A.

2nd Field of Application/Use In the use of exhaust gas thermal energy, the gas turbine generator unit provides economical power supply to the base power range. This type of energy conversion is known as combined heat and power (CHP). The useful heat is contained exclusively in the exhaust gas, and namely in that for the waste heat and reasonably high temperature area. The unit thereby has special advantages, where, along with electrical energy, a correspondingly high grade heat requirement is to be covered. Depending on the utilisation of the exhaust gas temperature and the respective environmental conditions, electrical efficiency lies in the range of 30%, and fuel consumption efficiency in the range of 70% to 85%. Gas turbines work as shown in the following simplified process: Ambient air is drawn in and compressed in the compressor stages. Compressed air and fuel are ignited in the combustion chamber. The resulting volume of hot gas is directed to the turbine stages. Through the inclination of the turbine blades, the volume of hot gas is directed in a particular direction, causing the turbine wheel to rotate. This rotating movement is carried from the turbine rotor to the gear. With the necessary gear ratio of the gear, a rotational speed is created, which is converted by the generator into an electrically useful rotational frequency.

r"

Rough schematic sketches of a gas turbine generator unit The gas turbine is an industrial gas turbine, built as an single-shaft engine, in accordance with the open loop principle and a practically constant output speed. This gas turbine was developed exclusively for the drive mechanism of power generation. Power generation: A KAWASAKI gas turbine generator unit is mainly used for power generation. Waste heat utilisation The arising thermal energy of the turbine exhaust gases is used in many different ways. This therrqal energy is mainly converted into: Process steam, which is used, for example, in the paper industry for drying purposes.

Hot water, which is used in heating networks. Cold water generation through absorption freezing machines.

Operating condition The normal operating condition of the gas turbine generator unit is largely network-parallel. Isolated operation is occasionally possible and in emergency situations. The gas turbine generator unit is designed for operating in automatic mode. During normal operation, the gas turbine generator will be remotely monitored. Handling of the machine technology within the sound enclosure during normal operation of the gas turbine generator unit is not necessary.

All other or abnormal application and use of the gas turbine generator unit is not permitted. Kawasaki Gas Turbine Europe GmbH accepts no liability for damage to persons or material!

B Safety
B. 1 KAWASAKI safety concept (protection from explosions) Due to the high quality and safety standards at KAWASAKI, the concept for the gas turbine generator unit has been in reliable use for years. KAWASAKI takes precautions to prevent danger from arising, monitors the installationconstantly and has also installed safety measures to eliminate danger. > In addition, an inspection was carried out in accordance with the ATEX Directive 94/9EC and concludes with an evaluating description. This separate safety concept can be seen at KGE on request, (document no.: EFR3389-091214)

B.

3 Warning systems The gas turbine generator unit GPB80D has its own gas warning and fire detection system.The Gas Turbine Generator Unit GPB80D has its own gas warning and fire detection system. Rotating beacon gas (yellow) Rotating beacon fire (red)

Image 1 Exampl e

Gas warning system

Fire detection system

Image 2

WARNING FIRE ALARM ACOUSTIC

&

OPTIC

\I/ n'

WARNING FIRE EXTINGUISHING ACOUSTIC ffl

&

OPTIC

% i /n

WARNING GAS ALARM ACOUSTIC OPTIC

&

DANGER
Extinguishing process with C02 (carbon dioxide). The noise enclosure is to be vacated immediately and the door to be kept closed. C02 can be detected by a slight lemon smell. Opening the door is then only possible following intensive ventilation and approval by the fire service.

C Equipment Description
The system description for all components is arranged as follows: - Description included in the register: - Drawing - Parts list and finally the manufacturer's documentation: - Datasheets C.1 Description The gas turbine generator described here is a GPB80D unit. The model GPB80DDual-Fuel (# 3044 Bacau) is described as follows.

Gas Turbine Power Base which comprises a complete gas turbine generator unit. In this case, no adjacent exhaust system (vessel) is delivered by KAWASAKI Gas

A gas turbine generator unit GPB80 with gas turbine model M7A-03 and an electrical current of approx. 7,500 kWe.

Is the most modern form of combustion technology and means Dry Low Emission. Using this technology, the currently required exhaust gas values for NOx and C02 are reached. As no water or steam spraying is necessary here, one talks of "Dry" (dry combustion).

Turbine Europe GmbH.

The Gas Turbine Generator Unit GPB80 consists of the following main components (unit parts which are not included in the standard configuration will be marked as "part of delivery" or "not part of delivery"!) I. Noise enclosure 1.1 Gas turbine 1.2 Gear 1.3 Coupling 1.4 Generator 1.5 Base frames 1.6 Auxiliary system 1.7 Air pressure system, exhaust system, motors 1.8 Gas warning and fire extinguishing systems 1.9 Noise enclosure, cooling and combustion air system

II. Power house (sound enclosure) 1.10 Electrical control system 1.11 Circuit diagrams III. Filter house and air ducts 1.12 Air ducts 1.13 Filter house (not including technical room) IV. Gas compressor (ELTACON (NL) (#3044 Bacau) V. Vessel (this time, not part of KGE delivery)

In detail, the unit components are fitted with the following subcomponents: Noise enclosure This includes the basic frame and its components. Base frames with installed components, such as: Gas turbine Gear* Generator Lube oil system Air pressure system Fuel system

Filter house the following components are included in the installation on the noise enclosure: Cool air filter for the noise enclosure Cool air entry ventilators Cool air entry blinds Cool air entry sound absorbers Combustion air filter Combustion air sound absorbers Cool air exit blinds Cool air exit ventilators Cool air exit sound absorbers Technical room with: C02 fire extinguishers Oil mist separator Oil cooler Control cabinet house installed on the side of the noise enclosure facing the generator and includes the following systems: Turbine control Feeder Central fire alarm system with gas warning system Frequency converter for the starter motor

As a standard, KGE provides the control cabinet house with a control system. There is, however, the possibility to install individual fields. This mostly occurs for reasons of space'and at the special request of the customer.

C.2 Gas turbine Description Manufacturer: KAWASAKI Heavy Industries, Ltd. Japan Type: M7A-03D As a heavy duty industrial gas turbine, the gas turbine M7A-03D is specially designed for continuous use in CHP units and works in a simple open cycle. As a single-shaft unit for the generator drive, compressors and turbines are fixed to a common shaft. Technical data about the Gas Turbine M7A-Q3D (#3044 Bacau) and its installation conditions Installation height: Suction pressure loss: Exhaust gas pressure loss: Suction air temperature Generator efficiency: Fuel: Heating value: Terminal power Fuel Consumption: Air intake: Exhaust gas temperature Exhaust mass flow: Compression ratio: Rotating speed (gas turbine): 184 m (Anlage 1 der Generatorbestellung) 10 mbar, 30 mbar, *9C *97,5% (100%, Cos Phi 0,8) *EGT approx. 489 C (20C) *25,98 kg/s (-3%) 15.9 13,790 rpm (50 Hz)

The gas turbine-specific description is shown in the following table: Gas turbine type: Compressor Combustion chambers Turbine, power section Bearings Single-shaft machine, open, simple cycle Axial compressor, 11 stages 6 combustion chambers Axial flow through, 4 stages Compressor side: No. 1 Axial bearings 2 levels No. 1 Radial bearings Turbine side: No. 2 Axial bearings All bearings are designed as sleeve bearing versions with external lubrication via the lube oil system. Coupling to gear Dimensions Weight Diaphragm coupling L x B x H : 4.780 x 1.460 (1.900 with manifolf) x 1.702 mm 6,300 kg

Gas turbine sound level Frequency, 63 125 Hz

250

500

1000

2000

4000

8000

Sound pressure level dB(A), 2m distance from the suction opening 80 84 92 98 100 104 110 102

Sound pressure level dB(A), 1 m distance from the exhaust flanges 90 102 114 116 114 112 108 104

Sound pressure level dB(A), 1 m distance from the turbine housing 70 86 88 92 96 100 104 98

Main components Air inlet housing 11 -stage axial compressor with variable stator vane (VSV) of the first 3 stages in the compressor 6 single-pot combustion chambers with primary fuel nozzles, secondary burners and 2 DLE ignition plugs DLE ignition plugs Gas turbine housing 4-stage axial turbine 2 sleeve bearings, 1 thrust bearing Lube oil system Fuel system Compressor washing system Exhaust gas diffuser Control system Monitoring system

Image 6 Example

The turbine housing is constructed in individual sections and consists of the suction house, the Bellmouth, the compressor housing, the turbine housing and the exhaust gas diffuser. The housing parts are connected to each other in an airtight manner, but can be dismantled individually. The bearing seat and main blade is installed in the air suction housing and exhaust gas diffuser. The bearings in the air suction housing is marked as "cold bearings" with "bearings #1"; the bearings in the exhaust gas diffuser as "hot bearings" in "bearings #2". Each turbine wheel is designed with gears so that all wheels are connected to each other. Bolts are also used as additional fixing. The compressor wheels are coupled with the turbine wheels using a rigid clutch. The torque is transferred over this coupling.

The "Power Section" consists of three main components. A. Compressor

B. Combustion chamber system C. Turbine

Image 7

Compressor The compressor draws in ambient air and compresses it for operating the gas turbine. To achieve a high level of efficiency, an axial compressor was selected. The compressor rotor segments consist of several wheels, which are welded together using an electron beam method. The compressor has 11 stage rotor blades (on the rotor) and 11 stage guide vanes, as well as inlet guide vanes (IGV) and outlet guide vanes (OGV). The suctioned air is accelerated through the Bellmouth and directed to the IGV's. The first four stages (including IGV) are adjustable (VSV system), in order to achieve a high level of efficiency and to avoid flow separation during the start-up procedure. The air is compressed in stages, reaching a pressure of approx 1.2 MPa (12 bar) at a compression ratio of 15.9:1 resulting in:

Image 8

Combustion chambers The 6 combustion chambers are arranged over external, concentric distribution pipes and supplied with fuel. Each of the six combustion chambers consists of a transition duct and the actual combustion chamber. The combustion chambers are conical, point backwards and are arranged on the turbine surface. A large part of the compressed air is fed between the combustion chamber and the combustion chamber housing for cooling purposes. The remaining part is fed into the combustion chamber and burned as a gas mixture. It is then fed into the gas turbine.

Each combustion chamber has a fuel nozzle system, over which the different load conditions of the gas turbine can be achieved. Image 9 shows an example of the nozzle of a combustion chamber.

Combustion chambers 2 and 3 are both fitted with an ignition plug, which ignites the fuel at start-up. To transfer the flames in the adjacent combustion chambers, they are connected by a flame transfer tube (not No. 5 and 6). Combustion chambers 5 and 6, which are last in the firing order, are fitted with flame detectors. The flame detectors inform the operator about the control of the gas turbine, as to whether ignition is completed.

Turbine The guide tube directs the hot, high-pressure combustion gases to the first baffle plate of the first turbine level. In the 4 axial turbine levels, the energy of the gaseous medium is converted into torque by releasing the approximate ambient pressure. When leaving the turbine, the gases have significantly lower pressure and a lower temperature (approx. 550 C, depending on the ambient conditions). The exhaust gas diffuser stops the flow of exhaust gas, which is then fed over the connected bellows expansion joint and through the exhaust gas pipe and out of the turbine.

Thermal expansion of the gas turbine. Temperature distribution Image 11 shows the thermal expansion of the gas turbine under nominal conditions. The vertical movement is very slight (under 0.7 mm) and can be ignored. On the contrary, the horizontal length variations are not to be ignored. The exhaust flange shifts about 10.2 mm across the length of the gas turbine. These data are to be considered when designing exhaust gas expansion joints and other piping. When using the exhaust gas expansion joints provided by Kawasaki inside the noise enclosure, these thermal length changes are worked in. The image also hows the temperature distribution of the gas turbine under the same conditions. These data are important for the design of cooling, ventilation and heat protection.

Sensors The gas turbine has several sensors for the following functional areas: Control: The sensor signal serves the turbine control. Safety: To guarantee safe turbine operation, an alarm and emergency shut-down system is integrated. The turbine control monitors the sensor signals and triggers an alarm or shut-down signal if the sensor signal lies outside the intended range. The layout of the sensors is shown in image 29.

2 3 5 6 8 9 10

Vibration pick-up Bearing #1 Vibration pick-up Bearing #2 Temperature Sleeve bearing #1 Temperature Thrust bearing #1 Delta P measuring device CDT Sensor Exhaust back pressure

11 12 13 14 33 35

Flame detector Revolution Revolution Exhaust gas temperature CDP Sensor VSV-gage
15.11.2012

Nozzle guide C.3 Gear Box Description

N-155

KM-S402

The reduction gear is primarily for reducing the gas turbine wave velocity from 13,790 rpm to the generator-required 1,500 rpm. In addition, connections for the auxiliary drives, such as lube oil pumps and starter motors are integrated with relevant overhaul clutches.

Technical details Input speed Output speed Overspeed Max. peak torque Max. constant load Gear type Operating conditions Lubrication

Lifespan Efficiency Scope of delivery:

Total weight 13.790 1/min 1,500 1/min 111% for 2 minutes 400% of constant load 9,0 KW Planetary gear Continuous operation ~ 2.0 bar under pressure 250 l/min +/- 40 l/min. 30 - 50C oil temperature, Supply from the gas turbine oil tank Gas turbine 32.000 hours 98% 6,800 kg

Description

Amount

Planetary gear fitted with: - Lube oil pump (MLOP) - Starter/Turning unit Specification: The generator specification depends on the gas turbine application. The manufacturer's operating manual of the gear is listed under "Manufacturer and Supplier Documentation".

Couplings Description The gear is connected over two diaphragm couplings as torsionally elastic connections for compensation for misalignment and for torsional damping. As a diaphragm coupling, the clutch is small and lightweight, which offers advantages in installation and maintenance work. To avoid risk of accident, both clutches are equipped with perforated sheeting (see C.7 "speed measurement"). Manufacturer: KAWASAKI Heavy Industries, Ltd. Japan The high-speed coupling provides a direct connection to the output end of the gas turbine.

The iow-speed coupling is between the gear-box and the generator. This clutch is fitted as a safety clutch for the connection from the gear and generator to the bolts to protect against overload of the unit, and also against short-circuits during synchronisation and network failure.

Image 16

The generator has the primary function of power generation. C.4 Generator Description A further function is the connection of the auxiliary drives, such as the main lube oil pump, starter / turner motor etc.

Image 19

Technical details (according to Lieferschein) Type: 6,300 V Speed 50 Hz Synchronous Nominal output 0.8 Voltage Frequency Power IP23 factor IP23 Protection class generator IC0A1 Protection class terminal Brushless boxes AREP Cooling 1x 500 W under 230 V Stimulation 17.0 kg Control type: Heating during stop Total weight LSA56 BMBL130 4p 1,500 1/min Rotary current 10,111 kVA (15C) H/F

C.5 Base frame Description The machine base is used for integrating and fastening the gas turbines, gears and required auxiliary systems. Construction: KAWASAKI Gas Turbine Europe GmbH Manufacturer: LindenbergAnlagen GmbH In detail, this consists of: Rigid hollow-section frame and steel profile Mounting plates and elements Elastic turbine connections and tube connections Oil tank integrated between the side rails Elastic mounting of the base frame on the foundation

Image 20

C.6 Speed measurement

Description The speed measurements (three measurements) provide constant control of the turbine and connection to the generator. Differences in the rotational speed are registered here and are initiated in the event of a shut-down, in order to avoid damage. Precisely in the lowspeed clutch, the predetermined breaking point (shear pins) is monitored, in order to shut down in the event of a disconnection between the generator and turbine. In detail, this consists of: Sensors (1x to the low-speed coupling, 2x to the turbine indirectly over the vibration measurement) Evaluation (in the control station)

C.7 Auxiliary System Description All required auxiliary and monitoring systems are available for operating the gas turbine generator unit.

Image 21

Example

In detail, these are: Lube oil system for fully installed gas turbines, gears and generators consists of: Oil sump, 2,000 I with level monitoring, Pump for filling Oil - water cooler Oil mist separators Oil mist separators separate oil vapours which are in the gear and oil sump, and return the captured oil. The fitting of the filter unit guarantees separation of very high concentrations of oil vapour. Concentrations of oil vapour The relevant negative pressure in the oil tank is obtained by tuning the device. The exhaust gas flows through the device where dirt particles are filtered out. Main oil pump, driven mechanically from the gear. Pre-/post lube pump, 3 bar, with an AC motor, 400 VAC, 2.2 kW Emergency oil pump, 1 bar, with DC motor, 24 V DC, 0.4 KW Double filter, switchable with differential pressure monitoring Different armature filters Thermostat/pressure control valves Pressure and temperature switches Manometer, thermometer Hose line, piping for internal distribution in high-grade steel Technical details of the lube oil system Lube oil Heat removal Oil amount Circulation Oil pressure Operating temperature Consumption The ISO VG 46, mineral oil with additives -220 kW ca. 2,000 I ca. 530 l/min ca. 1.5 - 2.0 bar (g) 30 - 50C ca. 0.5 l/h (when using oil mist separator approx. 1.5 l/day) corresponding safety data sheet for the above-mentioned lube oil is available under "oils, lubricants and other liquids".

Fuel system: Gas fuel and Liquid fuel (#3044 Bacau) The gas turbine is fitted as a DLE variant with a natural gas fuel system. The fuel control system enables monitoring and control of all required operating conditions, such as start up, different accelerating and load conditions from zero to full load Natural gas fuel and liquid fuel system, consisting of: Natural gas main filter and Liquid fuel double sided main filter Gas-fuel:Main shut-off valve combination (2 each valves), with ventilation and open close feedback-position system, DVGW approved / Liquid fuel: Main shut-off valve combination with ventilation, (2 each valves) / with ventilation and open close feedback-position system Filling gas valve, DVGW permitted Gas leakage detector, DVGW permitted and Oil leakage detector Natural gas control valve and DLE control valve and liquid fuel control valves Natural gas and liquid fuel distributor rings Multi-burner unit, controlled by air pressure Safety gas purge valve (NO), (NO = normally open function) Pressure monitoring with switches and manometers Flexible tubes High-grade stainless steel pipings from the base frame connection to the gas turbine The approved fuel is natural gas H (with methane as its main component) which is delivered controlled, filtered, dry and clean and with the necessary supply pressure. Fuel: Natural gas H (physical properties calculated according to DIN 51817), filtered, clean and dry Filtering: < 10 |jm with steam trap Temperature: -20....+65C (at least 50C above dew point and free from steam at the interconnection point Pressure: 22 bar (g) +/- 0,3 bar (g) (at the interconnection point of the noise enclosure) Gas composition (requested min. standard values) Natural gas H LHV 10,034 kWh/m3 Sulphur content: max. 0.1 % wt X LHV (kJ/kg)/43,116 Impurities < 10pm, max. 30 ppm x LHV(kJ/kg)/43,116 No liquid components or hydrocarbon which can be condensed Starter motor As as starting help for a speed of 0-70%, a three-phase current squirrel cage rotor is used. A robust frequency converter for high output drives, which is suitable for different industrial operating environments, enables the management and control. IGBT and DTC technology is integrated for low-loss control of the three-phase current squirrel cage rotor motors. Turning gear After shutting down the gas turbine, this must be turned at low speed in order to avoid warpage

of the blade from different cooling in the gas turbine. For this, the aforementioned starter motor is used. Air pressure supply Pressure 6...7 bar (g); min. 5bar (g) Total air pressure requirement during: ~ 200 Nm3/h of the start/stop procedure Consumption during: ~ 50 Nm3/h of operation Quality: Instrument air, oil-free, dried and filtered Start-bleed system This system is used during the start up procedure. Here, compressed air is blown from the gas turbine compressor over a flap valve into the exhaust system, in order to avoid flow separation in the gas turbine compressor. Bleed-system to DLE control During partial load operation of the gas turbine, too much ambient air is drawn in and compressed by the turbine compressor. Due to the combustion-related procedures within the gas turbine, and the excess air, the required exhaust gas values can be exceeded. For this reason, not only the fuel is regulated during partial load operation, but also part of the compressor air which is determined in the combustion chamber is fed directly into the exhaust gas duct. Electrical components, control and monitoring equipment To operate the gas turbine and to monitor it during operation, additional sensors are installed in the gas turbine. Control and recording of the measuring signals takes place in one of the terminal boxes which are built into the gas turbine: Ignition coils, ignition plugs, 2 pcs Flame detectors with evaluation module, 2 pcs CDT (Compressor Discharge Temperature) sensor Outlet temperature sensor CDP (Compressor Discharge Pressure) sensor Speed sensors, 3 pcs with monitor

Vibration sensor and monitors, 2 pcs each for the gas turbine, the gear and the generator. Thermal elements for monitoring the exhaust gas temperature, 12 pcs with display Resistance thermometer PT100 Compressor-cleaning equipment To maintain the effectiveness of the gas turbine and to avoid erosion/corrosion on the compressor blades, the gas turbine is fitted with a compressor cleaning device. This separate component consists of: a storage tank, a pump unit and a connecting hose to the gas turbine. The cold wash procedure is carried out when the machine is switched off. Fluid amount: 191 per wash Cleaning agent: Clean water/cleaning agent in a ratio of 4:1.

Description The lube oil system of the gas turbine generator unit largely consists of the following main components: Main lube oil pump (MLOP) Oil cooler Thermostatic valve Main oil filter Oil pressure controller Oil mist separator Oil tank Lube oil Pre-/post-lube pump (PPLOP) with AC motor 3 bar, 400 VAC 2.2 kW Emergency lube oil pump (ELOP) withDC motor 1 bar, 24 V DC 0.25kW Double filter, switchablewith differentialpressure monitoring Oil mist separator with side channelblowers, 400 VAC, 1.5 kW different armature filters Pressure and temperature switches Manometer, thermometer Hose line, piping for internal distribution in high-grade steel Tank heating, 400 VAC, 5 kW

The purpose of the lube oil system is the: Lubrication of the turbine As the turbine is operated at high speeds and temperatures, a wellfunctioning lubrication system is particularly important, in order to ensure correct functionality of the entire system. The bearings are lubricated with different parameters, during and after operation of the gas turbine. The data are summarised in the following table.

Bearings

Operation

Pre-/post-lubri cation

Emergency Post-lubrication

Filtering

No. #1 Axial bearings No. #1 Radial bearings No. #1 Axial bearings No. #2 Axial bearings

Over Volume pressure flow 0.98 bar 25 l/min

Over pressure 0.98.. 2.94 bar

Volume Over flow pressure 12 l/min

Volum e flow

10 pm nom.

0.98 bar

> 49 l/min

0.98.. 2.94 bar

> 22 l/min

0.98 bar

22 l/min

0.98.. 2.94 bar

> 10 l/min

0.98 bar

> 35 l/min

0.98.. 2.94 bar

2> 16 l/min 0.98 bar

10 l/min

All values mentioned above are approximate, and are inc commissioning. Gear and generator lubrication

ividually se

during

The lube oil system supplies the lube oil not only to the gas turbine, but also to the gear and generator bearings. The amount of lube oil for the gear is summarised in the following table: Reduction gear Overpressure 1.47 bar Operation Volume flow >214 l/min Filtering 10 pm nom.

The amount of lube oil for the generator depends on its size and manufacturer. For this, the lube oil system provides a volume of 501/min with a positive pressure of 1.5 bar. The manufacturer-specific data can be set using a pressure reducer and a flow metre.

System description The gas turbine lube oil system consists of the oil tank, pumps, filters, oil coolers and other devices for controlling the required components. A good description and presentation of the components is available in the respective datasheets. The lube oil is drawn in from the oil tank, over a check valve and dirt trap, and compressed at a constant pressure of 5 bar. The constant pressure of 5 bar is set using an internal pressure control valve, in order to protect other components. A thermostat regulates the oil feed in accordance with the oil temperature. Cold lube oil is fed directly in to the circulation, from the lube oil cooler over a bypass. From a temperature of about 30C, the thermostat valve is activated, so that a partial flow can first be directed over the oil cooler. Depending on the temperature, the thermostat opens or closes and maintains a lube oil temperature of about 40C. After this, the lube oil is fed from the cooler through a switchable double filter * (10 pm), which secures the required oil purity. After the double filter, the lube oil is distributed in the respective lube oil volumes and temperatures. A secondary exhaust gas valve regulates the pressure of the lube oil at 1.5 bar. A partial flow of 131 l/min is set over an aperture, for lubrication and cooling bearings #1 and #2. The remaining lube oil (approx. 398 l/min) is fed to the gear and generator. The relevant measuring points for the thermometers, pressure sensors and pressure switches are integrated into the oil system. The respective data are hereby monitored during the start-up procedure and operation, and relevant measures are taken. All feed points for lube oil in the gas turbine generator unit are fitted with a return pipe. The lube oil is thereby transported back to the tank, where the flow is steadied and gas bubbles are eliminated. Similarly, oil mist, which arises from torsion in the bearing seals, is fed over a pipe in the oil tank and cleaned in an oil mist separator.

Image 22

(imiti Technical details Type: Gear pump Output 570 Liters / min Nominal pressure 0.5 MPa Speed: 1,141 rpm Installation location: flange mounted on the gear

Oil cooler

Image 23 (Exampl e

Image 24

niiHi)
Document 1 Page 56 of 208 11.02.2010

Technical details Type: screwed plate heat exchangers Water volume: 24 m3/h Water temperature on: max. 32 C(# 3044 Bacau) Water temperature off: approx. 42 C Pressure loss water 33 kPa Oil volume: 34.20 m3/h Oil temperature on: 60 C Oil temperature off: 40 C Pressure loss oil 46 kPa Designed heat-power: 324 kW Installation location: in the technical room of the filter house

NOTE
The power dissipation, which is fed over the lube oil has the following values: for the gas turbine: approx. 70 kW, for the gear: approx. 130 kW

Thermostatic valve for regulating the lube oil temperature

Thermostatic valve

The thermostatic valve starts to open at approx. 27 - 30 C, and reaches a mixed oil temperature whereby more and more lube oil is fed over the lube oil cooler. Before the automatic thermostatic valve starts opening, the lube oil flows into the cycle, and thus not over the oil/water cooler. Should the spring-loaded function be faulty, the thermostatic valve can also be manually engaged. Options: Completely "open" or completely "closed"

Main oil filter Main lube oil filter, switchable, for permanent filtering of the lube oil. Main lube oil filter

(Example)

The main lube oil filter is fitted with a double filter and can be switched off while the turbine is running. BUT: It should be noted that the filter which is not yet used must first be slowly filled with lube-oil and simultaneously ventilated before final switching. Details can be found in the manufacturer and supplier documentation. Main lube oil pressure controller, adjustable (is adjusted during the IBS) Controls the main lube oil pressure in the system for the gas turbine, gear and generator.

Image 28

Technical details Configured lube oil pressure: approx. 2 bar (g) Outflow volume in control range: approx. 173 +/- 40 l/min Site of assembly: on the base frames

Oil mist separator The oil mist separator is responsible for drawing oil mist out of the lube oil tank, and separating the air from the oil. After filtering, the air is directed in this case over the roof and into the open air. The separated oil is fed back into the lube oil tank. All oil drains and oil vapour openings are then attached to the gas turbine using light suction pressure, taken from the negative pressure from the oil mist separator in the lube oil tank. In this way, the retention time of the lube oil inside the gas turbine is reduced, although leakages rarely occur. Clean air pipe, (is directed over the roof) Filter housing Technical details approx. approx. 5 approx. approx. 10 mbar Residual oil content: 20 mg I Nm3 Exhaust air volume: Bleed air intake Nm3/min Negative pressure: 15 mbar Negative pressure: 10 mbar configured Vacuum switch: approx. Oil mist suction pipe (from tank) configured Installation location: In technical room of the house

the filter

Oil tank Tank capacity The internal capacity of the lube oil tank is ~2,2 m3, the filling quantity of the first filling is 2,000 Liters. Lube oil tank equipment Lube oil level display: This enables the lube oil to be checked from outside the package. The lower limit is the lower part of the suction opening of the pump. The upper limit is established by the volume of oil. Lube oil level switch for external alerts of the oil tank content. Suction side dirt traps for the mechanical main lube oil pump, electrical auxiliary pump and control oil pump. Lube oil tank heating and temperature sensor. When the gas turbine is stopped, the lube oil temperature should be regulated at approx. 10C. Should the lube oil temperature fall below 10C, the the lube oil tank heating is switched on via the lube oil temperature switch, so that the lube oil is warmed up. The heating system is turned off when the oil temperature has reached ~15C. Oil mist separator: This separates the oil vapours in the gear and oil sump, and feeds the oil which has been captured from the oil mist back into the tank. This recirculation reduces oil consumption, while the clean air from the oil can be emitted into the environment. Oil mist is suctioned from the tank and its connected systems by a ventilator with an air inlet, in order to establish a certain vacuum in the system. This vacuum prevents oil leakages into the bearing sealings of the gas turbine and the gear. Negative pressure inside the oil tank must be kept at -100 mmWC. At 5m3/min, the ventilator capacity should have a negative pressure of -100 mmWC. A tank filling pump is provided for filling and emptying the lube oil tank; its relevant function can be selected using a 3-way valve.

C.8 Fuel system Description Requirements of gaseous fuels. 1. Gas temperature -20C to +65 C 2. Lower heating value (LHV) 3. Sulphur content 33,500 to 41,860 kJ/Nm3 9.31 to 11.64 kWh/Nm3 0.5% weight x LHV (in kJ/kg)/43,116, only for the gas turbine 0.1 % weight x LHV (in kJ/kg)/43,116, only for gas turbines with waste heat boilers ^ 30 ppm x LHV (in kJ/kg)/43,116, 10 pm 0%

4. Foreign objects, total 5. Particle diameter 6. Water and liquid hydrocarbon

The gas must be provided dried, filtered and oil-free. The natural gas system is fully integrated into the base frame of the gas turbine generator unit and complies with the relevant standards and regulations. The natural gas system inside the gas turbine system generator largely consists of the following main elements:

Natural gas main filter 2x safety shut-down valves 1/2 with interim ventilation Safety blow-off valve (Start gas) Natural gas control valve and DLE control valve Natural gas distributor ring Natural gas - injectors

HK Kawasaki
Installation of the Gas-/ & Liquid-fuel system (# 3044 Bacau) The gas turbine is designed as a DLE variant with a single fuel system. The fuel control system enables monitoring and control of all required operating conditions, such as start-up, different accelerating and power conditions from zero to full power. (see P&ID E3029 080 102 and E3029 080 103)

Before each start, a control of the leak-tightness is carried out over a valve combination. By using the pressure controllers for monitoring the fuel pressure, in the event of leakage or too low pressure, a start-up is prevented (it is not possible to operate the gas turbine with gas fuel). During operation, the configured speed is maintained using a speed control circuit. The actual value signal comes from one of the magnetic encoders which are mounted on the turbine blades. The main components of the Gas fuel system are: Switchable double-filter-unit Safety shut-off valve combination, DVGW permitted, with position feedback system Safety ventilation valve, DVGW permitted, with position feedback system Gas Leakage detector, DVGW permitted Gas measurement valve (main gas fuel governor) Multi-burner unit, air pressure controlled Parallel ring piping 6 each fuel chambers with nozzles Pressure monitoring with switches and manometers Gas fuel flexible tubes Piping from the connecting flanges on the base frame to the gas turbine in stainless steel.

The approved fuel is natural gas H (with methane as its main component), which is delivered controlled, dry and clean, and with the necessary supply pressure. A main manually operated shut-off valve is fitted in front of the entrance to the gas turbine generator unit.

The main components of the Liquid Fuel system (# 3044 Bacau) are: Switchable double-filter-unit Double Safety shut-off valve combination, with position feedback system Safety ventilation valve, DVGW permitted, with position feedback system Liquid fuel Leakage detector Liquid fuel, high-fuel pressure unit, (installed inside of liquid fuel module) Liquid fuel ,main- and start-fuel governor unit, (installed inside of liquid fuel module) Liquid fuel ,air- / water purge unit (installed inside of liquid fuel module) Liquid fuel .drain unit (installed inside of blue GT-base frame) Multi-burner unit, air pressure controlled Parallel ring piping Fuel chamber with nozzles Pressure monitoring with switches and manometers Liquid fuel flexible tubes Piping from the liquid fuel module to the connecting flanges on the base ^ frame to the gas turbine in stainless steel.

Liquid fuel valves, tightness control transmitters Liquid fuel pressure control transmitters

Low pressure water tank General view: Liquid fuel system

Image 33.2

Image 33.4

Image 33.3

Combustion chamber and manifolds Gas- / LiquidFuel Manifolds 5 x flametransfer tubes 2x3 = 6-each - combustion chambers

Image 33.5

Manifolds The manifolds are responsible for consistently supplying natural gas to the individual injectors. This is done in accordance with the respective operating conditions of the gas turbine. Combustion chambers The gas turbine has 6 separate combustion chambers. 3 per side, which are connected to each other by flexible metal hoses (flame pipes). The two lower combustion chambers on each side are those which are ignited. Following ignition, there is a flame rollover to the third/most upper combustion chamber. Flame tubes Following ignition, the flames are fed through the flame tubes to the two lower combustion chambers and the combustion chambers lying above. Flame detectors During the start-up procedure, a flame must be detected in the uppermost combustion chamber. If this does not happen, start-up is immediately aborted. Ignition plugs The two lower combustion chambers are installed with ignition plugs. During the start up procedure, at approx. 7% of the nominal speed, each of the two lower combustion chambers on each side is ignited.

V C.9 Starter motor, purge and turn system Description Starter system General The role of the starter, purge and turn motor is to turn the turbine for 48 hours after shut-down, in order to ensure even cooling of the turbine components. In this way, bending of the blades from its own weight and resulting rotor grinding on the stator is avoided. The operation of the starter, purge and turn motor is monitored and controlled by the gas turbine control system. The starter system consists of a three-phase asynchronous motor, which is flange mounted to the gear housing, and a frequency converter, which is in the control room. It is monitored and controlled by the Engine Controller. The torque of the starter motor is transferred over the gear to the turbine, so that they start turning. Once the turbine has reached a nominal speed of 65%, the starter motor is mechanically decoupled from the gear, using a synchro self- shifting clutch, and is simultaneously electrically switched off over a shut-down signal from the control system.. The converter supplies the motor with the variable frequency necessary for this case. The motor is operated in a closed loop, in order to also bring the required torque at zero speed. This also enables stable operation with maximum torque. The output part of the converter has the classic configuration: network-side rectifier diode bridge, voltage and current equalisation and IGBT-inverter as a 6-pulse bridge. In addition there are the control circuits. In the engine control, the DCT technology (direct torque control) is used, in order to ensure low-loss and stable control.

C.10 Ignition system Description

CAUTION
The ignition plugs may only be switched on when the ignition cables are securely fastened in their plugs! General This system consists of two electronic ignition triggers with high-voltage calbes and 2 ignition plugs in each of the two combustion chambers. When the turbine speed has reached about 5 to 8% of nominal speed, the ignition impulse is initially transferred to two ignition plugs. The air/fuel mixture is sparked in the combustion chamber and the flames are carried to the other combustion chambers over the flame tubes. When the turbine speed has reached 25% of the nominal speed, the ignition trigger voltage is switched off and combustion runs independently. The ignition signal is controlled and monitored by the turbine control system. Ignition system specification Ignition trigger Type:

Condenser discharging impulse

Nominal data 24 VDC, 1 A Ignition plugs Type: NGK spark plug Type GL-501-2 (P/N 00-840-570-02) 100 MQ

Isolation resistance Installation:

The ignition trigger can be installed at a customer-preferred "cold" position, but the ignition cable should be kept as short as possible.

C.

11 Bleed Air Ventil IVSV Control System Description DLE Bleed General This regulator controls the flow of compressed air pressure from the turbine main house to the exhaust gas pipe. The measure enables "compressor pumps" to be avoided during start-up of the turbine. See system diagram (next page) Specification The following table summarises the specification. Type: Flap valve, from Nippon Keystone Corp. Nominal diameter Discharge air pressure Electrical data 150 mm Nominal pressure 1.6 MPa 100 VAC, 50/60HZ (AC) Nominal pressure 1.55 A /1.72 A Control signal 4 mA DC for flap completely closed" 20 mA DC for flap completely open" The signals come from the Engine Controller

Start Bleed This controls the increasing compression pressure of the combustion air pressure. The

measure serves to drive the increasing compression pressure during the start-up procedure to the exhaust gas pipe, thereby relieving the starter motor. At the beginning of the start-up, the valve is completely opened and is slowly closed when there is increasing speed. At 70% rpm, the start-bleed valve is completely closed. Specification The following table summarises the specification. Type: Flap valve, from Nippon Keystone Corp. Nominal diameter Discharge air pressure Electrical data 150 mm Nominal pressure 1.6 MPa 100 VAC, 50/60Hz (AC) Nominal pressure 1.55 A /1.72 A Control signal 4 mA DC for flap completely closed" 20 mA DC for flap completely open" The signals come from the Engine Controller

The details are summarised in the following table. Turbine speed "Seal-Air" System (as a percentage of the nominal speed) 0 to 25 In this speed range the compressor input pressure is about the same as the ambient pressure. Seal air is not required. In this speed range the compressor pressure is low and unstable. The external source of compressed air is therefore used. Pressure level of the compressed air after the fifth stage is sufficient for pressing on the seal.

25 to 85

85 to 100 Specification

The specification for seal air is as follows: Seal air 1) Instrument air, oil-free and filtered 2) Pressure: 0.13 bis 0.14 MPa 3) Volume flow > 2,0 Nm3/min instrument air, 4) through a command from the turbine control centre: - Solenoid valve open at 25%^N^85% - Solenoid valve closed at N^25%, or N85%, where N = turbine speed. Seal air system components 1. 2. C. Air pressure shut-off valve Air pressure control valve 13 Cleaning system compressor Description General

The aim of the compressor cleaning is to maintain a high level of efficiency and to prevent erosion/corrosion. To guarantee the performance of the gas turbine over a longer period of time, the compressor in the gas turbine is washed at predetermined time intervals. This work is carried out by Kawasaki Service Peronnel Two cleaning methods will be used: 1. 2. The hot compressor wash ("hot wash") for running gas turbines The cold compressor wash ("cold wash") for idle gas turbines. The turbine is driven by the starter motor. The interval for cleaning the compressor depends on the degree of soiling and can be determined by continuously monitoring the gas turbine performance.

Image 37

Washing water storage tank Capacity: approx. 75 litres Filling: Manual shut-off valve in the supply pipe Water quality VE water Washing water driver motor

Output: 0.75 kw Voltage: 400 VAC 50Hz Washing water pump Output 10 litre / min Pressure level: 1.0 mP Specification: Cleaning fluid

Specification

Mixture of cleaning agent (1 part) and water (4 parts) Cleaning agent: Z0K27 or similar Hot wash: (optional) Cold wash: approx. 191 per wash procedure

Total volume:

Cleaning pump

Type: Nominal pressure Mass flow

Portable pump (KYC-300, from Kyowa) 0.3 MPa 6 l/min 220/110/100 VAC, 0.75 kW

Supply: Tank for cleaning agent Drain tank C. 14 Drain Tank Description

Volume approx. 1001 see section "Drain Tank"

To drain off condensation or other liquids in the turbine, a collecting tank is fastened to the base frame. The outflow is cleaning agent. The following pipes are necessary for the connections to the collecting tank and are turned off using a manual shut-off valve.

Pipe No. 1 2 3 4 5 6

Pipe position Suction collector Compressor housing (discharge "seal air") Compressor housing (discharge "turbine cool air") Air discharge, elbow pipe Main housing Lowest combustion chamber (only for liquid fuel)

The tank can be emptied into a collection container using a manual valve.

Gas warning and fire extinguishing system C.16 Description The Gas Turbine Generator Unit GPB80D has its own gas warning and fire detection system.

Image 38

Gas warning system The gas warning system consists of 2 gas sensors, which are installed in the noise enclosure in the area of the gas injection (1 at the front at the gas inlet, and 1 above the gas supply in the ceiling area). The evaluation system is installed in the control cabinet. Both sensors have the following switching thresholds: 20% LFL (LFL = lower flammability limit) 40% LFL (LFL = lower flammability limit) pre-alarm pre-alarm with shut-down of the gas turbine and closure of the main gas valve

In the event of one of the two gas detectors sounding, an alarm message is triggered if there is a threshold of 20% LFL (lower flammability limit). If a threshold of 40% LFL is reached, an emergency shut-down of the gas turbine is initiated. The gas valve inside the noise enclosure is closed and the gas ventilation opened. The noise enclosure ventilation remains on, in order to lead the escaped gas over the sound enclosure ventilation system, out of the sound enclosure and into the open air. Further users are switched without voltage. An optical and acoustic notification of a gas alarm is given by one of the yellow flashing lights installed at the front exterior wall of the sound enclosure, and by an alarm sound apparatus installed int he same place.

Image 41.1 Example

Filter house /

Filter house with platform, contains (details can be found in the manufacturer and supplier documentation): Weather protection grid with bird screen Filter of the filter stages 1 (combustion air) and 2 (cooling air)

> Coalescer-Filter stage 1: Rough filter of grade G2 > Filter stage 2: Pre-filter of grade G4 Filter of filter stages 3 and 4 (only for combustion air) > Filter stage 3: Fine filter of grade F7 > Filter stage 4: Hepa-filter of grade H10

sound absorber (bottom 1/3, front of filter house)

Cool air inlet channel with

Combustion air channel to the gas turbine with sound absorber (the upper 2/3 of the filter house front)

filter cassettes during maintenance.

Platform with steps (outside) External crane for lifting the

Gas turbine control system From installation on, the gas turbine control system is described in the manufacturers documents; the functions are described under "Electrical Control Systems". Air ducts Air ducts inside and outside the building, which are responsible for air (supply, exhaust) will be supported by the ventilators. A detailed description of this component can be found in the manufacturer's documentation.

Combustion air The gas turbine generator unit has an air inlet In this air inlet housing, which is protected against weather and birds, the first two filter levels of class G2 droplet separator (coalescer) and G4 (prefilter) are installed. Using an air duct, all the air, cool air to the package and combustion air is then directed to the gas turbine over separate sound absorbers in the actual filter house above the package. The two main filter stages for the combustion air are in the filter house - F7 (fine filter) and H10 (Hepa-filter). Using these filters, the combustion air required for operating the gas turbine is cleaned. The combustion air reaches the gas turbine over a connected redirection with flow metal sheets, via a connected sound absorber, a transmission channel and expansion joint. The cool air for the package is blown out of the air ducts, without further filtering, directly into the sound enclosure, through two ventilators which are installed in two separate areas of the filter house. It is then drawn in again by two ventilators located on the opposite side. On the exhaust gas side, the gas turbine is connected, via the exhaust gas expansion joint and the exhaust gas pipe, with the exhaust gas flange which is installed on the sound enclosure. Pressure loss The specific values of suction loss are described in the following section. Suction pressure loss indicates the difference between the ambient pressure and the pressure at the upper air inlet of the turbine. This difference must be under 20 mbar. Exhaust gas back pressure indicates the difference between the pressure at the exhaust gas flange of the turbine and the ambient pressure. This difference must be under 40 mbar. These differences in pressure reduce the turbine output and can lead to damage to the turbine when exceeded. They are therefore important criteria when designing gas turbine generator units. Furthermore, when the suction pressure loss exceeds the design values, countermeasures must be taken (e.g. exchange the filter). Combustion air filter

The ambient conditions largely depend on the installation site of the turbine, but it must always be ensured that the pre-combustion air is free from foreign objects and corrosive material. The following measures are intended in this regard: 1. Intake port for external air: Here a safety measure in the form of a weather protection grill with a bird screen is provided. There is an air velocity of 2.8 m/s inside the weather protection grill and bird screen. 2. The actual fine filtration of air into combustion air for the gas turbine takes place in the "filter house". The load limit of the filter is typically approx. 3 m /h. The lower the inflow, the longer the downtime of the individual filters and the risk of icing. The following table summarises the filter specification. Efficiency >99.97% at 0,3p with the DOP method in accordance with the standard MIL-STD-282 Pressure loss Starting conditions: approx. 500 Pascal, or less Limit for exchange Filter 1 (PDT 3122) approx. 300 Pascal Filter 2 (PDT 3104) approx. 800 Pascal Filter 1+2 (PDT 3126) approx. 1200 Pascal Recommended values. Dependent on the filter strength and the previous system in terms of pressure loss.

Electrical control system Description Gas turbine control, includes in the model with individual control cabinets, or as a control cabinet connected with the sound enclosure: Control cabinets with power supply, security and all necessary switching devices Control system for the Gas Turbine Generator Unit GBP80D Visualisation system Frequency converter for the start, purge and turn motor Gas warning and fire detecting unit Air conditioning unit UPS to buffer the control system. Batteries for the ELOP (Emergency Lube Oil Pump), which are located in the battery cupboard Turbine control Control cabinet +1U01, Turbine control Control cabinet +1U01, 400 VAC power feed and +1N01 distribution

Image 48

MiHli

All security devices, switching, monitoring and control devices necessary for operating the gas turbine generator control unit, as well as the visualisation are built into the control cabinet. The most important operating and monitoring systems are in the control cupboard opposite the entry door of the electrical switching house. These three control cupboards are assembled and fulfil the following individual functions (list from left to right): +1U01 +1U01 +1N03 Turbine control Field Turbine control Field 1 2

400VAC - feeding and distribution

Turbine control Field 2, +1U01 Buzze r Failur e Shutdown

GT speed

GTstart counter

GT exhaust gas tempera GT - peak load counter

Image 50

Turbine control Field 3, 400 VAC - Feeding field, +1N01 WINNCC touchscree n Control panel PP17II Manual Synchronisatio n Wash turbine Automatic Synchronisatio n Synchronisation Hand Automatic Synchronisati on Geno network Release turbine EMERGENC Y SHUT-DOWN Control location remote

Failure Acknowledgem t

Document 1

Page 115 of 208

11.02.2010

Turbine control Field 3, 400 VAC - Feeding field, +1N01

Shows voltage and power of battery system

Image 52 Example

CAUTION
As a general rule, full load drops over the 60kV switch are to be reported to KAWASAKI Gas Turbine Europe!