FIGURES

Figure 1. Calpine Wolfskill Energy Center “Gas Blow” ......................................................................... 6

Figure 2. Kleen Energy “Gas Blow”, 7 February 2010........................................................................... 6

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GEK 116771 GE Energy recommendations

I. INTRODUCTION

GE Energy provides a variety of equipment for power generation facilities powered by Gas Turbine en-
gines. The scope of the equipment typically includes the “flange-to-flange” turbine proper plus the essential
accessory assemblies: Gas Module, Lubrication Oil Module, Liquid Fuel/Atomizing Air Module (if liquid
fuel is used), and Engine Controller and Motor Control Center equipment (may be in a-packaged enclosure)
to name the major elements. Other components, such as gas fuel heaters, filters and absolute separators are
supplied as “Customer Options”.

Once all the components are at site and the equipment foundations are all in place, assembly of the turbine
and supporting systems and components commences. For the fuel gas system, the client’s construction
contractor will field fabricate interconnecting piping configured to meet the specifics of the site layout.
Although flanged or threaded fittings will be used in some locations to facilitate potential disassembly for
maintenance, most of the fabrication will be accomplished by welding. Invariably, the process of field weld-
ing results in some amount of residual debris such as metal oxides, solidified welding flux, metal “spatter”
etc. inside the piping. Debris can also enter the system through uncapped pipe either during construction
or on site storage prior to fabrication. Additionally, iron piping that is sourced without protective internal
treatments can rapidly oxidize, further contributing to the total amount of debris within the system.

The debris from these sources is often of a size and hardness that clog small orifices in the engine gas
delivery system or erode gas injection nozzles resulting in damaging thermal variations, damage the sealing
surfaces of valves preventing proper shut off of the gas flow, or damage the leading edges of both static
and rotating turbine hot section airfoils leading to potential airfoil failure in service.

Because of the potential damage caused by residual pipe fabrication debris, GE Energy has established
specific cleanliness requirements for the various accessory systems. These requirements must be demon-
strated as a precondition of warranty prior to the first engine start.

II. SCOPE

This document is intended to provide information on:

1. Known cleaning practices for the fuel systems that GE believes can achieve the warranty cleanliness
requirements,

2. Minimize the amount of field cleaning needed to meet warranty cleanliness requirements, and

3. Minimize the introduction of debris into the systems.

This document is not intended to be comprehensive statement of equipment / piping preservation and pro-
tection techniques, or of all cleaning methods. The entity responsible for assembly of the equipment and
interconnecting piping is not restricted to the methods contained herein as long as it can be demonstrated
that the system meets warranty cleanliness requirements.

III. BACKGROUND

Traditionally, most gas fuel piping systems for gas turbines have been cleaned using the readily available
natural gas (or other gas fuel) supply to “blow” the debris from the piping. The practice has been shown
to be very effective as long as the Cleaning Force Ratio (CFR) is sufficient. The principle behind CFR
is to achieve a flow velocity in the piping that is significantly higher than the maximum expected under

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GE Energy recommendations GEK 116771

operating conditions. The theory being any debris not moved by the higher velocity will remain in place
under normal service conditions.

Although the use of “gas blows” for pipe cleaning has been an effective and widespread practice, recent
events have highlighted the extreme danger of the practice. In the United States, there have been three
instances of gas ignition during a gas blow in the past ten years:

1. In October of 2001, a unit at the FirstEnergy power generation station in Lorain, Ohio was being
commissioned and the fuel gas piping leading to the turbine was initially cleaned through the use of
an air blows and pigging. For the final cleaning, a high-pressure natural gas blow was planned. The
gas was released through a three-foot vertical stack installed to serve as the fuel gas outlet during the
blow. The gas ignited shortly after the start of the blow causing a flame to shoot approximately 30 to
40 feet from the stack outlet. The gas flow was immediately shut off and the fire extinguished. There
were no injuries, but there was fire damage to nearby electrical cables. Although the ignition source
was not positively identified, the investigators felt the most likely scenario was a metal particle exiting
the piping during the blow struck a nearby metal surface causing a spark.1

2. On January 26, 2003, a natural gas blow was being conducted at Calpine’s Wolfskill Energy Center
natural gas power plant in Fairfield, California (see Figure 1). High-pressure natural gas was being
vented through a four-inch diameter pipe directly to the atmosphere to flush out debris. The discharge
was in a congested area approximately 10 feet from the turbine building that also had an overhanging
filter house inlet. The explosion resulted in substantial damage to the facility proper and shattered win-
dows a quarter mile away. Fortunately, here were no injuries resulting from the explosion. The Calpine
mishap report suggested the gas was ignited by static electricity from the gas flow itself. The Calpine
report, when discussing the cause factors discussed the fact that safer alternative cleaning methods were
not used. The Calpine report specifically stated “Use of natural gas is convenient, but certainly is not
the only method for cleaning the pipes. Other Calpine facilities do not allow the use of natural gas for
such purposes and instead use compressed air.”2

3. On February 7, 2010, six workers were killed and at least 50 other workers were injured at the
Kleen Energy power plant project in Middletown, Connecticut when natural gas being released by a
gas blow operation was ignited and exploded. A US Chemical Safety and Hazard Investigation Board
(CSB) investigation team was mobilized to the site and provided a detailed report of the mishap. In
their report, the CSB points to the fact that a very large quantity of gas was released in a congested
(scaffolding, building structure, etc.) location, that the release direction was horizontal, and the gas was
released into an area that was closed in on three sides; the turbine hall to the south and the two Heat
Recovery Steam Boilers (HRSGs) on either side (east and west) (see Figure 2). Although the area of
the HRSGs and locations to the north were evacuated of workers, the building itself was occupied and
there was ongoing “hot work” (welding). Additionally, there were a number of diesel-fueled heaters
in operation at the time. The CSB was not able to definitively identify the ignition source. The force
of the explosion caused extensive damage to the power plant.3

1US Chemical Safety and Hazard Investigation Board (CSB) Urgent recommendations issued 28 June 2010. http://www.csb.gov/UserFiles/file/FINAL%20Ur-
gent%20Recommendation.pdf.
2Ibid
3Ibid

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GEK 116771 GE Energy recommendations

Figure 1. Calpine Wolfskill Energy Center “Gas Blow”

Figure 2. Kleen Energy “Gas Blow”, 7 February 2010

The CSB made a number of very significant recommendations in their final report that were directed to
several organizations. The message from these recommendations is very clear; the release of quantities of
flammable gas into the atmosphere is an inherently dangerous activity that should no longer be allowed.4

4Ibid

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GE Energy recommendations GEK 116771

IV. THE GE ENERGY POSITION

In reviewing the circumstances of the mishaps associated with gas blows and the February 25th public
statement of the CSB Lead Investigator5 , it became clear that additional guidance regarding gas blows was
necessary. Given the dangers highlighted by the mishap history, GE Energy considers the use of a gas blow
to clean piping as the method of last resort. Alternate cleaning methods should be reviewed and a selec-
tion made from the alternatives considering the specific circumstances presented by each installation. GE
Energy strongly discourages the use of gas blows for cleaning of piping and does not foresee any scenario
in which all of the alternate cleaning methods will be shown to be not feasible.

Consistent with the above position, GE Energy has adopted a policy that states no GE employees will
remain on a plant site where a gas blow is being conducted.

V. CONSIDERATIONS FOR ALTERNATIVE CLEANING METHODS

The following cleaning methods are those that GE Energy believes are the most common. This list is NOT
all encompassing and the contractor is free to choose any cleaning method that will achieve the necessary
level of cleanliness, and meet all local and regional regulatory restrictions. It is the responsibility of the
entity installing and commissioning of the piping system to assess the available options and determine
the most cost effective approach for the specific circumstances at the site. There are many companies
offering “pipeline cleaning services”; these are readily found via Internet search. The GE Oil & Gas
business has experience in this activity. GE urges the installation and commissioning contractor to
avail itself of the expertise these companies have in determining the cleaning methods available and
assessing the potential effectiveness thereof.

A. Pneumatic Blows, Air, Nitrogen and Steam

In order to effectively clean gas lines prior to plant start up GE recommends following the same pro-
cedure commonly used to clean steam lines.

The procedure involves developing process conditions within the piping system based on a momentum
ratio greater than one. The momentum or cleaning force ratio compares the mass velocity head during
cleaning with that developed during plant operation at maximum flow conditions.

A momentum ratio greater than one ensures that the mass velocity during cleaning is greater than that
developed at the maximum flow conditions during operation. The intent is to remove any debris or
particulate matter which might dislodge during normal operation.

The cleaning force ratio is calculated by taking the mass flow squared times the specific volume of
the gas at design conditions, that value is the denominator in the equation. Similarly the numerator is
determined by adjusting the mass flow and specific volume during blow conditions so that the ratio of
numerator divided by the denominator is greater than one.

This approach is represented by the following formula:

M(blow)2 X V(blow)
CFR =
M(Ref)2 X V(Ref)

5Statementof CSB Investigations Supervisor Don Holmstrom Updating the Public on the CSB’s Investigation of the Catastrophic Accident at Kleen energy,
Middletown, Connecticut, http://www.csb.gov/assets/news/document/CSB_statement_2_25_2010.pdf.

© General Electric Company, 2010. GE Proprietary Information. All Rights Reserved. 7

GEK 116771 GE Energy recommendations

Where:

• CFR = Cleaning Force ratio

• M(blow) = Actual mass flow during blow (lbs / hr)

• V(blow) = Specific volume during blow (ft³ / lb)

• M(Ref) = Reference design mass flow (lbs / hr) – maximum design operating conditions

• V(Ref) = Reference design specific volume (ft³ / lb) – maximum design operating conditions

The flow from either the continuous blow or the blow-down method must achieve a minimum CFR
of. 1.2. Exceeding this CFR should not be necessary to achieve the cleanliness goal and only serves to
increase the complexity and cost of the cleaning activity

The options for the air or nitrogen source are:

• A portable air compressor combined with a pressure vessel volume tank with adequate
ports/nozzles and fast acting valves. Just pressurizing the piping and releasing only creates
adequate CFR at the vent to atmosphere end of the piping. Thus, a volume tank that can create the
correct CFR the whole length of piping is key.

• Large air compressors (several ganged together if needed) can provide sufficient air for a con-
tinuous flow, mostly applicable to smaller pipe sizes.

• At least one service company offers a high volume nitrogen capacity that provides a near con-
tinuous source of gas.

• A rack of bottles or a high-pressure tube trailer can provide adequate volume for “blow down”
events, which are repeated until an adequate cleanliness has been achieved.

• A properly sized compressor provides for a reasonable recharge cycle when air is used.

• If the plant has a fired boiler of sufficient capacity, steam can also be used as a blowing media.

Following any of these cleaning methods, the piping must be checked for residual moisture. This is
particularly important for carbon steel piping. A flow of heated dry air or pulling a vacuum on the
piping should reduce residual moisture in the piping to an acceptable level.

CAUTION

If Nitrogen is used, indoor areas where system leaks can reduce the oxygen con-
tent and the area surrounding the gas release point must be monitored for oxygen
content. A reduction in oxygen is the basis for aborting the blow. The Gas release
point should be located outdoors.

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GE Energy recommendations GEK 116771

CAUTION

If Steam is used for cleaning, the surface temperature of piping and other equip-
ment in the flow path will be elevated above safe limits. The area around the piping
and equipment must be cordoned off and personnel prohibited from access until
the piping and equipment has cooled to below 140ºF (60ºC).

B. Pipeline Pigging

Where the piping is a constant diameter, pipeline pigs can be used for cleaning with some limitations
that must be considered during the plant design effort. This is almost always used for the piping up to
the site’s connection point. The onsite piping often is not configured to be “pig friendly”. However,
this is a paradigm shift that would expand the use of pigging methods.

• Bends in the piping must be of sufficient radius to allow the pigs to negotiate the directional
change.

• The pig requires entrance and exit points. Cleaning the piping from one flange connection point
to the next during construction is a cost advantaged option to providing “traps” for insertion and
removal of the pig. Piping so cleaned must be protected from intrusion of contaminants if not
immediately installed in the system.

If the piping is sequentially cleaned then verified clean as it is assembled, the completed assembly will
be clean.

C. High-pressure water jet flushing

Other methods that have recently been used for cleaning steam cycle piping with good results can also
be considered for gas line cleaning.

One approach is the use of high pressure/velocity water spray followed by a borescope inspection.

Another approach uses a combination of high-pressure water mixed with a detergent to provide a high
volumetric flowrate through the piping system. This high volumetric flowrate produces CFR's well in
excess of one. However, this is often not practical for below grade piping that will not drain. If this
method is planned for properly the drains may be installed at low points below grade and vented to a
point above grade for separate blowdowns.

As for the case of using steam to clean the piping, thorough drying, especially for carbon steel piping
is required immediately following the cleaning.

D. Routing Gas to a Flare System

Recall that the recurring theme of the CSB recommendations is to avoid releasing raw gas to the at-
mosphere. The use of a flare stack to safely burn gas used as a cleaning medium is a potential option
when weighing the cost of the various alternatives.

• The use of a diffuser reduces the velocity and pressure to values that may permit the use of low
cost plastic or composite pipe to route the gas to the flare location.

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GEK 116771 GE Energy recommendations

• Thermal radiation must be considered when designing the flare and establishing the flare loca-
tion.

CAUTION

Thermal radiation from a flare stack can exceed exposure limits for unprotected
skin. The thermal limit radius must be calculated and the safe approach limit
marked to assure all personnel avoid the area of unacceptable exposure.

There are many companies that specialize in the design of flare systems that can be found via Internet
search on “flare stack design”.

VI. START WITH CLEAN COMPONENTS TO REDUCE THE FIELD CLEANING EFFORT

The task of cleaning the piping and components during the commissioning phase can be minimized if the
hardware is delivered clean from the suppliers and kept clean through a disciplined environmental pro-
tection approach. Equipment supplied by GE Energy is provided in a warranty compliant clean condition
with protective covers on all openings. Orders for equipment and materials should specify the cleanliness,
contamination protection and preservation requirements needed to minimize the on site cleaning efforts.

VII. CLEAN AS YOU GO

As each section of field-routed piping is completed, it should be detail cleaned and certified. Cleaning can
be by hand or, where the size or geometry precludes access to all areas by hand, with any other method the
fabricator wishes to employ. Once cleaned, proper covers should be placed on the piping ends to preclude
contamination if the piping section is not immediately installed in the system.

VIII. FINAL CLEANING AND VERIFICATION

With the individual components comprising the gas fuel system having been cleaned in detail, full system
cleaning after assembly will be minimized. If the detail cleaning was sufficient, the final step will consist of
a cleanliness verification ONLY as the first step. If the system fails to pass cleanliness, full system cleaning
cycles will be needed to bring the debris / contamination levels to within specifications.

Achieving the proper system cleanliness is an essential part of achieving full equipment life and minimizing
operational anomalies. The following GE Energy documents are typically provided for each project defin-
ing specific gas fuel cleanliness requirements and / or methods for overall system cleanliness validation:

• GEI 41040, Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines.

• GEK 110483, Cleanliness requirements for Power Plant Installation, Commissioning, and Mainte-
nance.

• MID-TD-000-1-2009, Process Specification, Fuel Gases For Combustion In Aeroderivative Gas

Turbines.

Although written for cleaning of steam piping, the following documents may also be of use:

• GER 3636, Experience with Compressed Air Cleaning of Main Steam Piping.

• GEK 41745, Cleaning of Main Steam Piping for Combined Cycle Plants.

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GE Energy recommendations GEK 116771

• GEI 69688 Cleaning of Main Steam Piping and Provisions for Hydrostatic Testing of Reheater.

Additional references are contained within these documents and documents specific to any given instal-
lation my also be applicable. To obtain copies of these and other reference documents, or if you have
questions regarding the contents, of any GE Document please contact your GE Energy Technical Advisor,
Project Manager, Service Manager or Contract Performance Manager (CPM).

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GEK 116771 GE Energy recommendations

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