مارك 6
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OPERATION TRAINING BOOK SAUDI ELECTRICITY COMPANY
ARAR POWER PLANT SAUDIA ARABIA MS7001EA Gas Turbine FRAME (7) - MARK (IV)
By: Engr. Rushdi A. Taman
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TABLE OF CONTENETS OPERATION TRAINING BOOK ITEM #
ITEM NAME
PAGE #
01
- GAS TURBINE UNIT.
3-6
02
- OPERATION CHECK LIST.
7
03
- CHECK PRIOR TO OPERATION.
8
04
- CHECK DURING START-UP.
05
- UNIT START-UP PROCEDURES.
12 - 18
06
- UNIT SHUTDOWN PROCEDURES.
19 - 21
07
- UNIT AUXILIARY COMPARTMENTS.
22 - 25
08
- UNIT ANNUNCIATORS.
26 - 33
09
- DEVICES SETTING.
34 - 44
10
- STARTING SYSTEM.
45 - 50
11
- LUBRICATION SYSTEM.
51 - 59
12
- HYDRAULIC SYSTEM.
60 - 64
13
- TRIP OIL SYSTEM.
65 - 68
14
- LIQUID FUEL SYSTEM.
69 - 78
15
- ATOMIZING AIR SYSTEM.
79 - 82
16
- COOLING AND SEALING SYSTEM.
83 - 88
17
- COOLING WATER SYSTEM.
89 - 96
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9 - 11
1. GAS TURBINE UNIT. The package power plant, as furnished for this installation, is comprised of the single-shaft, heavy duty gas turbine unit driving a synchronous generator, its auxiliary equipment, required control equipment and those off base auxiliaries that are essential to overall operation. Basically, the power plant requires only fuel and fuel connections, generator breaker connections and a source of ac power to become operational fuel and air are used by the gas turbine unit to produce the shaft horsepower necessary to drive certain accessories and ultimately the driven load generator. The turbine unit is composed of an axial-flow compressor, a multi-stage turbine, support systems combustion system components, and a starting device. Both compressor and turbine are directly connected as an in-line, single-shaft rotor supported by pressure lubricated bearings. The inlet end of the rotor shaft is coupled to an accessory gear having integral shafts that normally drives the main hydraulic pump, main lubrication pump, and may drive other system pumps as required for a given installation.
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The design of any gas turbine must meet essential based on operational considerations: 1. High efficiency. 2. High reliability and thus high availability. 3. Ease of installation and commission. 4. Ease service. 5. Conformance with environmental standards. 6. Incorporation of auxiliary and control systems, which have high degree of reliability. 7. Flexibility to meet various service and fuel needs.
GAS TURBINE CYCLE
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The Brayton cycle in its ideal consists of two isobaric processes and two isentropic processes. The two isobaric processes consist of the combustor system of the gas turbine and the exhaust hot gases. The two isentropic processes represent the compression (compressor) and expansion (turbine) processes in the gas turbine. 5 PDF created with pdfFactory Pro trial version www.pdffactory.com
The MS7001 is a single-shaft gas turbine designed for operation as a simple-cycle unit or in a combined steam and gas turbine cycle. The MS7001 gas turbine assembly contains six major sections or groups: (1) Air inlet (4) Turbine
(2) Compressor (5) Exhaust
(3) Combustion system (6) Support systems
This section briefly describes how the gas turbine operates and the interrelationship of the major components. Typical illustrations and photographs accompany the text. The flange-to-flange description of the gas turbine is also covered in some detail. A separate section is devoted to the air inlet and exhaust systems. Support systems pertaining to lube oil, cooling water, etc. are also covered in detail in individual sections.
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2. OPERATION CHECK LIST. A.STANDBY POWER REQUIREMENTS: 1. Heating and circulating of turbine lube oil at low ambient temperatures to maintain proper oil viscosity. 2. Control panel heating. 3. Generator heating. 4. Auxiliary lube oil pump should be run at periodic Intervals to prevent rust formation in the lube oil system. 5. Where fuel heaters are furnished, heat and circulate fuel oil to maintain proper fuel oil viscosity during periods of low ambient temperature. 6. Compartment heating. 7. Operation of control compartment air conditioner during periods of high ambient temperature to maintain electrical equipment insulation within design temperature limits. 8. Battery charging (where applicable).
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3. CHECK PRIOR TO OPERATION. •
Check that all piping and turbine connections are securely fastened.
•
Close work permit.
•
Check lube oil, Fuel and cooling water level.
•
Ratchet system ON.
•
Turbine and generator lube oil mist eliminator on service
•
Temperature, Pressure, Vibration indicators, etc must be all in good condition.
•
Must be no indication alarms and trips.
•
Unit must be cleaned before start-up.
•
Turbine compartment must be in good condition.
•
Accessory compartment must be in good condition as well
•
Know operation data limit for alarm and trip.
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4. CHECK DURING START-UP. The following is a list of important checks to be made on the turbine with the OPERATION SELECTOR in various modes the control specifications control systems adjustment should be reviewed prior to operating the turbine.
1- Crank A- Listen for rubbing noises in the turbine compartment Shutdown and investigate if unusual noise occurs. B- Check for unusual vibration. C- Inspect for water system leakage.
2- Fire A- Bleed fuel oil filters, if appropriate then check entire fuel system and the area immediately around the fuel nozzle for leaks In particular check for leaks at the following points: Turbine Compartment (1) Fuel piping/tubing to fuel nozzle. (2) Fuel checks valves. (3) Atomizing air manifold and associated piping.
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Accessory Compartment Fuel and water module (1) (2) (3) (4)
Flow divider. Fuel and water pumps. Filter covers and drains. Cooling water heat exchangers.
B- Monitor FLAME status on the HMI to verify all flame detectors are correctly indicating flame. C- Monitor the turbine control system readings on the HMI for unusual exhaust thermocouple temperature, wheel space temperature, lube oil drain temperature, highest to lowest exhaust temperature spreads and “hot spots” i.e. combustion chamber burning hotter than all the others. D- Listen for unusual noises and rubbing. E- Monitor for excessive vibration.
3-Automatic, Remote Record all data and notes for future comparison and investigation. A- Continue monitoring for unusual rubbing noises and shutdown immediately if noise persists.
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B- Monitor lube oil tank, header and bearing drain temperatures continually during the heating Summary Sheets for temperature guidelines. Adjust (VTR1, 2) if required C- At this time a thorough vibration check is recommended, using vibration test equipment It is suggested that horizontal, vertical and axial data be recorded for the: (1) (2) (3) (4) (5)
Accessory gear forward and aft sides. All accessible bearing covers on the turbine. Turbine forward compressor casing. Turbine support legs. Bearing covers on the generator.
D- Monitor HMI display data for proper operation. E- After the unit is FSNL and the generator synchronize check the generator reading. F- Record all data in operation log sheet and compare with guide or recommended data.
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5. UNIT START-UP PROCEDURES. 1. Using the cursor positioning device, select (MAIN) display. 2. Make rest for diagnostic and press OK. 3. Make rest for master and press OK. 4. GO to start check display and must be all indications are in green collar. 5. GO to trip diagram display and must be all indications are in green collar. 6. The main display well indicates speed temperature, varions condition. 7. Select (AUTO) and press OK. 8. The (HMI) display well change to: • Start-up status. • Ready to start. • Auto. • Speed level (14 HR). 9. Select start and OK. 10. during start signal and ok: • Starting motor (88CR) should be run. • Emergency lube oil pump (88QE) should start for testing and stop immediately. 12 PDF created with pdfFactory Pro trial version www.pdffactory.com
11. After five (5) seconds of start signal the main unit clutch will engage and ratchet system off after getting few rotation of the shaft. 12. at a) b) c) d) e)
1.5 % speed after start signal: Cooling water pump motor (88WC) Load. Compartment cooling air Fan (88VG). Atomizing air booster (88AB). Auxiliary hydraulic supply pumps (88HQ). All these equipments are running.
13. The (HMI) display will change to Start-up status\cranking. 14. When the unit reaches approximately 10 % speed purging start 15. At 20 % speed, the minimum speed signal (14 HM) will be displayed on the (HMI). 16. After purging (23 % - 24 %) speed the main unit Clutch disengage and starting motor still running 17. The unit speed de-accelerates up to 9.5 % speed. 18. At 9.5 % speed main unit clutch re-engage. 19. at 10 % speed fuel stop valve (LSV) and fuel control valve (LCV) opened and fuel reached to the combustion chamber.
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20. At approximately 10 % speed flame established and cooling water fans start one by one with a gap time of fifteen (15) seconds and turbine compartment cooling air fan (88BT) well start. 21. After flame established exhaust temperature Increase. 22. At 50 % speed exhaust temperature around 5400C and acceleration speed signal “14HA” will be displayed on the (HMI). 23. At 60 % speed exhaust temperature around 5180C and main unit clutch disengage and starting motor still running. 24. After five (5) minutes from main unit clutch disengagement starting motor stop. 25. Unit acceleration increase. 26. At about (82 % - 85%) speed the 1GV will be start opening depending on the ambient temp. 27. At about (89 % - 92%) speeds IGV will be come fully opened & exhaust temperature decrease 28. at • • •
95 % speed: Aux hydraulic pump motor (88HQ) stops. Atomising air booster (Q88HQ) stop. Aux. Lube oil pump motor (88QA) stop.
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• Turbine exhaust frame cooling air fan (88TK1) starts and with a five (5) seconds time delay (88TK2) starts. 29. At 97% speed exhaust temperature around 2720C. 30. at (98 % - 100 %) speed excitation “ON”. 31. At 100 % speed the auxiliaries listed below must be stopped: • Auxiliary hydraulic pump motor (88HQ). • Atomising air booster (88AB) and • Auxiliary lube oil pump motor (88HQ) the (HMI). Will be change to full speed no load (FSNL) and the unit ready to synchronize. 32. at 100 % speed if any one of these auxiliaries listed below: • Auxiliary hydraulic pump motor (88HQ). • Atomising air booster (88AB). • Auxiliary lube oil pump motor (88QA) Is not stopped automatically the HMI display will be shown acceleration and droop, shown alternately on the screen. 33. The problem should be corrected to that the (HMI) display would be change to full speed no load (FSNL). 34. After full speed no load (FSNL), the unit ready to synchronize. 35. From main menu (HMI) select synchronize display. 15 PDF created with pdfFactory Pro trial version www.pdffactory.com
36. Go to synchronize control and select auto synchronize and press OK. 37. Select generator synchronizer start and press OK. 38. The generator synchronizer starts rotating and correct automatically its frequency and voltage until the generator will be the same voltage and frequency with the bus bar. 39. The generator circuit breaker (52G) will be closed automatically. 40. IF the generator synchronizer fails to synchronize can you make synchronizer reset and tray again to synchronize Can be make manual synchronize if need. 41. After generator circuit breaker closed the (HMI) Display change to synchronizer off and compressor Bleed value close. 42. Now, can be controlled the MW and MVAR as depending on the customer demand. 42. The unit is protected under the safety condition. 43. Record all data in operation log sheet and compare with guide or recommended data.
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6. UNIT SHUTDOWN PROCEDURES. 1. Unit shutdown requested by order from main control supervisor due to customer demand load decrease or planning maintenance work or forced shutdown due to any problem. 2. Before unit shutdown must be check the unit and record all notes and data. 3. Using the cursor positioning device, select (MAIN) display. 4. Select (STOP) and press (OK). 5. The load (MW, Mvar) automatically decrease up to generator circuit breaker (52G) open by reverse power protection at -1.5 MW. 6. After generator circuit breaker (52G) open the turbine speed de- accelerates up to (ZERO) speed and ratchet system on.
. During unit shutdown
:
The following are the list of important checks to be made on the turbine with the: a. At generator circuit breaker (52G) open compressor bleed valves (CB1O, 2O) open. b. At 97 % speed exciter circuit breaker (52S) open. 19 PDF created with pdfFactory Pro trial version www.pdffactory.com
c. At 95 % speed inlet guide vanes (IGV) closed. d. At 94 % speed turbine exhaust frame cooling air fan (88TK1, 2) stop. e. At lube oil Header pressure less than 70 psig auxiliary lube oil pump (88QA) ON. f. At lube oil header pressure less than 9 PSI emergency lube oil pump (88QE) ON. g. At lube oil header temperature less than 50.50C (1230F) cooling water Fans (88FC) OFF. h. At turbine compartment temperature less than 460C (1150F) turbine compartment cooling air fan (88BT) OFF. j. At lube oil header temperature less than 430C (1100F) cooling water pump motor (88WC) OFF. k. At load compartment temperature less than 390C (1030F) load compartment cooling air fan (88VG) OFF. ●
When the unit on cool down:
The following are the list of important checks: • At lube oil header pressure less than 9 PSI emergency lube oil pump (88QE) ON 16min and off 3 min up to (88QA) restart.
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• When (88QA) not running and bearing metal temperature more than 65.50C (1500F) emergency lube oil pump (88QE) 16min ON and 3 min OFF up to (88QA) ON. • When lube Oil header temp. More than (48.80C) (1200F) cooling water pump motor (88WC) start up to lube oil header temperature less than 430C (1100F) (88WC) stop again. ●
When the unit off cool down:
The following are the list of important checks to be made on the turbine with the: • Auxiliary lube oil pump (88QA) OFF. • Emergency lube oil pump (88QE) OFF. • Turbine and generator lube oil mist eliminator OFF. • Ratchet system OFF.
Must be the unit & auxiliaryis ready to start before re-start.
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7. UNIT AUXILIARY COMPARTMENT.
Auxiliary name
- Main unit clutch
- Starting motor
- Cooling water fan (88 FC).
- Auxiliary lube Oil pump (88QA).
No. Of Aux
Start
Stop
1
- Engagement after - Disengagement five (5) seconds of After purging. signal start. - Disengagement - Engagement at 9.5% at 60% speed speed
1
- Five (5) seconds after start signal
- Five (5) minutes after main unit clutch disengaged
8
- At flame, fans start one by one With a gap time of fifteen (15) Seconds. - Lube oil header temperature More than 54.50C (1300F)
- Lube oil header temperature less than 50.50C (1230F)
1
- Ratchet system “ON” - When unit running the lube oil Header press. Less than 70 PSI.
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- At 95% speed. - Ratchet system “OFF”
Auxiliary name
- Emergency lube Oil pumps (88QE).
- Turbine compartment cooling air fan (88 BT).
- Load compartment cooling air fan (88VG).
- Turbine exhaust frame cooling air fan (88TK).
No. Of Aux
1
2
Start
Stop
- With start signal for testing. - When unit is shutting down -When unit lube & oil shutdown lube bearing header oil header pressure more pres. less than than 9 PSI. 9 PSI. - When unit is in - When unit is in zero speed zero speed, (Cool down) bearing metal 88QA not temperature running & less than 65.50C bearing metal (1500F) temperature more than 65.50C (1500F)
- At flame
2
- At 1.5% speed after signal start
2
- At 95% speed when unit start-up.
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- At turbine compartment temperature less than 460C (1150F) - At load compartment temperature less than 390C (1030F).
- At 94% speed when unit stop.
Auxiliary name
No. Of Aux
Start
Stop
1
- Accessory compartment temperature less Than 37.80C or 1000F.
- Accessory compartment temperature more than 460C or 1150F.
1
- Ratchet system “ON” - Unit running.
- Ratchet system “OFF”
1
- Ratchet system “ON” - Unit running.
- Ratchet system “OFF”
- Compressor bleed Valves (CB10, 20).
2
- After generator circuit breaker close.
- After generator circuit breaker open.
- Torque adjuster drive motor (88TM).
1
- Clutch engages. - After purging. After warm-up. - After 60% speed.
- Accessory compartment space heaters (23HA).
- Generator Lube oil mist eliminator.
- Turbine Lube oil mist eliminator.
- Atomising air booster (88AB).
- Heating air fan (88HT).
1
1
- Start signal.
- At 95% speed when the unit start.
- Turbine - Turbine compartment compartment temperature temperature 0 less than 100 F more than 0 or 37.8 C 88BT 1150F or 460C is not running.
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Auxiliary name
- Dust collector system blower Motor (88IC). - Inlet guide vanes.
No. Of Aux
1
1 group
Start
Stop
- At air inlet filter ∆P more than IN 2.5 H2O
- At air inlet filter ∆P less than 2.5 IN H2O
- At (82 % -85 %) speed
- At (82 % -85 %) speed
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8. UNIT ANNUNCIATORS. ANNUNCIATOR
ALARM
TRIP
- Cooling water module discharge temperature high.
57.20C or 1350F
-
- Cooling water module discharge temperature low.
50C or 410F
-
- Turbine control panel temperature high.
43.30C or 1100F
-
- Compressor discharge temperature spread limit.
100C or 500F
-
- Compressor temperature.
2700C or 5190F
-
- Atomizing air temperature alarm.
1350C or 2750F
-
35 PSI
-
- Compressor discharge press sensor limit.
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ANNUNCIATOR
ALARM
TRIP -
- Load compartment 204.40C or 4000F high temperature.
- Air inlet filter ∆ P. - Fire detector accessory compartment. - Fire detector.
152.4 MMH20 or 203.2 MMH20 or 6 INH20 8 INH20 162.80C or250F 3850C or 7250F
- Fire detector turbine 315.60C or 6000F compartment.
-
- Lube oil header temperature.
73.90C or 1650F
79.40C or 1750F
- # 1 turbine journal bearing drain temperature.
90.50C or 1950F
-
- # 2 turbine journal bearing drain temperature.
98.90C or 2100F
-
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ANNUNCIATOR
ALARM
TRIP
- # 3 turbine journal bearing drain temperature.
98.90C or 2100F
-
- # 1 turbine thrust bearing drain temperature.
93.30C or 2000F
-
- Lube oil thermocouple bearing drain temperature.
93.30C or 2000F
-
- Bearing metal temperature.
129.40C or 2560F
-
70.0 + 1.0 PSI
-
- Lube oil bearing header pressure low.
-
9.0 +- 0.5 PSI
- Bearing sealing air pump pressure.
127 MMH20 or 5 INH20
-
- Low lube oil header pressure.
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ANNUNCIATOR
ALARM
TRIP
- Hydraulic oil filters differential pressure.
60.0 + - 3.0 PSI
-
- Hydraulic oil trip circuit pressure liquid fuel system.
20.0 + -1.0 PSI
-
- Hydraulic oil supply pressure low.
1350 + - 15.0 PSI 94.91 + 1. BAR
-
- Distillate fuel low pressure.
30.0 +-1.0 PSI
-
- Liquid fuel filters differential pressure.
25.0 +- 1.0 PSI
-
- Cooling water pressure low.
38.0 +- 1.0 PSI
-
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ANNUNCIATOR
ALARM
TRIP
- Generator temperature 62.80C or 1450F monitors cold gas.
-
- Cold gases temperature spread.
-
150F
- Generator temperature monitor RTD low limit.
37.77C or 1000F
- Generator hot gas high temperature limit.
1000C or 2120F
- Generator temperature monitor RTD high limit.
426.70C or 8000F
- Generator temperature stator collector end.
129 C or 264 F
- Generator temperature cold gas collector end.
50 C or122 F
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-
ANNUNCIATOR
ALARM
TRIP
If two (2) or more generator winding temperature RTD’s reading 1350C or 2750F unit will shutdown. If generator cold gas temp. RTD’s reading less than -37.80C or -1000F or more than 426.70C or 8000F the RTD’s is defective If generator cold gas temperature differential reading more than 150F the unit will shutdown. If load tunnel inner barrel temp. TTIB 212.70C or 4150F load tunnel inner barrel temp high alarm appears. If load tunnel inner barrel temperature TTIB 2210C or 300F turbine load decrease up to generator circuit breaker (52G) open.
If load tunnel inner barrel temperature high TTIB 2600C or 5000F turbine trip.
- Exhaust temperature high.
ALARM AT:
TRIP AT:
Exhaust Reference Temperature +250F
Exhaust Reference temperature + 400F
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ANNUNCIATOR
ALARM
TRIP
426.70C/ 8000F 426.70C/ 8000F 510 0C / 950 0F 5100C / 9500F 5100C / 9500F 5100C / 9500F 5100C / 9500F 5100C / 9500F 482.0C / 9000F 482.20C / 9000F 426.70C / 8000F 426.70C / 8000F
-
- Wheel space stage spread temperature limit for water Wash.
650C or 1500F
-
- Start up alarm set point bias temperature.
21.10C or 700F
-
5.9 mils
8.66mils
- Wheel space temperature. 1FI-1 1FI-2 IAO-1 IAO-2 2FO-1 2FO-2 2AO-1 2AO-2 3FO-1 3FO-2 3AO-1 3AO-2
- Turbine bearing radial vibration.
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-
ANNUNCIATOR
ALARM
TRIP
- Generator bearing redial vibration
5.9 mils
8.66 mils
0.5 IN/SEC or 12.5 MM/SEC.
1.0 IN/SEC or 25.4 MM/SEC.
- Axial vibration sensor Turbine bearing #1
25 mils
30 mils
- Turbine lube oil mist eliminator
At filter ∆P 30 INH2O must change filter.
- Seismic vibration
- Lube oil tank low level.
17 IN (254 MM) to blow top of oil tank.
- Lube oil tank high level.
10 IN (254 MM) to blow top of oil tank.
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9. DEVICES SETTING. Device
Name
Setting
Apu cooling fan temperature switch.
Increasing: 110.0 +5.000F or 43.33 +2.7780C.
Apu thermostat.
Decreasing: 45.00 +1.000F or 7.222 +0.55556 C.
26AP - 2
Apu over temperature switch.
Increasing: 145.0 +5.000F or 62.78 +2.778 C (decreasing: 142.0 +- 5.000F or 61.11 +- 2.778 C).
26BT - 1
Turbine compartment temperature switch.
Increasing: 300.0 +5.000F or 148.9 +2.778C
26BT - 2
Turbine compartment temperature switch.
Increasing: 115.0 +5.000F or 46.11 +2.778C
26HT - 3
Turbine compartment thermostat.
Decreasing: 100.0 +2.000F or 37.78 +1.111C.
26AD - 1
26AP - 1
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Device
Name
Setting Increasing: 165.0 +3.000F or 73.89 +1.667C Decreasing: 159.0 +- 3.000F or 70.56 +- 1.667C. Decreasing: 70.00 +3.000F or 1.11 +1.667C Increasing: 84.00 +- 8.000F or 28.89 +-4.444C Decreasing: 60.00 +3.000F or 15.56 +1.667C Increasing: 61.25 +- 0.7500F or 16.25 +- 0.4167C. Increase: 175.0 +3.000F or +- 1.667C Decreasing: 169.0 +3000F or 76.11 +1.667C
26QA - 1
Lube oil header high temperature alarm.
26QL - 1
Lube oil tank temperature heater on/off.
26QN - 1
Lube oil tank temperature normal.
26QT - 1A
Lube oil header high temperature trip.
26VG - 1
Load compartment high temperature alarm.
26VW - 3
Operate vent fan at 95 degrees F increasing. Temp. Element operate space heater for compartment at 650F decreasing. space heater Alarm at 430F and vent fan. decreasing. Alarm at 1300F increasing.
Increase: 400.0 +2.000F or 04.4 +1.111C.
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Device
Name
Setting
39V - 4A
Generator vibration sensor.
Output at 0.5”/sec 150.0MV.
45FA - IA
Fire detector accessory compartment.
Increasing: 325.0F or 162.8C
45FLC-20A Fire detector.
45FT - IA
Fire detector turbine compartment.
63AD - 4
Apu low pressure switch.
63AD - 1A
Increasing: 725.0F or 385.0C. Increasing: 600.0F or 315.6C
Decreasing: 85.00 +5.000 PSI or 5.976 +0.3515BAR. Decreasing: 15.00 +0.7500 PSI 1.055 +Main atomizing air 0.527 BAR. compressor diff. Decreasing: 18.00 +pressure switch. 1.000 PSI 1.266 +0.07 BAR
63AG - 1
Load Decreasing: 0.4000 compartment air INH20 or 10.16 pressure switch. MMH2O
63CA - 1
Inlet air filter Decreasing: 60.0 +compressed air 5.00 PSIG or 4.218 pressure switch. +- 0.3515 BAR. 36
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Device
Name
Setting
63FD - 3
Decreasing: 30.0 +1.00 PSIG or 2.106 Distillate fuel low +- 0.0703KG/CM2 pressure alarm. Increasing: 35.0 +1.00 PSIG or 2.461 +- 0.0703 KG/CM2
63FL - 2
Liquid fuel pressure switch
63FV - 82
Decreasing: 30.000 +2.000 PSIG or 2.109 +- 0.1406 KG/CM2G
Hp fuel filter unit Decreasing: 0.2000 +vent fan 0.0100INH2O. pressure switch
63HF - 1
Hydraulic oil filter diff. pressure alarm.
693HL - 1
Hydraulic oil trip circuit pressure liquid fuel system.
63FL - 8
Liquid fuel diff. pressure switch.
Increasing: 60.00 +3.000PSID or 4.218 +- 0.2109KG/CM2D (decreasing: 57.50 +2.000PSID or 4.043 +- 0.1406 KG/CM2D) Decreasing: 20.00 +1.00PSIG or 1.400.0703KG/CM2G Increasing: from 20.1to 24PSIG Increasing: 25.00 +1.000PSID or 1.758 +- 0.0703 KG/CM2D
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Device
Name
Setting
63HQ - 1
Decreasing: 1350 +15.00PSIG or 94.91 Low hydraulic oil +- 1.055 KG/CM2G supply Increasing: 1375 +pressure alarm. 10.00 PSIG or 96.67 +- 0.7031 KG/CM2
63QA - 1
Low lube oil pressure aux pump start.
Decreasing: 70.00 +1.000PSIG or 4.921 +- 0.0703 KG/CM2D Increasing: 71.80 +1.20 PSIG or 5.048 +- 0.0844 KG/CM2G
63QT - 2A
Low lube oil pressure – trip load.
Decreasing: 8.000 +0.30 PSIG or 0.5625 +-0.0211KG/CM2G increasing: 9.000 +0.50PSIG or 0.6328 +-0.0352KG/CM2G
63QQ - 1
Increasing: 15.00 +1.000PSID or 1.055 +Main lube oil filter 0.0703 KG/CM2D differential Decreasing: 14.40 +pressure alarm. 0.40 PSI or 1.012 +0.0281 KG/CM2D
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Device
Name
Setting
63TF - 1
Turbine inlet air filters excessive pressure drop alarm.
Increasing: 6.0 +- 0.25 INH2O or 152.4 +6.350 MMH2O
63TF – 2A
Turbine inlet air filter excessive pressure drop.
Increasing: 8.0 +- 0.25 INH2O or 203.2 +6.350 MMH2O.
63QV - 1
Lube oil tank air pressure switch.
Decreasing: 5.000 INH2O or 127.0 MMH2O
63HR - 1
Hydraulic ratchet forward stroke pressure switch.
Increasing: 108.0 PSIG or 7.593 KG/CM2G Decreasing: 98.00 PSIG r 6.890 KG/CM2G
63HR - 2
Increasing: 108.0 PSIG or 7.593 KG/CM2G Hydraulic ratchet pressure (decreasing: 93.00 switch return PSIG or 6.539 stroke. KG/CM2G)
63LF - 7
Secondary fuel filters delta pressure.
Increasing: 15.00 +2.000OSID or 1.055 +- 0.140KG/CM2D
63FL - 8
Liquid fuel diff. pressure switch.
Increasing: 25.00 +1.00PSID or 1.758 +0.070KG/CM2D
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Device
Name
Setting
63TK-1
Turbine shell & exhaust frame blower discharge pressure switch.
Decreasing: 25 +- 0.8 INH2O or 635.0 +20.32 MMH20 Increasing: 28. +- 0.8 INH2O or 711.2 +20.32 MMH20.
63TW - 1
Turbine / compressor wash water pressure.
Decreasing: 93.00+2.000PSIG or 6.539 +0.1406KG/CM2G.
63TW - 2
Turbine / compressor wash water pressure pump trip.
Increasing: 4.000 INHG or 101.6MMHG
63WC - 1
Low cooling water pressure switch.
Decreasing: 38.0+- 1.0 PSIG or 2.672 +0703 KG/CM2G. 4.0 +- 0.20MA = 22.00 INHG or 558.8MMHG 20.+- 0.2MA = 37.00 INHG or 939.8 MMHG
Barometric 96AP - 1A pressure transmitter.
96BD - 1
Compressor bell 4.000MA = 0.0INH2O or mouth differential 0.0MMH2O 20.00MA pressure = 138.5 INH20 or transmitter. 3518 MMH20
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Device
Name
Setting
96CS - 1
Inlet air total pressure transmitter.
96EP - 1
Exhaust pressure transmitter.
96QL - 1
Lube oil tank level transmitter.
4.0 +- 0.2MA = 0.0 INH2O or 0.0 MMH2O 20.0 +0.2MA = 11.10 INH2O or 281.MMH2O 4.000MA = 0.0 INH2O or 0.0MMH2O 20.0 MA= 27.70 OMJ20 or 703.6 MMH2O 4.000 MA = 0.0 INH2O or 0.0 MMH2O 20.00MA = 25.00INH2O or635.0 MMH2O
4.000 +- 0.5000MA = Dew point sensor / 49.00f or –45.0C 20.0 96TD - 1A +- 0.5MA = 167.0F or transmitter. 75.00C. Turbine inlet filter differential 96TF – 1A pressure transmitter.
4.000MA = 0.0INH2O or 0.0MMH2O 20.00MA = 10.00INH2O or 254.0 MMH2O.
Bearing metal BT-GJI -1A temp generator bearing # 1.
Alarm at 260F
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Device
Name
Setting
Generator tempDT-GGC10 cold gas coupling Alarm = 122F end. Generator tempDT-GGH-18 hot gas coupling end.
Alarm = 212F
Generator temp – DT-GSA - 5 stator collector end.
Alarm = 264 or 129C
LT-G2D 1B
Lube system temp. Generator # 2 Alarm = 200F bearing drain.
Lube oil LT-TH - 1A thermocouple turbine header.
Alarm at 165F (73.9C) Trip at 175F (79.4C)
VPR2 - 1
Lube oil header Pressure regulator valve.
Set 26.0 +- 1.0 PSIG or 1.828 +0.0703KG/CM2G.
VPR3 - 1
Compensator Set 1510 +- 10.00 PSIG hydraulic oil or 106.2 +supply pumps (in 0.7031 KG/CM26. pump). 42
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Device
Name
Setting
Liquid fuel supply VPR53 - 1 pressure regulator valve.
Set 65.00 +- 2.000 PSIG or 4.570 +0.1406KG/CM2G
Air filter blow down VPR67 - 1 regulator Valve.
Set 110.0 +- 5.000PSIG 7.734 +0.3515KG/MC2G.
Apu pressure relief valve.
Set 150.0 +- 1.000PSIG or 10.55 +0.0703KG/CM2G
Pressure regulator starting a VPR68 - 1 compressor isolation valve.
Set 65.00 +- 5.000PSIG or 4.570 +- 0.3515 KG/CM2G.
VR14 - 1
VR1 - 1
Main lube oil pump Set 101.0 +- 1.0PSIG or 7.101+pressure relief valve. 0.0703KG/CM2G.
VR21 - 1
Main hydraulic oil supply pump pressure relief valve.
Set 1700 +- 20.00 PSIG or 19.5 +- 1.406 KG/CM2G.
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Device
Name
Setting
VR22 - 1
Auxiliary hydraulic oil supply pump pressure relief valve.
Set 1700 +- 20.00PSIG or 119.5 +1.406KG/CM2G.
VR4 -1
Main fuel pump pressure relief valve.
Set 1200 +- 5.000PSIG or 84.37 +03515KG/CM2G.
VR5 - 1
Ratchet pump relief valve.
Set 900.0 +- 50.00 PSIG or 63.28 +3.515KG/CM2G.
VR53 - 3
Inlet pressure relief valve.
Set 18.0 +- 5.000PSIG or 12.66 +0.3515KG/CM2G.
VTR1 - 1
Lube oil header temperature regulator valve.
Set 130.0 +- 8.000F or 54.44 +- 4.444C.
VTR2-1
Atomizing air pressure cooler air discharge temperature regulator valve.
Set 225.0 +- 8.000F or 107.2 +- 4.444.C
VR64 - 6
Heat exchange atomizing air
Set 150.0 +- 5.000 PSIG or 10.55 +0.3515 KG/C2.
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10. Starting System. - Starting System function: Before the gas turbine can be fired and brought to operating speed it must first be rotated or cranked by Accessory equipment. This is accomplished by an induction motor, operating through a torque converter to provide the cranking torque and speed required by the turbine for startup. Also at shutdown, this same equipment continues to rotate the turbine rotor at slow speed for cool down purposes. Cranking and turning power are both supplied by the starting system during gas turbine startup and shut-down.
- Starting System Components: - An induction motor (88CR-1): The starting motor is a horizontal induction motor and drives the torque converter through a flexible disc pack style coupling. Power supply (4160 V, 3 PH, 60HZ) AC Motor Speed = 3600 RPM
Power = 800 HP
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- Hydraulic ratchet pump (88HR-1): Power supply 120V DC Motor Speed = 2200 RPM
Power = 3.4 HP
- Torque converter system: - Torque adjustor drive motor Power supply (460 V, 3 PH, 60HZ) AC Motor Speed = 1800 RPM
Power = .39 HP
The torque converter provides the required torque multiplication for the starting motor to drive the turbine.
Hydraulic oil pressure is supplied by (88HQ-1) A.C. auxiliary hydraulic pump. The torque converter is coupled to the accessory gear through a flexible disc pack style coupling. Switches (33TM-5, 33TM-7 and 33TM-8) provide the proper torque adjustment settings for purging, accelerating, and firing of the gas turbine. Also control of the torque converter is achieved via an integrally mounted unloading solenoid valve (20TU-1) and hydraulically–operated dump valves.
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- Startup Functions And Sequences In the normal starting sequence the starting motor (88CR-1) is energized and the torque converter adjustor is set at the (33TM-5) limit switch setting after a five-second delay to allow starting motor (88CR) to accelerate to speed, fluid is admitted into the torque converter hydraulic circuit from the lubrication system by the integral (20TU-1) valve. The ratchet system is energized by the (20HR-1) valve at about 200 RPM, the ratchet system has been completely reenergized by the (20HR-1) valve, and the Turbine goes to purge speed (approximately 20% speed) as governed by (33TM-5).
At this time, the torque converter is drained and the gas turbine is allowed to coast down to firing speed at the (14HM) relay set point. The torque converter adjustor is then set at the (33TM-8) limit switch setting and the torque converter is filled so as to hold firing speed constant through the firing and warm–up cycle. Readjustment of the torque converter to the (33TM-7) limit switch setting at the end of warm up allows the torque converter to assist in accelerating the unit up to self– sustaining speed (approximately 65% speed). At this speed, the torque converter hydraulic circuit is drained 47 PDF created with pdfFactory Pro trial version www.pdffactory.com
by de–energizing solenoid valve (20TU-1) which effects disconnect of the starting system from the gas turbine.
- Rotor Cool–Down After the gas turbine has come to a complete stop, the cool– down cycle begins. The A.C. auxiliary hydraulic oil pump (88HQ-1) is energized by the (20HR-1) ratchet solenoid and start cool–down rotation timer. When the ratchet has completed its stroke by signal of the (63HR-2) pressure switches, the (20HR-1) solenoid and A.C. pump/motor are de–energized. The ratchet stroke should last about 30 seconds and should rotate the shaft about 45 degrees. The return stroke for the ratchet should also last about 30 seconds. The timer for setting ratchet stroke intervals should be set for 180 seconds. When the interval timer times out, the A.C. pump/motor (88HQ-1) and (20HR-1) solenoid are de–energized to Start another ratchet cycle. The ratchet cycle will continue until the cool–down cycle is complete, or another start–up sequence is initiated.
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The internal ratchet mechanism of the torque converter is controlled by pressure switches (63HR-2) return stroke and (63HR-1) forward stroke. Prior to start–up the ratchet mechanism goes into continuous operation for breakaway (one cycle is enough) The cool down cycle for the ratchet is as mentioned above. In addition a (43HR-1) jog switch can be operated which on contact closure will energize (88HR-1) hydraulic DC pump and (20HR-1) solenoid to put ratchet in forward stroke for as long as the button is held in. Once button is released (20HR-1) de–energizes with (88HR-1) and the ratchet stroke is returned. This allows the intermittent jogging of the shaft for bores coping, alignment, and other maintenance purposes. If the (43HR-1) contact is held in long enough the ratchet stroke will complete a 45 degrees rotation of the shaft and operation will be controlled by (63HR-2, -1) pressure switches.
(88HR-1)DC hydraulic pump can only be energized when the main lube oil auxiliary pump or DC pump is energized to supply oil to this pump and lubricating oil to the turbine train bearings for ratchet rotation.
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Starting System Drawing 50 PDF created with pdfFactory Pro trial version www.pdffactory.com
11. Lubrication System. - Lubrication system function: The system provides lubrication and absorbs the heat rejected by turbine and generator bearings, oil supply to hydraulic control, trip system, starting means and accessory gear box.
- The lubrication system Components. 1. Lube Oil Reservoir. Oil reservoir is 3300 gallons (12492 liters) of oil Lube Oil viscosity should not exceed 800 SSU (150 centipoises).
2. Main Lube oil Pump. A positive displacement gear pump which is shaft driven by the lower drive of the accessory gear. Pump Speed = 1425 RPM Flow rate = 460 GPM
Power = 60 HP Pressure = 100 PSI
3. Auxiliary Lube oil Pump (88QA-1). Centrifugal pump type, vertical position, AC motor driven pump is mounted on the top of the accessory base.
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Motor Power supply (460 V, 3 PH, 60HZ) AC
Pump Speed = 3600 RPM Flow rate = 460 GPM
Power = 60 HP pressure = 110 Psig
4. Emergency Lube oil Pump (88QE-1). Centrifugal pump type, vertical position, DC motor driven pump is mounted on the top of the accessory base. Motor Power supply 120 VDC Pump Speed = 1750 RPM Flow rate = 250 GPM
Power = 7.5 HP Pressure = 20 psig
5. Coolers. Two lube oil fluid heat exchangers are mounted internal to the accessory base. These dual coolers are of shell and tube construction and are piped in parallel to a transfer valve under normal operating conditions only one cooler is in service at a time.
6. Filters. Two lube oil filter casings containing synthetic cartridges are mounted internal to the accessory base providing β15 = 200 filtration.
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These filters are piped in parallel to a transfer valve directing oil flow through either filter. Only one filter is in service at a time and change at ∆P15 psig.
7. Pressure Regulator (VPR2-1). Oil pressure in the bearing header is maintained at approximately 25 psig.
8. Pressure Relief Valve (VR1-1). Oil pressure in the bearing header is maintained at approximately 100 psig pressure relief valve sets the main pump discharge pressure at approximately100 psig and relieves excess
9. Immersion Heaters (23QT-1, 2). Two heaters, mounted on the side of the accessory base and submerged into the lube oil reservoir, are used during stand-by periods to ensure the oil maintains proper viscosity for turbine start-up.
10. LUBE OIL Level Switch (71QL, 71QH). A magnetic type lube oil level switch is flange mounted to the top of the accessory base (oil reservoir) to monitor high and low oil levels.
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- High level alarm set to 10 top of oil tank.
INCHES (254 MM) to blow
- Low level alarm set to 17 top of oil tank.
INCHES (432 MM) to blow
11. Gauge Panel. A gauge panel mounted on top of the accessory base locates various instrumentation devices such as pressure gauges, pressure switches, and test valves for the lubrication oil, hydraulic oil and trip systems.
12.Transfer Valves. The lubricating system employs two transfer valves, one is used to direct flow to one of two heat exchangers and the other is used to direct flow to one of two filters this permits component servicing while the turbine is on line.
13. Pressure and Temperature Switches. Pressure switches (63QT-2A, B) located in the load package will trip the unit if the lube oil pressure drops below the predetermined setting. - pressure switch (63QA-1) is a located in the pump header that signals an alarm and starts the auxiliary lube pump (88QA-1) if the lube pressure falls below its predetermined setting.
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- Temperature switches (26QT-1A, B) located in the turbine bearing header will trip the unit when the lube oil temperature exceeds the preset limit. - Temperature switch (26QA-1) will sound an alarm when the lube oil temperature decreases to preset limit.
-
Temperature switch (26QN-1) prevents turbine start up if the temperature of the lube oil decreases to less than 60°F (10°C).
14. Mist Eliminator: Lube oil mist eliminator motor(88QV-1A) Motor Power supply (460 V, 3 PH, 60HZ) AC Speed = 3600 RPM
Power = 10 HP
The turbine lubricating system vents through a mist eliminator. This vessel consists of one or more coalescing filter elements used to remove oil from the air, a blower to overcome the pressure drop across the filter elements, a throttling valve to adjust the pressure and a bypass damper to protect the system from overpressure in the event of a blower failure. The mist eliminator is set to maintain a slight negative pressure in the reservoir tank.
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A loop seal integral to the mist eliminator prevents the blower from pulling a vacuum on the drain line and ensures oil flow from the demister to the reservoir junction box; oil collected on the filter is drained back to the reservoir..
15. Thermocouples. Thermocouples (LT-B1D, LT-B2D and LT-B3D) are installed in the drain piping on each of the three turbine bearings Thermocouple (LT-TH) is installed in the lube oil bearing header.
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Lubrication System Drawing
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12. Hydraulic System. - Hydraulic System FUNCTION. Oil supply to hydraulic system taken from the bearing lube oil header by: Flow rate =15 GPM, and pressure =25 psig. This fluid furnishes the means for opening or resetting of the fuel valves, in addition to the variable turbine inlet guide vanes and the hydraulic control devices of the gas
- Hydraulic System components: - Main hydraulic supply pump. Variable - displacement pump driven by a shaft of the accessory gear Pump Speed = 1425 RPM Flow rate = 13.2 GPM,
Power = 60 HP Pressure = 1500 Psig.
- Auxiliary hydraulic supply pumps(88QH). The auxiliary hydraulic pump operates whenever the main hydraulic pump pressure output level is Inadequate for turbine operation, such as during startup or low Speed conditions.
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When the main pump is operating and it fails to maintain adequate pressure. Motor power supply (460 V AC, 3 PH, 60HZ) Pump Speed = 1750 RPM Flow rate = 16.5 GPM
Power = 20 HP Pressure = 1500 Psig
- Pressure Regulator (VPR3-1). Hydraulic oil, pressurized by the hydraulic pumps, is controlled by pressure compensators (VPR3-1).
- pressure switch (63HQ-1). When the main pump is operating and it fails to maintain adequate pressure, the condition will be sensed by pressure switch (63HQ-1) and the auxiliary pump will be started by a signal from this switch.
- Air bleed valves (VAB1-1 ,VAB2-1). The air bleed valves (VAB1-1,VAB2-1) vent any air present in the pump As soon as system pressure reaches 140 psig and a steady stream of oil is present the valve closes.
- Check valves (VCK3-1, VCK3-2). Check valves (VCK3-1, VCK3-2) prevent oil from flowing into the out-of-service pump. 61 PDF created with pdfFactory Pro trial version www.pdffactory.com
The check valves also keep the hydraulic lines full when the turbine is shut down and Rating is 20 GPM at pressures to 5000 psig.
Free flow pressure drop is 10 to 30 psig, depending upon flow velocity.
- Relief valves (VR21-1 ,VR22-1). Relief valves (VR21-1, VR22-1) which will relieve pressure should the pressure regulator fail and adjustable pilot-operated valves, rated at 30 GPM for a pressure relief range of 100 to 3000 psig.
- Hydraulic supply manifold assemblies. Manifold is an enclosure designed to provide a means of interconnecting a number of small components. Contained within the manifold assembly are relief valves
- Filters (FH2-1, FH2-2). The hydraulic supply system filters prevent contaminants from entering the control devices of the inlet guide vane system, the fuel control servo valves and other hydraulic devices; Only one filter is in service at any time during system operation, The dual filter assembly complete with fill valve and integral transfer valve (VM4-1) is provided to permit changeover to the second filter without interrupting the operation of the system, A differential gauge is provided to indicate the oil pressure
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across the filters when the gauge indicates a low pressure of 60 psig.
- A hydraulic accumulator (AH1-1). A hydraulic accumulator (AH1-1) is also connected in the high pressure line of the hydraulic supply system to absorb any severe shock that may occur when the supply pumps are started.
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Hydraulic Supply System Drawing 64 PDF created with pdfFactory Pro trial version www.pdffactory.com
13. Trip Oil System - Trip Oil System FUNCTION. Oil supply to Trip Oil System taken from the lube oil header by pressure =101 psig. The hydraulic trip oil system is the primary protection interface between the turbine control and protection System circuits (SPEEDTRONIC™ Control System. The devices that cause a turbine shutdown through the trip system do so by dumping fluid pressure from the system either directly or indirectly through electro hydraulic dump valves (20FL or 20TV). When the turbine is started, the dump valves are energized to reset at the desired point in the starting sequence permitting oil pressure to open the fuel stop valves and inlet guide vanes. The fuel stop valves remain open until some trip action occurs or until the unit is shut down.
- Trip Oil System components: - Liquid Fuel Stop Valve Solenoid valve (20FL). Liquid fuel solenoid dump valve (20FL) is a spring biased spool valve which relieves trip oil pressure causing the liquid fuel stop valve to trip shut.
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The dump valve is energized to run and reenergized to trip from the SPEEDTRONIC™ panel. Since this dump valve is spring biased to trip, it protects the turbine during all normal situations as well as those times when loss of dc power occurs.
- Variable Inlet Guide Vane System (HM3). The modulated inlet guide vane system is activated by the action of the trip oil system using low pressure trip oil (OLT) in conjunction with high pressure oil (OH) from the hydraulic supply system. During normal operation trip oil (OLT) is pressurized and dump valve (VH3) is energized which allows hydraulic oil from the hydraulic supply system to flow through servo valve (90TV). The controlled or modulated position of inlet guide vane servo valve (90TV) determines the flow of hydraulic oil through the servo valve and dump valve (VH3) to the inlet guide vane hydraulic actuator (ACV1–1). The hydraulic pressure applied to the actuator determines the position of the inlet guide vane control ring ln a trip condition trip oil is dumped, by action of dump valve (20TV) this causes inlet guide vane. When the turbine is at rest, the inlet guide vane angle position is at the designed closed position. This closed guide vane angle is the position established to limit the air flow through the compressor during the turbine accelerating and decelerating sequence. 66 PDF created with pdfFactory Pro trial version www.pdffactory.com
Trip Oil System Drawing 67 PDF created with pdfFactory Pro trial version www.pdffactory.com
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14. Liquid Fuel System. - liquid fuel system FUNCTION. A liquid fuel (diesel) taken from the diesel tank to forwarding system by flow rate depend on the unit load. A liquid fuel system pumps and distributes fuel as supplied from the fuel forwarding system to the ten nozzles of the combustion system. After being filtered, the fuel flow is divided into ten equal parts for distribution to the combustion chambers at the required pressure and flow rate. The entire liquid fuel system must be pressurized, with all valves in the open position, before starting of the gas turbine. Controlling the position of the fuel pump bypass valve, VC3, regulates the amount of fuel input to the turbine combustion system by varying the amount of bypassed fuel. Information on control of the fuel system is provided in Control and Protection Systems.
- liquid fuel system components: 1. Liquid fuel forwarding system consist of: a. Two duplex strainers.
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b. Two forwarding pump (Centrifugal pump type, horizontal position, AC motor driven pump Motor Power supply (460 V, 3 PH, 60HZ) AC Pump Speed = 3600 RPM
pressure = 120 Psig
2. Duplex low-pressure fuel filters (FF1-1,-2). Fuel oil at low pressure, from the fuel forwarding system is filtered by the low-pressure oil filters (FF1-1, FF1-2) before passing through the spring-operated fuel stop valve VS1. This is a duplex filter arrangement with associated transfer valve VM5. A differential pressure switch (63LF-1) gives a signal when the pressure differential across the filter being used reaches 15 psig (103.4kPa).
3. Fuel oil stop valve, (VS1-1). Fuel oil stop valve (VS1) is an emergency valve, operated from the protection system, which shuts off the supply of fuel to the turbine during normal or emergency shutdowns. This valve is a special purpose two position (open and closed). During normal operation of the turbine, the stop valve is held open by high-pressure hydraulic oil (OH-3) that passes through a hydraulic trip relay (dump) valve, VH4.
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This dump valve located between the hydraulic supply and the stop valve hydraulic cylinder When the turbine is shut down in the normal sequence, or by an emergency or over speed trip condition, the solenoid valve (20FL) causes the dump valve to operate in the same manner as above, dumping the high-pressure hydraulic oil from the stop valve cylinder, allowing the spring to close the stop valve. The fuel oil stop valve will fully close within a 0.5-second total elapsed time.
4. Liquid fuel pump, (PF1-1). Liquid fuel pump (PF1) is a positive-displacement, continuous-output, screw-type pump (fuel oil lubricated) Driven by the gas turbine accessory gear and sized to deliver an excess of fuel. Solenoid-operated clutch (20CF) allows the accessory gear to drive the fuel pump. This is a three-screw pump, consisting of a driver gear and two idler gears. Pump Speed = 2287 RPM Flow rate = 150 GPM
Power = 90 HP Pressure = 1000 Psig
5. Pressure Switch (63FL-2). Pressure Switch (63FL-2) is used to protect the fuel pump in the event of low fuel forwarding pressure.
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The pressure is taken from the downstream tap of differential pressure switch (63LF-8). At this location the fuel oil pressure is considered essentially the same as the fuel pump suction or inlet pressure.
6. Fuel pump discharge relief valve,( VR4-1). The fuel pump discharge relief valve (VR4) is located in a loop between the discharge and inlet of the pump. The valve prevents the fuel oil pressure from getting high enough to rupture any lines in the event of a flow divider malfunction or freeze up. This valve is set to operate in the range of 1200 to 1300 psig (8274 to 8963 kappa) and returns fuel to the inlet pipe.
7. Fuel bypass valve assembly,(VC3-1). The servo-controlled bypass-valve assembly (VC3) modulates high-pressure fuel flow from the pump. Components of this assembly include the bypass valve body, electro-hydraulic servo valve (65FP) and the hydraulic cylinder. This bypass valve is connected between the inlet and discharge sides of the fuel oil pump.
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8. Servo valve, (65FP). Servo valve (65FP) controls the bypass valve stroke according to the difference requirement and the sensed fuel flow. If the turbine fuel requirement exceeds the actual oil flow the bypass valve will close to increase the net oil flow to the turbine. The servo valve uses high pressure hydraulic oil (OH),
9. Flow divider, (FD1-1). The flow divider equally distributes input fuel flow to the ten combustion nozzles. The continuous flow freewheeling flow divider consists of ten gear pump elements in a circular arrangement having a common inlet with a single timing gear.
10. magnetic pickup assemblies (77FD-1, 2, 3). Three magnetic pickup assemblies (77FD-1, 2, 3) fitted to the flow divider, produce a flow feedback signal at a frequency proportional to fuel flow delivered to the combustion chambers. This signal is fed to the SPEEDTRONIC™ control panel where it is used in the fuel control system. 73 PDF created with pdfFactory Pro trial version www.pdffactory.com
11. Conical Strainers. Conical in-line strainers are mounted immediately upstream of the main fuel pump and of the flow divider. Differential pressure alarms are mounted across the strainers. In the event that the alarm annunciates, the strainer should be removed and cleaned as soon as is reasonably possible. At the output of the flow divider to allow monitoring of selected fuel oil pressure in the nozzle inlet line Positions 1 through 10 select the fuel nozzles, position 11 selects the fuel pump inlet pressure, and position 12 selects the fuel pump outlet pressure.
13. Three-way Purge Valves. A three-way valve is mounted in each of the ten primary fuel lines and each of the ten secondary fuel lines. These valves perform both the liquid fuel check and purge air check functions. They appear on the Purge Air System schematic and are discussed under the Purge Air System section of the Service Manual.
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13. Fuel nozzle assemblies. Combustion nozzles atomizing Air type.
14. False start drain valves (VA17-1, 2 ,5). In the event of an unsuccessful start, the accumulation of combustible fuel oil is drained through false start drain valves provided at appropriate low points in the combustion/turbine area. The false start drain valve, normally open, closes as the turbine accelerates during startup. Air pressure from the discharge of the unit’s axial flow compressor is used to actuate this valve. During the turbine shutdown sequence, the valve opens as
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Liquid fuel System Drawing 76 PDF created with pdfFactory Pro trial version www.pdffactory.com
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15. Atomizing Air System. - Atomizing Air System Function Atomizing air taken from main air compressor to air precooler. Atomizing air systems provide sufficient pressure in the air atomizing chamber of the fuel nozzle body to maintain the pressure ratio, PR, of atomizing air pressure to compressor discharge pressure, PAA/PCC, at approximately 1.4 or greater over the full operating range of the turbine. Since the output of the main atomizing air compressor, driven by the accessory gear, is low at turbine firing speed, a starting atomizing air compressor provides a similar pressure ratio during the firing and warm-up period of the starting cycle, and during a portion of the accelerating cycle.
- Atomizing Air system components: 1. Main Atomizing Air Compressor. Main atomizing air compressor driven by the accessory gear. Power =90HP
SPEED =6600 RPM 79
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2. Starting Atomizing Air Compressor A starting atomizing air compressor horizontal position, AC motor driven, compressor is mounted on the top of the accessory gear box. Motor Power supply (460 V, 3 PH, 60HZ) AC Speed = 3600 RPM
3.
Power = 60 HP
Atomizing Air Heat Exchanger(HX1).
Air taken from the atomizing air extraction manifold of the compressor discharge casing passes through The air-to-water heat exchanger (pre-cooler) HX1 to reduce the temperature of the air sufficiently to maintain a uniform air inlet temperature to the atomizing air compressor. The atomizing air pre-cooler, located in the turbine base, uses water from the turbine cooling water system as the cooling medium to dissipate the heat. Refer to the cooling water system text the atomizing air pre-cooler entering the main atomizing air compressor becomes too high or too low. Atomizing air pre-cooler is water tube heat exchanger.
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5. Thermocouples (AATI-1A , AATI-1B). Thermocouples (AATI-1A, AATI-1B) are provided to send an alarm to the SPEEDTRONICS. When the temperature of the air from the atomizing air precooler entering the main atomizing air compressor becomes too high or too low when the atomizing air reaches the set temperature an alarm is activated.
6. Differential pressure switch (63AD-1A). Differential pressure switch (63AD-1A) located in a bypass around the compressor, monitors the air pressure and enunciates an alarm if the pressure rises across the compressor should drop to a level inadequate for proper atomization of the fuel.
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Atomizing Air System Drawing 82 PDF created with pdfFactory Pro trial version www.pdffactory.com
16. Cooling And Sealing Air System. - The Cooling And Sealing Air System Function: The cooling and sealing air system provides the necessary air flow from the gas turbine compressor to other parts of the gas turbine rotor and stator to prevent excessive temperature buildup in these parts during normal operation and for sealing of the turbine bearings. Atmospheric air from external centrifugal type blowers is used to cool the turbine exhaust frame.
- Cooling and sealing functions provided by the system are as follows: 1. Sealing the turbine bearings. 2. Cooling the internal turbine parts subjected to high temperature. 3. cooling of the turbine outer shell and exhaust frame. 4. Providing an operating air supply for air operated valves. 5. Compressor pulsation protection.
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- The Cooling And Sealing Air System components : 1. Turbine Exhaust Frame Cooling Blowers 2. Air Filter (with stone element) 3. Pressure Gauge 4. Dirt Separator
- Bearing Cooling and Sealing. Sealing air is provided from the fifth-stage of the turbine compressor during normal running operation of the unit and is piped externally to each of the turbine bearings. The pressurized air is used to cool the bearing and help contain the lubricating fluid within the bearing area that otherwise might seep past the mechanical seals.
- Turbine Cooling: - Turbine Exhaust Frame Cooling Blowers (88TK-1, 88TK-2). Motor Power supply (460 V, 3 PH, 60HZ) AC Speed = 3550RPM Pressure = 110 Psig
Power = 60 HP
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Cooling of the turbine exhaust casing and the exhaust frame is accomplished by two motor driven centrifugal blowers (fans) (88TK-1, 88TK-2) which are mounted external to the turbine.
From the bearing tunnel some cooling air flows into the 3rd stage aft wheel space after which it discharges into the exhaust, and the remainder discharges into the load tunnel and out the load compartment vent. The two blowers operating simultaneously normally provide cooling of the exhaust frame and turbine shell. A pressure switch (63TK-1 or blower discharge pressure.
-2) is provided to sense
If one of the blowers should fail, the switch will cause an alarm to be activated. The turbine will continue to run with the other blower providing cooling air at a reduced flow rate. If both blowers should fail, the turbine will be shut down in a normal shutdown sequence. During turbine startup (20CB) is de-energized and the eleventh stage extraction valves are open allowing eleventh stage air to be discharged into the exhaust plenum, thereby eliminating the possibility of compressor pulsation. Limit Switches (33CB-1, 2) on the valves provide permissive logic in the starting sequence and ensure the 85 PDF created with pdfFactory Pro trial version www.pdffactory.com
extraction valves are fully opened before the turbine is fired. The turbine accelerates to full speed and when the generator circuit breaker closes, the (20CB-1) solenoid valve is energized to close the extraction valves and allow normal running operation of the turbine. When a turbine shutdown signal is initiated and the generator circuit breaker is opened (20CB-1) is deenergized and eleventh stage air is again discharged into the exhaust plenum to prevent compressor pulsation during the turbine deceleration period.
- Pressurized Air Supply Compressor discharge air is also used as a source of air for operating various air-operated valves in other systems. In addition, compressor discharge pressure is monitored by pressure transducers (96CD-1, -1B, and -1C) for use in control of the gas turbine.
- Water Wash Provisions When water washing the gas turbine’s compressor or turbine section, it is important to keep water out of the componets that are actuated by compressor discharge air and out of the turbines bearings.
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To prevent water from entering these components and the bearings, isolation valves are provided in the sealing lines to the bearings, and in the (20CB-1) feed line. During normal operation of the gas turbine, all isolation valves are to be open. Before initiating water wash, the isolation valves must be closed and the drain and air separator blow-down valves opened. At the conclusion of water wash the isolation valves must be opened and the drain and separator blow-down valves closed to allow normal operation of the turbine.
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Cooling And Sealing Air System Drawing
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17. Cooling Water System. - cooling water system Function: The cooling water system is designed to accommodate the heat dissipation requirements of the lubricating oil system, atomizing air system, generator heat exchangers, turbine supports and flame detector mounts. The cooling water system capacity 1500 GALLONS, 35% propylene glycol and 65% water with corrosion inhibitors.
- cooling water system components. 1. Water radiator (four sections). 2. Eight Cooling water fans motor (88FC). Motor power supply (460 V AC, 3 PH, 60HZ) Speed = 1800 RPM
Power = 40 HP
3. Two cooling water pump motor (88WC). Motor power supply (460 V AC, 3 PH, 60HZ) Speed = 3600 RPM Flow rate = 1520 GPM
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Power = 200 HP Pressure = 125 PSI
4. Generator heat exchangers (four heat exchangers). 5. Lubricating oil heat exchanger (two heat exchangers). 6. Atomizing air heat exchanger (one heat exchanger) 7. Turbine supports and flame detector. 8. A temperature-regulating valve (VTR1-1,
VTR2-1)
The components of the cooling water system are located on the gas turbine base and the accessory module. Components include heat exchangers, butterfly valves, orifices, ball valves and temperature regulating valves.
A. Gas Turbine Cooling Water Piping The gas turbine cooling water piping connects the lubricating oil heat exchanger, atomizing air heat exchanger, turbine supports and flame detector mounts into one piping system. The lubricating oil cooling system components is consist of two shell-and-tube heat exchangers, a temperature regulating valve and butterfly valves. Two heat exchangers are provided so that one is in operation, cooling the lubricating oil while the other one is being maintained. Only one of the heat exchanger is to be in service at one time. 90 PDF created with pdfFactory Pro trial version www.pdffactory.com
- To change from one heat exchanger to the other while the gas turbine is operating the following steps are to be followed: 1. Open the lubricating oil fill valve and allow the heat exchanger to fill with oil until flow is observed in the sight glass. 2. Open the closed coolant isolation valve on the exchanger currently not in service. Coolant is now being circulated through both heat exchangers. 3. Operate the oil transfer valve to direct the total oil flow to the heat exchanger that will now be in service. 4. Close the coolant return isolation valve on the exchanger with no oil flow. A temperature-regulating valve (VTR1-1) is provided to control the lubricating oil header temperature. The three-way valve bypasses coolant around the heat exchanger allowing the correct coolant flow to maintain the oil within the temperature control range. Gas turbine operation can be maintained the temperature during using manual control.
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B. Atomizing Air System This system contains a heat exchanger, two butterfly valves and a temperature-regulating valve. Coolant is circulated through the atomizing air pre-cooler to lower the temperature of the air entering the atomizing air compressor. A temperature-regulating valve (VTR2-1) is provided to control the atomizing air temperature. The valve is a self-contained control system that has a temperature bulb, a capillary tube and a bellows actuator. Gas turbine operation can be maintained the temperature during using manual control.
C. Gas Turbine Base The piping on the gas turbine base distributes coolant to the turbine supports and flame detector mounts. The flame detector mounts are cooled to extend the life of the flame detectors. The coolant jackets on the flame detector mounts provide a thermal break in heat conduction from the combustion can house to the flame detector instrument. No temperature regulation is necessary for the turbine supports or flame detector mounts. 92 PDF created with pdfFactory Pro trial version www.pdffactory.com
D. GENERATOR The generator has two duplex air coolers located in its top section. Heat from the closed circuit gas stream is transferred to the coolant circulated through them. Under normal operation, all the valves are open.
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Cooling Water System Drawing
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