Doc. Ref.: MM-YAD-36-SOLA-028010
CTR Reference: NA
ES9-62
Phase: DE
System / Subsystem: 31
Equipment Type: DT
Status: IFI
Revision: 00
Rev Date: 30 Oct 2014
Discipline: CMG
Document Type: PRC
Class: 3
Page 1 of 10
BADAMYAR PROJECT
Ingestive Cleaning of Solar Gas Turbines
Rev.
Stat.
Date
00
IFR
30-Oct-2014
Revision memo
Issue for Review
Issued by
Checked by
Approved by
YH
KD
OE
SPECIFICATION
INGESTIVE CLEANING SOLAR TURBINE ENGINES
Data
Control
Level
1
SPECIFICATION NO. ES 9-62
ISSUED: 04-10-02; ERL 0716-1
(Date and PRD No.)
REVISION:
(Letter, Date and PRD/CR No.)
A; 10/10/78; EL 2336-1
B; 6/7/82; ERL 5459-1
C; 11/8/85; ERL 8100-3
D; 3/28/88; ERL 9707-1
E; 5/11/89; ERL 9348-5
F; 2/2/90; ERL 0164-1
Release
Stamp
Rev. Ltr/
G; 5/29/92; ERL 10236-1
H; 11/29/94; ERL 11248-1
J; 7/8/98; PRD13562-1
K; 04-10-02; PRD14714-1
L; 06/20/02; CR01511
M; 08/28/06; CR14043
CR#
Prepared By:
P
18323
Approved By:
Signature & Title
Date
Boe Lotton
10-10-07
Fred Koetter
ATTENTION
This copyrighted work and the information herein is proprietary to Caterpillar Inc., Solar
Turbines Incorporated, and/or subsidiaries of either. Without express, written proprietor
permission, any copying, disclosure, or use except that for which it is loaned, is prohibited.
Caterpillar: Confidential Green
Specification No. ES 9-62P
CONTENTS
Paragraph
1.0
Page
SCOPE
1
1.1
1.2
1.3
1
1
1
Purpose
Cleaning Procedures
Cleaning Solutions
2.0
DEFINITIONS
1
3.0
APPLICABLE DOCUMENTS
1
3.1
Specifications
2
GENERAL REQUIREMENTS
2
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
2
2
3
3
4
4.0
5.0
On-Crank Vs. On-Line Cleaning
Intervals Between Engine Cleaning
Cleaning Procedures
Cleaning Equipment
Ambient Temperature During Engine Cleaning
Engine Temperature During Engine Cleaning
Recuperated Cycle Applications
Flow Requirements
4
4
CLEANING PRODUCT
6
5.1
5.2
5.3
5.4
6
6
7
7
Water
Cleaning Product Composition [& Mix Ratios]
Emulsified Kerosene/Water Solutions
Abrasive Cleaners
TABLES
Page
Table
1
On-Crank Requirements for Water/Freeze Point Depressant Mix, Volume Ratio
In Cold Ambient Temperatures
4
2
On-Crank Cleaning Solution and Rinse Water Flow Requirements
5
3
On-Line Cleaning Solution and Rinse Water Flow Requirements
5
4
Solar Cleaning Solutions for On-Line and On-Crank Cleaning
6
ii
Specification No. ES 9-62P
1.0
SCOPE
1.1
PURPOSE - This specification establishes technical requirements for removing
contamination in the compressor air path of Solar turbine engines by ingestive cleaning.
1.2
CLEANING PROCEDURES - The requirements defined herein serve as a basis for
establishing proper cleaning procedures such that surface contamination in the compressor air
path can be removed without damage to the engine. Details of the cleaning methods, cleaning
instructions and suitable equipment for each engine model are not a part of this document as
they are provided in the Operation and Maintenance Instruction (OMI) manual and in Solar's
Service Bulletins.
1.3
CLEANING PRODUCTS - This specification provides the standards for product
acceptance to ensure that the cleaning product(s) used are not harmful to the materials of
construction.
2.0
DEFINITIONS
2.1
FREEZE POINT DEPRESSANT– Material used to depress the freezing point of the
cleaning product.
2.2
CLEANING EQUIPMENT - Accessory equipment used to properly introduce a cleaning
product (not solid cleaners) into the air inlet.
2.3
CLEANING MODE - The mode of operation of the engine (on-crank or on-line) while
cleaning is performed.
2.4
CLEANING PRODUCT – A chemical solution that is introduced into the air inlet for the
purpose of ingestive cleaning of the engine.
2.5
CLEANING SOLUTION – A detergent and/or solvent material that is mixed with water to
produce the cleaning product.
2.6
CLEANING SYSTEM - An appropriate combination of cleaning product, cleaning
procedure and cleaning equipment to be used for a particular engine model.
2.7
DETERGENT – Cleaning solution that liberates contamination by surface interaction
(surfactant).
2.8
INGESTIVE CLEANING - Engine compressor cleaning where cleaning product is
introduced through the air inlet.
2.9
ON-CRANK - Engine operation at maximum speed obtainable on starter alone with fuel
and ignition deactivated.
2.10 ON-LINE - Engine fired and operating at any power level ranging from idle (no load) to
full rated power and load.
2.11 SOLVENT – Cleaning solution that dissolves contamination through reaction at
molecular bonds.
3.0
APPLICABLE DOCUMENTS
1
Specification No. ES 9-62P
3.1
SPECIFICATIONS - The following documents of the latest issue in effect on the release
date of this specification form a part of this specification to the extent specified herein.
Solar
ES 9-98
Fuel, Air and Water (or Steam) for Solar Gas Turbine Engines
Military
MIL-D-16791
MIL-F-16884
MIL-E-9500
Detergents, General Purpose (Liquid, Nonionaic)
Fuel Oil, Diesel, Marine
Ethylene Glycol, Technical
American Society for Testing Materials
ASTM D482
Standard Test Method for Ash from Petroleum Products
ASTM D512
Chloride Ion in Water and Waste Water, Test for
ASTM D770
Standard Specification for Isopropyl Alcohol
ASTM D857
Standard Test Methods for Aluminum in Water
ASTM D858
Standard Test Methods for Manganese in Water
ASTM D1068
Standard Test Methods for Iron in Water
ASTM D1293
pH of Water, Test for
ASTM D1428
Sodium and Potassium in Water and Water-Formed Deposits by
Flame Photometry, Tests for
ASTM D1688
Standard Test Methods for Copper in Water
ASTM D1888
Particulate and Dissolved Matter, Solids, or Residue in Water
ASTM D2699
Standard Specification for Kerosene
4.0
GENERAL REQUIREMENTS
4.1
ON-CRANK VERSUS ON-LINE CLEANING - In general, on-crank cleaning tends to be
more effective to remove deposits in the compressor air path. On-line cleaning may be
performed in between on-crank cleaning cycles to extend time between on-crank cleaning and
to minimize further deposition onto cleaned airfoils. Because the engine is firing during on-line
cleaning, the cleaning liquid (either water or cleaning solution) ingested must meet the more
stringent requirements defined in this specification to minimize introduction of corrosive/fouling
contaminants.
4.2
INTERVALS BETWEEN ENGINE CLEANING – Appropriate intervals for both on-crank
and on-line cleaning should be determined by recording and trending engine performance
degradation. Cost of the maintenance outage versus that of continued operation with
compromised performance must also be considered. However, one should not delay cleaning
so long that contamination becomes impossible to remove completely by on-crank cleaning. Oncrank cleaning is recommended at maximum intervals of every 4,000 hours of operation, and
before full load power degrades more than 5%. For two shaft turbines operating at full load on
T5 topping this typically corresponds to a 2.5% drop in Pcd. For two shaft turbines operating at
full load on Ngp topping, degree of compressor fouling is more difficult to quantify. As the
compressor fouls, T5 will increase with little change in power or Pcd until T5 topping is
achieved.
On-line cleaning intervals should be determined by observing the effectiveness in restoring
performance. On-line cleaning is best suited to remove the initial buildup of contamination from
already clean airfoils. If the airfoils become significantly fouled between on-line cleaning
intervals, cleaning will be less effective. Initial on-line cleaning interval should be at most 48
hours of operation. Performance should then be evaluated to determine the effect of each
2
Specification No. ES 9-62P
cleaning operation, and overall rate of performance degradation. After completing an on-crank
cleaning, the on-line cleaning interval can be increased to 72 hours of operation. If no significant
difference in on-line cleaning effectiveness is observed, the interval may be increased again by
24 hours. Typically, the maximum interval for an effective on-line cleaning program is no more
than 96 hours of operation.
Recommended minimum intervals between cleaning operations to avoid excessive ingress of
cleaning product into the oil system are:
On-Crank Cleaning - at least 96 operating hours between each on-crank cleaning cycle
On-Line Cleaning - at least 24 operating hours between each on-line cleaning cycle
4.3
CLEANING PROCEDURES - Detailed cleaning procedures are described in the
Operation and Maintenance Instruction (OMI) manual provided with each package. An outline
of typical procedures are provided here:
On-Crank:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Shut down turbine normally
Cool until turbine case temperature at compressor to diffuser flange is less than 66C
(150F)
Open air inlet access covers
Open air inlet drain port
Disconnect and isolate Pcd, buffer air and air sensing lines at connection points to
compressor or diffuser
Disconnect combustor, torch and exhaust drain lines
Prepare cleaning product and cleaning equipment
Crank turbine on the starter motor and allow speed to stabilize
Apply cleaning product
Stop turbine and allow cleaning product to soak for a period of 20 minutes
Crank turbine on the starter motor and allow speed to stabilize
Apply rinse water
Verify that rinse water exiting from drains is clean, indicating that compressor cleaning
was effective and repeat cleaning operation as necessary
Continue crank for 5-10 minutes after rinse water is consumed
Stop turbine
Inspect inlet housing and compressor inlet to verify cleanliness
Reassemble and reconnect all components and lines
Restart turbine and operate for at least one hour to evaporate remaining rinse water
On-Line:
•
•
•
•
•
Verify that unit is operating normally with steady load and speed
Prepare cleaning product and cleaning equipment
Apply cleaning product
Apply rinse water
Isolate cleaning equipment
4.4
CLEANING EQUIPMENT - Use of cleaning equipment designed specifically for each
turbine model is important to ensure that adequate and uniform atomization occurs at the
3
Specification No. ES 9-62P
compressor inlet. This is particularly important for on-line cleaning to avoid overloading of
airfoils that can result from non-uniform distribution or excessively large liquid droplets. Use of
inappropriate equipment may result in compressor damage.
Cleaning product is introduced to the turbine inlet through manifolds and nozzles mounted
directly to the turbine inlet duct, with separate systems for either on-crank or on-line cleaning.
Cleaning product can also be introduced manually using a hand held sprayer wand, but only for
the on-crank cleaning procedure. With either application method, cleaning product volume and
flow rates must comply with the requirements defined in Section 4.8 of this specification.
4.5
AMBIENT TEMPERATURE DURING ENGINE CLEANING – On-line engine cleaning is
permitted only at ambient temperatures above 4°C (39°F).
On-crank engine cleaning is permitted only at ambient temperatures above -20°C (-4°F). When
the ambient temperature is between -20°C (-4°F) and 4°C (39°F), a mixture of water and freeze
point depressant must be used for on-crank cleaning. The ratio of the water/freeze point
depressant mix depends upon the type of freeze point depressant used, and recommended
ratios are listed in Table 1. In order to be effective, the solution must be well mixed immediately
prior to use.
Table 1. On-Crank Requirements for Water/Freeze Point Depressant
Mix Volume Ratio in Cold Ambient Temperatures
Ambient Temperature
Freeze Point
Depressant
Volume Ratio
Freeze Point Depressant :
Water
-20°C(-4°F) to 4°C(39°F)
Methanol
2:3
-20°C(-4°F) to 4°C(39°F)
Mono-ethylene Glycol
2:3
-10°C(14°F) to 4°C(39°F)
Isopropyl Alcohol
1:1
4.6
ENGINE TEMPERATURE DURING ENGINE CLEANING - Prior to on-crank cleaning,
the engine casing surface temperature, measured at the compressor to diffuser flange shall not
exceed 65°C (150°F).
4.7
RECUPERATED CYCLE APPLICATIONS - Water and/or cleaning solutions are not
permitted in recuperators except for Harrison and GEA models. For all other recuperator
models, on-crank cleaning must be performed at a reduced crank speed of 800 - 900rpm to
avoid depositing cleaning refuse in the recuperator. In addition, a "low-foam" cleaning solution
or anti-foaming agent must be used to ensure that cleaning products do not enter the
recuperator. On-line cleaning is not permitted for any recuperated units.
4.8
FLOW REQUIREMENTS - Tables 2 and 3 list the total volume of fluid and flow rate
required for on-crank and on-line cleaning for each model turbine.
4
Specification No. ES 9-62P
Table 2. On-Crank Cleaning Solution and Rinse Water Flow Requirements
Product
Family
On-Crank Cleaning
Product Volume
On-Crank Rinse
Water Volume
On-Crank Flow Rate
[FOR CLEANING OR RINSE]
Titan 130
75.7 – 94.6 liters
(20-25 Gallons)
94.6 – 189.3 liters
(25-50 Gallons)
17 to 20.8 liter/min
(4.5 to 5.5 gpm)
56.8 – 75.7 liters
(15-20 Gallons)
56.8 – 75.7 liters
(15-20 Gallons)
45.4 – 64.3 liters
(12-17 Gallons)
45.4 – 64.3 liters
(12-17 Gallons)
30.3 – 37.9 liters
(8-10 Gallons)
56.8 – 75.7 liters
(15-20 Gallons)
75.7 – 151.4 liters
(20-40 Gallons)
75.7 – 151.4 liters
(20-40 Gallons)
64.4 – 128.7 liters
(17-34 Gallons)
64.4 – 128.7 liters
(17-34 Gallons)
37.9 – 75.7 liters
(10-20 Gallons)
75.7 – 94.6 liters
(20-25 Gallons)
11.4 to 15.1 liter/min
(4 to 5 gpm)
7.5 to 11.3 liter/min
(4 to 5 gpm)
9.1 to 12.9 liter/min
(2.4 to 3.4 gpm)
9.1 to 12.9 liter/min
(2.4 to 3.4 gpm)
5.7 to 9.5 liter/min
(1.5 to 2.5 gpm)
6.8 to 7.6 liter/min
(1.8 to 2.0 gpm)
Mars
90/100
Taurus
65/70
Taurus
60
Centaur
40/50
Saturn
10/20
Mercury
50
Table 3. On-Line Cleaning Solution and Rinse Water Flow Requirements
Product
Family
Titan 130
Mars 90/100
Taurus
65/70
Taurus 60
Centaur
40/50
Saturn
10/20
Mercury 50
On-Line
Cleaning Product
Volume
On-Line
Rinse Water
Volume
[FOR CLEANING OR
RINSE]
75.7 – 94.6 liters
(20-25 Gallons)
94.6 – 189.3 liters
(25-50 Gallons)
11.4 to 13.6 liter/min
(3 to 3.6 gpm)
56.8 – 75.7 liters
(15-20 Gallons)
56.8 – 75.7 liters
(15-20 Gallons)
45.4 – 64.3 liters
(12-17 Gallons)
45.4 – 64.3 liters
(12-17 Gallons)
30.3 – 37.9 liters
(8-10 Gallons)
N/A
75.7 – 151.4 liters
(20-40 Gallons)
75.7 – 151.4 liters
(20-40 Gallons)
64.4 – 128.7 liters
(17-34 Gallons)
64.4 – 128.7 liters
(17-34 Gallons)
37.9 – 75.7 liters
(10-20 Gallons)
N/A
8.3 to 10.6 liter/min
(2.2 to 2.8 gpm)
5.3 to 7.6 liter/min
(1.4 to 2 gpm)
2.3 to 4.5 liter/min
(0.6 to 1.2 gpm)
2.3 to 4.5 liter/min
(0.6 to 1.2 gpm)
1.5 to 3.8 liter/min
(0.4 to 1 gpm)
N/A
5
On-Line Flow Rate
Specification No. ES 9-62P
5.0
CLEANING PRODUCT
5.1
WATER - Water to be used for ingestive cleaning (or rinsing) of any Solar turbine engine
shall comply with the requirements set forth in ES 9-98.
5.2
CLEANING PRODUCT COMPOSITION AND PHYSICAL PROPERTIES – Composition
and physical properties of cleaning products must comply with the limits defined in ES 9-98.
Failure to comply with these limits can cause corrosive attack and/or other harmful effects
resulting in rapid engine deterioration. When the cleaning product consists of a mixture of
cleaning solution concentrate and water, the limits in ES 9-98 apply to the resulting cleaning
product.
Solar offers various cleaning solutions that when properly mixed as a cleaning product, comply
with both on-crank and on-line requirements of ES 9-98. These are available through the Solar
Service Parts support network and part numbers are listed in Table 4. Three different types of
cleaning solutions are available, each in either concentrate or ready mixed solutions:
Table 4. Solar Cleaning Solutions for On-Line and On-Crank Cleaning
SOLAR PRODUCT NAME
Solar Gas Turbine Cleaner No. 1
(Petroleum Solvent Based)
Concentrate
Solar Gas Turbine Cleaner No. 1
(Petroleum Solvent Based)
Ready-To-Use
Solar Gas Turbine Cleaner No. 2
(Natural Solvent Water Based)
Concentrate
Solar Gas Turbine Cleaner No. 2
(Natural Solvent Water Based)
Ready-To-Use
Solar Gas Turbine Cleaner No. 3
(Non-Solvent Water Based)
Concentrate
Solar Gas Turbine Cleaner No. 3
(Non-Solvent Water Based)
Ready-To-Use
SOLAR P/N
P/N 701690C2 (6.5 gal)
P/N 701691C2 (55 gal)
P/N 701696C2 (6.5 gal)
P/N 701697C2 (55 gal)
P/N 701688C2 (6.5 gal)
P/N 701689C2 (55 gal)
P/N 701694C2 (6.5 gal)
P/N 701695C2 (55 gal)
P/N 1011634 (6.5 gal)
P/N 1011635 (55 gal)
P/N 1011636 (6.5 gal)
P/N 1011637 (55 gal)
Maximum Strength
Volume Ratio
(Water:Cleaning Solution)
4:1
Full Strength
4:1
Full Strength
4:1
Full Strength
5.2.1 Solar Gas Turbine Cleaner No. 1 – Petroleum solvent based solution is the most
effective type for cleaning oil and Carbon based fouling. However, local environmental
regulations may require special treatment of the waste from on-crank cleaning. Disposal is not
typically a consideration for on-line cleaning because the cleaning product is combusted
completely in the turbine.
5.2.2 Solar Gas Turbine Cleaner No. 2 - This biodegradable type of solution is formulated with
natural solvents and detergents and is generally less effective than petroleum based solutions.
6
Specification No. ES 9-62P
Warming the solution to approximately 30°C (86°F) and allowing longer soak time can improve
effectiveness.
5.2.3 Solar Gas Turbine Cleaner No. 3 – This biodegradable type of solution is formulated with
natural detergents and is generally less effective than solutions containing solvents. Warming
the solution to approximately 30°C (86°F) and allowing longer soak time can improve
effectiveness.
5.3
EMULSIFIED KEROSENE/WATER SOLUTIONS - An emulsified mixture of kerosene
and water or diesel fuel and water may be used for on-crank cleaning only. This mixture is
formulated by mixing diesel fuel per MIL-F-16884 and water with an emulsifier per MIL-D-16791
(Type II) such that a homogenous, sprayable solution is formed and conforms to the
requirements of ES9-62 and ES9-98. Other types of emulsifiers may be used, but they must
meet the requirements of ES9-62 and ES9-98.
5.4
ABRASIVE CLEANING – Abrasive cleaners, such as Carboblast, walnut shells, pecan
shells or rice, are not recommended for use in Solar’s gas turbines. Use of abrasive cleaners
can cause plugging of cooling air passages in nozzles and blades, resulting in loss of cooling air
and thermal degradation of the component. Abrasive cleaners may also have a detrimental
effect on compressor coating.
7