Som 6664417

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TITOLO - TITLE
Operation and Maintenance Recommendations for Gas turbine

Exhaust Systems
COMM. - JOB
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Laneri R.
Lascialfari G.
Italian language added

General Revision all pages. Rewording
GDS
Pucci
EMISSIONE - ISSUED
Pucci
09/10/09
Calza G. Marchetti 30/04/09
Calza G. Marchetti 05/01/09
REV
DESCRIZIONE - DESCRIPTION
PREP'D
CONT-CHK'D
2002 Nuovo Pignone S.p.A., all rights reserved
APP- APPR'D
N. SOM 6664417/4
DATA - DATE
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SOSTITUITO DA - REPLACED BY
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Electronically approved draw. GE NuovoPignone Internal DT-'N'

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INDEX
1 Introduction
2 Background
3 General Safety Prescriptions
4 Gas Turbine Exhaust System Installation
5 Gas Turbine Exhaust System Commissioning
6 Factors that may affect the proper operation of the Exhaust Systems
7 Gas Turbine Exhaust System Inspection
8 Inspection Schedule
9 Gas Turbine Exhaust System Maintenance
ATTACHMENT 1
Inspection and Maintenance Check List
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1. INTRODUCTION
The gas turbine Exhaust System is an important element of the plant whose proper
operation is often critical to production.
Owners, operators and users have an obligation to protect the health and safety of their
employees and others affected by the operation of the Gas Turbine Plant.
This obligation includes the responsibility to ensure that the exhaust system is properly
maintained and remains in a safe condition.
GT exhaust systems are subject to deterioration due to high temperature, high
turbulence and chemical attack as well as to the effects of the weather.
In order that GT exhaust systems remain safe and fit for continued service, they need to
be inspected and maintained at regular intervals.
Damage or deterioration to GT exhaust systems may not be readily apparent, partly
because access to damaged areas may be difficult, and partly because the damage
may not be visible until it becomes serious.
Neglect of maintenance can lead to the need for expensive emergency repairs and may
even result in structural failure.
Furthermore, inadequate inspections and low standards of workmanship can be costly
and may well reduce the service life of an exhaust system by causing damage and
promoting or increasing deterioration.
For example, careless replacement of insulation after an inspection may create hotspots; bolts or gaskets removed for inspection may be incorrectly re-installed; butt
welds may be replaced by fillet welds, etc.
This document is intended to provide the Gas Turbine operator with general guidelines
and suggestions to ensure proper installation, operation, inspection and maintenance of
the gas turbine exhaust system.
The procedures defined in this document will help to identify malfunctions and
determine their causes and corrective maintenance procedures.
The periodic inspection outlined in the following sections should enable the early
observation of wear and other defects, which when rectified, will maintain the
equipment in the required operating condition.
This document is not intended to replace the information provided as part of the Gas
Turbine Exhaust System Operation and Maintenance (O&M) Manual.
Should any conflict arise between this document and the GT Exhaust System O&M
Manual, please contact the local GE representatives for resolution.
This document does not cover the inspection and maintenance of electrical or
mechanical items such as gas sampling equipment, powered hoists or elevators.
Electrical systems may include aircraft warning lights, jib cranes, gas monitoring
systems and sometimes pressurization systems.
The maintenance of such equipment should be carried out in accordance with
recommendations provided by the manufacturer and supplier.
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2. BACKGROUND
The function of the Exhaust System is to direct exhaust gases from the Gas Turbine
exhaust plenum to the atmosphere or to a WHRU connecting flange with minimum flow
disruption and pressure drop.
The Exhaust System also attenuates noise from the GT exhaust plenum to acceptable
levels to meet contractual noise requirements.
Casings and Expansion Joints should also limit the breakout noise to acceptable levels
to meet contractual noise requirements.
The exhaust system shall be able to operate properly at the environmental conditions
specified for the installation site.
The following key components are typically part of a GT Exhaust System and each
component has special requirements and characteristics that must be taken into
consideration:
Expansion Joints
Insulation lagging system
Thermal and acoustic insulation system
Silencer baffles
Chimney
Supports (fixed and sliding)
Expansion Joints
Expansion joints are typically of the flexible membrane type (fabric) with an internal
bolster bag.
Expansion joints allow for free thermal expansion and shall always be installed where
there is a transition between an internally insulated area and an uninsulated area.
The outer gas seal membrane must have optimum mechanical strength and resistance
to abrasion to accommodate the thermal expansion of the duct in any direction, and
must have high resistance to chemical attack.
The outer seal membrane must be thermally insulated to withstand the gas
temperature also in the event of a failure of the bolster bag.
Insulation Lagging System
The Exhaust System is generally internally insulated and lagged.
The internal insulation is covered with high temperature, corrosion resistant steel
lagging applied in small pieces to allow movement relative to the attachment studs.
In general, the lagging sections should overlap in the direction of the gas flow.
The lagging and attachment studs are designed such that the insulation would not be
exposed to the hot gas flow with any movement of the lagging system.
The studs may be welded directly to the duct casing or to a scallop bar which in turn is
welded to the casing.
Most field-flanged joints are internally insulated and lagged at the site to provide a cold
field joint.
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Studs on the first row are provided with a plastic nut to keep the batten channels and
washers in place during transportation to avoid the risk of seizing of the stainless steel.
When the internal insulation cannot be continuous, C shaped end trims are provided.
Thermal and Acoustic Insulation System
Insulation materials in current use are approved products of long fiber, high
temperature basalt wool or Alkaline-earth silicate wool, able to operate properly in the
GT exhaust environment.
The insulation material is not classified under EU Directive 97/69EC (67/548/EEC
Amendment MMVF) and is excluded from carcinogen classification because of low
pulmonary bio-persistence. It shall be non-flammable, non-hygroscopic, non-waterretaining and vermin proof, and shall not contain sodium or asbestos.
If not otherwise required, the insulation thickness is at least 150 mm (nominal) in all
ductwork sections where personnel access may be expected (or personnel protection
devices must be provided). Other sections, located more than 7 meters off the ground,
have a 100 mm (nominal) minimum insulation thickness. An exception is granted for
expansion joints connected to exhaust plenums having thinner internal insulation, and
for exhaust systems that are protected by an acoustic wall.
The studs and the scallop bars support the insulation material. The studs and scallop
bars spacing is generally limited to around 300 mm to avoid sagging.
A layer at least 25 mm thicker than the nominal insulation thickness is installed every
150 mm to provide a spring effect to the insulation on the lagging system and to
minimize the possibility of air pockets which can cause degradation of the insulation
and impair the thermal and acoustic performance.
Pillows are required under perforated sheets.
The envelope of the pillow (made of high temperature textile) is cut and sewn to create a
depth of +5% over the required thickness of the pillow in order to ensure good contact
between the pillow and the perforated sheet.
Silencer Baffles
Silencer baffles are constructed of a steel framework filled with acoustic insulation
material (wrapped to protect it from flow erosion) and covered by perforated steel sheet
welded to the frame.
Silencer baffles are designed with an inlet bull nose and, if needed, a tapered exit to
promote smooth flow and minimize pressure losses.
The silencer baffle frame and bull nose are made of stainless steel.
The active sides of the silencer baffles are stainless steel perforated sheets.
The silencer baffle acoustic fill material is long fiber, high temperature acoustic basalt
wool able to operate properly in the GT exhaust environment this material is used to
fill pillows.
The insulation pillows are oversized to allow for complete filling of the space to be
insulated and tight contact with the perforated sheet.
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Chimney
The purpose of a stack is to vent process exhaust gases to the atmosphere.
The height and diameter are set by a balance between structural stability and function,
while at the same time meeting the requirements for air pollution control and the
dispersion of the gases into the atmosphere.
To limit the recirculation of hot gases, the elevation of the stack outlet flange should be
2.5-3.0 meters above the elevation of the highest point from which air enters the gas
turbine inlet system.
Cylindrical stacks must be designed and manufactured in accordance with the ASME
STS-1 or CICIND code.
For stacks made of carbon steel, a 1.5mm minimum corrosion allowance is specified.
No corrosion allowance is applied for stainless steel stacks.
The insulation system at the top of the stack is capped to prevent water from entering
the insulation system.
The stack has a drainable bottom lower than the horizontal duct floor level (for vertical
exhaust systems this requirement applies to the GT exhaust plenum).
A double drain design is applied to allow drainage from the top of the internal lining
and from the bottom of the stack casing under the insulation material.
The stack base skirt must include adequate cooling holes to limit the foundation
temperature to an acceptable level to avoid damage to the concrete.
Supports (Fixed and Sliding)
The following are critical components of the supports and sliding system of an exhaust
system.
The actual configuration of the system should be verified to be in accordance with the
design documents.
General considerations are detailed below.
Fixed Points
All ducts exposed to elevated temperatures experience thermal growth.
Each section of duct between two expansion joints must be secured to the
supporting structure in one and only one location (Fixed Point) so that it may
expand in all directions without resistance.
The Fixed Point does not have to be a gravity support.
Also, a Fixed Point may be artificial.
The intersection of two perpendicular lines of duct guides is the point of zero
movement. That point is considered a Fixed Point even though there may be no
physical attachment to the support structure at that location.
The Fixed Point should be located so as to minimize the shear across expansion
joints, to simplify the duct expansion behavior, to simplify the support structure
configuration and to equalize the duct expansions.
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For duct sections that have multiple sets of supports, it is best to place the Fixed
Point near the center of mass of the duct sections. This will reduce the friction
forces.
Fixed Points are typically formed by bolting the duct directly to its support structure
or by a shaft-to-pipe connection.
Duct guides
A duct guide is a connection between the duct and its support structure that
transfers the wind loads, seismic loads, expansion joint actuation forces,
unbalanced pressure, and unbalanced friction loads acting perpendicular to one
direction of thermal expansion from the duct to the support structure.
Duct guides should be on one of the principal anchor lines of the duct section and
always must allow thermal growth away from a Fixed Point.
If a Duct Guide is also a gravity support for the duct, a friction force is developed
along the anchor line as the duct expands thermally. A slide bearing plate is usually
under the gravity support base plate to keep this friction force to a minimum.
Guides are most often formed by installing bumpers or guide bars at duct sliding
points.
Duct sliding supports
The gravity connections between the duct and its support structure, where
unrestrained thermal growth is allowed, are called sliding supports.
As the duct undergoes thermal expansion, friction forces are developed which act in
both global directions away from the Fixed Point. A slide bearing plate is usually
used under a gravity support base plate to keep these friction forces to a minimum.
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3. GENERAL SAFETY PRESCRIPTIONS

Always obey your plants specific safety regulations and any applicable federal or state
regulations.
The safety of plant personnel during the operation and maintenance of GT Exhaust
System equipment is always of the utmost importance.
Because a GT Exhaust 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 under technically perfect conditions in accordance with
its designated use and the instructions specified in the Operating Manual. Any
functional disorders, especially those affecting the safety of the system, should
therefore be rectified immediately.
Only safety-conscious personnel who are fully aware of the risks involved in operating
the system should use the System. It is impossible to list all of the potential safety
hazards, 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 plant.
Make sure that whenever you are entering the exhaust system it has been properly
cooled and vented, and that the operation of gas turbine is prevented by an appropriate
isolation procedure.
Before entering the exhaust system put on eye protection and a hard hat.
Safety breathing equipment may be required by the Local Regulations as well.
Make sure that whenever you are entering the exhaust system you keep your coworkers informed.
If necessary make sure that someone is immediately outside the access door
maintaining visual and audible contact with anyone inside the exhaust system.
Prop the access door when you intend to leave it open.
WARNING!
Wear eye protection, protective clothing and gloves while outside a GT Exhaust System in operation or
inside a GT Exhaust System.
GT Exhaust Systems can present a respiratory hazard due to unburned hydrocarbons or improper venting.
When entering the exhaust system for installation or maintenance activities check for gases and purge the
room as necessary, and prevent restarting of the gas turbine.
Appropriate protection must be used when the atmosphere contains toxic process gases.
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Whenever inspecting an exhaust system in operation, the hazards of inspecting a

system on-line must be known to allow the proper protective equipment to be
furnished.
Do not touch external surfaces of an exhaust system in operation without protective
clothing and gloves.
Always de-energize all power supplies (if any) 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 that the
equipment must not be energized or operated.
WARNING!
Take all safety measures necessary to guard against injury or electrical shock to personnel.
Be very careful when working on the exhaust system.

Wet or icy conditions may cause the internal lining to become very slippery.
Stacks and chimneys require work at elevated levels and therefore, specialist access
and work procedures are necessary.
Contractors intending to carry out any work on a stack or chimney should submit risk
assessments and method statements for the work.
Very old exhaust systems may contain dangerous materials, particularly asbestos. In
these old systems, asbestos, lead and other hazardous materials may also be present in
coating materials.
Exhaust systems, mainly those built during the 90s, may also contain ceramic fibers.
Refractory ceramic fibers have been classified by the EU as a category 2 carcinogen.
All exhaust systems, even the most recent ones, contain man made vitreous insulating
fibers that are classified at least as irritants.
These hazardous materials may cause an environmental hazard during demolition or
maintenance.
Hazardous materials should be identified in advance of any work on an exhaust system
and the work should be carried out in accordance with local health and safety
legislation.
When removing this type of insulation from existing exhaust systems, care should be
taken to avoid creating airborne dust.
Dust-suppressing cleaning methods such as wet sweeping or vacuuming should be
used to clean the work area. If vacuuming, the vacuum must be equipped with an HEPA
filter.
The use of a full face-piece air purifying respirator equipped with an appropriate
particulate filter cartridge should be used during exhaust system tear-out and the
removal of used RCF (Refractory Ceramic Fibers) to control exposure to airborne fibers
and the potential existence of crystalline silica.
Workers shall always wear appropriate gloves, head covering and full body clothing as
necessary to prevent skin irritation. Safety glasses with side shields or other forms of
eye protection shall be worn.
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Take care to avoid fiber penetration into areas between personal protection equipment
(i.e., between gloves and clothing, shoes and clothing, etc.).
Similar precautions should be applied for handling any fibrous insulating material.
Check local, regional, state and provincial regulations to identify all applicable disposal
requirements.
Lifting must be done by experienced people, using adequate tools, equipment and
safety measures to prevent accidents and personal injury or product damage.
Use all lifting points, lifting lugs and spreader bars as recommended to prevent damage
due to over-stressing of the components.
Take care not to damage any parts during handling. If damage occurs, take
appropriate action to ensure personnel safety as well as exhaust system
performance/life.
Access systems should be installed in accordance with current codes of practice.
Ladder hooks, where present, should be closely examined during the initial ascent for
security of the attachment and suitability for use. If ladder hooks are to be retrofitted to
an existing exhaust system, the work should only be carried out by a certified welder
using an approved welding procedure and working from a suitable means of access.
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4. GAS TURBINE EXHAUST SYSTEM INSTALLATION

In order to avoid damage to the system components when rigging and lifting, it is
recommended that multiple lift points be used.
Caution should be exercised to ensure that multiple sections are not lifted in place as a
single unit unless multiple lift points are used to distribute the combined load properly.
Failure to follow this precaution may result in damage to the duct component and
possible injury to installation personnel.
WARNING!
Refer to Lifting Drawings for proper lifting configuration.
Severe damage to ductwork and danger to personnel can occur if ducts are lifted improperly.
Bracings (when provided) shall remain in place during lifting until the duct is installed.
All ducts shall be stored and positioned to allow drainage of the insulation should it
become wet.
All efforts should be taken to avoid water and dust contamination of insulation
materials.
Protective shipping coverings, if provided, shall remain in place as long as possible.
In addition, each duct section shall be supported 200-300mm off the ground to prevent
ponding and build-up of contaminants.
Insulation protection shall be removed just prior to the installation of the components.
If possible, store expansion joints in a building.
Do not store other equipment on top of expansion joints.
At temperatures below +5C, expansion joints show increased sensitivity to bending.
Therefore, warm expansion joints to +10C before handling.
Damage to the interior insulation and liner may occur if field installation personnel walk
on or place scaffolding or equipment directly on the liner sheet without first placing
plywood sheets or other rigid protection on the liner sheet to distribute the load.
It is the erectors responsibility to ensure that all insulation is properly installed and that
there are no gaps, especially at duct joints, in order to prevent potential hot spots.
No insulation gaps are allowed.
A common rule that the erector should follow for field cutting of insulation is as follows:
insulation length/width of 300mm or less should be cut at least 6mm longer than the
required length
insulation length/width of over 300mm should be cut at least 12mm longer than the
required length
Prior to installing the support structure, the contractor should verify that all elevations
and anchor bolts (if pre-embedded) have been set in accordance with the applicable
drawings and are within the tolerances establish by AISC Code.
When installing bolts, do not fully tighten them until the component is plumb, square
and level, since some adjustment may be necessary.
High strength bolts should by tightened using one of the following:
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turn-of-the-nut method
load indicating washers
calibrated wrenches
WARNING!
Proper tightening of nuts for field-installed liners is critical to proper system performance.
Always refer to the torque table in the applicable erection drawing.
Any modification procedure must be approved in writing by GE prior to the start of

work.
Any required straightening of material must be done following procedures that will
result in the minimum residual stress to the steel.
Straightening or bending anchor bolts by heating is prohibited.
Stacks must be true and plumb to within 25mm over a 30 meter distance.
Field Liner Splice installation Notes
Apply proper load distribution plates when stepping on the internal lining of internally
insulated exhaust systems.
In the field, remove and discard only the plastic nuts provided on the last row of studs (if
any).
Carefully save all clamping bars, channels and washers because these must be reused
during erection.
Carefully fill all duct splices with the proper quantity of insulation fill material.
Always stagger splices in insulation 300mm apart.
No through spaces or voids are allowed!
Install field liner trim; reuse existing clamping bars/channels and washers.
Visually inspect all threaded studs for damage and chase damaged threads using an
appropriate thread restoration tool. Apply antiseize lubricant to stud treads.
Install retaining nuts assuring that tight contact is made between the nut and the
washer, washer and channel, channel and field liner, field liner and shop liner, and shop
liner and support scallop bars.
Do not exceed 40 N*m of torque when tightening.
Use a calibrated torque wrench.
Then, back off or loosen the liner retainer nut exactly one half turn (counter-clockwise).
Then, weld the nuts to the studs when in a channel. Weld the nuts to the studs and
washers when not in a channel
Silencer Baffles
Silencer baffles are normally delivered loose for site installation inside the silencer
casing.
When installing baffles, always check they are free to move from thermal expansion.
Expansion Joints
Unpacked expansion joints must be moved extremely carefully.
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Do not drag expansion joints along the ground or across edges.

Transit clamps are fitted to the expansion joint flanges of complete units which are
ready for assembly to protect them during transportation. They also assure that the
correct installation dimensions are maintained.
They must be removed after installation and before start-up of the plant to allow for
free movement of the expansion joint.
Expansion joints are usually installed in the exhaust system to adsorb thermal growth of
the ductwork by compression.
It is of the utmost importance that the expansion joint be installed at or slightly greater
than its nominal extension.
If the location where the expansion joint must fit is less than the nominal dimension,
rework is required.
In the evaluation of accumulated tolerances (), X has to be algebraically added.

S is measured for each individual flange or as a combination of the out-of-planarity of
the two flanges.
WARNING!
During erection always install expansion joints at or slightly greater than their nominal extension.
Contact the expansion joint manufacturer if any of the above tolerances cannot be achieved.
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When an expansion joint is shipped to be joined at the site, the detailed instructions of
the textile vendor shall be carefully followed.
While silicone impregnated glass fiber cloth may be cold joined using an appropriate
caulk, a PTFE impregnated glass fiber cloth can only be thermally joined using
appropriate heating equipment.
Gasketting
Bolted gasket joints are provided throughout the exhaust system to prevent hot gases
from escaping from the system.
Joints must be leak-free.
High Temperature glass fiber gaskets are used at all bolted joints.
When installing gaskets, follow the recommendations listed below:
Apply gaskets to dry, dust free and degreased surfaces.
Prevent the gasket from being rolled by relative motion of the joined items during
erection.
Ensure the continuity of the seal.
Tighten bolts to the maximum torque only after the pre-assembly has been
completed to allow positioning, levelling and squaring.
All parts must be lifted with care and with the appropriate lifting methods, using
the eyebolts or lifting lugs 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 exhaust system that all gaskets and bolted joints are
installed correctly to help eliminate the risk of hot gas leakage.
It must be verified that the presence of and proper installation of gaskets complies with
the installation drawings and instructions provided by the exhaust system vendor.
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5. GT EXHAUST SYSTEM COMMISSIONING

Carefully protect internally insulated exhaust systems before and during erection to
avoid the ingestion of blowing dust or rain that could damage the insulation materials.
Close any open threaded pipe connection with plugs or caps.
All damaged surfaces have to be touched up.
Check that any transportation bracings (e.g., expansion joint transportation bars) have
been removed prior the GT start-up.
After the installation has been completed, it is important to do a walkthrough inspection
of the entire exhaust system in order to ensure that all equipment has been installed as
per the manufacturers recommendations and the system is free of dirt, debris, tools,
and all other potential foreign objects.
All internal surfaces downstream of the exhaust system should be cleaned.
Any debris detected must be removed.
Any objects that are brought in for inspection and maintenance should be tracked,
accounted for, and removed prior to operation.
Before the gas turbine start-up, the exhaust system should be thoroughly tested for gas
leaks.
Perform a light test to insure that all bolted and gasketted joints are fully airtight.
From the inside of the duct or plenum, inspect the joints for light entering from the
outside.
For gasket seals that fail the light test, retighten the flange bolts and re-gasket as
needed to create an airtight seal.
All sections of the Exhaust System must be completely installed, all drains must be open
or connected to the customer drain lines and all access hatches must be closed and
sealed prior to turbine start-up.
When all internal activities have been completed, remove any internal scaffolding, leave
the inside of the exhaust system, close the access-hatch, and prevent access by any
unauthorized person.
Paint touch-ups
All paint damage must be corrected before system start-up.
It is essential that the appropriate paint coats be applied based on the depth of the
damage.
An intermediate coat must be applied where necessary; a topcoat must be applied in
any case.
Allow for sufficient curing time before applying the next coat of paint and before any
other cleaning operation.
Refer to the project specific painting specification and to the paint technical data sheets
for details.
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6. FACTORS THAT MAY AFFECT THE PROPER OPERATION OF THE EXHAUST SYSTEM
Exhaust ductwork systems are often exposed to adverse chemical conditions and high
temperatures. Additionally, many ducts are also subject to the varying environmental
conditions associated with local weather and atmospheric pollution.
Each exhaust system is designed for a specific set of operating conditions.
These include the gas composition, the gas flow and the range of operating
temperatures.
The design range of these parameters should not be exceeded. Severe damage can be
caused to an exhaust system if the operating conditions are changed and the design of
the system is no longer suitable for the new operating conditions.
Temperature effects
High operating temperatures
The materials selected for use in exhaust ductworks will normally tolerate the
maximum temperatures to which they are subjected under normal operation without
adverse affect.
Where abnormal operation of the plant can produce higher flue gas temperatures,
these conditions should also have been considered in the design of the system.
This may not be so in cases where the plant has been modified since construction.
An increase in the temperature of a material causes thermal expansion.
Exhaust systems are designed to accommodate thermal expansion, and expansion
joints are incorporated into the construction.
Insulated ducts may experience thermal variations commonly known as hot spots at
areas where insulation has been damaged.
Thermal growth presents numerous opportunities for the development of structural
damage.
Such growth, whether uniform or distorted, produces friction forces within bottomsupported ducts that must be resisted by the supporting structure.
The original design typically anchors a duct at one location and guides the systems
thermal growth to other locations where slide-bearing plates are usually provided.
Progressive deterioration or misalignment can increase the friction forces.
Severe damage may be caused to the inside face of a casing if a flue liner is damaged
and flue gases come into contact with the casing shell.
Minimum operating temperatures
Extremely low ambient temperatures may cause frost damage to some materials or
increased wind loading due to icing.
Snowdrifts may melt and subsequently refreeze, expanding within the external
insulation and resulting in damage to the insulation and lagging.
Repeated damage could produce paths for further water intrusion. Water from
frequent dampness, rain or melting snow may find a path through seams in the
lagging to the underlying insulation, duct plate, stiffeners and expansion joints.
Differential temperatures
Exhaust system flues are subjected to high temperatures on the inside from contact
with flue gases and to lower temperatures on the outside from the atmosphere.
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Whereas an overall temperature rise in a flue can be accommodated by making

provision for the flue to expand, differential temperature through the wall of a flue can
cause locked-in flexural stresses.
The effects of differential temperature are exacerbated when the flue gas
temperature varies frequently, for example if the plant is in operation for only part of
each day.
Chemical attack
The materials in contact with flue gases are chosen to withstand the chemicals in the
flue gases under the design operating conditions for the specified design period of the
flues.
The fuels used in industrial plants, with the exception of natural gas, contain significant
amounts of sulphur, and sulfur oxides are produced during combustion.
Provided that the sulfur oxides remain in gaseous form they do not attack the flue wall.
If the temperature of the flue gases or the flue wall falls below the acid dew point,
sulphur oxides will condense as acids. Acid condensates can cause rapid corrosion of
mild steel and many stainless steels.
Frequent start-ups and shutdowns of the plant will increase the time that the flue is
exposed to low flue gas temperatures and will increase the damage caused by acid
condensates from the flue gases.
Guidance on environmentally induced corrosion risks is given in Table B1.
Environment
category
A
Table B1 Risk of environmentally induced corrosion

Environment
Description of environment
Normal inland
Polluted inland
Normal coastal
Polluted coastal
Heavily polluted,
Industrial
Most rural and urban areas.

(Note: Some rural and urban areas may be polluted
from industrial areas close by, depending on prevailing
winds).
Areas with high airborne SO2 and other contaminants
from industrial sources.
High airborne salt (CI-) levels.
(The salt contaminated zone may extend inland as far
as 2-3 km from the coast).
As with B but with high airborne salt levels. (The
contaminated zone may extend inland as far as 2-3
km from the coast).
Aggressive industrial environments such as areas
adjacent to acid plants, salt storage, electroplating
shops, chemical works, etc.
Steel
Corrosion risk
Low
Significant
High
Very High
Very high
Internal chemical attack is of major concern because it is not immediately apparent.

It can cause rapid deterioration if it is not detected and mitigated.
Corrosion is the most common form of deterioration, and sulfuric acid, formed from the
condensate of fuels containing sulfur, is the most corrosive agent.
Generally, the higher the sulfur content of the fuel, the greater the chance of sulfuric
acid condensing in a steel chimney. The sulfur content of some of the commonly
incinerated products is given in Table B2.
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To initiate corrosion, the acids must be in solution, i.e., the temperature at the surface of
the steel must be below the acid dew point. For sulphuric acid, this is between 120 and
160C, depending on the sulfur content.
When the plant is shut down regularly, the temperature in the exhaust system will
unavoidably fall below the dew point temperature, causing the acid to condense out on
the inner surface of the casings.
As long as the exposure of the exhaust system to acid attack is limited, the fact that the
temperature is below the acid dew point need not be serious.
Table B3 compares the length of off-load periods to susceptibility to acid attack.
Abrasion can also cause rapid deterioration, but this is limited to locations where the
flow in an exhaust system changes direction. However, if this effect acts in combination
with corrosion, the loss of material can be even more rapid.
Table B2 Classification of commonly incinerated products by sulfur content
Sulfur content
Classification of risk to chimney vs. fuel
Examples
sulfur content
0% to 0.3%
Low
Natural gas
0.4% to 1.5%
Medium
Diesel
Greater than 1.6 %
High
Industrial coal, heavy oil
Table B3 Relating time below acid dew point to risk of corrosion
Operating hours per year below
Risk of corrosion
acid dew point
<30 hours
Low
30-100 hours
Medium
>100 hours
High
Wind
Steel chimneys or stacks that are susceptible to across-wind oscillation due to vortex
shedding may suffer damage due to fatigue.
Vortex shedding occurs in steady wind conditions and the frequency of shedding
depends on the chimney diameter and the speed of the wind.
Fatigue damage is often first noticed by the failure of bolts in the flanged and bolted
connections between fabricated sections.
Failed bolts often fall to the ground.
This telltale sign of the problem may not be visible if the chimney is externally clad, so
specific inspection activities are needed to discover these faults promptly.
Fatigue failure may also occur in welds.
Wind causes down wash of flue gases at the top of stacks and chimneys. The gases are
cooled and may deposit acid condensates on the outside of the chimney near the top.
If permanent external access systems extend to near the top of the chimney, they will
be affected by acid condensates from the down wash of flue gases.
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Rain
Rain water can cause corrosion of steel components of exhaust systems if the materials
are not chosen correctly or are not adequately protected.
Some stainless steels may also be affected if the system is in a marine environment.
Changes to an existing Exhaust System
No change to an existing Exhaust System should be made without the prior approval or
concurrence of the Exhaust System Designer.
Operating conditions
Each exhaust system is designed for a specific set of operating conditions.
These conditions should not be changed without checking the effect on the system.
The flue gas temperature should not be increased without verifying that the materials
exposed to the flue gases including expansion joint materials are able to sustain the
increased temperatures.
The effects of increased or cyclical differential temperatures in the wall of the flue or
the casing should also be checked.
The gas flow should not be increased without a proper analysis of the consequences
that increased velocity will produce:
Additional pressure drop
Stress and wear of insulation material and insulation material facings
Additional self-generated noise.
New access systems
External access systems may have to be installed on existing stacks or chimneys
either for sampling purposes or to provide safer access for maintenance.
External access systems can add very considerably to the wind loading on a chimney.
Whereas chimneys are normally circular in section to minimize wind loads, access
system components are flat or angular and have a high wind force coefficient.
A structural design check should always be carried out before installing external
ladders or platforms on a chimney.
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7. INSPECTION OF GT EXHAUST SYSTEMS

The purpose of a preventive maintenance examination of an existing exhaust system is
to ascertain the structural adequacy of the ducting to function safely and efficiently as
originally designed after repeated exposure to adverse conditions.
The degree of any damage depends on how long the process of deterioration is allowed
to continue unchecked
In inadequately maintained exhaust systems, it may progress undetected until it is at
the point where it may affect or compromise the integrity of the system. This may result
in the collapse of the system (e.g., stack or chimney) or the need for an unplanned
system shutdown of unknown duration.
Sometimes the system configuration makes inspection difficult.
For instance, aluminium sheeting encasing the mineral wool insulation on a steel
chimney allows only limited access for inspection of the load bearing steel work.
Consequently, severe corrosion can take hold before it is noticed. In addition, the
appearance of the aluminium cladding can be misleading, giving the impression that
the chimney is in good condition.
It is important that in these cases the external surface of the casing is periodically
inspected to check for any corrosion phenomena.
Most exhaust system casings are fabricated from mild steel.
The steel is normally painted externally and has to be maintained in order to prevent
corrosion.
Often no allowance is made in the design of the exhaust system for external corrosion
of the casing, so serious damage could result if the paint is not maintained.
The exhaust duct must be completely clean and free of debris upon completion of an
inspection and prior to re-commissioning of the Gas Turbine.
Preliminaries
An inspection log should be maintained by the Owner summarizing previous inspection
results.
This should clearly state the date of the next inspection, modifications undertaken to
the process plant, changes in fuel or other items which may effect the operation and
stability of the system, and the details of previous remedial work.
Relevant information in this log as well as copies of previous inspection reports should
be made available to inspectors.
To assist inspectors, the north, east, south and west coordinates of the stack (or similar
90 reference axis) should be marked at the base of the stack, and these coordinates
should be used to orient defects found and referred to in any subsequent
documentation.
It is important that adequate access for inspection and maintenance is provided.
If there is not enough space to reach an item or if it is inaccessible, it is likely that it will
not be inspected and, consequently, not maintained.
Discuss the requirements (e.g., power sources, exclusion zones, etc.) for the inspection
and maintenance teams with the inspector and try to ensure that their requirements
are met.
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To facilitate the examination of both interior and exterior ductwork, sufficient time must
be invested in adequate preparation and pre-outage planning.
A basic understanding of the structural design of the duct system and its intended
behaviour can be beneficial (design documents should be made available before any
site inspection).
Every detail of an examination should be fully developed well in advance so that
valuable plant outage time is not wasted due to lack of access, equipment and support
personnel.
Field preparation activities, such as installation of temporary lighting, ladders and
scaffolding and the cleaning of interior surfaces should be planned ahead of time to
reduce the critical outage time committed to these tasks.
An allowance for cool down of the ductwork and Owner checkout must be factored into
the schedule.
Exterior walk downs
Observation of the external features of a duct system can provide valuable information
related to the ducts behavior and condition.
This type of examination may be performed in advance of a plant outage and the
subsequent detailed external and internal examination.
Furthermore, it should be performed on a very regular basis to detect any variation in
exhaust system conditions early.
Exterior walk downs should also include a cursory examination of duct system elements
that are remote or inaccessible from grade or viewing platforms.
A cursory examination may substantiate the need for a comprensive examination
necessitating the erection of scaffolding.
Both a hot on-line and a cold off-line exterior walkdown should be considered to
observe and record movement and thermal growth.
Sometimes the installation of thermal displacement measuring devices at strategic
locations on the ducts is helpful. Obtaining cold and hot duct location measurements
from a fixed reference point will indicate the amount and direction of thermal
expansion.
The assessment of the ductwork condition should include an investigation of any
indicators of potential damage.
The presence of such indicators may warrant a detailed rather than a cursory
examination of the key structural elements in the area where indicators are found.
Key indicators are listed below.
External Lagging
Visual observation of the lagging can provide information on the condition of a ducts
structural system. Indicators of potential problems include localized stains, general
deterioration, buckling, separation of seams, binding at supports or slide plates, and
the ponding of water.
The topographic condition of lagging surfaces can be an indicator of the shifting or
settlement of the duct surface beneath the lagging.
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External Insulation
A preventive maintenance examination should identify areas with missing, damaged
or non-uniform insulation. Hot spots that cause stress variations in these duct
sections may thereby be avoided or eliminated by repairing the insulation.
Expansion Joints
Inspect the entire expansion joint belt for cuts, worn sections, or cracks.
Inspect the metal backing bars and exterior hardware of the expansion joint for
corrosion and tightness.
Cracked or torn expansion joints may be an indicator of internal insulation damage
and unusual duct movement. A more careful examination of the duct supports
adjacent to damaged joints is suggested to determine the extent of any duct damage
and the amount of duct support thermal movement.
The material and design of any damaged expansion joint should be investigated to
assess its compatibility with the operating environment.
Expansion joint frames should also be examinated for damage.
Damage of these frames is usually caused by improper insulation, improper joint
seals or a joint that is unable to freely move.
The external membrane of a fabric expansion joint is able to withstand temperatures
of 200-300C. Any discoloration of the external membrane is an indication that the
thermal insulation protecting the external membrane is failing. A new expansion joint
textile should be purchased and the expansion joint replaced.
The frequency of Inspection of the fabric membrane should be increased to avoid any
risk of undetected failures that could cause a safety hazard.
Bolted joints
Inspect the duct flanges between adjoining sections for signs of gas leakage past the
flange gasket.
Inspect all access hatches to ensure an airtight seal, as well.
Inspect the plugs or caps of all ports not in use for instrumentation purposes to ensure
an airtight seal.
Check the tightening torque of bolts and retorque to the proper torque if needed.
Any bolt found loose should be investigated. Report the bolt position for future
monitoring.
Loose bolts could indicate the presence of differential thermal expansion between the
flanges and the bolts.
This condition is unusual for internally insulated ductwork, in which case loose bolts
may signify the deterioration of internal insulation in the area close to the flange
connection.
Sample bolts may be taken from the connecting joints of steel chimneys and tested
for fatigue damage.
Condition of Coatings and Linings
Small cracks in surface treatments can be an indication of the direction of stresses
within an element.
Peeled paint on adjacent support steel could indicate that the steel has been
subjected to very high temperatures, while the spalling of paint may indicate the
buckling of the underlying plate. If the support steel is painted in the vicinity of sliding
supports, worn paint surfaces can indicate the amount of thermal growth.
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For corrosion repair, please refer to the General Maintenance section of this
document.
Noise
During the walk along the duct casing, any audible metallic noise should be localized
and recorded. Noisy areas should be investigated in detail during the interior
inspection.
Deterioration of acoustical performance of the silencer is normal to a certain extent
but any sudden variation of noise level could indicate that structural damage to the
silencer baffles is occurring and should be investigated.
Differential pressure readings
It is recommended that the pressure drop across the exhaust system together with a
brief note on the environmental conditions and GT operating conditions be recorded
weekly.
An abrupt change in the exhaust systems pressure drop could indicate problems in
the silencer duct section (e.g., one or more baffles could have moved out of its guides
thereby reducing the flow area or some debris could have partially blocked the gas
path.
Interior walk downs
Since internal examinations may be limited with respect to time and schedule, the
examination team should work as efficiently and quickly as possible.
Other than the obvious condition of any structural element, observations include the
internal insulation condition, surface discoloration and the general alignment of parallel
members and walls.
This inspection requires the flue to be out of service for a sufficient time for it to cool and
to be vented of flue gases.
While the unit is shut down, the system access hatches may be opened and the interior
inspected as soon as the inside temperature has reached an acceptable level with the
permission of the owner and following the plant guidelines for entering confined spaces.
The main indicators that may be detected are listed below.
Internal Lagging
Visual observation of the lagging can provide information pertaining to the condition
of the internal insulation as well as the duct structural system.
Indicators of potential problems include localized stains, general deterioration,
buckling, separation of seams, binding at supports or slide plates, and excessive wear.
Scratches and wear at the overlapping zone and between washers and linings are a
clear indication of thermal growth movement. Their extension and direction can
indicate how the internal lining is reacting to the temperature rise and if free
expansion in some direction is being prevented.
The topology of lagging surfaces can be compared with the condition of the duct
surface beneath the lagging.
Any loose nuts, studs or washers that are detected should be noted and further
investigated.
Lagging should be firmly anchored to the studs; any undue vibration should be further
investigated.
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Internal Insulation
Knocking on the internal lagging and comparing the resulting sound can provide
useful information about the condition of the infill thermal material.
Expansion Joints
A careful examination of the expansion joint internal deflectors is suggested to
determine the extent of any wear and interference during the thermal expansion of
the system.
Silencer baffles
Access hatches are generally provided upstream and downstream of silencer baffles
to allow for inspection.
Check the acoustic insulation infill material to make sure that it is still in the silencer
baffle frame.
Insert a light in the gap between two baffles and see if it is visible from the adjacent
gaps.
Light spots should be reported along with their magnitude and location for future
comparison.
Check the bull nose for signs of cracks.
Inspect the silencer panel support brackets for signs of weld cracks.
Discoloration
Interior duct surfaces frequently exhibit a reddish brown or gray colour. A blankened
area may indicate the prior existence of an overheat condition; white or very light
colored areas may indicate severe inleakage of water.
Thickness measurement
Both internal and external duct elements may experience corrosion and erosion.
Thickness measurements are essential for determining an elements current structural
condition.
Ultrasonic thickness measuring devices are used to measure the thickness of steel
plates.
The measuring device is a small, handheld unit; the plate thickness is measured by
holding a small probe against the plate.
This method of thickness measurement requires access to only one side of the plate.
All paint, corrosion and general debris must be carefully removed without damaging the
element to obtain accurate thickness readings.
Temperature monitoring
During external on-line examination of operating ducts, temperature indicating crayons
or digital thermometers can provide accurate measurements of hot and cold spots on
the lagging and duct plate.
Always carefully report hot spot locations and size. When a hot spot is identified, the
frequency of inspection should be increased and the evolving situation duly monitored.
Thermographic photographs of the exterior of ducts, which show the variation of
surface temperatures, quickly provide very accurate and comparable information
related to gas leakage and poorly installed or deteriorated insulation and lagging.
Additional notes for stack inspection
An inspection report should include the outside face of the windshield, including any
paint treatment. It should highlight any defects in the surface.
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The survey should include the inside surface of the windshield of a multi-flue chimney
where access is available and the temperature within the airspace is not excessive.
The survey should also include the outside face of the flues and the condition of any
expansion joints or seals.
If access is available above the roof of the windshield, the condition of the outside of the
flues above roof level should be recorded, including the fastenings to any cladding.
Inspections carried out while the chimney is out of service will allow assessment of the
inside of the flue or flues.
Survey Report
The survey should include a record of the visual inspection and a commentary on the
general quality of the exhaust system and the condition of ancillary items.
This should include chimney aircraft warning and lightning protection systems, the
chimney cap (if any) or the exposed outside face of the liner, hand and foot supports or
ladder attachments, ladders and platforms.
Pictures or videos are normally included as part of an exhaust system inspection.
The advantage of a video recording is that the chimney inspector can add a
commentary to the record in order to amplify details that may be unclear in the
pictures.
During the survey, the location of any specific areas may be cross-referenced to the
commentary by indications made on the surface using a water-soluble marker.
The video commentary should be factual based on the evidence and the obvious
causes of any defects, but should not pre-judge the engineers report regarding the
type or extent of repair work required.
A written report should be made of any information that is not adequately conveyed by
the video record or the commentary.
The extent of any damage should be quantified to enable pricing by potential
contractors.
Recording of defects
Defects should be classified according to their type, extent and severity.
It is very important that there be no ambiguity in the inspection report and that the
information is presented in a consistent manner.
A suggested method of reporting which may be adopted is as follows:
Type
Corrosion (or other losses in thickness);
Cracks in steel shell or lining, flanges or welds;
Local deformation or distortion;
Wear;
Accidental damage;
Insulation breakdown;
Loss of tension (hardware), etc.
Extent
A. No defects noted
B. Not significant: Not more than 5% of the area affected by the defect.
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C. Significant: Between 5% and 30% of area inspected affected by the defect.

D. Very significant: Over 30% of the area inspected affected by the defect.
Severity
1. Not significant.
2. Minor.
3. Significant.
4. Severe.
Once identified, it is necessary to give advice about how the effects of defects are to be
minimized.
Table C1 suggests courses of action that may be taken.
Severity
2
3
Table C1 Recommendation for action following inspection

Extent of defect
B
C
D
Discuss reasons for
Discuss reasons for defect, possibility of
Discuss reasons for defect,
defect and
spread and timescales for repairs.
possibility of spread and
implications
monitor progress.
Carry out repairs
Repairs to be carried out within stated
Repairs to be carried out
within
time scales and discuss possibility of a
immediately, possibility that full
recommended time
more complete inspection to determine
extent of defect not established
scales, monitor
full extent of defect.
discussed with view to carrying
effectiveness of
out a more complete inspection.
repairs.
Repairs to be carried Repairs to be carried out immediately and Repairs to be carried out
out immediately.
further inspections of an additional 20% of immediately and re-inspection
the area around the defect to be carried
of larger areas of chimney, as
out to determine full extent of defect.
specified by a suitably qualified
organization.
Engineering Report
In case of reported faults, an Engineering Report may be required.
The engineers report provides the benefit of a qualified engineers training and
experience in assessing the condition of the exhaust system (especially important for
tall and slender chimneys) recorded in the Survey Report.
Engineering calculations may be required to supplement video evidence in the Survey
Report, to determine whether the deterioration that has occurred is sufficient to warrant
repairs, or to determine the cause of faults recorded in the Survey Report.
Calculations may include a structural analysis of the exhaust system or chimney,
particularly for an old steel chimney.
An engineers report is essential for the successful management of an industrial
chimney.
Chimney File
The engineers reports on the condition of a chimney should be kept in a dedicated
chimney file.
The chimney maintenance file should be kept together with the health and safety file for
the chimney.
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Those responsible for the operation or maintenance of industrial chimneys should keep
a file on each chimney. A copy of each available drawing should be kept in the file.
All inspection specifications, chimney survey reports and engineers reports should be
kept in the chimney file. The file should also contain a record of repair work carried out
with dates.
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8. INSPECTION SCHEDULE
The GE recommendation for preventative maintenance of the exhaust system includes
regular internal inspections (at least once a year or at any GT shut down) during
planned plant and/or turbine outages.
Take advantage of any GT shutdown to perform inspections and record the date and
results of such.
Only a few hours are required for a proper inspection of the exhaust system internals,
so dont miss any opportunity!
Exhaust System inspections should be carried out systematically and regularly, and not
left until damage becomes apparent.
This does not preclude scheduling inspections so that repair work can be arranged to
coincide with other plant outages.
Very useful inspections can be carried out while the exhaust system is in use.
These types of inspections are suggested on a reduced inspection cycle.
The type of inspection to be undertaken will, to some extent, vary with the nature of the
exhaust system and known inspection history, but the table shown below gives
guidance on the suggested Inspection Program.
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Recommended Inspection Program
Weekly
Record pressure drop through the exhaust system together with a brief note on the
environmental conditions and GT operating conditions.
Monthly
All weekly items +
Carry out Hot on-line Exterior walkdown
Carry out close visual examination over the complete exhaust system external face
and accessories.
Tap all flange bolts and hold-down bolts with a hammer to sound for any evidence
of cracking or loosening
Carry out some random temperature checks
Inspect flange joints for leakage.
On tall stacks, at least once a month, check for observable regular oscillations at the
prevailing wind speed (not to be confused with normal movement associated with
gusts.) Check for signs of damage after windstorms.
Annually or at GT shutdown
All monthly items +
Carry out Cold off-line Exterior walkdown
Carry out close visual examination over the complete exhaust system external face
and accessories.
Record differential thermal movements of the exhaust systems
Carry out Cold off-line Interior walkdown
Carry out a full inspection to determine the overall condition of the lining.
Any defective areas noted within the lining system should result in a particularly
detailed examination of the shell in the impacted area.
Defects within the lining system exposing the shell to flue gases should be rectified
prior to returning the stack to service.
Check torque settings on flange and hold-down bolts
Examine any installed lightning protection system for compliance with current
standards and carry out electrical tests for continuity and resistance to ground.
Carry out a detailed inspection of the insulation and cladding to determine its overall
effectiveness and resistance to rainwater ingress.
Take an exhaust system thermography (if hot spots have been identified).
Every 4 Years
All Annual items +
Remove 2 bolts from each chimney flange (or from the most stressed flanges where
adequate design drawings are available) for microscopic examination for defects.
These bolts should then be tested for ultimate tensile failure and compared against
the rated value of new bolts.
A noise survey by Sound Pressure readings is recommended
Carry out an ultrasonic survey of the exhaust system shell in sufficient detail to allow
any significant loss of thickness to be detected. Thickness readings should be
carefully plotted for future comparison.
Take an exhaust system thermography.
Every 8 Years
All Annual and 4-year items +
Carry out an ultrasonic survey of the bolts securing the stack to the foundation to
determine the extent of any corrosion present.
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9.

Exhaust Systems
GAS TURBINE EXHAUST SYSTEM MAINTENANCE

The following section provides instructions for general maintenance of the exhaust
system and associated hardware.
Not all repairs require the system to be taken out of service.
Appropriate Personal Protective Equipment (PPE) must be worn during all maintenance
repairs.
For internal inspections, a safety procedure must be in place to assure that the turbine
cannot be accidentally started
If issues observed during an exhaust system inspection are not addressed in this
section or questions regarding the applicability of this section to the issues found are
raised, please consult your local GE Oil & Gas Services Representative for clarification
and/or a recommended course of action.
It is essential that the findings of the inspection be acted upon.
Keep a record of all the actions taken and when they were carried out.
Remedial work should be carried out to an agreed specification prepared to reflect the
existing materials in use and the nature of the defects observed.
The repair specification should ensure that the exhaust system is returned to a
condition which is at least equal to the original design or consistent with alternative
design calculations if any.
Gasket Seal Repair
Gasket connections to seal the flue hot gas path from the ambient environment are
required at locations where individual sections are fabricated in pieces and bolted
together to accommodate fabrication, shipping or installation limitations.
GE approved gaskets are high temperature glass fiber ladder type tapes with an
uncompressed thickness of at least 3mm.
Gaskets are also found at access hatches used for inspections.
GE recommends that the gasket be replaced each time the hatch is removed for
inspection and/or maintenance.
For replacement of a torn or missing gasket, please contact your local GE Services
Representative for assistance.
Hardware
Any loose bolt should be investigated, and retightened to the correct torque
specification.
When the flange material is exposed to a temperature higher than the bolts, or bolt
material has a thermal expansion coefficient lower than the flange material at the same
temperature, differential thermal growth will occur.
This differential thermal growth could produce a stress level in the bolt material higher
than its yield strength and the bolt could suffer permanent elongation causing the
flanged joint to leak.
This phenomenon is not unusual on externally insulated or uninsulated exhaust
systems.
The use of specially designed bolts should be considered in similar installations and
hardware should be replaced.
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Exhaust Systems
Areas around the anchor bolts should be kept clean and free of particle deposits and
moisture.
Periodic (monthly) retightening of anchor bolts is recommended.
Paint Repair
The exhaust system is designed so that all surfaces that come in contact with water or
humid air are sealed with primer and an additional overcoat (as applicable) or
mechanically sealed.
Stainless steel surfaces are generally not painted, but are pickled and passivated.
For information on the specific paint system used for the exhaust system at 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 the paint system applied.
Contact the Paint Manufacturer for information on the paint system applied
Obtain the recommended paint in sufficient quantities to allow for application and
subsequent touch-ups (as needed).
Clean areas that requires paint repair due to rust, wear or other forms of paint
damage using power tools or sand blasting.
Prepare the area to the metal surface profile as recommended by the paint
manufacturer for proper adhesion of the specific paint system.
Apply the recommended paint thickness following the manufacturers guidelines for
curing time, temperature, dew point, etc.
Field Welding
Exhaust system sections are designed for bolted field assembly.
The use of field welding is kept to an absolute minimum unless required for weld repair
or for hardware locking with tack welds.
Field welding directly to the external shell plate of lined ducting is not a recommended
practice due to paint damage on the internal side of the shell plate during the welding
process and potential rusting of the shell plate if exposed to moisture.
Repair of Weld Crack Indication on Acoustical Linings of Silencer Baffles
The recommend process for repairing weld cracks on acoustical linings is as follows:
o Mark the cracked/broken weld to be repaired. A visual inspection should be
done (with the possible use of an NDE inspection to verify a crack indication) to
determine if the weld needs to be repaired.
o Mask off the adjoining perforated sheet sections surrounding the weld crack or
broken weld to prevent contamination of the acoustical pillows with metal
debris during the grinding and welding process.
o Grind out the cracked/broken welds.
o Re-weld (TIG welding only) the perforated sheet to the supporting framework
using stitch welding with 30mm (minimum) welds on 100mm (maximum)
centers.
o Thoroughly clean the weld including removal of all loose weld spatter, excess
welding materials, weld flash, metal chips/burrs and all other foreign materials
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Visually inspect the weld for defects and perform a weld repair if defects are
found. Welds should be 100% free of defects including crack indications,
porosity, lack of fusion, undercutting, etc.
After welding has been completed, remove the perforated sheet covers and all
dirt and debris that may be present
Repair of Weld Crack on Non-Acoustical Linings and Structural Components

The recommend process for repair of weld crack on non-acoustical linings and
structural components is as follows:
o Mark the cracked/broken weld to be repaired. A visual inspection should be
done (with the possible use of an NDE inspection to verify a crack indication) to
determine if the weld needs to be repaired.
o If a 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.
o Grind out the cracked or broken welds (and adjacent paint or galvanizing to
prevent weld defects or toxic fumes during the welding process).
o Re-weld the section using the appropriate welding electrode selected from the
list below and in accordance with the requirements of the applicable welding
code:
Base Metals
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
o
o
Electrode (or filler rod) designation

E7018
309
308
308L
309L
316L
DIN E19.9
If you are repairing a crack on solid material, make a hole to stop the crack,
repair the crank and fill the hole by welding.
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 materials.
Visually inspect the weld for defects and perform a weld repair if defects are
found. Welds should be 100% free of defects including crack indications,
porosity, lack of fusion, undercutting, etc.
Paint or cold galvanize the exposed carbon steel. Any burnt paint from welding
must be removed and repainted (in accordance with the paint repair section of
this document).
For galvanized structures, apply cold galvanizing touch up in accordance with
ASTM A780- Standard 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 internal gas path
Internal Lining Repair

The recommend process for the repair of damaged linings is as follows:
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Mask off the adjoining lining sheet sections to prevent contamination of the
acoustical/thermal insulation material with metal debris during the grinding and
welding process.
Grind out the welds holding the damaged section of lining sheet to the retaining
studs.
Remove the section of damaged sheet
Vacuum the acoustical pillows (if any) behind the lining sheet (if perforated) and
store in a clean, dry place or remove thermal insulation material.
Repair any damaged scallop bars or retaining studs.
Inspect the internal surface of the casing for corrosion. If present, the corroded
section (most likely painted carbon steel) must be sanded down to the correct
profile for paint re-application using the guidelines for paint repair discussed earlier
in this section. If the material is stainless steel, clean with pickling solution.
Re-install the thermal/acoustical insulation and the lining sheet.
Re-weld the retaining washers.
At each phase, 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 materials.
At each phase, visually inspect the weld for defects and perform a weld repair if
defects are found. Welds should be 100% free of defects including crack
indications, porosity, lack of fusion, undercutting, etc.
Repair the paint (Carbon Steel framework only) with touch up paint after welding
where necessary
Remove all dirt and debris from the exhaust duct
Expansion Joints
Lacerations in the expansion joint belt will allow hot gas bypass and must be repaired or
replaced.
For replacement parts, please contact your local GE Oil & Gas 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 or vulcanized using the appropriate method.
If cracks or discolorations 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.
Cracks may indicate improper installation or loading beyond the design intent.
Please contact the local GE Services representatives for all concerns.
Silencer baffles
Crack indications on the bull nose may be caused by differential temperature stresses
and are not so unusual on long silencer baffles with single-piece bull noses.
When cracks are identified on a bull nose, the affected zone should be removed by
grinding down to sound material and a cover trim should be added by welding on one
side only.
For silencer bracket weld crack indications, the correct procedure is to remove them
and de-burr the bracket to the duct interface if located upstream of the silencer panels.
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Prior to removing the brackets, the area must be masked off to prevent metal debris
from contaminating the insulation pillows in the vicinity.
Brackets located beneath the silencer panels will require weld repair after removal of
the baffle.
Please refer to the General Maintenance section of this document for the recommended
weld crack repair procedure.
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ATTACHMENT 1
INSPECTION and MAINTENANCE CHECK LIST

The checklist detailed below is not intended as a substitute for the contents of this document
and should not be considered as self-standing.
This checklist must always be used in conjunction with the rest of the document that must be
applied as a whole.
An X indicates the phase in which it is suggested that each inspection activity be performed.
INSTAL. means During Installation
OPERAT. means During System Operation
MAINTE. means During System Maintenance (i.e., when the GT is not operating)
ACTIVITY DESCRIPTION
Before entering the exhaust system after the system
commissioning, make sure that the system has been
properly cooled and vented.
Before entering the exhaust system after the system
commissioning, make sure that a proper safety procedure
has been applied to avoid an accidental GT restart.
Make sure that personnel working on the exhaust system
are wearing appropriate personal protection equipment
Verify that Insulation Materials and Silencer Baffles are
(and have been) properly stored
Assure that Lifting Sketch Drawings are available prior to
start lifting activities.
Assure that Expansion Joints are not handled at low
temperature; if below +5C, warm the expansion joint first.
During erection and maintenance, verify that all parts are
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.
Do not allow installation/maintenance personnel to walk
on and/or place scaffolds or equipment directly on liner
sheets of internally insulated exhaust systems; place
plywood sheets or other rigid protection to distribute
these loads.
Be sure that installation crews have been trained to
properly install insulation materials.
I
N
S
T
A
L.
O
P
E
R
A
T.
M
A
I
N
T When
E. (During operation)
X
X
Always
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Verify that the position of anchor bolts is in compliance

with AISC installation tolerances.
Check that high strength bolts are tightened to the torque
values established on the site erection drawing in
accordance with an approved method.
Record the method used.
Verify that bolts have been tighten to their maximum
torque only after the pre-assembly has been completed
to allow free positioning, levelling and squaring.
Check the tightening of anchor bolts and and retorque as
necessary.
Assure that any modifications are made in accordance
with approved procedures.
Record the modifications and applicable procedures.
Check that anchor bolts have not been straightened by
applying heat.
Check that the stack erection tolerances are within the
ASME STS-1 limits. Record the actual values.
Check that field installed liners are in tight contact.

Check the specified torque values and make sure that
they are not exceeded.
Assure that the correct tightening procedure has been
followed.
Verify that all bolts within the gas path have been tack
welded.
Make sure that the silencer baffles are free to expand
after installation
Assure that Expansion Joints are properly handled
X
X
X
X
X
Assure that Expansion Joint Transit clamps have been X
X
X
X
Verify that any open threaded pipe connections have X
X
X
removed before GT start-up.

Assure that Expansion Joints have been installed at their
nominal (or slightly greater) length.
Check that the installation space for the Expansion Joint is
within the specified tolerances.
Assure that the erection crews have received the site
installation/joining kit when an expansion joint has to be
site joined.
Verify the proper sealing of all external gasket joints that
separate hot gas from the ambient environment.
Verify that all damaged surfaces have been touched up.
been closed with plugs/caps or have been connected to

their lines.
Monthly
Monthly
Monthly
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After installation is complete, do a walkthrough inspection X

of the entire exhaust system to ensure that all equipment
has been installed as per the manufacturers
recommendations.
Verify that any inspection and access hatches have been X
properly sealed before the GT start-up.
Any objects that are brought inside the exhaust system X

for inspection and maintenance purposes must be
tracked, accounted for, and removed prior to operation.
Record the pressure drop periodically and relate it to the
environmental and GT operating conditions (if they are
recorded in the GT control board).
Check for any increase or decrease in pressure drop that
could indicate a problem in the silencer duct that may
require immediate action.
Record any change in the exhaust system operating
conditions.
Record the fuel characteristics and any changes.
Record the accumulated operating hours and start-ups (if

they are recorded in the GT control board).
Check for failed bolts during the external walkdown.
Assure that an Inspection Log is maintained and made
available at each new inspection
Assure that proper access is available for inspection and
maintenance
Weekly
Whenever pressure
drop variations occur
On occurrence
X
X
On occurrence
Monthly
Monthly
X
X
Assure that all defects are properly located and described

in the Inspection Report
Periodically inspect the exhaust system exteriors.
X
X
Periodically inspect the exhaust system interiors.

Check for any increase in noise level that could indicate a
problem in the silencer duct that might require immediate
action.
Check the sealing efficiency of each gasket.
X
X
As required to assure
proper On-line and
Off-line inspection
and maintenance
Monthly
At least once a year
or at any first GT shutdown
Upon occurrence of
noise level variations
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While the GT is not in operation, enter the duct and

check if any light is visible looking outward
check the inner surface for any visible damage of
the internal linings
check the condition of the silencer baffles
check if the acoustical infill material is still in
position in the silencer baffles
Inspect all expansion joint belts (exterior and interior) for X
cuts, worn sections, or cracks.
Inspect the metal backing bar and hardware on the X
exterior of the expansion joints for corrosion and
tightness.
Inspect the exterior of the duct for signs of corrosion.
X

Monthly externally.
or at any first GT shutdown, internally
Monthly
Monthly

Monthly
Inspect the interior of the duct for signs of corrosion.
Make some random temperature readings.

Carefully record the extent and location of any hot spot.
Carry out a thermographic inspection
Inspect the acoustical lining in the wall, ceiling, and

silencer panels for signs of rust stain, dirt, or debris.
Knock on the lining and listen for any unusual acoustic
feedback.
Inspect the silencer panel support brackets for weld crack X
indications.
Annually if hot spots

have been identified;
otherwise every 4
years.
Inspect any external insulation covering for signs of

thermal leakage (discoloration).

Monthly
Carry out an ultrasonic survey of the exhaust system shell

in sufficient detail to allow any significant loss of material
in a section to be detected. Thickness readings should be
carefully plotted for future comparison.
Remove 2 bolts from each chimney flange (or from the
most highly stressed flanges where adequate design
drawings are available) for microscopic examination for
defects. These bolts should then be tested for their
ultimate tensile failure for comparison against the rated
value of new bolts.
Every 4 years
Every 4 years for

stacks
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A noise survey using Sound Pressure readings is

recommended.
Suggested every 4
years
Carry out an ultrasonic survey of bolts securing the stack

to the foundation to determine the extent of any corrosion
that may be present.
Every 8 years for

stacks
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Som 6664417

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Operation and Maintenance Recommendations for Gas turbine

Italian language added

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

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

Operation and Maintenance Recommendations for Gas turbine

Operation and Maintenance Recommendations for Gas turbine

Italian language added

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

Operation and Maintenance Recommendations for Gas turbine

Italian language added

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

Operation and Maintenance Recommendations for Gas turbine

Italian language added

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

Operation and Maintenance Recommendations for Gas turbine

Italian language added

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

Operation and Maintenance Recommendations for Gas turbine

Italian language added

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

Operation and Maintenance Recommendations for Gas turbine

Italian language added

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

Operation and Maintenance Recommendations for Gas turbine

3. GENERAL SAFETY PRESCRIPTIONS

Italian language added

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

Operation and Maintenance Recommendations for Gas turbine

Whenever inspecting an exhaust system in operation, the hazards of inspecting a

Be very careful when working on the exhaust system.

Italian language added

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

Operation and Maintenance Recommendations for Gas turbine

Italian language added

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

Operation and Maintenance Recommendations for Gas turbine

4. GAS TURBINE EXHAUST SYSTEM INSTALLATION

Italian language added

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

Operation and Maintenance Recommendations for Gas turbine

Any modification procedure must be approved in writing by GE prior to the start of

Italian language added

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

Operation and Maintenance Recommendations for Gas turbine

Do not drag expansion joints along the ground or across edges.

In the evaluation of accumulated tolerances (), X has to be algebraically added.

Italian language added

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

Operation and Maintenance Recommendations for Gas turbine

Italian language added

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

Operation and Maintenance Recommendations for Gas turbine

5. GT EXHAUST SYSTEM COMMISSIONING

Italian language added

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

Operation and Maintenance Recommendations for Gas turbine

Italian language added

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

Operation and Maintenance Recommendations for Gas turbine

Whereas an overall temperature rise in a flue can be accommodated by making

Table B1 Risk of environmentally induced corrosion

Most rural and urban areas.

Internal chemical attack is of major concern because it is not immediately apparent.