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TITOLO - TITLE
Operation and Maintenance Recommendation for Gas turbine

Inlet Systems
COMM. - JOB
ITEM
AGGIUNTA LINGUA ITALIANA
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REV
DESCRIZIONE - DESCRIPTION
2002 Nuovo Pignone S.p.A., all rights reserved
GDS
Laneri R.
01/10/09
Marchetti Bartolozzi. S Marchett 01/06/07
PREP'D
CONT-CHK'D
Lascialfari G.
APP- APPR'D
N. SOM 6664411/4
DATA - DATE
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SOSTITUITO DA - REPLACED BY
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INDEX
1 Introduction
2 Background
3 Gas Turbine Air Filtration Systems
3.1 Self-cleaning Air Filtration Systems
3.2 Low Velocity Static Barrier Air filtration Systems
3.3 High Velocity Static Barrier Air Filtration Systems
4 Filter Elements
4.1 Filter Elements Storage and handling
4.2 When to service Filter Elements
4.3 Source the most appropriate Filter Elements
4.4 Filter Elements Maintenance
4.4.1 Barrier Filter Elements
4.4.2 Self-cleaning Filter Cartridges
4.4.2.1 Life of the self-cleaning filter cartridges
4.4.2.2 Filter cartridge installation on a vertical flow self-cleaning Air
Filtration System
4.4.2.3 Filter cartridge installation on a horizontal flow self-cleaning
Air Filtration System
5 Gas Turbine Inlet System Installation, operation and Maintenance Requirements
5.1 Droplet Catchers
5.2 Demister
5.3 Gasketting
5.4 Inlet System Commissioning
5.4.1 Cleaning
5.4.1.1 Air/water cleaning of the clean air plenum
5.4.1.2 Paint touch-ups in the clean air plenum
5.4.1.3 Vacuum cleaning of the clean air plenum
5.4.1.4 Fine water cleaning on the clean air plenum
5.5 Inlet System Operation
5.6 Air Filtration System Maintenance
5.7 Inlet Duct System Maintenance
6 Maintenance Procedures
6.1 General Safety Prescriptions
6.2 Gasket Seal Repair
6.2.1 Light test
6.2.2 Water Spray Test
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6.3 Paint Repair

6.4 Field Welding
6.4.1 Weld Crack Indication Repair on Acoustical Lining
6.4.2 Weld Crack Indication Repair on Non-Acoustical Lining and Structural
Components
6.5 Corrosion Repair
6.5.1 Corrosion repair for Acoustical lining
6.5.2 Corrosion repair for Non-Acoustical Lining and Structural Components
ATTACHMENT 1
Maintenance Check List
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1 INTRODUCTION
Gas turbines manufactured by General Electric Company are operating successfully in rural areas
and heavy industrial zones, in Polar Regions and the tropics, in deserts and in coastal or offshore
installations.
In order to adapt machines to a variety of environments while realizing their full potential in
performance and reliability, it is necessary to treat the air that they consume.
Even in relatively clean environments, a gas turbine may ingest hundreds of kilograms of foreign
matter each year.
Whether or not this will cause a problem depends on the amount of this material, its physical
properties, and its chemical composition.
Trouble free operation of the Gas Turbine Filtration and Inlet Systems is based on a sound
operational and maintenance program comprising preventive maintenance scheduled and carried out
on a periodic basis.
In the extreme case, the misoperation and/or incorrect installation of the gas turbine inlet system can
result in severe contamination of the gas turbine and have extremely serious consequences in terms
of forced outage time needed for maintenance, repair, and replacement of gas path components.
Therefore, it is critical that the inlet system be installed and maintained properly, with no leaks or
bypasses into the clean air section.
This document is intended to provide the gas turbine operator with general guidelines and
suggestions to ensure proper operation and maintenance of the gas turbine inlet system.
The procedures defined in this document will help to detect malfunctions and determine their causes
and corrective maintenance procedures, too.
The periodic inspection outlined in the following sections enables an early observation of wear and
other defects, which when rectified will maintain the equipment to the required operating condition.
This document is not intended to replace the informations provided as part of the Gas Turbine
Operation and Maintenance (O&M) Manual. Should any conflict arise between this document and the
O&M Manual please contact the local GE representatives for resolution.
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2 BACKGROUND
Air quality can have an enormous impact on gas turbine performance and reliability and is heavily
influenced by the surrounding environment in which the unit is installed.
Furthermore, within any given location, the quality of air can change dramatically over a years time
or, in some situations, within hours.
The entire purpose of cleaning the combustion air of a gas turbine is to prevent damaging
contaminants and performance inhibiting materials from reaching the component parts of the gas
turbine.
Poor air quality may lead to compressor fouling or compressor erosion as well as corrosion and
cooling passages blockage in the hot parts of the gas turbine:
Coarse (large) particles of airborne dust that have substantial mass and hardness can cause
erosion of the rotating parts of the machine (see picture below) and premature wear or
component failure.
These particles are generally above 5 to 10 m in size and are easily caught even by low to
medium efficiency filters installed in a properly operating filtration system.
Compressor erosion may lead to Gas Turbine catastrophic fault if not early detected.
Some contaminants can react with moisture or other chemicals in the air and/or fuel to form
compounds that can corrode component parts and shorten their normal life.
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Finally, very small particulate, often well below 1 m, can build up a coating on compressor
blades (compressor fouling) and cooling passages and so spoil the efficiency and reduce the
output of the gas turbine.
Environmental conditions play a major role in the selection and design of the inlet filtration system
and its subsequent performance.
Desert regions with high dust concentration and coastal regions with high humidity and airborne salt,
produce two of the extreme conditions that have to be taken into account when designing the air inlet
compartment.
Three different main types of Air Filtration Systems are provided on GEO&G Gas Turbines:
Self-cleaning Systems
Low velocity Static Barrier Systems
High Velocity Systems for Off-shore installations
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3 GAS TURBINE AIR FILTRATION SYSTEMS

3.1 Self-cleaning Air Filtration Systems
The major difference between a static (barrier) and a pulse (self-cleaning) Air Filtration System is that
a self-cleaning system is capable of automatically cleaning the filter elements via a reverse pulse of
air. This extends the overall life of the filter element (the actual extension being a function of site
contaminants and environmental conditions).
Dust in the air is trapped on the surface of the filter media, which is formed from specially treated
cellulose, synthetic, or combination cellulose/synthetic filter paper. The quality of the filter media is
based on criteria of efficiency, pressure drop, and / or dust holding capacity for a given application.
As the filters accumulate dust, the pressure drop gradually rises.
When the filter element pressure drop reaches a particular value (clogged / dirty filter) the cleaning is
initiated.
Hence, upon command from the automatic sequencing control, a solenoid-operated air valve directs
a blast of high-pressure reverse airflow into the filters.
This shocks and causes a momentary backflow through the filters, dislodging accumulated dust from
the outside of the elements and allowing it to disperse.
The filter cartridges may be vertically or horizontally hanged to the filter wall.
Vertically hanged filter cartridges (see Fig.1A & 1B) are always cylindrically shaped while horizontally
hanged filter elements generally consist of a conical and a cylindrical section, which are mounted
together to the tube sheet by means of a yoke assembly (see Fig.2A &2B).
Vertical Flow Self-cleaning System Scheme

FIG. 1A
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Vertical Flow Self-cleaning System Filter Elements Arrangement

FIG. 1B
The cylindrical and conical filters have a continuous circular closed cell neoprene gasket permanently
affixed to each element to help prevent air bypass.
Systems with horizontally hanged filters have installed some protections as weather hoods, droplet
catchers or coalescer panels to remove moisture droplets from the incoming airflow while systems
with vertically hanged filters have filter cartridges simply protected by a skirt.
Self-cleaning systems are the recommended air filtration systems in desert environments as well as
in artic environments.
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Horizontal Flow Self-cleaning System Scheme

FIG. 2A
Horizontal Flow Self-cleaning System Filter Elements Arrangement

FIG. 2B
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3.2 Low velocity Static Barrier Air Filtration Systems

In environments where the concentration and type of airborne contaminants make it impractical to
pulse clean inlet filters or other considerations apply (e.g.: the clean efficiency level), the low velocity
static (barrier) filtration systems are used.
These systems typically have two stages of filtration (see Fig.3).
The first stage consists of low cost pre-filters (generally bag filters to increase Dust Holding Capacity
at a lower pressure drop) that are used for the removal of larger contaminants and as mist
eliminators as well.
The pre-filters protect and extend the life of the more expensive high efficiency filters.
The high efficiency filters are placed downstream of the pre-filters and remove finer particles.
High Efficiency static filter elements are generally panel (rectangular) shaped with mini pleated media
(to increase media surface).
Panel shaped filters are mounted side by side in a framing system in the air inlet compartment.
Static filter media is typically depth-loading media (micro glass fiber for high efficiency elements).
The particles are trapped within the body of the media.
This media has a billowy texture, which allows the particle to penetrate and deposit.
With extended use, static filter media will become laden with particulates from the surrounding
ambient.
Once the static filter media becomes loaded with particulates, it should be replaced with new similar
filter media type, as dirty media will inherently have higher pressure drop which reduces turbine
efficiency.
The specific replacement timing will depend upon surrounding environmental conditions, and gas
turbine operational practices.
Replacement timing is usually a compromise between machine efficiency, maintenance cost, and
required availability (outages).
Static air filtration systems have installed some protections as weather hoods, droplet catchers or
demister vane separators to remove moisture droplets from the incoming airflow.
Static air filtration systems are the best choice for industrial areas, urban installations, tropical areas
and temperate areas where the expected dust content in the air is limited and nature of contaminants
may discourage the use of a self-cleaning system.
The particle efficiency of a high efficiency filter installed as final stage may be as 50% to 30 times
(and more) higher than a self-cleaning cartridge.
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Static Barrier Filter House

FIG. 3
3.3 High Velocity Static Barrier Air Filtration Systems
Coastal, marine and offshore platform and FPSO installations present unique problems of inlet air
contamination, as salt from seawater can become airborne in significant quantity due to wind and
wave action.
Whether salt particle will exists as dry crystals or saturated droplets depend primarily on the relative
humidity.
If the salt particles start out as droplets, as they will at the high humidity present at the water/air
boundary, they will remain as supersaturated droplets until the relative humidity falls to 45% or less.
Conversely, once the salt is in crystalline form, it will not deliquesce until the relative humidity rises to
about 73%.
Since relative humidity in maritime air very rarely falls below 45 %, salt will almost always be present
in droplet form.
High Velocity Filtration Systems suitable for the removal of liquid salt from the incoming air stream
typically consist of a three (or four) stages (see Fig.4).
The first stage is a demister vane separator that separates entrained droplets imposing several
direction changes to the incoming air. Droplets, due to their greater mass, impinge upon of the sides
of the vanes. The effectiveness of such a system is proportional to the velocity of the air stream and
thus the momentum of the droplets (see Fig.4A).
A coalescer/high efficiency element is installed downstream the demister stage.
The coalescer/high efficiency stage captures smaller droplets that were not removed in the first stage
of the separator.
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After capture these droplets may either drain down to the catch through below or agglomerate with
other droplets to form larger droplets which become re-entrained in the air stream.
These agglomerate droplets are captured by the last stage of vanes, which is typically identical to the
first stage.
In location where a high dust load in the air is expected a prefilter stage is added to the system to
extend the life of the high efficiency coalescer stage whose particle efficiency level is increased to
more effectively remove the solid particles (four stages system).
1st Demister
stage
Prefilter Stage
High efficiency stage
High Velocity Filtration System

FIG. 4
Demister Van Separator Principle Illustration

FIG. 4A
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4 FILTER ELEMENTS
4.1 Filer Elements Storage and Handling
If erection is not foreseen immediately after receipt of the material, it is then recommended to
proceed to a correct storage of the material.
Damage to replacement filter elements can occur if they are not properly protected from
exposure to weather.
Store filter elements in a dry, well-ventilated warehouse, free of inclement weather and at a
temperature not exceeding 55 C (130 F), in their original, unopened wrappings. NOT left in
pallets outside.
If storing elements inside a building is not possible, store them so that they are protected from
exposure from weather and direct sunlight.
The packing in which elements are shipped may be not sufficient protection from weather (refer
to box and crates labels).
If not other ways stated in the User Manual, filter elements may be stored up to three years after
their manufacturing date.
Elements stored for longer periods or not stored under adequate conditions cannot be
guaranteed for their full operating life any longer.
Always handle elements with care. They may look sturdy, but dropping them or denting them can
result in holes in the media, improper sealing and/or fit, or other potentially damaging situations.
If an element has been damaged in shipping, dont use it!
For maximum handling protection, when its time for filter change out, keep elements in their
original cartons and lift them into the filter house.
Transport and handling damages are bound to happen. Acquire some extra pieces to replace
the damaged ones and ensure adequate protection of the machine.
4.2 When to service Filter Elements
Actual filter element life is subject to restricting factors that cannot be influenced by the manufacturer.
Final stage high efficiency barrier element life may be extended by properly selecting the prefilter
stage efficiency and dust holding capacity.
Experience has shown that life expectancy of carefully selected final stage filter element with a
carefully selected prefilter stage ranges from 4 - 6 months in the most unfavorable and to 1 year and
more in the most favorable conditions.
Extremely fine particles as well as certain amorphous carbonaceous contaminants are difficult to fully
remove from the filter elements of a self-cleaning system by pulsing only.
The ability of the filter to cope with such contaminants also depends on the presence of dry, solid,
coarser material.
In general they cause a steady increase in pressure drop over time, whereby the limiting factor of
filter life is the maximum allowable pressure drop that the engine can handle for technical or
economical reasons.
Experience has shown that life expectancy of carefully selected element in a self-cleaning air filtration
system ranges from 8 - 10 months in the most unfavorable and up to 2 years in the most favorable
conditions.
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Due to exposure to atmosphere the media looses its strength over time.
This process of ageing is independent of whether the filter is in operation or not and limits the life of
the elements.
Presence of aggressive chemicals (even limited quantities) may speed up this degradation process.
Please consider that an increasing pressure drop through an air filtration system is absolutely
normal; you should be concerned if the pressure drop of your system does not growth at all
under tough environmental condition, too!
For the same reason, when comparing the performance of two different filter elements, be
aware that a reduction in pressure drop could come from a better selected filter element
media as well as a lower filtration efficiency!
The filter elements should be removed if the dirty filter pressure drop is higher than the alarm set
point.
It is anyhow important to note that the dirty filter is able to safely accommodate higher pressure drops
and that the GT operational limits (trip set point) will be met long before element safety issues are
met.
Filter elements should also be removed and replaced when filter media characteristics have
deteriorated due to time, weather or other circumstances.
Visually inspect filter elements on a regular basis, at least every 3 months.
Visually inspect for tears or holes in the media and leaks in the area around the gasket seal.
If a leak is suspected, serious media rupture must be expected.
This can normally be observed by careful visual inspection.
Should such inspection fail to give any results, with the GT shut off, remove filter elements from the
installation and check for dust spots inside the filter element or for dust streaks through the gasket
area.
Note:
Dust inside a self-cleaning filter element does not always mean that the element is faulty!
Dust may have come from adjacent leaking elements and blown into it by the pulse air injection.
Another method is to insert a light into the filter (for cylindrical or conical cartridges) or behind the
filter (for a panel filter) and look through the media.
A leak will show as a very bright spot.
Replace any elements that are found to be leaking.
Change all the elements at once. Never leave used ones. Mark up installed date codes on the
end caps as well as the inspection identifications.
4.3 Source the most appropriate Filter Elements
Use only GE provided original Filter Elements for replacement for which the reference part number
can be found in the Spare Parts List.
Damage to the turbine due to the use of other elements invalidates the GE warranty.
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Performance (filtration efficiency and pressure drop) of the GE Air Filter System is directly related to
use of high quality, high performance GE provided elements.
Failure to source the correct type/style of replacement filters, or maintain them, may result in failure
of the filter element during operation and the contamination of the clean airside of the gas turbine.
All GE provided gas turbine inlet filter elements underwent through very demanding tests to
demonstrate they capability to properly operate when installed on a Gas Turbine Air Filtration System
and to comply with a long list of very detailed requirements about their construction features.
Filter element structural strength is important to ensure that the final filter element maintains its
integrity during normal gas turbine operating conditions.
This is true for both static and self-cleaning applications.
Failures typically occur when the filter element is wet due to humidity or from water carryover into the
inlet filter house (see FIG.6A & 6B).
Filter element suppliers not approved by GE, may not test the structural integrity of their filter
elements during wet conditions.
This could cause the reported burst strength to only be true when the filter element is dry.
Filter Elements collapse
FIG. 6A
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Water induced collapse of pre-filter
FIG: 6B
GE provided self-cleaning filter elements have an external protection mesh.
GE provided static barrier filter elements have an external protection mesh at least on the external
sides of the panel.
This will allow you to handle the filter element without the risk to damage the media.
Self-cleaning filter elements have a spiral bead of glue, which binds the inner and outer mesh to the
filter element media. This glue needs to be pressed into the filter element mesh such that it properly
bonds to the filter media.
GE recommends that self-cleaning filters be inspected when they are received or before they are
installed to ensure that the spiral glue bead is pressed into the filter element mesh.
Spiral wound glue that is not properly bonded to the filter element media (including glue strands), run
the risk of liberating into the clean air path, and being ingested in the gas turbine (see Fig.7)
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Glue detaching from the filter element
FIG.7
GE has also found that some non-qualified filter element suppliers (self-cleaning and static) do not
provide a gasket on the final filter, or they do provide a gasket but the gasket material is not airtight.
Always source a new gasket when installing a new final filter element.
Source also a new retention washer for a self-cleaning element pair on a horizontal flow self-cleaning
air system.
4.4 Filter Elements Maintenance
4.4.1
Barrier Filter Elements
Verify prefilters and final filters to be installed according to the manufacturers installation
instructions.
Prefilters shall be secured tightly against the final filters or supporting framework (depending
on arrangement) in order to minimize air bypass.
Final filters shall also be secured tightly against their supporting framework as to maintain
integrity between the dirty and clean airside of the gas turbine.
Gaskets on coalescers / prefilters, and final filters (as applicable) shall be inspected for
damage that may contribute to additional air or water bypass and replaced accordingly.
As the prefilters are protecting the high efficiency filters from fouling, the prefilters must be
replaced at least once a year.
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Recommended final resistance is ranging between 250 Pa (flat panel filter elements) and to
450 mm (bag filters).
When replacing the pre-filter take in consideration that the bag prefilters shall always be
assembled with the filter bags vertically.
Common size of prefilter bag filter is 592x592 (front) with a length ranging from 300 mm up to
650 mm.
See below typical prefilter wall arrangement and typical detail of a filter holding frame.
FIG. 8
FIG. 8A
The maximum lifetime of the high efficiency filter elements is up to two years operation.
Then they must be replaced whether or not they have reached their final pressure drop.
The high efficiency filter elements have a recommended final resistance of 600650 Pa.
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When mounting the High Efficiency Filter be sure that the gasket on the air leaving side is not
damaged. Place the filter cartridge in the holding frame and be sure to insert them in proper
direction to the airflow. The filter elements shall always be assembled with the filter separators
vertically.
Filter elements shall be inserted in proper direction of airflow.
Eyes shall be on the upper side of the filters looking at you (see Fig.9).
Do not tighten the fixation devices too hard so you will break the plastic filter frame, only to
ensure that there is no leakage between the filterbank and the filter.
Common size of high efficiency filters is 592x592 (front) with a length ranging from 292 mm
up to 400 mm.
High Efficiency Barrier Filter

FIG. 9
To limit water carryover through the final stage, the filter elements shall have the media fully
sealed (by caulk) to the frame.
Glass fiber or synthetic wool, inserted between the filter element frame and the filtration
media, is a NOT acceptable media sealing method.
4.4.2
4.4.2.1
Self-cleaning Filter Cartridges

Life of the self-cleaning filter cartridges
The maximum filter element life is 5 calendar years from the production date marked on it, if
the storage is done in correct conditions.
Warranty is only valid five years after date of manufacturing of the element.
The maximum filter element operating life is 2 calendar years after installation in the filter
house.
Therefore, for the most profitable use of the filter element, the storage period should be
limited to 3 years, e.g. 3 years storage + 2 years installation = 5 years (max. life).
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Elements stored over longer periods or not stored in an adequate manner cannot be
guaranteed to give their full economical life any longer.
Replace any element that is found to be leaking.
4.4.2.2
Filter cartridge installation on a vertical flow self-cleaning Air Filtration System

Figure 10 shows the element installation process:
Hold element by the top and by the hand crank. Push crank as far into the element as possible.
Guide element onto collar
Insert crank rod into center of quick-nut and push crank into quick-nut. Center element over
collar.
Turn crank clockwise about two turns until element is drawn tight against plate. Check that
element is properly seated and secured.
Vertically Hanged Type Filter Element Replacement

FIG.10
If you are replacing a clogged filter element after removing it, immediately inspect the clean
airside of the housing for dust streaks.
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Excessive dust marks indicate that gasket or filter medium has been damaged or that filter
was incorrectly installed.
4.4.2.3
Filter cartridge installation on a horizontal flow self-cleaning Air Filtration System

Always have all filter elements installed. Failure to do so will endanger the cleanliness of the
downstream filter side and expose the turbine (protected equipment) to serious hazard
danger, enforcing the whole system clean up.
Always check the filter elements before installing them.
Reject damaged filter elements, never install them!
As filter handling can be awkward, we recommend that filter change out be done by two
people at least.
Proceed as follows:
Element retention bolts, nuts and flat washers may be shipped separately with the yoke
assembly rods tied together with black cable ties or stainless steel wires. In this case, cut
the cable tie, align rods in correct configuration as shown on figure 11 and replace the
cable tie by the element retention bolt, nut and flat washer in order to connect the three
legs of the element support together.
Inspect filter elements (gasket and dealing surface for damage). Filter elements with gasket
or with damaged or dented expanded metal protection liners may not be installed.
Yoke assembly preparation for element installation

FIG.11
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Position the filter elements with their gasket upward on the service platform such as not to
rip these gaskets with the platform grating.
Start installing elements on the top row and proceed from top to bottom.
Slide (one) conical filter element onto the element support yoke in a parallel manner as
shown in Fig.12 below until the gasket at the large end touches the tube sheet. Make sure
that the element does not impact against the retention bolt. If damage to the filter element
occurs, such as a hole, dont use the element. Take care not to damage the yoke, too.
Proper filter element installation over yoke assembly

FIG.12
Slide (one) cylindrical filter element onto the element support yoke in a parallel manner
until the cylindrical filter element is against the conical filter element. Again, take care to
avoid internal damage. During this phase take care to keep the conical element gasket flat
on the tube sheet. Having installed the yoke legs with the correct sequence helps to
assure a proper sealing of the elements on the filter wall.
Make sure the yoke bolt protrudes from the hole in the end cap of the element. Gently push
the 2nd element toward the rear element so that the seal snugs up to it. Any damaged
element, gasket washer or nut shall be rejected.
Place the gasket washer (generally taped to the cylindrical element) and element-retaining
nut over the threaded retention bolt on the yoke as shown in fig.13.
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Tighten the nut until the elements fit tightly against the tube sheet and against each other.
No air must be able to penetrate in between the filter elements or in between the conical
element and the tube sheet. Filter elements shall not rotate around their axis.
Do not over tighten elements. Damage could result.
A torque value of 20-Nm should not be exceeded (in case of clean bolts) and it is generally
enough to properly compress the gaskets.
In any case the gaskets should be compressed from approx. 13-mm up to a thickness of
approx. 7-mm.
Filter element installation and retention

FIG.13
Additional Notes for Filter cartridges replacement:
A. Take the opportunity to trial install the filter elements pair on one of the lower rows of a
filter module. Here you may easily check if the cartridges are correctly installed
inspecting gaskets from the walkway and from the clean air plenum as well. This will
allow you to make practice for a correct installation avoiding catastrophic leakages.
B. When you are sure that the filter element is properly tighten against the filter wall take a
measure of the length of the retention bolt protruding over the special nut. Use this value
as reference to the other elements installation.
C. Always use a new special washer and the special nut to fix the filter pairs. Use of not
original fixation hardware may result in failure to achieve a proper leakage.
D. Yoke legs may be identified with letters at the star hole end instead of Hex-RoundSquare holes. In this case the shortest leg is identified as A, the medium with as B
and the longest as C. The letters are stamped close to the star holes (may be
underneath, too)
E. The standard position of the Yoke legs is with the round hole (C) at noon, the hex hole
(B) at eight and the square hole (A) at four (with the filter module in the erected position).
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F. Air filter element replacement must be done during turbine downtime. Although the
elements are replaceable while the turbine is running, for maximum turbine protection,
GE strongly recommends replacing only while the rotating equipment is standstill.
G. Brush or vacuum clean any dust that could have accumulated over the elements at the
tube sheet level and at any other location where it might fall off into the clean airside
while changing the elements.
H. Start doing this at the top row of elements. This is to eliminate any risk of clean airside
contamination.
I. Clean up the retention bolt with WD40 or any similar anti-rust/anti-friction penetrating
agent to prevent any nut thread damage due to particular dirt.
J. Dispose the dirty elements in an environmentally friendly manner.
K. Inspect elements support yokes for damage. Note that yokes are not made to bear any
more weight than the element pair (about 33 kg). Any excessive load will damage the
yoke, create bad alignment of the filter element and result in a poor seal between the
tube sheet and the element. Make sure that yokes are centered on the tube sheet hole
to ensure proper element sealing. Damaged yokes shall be replaced.
L. After removing elements, immediately inspect the clean airside of the housing for dust
streaks. Excessive dust marks indicate that gasket or filter medium has been damaged
or that filter was incorrectly installed.
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5 GAS TURBINE INLET SYSTEM INSTALLATION, OPERATION, and MAINTENANCE REQUIREMENTS

5.1 Droplet Catchers
Droplet Catchers remove large moisture droplets from the incoming airflow.
They may be installed horizontally in the weather hoods in self-cleaning or barrier filtration systems to
allow for draining of water droplets through the S-shaped channels in the direction opposite to airflow
(see Fig.14).
Due to their installation orientation, they can be installed backwards without any impact on their
performance.
Complete interlock (0.50-inch nominal and 0.25-inch minimum) is required between adjacent pieces
of moisture separator panels.
The last piece of moisture separator panel is cut to interlock with the adjacent piece and fit tightly
against the opposite end of the weather hood side panel.
Droplet Catchers shall be inspected for damage after installation, and prior to operation.
Separation between layers within a panel is common when moisture separators are left exposed to
direct sunlight and UV rays for long periods of time.
Since Droplet Catchers play a key role in the protection and operation of the high efficiency filters,
damaged pieces must be replaced immediately.
FIG. 14
5.2 Demister
The purpose of the vane separator is the inertial interception any airborne droplets.
The vanes have pockets built into them that run their entire length. The droplets separated onto the
vane surface, collected by the pockets and drained into a trough at the bottom of the casing.
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Water collected runs from the trough into a manometric drain trap.
All drain shall be periodically checked for leakage and checked (at least once a week) to ensure that
drain box is full of water to avoid any risk of dirty air by-pass.
5.3 Gasketting
Bolted gasket joints are provided throughout the inlet system in order to prevent dirty air bypass and
allow for air management between modules.
Joints that separate clean air sections from the outside must be dust and air tight.
Neoprene (closed cell) gaskets are used at all dirty-to-clean air bolted joints (external joints) as well
as module-to-module connections.
It is recommended to seal off external gasket joints with a caulk profile on the outside to create a
redundant approach in sealing the clean airside.
GE approves the following sealant for this process:
a. Sikaflex-221.
b. Dow Corning 832 Multi-Surface, Adhesive Sealant.
Sikaflex 221 is mono-component polyurethane adhesive with excellent adhesion properties, which is
resistant to UV radiation and has good compatibility with the paints generally used in the gas turbine
market.
Always check whether the sealant expiry date has been reached or not. If this date has passed
already, do not use the sealant anymore.
When installing gaskets follow the recommendations listed here below:
1. Apply gasket and caulking on dry, dust free and degreased surfaces.
2. Prevent the gasket from being rolled by relative movement between the items during erection.
3. Ensure the continuity of the seal: cross gasket at corners and create a dove-tail joint by a cutter,
overlap ends and create a dove-tail joint by a cutter, extend by 25 mm at ends to merge the cross
seal.
4. Caulk all open external joints with Sikaflex. Apply with fingertip between the mating surfaces.
5. Gasket to be flushed with edge of vertical angle for a length of minimum 160 mm. This occurs
where horizontal mounting of transition(s) and module-to-module connections are made.
6. Tighten bolts to maximum torque only after the pre-assembly is completed to allow free
positioning, levelling and squaring.
7. All parts are to be lifted with care and with the appropriate lifting methods, using the eyebolts
provided or required by the drawings. If necessary, temporary bracing must be installed before
lifting. Care must be taken not to damage any parts during erection.
It is essential to the integrity of the inlet system that all gaskets and bolted joints are installed
correctly as to help eliminate the risk of dirty air and/or water contaminating the clean air side of the
gas turbine. Gasket use and presence shall be verified to meet the installation drawings and
instructions provided by the inlet system suppliers.
Most of the final filter elements have a particle efficiency level (in the clean condition, too)
higher than 70% on 0.4 m particles. These particles are 5 times smaller than a bacterium.
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There is no sense to have installed a so high efficient and expensive filter element if your air
filtration system is not perfectly leak free.
5.4 Inlet System Commissioning
Carefully protect clean air plenums before and during erection to avoid ingestion of blown dust.
It is important to remember that the filter compartment and associated hardware represent the
physical barrier between the outside ambient air and the clean airside of the gas turbine.
Thus, it is key that steps are taken to ensure the integrity of this location.
On a self-cleaning system, cover compressed air manifolds to protect them from dirt and damages.
Close any open threaded pipe connection with plugs or caps.
All bolting inside the clean air section have to be tack welded unless nut are approved self-locking
type.
All damaged surfaces have to be touched up.
Do not step on any of the air manifolds, air tubes or the element yokes inside the filter module
assemblies because damage will result.
Equipment is not warranted unless proper and responsible erection procedures are followed.
Check that any protections around the nozzles of the blowpipes are removed in a self-cleaning
filtration system.
Close all the doors and hatches tightly.
After installation is complete, it is important to do a walkthrough inspection throughout the entire filter
house in order to ensure that all equipment has been installed as per the manufacturers
recommendations.
All surfaces downstream of the filter media and tube sheet (clean air plenum) shall be cleaned.
Inspection windows in the filter compartment module doors and access hatches shall be clean and
free of damage (scratches, cracks, etc.) to allow for a clear view of the gas turbine compartment
surfaces and walkways.
Any objects that are brought in for inspection and maintenance downstream the final filter stage shall
be tracked, accounted for, and removed prior to operation.
Any loose hardware shall be tightened, secured or removed from the clean airside of the gas turbine
to minimize risk of Foreign Object Damage.
Before the gas turbine start-up the inlet system shall be thoroughly tested for air leakage.
Perform a light test and a Hose Test to check all bolted and gasket joint to be fully airtight.
From the inside of the duct or plenum, inspect the joints for light coming in from the outside.
If light is not visible through the gaskets, proceed to the hose test.
The Hose Test is recommended to inspect gaps in the gasket seal that will allow water and dirty air
to seep into the duct and plenum. To conduct the hose test requires two people. One person with a
water hose is positioned outside of the duct and sprays water from the hose onto the suspected
gasket seal for two to five minutes. Another person on the inside of the duct inspects the seal for
water bypass.
For gasket seals that fail the light test or hose test, clean and dry off the gasket surface and apply
sealant to the area to create an airtight seal.
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5.4.1 Cleaning
Cleaning is an essential operation for the future proper operation of the air intake system.
Therefore it is required that only trained people perform those cleaning actions.
These operators must wear clean clothes and shoes.
All tools must be cleaned as well before any cleaning task.
It is recommended that the operators wear a convenient overall and hair protection for the final
cleaning operation.
Once the cleaning operation is done, no unauthorized persons are allowed to enter any part of the
cleaned air intake ducting.
5.4.1.1 Air/Water cleaning of the clean air plenum
The complete clean air plenum must be cleaned by an air or water jet (depending on actual
status of the erected assembly) to remove the bigger dirt spots as lifted to the final elevation.
It is not necessary to clean it thoroughly at this stage.
The cleaning must start from the clean air section of the filter modules and then further on to
the transition/ventilation duct. Water, when used, must be directed to the next intake duct
section.
To allow the water to leave the clean airside section of the filter house modules, each module
has a plugged drain in its bottom panel (a coupling with a plug) on most of installations.
Remove this plug for draining of the cleaning water that will be, inevitably, collected on the
bottom of the filter house modules.
Do not forget to place back the plugs that have been removed for draining the cleaning water.
These plugs are required to guarantee the air tightness of the clean air plenum.
If your actual installation has no drain hole on the modules, use air jet or collect water and dry
by clothes.
Note:
The scaffolding (if used) will be cleaned first.
5.4.1.2 Paint touch-ups in the clean air plenum
When the internal walls of the clean air section of the filter house modules and the transition
duct are water cleaned, all paint damage (painted air inlet systems) must be corrected. It is
essential that the appropriate paint coats be applied according to the depth of the damage.
Intermediate coat must be applied where necessary; topcoat must be applied in any case.
Allow for sufficient curing time before applying the next paint coat and before any other
cleaning operation.
5.4.1.3 Vacuum cleaning of the clean air plenum
When all paint touch-ups are done and cured, use a vacuum cleaner to clean all the internal
surfaces of the clean air section of the filter house modules, the transition duct and the inlet
duct.
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5.4.1.4 Fine water cleaning of the clean air plenum:

The surfaces of the inlet system must now be cleaned by means of humid cloths. Make sure
to use only non-fluffy cloths.
When everything is cleaned, remove the internal scaffolding, leave the inside of the intake
system, close the access-hatch and forbid the access to any unauthorized person.
Note:
It is important that no loose objects are left in the clean airside of the filter house. The turbine might
get damaged.
All exterior seams must be sealed. Verify and apply paintable sealant to all unsealed connections.
Inlet system must be clean of all weld splatter; drill shavings and other foreign material before
turning on turbine or damage to the turbine could result.
5.5 Inlet System Operation
Prior to operation of the gas turbine, the Inlet System and all its associated hardware must be
thoroughly inspected to ensure that the gas turbine clean air path is free of dirt, debris, tools, cleaning
equipment, and all other potential foreign objects.
All sections of the Inlet System must be completely installed, and all applicable instrumentation must
be tested and calibrated to ensure that it is in proper operating condition and all access hatches
(including the external doors on the plenum viewing hatches when applicable) closed and sealed
prior to turbine start up.
It is important to note, that due to the very nature of the coalescing process, and the materials
associated with their construction, coalescer filters will operate in a very similar fashion to coarse
filters / prefilters.
Larger trash pieces and/or debris will accumulate in coalescer filters while finer smaller particles will
travel through the filter onto the final filters.
Fouling and blockage of the coalescer filter media area will render the coalescer ineffective at
performing its function of removing water droplets from incoming airflow.
Therefore, it is essential to monitor coalescer filter pressure drop and replace when excessive build
up is found.
Some coalescing pads are washable, and do not necessarily need to be replaced when dirty.
End users shall consult vendors O&M manual and/or other supporting documentation regarding
appropriate cleaning methods and maximum number of cleaning cycles prior to replacement of pads.
While the local gage is useful in providing an overall pressure drop reading across the entire stage of
coalescer filters, it is important to remember that this is not necessarily reflective of the condition
across individual filters.
Therefore, it is recommended that weekly monitoring of this pressure drop reading be complimented
with multiple walkthroughs (1 2 times per month) across all filter compartment walkways in the dirty
air side in order to look for signs of excessive wear, tear, corrosion, and fouling of individual filters
that may not be performing at optimal levels.
More accurately visually inspect filter elements on a regular basis, at least every 3 months.
Visually inspect for tears or holes in the media and leaks in the area around the gasket seal.
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Bird Screens and other similar components must be inspected, tested, and cleaned of any debris
accumulation during operation.
Bird Screens, Moisture Separators, and Coalescers must be removed during the winter and/or
applicable seasonal changes when theres an inherent risk of icing of these components (as on selfcleaning systems where anti-icing system is not foreseen).
Icing formation on these components could result in partial or total blockage of the gas turbine air
inlet system with increased pressure drop. This excessive pressure drop may result in a fired
shutdown of the gas turbine.
5.6 Air Filtration System Maintenance
No air filter system can be expected to protect the turbine from contamination if there are leaks
downstream of the filters.
Periodically inspect the inlet system for any evidence of dust by-pass.
The GE recommendation for preventative maintenance of the inlet compartment includes regular
visual inspections (at least once a year or at any GT shut down) during planned plant and/or turbine
outages. Take advantage of any GT stop to perform inspections and record date and results. You
need only very few hours for a proper clean airside inspection. Dont miss any opportunity!
While the unit is shutdown, the clean air access hatches may be opened and the clean air path
inspected with permission by the owner and conforming to plant guidelines for confined space entry.
Any leaks found should be resealed with a suitable sealing compound.
The recommended way for the detection of leaks:
because the clean air system is a vacuum, when compared to ambient, dirty air will flow from the
outside to the inside. This will cause dust streaks to appear at or around any leaks.
also, when light penetrates there is a sure sign of a leak.
It is recommended to record weekly the pressure-drop across the filters together with a brief note of
the environmental conditions and GT operating conditions.
GE recommends checking the functionality of the pressure sensing instruments periodically per the
provided filter house manufacturers recommendations.
When gas Turbine is operating check filter cartridges for leakage from dirty air plenum, too (refer to
Fig.15 below for a simple method).
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Fig.15
Heavily fouled or damaged areas in the filtration media are often a source for air and water bypass.
An inspection should also be carried out if possible during or after a heavy wind, rainstorm,
sandstorm, or an environmental fog event for evidence of filter damage and or saturation of the clean
airside of the filter elements.
Self-cleaning filter element frames are typically made of galvanized carbon steel, per current gas
turbine industry standards.
Filter elements may have an average useful life of 1 2 years depending on the type of filter, local
environment (dust loading, rainfall, humidity, etc.), and the presence of certain hydrocarbons and
other fouling elements in the surrounding air that can accelerate filter loading.
Other factors, such as manpower, pressure drops, heat rate, and corresponding gas turbine
efficiency, may be considered in the replacement scheme of gas turbine filters.
Minimal corrosion in the dirty air section of the filter compartment is not a reason for concern.
However, excessive corrosion (as seen below on fig.16) is representative of an environment in which
the inlet filters are exposed to surrounding ambient air contaminants.
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Fig.16
Deterioration of the inner and outer mesh of the filters is a good indication of an extremely corrosive
environment.
Corrosion is typically the result of acids formed by water mixing with corrosive salts such as
chlorides, sulfates, and nitrates.
Inhibiting water transport of these corrosive elements can significantly minimize the rate of corrosion.
Moisture separators and/or coalescing filters are recommended to reduce water droplet transport into
the filter compartment.
Additional evidence of possible contamination of the clean air section of the gas turbine is the
formation of salt deposits and/or other corrosive elements found on pulse piping or other internal
structures (see Fig.16A).
Fig.16A
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Gaskets between bolted joints minimize dirty air and water transgression into the clean airside.
They are also used for air and water management within the compartment.
Light and Water Spray tests are useful in locating missing gaskets.
Missing gaskets can be corrected by use of caulking depending on gap size.
The use of correct caulking profile and application procedures is critical.
While applying caulk, one must ensure that the surface is clean and dry as to ensure good caulk
adhesion to the receiving surface.
All drains and associated piping shall be inspected on a regular basis to remove any debris that may
prevent proper draining.
All internal and external piping shall be inspected for leaks and replaced or repaired as appropriate.
Heat tracing around steam supply piping, air manifolds, and / or electrical equipment shall be tested
to meet manufacturers recommended operational parameters.
Units with Chiller Coils or Steam Heating Coils shall be inspected as a minimum at the beginning and
end of the running season (twice per running season) to verify that there are no leaks present in the
system.
Steam Leaks in the Upfront Steam heaters may present a personnel safety risk unless adequate
procedures are followed.
Leaks from steam coils can also foul and permanently damage gas turbine filters.
Inlet Chiller Coil leaks are potentially dangerous to the gas turbine due to the nature of the coolant
fluid (ammonia, ethylene glycol or propylene glycol), and the location of the coils themselves
downstream of the filtration system.
In case of severe leakage, system drains provided as part of the inlet compartment may contain
steam, hot water, water glycol or ammonia as appropriate.
Therefore, care must be taken to safely route these system drains to proper locations for disposal of
these products.
Any increase or decrease in pressure drop can indicate a problem in the filter house (plugged filter
elements, leaks, cleaning malfunction or other cause) that requires immediate action.
A pressure drop that remains stable for a long period of time should make suspect arising for
possible leakages.
On an air filtration system the following maintenance duties are performed daily, weekly, monthly,
every six months and yearly.
Maintenance duties are broken down into six intervals, and they are listed below:
Daily - The droplet catcher, or anti-icing heater, (whichever is located most upstream) should be
inspected for obstruction by paper, trash, etc.
Weekly - Record the filter resistance. Check to see that each filter is straight and square to its frame.
Fill up the drain trap (if any) with fresh water during the dry season.
Three months - Inspect the filter media for signs of damage (filter types should have a similar color
and appearance) and ensure that dirty air plenum is free from foreign matter.
One year (or at each possible GT shut-down)- Check the clean air plenum for degradation and
moisture build-up. Check all joints for evidence of air or dust leakage.
One year - Pre-filters to be replaced (also if pressure drop is below the specified value). Check all
surfaces for corrosion.
Two years Final stage filters to be replaced (also if pressure drop is below the specified value).
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WARNING
The filter elements are not designed to be cleaned by maintenance crews and returned to operation
with the exception of some coalescing filters.
Dirty filter elements that are cleaned in this manner run the risk of tearing the filter media, and
allowing air bypass. It may also contaminate the clean airside of the filter element with dirt and
debris, which would be ingested by the gas turbine.
Any attempt to clean dirty filters for re-use is not recommended by GE.
5.7 Inlet Duct System Maintenance
The GE recommendation for preventive maintenance of the inlet duct system includes regular visual
inspections (at least once a year or at each GT shut down) during planned plant and/or turbine
outages using the visual inspection guidelines for each component listed in sections here below.
While the unit is shutdown, the access hatches may be opened and the duct and plenum inspected
with permission by the owner and conforming to plant guidelines for confined space entry.
The inlet duct must be completely clean and free of debris upon completion of inspection and prior to
commissioning of the turbine.
Recommended maintenance inspection of the Duct Sections is as follows:
Inspect the entire expansion joints belt (exterior and interior) for cuts, worn sections, or cracks.
Inspect the metal backing bar and hardware of the expansion joints on the exterior for corrosion
and tightness
Inspect the exterior and interior of the duct for signs of corrosion.
Inspect the flange interfaces of the duct with the adjoining section for signs of air and water
leakage past the flange gasket.
Inspect the acoustical lining in the wall, ceiling, and silencer panels for signs of rust staining, dirt,
or debris.
Ensure that not-insulated duct walls, ceiling, and floor contain no visible dirt and debris.
Inspect all access hatches for an airtight seal.
Inspect all ports for plugs/ caps (if not in use for instrumentation purposes). All ports require an
airtight seal.
Inspect the silencer panel support brackets located at the top and bottom of the panels on the
ends for signs of weld crack indications.
Inspect the acoustic insulation retention sheet/perforated sheet welds for signs of weld crack
indications.
Inspect the Inlet Bleed Heat (if any) Pipe and Pipe Guides for sign of weld crack indications.
Inspect the Inlet Bleed Heater (if any) Pipe Insulation covering the externally mounted section on
the top of the duct for signs of thermal leakage (discoloration).
Inspect the woven mesh screen for tautness to prevent excessive vibration. Although the screen
tautness requirement is not as strict as those required for a typical house window screen, large
deflections in the screen (greater than 4 inches) when moderate hand pressure is applied are not
acceptable and the trash screen section should be replaced.
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Inspect the mesh screen and framework for loose screen wire. Any loose wires found should be
removed to eliminate a potential FOD risk.
Inspect the trash screen mesh for signs of rubbing against duct bracing. Rubbing, if present, will
wear away at the corrosion protective layer on the bracing, which will result in corrosion in the
clean air path.
Inspect for any broken wires or missing screen sections. Sections with broken wire and/or missing
screens must be replaced.
The IBH Module described above is one design representation of the Inlet Bleed Heater.
If the site Inlet Bleed Heater does not match this description, please refer to the O&M Manual.
Lacerations in the expansion joint belt will allow dirty air bypass into the inlet system and must be
repaired or replaced.
For replacement parts, please contact your local GE Energy Services dealer.
For minor repairs (small cuts no greater than two inches), the expansion joint may be patched with
sections of the same material placed on the outside dirty air side of the expansion joint and sealed
with RTV (Red or Blue) silicone gasket sealer in accordance with the directions on the tube.
If cracks are present in the belt, the belt must be replaced.
Potential sources of cracks include exposure to higher temperatures and/or greater stresses than the
design was intended for.
The expansion joint is designed for normal environmental conditions and, therefore, cracks present in
the belt may indicate improper installation or loading beyond the design intent.
Please contact the local GE Services representatives for all concerns.
Signs of air and water leakage include dirt and water staining and constitute a breach in the intended
air and watertight seal.
For silencer bracket weld crack indications, the correct procedure is to remove them and de-burr the
bracket to duct interface if located upstream of the silencer panels.
Prior to removing the brackets, the area must be masked off to prevent metal debris from
contaminating the insulation pillows nearby.
Brackets located downstream of the silencer panels will require weld repair.
Any concerns regarding the integrity of the trash screen upon visual inspection should be addressed
with the local GE Services Representative.
Please refer to the General Maintenance section of this document for the recommended weld crack
repair procedure.
For gasket seal repair, please refer to the General Maintenance section of this document.
For gasket on the removable panel and access hatch, GE recommends that the gasket be replaced
every time that the panel and hatch are removed for inspection and/or maintenance.
For corrosion repair and hardware replacement, please refer to the General Maintenance section of
this document.
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6 MAINTENANCE PROCEDURES
The following section provides instructions for general maintenance of the inlet filter compartment
and associated hardware while performing the recommended routine maintenance inspections.
Appropriate Personal Protective Equipment (PPE) must be worn during all maintenance repairs.
Note: If issues observed during visual inspection are not addressed in this section or doubts are
raised of the applicability of this section to the issues found, please consult with your local GEO&G
Services Representative for clarification and/or recommended course of action.
6.1 General Safety Prescriptions
Always obey your specific plants safety regulations and any applicable federal or state regulations.
The safety of plant personnel during the operation and maintenance of GT Inlet System equipment is
always of utmost importance.
Because a GT Inlet System can present safety concerns and most accidents are caused by
unfamiliarity with the equipment or carelessness, we have included this section to help heighten your
awareness of those areas and discuss some of the practices that should be adhered to.
The system must only be used in technically perfect conditions in accordance with its designated use
and the instructions set out in the operating manual.
Only safety-conscious persons who are fully aware of the risk involved in operating the system must
use the System. Any functional disorders, especially those affecting the safety of the system, should
therefore be rectified immediately.
It is impossible to list all of potential safety hazard, but it is imperative that personnel involved with the
equipment or systems are instructed to conduct themselves in a safe manner and follow the general
safety rules of the plants.
Before entering the walkway section, shut off pulse cleaning either by turning off power to the air filter
control box or shutting off the compressed air and venting the manifolds.
Pulses of air are harmful if the pulse occurs too close to the eardrums.
Also, wear eye protection when servicing the filter elements.
The exposed filter yokes are a hazard to unprotected eyes as well air suspended dust itself.
Make sure whenever you are entering the inlet system that you keep your coworkers informed. If
necessary make sure someone is immediately outside the door maintaining visual and audible
contact with anyone inside the inlet system.
Fix the maintenance door when you intend to leave it open.
Entering the Filter House while the GT is operating you may not be able to overcome the pressure
drop and open the door. Ensure that person outside the Filter House knows you are working inside.
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WARNING!
Wear ear protectors and eye protectors while inside or in the neighbourhoods of the filter system.
Pulse cleaning system shall be disabled before entering the filter house.
People shall wear appropriate protection when the atmosphere contains toxic process dust and gases. All
media can over time present breathable hazard due to bacteria accumulation and mold growth on filter
elements.
All media used in this filtration system are combustible.

Most of inlet treatment media (e.g. drift eliminators, evaporative cooler media and drift eliminators)
are flammable, too.
Use all cautions necessary to ensure that media is kept clear of all heat sources
Dont smoke or weld near the air filtration system.
All welding or other hot work must be done before installation of all inlet treatment, cooling media and
filtration media. Once installed, welding or smoking near filter house is prohibited.
Extreme caution shall be used with other potential ignition sources (lighting, power tools, etc).
Dont leave lights or any heat source unattended.
Leave enough space between the lights/heat source and the flammable media to avoid any fire risk.
WARNING!
Depending on system design the air inlet system could entraps explosive gases leakages. When entering
inside for erection or maintenance activities check for gas detection and purging room as necessary.
Always de-energize all power supplies and other energy sources (i.e. compressed air) and lock out
electrical power to prevent electric shock or injury.
Place a sign on the controls noting that the unit is being serviced and equipment must not be
energized/operated.
Operate the system with all access doors, covers and guards on moving equipment securely in
place.
Do not attempt to clean, oil or adjust any machinery while it is in motion.
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WARNING!
Take all safety measures necessary to guard against injury or electrical shock to personnel.
Be very careful when working on the inlet system. Wet or icy conditions may cause service walkways
to become very slippery.
Lifting must be done by experienced people, using adequate tools, equipment and safety measures
to prevent accidents and personnel injury or product damage.
Use all lifting points, lifting lugs and spreader bars as recommended to prevent damage due to overstressing of the components.
Take care not to damage any parts during erection. If damage occurs, take appropriate action to
ensure personnel safety as well as inlet system performance/life.
The product must be stored in an appropriate location so as to avoid multiple handling and/or
damage.
6.2 Gasket Seal Repair
Gasket sealed connections separating the clean air path from the dirty airside are required at
locations where individual sections are required to be fabricated in pieces and bolted together due to
fabrication, shipping or installation limitations.
GE approved gasket closed cell neoprene gasket with an uncompressed thickness of 6-mm or 12mm.
Gaskets are also used within the modules for air management (clean air to clean air), and at access
hatches, and doors used for inspections.
None of the gasket bolting joints shall have gaps that allows unfiltered air or water to seep into the
clean airside of the gas turbine.
Signs of air and water ingress include dirt and water staining and constitute a breach in the intended
air and watertight seal.
For replacement of torn gasket or missing gasket, please contact your local GE Services
Representative for assistance.
The recommend process for gasket inspection and repair is as follows:
Perform a light test on the suspected gasket seal. From the inside of the duct or plenum, inspect
the gasket for light coming in from the outside. If light is not visible through the gasket, proceed to
the hose test
The Hose Test is recommended to inspect gaps in the gasket seal that will allow water and dirty
air to seep into the duct and plenum. To conduct the hose test requires two people. One person
with a water hose is positioned outside of the duct and sprays water from the hose onto the
suspected gasket seal for two to five minutes. Another person on the inside of the duct inspects
the seal for water bypass.
If the light test and hose test fail to prove that there is a leak in the gasket, clean the section of dirt
and/ or water stain and continue inspecting the remainder of the inlet duct and plenum.
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6.2.1 Light Test

From the inside of the inlet system, inspect the suspected gasket for light coming in from the
outside.
All access doors and hatches shall be closed, and all viewing ports covered to prevent additional
light sources.
Internal lights inside the compartment (if any) shall be turned off.
Recommended equipment is a flashlight to allow for controlled lighting, and safe inspection inside
the system.
A light test may also be performed within the inlet system with one person standing behind the
suspected joint shining a flashlight while another person stands directly behind the joint.
Light tests are very successful at troubleshooting for missing gasket areas or improper seating of
filter elements against the supporting framework and tube sheet.
Light tests may also be used to look for air / water bypass on module-to-module interfaces.
6.2.2 Water Spray Test
The Water Spray Test or Hose test is recommended to inspect gaps in the gasket seal that will
allow water and dirty air to seep from the dirty airside into the clean airside (external joints).
This test is not recommended for inspections within the filter module as direct water impingement
may decrease the overall performance of the filters.
Two people are required as a minimum to conduct a water spray test: one person sprays water
from outside of the inlet system onto the suspected gasket seal for two to five minutes while
another person on the inside inspects the seal for water bypass.
If the light test and hose test fail to prove that there is a leak in the gasket, clean the section of dirt
and/ or water stain and continue inspecting the remainder of the inlet system.
The joint may require further surveillance to fully determine whether this is an area of concern.
This may be done through inspection doors and access hatches provided in the filter compartment
during operation or while the unit is shut down for added inspecting ability.
For gasket seals that fail the light test or water spray test, clean and dry off the gasket surface and
apply sealant to the area to create an airtight seal. Gas Turbine grade Caulk (Sikaflex 221 or
similar as approved by GE Engineering) may be used to seal off any potential air bypass locations
or non-conforming bolted gasket flanges.
Gaps equal to 6-mm or below can be readily corrected by caulking.
Gaps in excess of 6-mm shall be submitted to GE Services for further evaluation and approved
recommended method.
Sealant should be applied per the manufactures guidelines.
Note:
For extreme cold weather design conditions (below -30 degrees Celsius), use a sealant rated for
the minimum temperature required.
After the sealant is allowed to dry according to the recommendations on the manufacturer, perform
the Light or Water Spray test (as appropriate) on the gasket seal to ensure that it is air and
watertight.
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If the joint yields unsatisfactory results, repeat the process until no air or water leaks into the gas
turbine clean airside are found.
6.3 Paint Repair
The inlet system is designed so that all surfaces that come in contact with water or humid air are
sealed with primer and additional epoxy overcoat (as applicable) or mechanically sealed.
Stainless steel surfaces are generally not painted unless welded to carbon steel or required under
contract.
For information on the specific paint system used for the inlet system on a particular location, please
refer to the Project Painting Specification to determine paint products and coating systems used.
The recommend process for paint repair is as follows:
Consult the Project Painting Specification for paint system applied.
Contact the Paint Manufacturer for information on the paint system applied
Obtain recommended paint in sufficient quantities to allow for application and subsequent touchups (as needed).
Power tool or sand blast clean the area that requires paint repair due to rust or wear or other
forms of paint damage.
Prepare the area to the metal surface profile as recommended by the paint manufacturer for
proper adhesion of the intended paint system.
Apply recommended paint thickness while abiding to the manufacturers guidelines for curing
time, temperature, dew point, etc.
6.4 Field Welding
Inlet system sections are designed for bolted field assembly. The use of field welding is kept to an
absolute minimum and limited to assemblies external to the clean air path unless required for weld
repair or for hardware locking by tack welds. Field welding directly to the external shell plate of lined
ducting and the inlet plenum is not a recommended practice due to paint damage on the internal side
of the shell plate during the welding process and potential rusting on the shell plate if exposed to
moisture. In some cases, rust behind the perforated sheet liner and pillow has managed to reach the
clean airflow path where it could break loose and cause potential harm to the compressor blades.
6.4.1 Weld Crack Indication Repair on Acoustical Lining
The recommend process for weld crack repair for acoustical lining is as follows:
Mark the cracked/broken weld to be repaired. A visual inspection should be done (with
possible NDE inspection to verify a crack indication) to determine if the weld needs to be
repaired.
Mask off the adjoining perforated sheet sections surrounding the weld crack/broken weld to
prevent contamination of the acoustical pillows with metal debris during the grinding and
welding process.
Grind out the cracked/broken welds (and adjacent paint or galvanization to prevent weld
defects or toxic fumes during the welding process).
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Re-weld (TIG welding only) the perforated sheet to the supporting framework using stitch
welding with 30-mm (minimum) welds on 150-mm (maximum) centres.
Thoroughly clean the weld including removal of all loose weld spatter, excess welding
materials, weld flash, metal chips/burrs and all other foreign
Visually inspect the weld for defects and perform weld repair if defects are found. Welds should
be 100% free of defects; crack indications, porosity, lack of fusion, undercutting, etc.
After completion of welding, remove the perforated sheet covers and vacuum the pillow
insulation cavities of all dirt and debris if present
Remove all dirt and debris from the clean air plenum.
6.4.2 Weld Crack Repair on Non- Acoustical Lining and Structural Components
The recommend process for weld crack repair for non-acoustical lining and structural components
is as follows:
Mark the cracked/broken weld to be repaired. A visual inspection should be done (with
possible NDE inspection to verify a crack indication) to determine if the weld needs to be
repaired.
If weld repair is recommended for that component as a follow up requirement to visual
inspection; Mask off the welds from the adjoining areas to prevent contamination of metal
debris during grinding and welding.
Grind out the cracked/broken welds (and adjacent paint or galvanization to prevent weld
defects or toxic fumes during the welding process).
Re-weld the section using the appropriate weld electrode from the list below and per the
requirements of the applicable welding code:
Base Metals
Electrode (or filler rod) designation
Carbon Steel-Carbon steel

409-409, 304-409, 409 or 304-carbon steel
304-304
304L-304L
304L-Carbon Steel
316L-316L
321H or 321
E7018
309
308
308L
309L
316L
DIN E19.9
Thoroughly clean the weld including removal of all loose weld spatter, slag, excess brazing or
welding materials, weld flash, metal chips/burrs and all other foreign
Paint or cold galvanize the exposed carbon steel. Any burnt paint from welding must be
removed and repainted (in accordance with paint repair section of this document).
For galvanized structures, apply cold galvanization touch up in accordance with ASTM A780Standard practices for Repair of damaged Hot Dip Galvanized Coating. For all painted
structures, please refer to the section for paint repair.
Remove all dirt and debris from the clean air plenum.
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6.5 Corrosion Repair

6.5.1 Corrosion Repair for Acoustical Lining
The recommend process for corrosion repair for acoustical lining is as follows:
The perforated sheet must be cleaned of corrosion or replaced with new perforated sheet
(304L/316L SS or galvanized perforated sheet for older units). The framework should be
repaired if necessary.
Mask off the perforated sheet to be removed and the adjoining perforated sheet sections to
prevent contamination of the acoustical pillows with metal debris during the grinding and
welding process.
Grind out the welds holding the corroded section of perforated sheet to the framework (and
adjacent paint or galvanization to prevent weld defects or toxic fumes during the welding
process).
Remove the section of perforated sheet
Vacuum the acoustical pillows behind the perforated sheet and store in a clean, dry place (rust
bleed on the pillows will require the pillow to be replaced)
Clean off the perforated sheet section and store in a clean dry place away from
grinding/welding activities.
Inspect the framework for corrosion. If present, the corroding piece (most likely painted carbon
steel) must be sanded down to the correct profile for paint re-application using the guidelines
for paint repair discussed later on in this section. If the material is stainless steel, clean with
pickling solution.
Re-install the acoustical insulation and the perforated sheet.
Re-weld the section using the TIG process:
Thoroughly clean the weld including removal of all loose weld spatter, slag, excess brazing or
welding materials, weld flash, metal chips/burrs and all other foreign
After completion of welding, remove the perforated sheet covers and vacuum the pillow
insulation cavities of all dirt and debris if present
Paint repair (Carbon Steel framework only) with touch up paint after welding where necessary
Remove all dirt and debris from the inlet duct
6.5.2 Corrosion Repair for Non Acoustical Lining and Structural Components
For details on corrosion repair for non-acoustical lining and structural components, please refer to
the Paint Repair Section for recommended guidelines.
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ATTACHMENT 1
MAINTENANCE CHECK LIST
The checklist detailed here below is not intended to substitute the content of this document and
cannot be considered as self-standing.
The most applicable paragraph of the document is referred in the Para. Column.
This checklist has always to be used in conjunction with the rest of the document that has to be
applied as a whole.
An X indicates the phase when it is suggested to perform each inspection activity.
INSTAL . means During Installation
OPERAT. means During System Operation
MAINTE. means During System Maintenance (so when the GT is not operating)
ACTIVITY DESCRIPTION
Air Filtration System
Para.
I
N
S
T
A
L
.
O
P
E
R
A
T
.
M
A
I
N
T
E When
. (during operation)
Verify Filter Elements are (and have been) properly stored
4.1
Verify storage period to be not longer than 3 years from FE 4.1

manufacturing date
Verify FE are lift inside the filter house kept in their original 4.1
cartons
Record pressure drop behaviour periodically and link to 4.2

environmental and GT operating conditions.
Weekly
Verify alarm and GT shut-down set values
4.2
At least every 3
months
Visually inspect filter elements on a regular basis.

4.2
Visually inspect for tears or holes in the media and leaks in the
area around the gasket seal.
Check any filter element suspected for leakage by inserting a 4.2
light inside the clean air side
At least every 3
months
Verify that all filter elements have been changed at once
4.2
X
Once each set of filter
elements
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4.1
X X X Once each set of filter

elements
Verify filter elements have been sourced from approved 4.3

vendor and are of an approved type

elements
Verify FE have an external mesh

elements
Verify date of production of the installed filter elements
4.3
Check the spiral bead of glue to properly adhere to the filter 4.3
media, for self-cleaning cartridges.
Verify that filter elements come with a new sealing gasket and 4.3
with a new retaining washer (for self-cleaning cartridges)
X Once each set of filter

elements
Verify that the new retaining washer and special nut has been 4.3
installed (for self-cleaning cartridges)

elements
Verify bag prefilters to be installed with the filter bags vertically
4.4.1.

elements
Verify barrier filter elements to be installed with the filter 4.4.1.

separators vertically and in proper direction of airflow

elements
Check self-cleaning cartridges dont turn
X X X At least every 3
months
4.4.2
When removing cartridges, immediately inspect the clean 4.4.2

airside of the housing for dust streaks (e.g.: the tube sheet for
a self-cleaning filtration system).
Check yoke legs correct sequence and correct orientation
4.4.2.3.
X
X
Inspect Filter Elements (gasket and dealing surface for 4.4.2.3.

damage).
Verify filter elements to be positioned with their gasket upward 4.4.2

on service platform.
Verify Filter Elements installation starts from the top row and 4.4.2.3.
proceed from top and bottom
Make sure elements are installed in a proper way by 4.4.2.3.

experience crew (verify at least the assembly of some
elements with the crew)
Verify Filter Elements fit tightly against the tube sheet and 4.4.2.3.
against each other.
Check gasket compression and retaining bolt protrusion out of
the Filter Element cap.
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Check each Filter Element installed for leakage from CAP
4.4.2.3.
Check each Filter Element installed for leakage from DAP
5.6.
Verify brush or vacuum clean of any dust that could have 4.4.2.3.
accumulated over the elements at the tube sheet level and at
any other location where it might fall off into the clean airside
while changing the elements.
Start doing this at the top row of elements.
Check droplet catchers properly fit against weather hoods
5.1.
X At each GT shut
down if dust is found
in the CAP
X
At least every 3
months
X
X X X At least every 3
months
Check droplet catchers integrity
5.1.
X X X Weekly
Check water level inside the drain box
5.2.
X X X Weekly
Verify all external gasket joints that separate dirty air from 5.3
filtered air side have been sealed off with a caulk profile on the
outside to create a redundant approach in sealing the clean
airside.
Verify sealant type used
5.3
Verify sealant expiry date
5.3
Verify bolts are tighten to maximum torque only after the pre- 5.3
assembly is completed to allow free positioning, levelling and
squaring.
During erection verify, all parts are to be lifted with care and 5.3
with the appropriate lifting methods, using the eyebolts
provided or required by the drawings. If necessary, temporary
bracing must be installed before lifting. Care must be taken
not to damage any parts during erection.
Verify that all bolting inside the clean air section have been 5.4
tack welded unless approved self-locking nuts are used.
Verify all damaged surfaces have to be touched up
5.4
Check that any protections around the nozzles of the 5.4

blowpipes are removed in a self-cleaning filtration system.
X X X Each time sealant is

applied
X Each time sealant is
applied
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Verify that any open threaded pipe connection have been 5.4.
closed with plugs or have been connected to their lines.
X X X Every 3 months
After installation is complete, do a walkthrough inspection 5.4.

throughout the entire filter house in order to ensure that all
equipment has been installed as per the manufacturers
recommendations.
Verify that all surfaces downstream of the filter media and tube 5.4.
sheet (clean air plenum) have been properly cleaned.
Verify that any inspection windows in the filter compartment

module doors and access hatches is clean and free of damage
(scratches, cracks, etc.) to allow for a clear view of the gas
turbine compartment surfaces and walkways.
Any objects that are brought in for inspection and maintenance
downstream the final filter stage shall be tracked, accounted
for, and removed prior to operation.
Before the gas turbine start-up the inlet system shall be
thoroughly tested for air leakage.
Perform a light test and a Hose Test to check all bolted and
gasket joint to be fully airtight.
Before the gas turbine restart-up the inlet system shall be
thoroughly tested for air leakage. Perform a light test and a
Hose Test to check all bolted and gasket joint to be fully
airtight.
Verify that all applicable instrumentation have been tested and
calibrated to ensure that it is in proper operating condition.
5.4.
5.4.
5.4.
5.4.
5.5.
Check that large trash pieces and/or debris droplet catchers, 5.5.
bird screens and coalescer stages
Weekly
Monitoring of the pressure drop reading shall be complimented 5.5

with multiple walkthroughs across all filter compartment
walkways in the dirty air side in order to look for signs of
excessive wear, tear, corrosion, and fouling of individual filters
that may not be performing at optimal levels.
Accurately inspect filter elements for tears or holes in the 5.5
media and leaks in the area around the gasket seal (ref. to
fig.15, too)
Periodically inspect the clean air plenum.
5.6
1 2 times per month
Every 3 months
At least once a year

or at any GT shut
down
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Check for heat tracing around steam supply piping, air 5.6
manifolds, and / or electrical equipment to meet
manufacturers recommended operational parameters.
Every 3 months
Check for any increase or decrease in pressure drop that can 5.6
indicate a problem in the filter house (plugged filter elements,
leaks, cleaning malfunction or other cause) that requires
immediate action.
Check each gasket sealing efficiency (on all the perimeter of 5.7.
each flange).
Pay maximum attention at the corners and at each gasket
joint.
Check also if any leakage is through the bolts.
5.7.
As pressure drop
variation happens

or at any GT shut
down
Consider all the flanged joints (between transition and duct, 5.7.
between transition and filter modules, between the filter
modules, at the man hatches).

or at any GT shut
down
or at any GT shut
down
X At least once a year
or at any GT shut
down
While the GT is not in operation, enter the duct and

5.7.
check if any light is visible looking outward
perform an hose test
check the inner surface of the clean air plenum for
sand/dust/water presence (in the corners or near any
obstruction in the air flow, too).
Note:
If a contamination of the clean air plenum and inlet duct
happened, before restarting the GT, vacuum clean the inlet
system clean air system (clean the silencer baffles, too).
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Remove (at least random) some filter elements and check the
tube sheet sealing (dark to bright surface on the tube sheet).

or at any GT shut
down
From the clean air side (and using blow pipes to reach all the
levels) check visually for any gap between the conical element
gasket and the filter wall (see figure below)

or at any GT shut
down
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Inlet Duct System

Inspect the entire belt of the expansion joints (exterior and 5.7.
interior) for cuts, worn sections, or cracks.
Note:
Check not only inlet duct expansion joints but also fans
expansion joints.
Inspect the metal backing bar and hardware on the exterior of 5.7.
the expansion joints for corrosion and tightness
Inspect the flange interfaces of each duct section with the 5.7.
adjoining section for signs of air and water leakage past the
flange gasket.
Inspect the exterior of the duct for signs of corrosion.
5.7.

or at any GT shut
down
Inspect the interior of the duct for signs of corrosion.

or at any GT shut
down
or at any GT shut
down
or at any GT shut
down
X
or at any GT shut
down
X
or at any GT shut
down
X X Every 3 months
5.7.
Ensure that interior duct walls, ceiling, and floor (of not 5.7.
insulated sections) contain no visible dirt and debris.
Inspect the acoustical lining in the wall, ceiling, and silencer 5.7.
panels for signs of rust stain, dirt, or debris.
Inspect the silencer panel support brackets located at the top 5.7.
and bottom of the panels on the ends for sign of weld crack
indications. Inlet Bleed Heat Module
Inspect the internal Inlet Bleed Heat Pipe and Pipe Guides for 5.7.
weld crack indications.
Inspect the Inlet Bleed Heater Pipe Insulation covering the 5.7.
externally mounted section on the top of the duct for signs of
thermal leakage (discoloration).
Inspect all ports for plugs/ caps (if not in use for 5.7.
instrumentation purposes). All ports require an airtight seal.
Inspect all access hatches for an airtight seal.
5.7.
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Inspect the woven mesh screen for tautness to prevent 5.7.

excessive vibration. Large deflections in the screen when
pressed are not acceptable and should be replaced.
Inspect the mesh screen and framework for loose screen wire 5.7.
and remove as a potential FOD risk
Inspect the framework of the trash screen for signs of rubbing 5.7.
against duct bracing. Rubbing, if present, will wear away at the
corrosion protective layer on the bracing.
Inspect for any broken wires or missing screen sections. 5.7.
Sections with broken wire and/or missing screens must be
replaced.

or at any GT shut
down
or at any GT shut
down
or at any GT shut
down
or at any GT shut
down
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Nuovo Pignone

Operation and Maintenance Recommendation for Gas turbine

AGGIUNTA LINGUA ITALIANA

2002 Nuovo Pignone S.p.A., all rights reserved

Electronically approved draw. GE NuovoPignone Internal DT-'N'

Operation and Maintenance Recommendation for Gas turbine

Operation and Maintenance Recommendation for Gas turbine

AGGIUNTA LINGUA ITALIANA

2002 Nuovo Pignone S.p.A., all rights reserved

Operation and Maintenance Recommendation for Gas turbine

6.3 Paint Repair

AGGIUNTA LINGUA ITALIANA

2002 Nuovo Pignone S.p.A., all rights reserved

Operation and Maintenance Recommendation for Gas turbine

AGGIUNTA LINGUA ITALIANA

2002 Nuovo Pignone S.p.A., all rights reserved

Operation and Maintenance Recommendation for Gas turbine

AGGIUNTA LINGUA ITALIANA

2002 Nuovo Pignone S.p.A., all rights reserved

Operation and Maintenance Recommendation for Gas turbine

AGGIUNTA LINGUA ITALIANA

2002 Nuovo Pignone S.p.A., all rights reserved

Operation and Maintenance Recommendation for Gas turbine

3 GAS TURBINE AIR FILTRATION SYSTEMS

Vertical Flow Self-cleaning System Scheme

AGGIUNTA LINGUA ITALIANA

2002 Nuovo Pignone S.p.A., all rights reserved

Operation and Maintenance Recommendation for Gas turbine

Vertical Flow Self-cleaning System Filter Elements Arrangement

AGGIUNTA LINGUA ITALIANA

2002 Nuovo Pignone S.p.A., all rights reserved

Operation and Maintenance Recommendation for Gas turbine

Horizontal Flow Self-cleaning System Scheme

Horizontal Flow Self-cleaning System Filter Elements Arrangement

AGGIUNTA LINGUA ITALIANA

2002 Nuovo Pignone S.p.A., all rights reserved

Operation and Maintenance Recommendation for Gas turbine

3.2 Low velocity Static Barrier Air Filtration Systems

AGGIUNTA LINGUA ITALIANA

2002 Nuovo Pignone S.p.A., all rights reserved

Operation and Maintenance Recommendation for Gas turbine

Static Barrier Filter House

AGGIUNTA LINGUA ITALIANA

2002 Nuovo Pignone S.p.A., all rights reserved

Operation and Maintenance Recommendation for Gas turbine

High efficiency stage

High Velocity Filtration System

Demister Van Separator Principle Illustration

AGGIUNTA LINGUA ITALIANA

2002 Nuovo Pignone S.p.A., all rights reserved

Operation and Maintenance Recommendation for Gas turbine

AGGIUNTA LINGUA ITALIANA

2002 Nuovo Pignone S.p.A., all rights reserved

Operation and Maintenance Recommendation for Gas turbine

AGGIUNTA LINGUA ITALIANA

2002 Nuovo Pignone S.p.A., all rights reserved

Operation and Maintenance Recommendation for Gas turbine

Filter Elements collapse

AGGIUNTA LINGUA ITALIANA

2002 Nuovo Pignone S.p.A., all rights reserved

Operation and Maintenance Recommendation for Gas turbine

Water induced collapse of pre-filter

AGGIUNTA LINGUA ITALIANA