TROUBLESHOOTING REPORT: WATER INJECTION PURGE AIR CHECK VALVES

Incident Summary:
Leakage was identified on the GT11 Water Injection Purge Air Check Valve during operation, leading
to a pressure drop signal from the Pressure Indicator Transmitter to the control room.

Observations and Findings:

All fourteen (14) purge air check valves were removed and inspected. Dismantling and examination
of the check valves revealed the following observations:
1. Cracks were identified on the plugs of the poppet valve. See fig. 1 and 2 below.
2. Dirt was present in the check valve internals.
3. Valve face O-rings were damaged. See fig. 3 below.
4. A pressure leak test at 1300 psi +/- 25 psi was conducted on all fourteen check valves,
resulting in the following results:

Check Valve Number Serial Number Results of Pressure Leak Test

(1300 +/- 25 PSI)
#1 50140 Failed
#2 30001 Passed
#3 50108 Failed
#4 50135 Failed
#5 50111 Failed
#6 30014 Passed
#7 30006 Passed
#8 30012 Passed
#9 30011 Passed
#10 30017 Failed
#11 49391 Passed
#12 50125 Failed
#13 50115 Failed
#14 50109 Failed

Corrective Actions:
To address the issues, the following corrective actions were implemented:
1. New check valves, along with face O-rings, were installed on the water injection line. The
serial numbers of the check valves are as follows:
Check Valve No. Serial Number Check Valve No. Serial Number

#1 52637 #8 ⁠52620
#2 52617 #9 52640

#3 52614 #10 52618

#4 52634 #11 52615
#5 52632 #12 52638
#6 52623 #13 52621
#7 52625 #14 52635

2. The unit underwent testing, and no leakage was observed.

3. The check valves were immersed in diesel oil for effective cleaning of seats and internals,
followed by disassembly using specialized tools.
4. Further cleaning with WD40 was conducted.
5. All old poppet assemblies were replaced with new ones.
6. Pressure leak testing, following the OEM recommended procedure, was carried out, and all
fourteen valves passed without leakage at 1300 PSI.

Figure 1: Cracks on the face of poppet assembly plug Figure 2: Cracks on the face of poppet assembly
plug
Figure 3: Damaged valve face O-rings Figure 4: Valve leak test pressure