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LM6000-50/60 HZ Gas Turbine Generator Set Product Specification
GE Energy 1333 West Loop South Houston, TX 77027 Telephone: 713-803-0900 THIS PRODUCT MANUAL IS SUBMITTED WITH THE UNDERSTANDING THAT THE INFORMATION CONTAINED HEREIN WILL BE KEPT CONFIDENTIAL AND NOT DISCLOSED TO OTHERS OR DUPLCIATED WITHOUT THE PRIOR CONSENT OF GE ENERGY DATA AND SPECIFICATIONS MAY BE UPDATED FROM TIME TO TIME WITHOUT NOTICE. DATE OF ISSUE-6/2008
Table of Contents
Tab
Introduction LM6000 Introduction
1
Data Sheet
2
Codes and Standards
3
Typical Performance Specifications
4
Typical Performance Curves
5
Technical Data
Performance
Description of Equipment Major Equipment
6
System Descriptions – Major Equipment
7
Optional Equipment
8
Mechanical Outlines
9
Generator, Exciter and Voltage Regulator
10
One-Line Diagram
11
Control System Description
12
Equipment and Services by Buyer
13
Reference Specifications
14
Maintenance, Special Tools and Spare Parts
15
LM6000 - 60Hz Classic 6/2008 TABLE OF CONTENTS
Index I
Tab
Services Customer Drawings
16
Extended Scope Equipment and Services
17
Training
18
Aftermarket Services
19
LM6000 - 60 Hz Classic 6/2008
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1.
1.1
LM6000 Introduction
Equipment Capabilities
GE is pleased to offer the LM6000 Aeroderivative Package. With the ability to deliver over 49 MW on a gross electrical basis, the LM6000 maintains the proven reliable technology with modern design enhancements to improve maintainability and reliability. Additional benefits of the LM60000 Package are the lower overall installed cost, shorten installation time, reduced customer interfaces and enhanced safety. The Package features the GE LM6000 gas turbine and a matching electric generator. It is designed for simple-cycle, combined-cycle, and cogeneration installations. The LM6000 is built with rugged components for base-load utility service. It can also start and stop easily for “peaking” or “dispatched” applications. Additionally, quick dispatchability is available in simple-cycle applications with the 10-minute fast start feature. Package Type (60 Hz) LM6000 PC SPRINT® – Natural Gas and Water Injection LM6000 PC – Natural Gas and Water Injection LM6000 PC – Natural Gas and Steam Injection
kW
Btu/kWh
KJ/kWh
50,337
8457
8923
43,882
8,511
8,980
43,854
7,879
8,312
Conditions: Power at generator terminals NOx = 25 ppm (SAC-Water) 59º F / 15 ºC, 60% RH 13.8kV, 0.85 pf Losses: 0”/0” H2O Inlet/Exhaust Fuel: Spec Gas (19,000 Btu / Lb, LHr) at 77º / 25ºC VIGV option included
1.1.2 Engine Heritage The LM6000 gas turbine is derived from the GE commercial CF6-80C2 aircraft engine. This engine first entered aircraft service in 1985 and is used extensively in wide-body commercial airliners. More than 2000 “80C2” engines are either on order or in use today.
1.1.3 Simple Design The LM6000 package is offered in a 50 Hz and 60 Hz design. This document covers the 60 Hz design. The LM6000 is a 2-shaft gas turbine engine equipped with a low-pressure compressor, highpressure compressor, combustor, high-pressure turbine, and low-pressure turbine.
LM6000 - 60 Hz Classic 6/2008
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1.1.4 Emissions Control The table below shows the emission levels for each configuration at 15% O2 dry. Fuel
Combustor
Diluent
Power Augmentation
NOx Level
LM6000 SAC, 60 Hz
Gas, Liquid or Dual Fuel
Single Annular (SAC)
Water
None
25 ppm gas/ 42 ppm liquid
LM6000 DLE, 60 Hz
Gas
Dry Low Emissions (DLE)
None
None
15 ppm
Product Offerings
LM6000 Emissions Abatement Configurations
1.1.5 Output Enhancements Various options are available to improve the typical OUTPUT-MW profile of the LM6000 gas turbine. To improve high ambient temperature performance, either evaporative cooling or coils for mechanical chilling are available.= GE Energy will work with the customer to determine the applicability of of these enhancements to their particular case.
1.1.6 High Availability and Reliability The LM6000 gas turbine generator set has a proven record of high availability and reliability. With more than 700 units installed since 1992, the LM6000 gas turbine generator set leads the industry in reliability greater than 99.7%* and availability above 98.6%*. Each gas turbine is factory tested to full speed and full load for performance and mechanical integrity. Every package is static tested to check each system of the package. Refer to section 1.2.1 for static testing summary. Leveraging aircraft experience and design, the aeroderivative design approach incorporates features such as split castings, modular construction, individual replacement of internal and external parts, and GE’s “lease pool” engine program. The extensive use of high quality components common with its parent aircraft engine validates engine reliability and offers reduced parts cost. Various inspections and hot section repairs can be performed on the gas turbine at site within the turbine enclosure. The “Hot Section”,HPT and combustor, can be removed/replaced in the field within seventy-two hours allowing for greater availability during planned maintenance. Greater availability is achieved by the on-condition maintenance program, which inspects and repairs only as necessary to desired operational condition. * 50th percentile of 233 units reporting into ORAP® as of July 2007.
LM6000 - 60 Hz Classic 6/2008
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1.1.7 Simple Cycle Simple cycle aeroderivative gas turbines are typically used to support the grid by providing quick start (10 minutes to full power) and load following capability. High part-power efficiency, as shown in Figure 1.1, enhances load following and improves system-operating economics.
39%
Efficiency, %
37% 35% 33% 31% SAC-Dry 29%
SAC-Water DLE
27% 25% 50%
55%
60%
65%
70%
75%
80%
85%
90%
95%
100%
% of Baseload
Basis of Performance: Amb 59ºF RH of 60% with 0” H20 inlet/exhaust losses at 0 ft. ASL, Fuel natural Gas (19,000 Btu / Lb), 60Hz, 13.8 kV, 0.85pf. Not for guarantee. NOx Water, Steam and DLE are to 25 PPMVD Nox at 15% 02
Figure 1.1: Part Power Efficiency
1.2
Factory and Service Capabilities
A full range of services are available for the LM6000:
1.2.1 Factory Static Testing The standard factory test for the package is a 400-point static test to confirm: • Temperature element output and wiring • Transmitter range, output and wiring • Solenoid operation • Control valve torque motor, excitation and return signal • Fire system continuity and device actuation LM6000 - 60 Hz Classic 6/2008
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• •
System cleanliness Control system software loading and validation
1.2.2 Factory String Testing Available as a factory option. Reference section 8.2.28 for more details on String Testing.
1.2.3 Drawings and Service Manuals Drawings are supplied which allow a buyer to design foundations for the package and offbase auxiliary modules, make station layouts, order long lead buyer-supplied equipment and prepare an installation bid package or plan. The Operation and Maintenance Manuals are provided in CD form in the English language, using standard (U.S.) customary engineering units. The manuals include basic concepts in operating the power generating equipment, guides to troubleshooting, equipment schematics, and general arrangement and flow and instrument diagrams. The copies of the Installation and Commissioning (I&C) manuals will also be provided.
1.2.4 Recommended Spare Parts Supplied with the Operation and Maintenance Manual are lists of the recommended spare parts for the turbine, generator, exciter, unit controls and off-base accessories. Additionally, specialists are available to assist you with your parts planning and ordering activities.
1.2.5 Installation and Start-Up Services Field service consultation for installation and startup is available as an option with the basic unit. This extended service can be supplemented with the full range of in-house product support services available with various GE divisions and GE Energy in Houston, including supervisory services for field assembly of the major equipment components, commissioning and initial operation. Refer to Section 17 for details. (do a find and replace where appropriate for “See Section” to Refer to)
1.2.6 Operation and Maintenance Training The basic scope includes a Gas Turbine Familiarization Course in Cincinnati, Ohio and an Operator’s Training Course at the GE Energy Jacintoport facility. These courses include basic concepts of an aeroderivative gas turbine generator set plus the normal operating guidelines and maintenance practices. Additional training courses are available (i.e., for controls) at other GE Training Centers. The training material is also available for purchase in CD format for reference.
LM6000 - 60 Hz Classic 6/2008
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1.2.7 Field Verification of Performance GE Energy will assist with field performance testing to demonstrate that the generator electrical output and heat rate achieve guaranteed levels.
1.2.8 Summary In summary, the LM6000 is unique to the power generation industry. As the most trusted and reliable gas turbines in the world, we recommend the LM6000 as a standard 40-50 MW building block for utility and industrial applications.
LM6000 - 60 Hz Classic 6/2008
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2.
Data Sheets
This section provides additional data for a typical LM6000 gas turbine generator package (60 Hz), including: auxiliary power loads, optional auxiliary power loads, and shipping dimensions and weights.
2.1
LM6000 Auxiliary Power Loads (60 Hz) Normal Operating Load
Standard Electric Loads Turbine Vent Fans Generator Vent Fans Hydraulic Start Pump Generator Aux. L.O. Pump Generator Jacking Oil Pump Gas Turbine Lube Oil Heater Generator L.O. Heater Hyd. Starter L.O. Heater Generator Space Heater Turbine Air/Oil Separator Lighting & Low Voltage Distribution System Water Wash Supply Pump Hydraulic Starter Oil Heat Exchanger Fan Turbine Water Wash Tank Heaters Total (kW)
LM6000 - 60 Hz Classic 6/2008
Required for Black Start
Qty 2 2 1 1 1 1 2 1 1 1
Aux Rating 125 hp 100 hp 200 hp 7.5 hp 15 hp 3 kW 4 kW 3 kW 4 kW 1 hp
Total Qty 1 1 0 1 0 0 0 0 0 1
KW 93 75 0 5.6 0 0 0 0 0 0.75
Total Qty 1 1 1 1 1 1 2 1 1 1
kW 93 75 149 5.6 11.2 3 8 3 4 0.75
1 1
45 kVA 2 hp
1 1
45 1.5
1 0
45 0
1
3 hp
1
2.2
1
2.2
2
9 kW
2
0 222
2
0 397
Page 8 of 156
2.2
Optional LM6000 Auxiliary Power Loads
Optional Electrical Loads Auxiliary Skid Vent Fans Liquid Fuel Pump Water Inj. Pump - Gas Fuel Water Inj. Pump - Liquid Fuel Evap Cooler Recirc. Pumps Auxiliary Skid Heater Fuel Pump Skid Vent Fans Gen. Vent Fans - TEWAC Control House A/C Sprint Skid Pump Liquid Fuel Pump Skid Heater Turbine Enclosure Heaters Turbine Enclosure Heaters Generator Enclosure Heaters Generator Enclosure Heaters
LM6000 - 60 Hz Classic 6/2008
Qty 2 2 2
hp 1 100 75
2 2 1 2 2 2 1
125 5 3 kW 1 25 4.1 kW 10
1 2 2 2 2
3 kW 5 kW 10 kW 5 kW 10 kW
Normal Operating Load Total Qty kW 2 1.5 1 74.6 1 55.9 1 2
Required for Black Start Total Qty kW 2 1.5 1 74.6 0 0
2 1 1 1
93.2 7.46 3 1.5 18.6 4.1 7.5
1 2 1 2 1 2 1
93.2 7.46 3 1.5 18.6 8.2 7.5
1 0 0 0 0
3 5 5 10 10
1 2 2 2 2
3 5 5 10 10
Page 9 of 156
2.3
Preliminary Shipping Dimensions and Weights for One (1) LM6000 Gas Turbine Generator Unit
GROSS WEIGHT LENGTH Description lbs kg in cm Turbine Base 120,000 54,432.0 371.00 942.3 Shear Lugs 1,020 462.7 45.00 114.3 H-Frame 2,085 945.8 174.00 442.0 Ruffneck heaters 1,050 476.3 67.00 170.2 CDP Purge 1,185 537.5 80.00 203.2 VBV Expansion Joint 695 315.3 90.00 228.6 Exhaust Flashing 725 328.9 62.00 157.5 Mechanical Shiploose 2,785 1,263.3 170.00 431.8 Alignment Tool 530 240.4 104.00 264.2 Turbine Lift Fixture 1,410 639.6 128.00 325.1 LM6000 Generator Base 68,000 30,844.8 337.00 856.0 Brush Generator 176,000 79,833.6 301.00 764.5 Generator Lube Oil Piping 1,420 644.1 212.00 538.5 Run down tanks 1,455 660.0 106.00 269.2 Generator transition throat 1,800 816.5 125.00 317.5 Generator exhaust hood 9,070 4,114.2 174.00 442.0 Electrical Shiploose 1,105 501.2 96.00 243.8 Lucas Coupling 1,445 655.5 120.00 304.8 Roof Skid Transition 44,000 19,958.4 470.00 1193.8 Raincap 1,320 598.8 82.00 208.3 Raincap 1,320 598.8 82.00 208.3 Ventilation Silencer 3,100 1,406.2 80.00 203.2
LM6000 - 60 Hz Classic 6/2008
WIDTH in cm 171.00 434.3 25.00 63.5 35.00 88.9
HEIGHT in cm 178.00 452.12 17.00 43.18 36.00 91.44
VOLUME ft3 m3 6535.0 185.03 11.1 0.31 126.9 3.59
36.00 48.00
91.4 121.9
67.00 24.00
170.18 60.96
93.5 53.3
2.65 1.51
32.00
81.3
24.00
60.96
40.0
1.13
62.00
157.5
17.00
43.18
37.8
1.07
48.00
121.9
43.00
109.22
203.1
5.75
30.00
76.2
32.00
81.28
57.8
1.64
76.00
193.0
17.00
43.18
95.7
2.71
171.00
434.3
178.00
452.12
5936.1
168.08
159.00
403.9
130.00
330.20
3600.5
101.94
32.00
81.3
21.00
53.34
82.4
2.33
46.00
116.8
30.00
76.20
84.7
2.40
125.00
317.5
39.00
99.06
352.6
9.98
150.00
381.0
87.00
220.98
1314.1
37.21
48.00
121.9
38.00
96.52
101.3
2.87
32.00
81.3
40.00
101.60
88.9
2.52
172.00 82.00 82.00
436.9 208.3 208.3
149.00 54.00 54.00
378.46 137.16 137.16
6970.6 210.1 210.1
197.36 5.95 5.95
80.00
203.2
131.00
332.74
485.2
13.74
Page 10 of 156
2.3
Preliminary Shipping Dimensions and Weights for One (1) LM6000 Gas Turbine Generator Unit (Cont.)
Description Ventilation Silencer VBV Duct VBV Silencer VBV Hood Roof Skid Transition Generator Fan Exp Jpint Demister Plenum LH Coil Module RH Coil Module Walkways & Handrails Coil Module Parts Support Structure & Ladder Pre-Filter Doors (16) Pre-Filter Doors (16) Nuts & Bolts Shiploose Paint (1-5 gal) Flex Hoses Auxiliary Module Lineside Cubicle Neutral Cubicle Acid CO2 Cover & Rack CO2 Bottles BUS Relay station
GROSS WEIGHT lbs kg
LENGTH in cm
WIDTH in cm
HEIGHT in cm
VOLUME ft3 m3
3,100 15,600 19,800 6,460
1,406.2 7,076.2 8,981.3 2,930.3
80.00 158.00 172.00 140.00
203.2 401.3 436.9 355.6
80.00 150.00 146.00 102.00
203.2 381.0 370.8 259.1
131.00 102.00 82.00 108.00
332.74 259.08 208.28 274.32
485.2 1399.0 1191.7 892.5
13.74 39.61 33.74 25.27
1,710
775.7
148.00
375.9
73.00
185.4
34.00
86.36
212.6
6.02
450 204.1 51.00 129.5 51.00 720 326.6 36.00 91.4 36.00 24,400 11,067.8 394.00 1000.8 146.00
129.5 91.4 370.8
24.00 74.00 149.00
60.96 187.96 378.46
36.1 55.5 4960.1
1.02 1.57 140.44
43,500 19,731.6 400.00 1016.0 153.00
388.6
149.00
378.46
5277.1
149.42
43,500 19,731.6 400.00 1016.0 153.00
388.6
149.00
378.46
5277.1
149.42
3,640
1,651.1
152.00
386.1
60.00
152.4
44.00
111.76
232.2
6.58
1,225
555.7
44.00
111.8
44.00
111.8
38.00
96.52
42.6
1.21
5,620
2,549.2
312.00
792.5
81.00
205.7
62.00
157.48
906.8
25.67
2,010
911.7
129.00
327.7
56.00
142.2
52.00
132.08
217.4
6.16
1,940
880.0
129.00
327.7
56.00
142.2
52.00
132.08
217.4
6.16
1,750
793.8
48.00
121.9
48.00
121.9
36.00
91.44
48.0
1.36
130 260
59.0 117.9
24.00 64.00
61.0 162.6
18.00 19.00
45.7 48.3
23.00 14.00
58.42 35.56
5.8 9.9
0.16 0.28
85,000 38,556.0 564.00 1432.6 168.00
426.7
168.00
426.72
9212.0
260.83
2,800
1,270.1
68.00
172.7
68.00
172.7
124.00
314.96
331.8
9.40
4,400 650
1,995.8 294.8
96.00 47.00
243.8 119.4
68.00 19.00
172.7 48.3
120.00 33.00
304.80 83.82
453.3 17.1
12.84 0.48
3,180 3,885
1,442.4 1,762.2
110.00 47.00
279.4 119.4
45.00 37.00
114.3 94.0
115.00 72.00
292.10 182.88
329.4 72.5
9.33 2.05
6,500
2,948.4
72.00
182.9
36.00
91.4
36.00
91.44
54.0
1.53
LM6000 - 60 Hz Classic 6/2008
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2.3
Preliminary Shipping Dimensions and Weights for One (1) LM6000 Gas Turbine Generator Unit (Cont.)
GROSS WEIGHT LENGTH Description lbs kg in cm Lift pins 7,260 3,293.1 114.00 289.6 Air Filter spreader bar 4,650 2,109.2 440.00 1117.6 Main Unit Spreader bar 1,800 816.5 211.00 535.9 Generator spreader bar 1,400 635.0 133.00 337.8 Slings & Shackles 10,000 4,536.0 139.00 353.1 Additional Cable (3 rolls) 3,000 1,360.8 72.00 182.9 Vent(Anti icing system) 15,600 7,076.2 158.00 401.3 Vent(Anti icing system) 15,600 7,076.2 158.00 401.3 Ladders 1,250 567.0 339.00 861.1 Platforms 8,325 3,776.2 202.00 513.1 Nuts & Bolts Shiploose 670 303.9 61.00 154.9 High Pressure Demin Water Filter 460 208.7 27.00 68.6 Fire 700 317.5 36.00 91.4 Misc Parts for water system 50 22.7 48.00 121.9 Relay Panels 900.00 408.2 72.00 182.9 Switch Board 750.00 340.2 72.00 182.9 Switch Gear 5,000.0 2,268.0 77.00 195.6 Switch Gear 18360.0 8,328.1 181.00 459.7 Switchgear Accessories 1,250.0 567.0 88.00 223.5 Switchgear Accessories 1,350.0 612.4 110.00 279.4 Switchgear Accessories 850.00 385.6 94.00 238.8 Switchgear Accessories 290.00 131.5 60.00 152.4
LM6000 - 60 Hz Classic 6/2008
WIDTH in cm 78.00 198.1
HEIGHT in cm 30.00 76.20
VOLUME ft3 m3 154.4 4.37
33.00
83.8
12.00
30.48
100.8
2.85
26.00
66.0
12.00
30.48
38.1
1.08
26.00
66.0
12.00
30.48
24.0
0.68
96.00
243.8
42.00
106.68
324.3
9.18
36.00
91.4
36.00
91.44
54.0
1.53
150.00
381.0
102.00
259.08
1399.0
39.61
150.00 59.00 102.00
381.0 149.9 259.1
102.00 48.00 59.00
259.08 121.92 149.86
1399.0 555.6 703.5
39.61 15.73 19.92
43.00
109.2
42.00
106.68
63.8
1.81
27.00 36.00
68.6 91.4
48.00 72.00
121.92 182.88
20.3 54.0
0.57 1.53
24.00 48.00 36.00 106.00 106.00
61.0 121.9 91.4 269.2 269.2
55.00 72.0 72.0 116.0 116.0
139.70 182.88 182.88 294.64 294.64
36.7 144.0 108.0 547.9 1287.9
1.04 4.08 3.06 15.51 36.47
48.00
121.9
48.0
121.92
117.3
3.32
39.00
99.1
29.0
73.66
72.0
2.04
46.00
116.8
20.0
50.80
50.0
1.42
31.00
78.7
17.0
43.18
18.3
0.52
Page 12 of 156
2.3
Preliminary Shipping Dimensions and Weights for One (1) LM6000 Gas Turbine Generator Unit (Cont.)
GROSS WEIGHT LENGTH Description lbs kg in cm Switchgear Accessories 475.00 215.5 96.00 243.8 Switchgear Accessories 1,600.0 725.8 125.00 317.5 Switchgear Accessories 90.00 40.8 25.00 63.5
WIDTH in cm
HEIGHT in cm
VOLUME ft3 m3
50.00
127.0
50.0
127.00
138.9
3.93
95.00
241.3
60.0
152.40
412.3
11.67
15.00
38.1
15.0
38.10
3.3
0.09
Note: Some equipment listed in this table may not be applicable to specific projects. .
LM6000 - 60 Hz Classic 6/2008
Page 13 of 156
3.
3.1
Codes and Standards
Codes and Standards for Gas Turbine Generators
GE Energy considers the applicable sections of the following US and ISO Codes and Standards to be the most relevant standards for gas turbine equipment. Our designs and procedures are generally compliant with applicable sections of the following: ANSI A58.1
Minimum Design Loads for Buildings and Other Structures
ANSI B1.1
Unified Inch Screw Threads
ANSI B1.20.1
Pipe Threads
ANSI B16.5
Steel Pipe Flanges and Flanged Fittings
ANSI B16.9
Factory-Made Wrought Steel Butt Welding Fittings
ANSI B16.21
Non-Metallic Flat Gaskets for Pipe Flanges. (Spiral-wound gaskets per API 601 may be used, particularly in turbine compartment piping)
ANSI B31.1
Pressure Piping and Gas Turbine Piping Systems Comply
ANSI B133.2
Basic Gas Turbine
ANSI B133.3
Gas Turbine Auxiliary Equipment.
ANSI B133.4
Gas Turbine Controls and Protection Systems
ANSI B133.5
Gas Turbine Electrical Equipment
ANSI B133.8
Gas Turbine Installation Sound Emissions
ANSI/NAFPA 12
Carbon Dioxide Extinguishing Systems
ANSI/NFPA 70
National Electrical Code
ANSI C31.1
Relays Associated with Electric Power Apparatus
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3.1
Codes and Standards for Gas Turbine Generators (Cont)
ANSI IEEE C37.2
Electrical Power System Device Function Numbers
ANSI C37.90a/ IEEE-472 ANSI C50.10
Guide for Surge Withstand Capability (SWC) Tests General Requirements for Synchronous Machines
ANSI C50.14
Requirements for Combustion Gas Turbine Driven Cylindrical Rotor Synchronous Generators
ANSI C57.94
American Standard, Guide for Installation and Maintenance of Dry Type Transformers
ANSI C83.16
Relays
ANSI/IEEE 100
IEEE Standard Dictionary of Electrical and Electronic Terms
ANSI/NEMA MG1
Motors and Generators
ANSI/NEMA MG2
Safety Standard for Construction and Guide for Selection, Installation and Use of Electric Motor and Generators
ANSI S1.2
Method for the Physical Measurement of Sound
ANSI S1.4
Specification for Sound Level Meters
ANSI S1.13
Method for the Measurement of Sound Pressure Levels
ANSI S6.1/ SAE/J184A
Qualifying a Sound Data Acquisition System
AGMA 421
Standard Practice for High Speed Helical and Herringbone Gear Units
IBC 2000
International Building Code
IEEE Std 421
IEEE Standard Criteria and Definitions for Excitation Systems for Synchronous Machines
EIA RS-232
Interface between Data Terminal Equipment and Data Communication Equipment Employing Serial Binary Interchange
LM6000 - 60 Hz Classic 6/2008
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Note: ATEX and CE Codes and Standards are applied when required. EN 61010-1 Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use, Part 1: General Requirements CAN/CSA 22.2 No. 1010.1-92 Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use, Part 1: General Requirements ANSI/ISA S82.02.01 1999 Safety Standard for Electrical and Electronic Test, Measuring, Controlling, and Related Equipment – General Requirements UL 796 Printed Circuit Boards ANSI IPC Guidelines ANSI IPC/EIA Guidelines EN 55081-2 General Emission Standard EN 50082-2 Generic Immunity Industrial Environment EN 55011 Radiated and Conducted Emissions IEC 61000-4-2 Electrostatic Discharge Susceptibility IEC 61000-4-3 Radiated RF Immunity IEC 61000-4-4 Electrical Fast Transit Susceptibility IEC 61000-4-5 Surge Immunity IEC 61000-4-6 Conducted RF Immunity IEC61000-4-11Voltage Variation, Dips & Interruptions ANSI/IEEE C37.90.1 Surge EN 61010-1 Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use, Part 1: General Requirements EN 50021 Electrical Apparatus for Potentially Explosive Atmospheres
LM6000 - 60 Hz Classic 6/2008
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The GE Gas Turbine Drafting Standards are based on the following Standards as appropriate to the gas turbine. Please note that in several instances, symbols, etc. have been devised for GE’s special needs (such as flow dividers and manifolds: ANSI B46.1
Surface Texture
ANSI Y14.15
Electrical and Electronics Diagrams (On base gas turbine and accessory base equipment)
ANSI Y14.17
Fluid Power Diagrams
ANSI Y14.36
Surface Texture Symbols
ANSI Y32.2/CSA
Graphic Symbols for Electrical and Electronics
299/IEEE 315
Diagrams
ANSI Y32.10
Graphical Symbols for Fluid Power Diagram
ANSI Y32.11
Graphical Symbols for Process Flow Diagram
ANSI Z32.2.3
Graphical Symbols for Pipe Fittings, Valves & Piping
AWS A2.0-68
Welding Symbols
LM6000 - 60 Hz Classic 6/2008
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4.
4.1
Typical Performance Specifications
LM6000 ISO Performance Data Simple Cycle Gas Turbine 60 Hz Applications (Natural Gas) Engine
Fuel Configuration
Single Annular Combustor Single Annular Combustor
Natural Gas Natural Gas and Water Injection Natural Gas and Steam Injection Natural Gas
Single Annular Combustor Dry Low Emissions
Power kW 43,284 43,882
Heat Rate LHV BTU/kW-hr KJ/kW-hr 8,133 8,581 8,511 8,980
43,854
7,879
8,312
42,300
8,315
8,773
Conditions: Power at Generator Terminals NOx = 51 mg / Nm³ (SAC-Water, SAC-Steam, and DLE) 15°C, 60% RH 11.5 kV,PF: 0.85 Losses: 0/0mm H2O Inlet/Exhaust Fuel: Spec Gas (44,194 kJ/kg, LHV) at 25ºC VIGV Included
Simple Cycle Gas Turbine 60 Hz Applications (Liquid Fuel) Engine
Fuel Configuration
Single Annular Combustor Single Annular Combustor
Liquid Liquid and Water Injection Liquid
Dry Low Emissions
Power kW 41,784 43,053 40,179
Heat Rate LHV BTU/kW-hr KJ/kW-hr 8,253 8,708 8,631 9,106 8,421
8,885
Conditions: Power at Generator Terminals NOx = 86 mg / Nm³ (SAC-Water) 15ºC, 60% RH 11.5 kV, PF: 0.85 Losses: 0/0mm H²O Inlet/Exhaust Fuel: Spec (42,798 kJ/kg) Liquid with ≤ 0.1% Sulfur VIGV Included
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Simple Cycle Gas Turbine 60 Hz Applications (Natural Gas with SPRINT®) Engine
Fuel Configuration
Single Annular Combustor Single Annular Combustor
Natural Gas Natural Gas and Water Injection Natural Gas and Steam Injection Natural Gas
Single Annular Combustor Dry Low Emissions
Power KW 46,673 50,337
Heat Rate LHV BTU/kW-hr KJ/kW-hr 8,142 8,591 8, 8,980
50,500
7,895
8,329
46,903
8,272
8.727
Conditions: Power at Generator Terminals NOx = 25PPM (SAC-Water, SAC-Steam, and DLE) 15ºC, 60% RH 13.8 kV, 0.85 pf Losses: 0/0mm H²O Inlet/Exhaust Fuel: Spec Gas (44,194 kj/kg), LHV) at 25 ºC VIGV included
Simple Cycle Gas Turbine 60 Hz Applications (Liquid with SPRINT®) Engine
Fuel Configuration
Single Annular Combustor Single Annular Combustor
Liquid Liquid and Water
Power KW 41,769 43,811
Heat Rate LHV BTU/kW-hr KJ/kW-hr 8,291 8,748 8,311 8,769
Conditions: Power at Generator Terminals NOx = 86 mg / Nm³ (SAC-Water) 15ºC, 60% RH 11.5 kV, 0.85 pf Losses: 0/0mm H²O Inlet/Exhaust Fuel: Spec (42,798 kj/kg) Liquid with ≤ 0.1% Sulfur VIGV Included
4.2
Performance Data and Curves
Performance curves are included in Performance Curves Section 5. From these curves it is possible to determine performance at ambient temperatures, altitudes, and conditions differing from those listed in the performance specifications.
4.3
Guarantee Basis
Performance guarantees for power and efficiency are based on the condition and cleanliness of the gas turbine. If more than 200 fired hours have elapsed before conducting a
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performance test, a GE Energy representative has the right to inspect the unit to ensure condition and cleanliness standards have been met. The guarantees are also based on a site test conducted in accordance with GE Energy’s standard practices and protocols as described in the Test Specifications. GE Energy reserves the right to have a representative present during the performance test.
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5.
5.1
Performance Curves
Turbine Performance Curves
5.1.1 Turbine Curves –at 60 Hz/ 13.8 kV* • LM6000 performance at various ambient temperatures • LM6000 with SPRINT performance at various ambient temperatures • LM6000 heat rate at various ambient temperatures • LM6000 with SPRINT® heat rate at various ambient temperatures • LM6000 part power heat rate • LM6000 with SPRINT® performance at various altitudes • LM6000 part power heat rate (LHV) • LM6000 with SPRINT part power heat rate (LHV) • LM6000 part power efficiency • LM6000 with SPRINT™ part power efficiency • LM6000 10-minute start cycle
Figure 5-1 Figure 5-2 Figure 5-3 Figure 5-4 Figure 5-5 Figure 5-6 Figure 5-7 Figure 5-8 Figure 5-9 Figure 5-10 Figure 5-11
* Note - The performance curves may change slightly upon finalization of the product design and/or generator manufacturer selection.
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Power at Generator Terminal, kW
55000
50000
45000
40000
35000 SAC DRY
30000
Water DLE
25000 -20
-10
0
10 Temperature,
20 O
30
40
C
Figure 5- 1: LM6000 performance at various ambient temperatures Basis of Performance: RH of 60% with 0 mm H20 inlet exhaust losses at 0m ASL, Fuel: Natural Gas (44,194 kJ/kg), 50Hz, 11.5kV, 0.85pf. Not for guarantee. Nox Water and DLE are to 51 mg / Nm³.
Power at Generator Terminal, kW
55000
50000
45000
40000
35000 SAC DRY
30000
Water DLE
25000 -20
-10
0
10 Temperature,
20 O
30
40
C
Figure 5- 2: LM6000 with SPRINT performance at various ambient temperatures Basis of Performance: RH of 60% with 0 mm H20 inlet exhaust losses at 0m ASL, Fuel: Natural Gas (44,194 kJ/kg), 60Hz, 11.5kV, 0.85pf. Not for guarantee. Nox Water and DLE are to 51 mg / Nm³.
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10400
Heat Rate, kJ/kW-hr, LHV
9900 9400 8900 8400 SAC DRY
7900
Water DLE
7400 -20
-10
0
10
20
30
40
O
Temperature, C
Figure 5- 4: LM6000 heat rate at various ambient temperatures Basis of Performance: RH of 60% with 0 mm H20 inlet exhaust losses at 0m ASL, Fuel: Natural Gas (44,194 J/kg), 60Hz, 11.5kV, 0.85pf. Not for guarantee. Nox Water and DLE are to 51 mg / Nm³.
9900
Heat Rate, kJ/kW-hr, LHV
9400
8900
8400
7900
SAC DRY W ater DLE
7400 -20
-10
0
10 Temperature,
20 O
30
40
C
Figure 5- 3: LM6000 with SPRINT heat rate at various ambient temperatures Basis of Performance: RH of 60% with 0 mm H20 inlet exhaust losses at 0m ASL, Fuel: Natural Gas (44,194 J/kg), 60Hz, 11.5kV, 0.85pf. Not for guarantee. Nox Water and DLE are to 51 mg / Nm³.
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140%
Heat Rate, % of Baseload
135% 130% 125% 120% 115% SAC DRY
110%
SAC W ater DLE
105% 100% 50
60
70
80
90
100
% of Baseload
Figure 5- 6: LM6000 60Hz with SPRINT performance at various altitudes Basis of Performance: RH of 60% with 0 mm H20 inlet exhaust losses at 0m ASL, Fuel: Natural Gas (44,194 J/kg), 60Hz, 11.5kV, 0.85pf. Not for guarantee. Nox Water and DLE are to 51 mg / Nm³.
52000
Power at Generator Terminal, kW
50000 48000 46000 44000 42000 40000 SAC DRY
38000
W ater DLE
36000 34000 0
200
400
600
800
1000
1200
1400
1600
Altitude, M eters above sea level
Figure 5- 5: LM6000 part power heat reate Basis of Performance: RH of 60% with 0 mm H20 inlet exhaust losses at 0m ASL, Fuel: Natural Gas (44,194 J/kg), 60Hz, 11.5kV, 0.85pf. Not for guarantee. Nox Water and DLE are to 51 mg / Nm³.
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140%
Heat Rate, % of Baseload
135% 130% 125% 120% 115% SAC DRY
110%
S A C W a te r D LE
105% 100% 50
60
70
80
90
100
% o f B a s e lo a d
Figure 5- 7: LM6000 60Hz with SPRINT part power heat rate (LHV) Basis of Performance: RH of 60% with 0 mm H20 inlet exhaust losses at 0m ASL, Fuel: Natural Gas (44,194 J/kg), 60Hz, 11.5kV, 0.85pf. Not for guarantee. Nox Water and DLE are to 51 mg / Nm³.
140%
Heat Rate, % of Baseload
135% 130% 125% 120% 115% 110%
SAC DRY SAC Water
105%
DLE
100% 50
60
70
80
90
100
% of Baseload
Figure 5- 8: LM6000 60Hz part power heat rate (LHV) Basis of Performance: RH of 60% with 0 mm H20 inlet exhaust losses at 0m ASL, Fuel: Natural Gas (44,194 J/kg), 60Hz, 11.5kV, 0.85pf. Not for guarantee. Nox Water and DLE are to 51 mg / Nm³.
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50%
Efficiency, %
45%
40%
35%
30% SAC DRY 25%
SAC WATER DLE
20% 50
55
60
65
70
75
80
85
90
95
100
% of Baseload
Figure 5- 10: LM6000 60Hz part power efficiency Basis of Performance: RH of 60% with 0 mm H20 inlet exhaust losses at 0m ASL, Fuel: Natural Gas (44,194 J/kg), 60Hz, 11.5kV, 0.85pf. Not for guarantee. Nox Water and DLE are to 51 mg / Nm³. 50%
Efficiency, %
45% 40% 35% 30% SAC DRY
25%
SAC W ATER DLE
20% 50
55
60
65
70
75
80
85
90
95
100
% of Baseload
Figure 5- 9: LM6000 60Hz with SPRINT part power heat rate (LHV) Basis of Performance: RH of 60% with 0 mm H20 inlet exhaust losses at 0m ASL, Fuel: Natural Gas (44,194 J/kg), 60Hz, 11.5kV, 0.85pf. Not for guarantee. Nox Water and DLE are to 51 mg / Nm³.
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10-Minute Simple Cycle Start Cycle for LM6000 with SPRINT®
Figure 5- 11: LM6000 10-minutes start cycle
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6.
6.1
Major Equipment
LM6000 PC Gas Turbine
Base-mounted, simple cycle, two (2) spool gas turbine in a fully enclosed turbine compartment: • • • • • • • • • • •
Two-shaft configuration with direct drive output at (50 Hz) 3600 rpm… match apps for PC & PD Radial inlet Five stage low pressure compressor (LPC) Fourteen stage high pressure compressor (HPC) with horizontal split casing Combustor Thirty fuel nozzles and dual igniters (DLE is option) Two stage high pressure turbine (HPT) Five stage low pressure turbine (LPT) Borescope ports for diagnostic inspection Accessory drive gearbox for starter, lube & scavenge pumps Flexible dry type main load coupling and guard
6.1.1 Fuel Systems • • •
Natural gas fuel system Water Injection for NOx Liquid/Dual Fuel
6.1.2 Starting System The hydraulic start system mounted on the auxiliary skid will include: • • • • •
40 gallon / 151 l Reservoir tank (should the dimensions be included in the Greybook or contract) Hydraulic pump assembly LP return filter Case drain filter Heat exchanger
6.1.3 Inlet Air System
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• • •
High efficiency inlet filter system Silencing system Support structure, ladders, and platforms
6.1.4 Exhaust System • •
Axial exhaust collector system Connection flange at the wall of the turbine enclosure
6.1.5 Lube Oil Systems The synthetic lube oil system for the turbine will include: • 304 stainless steel tank (150 gallons / 568 l) and piping mounted on turbine skid • Valves with stainless steel trim • Duplex filters (supply) mounted on turbine skid • Duplex filters (scavenge) mounted on auxiliary module • Duplex shell and tube coolers mounted on the auxiliary module • Shaft-driven positive displacement supply • Scavenge pump
6.1.6 Turbine Engine Compartment •
For weatherproofing, acoustics, ventilation and fire system
6.1.7 Fire Protection System – CO2 • • •
Gas detectors, optical flame detectors and thermal detectors Primary and secondary high pressure CO2 cylinders Automatic vent fan shutdown and damper closure
6.1.8 Compressor Cleaning and Water Washing • • • •
On-line water wash system Off-line water wash system 100 gallon / 379 l - 304 stainless steel reservoir mounted on the auxiliary skid Motor-driven pressurizing pump
6.1.9 Base Scope Auxiliary Equipment Module Base auxiliary equipment module is provided with the unit to integrate several functions. Auxiliary components and fuel system components can be equipped with optional enclosures. The following is included:
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Auxiliary equipment • Synthetic lube oil reservoir, duplex scavenge oil filter and duplex shell/tube oil-to-water heat exchangers • Electro-hydraulic start system • CO2 cylinders • On-line/off-line water wash system (including instrument air filter) Note: In the base configuration the TCP and 24 VDC battery systems are shipped separately to be installed by others.
6.2
Generator & Excitation
6.2.1 • • • • • • • • • • -
Totally Enclosed, Open – Ventilated, Brushless Excitation
Stator winding with Class F insulation and Class B temperature rises Cylindrical forged steel rotor with Class F insulation and Class B temperature rises Open ventilated air cooling with unit mounted filters Strip heaters (to prevent condensation during periods of shutdown) Resistance temperature detectors (RTD) embedded in the stator windings in the air stream Displacement probes with internal proximeters for vibration monitoring Bearing metal and drain RTDs for temperature monitoring Rotating rectifier excitation system including: Three-phase rotating armature Three-phase rotating rectifier Exciter field GE EX2100 automatic digital voltage regulator located in the turbine control panel (TCP). Provisions for a key phasor (add to options) Permanent magnet generator (PMG) for the excitation system
6.2.3 Generator Auxiliaries • -
As viewed when looking at generator non-drive end: Instrument and control termination box (MGTB), right side Lineside termination cubicle (containing lightning arrestors and surge capacitors) left side (very this is standard) Neutral cubicle containing CTs and a HI Z (impedance) grounding system, right side
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6.3
Unit Controls
6.3.1 Turbine Control Panel •
• • • • • • • • • •
Free standing, for indoor location: 9 ft – 6 inch W x 2 ft – 6 inch D x 7 ft -6 inch H / 289.6 cm W x 76.2 cm D x 228.6 cm H Woodward Micronet Plus Sequencing, control, protection, monitoring Desktop display and keyboard for operator I/O Metering readouts shown digitally on the display Plant ethernet port to user’s DCS Protective relaying and metering Rack-mounted electronic voltage regulator Vibration monitoring system Fire monitoring system Generator controls
6.3.2 24V Control Battery and Redundant Charger • • •
Battery: 19 cells, 24 VDC, Ni-CAD type Charger: 230 V (service voltage), 150 amps 323 AH
6.3.3 24V Fire and Gas Battery and Charger • • •
Battery: 19 cells, 24 VDC, Ni-CAD type Charger: 120 V (service voltage), 25 amps 138 AH
6.3.4 125 V Battery and Charger (SAC) • • •
Battery: 45 cell blocks, 125 VDC, Ni-CAD type Charger: 230 V (service voltage), 3-ph, 50 amps 84 AH
6.3.5 125 V Battery and Charger (DLE) • • •
Battery: 45 cell blocks, 125 VDC, Ni-CAD type Charger: 230 V (service voltage), 3-ph, 50 amps 112 AH
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6.4
Drawings, Documentation and Training
In addition to the supply of the equipment, for each unit GE Energy will: •
Coordinate engineering, manufacturing, and shipping schedules to meet contractual requirements
For the site, Services include: •
Provide Buyer’s drawings and six (6) copies of the Operation and Maintenance Manuals in CD form
•
Provide Installation and Commissioning Manual
• •
Provide field technical direction for performance tests per GE standard test procedures. Conduct a Gas Turbine Package Familiarization and Operator’s Training Course for customer personnel at the GE Energy Jacintoport facility. See Section 18 for further details.
6.5
Testing and Transportation
In addition to the supply of the equipment, for each unit GE Energy will: •
Conduct standard factory tests of the equipment and conform to carefully established quality assurance practices
•
Static test the LM6000 gas turbine package before shipment from Houston utilizing contract unit controls
•
Prepare the equipment for domestic shipment
•
Deliver the equipment, ex-works factory Houston, Texas
Note: A recommended installation schedule will be prepared by GE, which will define the manpower loading, and classification of the supervisors provided, as well as the schedule of events. (BD to verify)
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7. Mechanical Descriptions - Major Equipment
7.1
Turbine Engine
The LM6000 is a 2-shaft gas turbine engine derived from the core of the CF6-80C2, GE's high thrust, high efficiency aircraft engine. More than eighteen hundred CF6-80C2s are in service and 2,000 or more are on order or option. The CF6-80C2 has logged more than 30,000,000 flight hours in the Boeing 747 and other wide-body aircraft, with a 99.88% dispatch reliability and commercial aviation's lowest shop visit rate. GE used this 30 million hour flight experience to create the LM6000. Both engines have a common design and share most major parts. The Low Pressure Turbine, High Pressure Compressor, High Pressure Turbine, and Combustor are virtually identical. This use of flight-proven parts, produced in high volume, contributes to the low initial cost and high operating efficiency of the LM6000.
LM6000 Turbine Engine
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7.1
Turbine Engine (Cont)
Major Engine Components: • • • • • •
5-stage low-pressure compressor (LPC) 14-stage variable geometry high pressure compressor (HPC) Annular combustor 2-stage air-cooled high pressure turbine (HPT) 5-stage low pressure turbine (LPT) Accessory Gear Box
The LM6000 has two concentric rotor shafts: The LPC and LPT are assembled on one shaft, forming the Low Pressure Rotor. The HPC and HPT are assembled on the other shaft, forming the High Pressure Rotor. The LM6000 uses the Low Pressure Turbine (LPT) to power the output shaft. By eliminating the separate power turbine found in many other gas turbines, the LM6000 design simplifies the engine, improves fuel efficiency and permits direct-coupling to 3600 rpm generators for 60 Hz power generation. The LM6000 gas turbine drives the generator via a flexible dry type coupling connected to the front, or “cold,” end of the LPC shaft.
7.1.1 Turbine Cycle • • • • • • • • • • •
Filtered air enters the bellmouth and flows through guide vanes to the LPC LPC compresses air by 2.4:1 ratio Air flows from LPC through the front frame & bypass air collector to HPC Air enters HPC through Inlet Guide Vanes The HPC compresses air by 12:1 ratio 30 Fuel (SAC) nozzles or 75 fuel (DLE) nozzles mix air and fuel Air-Fuel mixture is ignited in Annular Combustor Hot combustion gases expand through HPT driving the HPC Hot combustion gasses expand further through LPT driving the LPC and load Flanged end of the LPC shaft drives the electric generator load. Exhaust gasses exit engine/package at the exhaust flange
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7.1.2 Inlet and IGV Section The turbine inlet straightens the air stream and directs it into the Low Pressure Compressor (LPC).
7.1.3 Low Pressure Compressor The Low Pressure Compressor (LPC) is a 5-stage axial flow compressor with a 2.4:1 pressure ratio. It is derived from the CF6-50 flight engine. A horizontally split casing provides access to blades and vanes. Borescope ports permit flow path inspection.
7.1.4 Bypass Air Collector The LM6000 matches the airflow between the Low Pressure (LP) and High Pressure Compressor (HPC) with 12 hydraulically actuated variable bypass valves mounted in the turbine front frame. During start-up and part-load operation these valves open partially and vent excess air to the bypass air collector. The bypass air collector also supports the accessory gearbox.
7.1.5 High Pressure Compressor The LM6000 High Pressure Compressor (HPC) is a 14-stage unit. Variable stators in stages 1-5 ensure high efficiency throughout the starting and operating range. The stator geometry of stages 6 through 14 is fixed horizontally. This allows ready access to the stator vanes and rotor blades for inspection or replacement.
7.1.6 Combustion Section 7.1.6.1 Singular Annular Combustor (SAC) Thirty nozzles feed fuel into the LM6000 annular combustor, providing a uniform heat profile to the High Pressure Turbine (HPT). This produces maximum output with low thermal stress. The swirler-cup dome design produces a lean thoroughly mixed, mixture in the primary zone of the combustor. This provides cleaner combustion and reduces NOX. Available nozzle designs allow natural gas, distillate or dual-fuel operation. The nozzles also permit NOX reduction with water injection (natural gas and distillate fuels) and steam injection (natural gas fuel only). The annular combustor design provides low pressure loss, low exit temperature and extended operating life. A Hastelloy X inner liner resists corrosion and extends combustor life. 7.1.6.1.1
Dry Low Emissions (DLE) Combustor
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The DLE system controls NOx emissions without the use of water or steam. GE Energy installs special combustors, manifolds, nozzles and metering to control flame temperature and reduce emissions of NOx, CO and unburned hydrocarbons. This DLE system reduces emissions over the entire power range, not just at high power settings. The fuel system hardware supplied with the DLE gas turbine includes a base mounted gas manifold, hoses, staging valves, and a set of thirty fuel premixers. The LM6000 DLE gas turbine utilizes a lean premix combustion system designed for operation on natural gas fuel as well as dual fuel. Gas fuel is introduced into the combustor via 75 air/gas premixers packaged in 30 externally removable and replaceable modules. The premixers produce a very uniformly mixed, lean fuel/air mixture. The triple annular configuration enables the combustor to operate in premix mode across the entire power range, minimizing nitrogen oxide (NOx) emissions even at low power. The head end or dome of the combustor supports 75 segmented heat shields that form the three annular burning zones in the combustor, known as the outer or A-dome, the pilot or Bdome, and the inner or C-dome. In addition to forming the three annular domes, the heat shields isolate the structural dome plate from the hot combustion gases. The heat shields are an investment-cast superalloy and are impingement and convection cooled. The combustion liners are front mounted with thermal barrier coating (TBC) and no film cooling. Fuel to the gas turbine will be controlled based on control mode, fuel schedules, and the load condition. For normal start sequence (13 minutes), gradual load changes are preferred with at least 5-minute ramp from idle to maximum power. If a fast start (10 minutes) is required, the load may be ramped from idle to full load in 4 minutes as part of the start sequence provided in Operation. Normal load reduction transients should be no faster than 2-3 minutes from maximum power to synchronous idle.
7.1.7 High Pressure Turbine The High Pressure Turbine (HPT) is a 2-stage, air-cooled turbine rotated by the hot gasses exiting the combustor. The HPT powers the High Pressure Compressor (HPC) to supply highpressure air to the combustor. Turbine disks, blades and stator are air-cooled for efficiency. Blades are coated to resist erosion and corrosion.
7.1.8 Low Pressure Turbine The 5-stage Low Pressure Turbine (LPT) receives the outlet flow from the HPT. The LPT drives the Low Pressure Compressor and the driven load (generator, compressor, etc.) through a shaft concentric to the HPT shaft.
7.1.9 Gas Turbine Support Structures
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The LM6000 gas turbine uses three frames to support the LP and HP rotors, the front frame, compressor rear frame and the turbine rear frame. This configuration produces excellent rotor stability and closely controlled blade tip clearance.
7.1.9.1
Front Frame
The LM6000 front frame is a major engine structure that provides sup-port for the LPC shaft and the forward end of the HPC shaft. The frame also forms an airflow path between the outlet of the LPC and the inlet of the HPC. The front engine mounts attach to the front frame. The front frame contains the engine “A” sump that incorporates the thrust and radial bearings to support the LPC rotor and a radial bearing which supports the forward end of the HPC rotor. Lubrication oil supply and scavenge lines for the “A” sump are routed inside the front frame struts. The accessory gearbox drive shaft is located in the “A” sump and extends out through the strut located at the six o’clock position. Pads are contained on the frame outer case for mounting of the two High Pressure Compressor inlet temperature sensors.
7.1.9.2
Compressor Rear Frame
The compressor rear frame consists of an outer case, 10 struts and the “B-C” sump housing. The outer case supports the combustor and 30 fuel nozzles. The hub supports both the thrust bearing, the radial bearing and in turn, the mid-section of the HP rotor system.
7.1.9.3
Turbine Rear Frame
The turbine rear frame supports the rear engine mount and contains the D-E sump. The 14strut rear frame guides and straightens the exhaust flow for lower pressure drop and greater efficiency.
7.1.10 Accessory Drive System The hydraulic starter, lube and scavenge pump, variable geometry hydraulic pump, and other accessories are mounted on and driven by the accessory gearbox. The accessory gearbox is located below the front HPC casing at the six o'clock position on the LPC bleed air collector and is driven by the transfer gearbox through a short horizontal shaft. The transfer gearbox is driven by the high-pressure rotor system. The gearbox is supported from the LPC bleed air collector.
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7.2
Auxiliary Equipment Module
The base auxiliary equipment module is provided with the unit and integrates several functions. The auxiliary and fuel systems can be equipped with optional separate enclosures. The following is included as part of the standard auxiliary equipment module: Auxiliary Module • • •
Synthetic lube oil system components including: reservoir, duplex oil filter and duplex shell/tube oil-to-coolant heat exchangers Electro-hydraulic start system components, including: electric starting motor, variable displacement hydraulic pump, reservoir, air/oil cooler, low pressure return filter, and case drain return filter On-line/off-line water wash system, including: reservoir, supply valves, solenoid valves, pump, electric tank heater, in-line water filter, and instrument air filter
7.3
Fire Protection CO2 cylinders
•
Optional sun shield • Optional heated enclosure
7.4
Inlet Air System Multi-Stage Design
The GE Energy air inlet system is designed to protect the gas turbine, generator and equipment compartments from effects of air-borne dirt, contamination and foreign objects. It also provides a pre-engineered, modular design to minimize field assembly and eliminate field welding.
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COIL OPTIO N
I
TE PDI 4084 4105
I
TO ATM
AIR
COIL SECTION
DRIFT ELIMINATOR
GUARD FILTER
AIR
COMPOSITE FILTER CANISTERS
COMBUSTION AIR
COMPOSITE FILTER CANISTERS
COIL SECTION
DRIFT ELIMINATOR
GUARD FILTER
AIR LH SECTION "A"
RH SECTION "B"
TE MT 4082B 4000B
AIR
VENTIL ATION AIR
I
I
TO ATM
I
TO ATM PDT 4005A
I
PDI TE 4104 4083
ALARM: IF ICING CONDITION EXIST
TE MT 4082A 4000A
PDT 4005B
TO ATM
COIL OPTIO N
I
I
REL HUMIDITY SENSOR
REL HUMIDITY SENSOR
TE PDI 4086 4107
PDI TE 4106 4085
TO ATM I
PDT 4004
I
I
TO ATM
~105000 SCFM [2973 SCMM]
~45000 SCFM [1247 SCMM]
~60000 SCFM [1699 SCMM]
TO ATM
I
TE TE TE TE 4101A 4101B 4101C4101D
I
TE TE TE TE TE TE TE TE TE TE TE TE 4026 4026 4025 4025 4024 4024 4023 4023 4022 4022 4021 4021 A1 A2 A1 A2 A1 A2 A1 A2 A1 A2 A1 A2 ~45000 SCFM [1274 SCMM]
AIR
I
MOT 4103A
MOT 4103B
I
LO
TE 4102A1 TE 4102A2
A
~60000 SCFM [1699 SCMM]
PDT 4007 LO
I
~45000 SCFM [1274 SCMM]
I
B
~60000 SCFM [1699 SCMM]
TE TE 4030 4030 ATM A1 A2 HI PDT 4014
TURBINE ROOM EXHAUST HI
CO2 ACTU ATOR RESE T
PDT PDT 4011A 4011B I
I
I
MOT 4017A
I
A
B
MOT 4017B
TE 4001A1 TE 4001A2
GENER ATOR ROOM
TE 4031A1 TE 4031A2
I
I
GENER ATOR EXHAUS T
ATM
INLET
AIR
VOLUTE
TE 4054A1 TE 4054A2
STATOR TEMP SENSORS MGTB
I I I
HE 4051
INLET VOLUTE DRAI N TE 4091
I
MTTB
TURBINE ROOM
VBV DRAIN
TE TE MOT MOT MOT MOT 4090A14090A2 4019 4120 4121 4122 I
TE TE TE 4129 4128 4127 STATOR SPARES
HE 4050 I
TE 4093
TC HE 4053 4053 I
I
I
I
I
G-255-05
I
Simplified Schematic – Ventilation and Combustion Air System
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7.4.1 Filtration Specification The LM6000 static barrier filter removes more than 99.9% of all particles 5.0 micron and larger by utilizing a three-stage design. Engine Combustion Air
230,000 scfm / 6,514 m3/min
Turbine Ventilation Air
60,000 scfm / 1,699 m3/min.
Generator Ventilation Air
45,000 scfm / 1,274 m3/min.
Total Typical Air Flow
355,000 scfm / 9,487 m3/min.
7.4.2 General Arrangement The three-section inlet air filter mounts directly above the turbine enclosure, conserving space and providing compact, low-pressure loss ducting to the turbine inlet. The filtered air is partitioned within the filter house assembly, providing combustion air for the gas turbine and ventilation air for the turbine and generator compartments. The filter is designed for easy maintenance. A ladder and platform provides access to service doors on each filter section. Lighted internal walkways provide generous working room for replacement and maintenance of the filter elements.
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AIR FILTER
Air Inlet Filter Assembly
7.4.3 Filter House Materials The filter housing is constructed of 3/16 inch / 76 mm (verify units) steel plate. Protective paint is applied to the exterior and interior carbon steel surfaces. Floors and drain pans downstream of the optional evaporative cooler media or optional inlet air chiller coils are stainless steel to resist corrosion.
7.4.4 Inlet Screens/Weatherhood The weather hood provides a deflecting surface to prevent driving rain and snow from entering the filter house. In addition paper, leaves and wind-blown trash are blocked by the inlet screen. This structural component makes up the exterior face of the filter house and is manufactured from carbon steel.
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7.4.5 Barrier Filter The high-efficiency cylindrical barrier filter elements are mounted to the filter face of the inlet plenum and extend into the clean air plenum. The elements have extended surface area, large dirt holding capacity and low-pressure drop. Air flows through the elements from inside to outside keeping dirt safely trapped inside the element. The filter elements are designed specifically for gas turbine protection, and are particularly effective in filtering particles 5 microns or larger.
7.4.6 Clean Air Plenum Air passes through the barrier filters and enters the clean air plenum. This fabricated structure is the center section of the inlet filter assembly and separates ventilation air from combustion air.
7.4.7 Transition Ducts Combustion air flows through a transition duct from the clean air plenum to the combustion air inlet silencer. Ventilation air flows through transition ducts to the turbine and generator compartment.
7.4.8 Inlet Silencer The inlet silencer is a low-pressure-drop device located in the combustion air stream before the inlet volute. The silencer attenuates noise from the turbine and helps maintain the unit's low noise level.
7.4.9 Inlet Volute The inlet volute is stainless steel weldment that directs the combustion air flowing down from the filter and turns it 90° to flow axially into the turbine inlet. Vanes within the volute smooth the airflow and present a balanced air stream to the turbine bellmouth.
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7.5
Package Enclosures
The package is equipped with a generator and a turbine enclosures plus an optional auxiliary module enclosure is available. The unit enclosures are designed for outdoor installation with wind loads up to 150 mph / 240 km/h and to reduce the average near field noise to 85 dB (A) at 3 ft. / 1.0 m from the enclosure and 5 ft. / 1.5m above grade. Each compartment is provided with access doors and AC lighting. The turbine compartment contains an integral overhead bridge crane to facilitate engine removal. Enclosure walls are a “sandwich” construction filled with insulation blankets of high temperature, sound attenuating material. The inner wall panel is fabricated from perforated 1.21 mm / 18-gauge stainless steel. The outer wall panel is 1.9 mm / 14-gauge cold rolled carbon steel, painted with abrasion resistant, exterior quality epoxy paint. The turbine and generator compartment walls are supported by a structural steel framework that can withstand external wind loading and the internal pressure developed by the fire extinguishing system. External door hinges, latches and mounting hardware are stainless steel or chrome plated.
7.5.1 Enclosure Lighting AC lighting for the interior of the gas turbine and generator compartments is provided.
7.5.2 Enclosure Ventilation System The ventilation system removes heat from the turbine and generator compartments and removes combustible gases in the event of a fuel system failure. Both the turbine compartment and generator compartment are fully ventilated by redundant fans to improve reliability. Ventilation air is filtered to the same quality levels as the gas turbine combustion air.
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Gas Turbine Generator Package Airflow
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7.5.2.1
Turbine Compartment Ventilation
Ventilation air enters the turbine compartment around the inlet collector. Dual 125 hp / 93 kW exhaust fans (1 running / 1 standby) create an induced-draft airflow of approximately 60,000 scfm / 1,699 m3. 7.5.2.2
Generator Compartment Ventilation
Filtered air is forced into the generator compartment by dual 100 hp / 75 kW forced draft fans (1 running / 1 stand-by) through ducts from the inlet air filter. The 45,000 scfm / 1,270 m3/min. airflow cools the generator and the generator compartment. The ventilation fans produce a positive pressure in the generator compartment, providing additional isolation from the turbine compartment for gas leak protection purposes. This contributes to classification of the generator compartment as a non-hazardous area.
7.5.3 Noise Control The LM6000 enclosure and air inlet silencer reduce the average near field noise to 85 dB (A) at 3 ft. / 1.0 m from the enclosure and 5 ft / 1.5 m above grade. Lower noise limits can be provided with optional silencing equipment. Noise control will depend on the scope of the equipment supplied, the site plan, and project specific requirements.
7.5.4 Turbine Exhaust The LM6000 exhausts air is extracted axially through a flange located at the end of the turbine enclosure. This provides low restrictions and a direct path into optional, or customersupplied silencing or heat recovery equipment.
7.6
Baseplate
LM6000 generator sets are mounted on rugged I-beam baseplates to simplify shipping and installation. The basic equipment is supplied with the support structures consisting of a two-piece skid assembly, which is sectioned between the gas turbine and the generator. The full depth, bolted section is designed to provide the full structural properties of the wide flange I-beams. Full depth crossmembers are utilized to provide a rigid design that meets the requirements of IBC 2006 and is therefore suitable for installation in earthquake areas. The baseplate support system is enhanced by the installation of a heavy-duty, welded superstructure which utilizes 6 inch x 6 inch x 3/8 inch wall structural tubing for wall columns and roof beams. LM6000 - 60 Hz Classic 6/2008
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Tapered pins between the baseplates simplify field alignment and lifting spools are built into the baseplates providing a convenient structure for transportation.
7.7
Fuel System
The LM6000 gas turbine can be configured for gas, liquid or dual fuel operation. The basic gas fuel system is described below. Other configurations are available as options.
7.7.1 Gas Fuel System The gas fuel system contains the following major components. They are mounted in the turbine compartment, adjacent to the engine. • • • • • • • •
Fuel gas strainer Fuel gas flow meter Instrumentation Primary shutoff valve Fuel metering valve Secondary shutoff valve Fuel gas manifold Shipped loose manual shut-off valve
7.7.1.1
Gas Fuel Flow
Gas fuel must be supplied to the package baseplate connection at 675 +30/-20 psig / 4,053 – 4,962 kPag. Please see Section 14 for applicable fuel specification. Lower fuel supply pressure requirements for base load operation may be possible in certain circumstances. A customer supplied pressure regulator, pressure relief valve and GE supplied manually operated shut-off valve should be installed in the customer fuel supply system outside of main unit.
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11
I
I
24
EDGE OF MAIN SKID
PT 2027B
GAS FUEL VENT TO SAFE ARE A
FROM CDP PURGE SYSTEM
LC
EE
PT 2027A
GAS FUEL VENT TO SAFE ARE A
I
I I I
FSV 2006
SOV 2008
S
FO
I
EDGE OF MAIN SKID
FCV 2001
PT 2028
FSV 2004
E
M FC
SET: 40 PSI
SOV 2004 S
FT 2000
IN
CYL
IN
CYL
EXH
FO
EXH
FO
AA
TE 2032A2 I
TE 2032A1
GAS FUE L PURG E
I
I
G-249-05
30 FUE L NOZZLE S TOTAL
S
DD
SET: 40 PSI
FC
I
GAS MANIFOLD
I
FE 2000
10
GAS FUEL INLET
FC
SOV 2006
SECONDA RY FUEL SUPP LY
LO
Simplified Schematic – Gas Fuel System 7.7.1.2
Pressure and Temperature Monitoring
Pressure transmitters monitor the fuel supply pressure up stream and downstream of the fuel metering valve and forward the data to the fuel control and sequencer system. A platinum, dual element temperature RTD monitors fuel supply temperature and forwards the data to the fuel control and sequencer system. 7.7.1.3
Fuel Shutoff Valves and Safety Venting
Fuel shutoff valves manage gas flow to the combustor. Solenoid piloted fuel shutoff valves are quick-closure valve assemblies located upstream and downstream of the gas fuel metering valve. These fail-close valves are either fully open to allow fuel flow or fully closed to prevent fuel flow. During startup, the shutoff valves are opened and fuel flow to the gas manifold is metered by the gas fuel metering valve. During shutdown, when the shutoff valves are closed, a solenoidoperated vent valve opens to vent the fuel supply line between shutoff valves to a safe area. A gas fuel drain valve opens during certain shutdown conditions to purge the gas manifold and the engine.
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7.7.1.4
Fuel-Metering Valve
The electronically controlled fuel valve provides accurate, non-pulsating fuel flow to the turbine during starting, steady-state operation and dynamic load changes. Low fuel gas pressure starting is possible, using the electrical output of the LM6000 to power a fuel gas compressor. The LM6000 can start on a minimum 200 psig / 1,380 kPag fuel gas pressure. At this pressure the LM6000 produces enough electrical power to start a fuel gas compressor. The compressor then builds the fuel gas pressure up for full power output. This “bootstrap” starting simplifies gas utility requirements and eliminates high electrical “demand charges” for starting the gas compressor motors. Contact GE for your specific application.
7.8
Independent Lube Oil Systems
The LM6000 gas turbine is lubricated with synthetic lube oil (SLO) while a separate mineral lube oil (MLO) system lubricates the generator. Dual shell and tube coolers with valves for on-line changeover are used to cool both turbine and generator lube oil. The SLO & MLO coolers are mounted on the auxiliary module. Lube oil piping, fittings and reservoirs are Type 304 stainless steel and valves have stainless steel trim.
7.8.1 Gas Turbine Lube Oil System The gas turbine lube oil system has two lube oil circuits: Supply System - Provides filtered, cool oil to the turbine bearings. Scavenge System - Recovers (scavenges) the lube oil from the bearing drain sumps. It also filters and cools the oil and returns it to the reservoir. These two circuits cool, lubricate and protect the turbine. The turbine supply system contains the following major components: • • •
SLO reservoir Supply pump Supply filter
The scavenge system contains the following major components:
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•
LT 1002A LT 1002B
TE TE TE TE TE TE TE TE TE TE TE TE TE TE 1023 1023 1029 1029 1025 1025 1026 1026 1027 1027 1030 1030 1028 1028 A1 A2 A1 A2 A1 A2 A1 A2 A1 A2 A1 A2 A1 A2
I
I
A23 A24 A10
A9
TURBINE LUBE LG OIL RESERVOIR 1000 CAPACITY: 150 GALLONS [568 L ] LO
TE 1013A1
19 DRAIN
I
I
TE 1013A2
TE 1037 21
COOLING WATER RETURN
LC COOLER #1
TO ATM PSV 1056
TE 1036
FI 1086
D3
D4 D6
FI FI 1087 1088
NC PCV 1091
FI 1089 NC
MAIN SKID SUMP
229
LC
25
HEAT EXCHANGER ASSEMB LY C MOUNTED ON AUXILIA RY SKID
A TCV B 1001
228
57
57A
VENT TO SAFE AREA
PDT 1007
NC MANUAL SHUTTLE VALVE
PSV 1003
I
I
TO ATM PSV 1057
MAIN SKID TURBINE AREA
I
PDT 1006
COOLER #2
I
A51B A51A
D1 D2
6
COOLING WATER 20 SUPPLY
26
71A
SOV 1085
I
L4 L5 L8 L9
DISCHARGE
LC
L2
L3
SCAVENGE
HE 1004 TC 1004
L6
PUMP SUCTIO N
I
I
A28
L1
71
SUPPLY DISCHARGE
LSL 1002
A25
GG
VENT TO ATMOSPHERE
LL
DEMISTER/FLAME ARRESTOR
FUEL SYSTE M
FI 1005
LC
78A
I
AIR/OIL SEPARATOR DRAINS
FROM WATER WASH PURGE AIR
Scavenge filter/5-element scavenge pump • Duplex shell and tube water / oil or fin fan air/oil heat exchanger (optional) • Air/oil separator system
TE 1035
SUPP LY FILTER
NC MANUAL SHUTTLE VALVE SCAVENGE FILTER G-258-05
Simplified Schematic – Turbine Lube Oil System
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7.8.1.1
Turbine Lube Oil Supply Description
Approximately 130 U.S. gallons / 492 l of synthetic lube oil are stored in the 150 U.S. gallon / 568 l capacity stainless steel reservoir mounted on the auxiliary module. The reservoir is fitted with a low-level alarm switch, a level gauge, a level transmitter, a filler connection, and a demister/flame arrestor. The reservoir also includes a thermostatically controlled heater and a lube oil temperature transmitter. A positive displacement lube oil pump, mounted on the gas turbine accessory drive gearbox, takes suction from the lube oil reservoir. The pump discharge is filtered by a duplex, 6 micron (absolute), full-flow filter located on the auxiliary module. Filter elements can be changed while the turbine is running. The lube oil supply passes through an anti-siphon check valve and is distributed to the bearing chambers, where oil is sprayed onto each engine bearing. Pressure transmitters and temperature RTDs monitor lube oil supply with readout, alarm and shutdown at the turbine control panel. Chip detectors in the A and B sumps and in the common scavenge return provide alarms if metal chips are detected in the lube oil. A differential pressure transmitter senses filter differential pressure and warns the operator of dirty filter conditions. 7.8.1.2
Turbine Lube Oil Scavenge Description
Oil flows through the turbine bearings and accumulates in the bearing sumps. A 5-element scavenge pump is connected to a low point drain in each sump. Whenever the engine is turning the scavenge pump is working to remove oil from the sump drains. The scavenge pump discharge flows through a 6 micron (absolute) duplex filter, then is cooled by a shell and tube cooler, (1 running / 1 standby) and then returns the oil to the reservoir. A temperature RTD on each scavenge line measures temperature, with readout, alarm and shutdown at the turbine control panel. A check valve on the pump discharge prevents siphoning of oil back into the engine during shutdown. Each bearing sump is vented by the air/oil separator system, consisting of a pre-separator, airto-oil cooler, and a final separator. Recovered oil drains back to the reservoir to reduce emissions and oil consumption. A shell and tube cooler (1 running / 1 standby) rejects 600,000 Btu/hr / 633,100 kJ/hr from the turbine lube oil circuit. A thermostatic valve regulates the amount of hot oil that bypasses the cooler.
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7.8.2 Generator Lube Oil System The generator lubrication system provides approximately 46 gpm / 174 lpm of cooled and filtered mineral oil to the generator bearings. The generator lube oil reservoir, pumps and duplex filters and coolers are located near the rear of the generator and lube oil filters may be changed while the unit is operating. Filters have stainless steel plates. Valves are carbon steel bodies with stainless steel trim. The generator lube oil system has two lube oil circuits: Supply System – Provides cool, filtered oil to the generator bearings. The supply system contains the following major components: • • • • • •
MLO reservoir AC pump Generator driven mechanical pump Four-element jacking oil pump Duplex shell and tube heat exchanger Duplex filter
Return System - Recovers the lube oil from the bearing drain sumps and returns it to the reservoir. These two circuits cool, lubricate and protect the generator.
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Simplified Schematic – Generator Lube Oil System (Supply Flow) 7.8.2.1
Generator Lube Oil Supply Description
The 60 Hz generator lubrication system provides approximately 174 Lpm/46 gpm of cooled and filtered oil to the generator bearings The generator/gearbox lube oil reservoir, pumps and filters are located on a separate lube oil module. The lube oil filters may be changed while the unit is operating. The simplex shell & tube coolers serving the generator lube oil system are also located on the lube oil module. Filters have stainless steel plates. Valves have stainless steel trim. The stainless steel reservoir includes a sight level gauge, fill connection and drain valve. A switch provides a low-level alarm at the unit control panel. An immersion heater turns on at 32ºC falling temperature keeping the oil heated to prevent condensation when the unit is stopped. The 60 Hz lube system has three pumps mounted on the reservoir: o Main Pump – 1,250 Lpm/330 gpm with a 37.3 kW AC motor LM6000 - 60 Hz Classic 6/2008
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o Stand By Pump – 1,250 Lpm/330 gpm, with a 37.3 kW AC motor o Emergency Pump – 550 Lpm/145 gpm with a 12 kW DC motor o The reservoir assembly includes: o Duplex 100% filters o Duplex shell and tube heat exchangers sized to reject 2,943.8 MJ/hr o Oil-mist heat exchanger and motor-driven oil demister Rundown tanks provide additional protection if the AC lube pumps should fail, or if AC power is lost. A DC pump provides coastdown protection. The oil flows through the orifice and into the bearings and forms a film that cools and lubricates the journal. Pressure switches at the bearing supply header provide low pressure alarm and shutdown signals to the unit control panel. If the supply pressure drops, a low lube oil pressure switch automatically starts the auxiliary lube oil pump. An annunciator alarm indicates that the auxiliary pump is running. If the lube oil pressure falls to a lower level, the turbine generator set shuts down. The primary and auxiliary lube oil pumps can each supply 100% of the generator lube oil requirements. Each pump is equipped with a pressure relief valve piped to the reservoir. Lube oil pressure at the supply header is controlled by a pressure-regulating valve, which bypasses excessive oil flow to the reservoir. Duplex coolers are provided to reject 198.1 MJ/hr from the generator lube oil circuit. The amount of hot oil that bypasses the cooler is regulated by a thermostatic valve. The duplex generator / gearbox lube oil filters (6 micron absolute) are mounted on the lube oil module. Filters may be replaced during operation by switching the manual transfer valve. A pressure switch senses high filter differential pressure and provides alarm at 20 psid/138 kPa.
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(LUBE OI L SUPP LY)
I
PSV 0097 (JACKING OI L RELIEF LINE ) PSV 0096
I
I
LT
LT 0041B RUNDOWN TANK
I
RUNDOWN TANK
PT 0049
PT
I
TE
I
PT
I I
I
LT
LT
RUNDOWN TANK
TE
RUNDOWN TANK
LO
(JACKING OI L RELIEF LINE )
PSV 0094
TE I
TE
TE PI 0091
I I
(J.O. RELIEF LINE) MOT 0085
PI 0092
I
(J.O. RELIEF LINE)
I
PSV 0095
TE 0022
TE
JOURNAL BEARING THRUST BEARING
I
GENER ATOR
DRIVE END
EXCITER END TE 0057 I
TE
I
I
TE TE
PI 0093
I
I
PI 0090
TE FI 0067
FI 0068 G-252-05
Simplified Schematic – Generator Lube Oil System (Bearing Lubrication) 7.8.2.2
Generator Lube Oil Return Description
Each bearing has a gravity drain and sight glass to visually verify oil flow. A dual element RTD is embedded in each generator bearing to measure the actual metal temperature. These RTDs are continuously monitored at the unit control panel and provide alarm and trip signals at 183°F/91.6°C and 194°F/95ºC, respectively. The gearbox has a turning gear to rotate the shaft. The gearbox bearing RTDs alarm and trip at 225°F/107ºC and 241°F/116ºC respectively. For starting and water wash cycles, we lift the generator rotor off the bearing seats with a film of high-pressure oil from a small “jacking oil” pump. The oil film reduces bearing friction and helps the rotor “break away” and begin turning.
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7.8.3 Customer Cooling Water Requirements Customer provides continuous water to the lube oil cooler flange connections. Approximate cooling water requirements are 190 gpm at 95 °F / 719 lpm at 35 °C. Maximum water pressure is 100 psig / 689 kPag. Total heat rejection for turbine and generator is 787,800 Btu/hr / 831,200 kJ/hr.
7.9
Starting System
The LM6000 turbine is started by an electro-hydraulic system, including an electric motor, a pump, a hydraulic starter motor, and other equipment described below. The starter rotates the LM6000 high-pressure compressor shaft for purging, cool down, engine starting and water wash sequences. The hydraulic start system consists of a hydraulic starting motor / clutch mounted on the turbine accessory gearbox, the following equipment mounted on the auxiliary module: • • • • •
200 HP / 150 kW electric starting pump motor Variable displacement hydraulic pump 40 gal. / 151 l hydraulic reservoir Air/oil cooler Low pressure return filter and case drain return filter
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Simplified Schematic – Hydraulic Start System
7.9.1 Hydraulic Start System Flow The hydraulic circuit is a closed loop design with a 40-gallon / 151 L reservoir. The system requires an initial fill of approximately 35 gallons / 132 l of ISO VG 46 premium, anti-wear petroleum-based hydraulic fluid. During each start cycle a charge-pump portion of the main pump draws fluid from the reservoir to prime the system and supply control oil. Controls modulate the main pump flow from zero to approximately 55 gpm / 208 Lpm during the starting cycle. This permits accurate control of gas generator speed for purging, ignition and acceleration. The starter pump increases the hydraulic fluid pressure and delivers the pressurized fluid to the hydraulic starter motor. A portion of the return fluid from the starter motor is routed back to the starter pump. Before reaching the main hydraulic pump on the auxiliary skid, the oil is filtered through a low-pressure, return filter. Low-pressure hydraulic fluid from the starter motor case is routed off the main skid to the auxiliary skid. On the auxiliary skid, the hydraulic fluid flows through a case drain return filter and a air to oil heat exchanger before returning to the reservoir.
7.9.2 Starting System Operation To start the gas turbine, the hydraulic motor must: • • •
Rotate the gas generator to purge the engine Accelerate the gas generator to ignition speed Continue acceleration to self-sustaining speed
The starter accelerates the gas generator to 2,300 rpm and cranks for two minutes in typical simple cycle applications. This forces purging air through the gas turbine and exhaust stack to remove hydrocarbons that may have accumulated during the prior shutdown. Air-flow during the purge cycle is approximately 7842 scfm / 12,600 Nm3/h / 10 lbs/sec. After the purge cycle, the gas generator is slowed to 1700 rpm for light off. Fuel is initiated, igniters are actuated, and the turbine starts. Then the starter and the combustion accelerate the gas generator to 4500 rpm where the starter disengages automatically. The gas generator continues to accelerate until it reaches idle speed. The turbine is now selfsustaining. Overall start time varies with stack height; also units with heat recovery steam generators will require a longer purge cycle, typically 15 to 30 minutes.
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However, the typical LM6000 in simple cycle application can reach full power from a cold start in 10 minutes. See Section 5 for 10-minute start cycle curve.
7.10 Water Wash System All gas turbines demonstrate lower levels of performance if the airfoils are not in a clean condition. An integral soak wash system is provided for on/offline cleaning. See Section 14 for compressor cleaning water/detergent specifications. GE Energy LM6000 units include a unit mounted on-line cleaning system to remove deposits from the compressor airfoils. The off-line or “crank-soak” water wash system is for thorough removal of built-up deposits. This system requires the turbine to be off-line for a short time. The on-line cleaning system is used to remove deposits while the turbine is running. This system extends the intervals between crank-soak cleanings and reduces downtime.
Simplified Schematic – Water Wash System
7.10.1
Water Wash Equipment
Both on-line and off-line spray nozzles are mounted on the Inlet Air Volute on the main baseplate. The remaining water wash equipment below is mounted on the auxiliary module:
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• 100 gallon / 379 l stainless steel reservoir • Manual water and chemical supply valves • Solenoid valves to sequence water wash and purging • Motor-driven pressurizing pump • Electric heater in tank In-line water filter
7.10.2
Cleaning Solution Specifications
Cleaning agents conforming to GE Specification MID-TD-0000-5 are recommended for washing the gas generator section of the engine. The solvents are mixed within the reservoir and sprayed into the turbine inlet. Water is then sprayed in the inlet to rinse the turbine. A water/anti-freeze mixture must be used for dilution and rinsing in ambient temperatures of 50 °F / 10 °C, or below.
7.10.3
Water Quality Standards
Please see GE Specification MID-TD-0000-4 for water wash criteria.
7.10.4
Interface Requirements
Customer supplies a source of hot water and instrument/compressed air to purge lines at GE Energy flange connections on auxiliary module. Interconnecting piping and hoses to the permanently mounted turbine spray manifold is provided.
7.11
Fire Protection System
The LM6000 turbine generator set includes controls and sensors to detect fire, unsafe temperatures or explosive atmospheres in the equipment enclosure. The system releases CO2 if fire is detected. The package enclosure is designed to reduce the hazard of fire and explosion. A wall separates the turbine and generator compartments to provide isolation. Ventilation systems, with redundant fans, create a positive pressure in the generator compartment and a negative pressure in the turbine compartment. This maintains separation and forces hydrocarbons away from the generator. The enclosure is protected by gas detectors, thermal detectors, optical flame detectors and a CO2 extinguishing system conforming to NFPA 12.
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Fire and Gas Protection System
7.11.1
Gas Detectors
Four hydrocarbon gas detectors and two infrared gas detectors are provided. Two hydrocarbon gas detectors are located in the turbine compartment. One hydrocarbon gas detector is located below the turbine. A fourth detector is located in the front of the generator compartment. Two infrared gas detectors are located in the turbine enclosure near the ventilation exhaust duct. If the gas detectors in the turbine or generator compartments sense a gas concentration of 15% LEL, a warning is initiated. If a sensor detects a gas concentration of 25% lower explosion limit, an emergency shutdown is initiated. If an infrared sensor senses a gas concentration of 5% LEL, a warning is initiated. If a sensor detects a gas concentration of 10% LEL, an emergency shutdown is initiated.
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7.11.2
Optical Flame Detectors
There are three IR/Optical flame detectors mounted in the turbine enclosure and three mounted in the generator enclosure. A flame indication by a turbine enclosure sensor causes an emergency shutdown and release of CO2.
7.11.3
Thermal Detectors
The turbine enclosure temperature is monitored by two thermal spot detectors, initiating a shutdown at 450 °F / 232.2 °C. The generator enclosure temperature is monitored by two thermal spot detectors, initiating a shutdown at 225 °F / 107.2 °C. In addition to alarm and shutdown functions, the thermal spot detectors provide enclosure temperature signals for the turbine control panel HMI. The spot temperature detectors are bimetallic and respond to both temperature and rate-of-rise. They cause a unit shutdown and release of the CO2 when tripped.
7.11.4
Manual System Trip
Three manual trip stations are located on the main enclosure; one on each side near the center of the package, and the third at the exciter end of the generator.
7.11.5
CO2 Extinguishing System
The system components include: • • •
Main CO2 storage cylinders Reserve CO2 storage cylinders Valves, piping and wiring
The pressurized CO2 bottles are stored on a rack that includes manifolds, controls, valves and a weigh scale. The reserve cylinders are an “automatic backup,” and are released, if the detectors still indicate a hazard, 90 seconds after release of the main cylinders. GE Energy provides piping within the main enclosure from the pressure connection to the nozzles in the turbine and generator compartment. Release of the CO2 is controlled by the fire system control panel or by a manual valve at the unit. Signals from the equipment-mounted sensors are monitored by solid-state modules in the control panel. The panel-mounted unit includes logic, memory and output functions.
7.11.6
Dedicated Power Supply
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GE Energy furnishes a dedicated 24 VDC battery system with charger, to power the fire and gas protection and control system. This battery system conforms to NFPA 12 requirements.
7.11.7
Control System
A solid-state monitor mounted in the Turbine Control Panel compares the signal from each sensor to alarm and shutdown setpoints. Meters provide a read out of each gas detector signal. Any alarm signal sounds an alarm at the control panel and in the turbine enclosure. Any shutdown signal from a gas detector, optical detector, thermal detector, or manual station closes a contact and causes an emergency shutdown of the unit.
7.11.8
Defective Sensor Protection
Each sensor is connected with closed loop circuitry to verify its readiness. Should the sensor or its wiring become defective, a "fault" condition is indicated on the control panel.
7.11.9
CO2 Release Logic
When a shutdown signal is received the control system turns off the ventilation fans and sounds an alarm horn at the panel and both inside and outside of the turbine enclosure. After a time delay, CO2 is released into the generator and turbine compartments. A CO2 concentration sufficient to extinguish flames is reached in approximately 30 seconds. If the primary cylinders should fail to discharge within four seconds, the reserve cylinders are discharged. If flames are still detected 90 seconds after the primary CO2 cylinders have been discharged, the reserve cylinders are discharged.
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8. Optional Equipment
8.1
Optional Equipment List
The equipment and services listed in Section 6 and described in Section 7 are included with the LM6000 Gas Turbine Package basic price. Design variations are available as options to the basic package. Below is a list of design variations and services available followed by detailed descriptions. 1. 2.
Synchronous condenser clutch Totally Enclosed Water-to-Air Cooled (TEWAC) generator (in lieu of an open ventilated generator) 3. Power system stabilizer 4. Left-hand piping connections / right-hand piping connections 5. Left-hand cubicles / right-hand cubicles 6. Liquid fuel system 7. Dual fuel system 8. Water injection system 9. SPRINT® power boost system 10. Evaporative cooling 11. Inlet air chiller coil 12. Inlet air anti-ice coil – exhaust heat recovery unit 13. Inlet air anti-ice coil 14. Inlet air anti-ice coil – ventilation recirculation (legged housing) 15. Pulse filter (legged housing) 16. Static excitation 17. Air-oil cooler 18. Winterization 19. Medium voltage switchgear and generator bus duct 20. Unit motor control center 21. Remote work station 22. Lifting gear 23. Control module options (ACM and PCM) 24. 80 dB (A)(near field) 25. Remote monitoring and diagnostics services 26. Full load string test
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27.
Fuel filter / separator
8.2
Optional Equipment Descriptions
8.2.1 Synchronous Condenser The LM6000 generator set, with optional modifications, can operate as a synchronous condenser when an electrical grid needs VARs to improve the Power Factor (PF). For this option, GE adds a synchronous clutch, in an enclosure, between the gas turbine and generator. Modifications are also added to the protective relay system and the voltage regulator. These additions allow the unit to operate as follows: •
The gas turbine is started and brought up to speed
•
The generator is synchronized to the grid
•
The operator selects Synchronous Condenser operation with a switch on the Turbine Control Panel
•
The gas turbine begins a normal shutdown
•
As the turbine slows down, the Synchronous Clutch disengages
•
The generator remains running, and is now operating as a motor, powered by the grid.
•
The operator can now export or import VARs by raising or lowering the voltage set point on the Voltage Regulator (within limits designed to protect the equipment).
8.2.2
Totally Enclosed Water-Cooled Generator
GE Energy furnishes a Totally Enclosed Water-to-Air Cooled (TEWAC) generator for customers who prefer water-cooling. Customer must supply approximately 571 gpm / 2161 lpm of treated water at 85ºF / 29ºC, or cooler, at 100 psig / 690 kPa. If water is to be recycled, customer must supply a cooling loop to reject approximately 2 million BTU/hr / 2110 MJ/hr.
8.2.3
Power System Stabilizer
The GE EX2100 digital power system stabilizer integrates supplementary control signals to the generator’s voltage regulator to control power fluctuations and to help improve the stability of the power system.
8.2.4
Left-Hand Piping Connections
In the standard LM6000 configuration, the customer’s piping connections are on the right side, as viewed from the exciter. As an option, the unit can be built with the piping
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connections on the left side. The turbine removal area is located on the side opposite of the piping connections.
8.2.5
Left-Hand Cubicles / Right Hand Cubicles
In the standard LM6000 configuration the generator line side cubicle is on the right side as viewed from the exciter. The neutral cubicle is on the left side. As an option the unit can be configured with the line side cubicle on the left side and the neutral cubicle on the right side.
8.2.6
Liquid Fuel System
The LM6000 can be equipped to operate using liquid fuel instead of natural gas. Typical liquid fuels include DF1, DF2, JP4 or kerosene. Customer must supply liquid fuel at 20-50 psig /138-345 kPag and at least 20ºF / 11ºC above the “wax point” temperature (normally 35ºF / 1.6ºC). Maximum fuel temperature is 150ºF / 65ºC. Customer supplied fuel must be clean, filtered and meet required fuel specifications. See Section 14.
8.2.7
Dual Fuel System
Complete fuel systems for two different fuels, including piping, valves and controls. Fuels can be: • •
Natural gas with liquid fuel Two gaseous fuels • Two liquid fuels Manual or automatic transfer to backup fuel requires a reduction in power. However, if full load fuel transfer is required, an optional cooler is provided to cool the air stream used to purge the fuel nozzles during transfer. This cooler requires a continuous water flow of 20gpm / 76 lpm at 65psi / 448 kPag, 95 °F / 35 °C max.
8.2.8 Water Injection System The water injection system contains the following major components. They are mounted on the water filter skid, water injection pump skid and main skid. • • • •
Duplex low pressure filter Water injection pumps (primary and standby) Flow transmitter Flow metering valve
To control the amount of oxides of nitrogen (NOx) emitted by the gas turbine engine during normal operation, demineralized water is injected into the combustor section of the gas turbine through the water injection manifold. Demineralized water from a customer source is pressurized by the selected water injection pump and plumbed into the main skid. LM6000 - 60 Hz Classic 6/2008
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8.2.8.1
Water Filter and Water Injection Pump Equipment
Demineralized water supplied to the auxiliary skid must meet GE quality requirements MIDTD-0000-3 – See Section 14. Demineralized water flows through the duplex water injection filter, where water is filtered to 10 microns before being pressurized by the centrifugal water injection pump. Downstream of the filter, demineralized water flow branches to provide water to either water injection pump. Two identical water injection pumps are provided in the system (primary and standby). If there is a pump failure, the operator, after investigating the cause of the failure to verify the problem is not related to water supply or piping problems, can then select the standby pump from the human machine interface (HMI) screen. The standby pump becomes the primary pump and the operator can enable the water injection system. Necessary pressure and temperature instrumentation allow remote monitoring of the water injection system on the auxiliary skid.
8.2.8.2
Main Skid
Water flow enters the main skid piping at an operating pressure of 800-950 psig / 5,517 – 6,550 kPag for gas fuel operation an 1200-1320 psig / 8274-9101 kPag for liquid fuel. An electrically actuated water injection flow-metering valve modulates de-mineralized water flow to the engine manifold and to the water return in response to data received and processed by the control system. Downstream of the metering valve, de-mineralized water flows through a solenoid shutoff valve which opens when the control system commands the water injection system active and closes when the GTG set is stopped or the water injection system is commanded off. A flow transmitter sends a 4–20 mA proportional signal to the digital control system providing flow data used to totalize water use and calculate the water-to-fuel ratio. While the system is not in operation, any water in the manifold piping drains from the system through a manifold drain solenoid valve. Pressure in the downstream piping blows any residual water out of the system. The gas fuel purge flow from the engine manifold assists in clearing residual water from the system piping. Necessary pressure and temperature instrumentation allow remote monitoring of the water injection system on the main skid. All piping is stainless steel, and the valves are trimmed with stainless steel.
8.2.9
SPRINT® Power Boost System
SPRINT® Is A Spray Intercooling System That: •
Reduces combustion air temperature
•
Boosts turbine output power
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•
Increases exhaust energy by injecting fine water droplets into the inlet and interstage air stream
The SPRINT power performance curves are provided in chapter 5. Customer supplies demineralized water at 30 gpm / 114 lpm, and 275 psig / 1896 kPag and 150 ºF / 66 ºC nominal. Consult GE Energy for details.
8.2.10
Evaporative Cooling
Evaporative cooling lowers inlet temperature to the gas turbine for added power. This option is recommended when high dry bulb temperatures are common, with low/medium ambient humidity. This system is designed for recirculation of evaporative cooling water from a sump in the bottom of the inlet air filter. This option includes recirculation pump, conductivity probe, blowdown and make-up valves, piping and wiring. Customer must supply filtered, potable water to a flanged connection on the filter house and must dispose of waste water from the blowdown valve. Flow rates will vary based on blowdown.
8.2.11
Inlet Air Chiller Coil
To increase the output of the LM6000 during hot weather, GE Energy installs a chiller coil upstream of the static filter. A water/glycol mixture is circulated through the coil to lower inlet air temperature and improve turbine performance. The chiller system includes the following: •
High performance cooling coils
•
Can be offered separately or in conjunction with a mechanical chiller module with pumps, motors and controls for water/glycol circulation of 3,300 gpm / 12,493 lpm.
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8.2.12
Inlet Air Anti-Ice Coil – Exhaust Heat Recovery Unit (Primary Option)
GE Energy recommends an anti-ice system for safe operating during icing conditions and provides several anti-ice options. With this option, exhaust heat is utilized to provide anti-ice heating of the inlet air and can be used with the included anti-ice coils or with chilling coils provided separately. The three major components of this system are as follows: Waste Heat Skid The waste heat skid utilizes gas turbine exhaust gas to fluid heat exchanger. Exhaust gas from the gas turbine stack is extracted and flows through the plate fin and tube, all stainless steel heat exchanger. Exhaust gases then flow through a blower which boosts the exhaust gas pressure and returns the exhaust gas back to the stack. A flow control damper is provided at the blower discharge to control the air temperature rise across the inlet air going to the gas turbine. A water- glycol mixture is heated in the gas-to-fluid heat exchanger with a design duty of 4 mm BTU/hr. At ambient conditions when the anti-ice system is not required, dampers at the inlet to the waste heat recovery unit (WHRU) and outlet of the blower are closed. A purge blower is activated to inject air to prevent overheating the fluid. A temperature alarm set at 200° F / 93° C is also provided to start the fluid pump if the purge blower is inoperative or cannot provide sufficient purge air to prevent overheating. Fluid Pump Skid The heated fluid is pumped through an anti-ice coil located upstream of the static filter to heat the inlet air 15º F / 8.3º C. The pump skid is designed to circulate 300 gpm / 1136 lpm of fluid using duplex (2 x 100%) 7.5 kW / 10 hp pumps. The closed system includes a pressurized expansion tank and the entire anti-ice system contains approximately 350 gallons of fluid. Under normal conditions no make-up or discharge is required. A low flow switch is provided to shut down the pump and blower skid if flow disruption is detected and an alarm on the Turbine Control Panel alerts the operator to this condition. Please consult GE Energy sales for details. Anti-Ice Heating Coils
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Anti-ice coils are provided and installed in the air filter assembly. Coils are piped to a common manifold with customer connections on each side of the main skid. If chilling coils are present they will be utilized for both chilling and anti-icing duty.
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8.2.13
Inlet Air Anti-Ice Coil
With this option, GE Energy installs an anti-ice coil upstream of the static filter. The customer circulates a heated water-glycol mixture through the coil to heat the inlet air 15 ºF / 8.3 ºC. Check with GE Energy for details.
8.2.14
Inlet Air Anti-Icing - Ventilation Recirculation
With this option, GE Energy recirculates warm turbine room ventilation air back to the inlet air filter in order to keep ice from forming on the filter. Check with GE Energy for details.
8.2.15
Pulse Filter (Self Cleaning)
GE Energy uses a pre-engineered, self-cleaning filter option for job sites with special needs such as dust, pulp and paper fiber and snow. Self-cleaning filter elements are provided for combustion and ventilation air paths. The filter house mounts above the turbine enclosure and is supported with legs. Downward air-flow provides filtered air for combustion and ventilation. This compact filter design is easily installed in the field, and it eliminates customer supplied ducting. The filter system includes a stainless steel inlet silencer and a ladder and platform for inspection and servicing of the filter.
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8.2.16
Static Excitation
The supplied static excitation system is based on a GE EX2100 Potential Fed Excitation System. This excitation system is GE’s latest state-of-the-art control offering for both new and retrofit steam, gas, or hydro generation. The EX2100 incorporates a powerful diagnostic system and a control simulator to support fast installation, tuning of control constants, and training. Easy to use graphics are used for operating, troubleshooting and maintaining optimum generator performance. The architecture is a single control rack, one power supply rack, control power input module and the power module. The power module consists of a bridge interface sub-system, power bridge, ac and dc filter networks, and ac and/or dc isolation devices. The EX2100 will directly communicate to the Turbine Control Panel through Ethernet connection also has hand control switches on front of GT Turbine Control Panel for control
8.2.17
Air-Oil Cooler
The air-oil cooler replaces standard shell and tube coolers for customers who prefer aircooling of lube oil. The air-oil cooler includes dual stainless steel tube bundles (one for synthetic oil; one for mineral oil) and two electric motor-driven fans (one running and one backup).
8.2.18
Winterization
For equipment operating outdoors in cold climates, -20 - 40º F / -29 - 4.4º C, GE Energy recommends a winterization option. This option can include any and all of the following modifications: • • • •
Inlet air anti-icing Heat tracing and insulation of applicable unit-mounted piping Enclosing and heating exposed instrumentation and equipment, as specified by GE Energy Enclosing the auxiliary equipment module.
When enclosing the auxiliary module equipment for ambient temperatures below -20 ºF / -29 ºC, the above modifications plus additional special provisions will be required. Consult GE Energy for details.
8.2.19
Medium Voltage Switchgear and Generator Bus Duct
Medium Voltage Switchgear Outdoor NEMA 3R, non-walk in 15 kV, 3000 A three section line up to include 3000 A generator circuit breaker, 1200 A auxiliary circuit breaker, and 1200 A spare cell. Each circuit breaker is rated at 1000 MVA with an optional 1500 MVA rating available. Lineup
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includes current transformers, draw out potential transformers, protective relaying and metering are also included. Generator Bus Duct Outdoor, totally enclosed, non-ventilated, non-segregated, epoxy insulated bus duct rated at 15 kV, 3000 A, 3 phase with ground. Includes a heating system with thermostat. Standard length is ten feet from generator line side cubicle to medium voltage switchgear. The generator bus duct also includes all necessary supports.
8.2.20
Unit Motor Control Center
Free-standing lineup of motor controls for motors in GE Energy equipment. The MCC is suitable for indoor installation in optional modular control room or other non-hazardous area. Customer supplies feeder breaker to energize the MCC and interconnecting wiring to motors on main enclosure.
8.2.21
Remote Work Station
GE Energy offers a remote workstation consisting of a desktop Pentium® computer, HMI, keyboard and mouse. This station is linked to the main control and mimics the HMI located in the turbine control panel in monitoring and control features.
8.2.22
Lifting Gear
Three Options • • •
Option 1: Receive all applicable drawings – customer is free to choose supplier. Option 2: Purchase lifting gear equipment – customer purchases equipment directly from GE Energy. Option 3: Rent lifting gear equipment - Cost is $55,000.00 per set of gear required. If the equipment is returned pre-paid within 45 days of shipment (domestic) and 90 days (foreign) then GE will credit 50% of the original rental cost per set.
8.2.23
Control Module Options
8.2.23.1
Auxiliary Control Module (ACM)
The optional ACM comes complete with a basic auxiliary equipment module as described in Section 7 as well as an integral 15 ft / 4.6 m control room. The TCP and battery system are installed (wiring included) in the control room. The motor control center (MCC) is not included with this option.
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8.2.23.2
Power Control Module (PCM)
The optional PCM comes complete with a basic auxiliary equipment module as described in section 7 as well as an integral 25 ft / 7.6 m control room. The PCM control room houses the following GE provided equipment: TCP, battery system, and motor control center (MCC). In addition, GE will provide interconnect wiring between the MCC and the motors on the package and auxiliary skid, pre-wired before shipment. The MCC is a freestanding lineup of motor controls for all motors furnished by GE Energy. The MCC is provided installed and fully wired within the modular control room in accordance with GE Energy Industrial Motor Control Specifications. This option also includes providing and installing power cables for the following: -Hydraulic start motor -Water wash motor -Generator and turbine compartment ventilation fan motors -Lighting auxiliary transformer 8.2.23.2
Power Control Module (PCM) (Continued)
-Water injection motors (optional) -SPRINT® motor (optional) -Liquid fuel boost pump motors (optional) -Other auxiliary motors -Provide the auxiliary skid base penetrations thru ROX transition frames and will install cables to the respective motor termination boxes.
8.2.24
80 dB (A) (near field)
Additional silencing, enclosure, lagging etc. is added to reduce the average near field noise to 80 dB (A) at 3 ft / 1.0 m from the enclosure and 5 ft / 1.5 m above grade. Extent of scope will depend on the scope of equipment, Site Plan and Project Special Requirement. Start-up and Shutdown modes may exceed these levels.
8.2.25
Remote Monitoring and Diagnostics Service
Monitoring and Diagnostics Service helps aeroderivative turbine plant operators improve availability, reliability, operating performance, and maintenance effectiveness. Monitoring of key parameters by engine experts may lead to early warning of equipment problems and avoidance of expensive secondary damage. Diagnostic programs seek out emerging trends, prompting proactive intervention to avoid forced outages and extended downtime. The ability for GE engineers to view real-time operation accelerates troubleshooting and sometimes removes the need for service personnel to visit the plant. 8.2.25.1
System Overview
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GE Energy developed the Monitoring and Diagnostics System (M&D) to complete its comprehensive world-class service and support network. System Functionality •
GE’s Monitoring and Diagnostics System includes on-site hardware and software, which retrieves operating data from each plant’s control system and makes it available for transmission to GE’s centralized M&D offices.
•
Operating data is transmitted from the site over a standard telephone line, either on a continuous basis via a private Internet network, or in a periodic downloading session.
8.2.25.1
System Overview (Cont)
• The central office archives the operating data, conducts diagnostics on key parameters, and provides all data necessary for displaying or trending. Site Requirements •
A dedicated phone line or Internet connection must be available to access the Monitoring and Diagnostics System. If cellular data service is adequate at the site, GE may be able to provide a cellular modem.
•
The plant control system must be configured to send data to a serial or Ethernet port.
•
Mounting space and available power must also be supplied for the onsite M&D System equipment.
8.2.25.2
Product Features
The Monitoring and Diagnostics System enables aeroderivative gas turbine operators to access real-time remote monitoring, early problem identification, and proactive diagnostics. Key features include: On-Line Monitoring •
On-line, real-time monitoring allows GE specialists to be on-line to support maintenance and operations personnel.
•
On-line monitoring enables quick-response troubleshooting by factory experts, which may result in faster detection and corrective action to avoid potential forced outages.
Accelerated Troubleshooting Support from Factory Experts •
Internet access to the database and on-line monitoring by GE service network enables remote assistance to the customer’s site.
•
Certain faults can be diagnosed and corrected without a site visit by GE service representatives and engineers.
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•
Experienced LM monitoring analysts incorporate factory knowledge and enhanced service for diagnostics, parametric trending, and maintenance planning.
Customer Notification Report •
Customer Notification Reports (CNR) are issued to document anomalies and submit recommended actions for correction. Product Features (Cont)
Customer Notification Report •
Selected conditions will trigger early warning alerts to M&D Center monitors; the center analysts will then escalate the issue to the Customer Satisfaction Manager or directly to the site, along with CNR that documents the observations and recommended corrective action.
Vibration Monitoring System •
The Vibration Monitoring System complements the standard monitoring service by providing early and accurate detection of excessive vibration in the gas turbine.
•
The optional Vibration Monitoring System is designed to detect and filter discrete frequencies and display vibration magnitudes directly related to specific problems.
•
The system can be custom-designed to filter for any type of problem frequency, ensuring a more sensitive vibration signal for evaluating long-term degradation.
Access to M&D Data •
The M&D Website provides customers secure access to their plant’s data via the Internet.
8.2.25.3
Service Benefits
Performance capabilities provided by GE’s Monitoring and Diagnostics Service include: Early Warning of Changing Conditions •
Active monitoring by factory engineers may provide early warning of changing operating conditions, thus prompting appropriate on-site action and allowing proactive maintenance scheduling.
•
The Anomaly Alert and Escalation Process documents automated early warning alerts, trend shifts, and instrumentation faults in order to help avoid outages and equipment failure.
Proactive Recommendations for Action •
Diagnostic programs seek out emerging trends and alert monitoring personnel; this enables proactive intervention against potential outages and extended downtime.
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•
Daily trending of key parameters by factory experts may lead to early warning of equipment problems and avoidance of expensive secondary damage.
•
Factory assistance to on-site personnel speeds DLE gas turbine control mapping process.
•
When trips and failed starts are detected, GE support organizations are notified, alerting them to the possible need for assistance or outage cause investigations.
Reduced Downtime •
The Monitoring and Diagnostics Service may reduce plant downtime and costs by supporting investigations of systems such as the gas fuel system, purge valves, and sensory devices.
•
LM monitoring provides advanced knowledge, quicker resolutions, and optimal performance, which have resulted in an average down-time reduction of three days per gas turbine each year.
Optional Features The following features are available as options to the standard M&D service: •
Independent vibration monitoring system.
•
Wireless or landline communications management from site for data transmission.
•
Control system setup for M&D service.
8.2.25.4
Pricing
Annual pricing is dependent upon number of run hours per year, level of service and features desired as well as your plant operating profile. Standard service is offered on an annual fee basis, which includes on-site equipment. Some options may require upfront setup charges and/or annual fees. Contact your GE service sales representative for a customized proposal. 8.2.25.5
Contracts
Monitoring and Diagnostics Service is available under annually renewable or multi-year contracts, and may be included in Contractual Service Agreements or as independent service. M&D service is offered with the limitation that GE assumes no greater or lesser liability than it has under the terms of any other contracts as a result of the application of the on-site monitoring equipment and M&D System or use of data retrieval software to the monitored units. Also, GE shall not be responsible for failing to monitor the OSM or failing to notify the unit’s owner of abnormalities.
8.2.26
Full Load String Test
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A full load string test of the turbine package and control system, including flushing, and verification of safety alarm and shutdown setpoints is available in place of the standard nonfired test. The full load test includes starting the gas turbine and running to full power.
8.2.27
Fuel Filter/Separator
An optional gas fuel filter/separator removes moisture from the gas fuel and provides filtration to 3 microns absolute.
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9.
9.1
Mechanical Outlines
Contents 9.1.1
9.1.2
9.1.3
Turbine Generator Left Side
Figure 9-1
Right Side
Figure 9-2
Exhaust End
Figure 9-3
Generator End
Figure 9-4
Exhaust Flange Detail
Figure 9-5
Auxiliary Control Module Option (ACM) Left Side
Figure 9-6
End View
Figure 9-7
Power Control Module Option (PCM) Left Side
Figure 9-8
End View
Figure 9-9
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9.1.1 Turbine Generator
49'- 11 7/8 " [15237]
VBV DUCT WEATHER HOOD
42'-3" [12877] 46'-10 3/4" [14294]
AIR FLOW
VBV DUCT SILENCER GEN. VEN T. AIR INLET
TURBINE ENCLOSURE EXHAUST FAN
VBV DUCT
TURBINE COMBUSTION & VENTIL ATIO N AIR INLET
GENERATOR AIR/OIL SEPARATOR
GENER ATOR VENT AIR EXHAUST
AIR FLOW
LINESIDE CUBICLE TOP OF ENCLOSURE
DAMPER
14'-5 3/8" [4405] C L
C L GENER ATOR / TURBINE
TURBINE ENCLOSURE 9'-8 7/8" [2970]
"0" D ATUM AL L ELE VATIO N DIMENSIONS ARE TAKE N FROM BOT TOM OF SKID
7'-3" [2210]
4'-7 1/8" [1400]
49'- 11 3/4 " [15235] 55'-0 5/8" [16778] GROUNDING LUG 56'-6" [17221] END OF SKID
34'-9 7/8" [10615]
25'-9 3/8" [7857] GENER ATOR ENCL . ACCESS DOOR 2'-8 3/4" X 6'-10" [832 X 2083]
31'-1 1/2" [9487] INLET ACCESS H ATCH 5'-10 3/8" X 3'-8" [1708] X [ 1118 ]
8'-6 5/8" [2608] 13'-0 5/8" [3980] 1'-2" [356] GROUNDING LUG
"0" D ATUM ALL TAI L DIMENSIONS ARE TAKEN FROM GENER ATOR END OF SKID
38'-7 1/8" [11764 ] TURBINE ENCL. ACCESS DOOR 2'-8 3/4" X 6'-10" [832 X 2083]
Figure 9- 1 Turbine generator - left side
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9.1.1 Turbine Generator (Cont)
VBV DUCT AIR FLOWWE ATHER HOO D
VBV DUCT
AIR FLOW
2'-1" [635] SE RVIC E CLEARANCE
FILTER REMO VAL HEIGHT
8'-0" [2438]
GENER ATOR AIR/OIL SE PAR ATOR
GENER ATOR VENT AIR EXHAUST GEN. VEN T. AIR INLET
AIR FLOW TOP OF ENCLOSURE
TURBINE COMBUSTION & VENTIL ATIO N AIR INLET
25'-2 1/2" [7685] VBV DUCT
DAMPER
14'-5 3/8" [4405] NEUTRAL CUBICLE
GENER ATOR ENCLOSURE
TURBINE ENCLOSURE
C L TURBINE / GENER ATOR 7'-3" [2210]
"0" D ATU M AL L TAI L DIMENSIONS ARE TAKEN FROM GENER ATOR END OF SKID
8'-6 5/8" [2608] 13'-0 5/8" [3980]
25'-9 3/8" [7857] GENER ATOR ENCL . ACCESS DOOR 2'-8 3/4" X 6’-10” [832 X 220831]
45'-8 5/8" [13934]
55'-0 5/8" [16778] GROUNDING LUG 56'- 6" [17221] END OF SKID
27'-7 3/8" [8415] SPLIT LINE 31'-1 1/2" [9488] INLET ASS H ATCH ACCESS DOOR 5'-10 3/8" X 3’-8” [17881 X 1118 ]
36'-1 7/8" [11019 ] TURBINE ENCL. ACCESS DOOR 2'- 0 3/4" X 6’-10” [832 X 2083]
Figure 9- 2: Turbine genertor - right side
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9.1.1 Turbine Generator (With PCM Option) (Cont)
PCM SWITCHGEAR
13'-0 5/8" [3978] 9'-0" [2743]
3'-5" [1040]
21'-11 7/8" [6703]
13'-6" [4115]
9'-0 7/8" [2766]
8'-7" [2616]
UEXHAUST END VIEW
Figure 9- 3: Turbine generator - exhaust end
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9.1.1 Turbine Generator (With PCM Switchgear Option) (Cont)
Figure 9- 4: Turbine generator - generator end
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9.1.1 Turbine Generator (Cont)
Figure 9- 5: Turbine generator - exhaust flange detail
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9.1.2 Auxiliary Control Module (ACM)
Left Side
Figure 9- 6: Auxiliary control module - left side
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Figure 9- 7: Auxiliary control module - end view
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9.1.4 Power Control Module Option (PCM)
15'-0 7/8" [4596] 13'-1 1/8" LIQUID [3990] FUEL
12'-8 5/8" [3875] 12'-11 1/2" [3950]
FAN LIQUID FUEL ENCL.
8'-3 3/4" [2534]
1'-7 1/4" [489] 0"
21'-1 5/8" [6442]
1'-0" [305] GROUNDING LUG
38'-5 1/8" [11712]
41'-7 1/4" [12680]
46'-3" [14096]
48'-6" [14783] 49'-6" [15088]
Figure 9- 8: Power control module option - left side
Figure 9- 9: Power control module option - end
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10. Generator, Exciter and Voltage Regulator
10.1 Generator Design The generator is a synchronous, two-pole, cylindrical rotor machine. It has open-air cooling and a brushless excitation system with permanent magnet generator. The rotor is supported by two (2) split sleeve bearings lubricated by a pressurized mineral oil system. The generator has a design life of 30 years. The weatherproof acoustic enclosure reduces average noise levels to 85 dB(A) at three feet (1.0m) from unit and five feet (1.5m) above grade. The generator is conservatively sized, with capacity to spare. The stator, rotor and exciter have Class F insulation, and the generator can absorb all of the turbine's output power without exceeding Class B temperature rises. The generator can also supply the following overload or fault currents without measurable loss of life: • • •
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110% of normal current for 2 hours out of every 24 hours 130% of normal current for one minute 300% of normal current into a 3-phase fault for 10 seconds
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10.2 Generator Codes And Standards The generator is designed to meet codes and standards applicable to most areas of the world. The primary standards include ANSI C50.14 for 60 Hz. Other ANSI, IEE, IEC and NEMA standards also apply.
10.3 Stator Design 10.3.1
Stator Frame
The stator frame is fabricated from mild steel plate to form a rigid structure. The stator is equipped with substantial mounting pads with boltholes to secure the generator to the I-beam baseplate.
10.3.2 Stator Core The core is made of segmental laminations of low-loss, high permeability, high silicon content electrical steel, carefully deburred and coated with insulating varnish. To ensure uniformity, the core is hydraulically pressed at pre-determined stages during the building operation, and the finished core is clamped between heavy steel end plates. The core is subjected to a magnetizing test of the windings to check for the soundness of inter-laminar insulation and adequate tightness.
10.3.3 Stator Winding The stator is made of pre-insulated half-coils assembled into a two layer diamond array. Eddy current losses are minimized by dividing each conductor into smaller laminations. The laminations are insulated from each other by a resin-impregnated woven glass braid and are transposed to minimize circulating currents.
10.3.4 Insulation System The insulation system is based on a resin-rich mica glass tape that produces a high performance insulation system capable of continuous operation at temperatures up to 311°F / 155°C (Class F).
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The insulation possesses high dielectric strength, low internal loss and meets all current specifications. The resin system is thermo-setting, so that the resulting insulated coil sides are dimensionally stable. This resin insulation is highly resistant to most common electrical machine contaminants, such as hydrocarbons, acids, alkalis and tropical molds.
10.3.5 Coil Manufacture The insulated copper laminations are cut to length, stacked together and the coil ends are formed into shape on a fixture. The laminations are then clamped tightly together, taped with an initial layer of tape and hot pressed to consolidate the conductor stack. Following this, the main insulation is applied and pressed to size. The amount of the compression is carefully controlled to ensure correct resin flow and produce consistent void-free insulation. Each finished half-coil is subjected to dimensional checks to ensure a correct fit in the stator slot, and special tapes are added to the inner and outer coil surfaces to prevent corona discharge.
10.3.6 Coil Winding and Connections The half-coils are placed in the stator slots in two layers and wedged securely in position by synthetic resin bonded wedges prior to connection of the endwinding. In order to withstand the forces resulting from an accidental short circuit, the endwinding is securely braced to insulated brackets mounted on the stator frame. Spacer blocks are fitted between adjacent coil sides to produce a strong, resilient, composite structure. Finally, the completed stator is "baked" in an oven to fully cure the insulation. Resistance Temperature Detectors (RTD) are embedded in the windings at selected points, and anti-condensation heaters are fitted into the stator frame. To ensure electrical performance, the individual coils and the completed windings are given high-voltage tests.
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10.4 Cylindrical Rotor The cylindrical rotor is manufactured from an integral forging of vacuum poured nickel-chromium-molybdenum alloy steel. The resulting forging is thermally stable, uniform in composition, and has excellent tensile and mechanical properties. As assembly proceeds, slots are machined in the rotor surface, and insulated coils of highconductivity silver-copper strip are pressed into the slots. Then damper windings and wedges are added. Finally, end caps of non-magnetic manganese chromium steel are shrink-fitted to the ends of the rotor body. The rotor is then balanced dynamically and tested at 120% of normal speed for two minutes. Following high speed testing, the rotor is given a series of high voltage tests to prove the integrity of the insulation system.
10.5 Bearings The main bearings are conventional, white metal lined, hydrodynamic cylindrical bearings, split on the horizontal centerline for ease of inspection and removal. The two halves are bolted and dowelled together. Oil is supplied under pressure to the bearings with flow controlled by an orifice in the supply line. Drain oil collects in the bottom of the bearing housing and returns to the generator lube oil reservoir by gravity flow. The generator bearings are end frame mounted on specially stiffened and reinforced stator frames. A detachable solid ribbed steel plate, split on the bearing horizontal centerline, supports the lower half bearing housing. Pressurized air from the downstream side of the generator fans is used to seal the lubricating oil in the bearings. RTDs in the bearing metal and in the oil drain lines provide bearing temperature sensing.
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10.6Ventilation Systems Internal Air Circuit The generator is cooled by air forced through ducts in the stator and rotor by two axial fans mounted on the rotor shaft. The cooling air is supplied to the generator from the inlet air filter.
10.7Brushless Excitation System The generator is equipped with a low maintenance brushless excitation system consisting of: • • • • • •
Three phase rotating armature Three phase rotating rectifier Rotating permanent magnet generator (PMG) Exciter field GE EX2100 automatic digital voltage regulator located in the turbine control panel Provisions for a optional Key Phasor
The shaft-mounted PMG powers the voltage regulator and excitation system.
10.8Voltage Regulator The generator is furnished with a GE EX2100 microprocessor controlled voltage regulator system. The voltage regulator is rackmounted in the turbine control panel and maintains generator output voltage within ±0.5% under steady state operating conditions. The voltage regulator utilizes single phase sensing circuitry and includes: • • • • • • •
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Diode failure alarm Flux limiter Over-excitation limiter Under excitation limiter Auto follower & null balance Auto transfer to manual control Volts per Hz control
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The voltage regulator can be adjusted manually or by remote signals to: • •
Raise/lower voltage Raise/lower VARs or power factor (manual only)
10.9Generator Accessories 10.9.1
Stator Temperature Detectors Six duplex temperature detectors (two per phase) are embedded in the stator windings. The detectors are 100 ohm at 0°C platinum type RTDs.
10.9.2
Space Heaters Space heaters are located inside the generator to prevent condensation of moisture when the generator is not operating. The space heaters are suitable for operation on three-phase, 480 VAC power, 60 Hz. Automatic ON/OFF control for the space heater is provided by the unit control panel that controls a contactor in the motor control center.
10.9.3
Vibration Detectors Two vibration detectors are mounted 90° apart at each radial bearing (Total 4). The proximeters and cables are wired to the Main Generator Terminal Box (MGTB) in the generator compartment. Monitoring equipment is provided in the unit control panel.
10.9.4
Ground Fault Monitoring
This control system provides continuous electronic monitoring of the generator rotor winding and its connections. Indication of a ground fault is shown on the unit control panel.
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11. One Line Diagram
11.1 Contents 9.1.4
60 Hz One Line Diagram Typical Schematic
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Figure 11-1
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Figure 11- 1: LM6000 60 Hz typical one-line schematic
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12. Control System Description
12.1 Control System Overview
Vibration Monitor
Fire & Gas Monitor HMI (Human Machine Interface)
Hardwired I/O
Generator Controls
Generator Protection Distributive I/O System
Modbus Hardwired LinkNet LAN
Generator Monitoring
Sequencer/ Fuel Control
Distributive I/O System
To DCS
Turbine Control Panel
Equipment Package
The overall control systems for the LM6000 GTG set include all individual turbine-generator system monitoring and operating indicators, controls, and transmitters as well as central electronic control system.
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The turbine control panel (TCP) houses a majority of the control system equipment. From the TCP, an operator can initiate the turbine-generator’s electronic control system to perform automatic startup, fuel management, load assumption, and system operation. Critical parameters are constantly monitored and alarms or shutdowns are initiated automatically, as appropriate, for out-of-tolerance conditions. Automatic fuel control and turbine sequencing are controlled by the logic control system software and hardware. Also, an operator or anyone on site can initiate, as necessary, a manual emergency shutdown at any time.
12.1.1
Human Machine Interface (HMI)
The HMI displays turbine operation data and mimic screens. It includes operator input and function pushbuttons.
12.1.2
Vibration Monitoring
The Bently Nevada 3500 vibration monitoring system monitors the vibration levels at critical points along the turbine generator package.
12.1.3
Generator Monitoring
The Satec SA296 simplifies the monitoring and management of generator electrical conditions and output. In addition to displaying generator output conditions, control and alarm relays are programmed to activate alarms for measured output values, i.e. high or low current and voltage conditions.
12.1.4
Fire and Gas Monitoring
The fire and gas detection system is comprised of plug-in modules that link to flame, temperature, and gas detection sensors inside the turbine enclosure. The fire and gas detection system interfaces with the turbine control system to provide the necessary engine shutdown, ventilation fan on/off signals, and other operator messages.
12.1.5
Generator Controls
The GE AVR, EX2100 Brushless Regulator System is designed to control the excitation of a brushless generator.
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12.1.6
Generator Protection
The Beckwith 3425 integrated generator protection system (IGPS®) for generators is a microprocessor-based digital relay system that provides protection, control, and monitoring of the generator. Necessary drainage, including sumps and drain piping
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12.1.7
Digital Control and Monitoring System
Item
Control/Indicator
Abbreviation
1 2 3 5 6 7 8 9 10 11 12
Horn Lamp, Synchronizing Lamp, Synchronizing Meter, Digital Multifunction Switch, Synchronize Ammeter, Null Balance Relay, Lockout (Generator) Blower, Control Cubicle Blower, Termination Cubicle Switch, Circuit Breaker Control and Status “52G” Switch, PF/VAR Adjust
SL2 SL1 DMMF SS NBA 86G BLR1 BLR2 CBCS1 PFAS
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12.1.7
Digital Control and Monitoring System (Cont)
Item
Control/Indicator
Abbreviation
13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Switch, Voltage/PF/VAR Control Enable/ Switch, Manual Voltage Adjust Switch, Voltage Regulator “On/Off “(Inside Panel) Switch, Excitation Mode Switch, Automatic Voltage Regulator Adjust Regulator, Auto/Manual Voltage Human Machine Interface Switch, Emergency Stop “TCP” Switch, Local/Remote Selector Switch, Speed Adjust Integrated Generator Protection System Hole, Spare Panel, Fire & Gas Protection Monitor, Vibration Door, Access Switch Block, Test, Bus Voltage Switch Block, Test, Generator Voltage Switch Block, Test, Generator Current (Metering) Switch Block, Test, Bus Current (Protection) Switch Block, Test, Generator Current (Protection) Switch Block, Test, Spare Switch Block, Test, Spare Switch Block, Test, Generator Lockout Relay (86G) Digital Synchronizer Module Filter, Control Cubicle Filter, Termination Cubicle Nameplate HMI Keyboard Laptop Shelf Switch, Turbine Start-Stop
VCES MVAS ES EMS AVAS AVR HMI ES3 LRS SAS IGPS
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FPP VIB TSB1 TSB2 TSB3 TSB4 TSB5 TSB6 TSB7 TSB8 DSM FLTR1 FLTR2
TSS
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13.Equipment and Services by Buyer
13.1 Civil In order to provide a complete operational installation, additional equipment and services, not included in the basic unit scope, must be provided by the buyer or the installer. These include, but are not limited to, the following: • • •
Foundations – Design and construction with all embedments including sole plates, anchor bolts, and conduit Grounding grid and connections Necessary drainage, including sumps and drain piping
13.2 Mechanical •
• • • • • • • • •
Natural Gas: Provide 50 °F / 28 °C of heating above the dew-point. In addition, a gas shutoff valve located remotely from the unit must be provided to shut off the gas supply to the turbine when the unit is not in operation. GE fuel specifications are included in Section 14. #2 Distillate Oil: Provide storage tanks and piping to the fuel forwarding skid inlets, and from the forwarding skid outlets to the base auxiliary equipment module connections, and for treatment devices (centrifuge and duplex filters.) Demineralized water for the water injection system at required pressure Water injection pump skid (NOx control only) Compressed instrument air to pressurize off-base water washing tanks, pulse clean air filters as required Heated fluid for the inlet air heating system if required Fluid for inlet air chilling or evaporative cooling, if required Heated fluid for anti-icing system, if required Ventilation ducting, if required Exhaust expansion joint, ducting, elbow(s) and stack, if required
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13.3 Electrical •
Air conditioned control room for turbine/generator panels and other “indoor type” control equipment • 480V AC electrical power for gas turbine starting and accessories • Electrical power connections (power cable or duct) from the generator lineside cubicle to the buyer’s electrical systems • Electrical control connections from the on-base terminal points to the turbine control panel, to the generator control panel, and to the Buyer’s systems • Motor control centers (MCC) and auxiliary power transformers as necessary for station services such as: - Fuel gas compressors - Distillate fuel forwarding skids • The following cables: - Control cables between the turbine/generator panels and the MCC, fuel gas compressor, fuel forwarding skid, and other controlled and off-base devices - Power cables from the Buyer’s electrical system to the MCCs, and from the MCCs to their load devices. - Power cables to and from the 125 VDC battery and charger systems See the Typical One-Line for further definition.
13.4 Miscellaneous • • •
Transport, unload, place on the foundation and install the equipment Construction services including electric power, lighting, temporary heaters, test equipment, compressed air, crane(s) and all required standard tools Storage and security for equipment received.
13.5 Balance of Plant Equipment, if necessary • • • • • • • • • •
Exhaust system equipment Heat recovery boiler and by-pass stack Plant fuel gas scrubbers, filtration, separation or regulation De-aeration and chemical injection equipment Steam turbines and condensers Boiler feed pumps and auto level control assemblies Automatic blowdown controls Non-standard inlet filter house support structures De-superheater equipment Cooling tower and circulating water system
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• •
Power plant calibration tools Spare parts and consumables
13.6 Limits of Scope of Supply Listed below are the limits of GE Energy BaseScope of Supply. All piping, wiring, cables, duct, etc. connecting to these points will be furnished by the Customer (unless modified by specific agreement). • • • • • • • • • • • • • • • • • • • • •
All piping, including fuel gas, fuel oil, steam, cooling water, heating water, demineralized water, lube oil, compressed air, instrument air, hydraulic start oil Inlet air-to-filter Turbine cooling air exhaust and generator cooling air exhaust Turbine exhaust Power and control terminations at package skid edge Wiring from Turbine Control Panel High voltage connections Generator ground connection Bus bar in GE Energy lineside cubicle GE Energy neutral cubicle Terminal box on individual motor Ladders and platforms for inlet air filter maintenance only Battery terminals to baseplates (if supplied loose) Electric motors Ladders and platforms for air filter 24 VDC batteries and chargers* for control system and fire/gas system 125 VDC batteries and chargers* for optional DLE operation and medium voltage switchgear Flanged or threaded connection on GE Energy baseplates Atmosphere (non-standard duct by others) Exhaust flange on main baseplate Terminal box on baseplate * GE Energy will include installation of the TCP and batteries with the ACM option and installation of the TCP, batteries and MCC with the PCM option.
13.6.1 • • •
Additional Materials and Labor Furnished by Others
Civil engineering design of any kind Building and civil works Site facilities
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• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Support steelworks and hangers for the gas turbine ducting, silencing and pipework All inlet, exhaust and ventilation ducting other than included in the scope of supply Drains and/or vent piping from the gas turbine package to a remote point Fuel storage, treatment and forwarding system Site grounding Lightning protection Power systems study Sensing and metering voltage transformers Machine power transformers, and associated protection Grid failure detection equipment Off-loading, at site transportation and storage Training except as described in Section 18 Off-skid cabling, and design of off-skid cable routing Balance of plant and energy optimization controls Anchor bolts, embedments, and grouting Distributed plant control Customer’s remote control (quoted separately) Field supervision High voltage transformer(s), cables, and associated equipment Interconnect piping, conduit, and wiring between equipment modules Plant utilities, including compressed air supply and off-skid piping Battery containment Lube oil measurement other than that defined in the scope of supply Additional lube oil breather ducting other than that defined in the scope of supply Fuel transfer pump Fuel for gas turbine Off-skid fuel block and vent valves Fuel supply pipework beyond the scope of supply Generator controls other than that defined in the scope of supply Load sharing control Balance-of-plant control Site labor Ladders, stairs, and platforms (except those for inlet air filter) Lifting Gear (also an option) Site performance testing (GE Energy provides Power/HR test correction procedure and technical direction during test)
13.7 Start-Up/Test Materials and Labor Furnished by Others • •
Operating personnel for starting, preliminary runs and tests Lubricating fluid, greases, and supplies for starting, preliminary runs, tests and normal operation thereafter
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•
Fuel and load for tests.
•
All field performance tests. Such tests to measure quoted guarantees shall be in accordance with General Electric recommended test procedures.
Note: Various types of contracts are available from GE, thus the above may not reflect the contracted scope. In case of conflict, the agreed upon contract with GE prevails.
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14. Reference Specifications
14.1Contents Natural Gas Fuel for GE Aircraft Derivative Gas Turbines
MID-TD-0000-1
Liquid Fuel for GE Aircraft Derivative Gas Turbines
MID-TD-0000-2
NOx Suppression Water Purity Specification
MID-TD-0000-3
Compressor Cleaning Water Purity Specification
MID-TD-0000-4
Liquid Detergent for Compressor Cleaning
MID-TD-0000-5
Lubricating Fluid Recommendations for GE Aircraft Derivative Gas Turbine
MID-TD-0000-6
Water Supply Requirement for Gas Turbine Inlet Air Evaporative Coolers GEK-107158A
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15. Maintenance, Special Tools and Spare Parts
15.1 LM6000 Maintenance Advantages Down time is costly and in addition to labor and material for repairs, the owner loses profits while the turbine is down for maintenance. In most instances, the lost profit during down time exceeds the cost of repairs. The LM6000’s simplified design helps reduce these field costs. The entire LM6000 package is designed for easy maintenance. Enclosures are large and provide ample working space. Components are accessible and easily adjusted or repaired, and an internal bridge-crane speeds engine removal for major repairs. The result is more “up-time” and less “down-time.” The LM6000 fleet of generator sets operated by GE Energy has an average reliability of 99.5%, exceeding the industry average by almost a full percentage point. The LM6000’s simple package design and easy replacement of turbine modules contributes to this fine result.
15.2 LM6000 Repairs To speed repairs, members of GE’s engine lease pool can have stock replacement engines dispatched to the job site for either planned repairs or an unscheduled overhaul. The owner of an LM6000 package can easily remove the entire turbine engine in the event of serious failure. A replacement engine can be installed and on-line within 48 hours, and the customer's operations can return to normal while the engine is being repaired off-site.
15.3 Engine Compartment Design The GE Energy engine compartment includes a shock isolation mounting system that permits the LM6000 turbine to ship in the package. This eliminates field reassembly. The turbine arrives tested, wired and fully piped. The engine compartment includes built-in lighting, walkways and comfortable working space. The overhead bridge crane can easily lift and turn the engine for removal through the side doors.
15.4 “On Condition” Maintenance Maintenance on many gas turbines is scheduled on a “clock-hour” basis. Parts are replaced after a set number of operating hours. This can lead to unnecessary costs and maintenance. LM6000 - 60 Hz Classic 6/2008
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The LM6000 is designed for “On-Condition” maintenance. Every six months the engine is given a thorough borescope inspection. Twenty-one borescope ports permit close inspection of all major internal parts.
15.5 Preventative Maintenance Inspection This inspection reveals wear and mechanical problems. Maintenance is scheduled only when inspection shows a specific need, rather than replacing parts on an arbitrary schedule. GE Energy literature and training stress preventative maintenance and operator awareness. We teach the customer's operators to perform preventative measures, including: •
Condition monitoring of critical parameters
•
Trend analysis of performance
•
Visual inspection of auxiliary systems and external wiring
•
Borescope inspection
•
Water wash
•
Filter changes and inspections
• Lube oil sampling In addition, GE Energy teaches operators to perform routine " condition monitoring, " including: •
Gas generator speed
•
Power turbine speed
•
Gas generator exhaust gas temperature
•
Gas generator discharge pressure
•
Vibration
•
Oil pressure
•
Oil temperature
Condition monitoring, in conjunction with borescope inspections, can provide an essential history of engine condition-versus-operating time. This allows maintenance to be predicted and scheduled for an appropriate time.
15.6 Maintenance Levels Downtime for maintenance is reduced by the LM6000's modular design. Routine maintenance tasks are done on-site, while major engine repairs are performed at specialized off-site LM6000 - 60 Hz Classic 6/2008
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facilities, saving the customer the expense of tooling and equipment. On-site and off-site maintenance tasks are divided into categories, or “levels,” described below.
15.7 On-Site Maintenance 15.7.1
Level 1
On-site external maintenance and module replacement includes protective and corrective tasks such as: •
Adjusting or replacing externally accessible components
•
Engine replacement
15.7.2
Level 2
On-site internal maintenance requiring partial disassembly of the engine and replacement of components includes: •
Compressor blade/vane replacement
•
Hot section component replacement
•
HPT blade replacement
•
Gearbox replacement
15.8 Off-Site Maintenance 15.8.1
Level 3
Off-site internal maintenance. Includes all Level 2 capabilities, plus complete teardown and rebuilding of engine. Includes replacement of major subassemblies with spare subassemblies.
15.8.2
Level 4
Off-site overhaul. Includes Level 3 capabilities plus complete disassembly of the major subassemblies of the gas turbine and rebuilding subassemblies with replacement parts. A permanent shop and a test cell are required for a Level 4 overhaul facility. GE Energy has full Level 4 maintenance capabilities for customer’s needs. We feature fullload testing of the repaired engine to ensure maximum field performance.
15.9 Owner’s Maintenance
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In most cases, the Owner prefers to have his operators trained to perform Level 1 maintenance to the gas turbine, and Levels 2-4 maintenance tasks handled by outside contract. However, GE Energy can train operators for Level 2 maintenance tasks, if desired.
15.10 Special Tools Special tools are required to perform Level 1 and Level 2 maintenance activities. These tools are listed on the following pages and are priced separately for customers intending to perform maintenance themselves. GE Energy includes a lift fixture for the LM6000 turbine engine in the basic scope of supply. This fixture and the built-in crane are used during engine removal and replacement.
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15.11 LM6000 Level 1 and On-Site Maintenance Tooling for New Equipment (Minimum Recommandations) P/N 1C3569G3 1C6361G01 1C8182G02
1C8208G02
1C9353G02 1C9359G02
1C9393G01
1C9400G01
1C9428G01
2C6352G07 2C6613G01 2C6647G01
2C6925G02
2C8102G02 RC3501 RC3503 9448M18G01
Description Hydraulic Actuator Unit: Actuates Hydraulic System for checking VBV, VIGV, and VSV System Tool Set-Radial Drive Shaft: Necessary to remove and reinstall Radial Drive Shaft Fixture Set-Removal, Mating Seal: Used to remove and reinstall Transfer Gearbox Carbon Seal, Mating Ring and O Rings Drive Adapter, Borescope Motoring Fixture: Adapts between Ace. Gearbox and Ratchet for Manual Rotation in Borescope Inspection Tool Set-Rigging, VBV Doors: Used to position the Variable Air Bleed By-pass Valve and Linkage Rigging Set – VIGV: To check travel of Actuator Ring in Relation to Outer Vane Case Requires use of 1C3569G3 Adapt. Set, Pressure Test/Rigging-VIGV, VBV, VSV System: Necessary to pressure test VBV, VIGV, and VSV System Requires use of 1C3596G3 Fixture, Raise & Hinge - Upper Compressor Case: Necessary to raise, hinge, and prop open the Compr. Stator Case for Rotor Blade Maint. Adpt. Torque Breaking CSV Actuating Arm Retaining Nut: Used to break the torque of the Compressor Stator Vane Actuation Arm Retaining Nuts Wrench Set, Spanner - Airtube Nuts: Necessary to torque Circular Nuts on Air Tubes Gage, Immersion Depth –Igniter: Checks Igniter Plug immersion depth Wrench, Spanner-Compressor Stator Vane Spacer: Holds Spacer during Assembly and Disassembly of Compressor Stator Vanes Gage, Set -VSV Clevis Assemblies: Sets and Measures Variable Stator Vane Clevis Assemblies to proper length Fixture, Torque Measuring - VSV Assembly: Used to Measure Torque required to actuate Half Rings and Vanes Borescope Kit - Rigid Type: Used for visual inspection of internal components of engine Fiberscope 6mm: Necessary to inspect areas inaccessible to rigid borescope kit Hand Tool Kit (Snap-On): Contains Hand Tools necessary for General Maintenance
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WP (GEK) WP1112 WP2810 WP2813
WP4015
WP1312 WP1113
WP1112
WP2411
WP2412
MULT WP1516
WP1411
WP4015 WP4015
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15.12 LM6000 Tools - Optional P/N 1C6119G01 1C9408G01 2C 14699G02
2C6018G01 RC2000-LM FG145
Description Guide - Expandable Bushing: Necessary top install expandable bushing into Transfer Gearbox Fixture Set, Torque Measuring - Compressor VSV: Required for setting proper torque of VSV Assembly (low boss vanes) Fixture, Lift-Compressor Stator Vane Spacer: Used to remove and handle Compr. Stator Upper Half with Engine in the Horiz. Position Tool Set, Holding –VSV: Holds individual Variable Stator Vanes for Removal and Installation Fixture Drive Electronic Turning Tool - Borescope Inspection: Used to electronically rotate engine core for borescope inspection Borescope Camera With Coupler: Still camera attaches to borescope
WP (GEK) WP2811 WP2412 WP2411
WP2412 WP4015 WP4015
15.13 Transportation/Maintenance Dolly Assembly - Optional P/N 1C9371G01 1C9372G05
1C9373G01
1C9375G01 1C9376G01
1C9377G01
1C9378G02
Description WP (GEK) Ring Assy - Support IGV Stator Case: WP3012 Provides support for EGV Case Forward Flange required for 1C9372G05 WP3012 Maintenance Dolly-External Engine: Provides frame Assy for use with multiple adapters for Horiz. Engine Maint. /Transportation WP3012 Adapter Set - Pedestal Turbine, Rear Frame: Adapter from Mount Side TRF to Horiz. Engine Maint. /Trans Dolly required for 1C9372G05 WP3012 Adapter Set - Support Air Manifold: Provides support at Air Collector Forward Side required for 1C9372G05 WP3012 Jack Assembly, Support Compressor Rear Frame: Supports Aft Flange of HPC Stator Case for Horiz. Eng. Support required for 1C9372G05 WP3012 Adapter Set Assembly - Support LPC Forward: Supports Fwd Flange of LPC Case if VIGV is removed required for 1C9372G05 WP3012 Adapter Assembly - Maintenance Dolly: Adapter Assy's for Horizontal Engine Maint. /Transportation Dolly required for 1C9372G05
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15.14 LM6000 Level II Tools (Optional) P/N 8200 1C6804G04 IC6892GOI 1C9116G01 IC9150G02 IC9302G02 1C9316G02 1C9317G01 1C9327G03 1C9336G01 1C9338G02 1C9354G03 1C9358G02 1C9362G02 1C9385G01 1C9390G01 1C9397G01 1C9608G01 1C9609G01 IC9610GOI 1C9613G01 1C9616G01 IC9617GOI 1V9618G01 1C9619G01 IC9620GOI IC9622GOI IC9626GOI 1C9627G01 2C 14025G05 2C 14038G02 2C 14049G01 2C 14094G06 2C14131G02 2C 14199G09 2C14222G01 2C14664G01 2C 14672G02 2C14679P01 2C 14684G02 2CI4688G04 2C 14689G01 2C14691G01
Description Torque Multiplier (Sweeney) Tool Set, Jack Screw-Disassemble Flanges Push Bolt - CFF/TGV Bracket Fixture, Lift LP Rotor and Stator Fwd. Tool Set, Jack Screws Tool Set, Assembly, Install -Balance Piston Seals Adapter, Sleeve LPT Rotor Shaft Adapter, Support / Lift LPC Puller, LPT Module - Mid Shaft Fixture, Assembly, Install / Remove - Aft Drive Shaft Nut Fixture, Fwd Restraint - LPT RTR to STTR Dolly Assembly, LM600 Engine Changeout Fixture, Lift, HPT, Horizontal Adapter, Lift, Combustor & HPT Nozzle Stg 1&2 Fixture, Support-LPC Rotor/Stator Fixture Assembly, Lift & Turn VIGV Holder, Shim Pusher/Puller HPT (used with 2C 14199G09) Adapter Assembly Drive Rear Pilot, LP Mid Shaft, Aft Fixture, Lift and Turn LPT Horizontal (Strongback) Fixture, Seating Check LPTR Wrench, LPTS Coupling Nut Tool, Install/Remove LPT Snap Ring Fixture, Torque LPT Coupling Nut Gage Inspection, Fan Shaft to HPC Case Collar Center Wrench HPT Coupling Nut Fixture, Lift and Turn LPT Horizontal Pusher Set - Races / Seals HPTR Stg 1 Fixture, Lift - HPTR Aft Truck, HP Turbine Rotor Horizontal Fixture, Seal Check No. 4 Bearing and Seal Fixture, Seating Check Pusher/Puller HPTR Remove and Replace HPTR Seals Wrench Set, No. 5R Bearing Inner Race Nut Fixture, Lift - HP Turbine Assembly Forward Sleeve Retaining, No. 4 Bearing Stackup Tool Set, Remove / Install - HPC Sttr Vane Spacer Puller, Races and Seals HPTR Stg 1 Adapter, Lift - Combustor Fixture, Inst/Remove Combustor
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15.15 LM6000 Level II Tools (Optional) (Cont) P/N 2C 14693G01 2C14695G01 2C14703G01 2C14785G02 2C6348P02 2C6967G06 2C6968G02 8112B
Description Tool Set, Install / Remove - LPT Module - Core Module Fixture, Lift-Stage 1 HPT Nozzle Assembly Adapter, Lift-Stage 2 HPT Nozzle Fixture, Removal HPT Aft Air Seals Pin, Guide - Fan Rotor Installation Tool, Install, S-2, HPC Blade Retainer Lock Pin Tool, Removal, S-2, HPC Blade Retainer Lock Pin Torque Multiplier (Sweeney)
15.16 LM6000 Start-up and Commissioning Spares P/N Description 5VX1000 Belt, Generator, Supply Fan 5VS1250 Belt, Turbine, Exhaust Fan HC9600FKN13Z Filter Element, Turbine CONNTECT Waterwash (55 Gal Drum) 5000 HC9606FKS8Z Filter Element, HP Hydraulic AL1335 50 MA Fuses AL1328 2 Amp Fuses AL1310 0.1 Amp Fuse AL1269 4 Amp Fuse AL1308 31 MA Fuse P13-2582 3 Amp Fuse P13-5712 ¼ Amp Fuse 226166-001 Calibration, Gas Cylinder CGI-3L Gasket, Flg.4”-300# CGI-3p Gasket, Flg.6”-300# CGI-3Q Gasket, Flg.8”-300# CGI-6D Gasket, Flg 1”-600# CGI-6G Gasket, Flg.2”-600# CGI-6J Gasket, Flg.3”-600# CGI-6L Gasket, Flg.4”-600# HC9600FKD13Z Fuel Filter (Liquid) ACB2442440Y1 Filter Element, Turbine Hyd P16-5659 Filter Element, Hyd Start HUOO157956 Filter Element, Charge Pump
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Qty 4 6 4 1 2 5 5 5 5 5 5 5 1 5 5 5 5 5 5 5 2 1 2 1
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15.17 Recommended Spares Listed are the typical “minimum” recommended spare parts for a typical LM6000 gas turbine generator set. Special configuration specific lists can be prepared upon request.
15.18.1 P/N 1304M52G03 9392M95P04 L21131P02 L28490P05 L31967P01 L31967P06 L35166P01 L43563P01 RD34485 RD34489 RD35234 L44500P02
15.18.2 P/N L44684P01 L44736P01 L44745P01 L44745P02
15.18.3 P/N 9504M33P01 L31476P53 L31476P54 L45816P04 L45881P05 L45882P05 L45921P01 L45970G01 L45972G01
LM6000 Critical Spares (All Configurations) Description Plug, HPT Stage 2 Borescope Plug, Igniter Sensor, Speed XN25 Sensor, Flame Accelerometer Accelerometer Detector, Resistance Detector, Chip Screen Screen Screen Lube Oil Scavenge Pump
Qty 1 1 1 1 1 1 1 1 1 1 1 1
LM6000 Critical Spares (PC Configuration) Description Sensor, LP Speed Harness, T48 Upper Sensor, T2/P2 Sensor, T25/P25
Qty 1 1 1 1
LM6000 Critical Spares (Dual Fuel with Water Injection) Description Sensor, Temperature Nozzle, Fuel Nozzle, Dual Hose, Fuel Hose, Fuel – Primary Hose, Fuel – Secondary Gasket Tube, Fuel Tube, Fuel
LM6000 - 60 Hz Classic 6/2008
Qty 1 6 1 6 1 1 2 2 2
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15.18.4
Two-Year Spare Parts Recommendation
P/N 5VX1000 5VX1250 95-117 ACB2442440Y1 HC9600FKN13Z 132P46C6B 78R25N00A025T3 4E5 PG3000-01M-4812-21-XX-93 1151GP9E22B2D3 8915-877 HC9600FKD13Z 1151AP6E22B2D3 330100-50-01 330130-045-01-00 330130-085-01-00 86517-01-01-01-01 EJA310-DAS4B92NC/HAC PA3000-01M-4813-21-XX-93 PA3000-200-4813-21-XX-93 PA3000-500-4813-21-XX-93 100P44C6R 180P44C6R 273800 HU00157956 P16-5659 HC9606FKS8Z
Description
Qty
Ventilation and Combustion Belt, Generator Supply Fan Belt, Turbine Exhaust Fan Turbine Lube Oil Element, Filter-Lube Oil Tank Demister Element, Filter-VGV Pump Element, Filter-Lube Oil Gas Fuel System Switch, Pressure-Fuel Gas Sensor, Temperature-Fuel Gas
1 1
Transmitter, Pressure, Fuel Supply
1
4 6 1 2 4
Liquid Fuel System Transmitter, Pressure, Liquid Fuel Valve, Liquid Fuel Element, Filter Auxiliary Systems Transmitter, Pressure – HP Compressor Proximeter Cable, 4.5 Meter Cable, 8.5 Meter Module – Accelerometer Interface Transmitter, Pressure-Inlet Static
1 1 1 1 1 1
Transmitter, Pressure – Turbine HP
1
Transmitter, Pressure-LP Turbine Inlet
1
Transmitter, Pressure-Thrust Balance
1
Hydraulic Start System Switch, Pressure-Hydraulic Pump Switch, Vacuum-Charge Pump Overrunning Clutch Element – Charge Pump Element, Filter – Charge Pump Turbine Hydraulic System Element, Filter High Pressure
LM6000 - 60 Hz Classic 6/2008
1 1 2
1 1 1 1 4 2
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15.18.4
Two-Year Spare Parts Recommendation (Cont)
P/N 132P4S129 132P4S185 655R-EDR-2” 78R25N00A025T3 4E5 HC9600FKN13Z L-471-02-SG1 P16-7185 7J30D1/30501BH-D-6-C-007.5 C327335 C327345 C327405 1151GP6E22B2D3 86160R1W039A-1 132P49C6B 160P4S36 3051CG5A02A1A S5M5 3051TG3A2A214 B4E5 V6-EPB-S-S-3-S 10319HE 1530-X1061
Description
Qty
Generator Lube Oil System Switch, Pressure – Lube Oil Switch, Pressure Switch – Lube Oil Valve, Control – Generator/Pressure Sensor, Temperature – Lube Oil Supply
1 1 1 1
Element, Filter – Lube Oil Switch, Level – Rundown Tank Element, Filter – Jacking Oil Pump Purge System (Dual Fuel Only) Sensor, Purge Temperature
2 1 2 1
Control, Purge Flow (VB) Control, Purge Flow Vent (VV1) Control, Purge Flow (VA) Liquid Fuel Boost Transmitter, Pressure Supply Pump, Liquid Fuel SPRINT™ System Switch, Pressure Switch, Pressure Transmitter, Pressure
1 1 1
Transmitter, Pressure
1
Switch, Flow Switch, Temperature Valve, Solenoid
1 1 1
1 1 1 1 1
LM6000 Consumables 1337M46P03 1538M42P01 619E223P52 635E901P02 9009M74P01 9011M60P01 9013M28P02 9013M29P02 9013M30P02 9014M45P64 9016M30P02 9048M33P05 9057M50P01 9107M23P01 9107M55P01
Gasket Gasket Fitting Reducer Nut Self Locking Gasket, Round Gasket Gasket Gasket Gasket Clamp Seal, Ring Bearing Seal Gasket Shim
LM6000 - 60 Hz Classic 6/2008
2 5 1 5 1 2 1 1 1 1 30 3 1 5 2
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15.18.4
Two-Year Spare Parts Recommendation (Cont)
P/N
Description
Qty
9365M41P117 9365M41P122 9371M19P04 9371M19P06 9371M19P08 9371M19P10 9371M19P12 9378M31P01 9379M93P01 9397M22P02 9608M12P02 9609M13P02 9610M50P29 9629M48P02 9629M48P04 9629M48P06 9629M48P10 9649M39P04 AC-B244F-2440 AN960C10 AN960C10L AN960C416L AN960C516 AN960C616L An960C616L J1092P04 J1092P05 J219P02 J219P03 J219P04 J219P07 J221P216 J221P222 J221P224 J221P260 J221P904 J221P905 J221P906 J221P908 J221P910 J221P912
LM6000 Consumables (Cont) Packing Packing Seal Seal Seal Seal Seal Fitting Gasket Lock Washer Gasket Guide Nut Nut Nut Nut Nut Clamp Filter Element Flat Washer Flat Washer Flat Washer Washer Washing Flat Washer Nut Nut Gasket Seal Gasket Seal Gasket Gasket Seal Packing, Preformed Packing, Preformed Packing, Preformed Packing, Preformed Packing, Preformed Packing Packing Packing Packing Packing, Preformed
10 10 2 2 1 4 3 10 8 2 5 5 25 25 25 25 25 1 1 100 100 100 100 100 100 5 5 1 2 4 1 25 25 5 1 25 25 25 25 25 25
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15.18.4
Two-Year Spare Parts Recommendation (Cont)
P/N
Description
Qty
J221P916 J415P123A J515P04 J522P57 J534P06 J534P08 J534P10 J534P12 J628P06D J643P04B J643P12A J644P06D J644P07D J644P08D J644P09D J645P30A L22281P02 L34976P069 M83248/1-121 M83248/1-243 M83248/1-904 M83248/1-905 M83248/1-910 M83248/1-912 MS21083C4 MS21083C5 MS9193-04 MS9193-12 MS9202-042 MS9315-04 MS9315-12 MS9321-10 MS9404-04 MS9557-07 MS9557-10 MS9557-22 MS9567-14 NAS1291C8M R1316P007 R287P04 R287P06 R287P08 R287P10
LM6000 Consumables (Cont) Packing, Preformed Bolt Elbow Nipple Tube Nipple Nipple Tube Nipple Tube Nipple Nut Machine Bolt Machine Bolt Machine Bolt Bolt Machine Bolt Bolt Bolt Gasket Bolt Packing Packing Packing Packing Packing Packing Nut Self Locking Nut Connector Connector Gasket Tube Cap Cap Assy Washing Flat Plug Machine Bolt Machine Bolt Machine Bolt Bolt Nut Packing Nipple Nipple, Tube Nipple Nipple
25 6 1 1 1 1 2 2 5 25 10 5 10 90 5 10 1 5 1 1 1 1 1 3 5 5 5 1 2 25 5 100 5 5 5 5 5 1 1 4 1 2 2
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15.18.4
Two-Year Spare Parts Recommendation (Cont)
P/N
Description
1704M61P03 1704M62P04 1704M62P05 1704M63G07 1704M63G08 1704M63G09 1704M63G10 1704M63G11 1704M63G12 1774M59P01 705B276P5 9009M32P01 9108M27P03 9365M41P229 9397M20P02 9609M43P02 9628M16P02 9699M66P01 AN316C4R J1220G05 J1221G03 J1221G04 J1221G07 J1221G08 J1221G10 J201P04 J221P028 J221P138 J221P163 J221P219 J221P240 J221P903 J414P034A J511P106 J511P108 J511P110 J511P112 J644P10A J644P12A J816P072C L43073P01 L43616P01 L47372P01
Sleeve Spacer Spacer Arm Arm Arm Arm Arm Arm Seal Ring Washer Bolt Seal Bushing Washer Bolt Bolt Nut Clamp Clamp Clamp Clamp Clamp Clamp Nut Packing Packing Packing Packing Packing Packing Bolt Nipple Nipple Nipple Nipple Bolt Bolt Bolt Gasket Bolt Packing
Qty LM6000 Consumables - PC
LM6000 - 60 Hz Classic 6/2008
5 5 5 5 1 5 1 5 1 2 2 5 5 5 1 25 5 5 25 5 5 5 5 5 5 5 5 5 5 5 5 5 5 1 1 1 1 5 5 2 5 1 25
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15.18.4
Two-Year Spare Parts Recommendation (Cont)
P/N
Description
L47372P02 MS35842-15 MS9201-04 MS9371-15 MS9489-07 MS9556-06 MS9556-10 MS9557-06 MS9557-09 MS9557-14 MS9557-38 MS9565-05 MS9566-12 MS9902-03 MS9902-04 MS9902-06 MS9902-08 MS9902-10
Packing Clamp Nut Gasket Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Plug Plug Plug Plug Plug
Qty LM6000 Consumables
LM6000 - 60 Hz Classic 6/2008
25 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
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P/N
Description
Qty
00176-198 1174392/01 1327747/04 18711-115 25281-528 25711-012 25711-249 25711-425 25711-428 25715-005 25715-006 25715-010 25771-148 25771-163 25771-167 26632-032 26661-014 28239-088 28239-089 28278-218 28428-187 29812-761 3116456/52 3116682/01 312916/01 3127195/01 3128497/01 3130399/19 3130399/27 3135217/01 3135356/01 3140899/01 3142638/01 9602933/00 9602943/00 9602947/00 9607087/00 9608488/00 9611592/00 9615175/00
Generator Spares Seal Kit (L.O. Pump) (New) Brush Holder Fuse SF21 Gasket Cmpnd (HYLOMAR) 100 Heater Finned 650W Fuse 4F21 Fuse 20ET Fuse 315SBMT (3127032/01) Fuse 450SBMT (3132472/01) Fuse 250mA, Size 0 Fuse 500mA, Size 0 Fuse 2A, Size 0 Relay VP/2 26V Relay 24VDC 3P Relay COMAT 125VDC POT 500R + 500R POT Drive Unit Diode (6W12030VO) Diode (6W02030VO) Diode Bridge 36MB80 Thyristor N018R/H08 RTD Temp Detector Insulated Washer Set (20/set) Earthing Brush Exciter Heater RTD Air Temp Detector Seal Ring Spring Insulated Tube Set (20/set) Insulated Tube Set (20/set) Duplex RTD Bearing Metal Gasket F/Bearing L.O. Pump ACG045N5 L.O. Pump Coupling Assy Auto Power Card Assy PF Control Card Assy Volts Monitor Card Assy EHC CD, Aux Rack Assy Exciter Monitor Card MAVR Control Card, Type B Assy Exciter Lmtr CD, Type B
1 2 2 6 24 5 5 12 12 5 5 5 2 2 2 1 1 6 6 2 2 2 2 10 2 2 10 2 2 2 2 1 1 1 1 1 1 1 1 1
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16. Customer Drawings
16.1 General GE Energy prepares a comprehensive drawing package for each gas turbine generator set. The package includes: •
Proposal Drawings Drawings furnished with the proposal to assist customer evaluation of the product.
•
Approval Drawings Drawings requiring specific customer approval.
•
Information Drawings Drawings of standard manufactured items in the turbine package, furnished for customer information.
GE Energy provides all engineering drawings on-line at a secure server (www.projectnet.com). Each customer can enter this database and view, print or annotate his own project drawings. ProjectNet provides the customer with immediate access to the latest revisions of his drawings. ProjectNet speeds job completion and saves weeks of time mailing drawings back and forth.
16.1.1
Proposal Drawings - Typical
GE Energy prepares Proposal drawings to show: • General Arrangement of the Gas Turbine Generator Package • Electrical “One-Line” information. These drawings are “Preliminary” in nature. They help define the product for evaluation, and they form the basis for an Engineering “ODM” or Order Design Meeting after contract award.
16.1.2
Approval Drawings
After the ODM meeting, which defines the project details, GE Energy updates the general arrangement and one-line drawings and submits them for customer approval. 16.1.2.1
General Arrangement Drawings
These drawings define the orientation of the major GE Energy modules. A general arrangement drawing with Plan and Elevation views is prepared for each of the following major components:
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• •
Turbine generator set and associated skids Turbine Control Panel
•
Auxiliary control module
The general arrangement drawings include the following information: • • • • •
Overall dimensions of the equipment Access space required for removal or maintenance of major components Foundation loads, foundation bolt hole locations and sizes, plus any special requirements Lifting lug locations Customer piping connections with appropriate dimensions
16.1.2.2
One -Line Electrical Drawings
This drawing is an electrical schematic of the power system from the generator terminals to the purchaser's high voltage bus connections and ground, including the generator excitation and synchronizing systems. Also indicated are the protective relays, potential transformers, circuit breaker and auxiliary and main transformers, some of which may be furnished by others. In cases where the GE Energy equipment will be interfaced with an existing facility or with customer supplied devices, the customer's one-line drawing must be furnished to GE Energy for preparation of the GE Energy one-line electrical diagram. 16.1.2.3
Revisions to Approval Drawings
Customer should mark any requested revisions on one copy of the Approval Drawings and return them to GE Energy within two weeks. GE Energy will then reissue drawings showing mutually agreeable corrections. 16.1.2.4
Certified Drawings
GE Energy certifies only drawings showing anchor bolt locations, foundation loading and Customer's piping connection locations.
16.1.3
Information Drawings
The following drawings cover standard manufacturing items. They provide a reference for construction, maintenance and operations. The drawings are submitted for “information only” and are not subject to approval. 16.1.3.1
Electrical System Interconnection Plan
This drawing shows recommended sizes for interconnecting cables and corresponding minimum cable lengths between GE Energy supplied modules and the customer’s control room. The Interconnection Plan assists the customer in purchasing wire and cable for
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interconnection and helps in planning the site layout. Point-to-point interconnection wiring diagrams are also provided. These drawings are completed after other system drawings have been finalized. 16.1.3.2
Flow and Instrument Diagrams (F&ID)
F&IDs are issued for each of the fluid systems in the GE Energy scope of supply. This typically includes the following: • •
Fuel system Water injection system (optional)
• • •
Steam injection system (optional) Water wash system Hydraulic starting system
• • • •
Gas turbine lube oil system Electric generator lube oil system Fire protection system Evaporative cooling system (optional)
• • • •
Combustion air chilling system (optional) Air inlet and ventilation system Turbine auxiliary instrumentation Anti-icing system (optional)
Each F&ID drawing depicts the equipment components, piping, valves and instruments in the system, complete with line sizes. The part number of items on the F&ID are shown on a Bill of Material, which is part of each F&ID drawing. The F&IDs also show the pressure, temperature and volume limita-tions of the system, including set points for alarms and shutdowns. Each working fluid in the system is identified, and initial fill quantities for fluid reservoirs are shown. For clarity, the F&ID drawings are schematic in nature. Pipe elbows, fittings and similar details are omitted.
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16.1.3.3
Digital Control and Monitoring System
This drawing provides installation details for operator information. The drawing shows the front of the turbine control panel as viewed by the operator, including HMI screen, meters, indicator lights and switches. Overall dimensions and installation footprint are shown on this drawing. 16.1.3.4
Drawings with Manuals
In addition to the above drawings, a complete set of system wiring diagrams is included in the operation and maintenance manuals to serve as a reference for field check-out and troubleshooting.
16.2 Documentation GE Energy provides extensive documentation to help install, commission, operate and maintain the gas turbine generator package. Information includes:
16.2.1
Installation Manual
The Installation Manual provides detailed instructions on: • •
Receiving and Inspecting the Equipment Assembly of the Components
•
Scheduling, manpower and tooling
16.2.2
Commissioning Manual
The Commissioning Manual provides detailed instructions on: • Mechanical and electrical precommisioning activities complete with checklists • Commissioning activities including prestart testing, rotation test, initial fired start, and auxiliary systems •
Scheduling, manpower, and tooling
The Installation Manual and Commissioning Manual are each one- volume publications. Two copies of each are shipped to the job site approximately 1 month before shipment of the gas turbine generator.
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16.2.3
Operation and Maintenance Manuals
This multi-volume manual is prepared by a team of engineers, writers, illustrators and editors. It is specifically edited for each project, including project specific drawings and details. The O&M manual is designed as a reference for the operators and technicians in the field. It provides system descriptions, specifications, and procedures for field operation and maintenance. Included are project details and illustrations for the following: •
Product description
•
Turbine and generator specifications
•
Unit operating procedures
•
Turbine operating sequences
•
Generator operating data
• •
Gearbox operating data (if applicable) Control system components and operations
•
Fire & gas system
•
Electrical and Mechanical drawings (as listed in 16.2.4)
In addition to the above information, GE Energy includes vendor’s operation and maintenance data on all major systems and components. Six copies of the O&M manuals in CD form are shipped about 30 days after shipment of the Gas Turbine Generator. This provides GE Energy time to include the latest engineering drawings. The manuals are also available on a secure internet website.
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16.2.4
Typical Drawing List for GTG Package
Some drawings listed in this table may not be applicable to specific projects. Approval drawings are submitted to the customer for approval. Information drawings are provided for customer information only and are not subject to approval. Title
Submittal Time (Weeks) Approval Drawings
General Arrangement, Main Unit One Line Diagram
8 8
Information Drawings: Electrical Electrical Symbols, Abbreviations and Reference Data Interconnect Plan, Electrical Interconnect Wiring Diagram, customer Interconnect Cable Schedule Plan & Elevation, Turbine Control Panel Plan & Elevation, 24 VDC Battery System Plan & Elevation, 125 VDC Battery System Plan & Elevation, 240 VDC Battery System Plan & Elevation, Lineside Cubicle Plan & Elevation, Neutral Cubicle Three Line Diagram, Generator Metering Schedule, Motor Control Center Schematic Diagram, Motor Control Center Schematic Diagram, Circuit Breaker ControlDiscrete Control Schematic Diagram, Analog Control Schematic Diagram, Circuit Breaker Control System Schematic, Generator Excitation System Schematic, Lighting & Distribution System Schematic, Critical Path Emergency Stop, DC Power System Schematic, Communication Instrument Loop Diagram, Hydraulic Start System Instrument Loop Diagram, Ventilation & Combustion Air System Instrument Loop Diagram, Synthetic Lube Oil System Instrument Loop Diagram, Mineral Lube Oil System Instrument Loop Diagram, Turbine Hydraulic System Instrument Loop Diagram, Fire & Gas Protection System Instrument Loop Diagram, Gas Fuel System Instrument Loop Diagram, Liquid Fuel System Instrument Loop Diagram, CDP Purge System Instrument Loop Diagram, NOx Water Injection System Instrument Loop Diagram, NOx Steam Injection System Instrument Loop Diagram, Power Augmentation Steam Injection System Instrument Loop Diagram, Water Wash System Instrument Loop Diagram, SPRINT™ System
8 10 16 12 12 8 8 8 8 8 12 8 12 16 16 12 12 12 12 12 16 16 16 16 16 16 16 16 16 16 16 16 16 16
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16.2.4
Typical Drawing List for GTG Package (Cont)
Title
Submittal Time (Weeks) Electrical (Cont)
Instrument Loop Diagram, Vibration System Instrument Loop Diagram, Auxiliary System Generator Protective Relay Settings Mechanical General Arrangement, Air Filter General Arrangement, Water Injection Skid General Arrangement, Steam Skid General Arrangement, Liquid Fuel Pump Skid (Boost) General Arrangement, Auxiliary Skid Anchor Bolt & Shear Lug Detail (Main Unit) Installation Footprint (Main Unit) Lift Arrangement Shipping Data Flow and Equipment Symbols, Mechanical F&ID, Hydraulic Start System F&ID, Nozzle Steam Injection System F&ID, Ventilation and Combustion Air System F&ID, Turbine Lube Oil System F&ID, Gas Fuel System (DLE) F&ID, Turbine Hydraulic System F&ID, Fire Protection System (CO2) F&ID, Water Wash System F&ID, Liquid Fuel Pump (Boost) F&ID, Water Injection Pump F&ID, SPRINT™ System Instrument Skid, Auxiliary Systems Reference Drawings Wiring Diagram, Turbine Control Panel, Control Cubicle Wiring Diagram, Turbine Control Panel, Termination Cubicle Wiring Diagram, Turbine Skid Wiring Diagram, Auxiliary Skid Wiring Diagram, Air Inlet Filter Wiring Diagram, Generator Skid Wiring Diagram, Lineside Cubicle Wiring Diagram, Neutral Cubicle Wiring Diagram, Fire & Gas Protection System Nameplate List, Engraving Schedule, & Switch Development Fuel Control Layout Worksheet, Fuel Control Sequencer Layout Worksheet, Distributed I/O Configuration
LM6000 - 60 Hz Classic 6/2008
16 16 16 8 8 8 8 8 8 8 16 16 10 10 10 10 10 10 10 10 10 10 10 10 10 Included w/O&M Included w/O&M Included w/O&M Included w/O&M Included w/O&M Included w/O&M Included w/O&M Included w/O&M Included w/O&M Included w/O&M Included w/O&M Included w/O&M Included w/O&M Included w/O&M
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Digital MultiFunction Settings Digital Synchronizer Settings Area Settings Area Classification Drawings Area Classification Report
16.2.4
16 16 16 12 12
Typical Drawing List for GTG Package (Cont)
Notes: 1) Submittal time is for standard equipment and is shown in weeks after receipt of a mutually agreed upon purchase order, a fully conformed design specification, and the post award Order Definition Meeting (ODM). 2) Drawing dates for Standard equipment only. Custom designed features for specific project requirements may require additional submittal times. 3) Some of the above drawings may not be required on specific jobs. 4) A drawing is considered submitted when uploaded to the www.projectnet.com site Drawing Quantities and Format GE Energy places customers’ drawings on ProjectNet, a secure internet site, (www.projectnet.com). On this site the drawings can be viewed, printed and annotated by the customer. GE Energy provides all manuals in CD format for convient access and distribution. In addition, by using web-based technology GE Energy provides today’s customers instant and secure access to their unit’s operation and maintenance documentation with easy updates and “real time” information.
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17. Extended Scope Equipment and Services
Overview GE Energy has the capability to provide everything from individual pieces of balance of plant equipment to the complete power plant supplied on a “turn-Key” basis. GE Energy has a dedicated team of engineers who specialize in the design, procurement and construction of power plants and has successfully demonstrated the ability to do so for the following types of facilities: • • • • •
Simple Cycle Power Generation Cogeneration Power Plants Combined-Cycle Power Plants Turbine-Compressor Plants Compression Modules
GE Energy designs power plants with a focus on reliability and availability.
Turn-Key Services Engineering GE Energy can provide complete power plant design services, including civil, mechanical and electrical design. The plants we design are reliable and intended to maximize the owner’s profitability and minimize the total installation and construction duration. In order to achieve this, we utilize pre-engineered designs for plant applications wherever possible. These designs are proven and are ready for use today, saving engineering costs and project time, allowing for the lowest installed cost basis. To meet unique project requirements, we work with the Owner to adapt GE Energy’s standard plant designs to accommodate their particular needs. Most of our designs are for shop built modules or systems, reducing the complexities of field installation. This process saves weeks of time and hundreds of engineering man-hours.
Our field experience simplifies the job by bringing the knowledge and engineering skill gained from previous power plant projects to each new project.
Most of our simple-cycle engineering is done “in-house” to provide tight coordination for our customers. On large projects we call in experienced third-party engineering companies to
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work under our supervision. This approach helps us put units “on-the-line” quickly to meet owner’s deadlines. Procurement The GE Energy Extended Scope engineering team can provide procurement services for the entire power plant. We use the experience of the GE Energy organization to help us find the best balance of plant equipment vendors in the business. We utilize GE components to the extent possible to minimize cost, ensure highest quality, and maximize standardization between balance of plant components and the turbine package. We demand quality, dependability, and experience from each of our vendors while keeping an eye on minimizing installed costs. Most pieces of major equipment are purchased from vendors who have served us for years, with hundreds of successful applications. Construction Services and Start-Up Services The GE Energy project execution team can provide full construction and start-up services for the power plant. We place an experienced Construction Manager on each site. The Construction Manager and specialists from our Houston office select from a group of prequalified construction sub-contractors to provide skilled craftsmen for the job. The Construction Manager schedules and coordinates the work of the subcontractors. This individual verifies the quality and completeness of each element of the job, and ensures that the work progresses properly, with order and safety. A team of start-up specialists from GE Energy and from major equipment vendors arrives at the job when construction is nearing completion. These technicians check each plant system carefully. Then, in parallel with the combustion turbine Technical Advisory team and plant operations team, they commission the plant. After thorough operating checks, these specialists prepare the plant for performance testing and eventual turnover to plant operators. Extended Scope Services Combustion Turbine Package Installation and Commissioning Supervision Services GE Energy can provide technical advisory supervision services for the installation and commissioning of the combustion turbine package. Installation services include supervising the installation of the combustion turbine package by the Owner’s or by GE Energy’s construction contractor. Commissioning services include flushing supervision, checkout, and commissioning supervision of gas turbine mechanical systems, electrical systems, and control system. GE Energy provides all general hand tools required for the commissioning of the unit. Flushing and calibration kits can also be provided at GE Energy’s standard published rates.
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Engineering Studies GE Energy can provide other engineering support services including complex or new product design, troubleshooting, problem solving, and power plant conceptual layouts. Quite often, GE Energy will coordinate with third party expertise to meet the project requirements. Exhaust Emissions Testing GE Energy can provide complete and comprehensive gas turbine exhaust emissions mapping testing services for the project if required. For these services, GE provides a testing specialist at the jobsite to conduct the typical exhaust emissions testing services including:
•Oxygen (O2), nitrogen oxides (NOx), unburned hydrocarbons and carbon monoxide (CO) monitoring •Preliminary O2 traverse, if required A formal site data test report will be provided once the testing is completed.
Training In conjunction with the training provided by the gas turbine instructors, GE Energy can provide specialized operator training on each of the balance of plant systems as well as provide total plant maintenance training.
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Balance of Plant Equipment As options, GE Energy can supply almost all of the extended scope equipment required to complete the power plant installation. Simple Cycle Exhaust Stack GE Energy can provide an exhaust stack and silencer assembly capable of reducing the exhaust noise of the combustion turbine. Typical scope of supply for the exhaust stack and silencer assembly is as follows: • • • • • • • •
Expansion joint Transition duct Access door to stack base Silencer Stack Emission ports Ladders and platforms All bolting hardware, gaskets, and field insulation
The design characteristics of the standard exhaust stack / silencer assembly is as follows: Description Stack Height at 1m / 3 ft 1.5 m / – 5 ft Above Grade Far Field Silencing – at 122 m / 400 ft Exterior Casing Material Interior Liner Material Insulation Material
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Specification Project Specific 85 dB(A) 65 dB (A) ASTM A36 Carbon Steel 409 Stainless Steel High Temperature Ceramic Fiber
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SCR / COR Assembly GE Energy can provide a Selective Catalytic Reduction (SCR) / Carbon Monoxide Reduction (COR) assembly to reduce the gas turbine emissions to the levels dictated by local permitting agencies. The scope of supply for the SCR / COR assembly typically includes an expansion joint, ductwork, CO oxidation catalyst, NOx reduction catalyst, ammonia injection grid, ammonia injection skid, integral stack / silencer assembly, and the necessary ladders and platforms. The SCR is controlled by a PLC based control system installed in a NEMA enclosure on the ammonia injection skid. The assembly is designed and manufactured in a modular fashion in order to minimize site assembly costs and duration. If required, GE Energy can provide the following equipment associated with a SCR system: • • •
Tempering air or purge air fans Stainless steel ammonia storage tank (with unloading facility) Ammonia forwarding systems Continuous Emissions Monitoring System
GE Energy can provide a Continuous Emissions Monitoring (CEM)/Data Acquisition Historical Storage (DAHS) system for the gas turbine package. The system utilized will be an extractive sampling system that is capable of monitoring of NOX, CO, CO2, O2, and NH3. The system is provided in a walk-in shelter with a wall-mounted air conditioning unit. The system also consists of the necessary stack probes and sample lines. GE Energy can provide the following equipment and services, as an option, if required for the project: • • • • • •
Uninterrupted Power Supply (UPS) for PLC and analyzers Inlet NOX for SCR system / performance measurement Opacity monitoring system Installation and commissioning supervision Training Certification testing by a third party tester Air Inlet Chilling System
GE Energy can provide a packaged, modularized chilled water system, containing the equipment necessary to condition or chill the inlet air to the gas turbine and maintain the desired power output during hot day conditions. The chiller package consists of one “duplex” centrifugal chiller mounted on a heavy structural steel skid with packaged piping, cooling
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tower, valves, pumps, medium voltage (MV) and low voltage (LV) motor control centers MCC and controls installed and pre-wired. The chiller system will be prefabricated to the maximum extent possible such that field installation consists of setting chiller skids on the owner provided foundations, connecting utility services and control interfaces, and interconnecting chilled water and cooling water piping between modules, cooling towers, and cooling coils. The package is designed to require a single MV power feeder and a single LV power feeder. All MV and LV MCC’s, bus connections, and step-down transformers to utility and control voltages are included and pre-wired on the chiller package to minimize field wiring required at the site. Package comes complete with an insulated, weatherproof enclosure for the chillers, pumps and electrical systems. The enclosure provides weather protection and acoustical attenuation as well as thermal insulation.
A central control system is provided for controlling the entire inlet air chiller system. The system proposed monitors and controls chiller and all chiller related auxiliary equipment. Operation and monitoring of the system is provided, locally, through full color graphical touch screen HMI interface mounted in the package enclosure. Gas Fuel Booster Compressor GE Energy can provide a gas compressor if the gas-supply pressure at the facility is not of sufficient pressure to meet the needs of the gas turbine generator. The compressor will be skid mounted, and utilizes a compressor directly coupled to a horizontal induction electric motor. The system includes a suction scrubber, discharge coalescer, air-to-gas inter-stage / after cooler (if suction pressure requires), and control panel utilizing a GE 90-30 PLC. The design characteristics of the standard gas fuel booster compressor assembly is as follows: Description Installation Type Hazardous Area Classification Rated Discharge Pressure Rated Capacity
Specification Suitable For Outdoor Installation Class I, Group D, Div 2 700 psig 11 MMSCFD
An acoustical enclosure or sound barrier walls can be provided for jobsites with strict acoustical requirements, if necessary. Liquid Fuel Treatment Module GE Energy can provide a liquid fuel treatment module to remove water-based contaminants in the Owner supplied fuel system. This system treats fuel from the Owner supplied storage tank and forward to the Owner-supplied day tank. The standard system includes the following components:
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• • • • • • • •
Duplex strainer with differential pressure gauge and switch Fuel oil feed pumps with AC motors Self-cleaning centrifuge with AC motor Sludge pump with AC motor Associated valves and instrumentation Skid interconnect piping and conduit wiring Skid-mounted, combined control panel with motor control centers Self-supporting structural steel skid with sludge tank
Liquid Fuel Forwarding Skid GE Energy can provide a single skid consisting of two (2) 100% plant capacity liquid fuel forwarding pumps. The skid comes complete with centrifugal pumps, motors, motor starters, and all necessary instrumentation. This skid is designed to be located between the Owner supplied liquid fuel storage/day tank and liquid fuel filter skid. Demineralized Water Treatment System GE Energy can provide a modularized demineralized water treatment system (when provided with a raw water quality analysis). Each system incorporates any or all required facilities (i.e., multi-media filtration; anti-scalant; a reverse osmosis system including "clean-in-place" capability; and electrodeionization polishing system, etc.) to produce demineralized water at the quality, flow, and pressure in accordance with the GE requirements for NOx control and/or SPRINT power augmentation. A raw water analysis (provided by the owner) is necessary to specify a final design for the treatment system.
Included with the water treatment equipment system is a complete set of instrumentation and automatic valves (where required). This enables automated operation of the water treatment system via the control system, consisting of a single comprehensive programmable logic controller (PLC) with an operator interface. This system is provided, installed, pre-piped and pre-wired, in a modular building designed to house the equipment, to minimize overall field installation requirements. The normal operation of the treatment units is fully automatic through a PLC based control system. The plant is normally operated at full load to maintain the site required demineralized tank level. The following equipment is part of the standard demineralized water treatment system:
• • • • •
Two (2) sets of multimedia filters One (1) backwash pump Two (2) cartridge filters One (1) sodium sulphite chemical dosing tank and pump One (1) reverse osmosis pump
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• • • •
One (1) reverse osmosis unit One (1) reverse osmosis permeate storage tank One (1) EDI pump One (1) EDI unit Raw Water Forwarding Skid
GE Energy can provide a single skid consisting of two (2) 100% plant capacity raw water forwarding pumps. The skid is supplied complete with centrifugal pumps, motors, motor starters and all necessary instrumentation. This skid is designed to be located between the Owner supplied raw water storage tank and GE Energy or Owner supplied water treatment system. Demineralized Water Forwarding Skid GE Energy can provide a single skid consisting of two (2) 100% plant capacity demineralized water forwarding pumps. The skid is supplied complete with centrifugal pumps, motors, motor starters and all necessary instrumentation. This skid is designed to be located between the Owner supplied demineralized water storage tank and GE Energy supplied water injection boost skid. Piping construction will be stainless steel. Instrument Air Compressor GE Energy can provide a skid-mounted air compressor sufficiently sized for the air requirements of the gas turbine package and the auxiliary equipment. The air compressor system is self-contained and includes a control and indicator panel, air dryer, coalescing prefilters, particulate after-filters, and air receivers. The design characteristics of the standard instrument air compressor system are as follows: Description Compressor Type Rated Flow Rated Pressure
Specification Rotary Screw Design 150 SCFM 8.62 bar / 125 psig
GE Energy can provide the following equipment associated with the instrument air compressor system if required for the project: • • • •
Acoustic enclosure or sun shade Water cooled system in lieu of air cooled Service air line and air receiver
•
A larger air compressor skid can be provided to accommodate other power plant air requirements, if necessary.
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Initial Fill Lubricants GE can provide first fill of lubricants to which includes the turbine lube oil, generator lube oil, hydraulic start system oil and chemical water wash. Oil Type Turbine Lube Oil – Synthetic Generator Lube Oil – Mineral Hydraulic Lube Oil – Mineral Water Wash Chemical
Specification MIL-TD-0000-6 ISO-VG46 MIL-H-17672 MID-TD-0000-5
Combustion Turbine Package Anchor Bolts GE Energy can design and procure equipment foundation anchoring systems for the gas turbine generator package only. The scope of supply will include anchor bolts complete with nuts, embedded plates, washers and sleeves. The Owner is responsible for placing the embedments in the foundations per GE Energy specifications. Generator Step-Up Transformer GE Energy can provide the generator step-up (GSU) transformer rated with design characteristics as noted in the below table with off-load taps and CT’s. The GSU is sized to export power from the generator under all ambient conditions. Lightning arrestors will be provided and connected to the transformer high voltage bushing terminals.
The design characteristics of the standard generator step-up transformer are as follows: Description Primary Voltage Rating Secondary Voltage Rating Size Cooling Class Maximum Temperature Rise Impedance Primary Voltage Connection Type Secondary Voltage Connection Type
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Specification Project Specific 13.8 kV 45/60/75 MVA ONAN / ONAF / ONAF 65 °C / 149 °F Job specific Wye (with de-energized tap changer) Delta
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Medium Voltage Switchgear GE Energy can provide 4,160V switchgear as required to provide auxiliary power for plant operation. Auxiliary Transformer – Low Voltage GE Energy can provide pad mounted auxiliary transformers for the various plant loads as required. The size of the transformers are dictated by the plant design. Balance of Plant Motor Control Center GE Energy can provide motor control centers for the various balance of plant motor starters as required. The MCC line-ups can be provided in an appropriate NEMA enclosure suitable for either indoor or outdoor installation. Electrical Equipment Module GE Energy can provide a walk-in, pre-fabricated electrical equipment module designed for the installation of the various balance of plant electrical control equipment. Several preengineered designs and sizes are available to accommodate the project specific requirements. The module comes complete with an emergency lighting system, interior cable tray (if applicable), and lighting and convenience receptacles. Black Start Generator GE Energy can provide a diesel engine driven generator package to provide gas turbine generator start-up capability in the event of a loss of connection to the grid. For black starts, the diesel generator provides AC power for the gas turbine generator hydraulic starter motor, package ventilation fans, and various accessories. In addition to the diesel engine and generator, the black start system includes a breaker cubicle, distribution/ control panel, and fuel tank Supervisory Control System GE Energy can supply a Supervisory Control System (SCS) to provide a common operator interface that integrates the controls for the GE Energy supplied Balance of Plant equipment with the gas turbine generator. By using either a Mark VIe platform or a PLC based platform a completely integrated control system can be achieved, eliminating the multiple hardware and software interfaces typically encountered in most power plants. Each GE Energy supplied component and/or skid, including the gas turbine generator, supplied with local instrumentation and/or control systems will interface with the SCS for monitoring and supervisory control.
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Interface between each component and the SCS is established using a combination of hardwired instrument I/O, high-speed redundant Ethernet communications, and/or serial link connections. The instrumentation and controls provided will ensure the safe and efficient operation of the process over the complete range of operating conditions. A unified operator control interface is provided for operation from the Power Control Module (PCM) or owner supplied control room via CRT-based Human Machine Interfaces (HMIs). A graphical interface is created for both the turbine and plant controls using Cimplicity HMI software. Each HMI is powered by a Pentium class workstation PC. The SCS components are assembled in a control cabinet to be installed in the Power and Control Module (PCM) or Owner provided control room. Components installed in the SCS cabinet typically include the following: • • • • • •
MarkVI BOP control hardware Analog and Digital I/O termination boards Ethernet Network Switch Uninterrupted Power Supply (UPS) (for SCS only) Power Distribution Components and wiring Lighting
GE Energy can provide additional optional equipment and services for the SCS as follows: • • • • • • • • • • •
Control room DCS furniture Plant historian for both BOP and turbine data Additional local HMI servers/viewers Remote control room HMI servers/viewers Automatic Generator Control (AGC) Sequence of Events (SOE) Recording One Button Start Operator Training for Plant Controls LCDs in lieu of CRTs Interfacing with Owner supplied components Onsite commissioning services
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18. Training
18.1 Gas Turbine Familiarization 18.1.1
Objective
The Gas Turbine Familiarization course is designed to train operators and supervisory personnel to safely operate a gas turbine generator unit. Emphasis is placed on the operator’s responsibilities with regard to the auxiliary systems, operational data logging, and data evaluation. Operators are also instructed in how to interpret fault annunciation and how to determine if the annunciated fault can be remedied by operator action or by the assistance of instrumentation and/or maintenance personnel. The course, located in Houston, Texas, focuses on starting, loading, and specific operator checks of the various turbine support and auxiliary systems to ensure safe and reliable operation of the turbine unit.
18.1.2
Content
The typical Gas Turbine Familiarization course covers the following areas: • • • • -
Unit Arrangement Gas Turbine, Generator General Description Gas Turbine and Generator Major Components Support Systems Lube Oil Hydraulic and Control Cooling Water Cooling and Sealing Air Fuel(s) Starting Heating and Ventilation Fire Protection Generator Systems Control System Basic Control Functions and Operating Sequences Basic Protection Functions
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• • • -
Turbine Generator Operation Startup Operating Parameters Emergency Procedures Operator Responsibilities Data Logging and Evaluation Operating Limits and Required Operator Action on Various Annunciator Indications Unit Documentation Duration: Five (5) consecutive days in length, six (6) hours per day, exclusive of weekends and holidays. Textbook: Student textbooks will be supplied for fifteen (15) students and will be retained by the customer. Field Trips: Equipment walk around and panel familiarization will be dependent on equipment availability. Classroom: The customer is responsible for providing a classroom facility suitable for instructing fifteen (15) students. Language: English
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19.Aftermarket Services
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19.1 Services 19.1.1
Overview
From jet engines to power generation, financial services to plastics, and medical imaging to news and information, GE people worldwide are dedicated to turning imaginative ideas into leading products and services that help solve some of the world's toughest problems. As a major division of the GE Company, GE Energy provides reliable, efficient products, services and financing for the energy industry. We help businesses and authorities that generate, transmit or use electricity. We work in all areas of the energy industry including coal, oil, natural gas and nuclear energy, as well as renewable resources such as water and wind energy. GE Energy has a full portfolio of offerings to help its customers focus on their core business activities while we do the rest. Our LM6000 Services include: • • • • • • • • • • • • • • • • • •
Gas Turbine Parts Package Parts Power Turbine Parts Balance of Plant Parts and Services Tooling/Support Equipment Overhaul and Repair Services Conversions, Modifications, and Upgrades Rotable Exchange Programs New and Used Engine Sales and Exchanges Lease Pool Programs Field Services Engineering Services Remote Monitoring and Diagnostics Contractual Service Agreements Operation and Maintenance Agreements Training Programs and Video Tapes Technical Manuals Extended Warranty
19.2 Gas Turbine Parts 19.2.1
Overview
GE Energy Global Parts supports our customer needs for LM6000 Gas Turbine Parts via a worldwide parts network with a primary warehouse in Cincinnati, Ohio. Our Customer Account Managers are supported by engineering, configuration, planning and forecasting experts who are all committed to getting you the right part, to the right place, at the right time.
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Orders and Inquiries Office Hours: 8:00 AM - 5:00 PM EST Monday through Friday ph: 513-552-2000 fax: 513-552-5008 After-Hour Emergencies ph: 513-552-3272 ph: 877-432-3272 (Toll Free) All purchase orders and inquiries are to be directed to our spare parts sales organizations at: GE Aircraft Engines – Gas Turbine Spare Parts One Neumann Way, MD S133 Cincinnati, OH 45215-1988 U.S.A.. Attention: GE Energy Global Parts Sales
19.2.2
Parts Support
GE Energy Global Parts is committed to providing our customers with a total parts support package for every LM product line. With GE parts, you get more than just a part. You get the backing of our in-depth engineering design, operational, and total part-to-system experience. The underlying value is that each and every part is designed and supplied by GE with the goal to provide you, the customer, with optimal operating system performance. We are also upgrading our material solution offerings. Customer specific modifications/upgrades and improving our support are all examples of how GE Energy Global Parts is striving to be your source for the highest quality parts with the best delivery and service.
19.3 Package Parts 19.3.1
Overview
GE Energy Global Parts provides service to all aeroderivative package equipment owners and operators. Materials required for the operation of the Package are available through GE Energy Global Parts. •
Maintain specifications for all GE units produced.
•
Quotations for budgetary lists for new units are available through the sales group using your unit’s configuration. This is all done via a web based quotation program.
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•
In-house engineering resources to insure the material we supply is the correct material for your unit and application.
•
Exchange components to provide quick turnaround are available on a limited basis.
•
Requests for emergency material can be handled on a 7-day, 24-hour basis. (pager: 281267-9768)
Orders or quote requests can be sent direct to us at the numbers listed below or log onto the Internet at GEPartsEdge.com
19.3.2 • • • • • • • • • • • • • • • •
Package Components Supported
LM6000 Gas Turbine Spare Parts Generator Spares Control Systems Fire Equipment Vibration Systems GE Drive Systems Metal Scan Monitoring Systems Air, Fuel and Oil Hoses Air, Fuel and Oil Filters Overhaul and Field Maintenance Tools Fittings and Tubing Pumps for Fuel and Oil Valves – Solenoid and Manual Cables – RTD and Thermocouple Gauges – Pressure and Temperature Consumables
19.4 Power Turbine Parts 19.4.1
Overview
GE Energy Global Parts is a provider of spare parts in the power turbine industry. Our facility located in Houston, TX house the repair, refurbishment, and overhaul services. We work together as a team to provide your entire Power Turbine needs. Our global parts organization is prepared to assist you with all your spare part requirements. Please call your Customer Account Manager who will be available during our normal working hours of 8:00 am to 5:00 pm Monday through Friday, Central Standard Time. Service is our priority and we are dedicated to supporting your entire Power Turbine spare part needs.
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19.5 Tooling/Support Equipment 19.5.1
Overview
GE Structured Services, LP has supported engine products around the world for a quarter of a century. Our vision is “To be our customers One-Stop Shopping source, providing business solutions for a complete line of engines”. We support all tooling applications for aeroderivative engines, including industrial, power generation, marine and military.
19.5.2
Product Offerings
GE Structured Services offers a wide array of products used in the maintenance and operation of your GE gas turbine. Applications: Levels 1 and 2 are available for end users. Levels 3, 4, and 5 are available to authorized repair shops.
19.5.3
Products
Shipping containers, Maintenance tooling, Inspection and test equipment, Hand tools, Upgrade kits. In addition, by choosing GE Structured Services for your support equipment and tooling needs, you will receive the current OEM design. Our quality equipment allows for optimal safety conditions. Inquiries for support equipment and tooling should be directed to GE Structured Services, LP, or your GE Energy Services Team.
19.6 Overhaul and Repair Services 19.6.1
Overview
Overhaul and repair services are performed at our Service Center in Houston, Texas.
19.6.2
Parts
By choosing GE Energy as the overhaul provider the user is guaranteed that, when required, new original engine manufacturer parts are used. If a part can be repaired, the users can rest assured that the procedure used for the repair has been approved by GE Energy engineering. Many of the repairs were developed for use in the aviation industry and have been adapted for use in the industrial engine.
19.6.3
Service Bulletins
While the gas turbine is in the Service Center all pertinent service bulletins should be complied with. Compliance with service bulletins ensures the user that the latest technology available is being used.
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By taking advantage of the latest technology the user may be able to reduce the overall maintenance cost of operating a GE LM6000 product.
19.6.4
Cycle Reduction Initiative
GE Energy, through its Six Sigma quality program, is continually measuring both the internal and external processes that drive turn time. These processes include parts availability, repair technology, and customer reporting. The reduction in turn time can reduce then user’s cost of maintenance by reducing lease engine cost or downtime.
19.6.5
Testing
State of the art full power testing is available through the Service Center. Testing ensures the user that the overhaul or repair performed meets the GEK requirements and will meet or exceed all performance standards when put into service at the user’s site. The test is conducted in accordance with specifications of new production engines.
19.6.6 • • • • • • • • • • • •
Service Center Capabilities
Chemical and mechanical cleaning Non-destructive testing High speed rotor tip grind Coating and surface finishing Rotor build, balance and grind Weld shop and heat treat Machine shop and services Coordinate measuring center On-site test capability Gearbox shop, fuel systems, pneumatics shop Full inventory support Rotable support
19.7 Conversions, Modifications, and Upgrades 19.7.1
Overview
A conversion, modification or upgrade CM&U, is anything that improves the reliability, availability, maintainability, performance, efficiency, safety, or affects the configuration of the equipment. A CM&U can include the gas turbine engine, the package, and the balance-ofplant equipment. CM&U’s are available from GE Energy Services for GE and many non-GE aeroderivative gas turbine packages. The following list contains descriptions of many of our typical CM&U offerings, although new and customized upgrades are also available to suit
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individual needs. Please feel free to contact your GE Energy Services Sales Manager if you would like to discuss a potential CM&U for your operation.
19.7.2 • • • • • • • • • • • • • • • • • • • • •
Offerings
Liquid fuel treatment systems Reduced emissions (Wet) Water wash systems Anti-Icing systems (steam, electric, or gas fired water/glycol systems, or bleed air) Fire protection panel and halon to CO2 fire system upgrades HMI upgrades Fuel system upgrades Sensor upgrades Enhanced flow and speed upgrade STIG conversion Vibration system upgrades Inlet Filtration Systems Remote Monitoring and Diagnostics Lube Oil Chip Detectors MetalSCAN On-Line Oil Monitoring System Fuel Heating Systems Inlet Cooling/Heating Systems Dry Low Emissions (DLE) Upgrades Package Frequency Conversions Synchronous Condensors Control System Upgrade
19.8 Rotable Exchange Programs 19.8.1
Hot Section Exchange
GE Energy offers a package of hardware, tooling and labor to remove and install your LM6000 gas turbine engine and replace the Hot Section (HPT Rotor, Stage 1 and 2 Nozzle Assemblies) at a predetermined fixed price. Two GE field service representatives per shift will be provided for this work. This procedure can normally be accomplished in 1-3 days, thus eliminating the need for a lease engine, and sending the engine into the shop for repair. With the Aero Energy Hot Section Exchange, you get a fully balanced HPT rotor with factory established blade to shroud clearances to optimize performance. As with all of the Aero Energy Rotable EMUs, the Hot Section hardware carries a one year warranty. All returned EMUs are overhauled per GE specifications.
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The LM6000 Aeroderivative gas turbine is designed so that it is easy to replace major engine assemblies (also referred to as Engine Maintenance Units or EMUs) quickly to maximize gas turbine availability. GE Energy has developed a program that takes advantage of this engineering concept. In many cases, a Rotable EMU can be installed at the customer’s site eliminating the need to send the engine to a Service Center. The User benefits by on-site replacement of the EMU by eliminating the cost of using a lease engine and the second engine change-out if the damaged engine is sent to a Service Center for repair. GE Energy also has EMUs that are available to be used to shorten the time an engine is at a Service Center for repair. This reduces the cost of operating a lease engine (if installed) or can help expedite the return of the engine back to the site to meet a critical operating period. Removed EMUs (including Hot Sections) become the property of GE.
19.9 New and Used Engine Sales and Exchanges 19.9.1
Overview
GE Energy can offer both new and used LM6000 gas generators and gas turbines to customers that own or operate LM6000 gas turbine equipment. The new units are provided with a factory performance guarantee and carry a 1-year operation warranty. The used LM6000 gas generators or gas turbines offered have normally undergone a complete overhaul per GE specifications prior to availability for sale. These units also may carry a 1-year operational warranty. New and used units can be purchased outright, or purchased with the return of an existing LM6000 unit. GE Energy refers to this as our Engine Exchange Program. Through this program, a customer may trade the current unit in for the same model configuration or upgraded equipment for improvements in power and heat rate.
19.9.2 • • • • • • • • •
Customer Benefits
An estimated one-to-three day plant shutdown to complete the equivalent of an gas turbine overhaul program Elimination of spare gas engine lease usage fees One-time gas turbine change-out fees One-year new-gas turbine warranty New-engine output and heat rate factory performance guarantees New GE gas turbine technology Compliance with current service bulletins Fixed-cost transaction May reduce fuel and maintenance costs
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19.10 Lease Pool Programs 19.10.1
Overview
The GE Lease Program is designed to help customers minimize or reduce their overall life cycle costs and offers a low cost way for customers to maintain availability of their gas turbines. Customers can maximize site availability by leasing equipment from GE when their own equipment is at a Service Center for repair or when it cannot be repaired on site within a reasonable amount of time. Lease customers can continue operations to serve their customers and meet their business objectives. Lease assets are provided under either of two lease agreement concepts: Member or Non-member. GE has made the capital investment in these gas turbines and incurs costs for every operating and non-operating hour. Member and non-member rates and options are structured to reflect this.
19.10.2
Lease Engine Membership
A member agreement is a contract of six-year duration. It provides a guarantee of availability if the customer should need a lease gas turbine. The customer pays an annual membership fee and a weekly usage fee whenever a lease asset is installed at the customer site. Weekly fees are subject to Special Applications adjustments for liquid fuel operation, STIG, and SPRINT™ water injection applications.
19.10.3
Lease Engine Usage by Non-Members
A customer who has not opted for the six-year membership agreement may use a GE lease asset on a single event basis under the terms of a Non-member agreement. No guarantee of availability exists for non-member usage. An installation fee and a higher weekly charge apply to non-members. Non-member lease rates are calculated from the rates in the member tables. The weekly non-member rate is 3.5 times the weekly member rate, after any Special Applications adjustments. An installation charge applies to each usage plus actual transportation costs each way. Note: New customers who request a lease gas turbine within 45 days of executing a member lease agreement will be charged at non-member rates for that lease usage event.
19.11
Field Services
19.11.1
Overview
GE Energy Field Service is a world-class service and support network designed to anticipate and respond to our customers needs throughout the product life of GE LM6000 gas turbine and packages. The worldwide team supplies the highest quality parts, tools and support. This
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results in higher availability and lower costs for you, the customer. Please contact any one of our 10 regionally located offices around the world for any of your service needs, 24 hours a day, 7 days a week.
19.11.2
Offerings
GE Energy Field Service is dedicated to responding to your needs in an expedient manner. Aero Energy Field Service helps to minimize your downtime and provide a lower cost operation of by providing full technical coverage for your gas turbine and package. Our services include but are not limited to: Periodic Inspections of the gas turbine and package, Hot Sections, Generator Test and Inspection, Trim Balances, Vibration Surveys, Performance Testing, Controls Calibration, and all Level 1 and 2 Maintenance. In response to our customers’ requests for flexibility in commercial offerings, Aero Energy Field Services now provides the option for Firm Fixed pricing.
19.12
Engineering Services
19.12.1
Overview
Aero Energy Service Engineering provides engineering support to GE and non-GE industrial aeroderivative turbine products. A comprehensive Product Service Engineering and Conversion, Modification and Upgrades Engineering organization delivers field investigative support and product design, as well as engineered modifications to gas turbine, package and balance of plant equipment. In addition a New Product Introduction team develops engineered solutions for future upgrades. The combined service engineering groups of GE Energy support the product from factory shipment, through the course of service agreements and throughout the product life cycle.
19.12.2
Product Service Engineering
Full engineering services are available for owners and operators of GE and certain non-GE aeroderivative engines and packages. Services include operational reviews, data analysis, maintenance practices, fleet optimization, failure root cause analysis and other studies. GE Energy also provides a variety of field investigation services for industrial and marine products. Formal engineering studies are available.
19.12.3 Conversions, Modifications and Upgrades (CM&U) Engineering A range of standard upgrades and modifications are available (see Upgrade Services section) through the CM&U Engineering organization. Specialized engineering services are also offered to customers interested in package conversions. Upgrade kits covering a variety of gas turbine systems are available for each of the LM series of engines and certain non-GE
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aeroderivative engines and packages. In addition engineering services are available to support limited specialized upgrades. Contact Project Engineering to request an evaluation and quotation for required modifications.
19.12.4
Engineering Services
•
Hourly service support
•
Reliability, availability and maintainability improvement services
•
Unscheduled trips/outages reduction evaluation
•
Evaluation of gas turbine, package and BOP operational costs with the objective of improving site profitability
•
Hourly engineering service packages with CSA, RMD or CM&U/NPI
•
Engineering evaluation of gas turbine hardware service life with the objective of improving time between removals
•
On-site engineering specialty training for customer personnel
•
Detailed engineering failure investigation report to identify root cause
•
Engineering specialist for DLE operability, vibration, performance or emissions
•
Pre-start Operational Readiness Review (PSOR) of existing installations to identify operational problems
•
Analysis service of fuel, water, oil and emissions samples
19.13
Monitoring and Diagnostics Service
19.13.1
Overview
Monitoring and Diagnostics Service helps aeroderivative turbine plant operators improve availability, reliability, operating performance, and maintenance effectiveness. Monitoring key parameters by factory experts may lead to early warning of equipment problems and avoidance of expensive secondary damage. Diagnostic programs seek out emerging trends, prompting proactive intervention to avoid forced outages and extended downtime. The ability for GE engineers to view real-time operation accelerates troubleshooting and sometimes removes the need for service personnel to visit the plant.
19.13.2 • •
Product Features
On-Line Monitoring Accelerated Troubleshooting Support from Factory Experts
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• • •
Customer Notification Report Vibration Monitoring System Access to M&D Data
19.13.3 • • • •
Service Benefits
Possible Early Warning of Changing Conditions Proactive Recommendations for Action May Reduce Downtime Optional Features
19.14
Contractual Services Agreements
19.14.1
Overview
Utilities, independent power producers and oil and gas producers that own and operate gas turbines now have an easy way to get a handle on maintenance costs. GE Contractual Services Agreements (CSA’s) enable customers to get a full spectrum of maintenance options that takes the burden off of them, and allows them to focus on their core businesses.
19.14.2
Benefits to Customers
The benefits of GE CSA’s are numerous. For instance, a GE CSA can help keep equipment running properly, provide for reduced downtime, and lessen repair time. Also, depending on the type of CSA, the cost of maintenance can be uniformly distributed and easier to predict for the customer. GE CSA’s can be initiated at any time in the life of the equipment, but are most effective when started in conjunction with:
• • • • •
New engine purchases Upgrades Unscheduled engine replacements Engine exchanges Hot section exchanges or major overhauls
19.15 Operating and Maintenance Agreements 19.15.1
Overview
GE Energy’s Global O&M Services group is one of the world’s largest 3rd party providers of plant Operation and Maintenance services, currently with over 16,000 MW at 60 sites in 17 countries under O&M contract. Our global resources and experience base allow us to provide comprehensive services across the turbine island and balance of plant for both GE and nonGE equipment.
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With continuously evolving new technology, expertise and process improvements, GE Global O&M applies the latest cost-effective practices to ensure optimal economic performance.
19.15.2
Offerings
GE Global O&M offers a comprehensive suite of services to deliver maximum reliability, availability, and economy including:
•
•
•
Daily operation and maintenance of the plant
•
Complete plant staffing
Planned and unplanned maintenance services, including parts •
Local and remote monitoring and diagnostics
•
Comprehensive training
•
Environmental health and safety programs
•
Site documentation and procedure development
Site-specific computerized maintenance management software (CMMS) •
Switchgear maintenance and management
•
Power delivery
•
Fuel management
GE Global O&M follows a rigorous environmental health and safety program that is implemented at every plant where we provide O&M services. We are dedicated to providing a safe and secure environment for all GE and plant personnel on site. All of our O&M sites comply with local and government regulations as well as customer requirements and are held to our stringent company-wide environmental standards. Our ISO 9000-2000 Certified Quality Assurance Program combined with our Six Sigma methodology, places a premium on developing technology that improves the quality of our products and services while also meeting the expressed needs of the customer. GE Energy’s Global O&M services team helps ensure optimum performance at existing power plants as well as plants still in the planning stages. From initial project support to mobilization, through actual operation and maintenance, our highly trained specialists work with the customer to develop the ideal strategy for their particular site.
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With our worldwide inventory, manufacturing facilities, and global service centers, GE Energy has the expertise and ability to keep your plant running at peak performance.
19.16 Training Programs and Video Tapes 19.16.1
Overview
GE has developed comprehensive hands-on training classes to provide customers and authorized nonGE suppliers, Service Centers, and service providers the knowledge and ability to properly maintain their LM6000 gas turbines and package to ensure maximum availability and reliability.
• • • •
Classroom work with training manuals and video tapes Related hands-on disassembly and assembly tasks on LM6000 engines Led by experienced instructors Small class size
For more information, contact us for a Course Catalog and Class Schedule.
19.17 Technical Manuals 19.17.1
Overview
GE Energy Services supplies a complete set of technical manuals for the operation and maintenance of each aeroderivative gas turbine. Manuals are supplied with the gas turbine, but additional copies can be purchased on request. These are available to customers and authorized non-GE suppliers, Service Centers and service providers. Currently all manuals are published in printed format and most are available on CD version. Eventually all manuals will be published only in an electronic format.
19.18 Extended Warranty 19.18.1
Overview
The Extended Engine Warranty provides warranty coverage for months 13 through 24 from the initial startup of your gas turbine. •
Same thorough coverage as the standard New Engine Warranty
•
Provides for periodic inspection by GE Field Service representative
•
On-line support through Remote Monitoring and Diagnostics is available to customers until the end of initial New Engine Warranty.
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19.18.2 • • • •
Benefits
Protects your operation and investment Enhanced support by engine specialists Allows for early problem diagnosis Reduced risk of unscheduled maintenance costs
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