Start-Up in Steps Siemens V94.2 Gas Turbine at KAPCO

Start-up procedure for GT 1,2 Presented by: Fazal-ur-Rehman Babar Principal Engineer KAPCO Technical Training

Start up Step Wait Monit 1 0 10 s Commands

SLC Gen Auxiliaries SLC Oil Pumps SLC Jacking oil pump Emer bear oil pump SLC Turning gear SLC gen cooling water pumps Excitation Synchronizing Turning Gear valve Voltage Controller

on on on on off on on off close on

Ch. backs

All above commands feed back Press beh main oil pumps Main lube oil pump-1 Oil vapor extractor fan

ok >min (e.g. 3.5 bar) on on

Step Wait Monit 3 0 200 s

Commands Ch. back

HSD Shut off valve MBN10AA015 open HSD Shut off valve MBN10AA015 open

Step Wait Monit 4 0 4s

Commands

Lifting sol emerg trip Control oil pump Lube oil cool fans

energized on on

Ch. backs

Pr monit 1 trip act Pr governing oil

> min > min

Commands

Emergency bearing oil pump off SFC Frequency convertor prepare SLC Forw pps (if fuel oil selected) on

Ch. back

All above commands feed back

Step Wait Monit 2 0 8s

Step Wait Monit 5 4s 4s

ok

Step Wait Monit 6 0 5s

Commands

Ignition gas sol valve-1 BYP flush valve CCL/CCR

open close

Ch. backs

Pr ign gas beh sol valve-1 All air bleed/blow off valves

>min open

Commands

HSD forwarding pumps FO Start up pr limit valve FO Recirculation valve Shut down return valve Dosing system FO injection pump

on on pos to tank close on on

Commands Ch. back

FG globe/shut off vv CCL FG globe/shut off vv CCR FG line vent valve All above commands feed back

open open close ok

Commands

SFC (Breaker Close)

on

Commands

FO comb globe valve CCL FO comb globe valve CCR

open open

Ch. back

All above commands feed back Turbine speed

ok > 480 rpm

Commands

Ignition gas sol valve-2 SLC Turning gear Main lube oil pump-2

open on off

Ch. back

pr ign gas sol v-2 All above commands feed back

>min ok

Commands

Run-Up unit Solenoid valve FO ESV

raise open

Ch. back

FO ESV FO return shut off valve

>0% open

Commands

Run-Up unit Solenoid valve FG ESV

raise open

Ch. back

FG ESV

>0%

Fuel oil selected Step Wait Monit 7 60 s 60 s Fuel gas selected

Step Wait Monit 8 0 20 s

Step Wait Monit 9 0 40 s Fuel oil

Fuel gas

Step Wait Monit 10 0 40 s

Step Wait Monit 11 6s 6s Fuel oil

Fuel gas

Step Wait Monit 12 0 25 s

Step Wait Monit 13 0 10 s

Step Wait Monit 14 0 12 s

Commands Ch. back

Run-up unit

raise

Flame GTRB governor

on not fault

Step Wait Monit 15 0 30 s

Commands Ch. back

Run-up unit Ign gas sol valves 1&2 Turbine speed

raise close >900rpm

Step Wait Monit 16 0 170 s

Commands Ch. back

Run-up unit Turbine speed SFC

raise >2100 rpm off

Step Wait Monit 17 0 50 s

Commands Ch. back

Run-up unit Turbine speed

raise >2850 rpm

Step Wait Monit 18 5 s 5 s

Commands

Ch. back

Run-up unit Excitation Main lube oil pump-2 Emer bear oil pump Excitation

raise on off off on

Commands

Run-up unit

raise

Run-up unit Synchronizing Gen cool water fans # 1-4 Synchr breaker

raise on on on

Step Wait Monit 19 0 1s

Synchr breaker on

Step Wait Monit 20 0 200 s

Commands Ch. back

Step Wait Monit 21 2 s 2 s

Commands

Run-up unit Gen cool water fans # 5-8

raise on

Step Wait Monit 22 2 s 40 s

Commands

Run-up unit Unit Auxiliary

raise change over

Ch. back

Speed changer Run-up unit

100% open

Step Wait Monit 23 0 0

Start up sequence complete

Lube Oil System

Control System P & I Diagram of Control Oil

Oil from trip oil system at 9 bar Hydraulic Governor or Converter Orifice MBX 51 BP 021

Orifice MBX 51 BP 011

MBX 50 BY 001

Speed set point adjustor

MBX 51 BY 001

spring

Electric Signal from Electric Governor

Hydraulic Signal of Secondary Oil

EHC

MBX 61 CP 501

Actuator of Control Valve

Control Valve

MBX 61 AA 501

Turning Gear Rotor diaphragm

Secondary oil for Fuel Oil

Secondary oil for Fuel Gas

Drain MBV10BB001

MBX 51 BY 002 Run Up device MBX 61 CS 001

Governor Impeller

MBX 26 AA 051

MBX 52 CP 511

Lube oil system

MBX 26 AA 052

To trip oil system at over speed bolt MBX 21 BB 001 KA 04

Nitrogen filling

MBX 21 BB 001 MBX 21 BB 001 KA 03 MBX 21 AA 051 MBX 20 MBX 20 MBX 20 AA 501 AA 051 BT 001

MBV10 BB001

MBX 21 Control oil / AP 011 Booster oil pump

MBX 21 BP 001 MBX 21 BB 001 KA 01

MBX 25 BP 011

EHC for Fuel

MBX 52 Oil Control BY 011

MBX 52 AA 110 MBX 21 CP 011

MBX 21 AA 511 MBX 52 AA 321

Closing of Follow-up piston

Opening of Follow-up piston

Drain MBV10BB001

MBX 52 AA 120

Fuel oil control valve

MBX 25 BP 012 Drain MBV10BB001

MBX 52 CP 521

MBX 52 EHC for Fuel BY 021 Gas Control

Valve

MBX 52 BP 011

MBX 21 CP 511

Drain to lube oil tank

MBX 21 AA 301

Trip Oil System

MBX 25 BP 021

MBN 53 AA001

Valve

MBX 21 BB 001 KX 01

MBX 21 BB 001 KA 02

MBX 52 AA 512

MBN13 AA001 To FO ESV (See Trip oil drawing) Control oil

MBP 13 AA 002

Secondary oil MBX 52 BP 021

Primary oil

Fuel gas control valve

MBX 25 BP 022 Drain MBV10BB001

To Gas ESV (See Trip oil drawing)

MBP13 AA001

Fuel oil return (controlled) Fuel Gas

3.1-2000-0100

Thrust bearing trip

No Flame; Over speed Compressor surging Vibrations > limit Bearing Temperature High Turbine Temperature High Gas Turbine Trip Release Lube oil pressure low Start-up Operation: Shut down Program External Criteria Ignition Fuel Shut-off i.e. Step 54 i.e. Step 9 resp. 12

MBA 10 CG 011

GT Rotor

MBV10 BB001

MBX 22 AA 001

MBV10 BB001 Lube Oil Tank

MBN 13 AA 001

Overspeed bolts or Emergency governors

MBA 10 AA 010

MBX 23 AA 001

Pressure gauge

MBA 10 CG 001

MBX 35 CP 501

MBA 10 CG 002

Throttle valve

Test system for Overspeed MBX 35 Bolts AX 001

Closed Open

Solenoid valve remote trip MBV10 BB001 Lube Oil Tank

MBN 13 CP 401

MBX 41 AA 002

MBX 41 AA 001

Emergency MBX 41 push button GS 511

Change over valve

Hydraulic actuator for ESV

Automatic Trip Gear

MBX 41 GS 501

MBX 41 CP 501

MBX 41 AA 501

Self latch piston

MBV10 BB001 Lube Oil Tank

MBV10 BB001 Lube Oil Tank MBX 41 CP 001

FO ESV MBN13AA001

MBX 41 AA 301 MBX 41 CP 002

MBN 13 CP 402

MBN

Hydraulic actuator for ESV

MBP 13 AA 001

MBP 13 CP 401

MBN

MBX 41 AA 302

Solenoid valve for ESV

MBV10 BB001 Lube Oil Tank

MBP 13 AA 001A

MBP

MBP MBP 13

GAS ESV CP 402 MBP13AA001

Solenoid valve for ESV

MBV10 BB001 Lube Oil Tank

GT 1, 2 Safety & Protective Equipment P & I Diagram Trip Oil

3.1-4000-0100

1MBN13 AA003 FO filling valve

Drain to Leak oil tank

1MBN22 AA001 Glob valve CC right 1MBN22 AA002 Flushing valve

1MBN51 AA001 Return shut off valve

1MBN53 AA001 Return FO control valve 1MBN13 AA031

MBN12AA011 Startup Pressure limit valve

1MBN12 AA011 (Purging valve)

Pressure relief valve

1MBN20 AA002 Sol valve leakage line

GT 1, 2: FO Forwarding, Injection & Inhibitor Dosing system

1MBN21 AA001 Glob valve CC left 1MBN21 AA002 Flushing valve

1MBN13 AA001 (ESV) Emergency/FO Stop Valve

Thermometer

1MBN12 AA031 1MBN12 AA021

1MBN12 AP011 Fuel injection pump 1MBN11 AA001 Mixing chamber

1MBN55 AA001 Fuel recirculation valve

1EGC52 AP001

Leak oil tank

1MBN01 AP002 Low range pump

1MBN03 AP002 High range pump

1MBN70 AA015 FO shut‑off valve

AT002

1MBN60 AP002 Leak oil pump 1MBN60 AP001 Leak oil pump

Right Combustion Chamber Opens during flushing or FO operation 1EGD50 BR060 Furnace oil return to treated tanks

Dosing point

Fine Filters

M

Flow Monitor

Fuel oil return valve 7.0 bar 2.5 bar

1MBN73 AA001 Shut down return valve

1EGC51 AP001

HSD return line

1MBN55 AA003 1EGC52 AT001

Pressure relief valve

II

Open during HSD operation AT002 1EGD50 BR010 Furnace oil from treated tanks

heater

I

M

Left Combustion Chamber heater

1MBN70 AA017 BFO recirculation valve

1EGD50 BR030 To Injection Skid

1MBN10 AA015 HSD shut‑off valve

HSD incoming

1MBN01 AP001 Low range pump

1MBN00 BQ001 Inhibitor dosing storage tank

Drain to Leak oil tank 1EGC51 AT001

1MBN10 AA022 Isolating valve 1EGD50 BR040 Return Line from Injection Skid

1MBN03 AP001 High range pump

Inhibitor dosing incoming from FOTPs

1EKD20BP001 Gas Scrubber

1EKA20AA001

1EKA20AA201

To GT-1 1EKE10AA003

2EKD20BP001 Gas Scrubber

2EKE10AA002

1EKE20AA001

1EKD10AA002 Pressure reducer 1EKE10AT002 Gas Filter

2EKA20AA201

1EKE10AA004 1EKE10CF001 1EKE10AA007

1EKE10AA002

1EKE10AA005

2EKE10AA004 2EKE10CF001 2EKE10AA007 To GT-2

2EKD10AA002 Pressure reducer

2EKE10AA003

2EKE10AA005

2EKE10AT002 Gas Filter

GT 1,2: Fuel Gas Handling System (Off base) Gas Pressure Reducing, Filtering and Measuring Skid

MBP 15

AA 002 MBP 15

AA 001 MBP 21

AA 002

MBP 21 AA 001

AA 003

MBP14AA001

MBP13AA002 Gas Control Valve

MBP 21

1MBP21 AA001 Glob valve CC left

MBP13 CP003

Left Combustion Chamber

M

MBP 22

AA 002

Strainer Filter

MBP13AA001 Emergency Stop Valve

M

Orifice in body

AA 001 MBP 22

AA 003 MBP 13

AA 001A

GT 1,2 Gas System: On base

1MBP22 AA001 Glob valve CC right

MBP 22

Gas from off base system

Right Combustion Chamber

Control Signals

Motor Voltage detection

Link choke SFC breaker

1.3 mH

SFC Isolator external

SFC Isolator internal

Control Regulation

Excitation

11 KV 1.3 KV Excitation Transformer MKC 01 Mains Converter

Motor Converter

The Powerstage of the Start Up System

Main Step-up Transformer BAT 01

11 KV – 132 KV

SFC Supply Transformer MBJ 01

G S 04 5

132KV Circuit Breaker 132KV Bus Bar B G S 04 2 G S 04 4

132KV Bus Bar A

SFC; Static Frequency Converter

MBQ11 CP001

Ignition gas inlet MBQ11 AA022

MBQ11 AA021

MBQ11 AA031

Empty Cylinders

MBQ11 AA001

MBQ11 AA511

Filled Cylinders

MBQ11 CP002

1. Nozzle 2. Mixing tube 3. Ignition electrode 4. Ignition flame exit 5. Connector for igniter cable 6. Air Inlet 7. Ignition point

GT 1, 2 Propane Gas Supply as Ignition gas, gas circuit and ignition burner

132 KV Breakers