GE Power Product Service

Pyrophoric Event Inside Gas Fuel Delivery System Safety

PSSB 20190812A Bulletin
Overview
The purpose of this document is to create awareness on the possibility of a pyrophoric event occurring inside the gas fuel
delivery system and communicate best practices to help prevent and manage the potential pyrophoric event.

Application
This document applies to all heavy-duty gas turbines using a gas fuel delivery system.

Background
The gas fuel delivery system consists of various components and associated piping between the gas supply custody transfer
point and the inlet to the gas turbine’s gas control module. These components include an absolute separator, performance
heater, gas scrubber, gas fuel control module etc. and associated piping. The absolute separator vessel consists of a primary
cyclone separator section and a final coalescer filter section designed to remove both liquids and solids from the incoming gas
stream. Any contamination or black powder from upstream sections are collected in the absolute separator.

Figure 1: General arrangement of absolute separator vessel

Copyright © 2019 General Electric Company. This information is proprietary and is the property of GE Power. The content of this
document is provided for general information and awareness. Always refer to your unit's O&M manuals for detailed information relevant
to the operation and maintenance of your equipment. This document shall not be reproduced in whole or in part nor shall its contents be
disclosed to any third party without the written approval of GE Power Services Engineering
 Figure 2: Damaged filter elements

Recently a 9FA unit experienced damage to the absolute separator filter elements. This unit was under a prolonged outage for an
upgrade and when restarted, the absolute separator filter differential pressure increased to alarm limits in less than 70 hours of
operation. The unit was then shut down to inspect the filter elements. The absolute separator filter vessel was purged with an
inert gas to displace combustible gases and then purged with instrument air to prevent asphyxiation hazards prior to opening the
vessel for visual inspection. The site observed damage to the separator filter elements, as shown in Figure 2.

Further investigation revealed that the absolute separator filter element damage occurred due to a pyrophoric reaction inside the
vessel. There were pyrophoric debris that accumulated in the absolute separator vessel and reacted exothermically when
instrument air was admitted into the vessel during the purging process. Material analysis of the debris sample collected from the
absolute separator vessel indicated the presence of pyrophoric material - Iron Sulfide (FeS).

Pyrophoric Material Reaction:

Pyrophoric materials are substances that can ignite spontaneously upon exposure to air at or below 55 °C (130 °F). Various
forms of Iron sulfide are an example of a pyrophoric material found inside gas fuel transmission systems; this can form due to the
conversion of Iron oxides Fe3O4(magnetite)/Fe2O3(rust) into Iron sulfides over time. The chemical reaction requires the presence
of Hydrogen Sulfide (H2S) in the fuel. An example of one version of this reaction is given below

Copyright © 2019 General Electric Company. This information is proprietary and is the property of GE Power. The content of this
document is provided for general information and awareness. Always refer to your unit's O&M manuals for detailed information relevant
to the operation and maintenance of your equipment. This document shall not be reproduced in whole or in part nor shall its contents be
disclosed to any third party without the written approval of GE Power Services Engineering
In general, pyrophoric iron sulfide may exist in gas systems and remain dormant during unit operation. However, the potential of
a pyrophoric iron fire exists during shutdowns when equipment is opened for inspection or maintenance.

Advisory
It is advised to follow the below best practices to help prevent a pyrophoric event while performing coalescer filter replacements
in an absolute separator.

1. Ensure all personnel involved in the maintenance of the absolute separator vessel are wearing appropriate PPE.
Highly protective dust masks should be worn to protect against the potential volatile materials. The end user should
consider a mask with an air fed system for additional protection.
Personal gas monitors shall be capable of providing a warning if a hazardous atmosphere develops. The monitors shall
be capable of measuring the Lower Explosive Limit (LEL), Methane (CH4), H2S, oxygen concentration (O2) and Carbon
Monoxide (CO) etc. All monitors shall be calibrated and tested prior to use.
Wear heat resistant gloves.
2. Provide a water fire extinguisher and a bucket of water to ensure any volatile material removed from the vessel is passivated.
The water may be used to extinguish the reaction in the immediate work area by applying directly to the filter elements.
Considerable efforts shall be taken to ensure personnel are protected from steam produced by adding water to the
volatile condition in a hot system.
Consideration should be provided for equipment damage associated with the addition of water or creation of steam
during maintenance intervals. Care should be taken when removing debris or water from the system.

3. The absolute separator vessel shall be barricaded off with clear signage. The direction of the wind shall be taken into
consideration as fine dust particles may be scattered locally.
4. Ensure the vessel being inspected is isolated from the fuel supply, depressurized and purged with inert gas (N2) prior to
performing maintenance on the vessel.
5. Allow the absolute separator vessel to cool down to atmospheric temperatures (< ~50°C) before opening the cover.
6. The design of the filter vessel should be such that the filters can be removed easily without the need to completely enter the
vessel. If site configuration requires vessel entry for removal of filters or the inspection of vessel internals are required, the
system should be purged with air to prevent asphyxiation as per confined space work permit procedures. The vessel temperature
shall be monitored to determine a rate of rise due to possible pyrophoric reactions during the air purging sequence. If an increase
in temperature is noticed, keep the vessel cover closed until the temperatures decrease below ~50°C.
7. Back-flushing of the filter elements through the vessel and through specific sections of pipework is acceptable. Vessel vents
and drains may be blown through to remove dust from the equipment. The end user shall ensure dust is not ejected in an area
occupied by personnel.
8. The filters should be immersed in a water bath immediately after removal.
9. If an exothermic reaction occurs during maintenance, the system can be sealed back up (if safe to do so) and left for the
reaction to complete. The reaction may cause additional damage to the equipment; however this is considered an alternative
method of containment.
10. Any waste material removed from the absolute separator shall be labelled and disposed of properly based on the site specific
requirements.

Ensure gas fuel supply piping cleanliness as per GEK110483.

Copyright © 2019 General Electric Company. This information is proprietary and is the property of GE Power. The content of this
document is provided for general information and awareness. Always refer to your unit's O&M manuals for detailed information relevant
to the operation and maintenance of your equipment. This document shall not be reproduced in whole or in part nor shall its contents be
disclosed to any third party without the written approval of GE Power Services Engineering
In addition to the foregoing, the operator must conduct a site specific safety risk assessment before performing coalescer filter
replacements in an absolute separator and take all appropriate safety measures resulting from the risk assessment.

References:
GEK116533 - Fuel Gas Absolute Separator
GEK110483 - Cleanliness Requirements for Power Plant Installation, Commissioning, and Maintenance.
GEK116771 - Fuel Supply System Cleaning for Gas Turbines
GEI41040 - Specification for Fuel Gases for Combustion in Heavy-Duty Gas Turbines. ( Section IV C.7)

Please contact your local GE representative for additional information or assistance.

Copyright © 2019 General Electric Company. This information is proprietary and is the property of GE Power. The content of this
document is provided for general information and awareness. Always refer to your unit's O&M manuals for detailed information relevant
to the operation and maintenance of your equipment. This document shall not be reproduced in whole or in part nor shall its contents be
disclosed to any third party without the written approval of GE Power Services Engineering