Gas Turbine Operating Manule

Service and Maintenance Instructions for Gas Turbine
Hompu 1/2 - H.2100002.21

THM 1304-12
MAN TURBO AG
Version: 02.2008
Table of contents
1
General service and maintenance information .................................... 1

1.1
Safety information......................................................................1
1.2
Abbreviations.............................................................................2
1.3
Performance of service and maintenance measures.................3
1.4
Cleanliness ................................................................................3
1.5
Impact of adhesive tape.............................................................3
1.6
Consumables.............................................................................3
1.7
Examination of component parts ...............................................4
1.8
Identification of component parts...............................................4
1.9
Storage of spare parts ...............................................................4
1.10
Performance of welding work ....................................................4
1.11
Installation of O-rings.................................................................5
1.12
Use of graphite pastes...............................................................5
1.13
General notes on the exchange of component parts .................5

1.13.1
1.13.2
1.13.3
1.13.4
1.13.5
1.13.6
1.13.7
1.14
Use of SWAGELOK adapters....................................................7
1.15
Use of thread sealing tape and thread sealant ..........................8

1.15.1
1.15.2
Thread sealing tape ....................................................8

Thread sealants ..........................................................8
1.16
Storage and installation of hoses...............................................9
1.17
Installation of locking plates.....................................................10
1.18
Snap rings ...............................................................................11
1.19
Use of lockwire ........................................................................11
1.20
Tightening torques...................................................................15
1.20.1
1.20.2
1.20.3
Version 02.2008
Safety information .......................................................5

Exchange of pressure switches .................................. 5
Exchange of electric motors........................................5
Exchange of limit switches..........................................6
Exchange of thermometers and pressure gauges ......6
Exchange of swing check valves and shut-off
valves..........................................................................6
Exchange of transmitters (resistance
thermometers, pressure sensors, etc.) .......................6
Tightening torques for pipe flanged connections ......15

Tightening torques for base engine connections ......15
Tightening torques for other connections..................16
General service and maintenance information

MAN TURBO AG
1|1-5
1.21
Service and maintenance Definition of terms and

objectives ................................................................................ 18
1.21.1
1.21.2
1.21.3
Base engine........................................................................................1
2.1
System-related information ....................................................... 1

2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
2.1.6
2.1.7
2.1.8
2.2
2.3
Design and function of base engine ........................... 1

Functional principle .................................................... 1
Calculation of equivalent operating hours .................. 2
Safety information ...................................................... 3
Inspection measures V1, V2, V3, and V4................... 3
Maintenance............................................................... 4
General repair information.......................................... 4
Spare parts catalogue ................................................ 4
Gas generator ........................................................................... 5

2.2.1
2.2.2
2.2.3
2.2.4
Design and function of gas generator......................... 5

Modular design of gas generator................................ 5
Modules of gas generator........................................... 6
Inspection measures V1, V2, V3, and V4................. 15
Power turbine.......................................................................... 16
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
Inspection................................................................. 19
Maintenance............................................................. 19
Repair....................................................................... 19
Design and function of power turbine ....................... 16

Modular design......................................................... 17
LP1 stator blade carrier casing................................. 17
LP turbine rotor / LP2 stator blade carrier ................ 18
Support of LP turbine rotor ....................................... 19
Inspection measures V1, V2, V3, and V4................. 21
Instrumentation base engine...............................................................1

3.1

3.1.1
3.1.2
3.1.3
3.2
Speed measurement (nGG, nPT) ............................................. 3

3.2.1
3.3
Design and function.................................................... 4

Exchange of T4 thermocouple ................................... 6
Vibration measurement ............................................................. 6

3.4.1
3.5
Inlet temperature measurement on power turbine (T4) ............. 4

3.3.1
3.3.2
3.4

Inspection................................................................... 3
Phase angle measurement ....................................................... 7

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Version 02.2008
3.5.1
3.6
Bearing temperature measurement ...........................................7

3.6.1
3.7
System-related information........................................................1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
4.2
4.3
Design and function ..................................................11
Vent valve................................................................................11
4.6.1
4.7
Subcontractor documentation ................................... 11

Drawings...................................................................11
Trip valve .................................................................................11

4.5.1
4.6
Design and function ....................................................8
Fuel gas filter ...........................................................................11

4.4.1
4.4.2
4.5
Drawings.....................................................................8
Fuel gas metering valve.............................................................8

4.3.1
4.4

Fuel gas specification .................................................1
Service and maintenance ...........................................5
Inspection ...................................................................8
Repair .........................................................................8
Job-specific and system-related documents..............................8

4.2.1
Design and function ..................................................11
Pressure transducer ................................................................11

4.7.1
Subcontractor documentation ................................... 11
Ignition system ................................................................................... 1

5.1
System-related information........................................................1
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
5.2
5.3

Inspection ...................................................................1
Ignition test .................................................................1
Repair .........................................................................2
Ignition transformer....................................................................3
5.2.1
5.2.2
Version 02.2008
Fuel gas system ................................................................................. 1

4.1
Wear measurement on thrust bearing .......................................7

3.7.1

Replacement...............................................................3
Igniters.......................................................................................4

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5.3.1
6
Guide vane actuator............................................................................1

6.1
System information ................................................................... 1

6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
6.2
6.3
Blow-off and instrument air system .....................................................1

7.1

7.1.1
7.1.2
7.1.3
7.1.4
7.2
7.3

Replacement .............................................................. 4
Solenoid valves (for activation of blow-off valves)..................... 5

7.3.1
7.4

Inspection................................................................... 3
Repair......................................................................... 3
Blow-off valves .......................................................................... 3

7.2.1
7.2.2
Pressure sensors compressor discharge pressure / PT

inlet pressure ............................................................................ 6
7.4.1
Drainage system.................................................................................1
8.1

8.1.1
8.1.2
8.1.3
8.1.4
Switch - Calibration of guide vane positioning system .............. 4

6.3.1

Diagram guide vane angle vs. GG speed................... 2
Maintenance............................................................... 3
Inspection................................................................... 3
Position sensor ......................................................................... 3

6.2.1

Inspection................................................................... 1
Repair......................................................................... 2
Cleaning system .................................................................................1

9.1

9.1.1
9.1.2
9.1.3

Time of cleaning ......................................................... 1
Use of cleaning additives ........................................... 2

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9.1.4
9.1.5
9.1.6
9.1.7
9.1.8
9.1.9
9.1.10
9.1.11
9.1.12
9.2
Cleaning nozzles .......................................................................7

9.2.1
9.3
Use of antifreeze.........................................................2
Cleaning sequence .....................................................3
Wash water specification / approved cleaning
additives......................................................................3
Measures to be taken before initiating the
cleaning sequence ......................................................5
Performance of cleaning .............................................6
Measures after cleaning..............................................6
Examination of cleaning result ....................................7
Repair .........................................................................7
Mobile cleaning unit ...................................................................8

9.3.1
10 Annex ................................................................................................. 1
Version 02.2008
10.1
Spare Parts Catalog ..................................................................1
10.2
Curves .......................................................................................1

MAN TURBO AG
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1.1
Safety information
U DANGER
Danger to life and limb as well as risk of severe damage to
property!
Prior to performance of a service and maintenance measure
the Operating Instructions of Machine unit and the safety
information included in the system and component part
descriptions shall be observed.
ATTENTION
Damage to components of the gas turbine unit!
The general service and maintenance notes listed below
have to be observed to avoid damage to the gas turbine
unit.
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1.2
Abbreviations
AC
Alternating Current
AD
Outer diameter (Aussendurchmesser)
ANPT
American National Pipe Thread
BG
Subassembly (Baugruppe)
DC
Direct Current
DF
Remote data transmission (Datenfernbertragung)
DLN
Dry-Low-NOx, DLN combustion chamber combustor which is capable of

reducing the nitrogen oxides (NOx) generated during combustion, without
the injection of water.
GG
Gas generator
GT
Gas Turbine
HP
High Pressure
ID
Inner Diameter
MAX / Max. Maximum

MCC
Motor Control Centre (low-voltage switchgear unit)
MIN / Min.
Minimum
LP
Low Pressure
NPT
see ANPT
PT
Power Turbine (PT) = Low Pressure Turbine (LPT)
psia
pound per square inch absolute (absolute pressure)
psig
pound per square inch gauge (gauge pressure)
WAF
Width Across Flats
UNC
Unified National Course Thread
ZB
Assembly (Zusammenbau)
AC
Alternating Current

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MAN TURBO AG
Version 02.2008
1.3
Performance of service and maintenance measures

Gas generator, power turbine and coupling may only be replaced or
aligned under instruction by a representative of MAN TURBO AG, since
special knowledge is required for the performance of these measures.
This also applies to the performance of repair work on internal base
engine parts.
Service and maintenance work which is not described in the
documentation supplied may only be carried out by persons with special
qualification and skills to whom adequate information is available. Lacking
information may be requested from the competent contact for the plant
unit with the After Sales Service of MAN TURBO AG.
1.4
Cleanliness
Care has to be taken to ensure that dust, dirt, locking elements or other
foreign objects do not get into the gas turbine. Should this ever happen,
the service and maintenance activity must be interrupted until the
respective objects have been found, even if this requires a considerable
input of cost and time.
Suitable plugs, caps or other covers are to be used for the protection of all
non-covered openings. Protective caps for open pipes shall not be placed
inside but on top of the pipe ends in order to prevent their being installed
unintentionally. Use of adhesive tape is not permitted (see Section 1.5
Impact of adhesive tape [J 1 | 3] ).
Anti-corrosion agents, applied for the storage of component parts, as well
as dirt and packaging material shall be carefully removed prior to
installation of a part. Suitable solvents shall be used for the removal of
anti-corrosion agents.
After completion of service and maintenance work, especially the intake
area is to be thoroughly checked for foreign objects which might, for
example, get into the gas path of the base engine.
1.5
Impact of adhesive tape

Investigations have shown that remainders of adhesive tape on
component parts with increasing temperature attack the surface and
reduce the expansion capability. Remainders of adhesive tape are to be
removed carefully, before a component part is installed and exposed to
high temperatures.
1.6
Consumables
During each assembly operation all seals and rubber parts are to be
replaced. Prior to installation, non-metallic new parts have to be checked
for indications of damage resulting from extended periods of storage.
Consumables, such as for example locking wire, locking washers, locking
plates, split pins, etc., must not be reused.
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1.7
Examination of component parts

Prior to installation of a component part it has to be checked whether the
part to be installed is correct and undamaged. Use of incorrect or
damaged component parts or of other than original parts not procured
from MAN TURBO AG may result in failure or major damage to the plant
unit.
During disassembly of component parts watch out for indications of wear,
burns or other undesirable changes.
1.8
Identification of component parts

During disassembly note the installation location of each individual part for
ease of reinstallation. Mark the parts, if necessary, taking the following
notes into account.
Damaged component parts or subassemblies which cannot be reused are
to be marked with a tag in order to avoid unintentional installation.
The internal parts of gas generator and/or power turbine shall only be
marked using special pens. We recommend using the glass chromium pen
by Messrs Stade or a silver pen by Messrs Faber for the marking of
component parts.
1.9
Storage of spare parts

As a rule, spare parts procured from MAN TURBO AG are packaged and
preserved for storage according to requirements.
Spare parts shall be stored in a room at constant temperature between 15
and 25C. The relative humidity must not exceed 70%. Temperature
variations are to be limited to max. 1C per hour.
Anti-friction bearings are delivered in the manufacturer's original
packaging. As a rule, the maximum storage period is 2 years. After this,
exchange the parts if preservation proves too expensive.
Component parts from rubber-like materials, e.g. shaft sealing rings, Orings, flexible nozzles, vibration dampers, V-belts, etc. have to be
protected from light and seal-welded into black film. Check these parts
annually for elasticity and brittleness. The maximum storage period is 5
years or less, depending on the instructions by the respective
manufacturer. For this reason, these parts are to be marked with the date
of storage to permit checking.
Stored component parts with metallic surfaces are to be checked annually.
The preservation of machined surfaces has to be touched up, if
necessary. Bright, metallic surfaces are to be greased.
Stored component parts shall be identified with the material number of
MAN TURBO AG and recorded in an inventory list.
1.10
Performance of welding work

If welding work is carried out in the area of the GT base frame, proper
earthing must be ensured in order to avoid damage to the electrical

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Version 02.2008
components installed on the base frame. Additionally, appropriate fire

prevention measures are to be taken.
1.11
Installation of O-rings
For ease of installation, O-rings which come into contact with oil are to be
coated with the oil of the system in which the O-ring is used.
O-rings which come into contact with water may be coated with Vaseline
for ease of installation.
1.12
Use of graphite pastes

To facilitate future removal of screwed joints in hot areas, graphite paste
Never-Seez (Material No. S0913821) shall be applied to the thread faces.
1.13
General notes on the exchange of component parts
1.13.1
Safety information
U CAUTION
Hazard of personal injury and damage to property!
Prior to the dismounting of component parts the Operating
instructions for Machine unit shall be observed.
1.13.2
Exchange of pressure switches

Z Observe Section 1.13.1 Safety information [J 1 | 5] .
1. Shut down the plant unit and lock it to prevent restarting.

2. Isolate the measuring line, and depressurize.
3. De-energize the measuring circuit to exclude any risk of a short circuit
which may result in damage to digital/analog cards.
4. Exchange the pressure switch.
5. Use a calibration device to check the measuring range and the switch
point. Adjust the switch point, if necessary (for values see).
1.13.3
Exchange of electric motors

In the case of motors which are new, which have been cleaned or repaired
and in the case of motors which have been in store or shut down for 6
months, determine the minimum insulation resistance of the motor
winding. After an extended period of operation also check the critical
insulation resistance.
During and immediately after the measurement the terminals sometimes
have dangerous voltages and must not be touched.
If the minimum insulation resistance or critical insulation resistance has
decreased below the specified value, the motor must not be started up or
has to be shut down at once.
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Possible causes for this could be, for example, humidity, damaged
windings or winding parts.
2. Safely isolate the motor.
3. Lock the motor to prevent restarting.
4. Verify safe isolation from supply.
5. Ground and short-circuit the motor.
6. Cover or barrier off adjacent, live parts.
7. Reverse the above measures only after the motor has been completely
reinstalled and connected again.
1.13.4
Exchange of limit switches


3. Exchange the limit switch.
Note: If the limit switch is designed as initiator, make sure that the
polarity is correct.
1.13.5
Exchange of thermometers and pressure gauges


2. Isolate the piping, and depressurize.
3. Exchange the thermometer or pressure gauge.
1.13.6
Exchange of swing check valves and shut-off valves


2. Isolate the piping, and depressurize.
3. Exchange the swing check valve or shut-off valves. Use new gaskets
and observe the direction of flow.
1.13.7
Exchange of transmitters (resistance thermometers, pressure sensors,

etc.)

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Version 02.2008

3. Exchange the transmitter.
Note: If the transmitter is designed as initiator, make sure that the
polarity is correct.
4. For exchanging a resistance thermometer in case an immersion sleeve
is not installed: Isolate the piping, and depressurize.
5. Use a calibration device to check the setting or programming and
function, and pass through the entire measuring range for checking the
linearity (values see).
1.14
Use of SWAGELOK adapters

In the gas turbine area SWAGELOK adapters are used with a maximum
diameter of 25 mm since pre-assembly tools are not necessary up to this
size. SWAGELOK adapters can be loosened and re-tightened several
times without any of the parts shown in the illustration below having to be
exchanged.
SWAGELOK adapter
Cap nut
Front clamping ring
Rear clamping ring
Body
Z If an adapter has to be exchanged or installed all the same, take care to
ensure that the pipe end is rectangular and free from burs. Remnants
from burs and other contaminations must not get into the piping. The
following procedure has to be observed:
1. Insert the pipe into the assembled SWAGELOK adapter. Make sure
that the pipe has been introduced into the adapter up to the stop and
the cap nut tightened "finger-tight".
2. Prior to tightening the cap nut mark it in 6 o'clock position.
3. While holding the body with a wrench tighten the cap nut by 1-1/4 turns.
Note that the marking has to be turned further up to 9 o'clock position
after one complete turn.
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NOTE
Use of sealants.
Sealants must not be applied to SWAGELOK adapters.
On SWAGELOK adapters the measurement of tightening torques is not a
suitable means for checking the tightening. Merely the 1-1/4 turn of the
cap nut is the correct measure for adequate tightening. If the reference
gauge fits between the cap nut and the body hexagon, the adapter has not
been tightened sufficiently. If it does not fit, the adapter has been tightened
sufficiently.
1.15
Use of thread sealing tape and thread sealant
1.15.1
Thread sealing tape

NOTE
Use of thread sealing tape.
Thread sealing tape may only be used for tapered male threads. Use
for connections with flanges, cones or pipe unions is not allowed.
Z For tapered male threads with a diameter of 1/8", 1/4" and 3/8" a thread
sealing tape with a width of 1/4" is to be used. For a larger thread a tape
of " width is to be used. The following procedure has to be observed:
1. Clean the male and female threads in order to remove any anti-seize
compound or sealing residues.
2. Starting on the first flight, wind the sealing tape with slight overlap
around the thread in threading direction. For tapered threads from
special steel, winding the tape twice around the thread is
recommended.
3. Make sure that the tape does not protrude beyond the first turn of the
thread, since otherwise it might break and get into the structural
component.
4. Protruding sealing tape has to be cut off. The tape, especially the
overlapping ends, shall be pressed against the thread.
1.15.2
Thread sealants
NOTE
Use of thread sealants.
Thread sealants may only be used for tapered male threads. Use for
cable glands is not permitted.
Prior to the application of thread sealant the whole thread has to be
cleaned from oil, grease and other impurities. The thread sealant is to be
applied to the second and third flights.

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MAN TURBO AG
Version 02.2008
1.16
Storage and installation of hoses

NOTE
Open hose ends.
Open ends of stored hoses have to be capped or plugged in order to
prevent any accumulation of dirt in the hose interior.
Z The service life of a hose largely depends on the correct installation.
The following has to be observed for the installation of hoses:
1. Hoses shall be reeled and unreeled as shown in the following

illustration "Reeling and unreeling of hoses".
2. Check prior to installation that the hose interior is free from dirt. As a
precautionary measure blow the hose through with compressed air prior
to installation.
3. As a rule, the hoses are equipped with one loose and one fixed hose
connection fitting. The fixed hose connection fitting always has to be
tightened first to prevent torsional stress.
4. Always use a wrench as dolly to avoid co-rotation of the connection
mating piece or damage to the piping to be connected.
5. External straining of the hose by chafing on edges, surfaces or on the
ground has to be avoided, as the service life may be reduced
considerably by bending or by reduction of the wall thickness.
6. During installation care must be taken that the minimum bending radius
specified in the table below is maintained.
7. Attachment of a hose in the way such as illustrated in "Inadmissible
attachment of hose" is not permissible.
Reeling and unreeling of hoses
Hose minimum bending radius
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1 | 9 - 19
Inadmissible attachment of hose
Minimum bending radius for corrugated hoses of special steel
1.17
Nominal diameter (inch)
Bend minimum radius (mm)
3/8
200
1/2
220
5/8
300
3/4
330
390
1-1/4
410
1-1/2
490
570
2-1/2
680
770
960
Installation of locking plates

NOTE
Reuse of locking plates!
Locking plates must be used only once.
When using locking plates care has to be taken to ensure that the gap
between the bent-over tabs and the contact face is max. 0.50 mm. At least
75% of the securing tab must be in contact with the face of the structural
component.

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Version 02.2008
Installation of locking plates
1.18
Snap rings
Suitable pliers are to be used for the installation of snap rings. Internal
snap rings must not be pressed together beyond the point where the ends
of the rings meet. External snap rings must only be expanded to such an
extent that installation is possible without bending the rings. After
installation it has to be ensured that the snap ring rests firmly in the groove
and is neither loose nor deformed. Deformed snap rings have to be
replaced.
Chamfered snap rings additionally serve for absorbing the tolerance
clearance of the structural component to be retained. Such snap rings
have a chamfer of 15 on one side. Chamfered snap rings may only be
inserted in correspondingly chamfered grooves. The non-chamfered side
is to be directed towards the structural component to be retained.
1.19
Use of lockwire
NOTE
Use of lockwire.
The use of lockwire which has been in use before, which is bent or
damaged is not admissible.
No other than the lockwire supplied by MAN TURBO AG shall be used.
The bores for the lockwire are to be aligned as shown in the following
illustrations. During alignment the specified tightening torques must not be
exceeded. Subsequently, the lockwire is to be fitted as shown. The end of
the lockwire has to be bent over to avoid any hazard of injuries.
In THM gas turbine units lockwires with a diameter of 0.8 (material no.
S0293782) and 1.25 mm (material no. S0293781) are used.
In FT8 gas turbine units lockwire of material no. TAS3214-02 is mainly
used.
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Examples for the securing of component parts with lockwire

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Version 02.2008
1.20
Tightening torques
U CAUTION
Hazard of personal injury and damage to machinery.
If tightening torques are not observed, structural
components may work loose and - especially where rotating
structural components are concerned - may hit people in the
vicinity of the plant unit. Above that, hot and pressurized
liquids or gases may escape from pipes and casings and
likewise hit people in the vicinity of the plant unit.
NOTE
Prerequisites for the tightening of threaded unions.
Structural components shall only be tightened to the final torque after
room temperature has been reached.
Flanged connections are to be tightened crosswise alternately with
approx. 75% of the tightening torque, before the final tightening torque is
reached. Torque wrenches are to be calibrated regularly.
For information about the tightening torques for the driven machine and
other plant unit components please refer to the relevant documentation.
1.20.1
Tightening torques for pipe flanged connections

In most cases, threaded bolts with UNC thread are used for the
connection of pipe flanges. Flanged connections are to be tightened
alternately and crosswise by applying the following tightening torques. The
data apply for non-greased threaded bolts which are stamped with "B7" on
the front face. Where the stamping is different, other tightening torques
apply.
Tightening torques for stud bolts with UNC thread
1.20.2
Dimension (inch)
Tightening torque (Nm)
1/2
95
5/8
199
3/4
347
7/8
554
Tightening torques for base engine connections

The following table lists the standard tightening torques for the base
engine. Do not apply these tightening torques unless in the description of
service and maintenance measures express reference is made to the
tightening torques in this table. In all other cases special tightening torques
apply which must be observed by all means.
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Tightening torques for base engine connections
Bolt / nut diameter
Minimum (Nm)
Maximum (Nm)
M5
2.6
M6
4.8
M8
11
15
M 10
23
28
M 12
39
45
M 14
63
80
M 16
96
130
M 18
130
180
M 20
187
250
M 22
250
320
M 24
320
450
M 27
469
580
M 30
588
750
If not indicated otherwise, thread faces are to be greased.
1.20.3
Tightening torques for other connections

NOTE
Tightening torques for other connections.
The tightening torques listed in the table below are not valid for the
base engine and for flanged pipe connections.
The standard tightening torques for other connections are indicated in the
following table. Do not apply these tightening torques unless in the
description of service and maintenance measures express reference is
made to the tightening torques in the table below. In all other cases
special tightening torques apply which must be observed by all means.
Tightening torques for other connections (part 1 of 2)
Bolt / nut diameter
Bolt strength
category/
Material
Tightening torque
Ma (Nm)
MoS2 - lubr.
Tightening torque
Ma (Nm)
lightly oiled
M8
5.6
10
11
8.8
21
19
10.9
30
34
A2-70
12
13
A4-80
17
19

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Bolt / nut diameter
M10
M12
M16
M20
Bolt strength
category/
Material
Tightening torque
Ma (Nm)
MoS2 - lubr.
Tightening torque
Ma (Nm)
lightly oiled
1.7258
15
17
5.6
20
23
8.8
43
48
10.9
so
68
A2-70
23
26
A4-80
33
38
1.7258
29
33
5.6
33
40
8.8
71
85
10.9
100
120
A2-70
39
47
A4-80
56
67
1.7258
49
59
5.6
83
117
8.8
178
248
10.9
250
350
A2-70
97
136
A4-80
139
194
1.7258
122
171
5.6
150
200
8.8
320
426
10.9
450
600
A2-70
175
233
A4-80
250
333
1.7258
220
293
Tightening torques for other connections (part 2 of 2)
Version 02.2008
Bolt / nut diameter
Bolt
strength category/
Material
Tightening torque
Ma (Nm)
MoS2 - lubr.
Tightening torque
Ma (Nm)
lightly oiled
M24
5.6
267
367
8.8
569
782
10.9
800
1.100
A2-70
311
428
A4-80
444
611

MAN TURBO AG
1 | 17 - 19

Bolt / nut diameter
M27
M30
M36
1.21
Bolt
strength category/
Material
Tightening torque
Ma (Nm)
MoS2 - lubr.
Tightening torque
Ma (Nm)
lightly oiled
1.7258
391
537
5.6
417
550
8.8
889
1.173
10.9
1250
1.650
A2-70
486
641
A4-80
694
917
1.7258
611
807
5.6
550
733
8.8
1.173
1.564
10.9
1.650
2.200
A2-70
642
856
A4-80
917
1.222
1.7258
807
1.076
5.6
933
1.267
8.8
1.991
2.702
10.9
2.800
3.800
A2-70
1.089
1.478
A4-80
1.556
2.111
1.7258
1.368
1.858
Service and maintenance Definition of terms and objectives

Service and maintenance is aimed at maintaining or restoring the desired
condition of the plant unit. Service and maintenance which is carried out
regularly and carefully has a positive effect on the reliability of the plant
unit and contributes to reduction of the operating costs.
The following measures are covered by the term service and
maintenance:
Maintenance measures (cleaning, readjustment) for maintaining the
desired condition;
Inspection measures (measurement, check, diagnosis) for assessment
of the actual condition;
Repair measures (replacement, rework) for restoring the desired
condition.

1 | 18 - 19
MAN TURBO AG
Version 02.2008
1.21.1
Inspection
1.21.1.1
Routine inspections / walk-around checks

The overall process plant has to be inspected daily for external damage,
leakages and safe attachment. If continuous operation of the plant unit
does not allow inspection of the components installed inside the acoustic
enclosure they are to be inspected after every run-down.
1.21.1.2
Oil analyses
The oil analyses which are to be carried out regularly are aimed at
permitting statements about the degree of fouling, ageing or the additive
values, and at protecting the unit against inadequate cooling of the
bearings due to excessive viscosity, detrimental deposits and corrosion in
the areas of the lube-oil system of gas generator and power turbine. For
information about the applicable requirements please refer to the lube oil
specification.
1.21.1.3
Checking of major functional component parts and protective equipment

Service and maintenance is aimed at maintaining or restoring the desired
condition of the plant unit. Service and maintenance which is carried out
regularly and carefully has a positive effect on the reliability of the plant
unit and contributes to reduction of the operating costs.
The following measures are covered by the term service and
maintenance:
Maintenance measures (cleaning, readjustment) for maintaining the
desired condition;
Inspection measures (measurement, check, diagnosis) for assessment
of the actual condition;
Repair measures (replacement, rework) for restoring the desired
condition.
1.21.2
Maintenance
Major maintenance measures include regular filling of the lube oil tank,
cleaning of the gas generator compressor and relubrication of motors. The
information in the respective system or component part description has to
be observed before maintenance work is started.
1.21.3
Repair
Repair of component parts or subassemblies is mainly carried out
depending on the respective actual condition, which means that fixed
dates and/or regular intervals for repair measures are not specified.
Relevant information provided by MAN TURBO AG shall only be regarded
as reference values for planning purposes. Point in time and scope of
necessary repairs depend on the operating conditions and on the state
and/or operating behaviour of the plant unit.
Version 02.2008

MAN TURBO AG
1 | 19 - 19
Base engine
2.1
System-related information
2.1.1
Design and function of base engine

Gas generator and LP turbine are the core components of the gas turbine
unit. They are collectively referred to as base engine which is mounted on
a base frame.
2.1.2
Functional principle
The THM is a twin-shaft gas turbine operating according to the
conventional simple principle of combustion at constant pressure.
This principle (see the figure below) comprises the following steps:
Adiabatic compression of air (i.e. without exchange of heat) in an axialcentrifugal compressor.
Combustion of a mixture at constant pressure in two combustion
chambers. The mixture consists of the air discharged from the
compressor and the fuel (liquid fuel or fuel gas) which is routed to the
combustion chambers via nozzles.
Initial expansion of the pressurized hot gases from the combustion
chambers takes place in a two-stage backpressure turbine which is
referred to as high-pressure turbine (HP turbine) and which is used for
drive of the axial-centrifugal compressor.
Secondary expansion of the hot gases leaving the HP turbine takes
place in a second backpressure turbine which is referred to as lowpressure turbine or power turbine (LP turbine or PT). This turbine
supplies the energy required for driving a processing machine (e.g.
pipeline compressor or electric generator) via a shaft that is not
connected to the HP turbine of the gas generator.
Version 02.2008
Base engine
MAN TURBO AG
2 | 1 - 22
Functional principle of gas turbine
2.1.3
Gas generator compressor
Driven machine
Combustion chamber
Temperature curve
Gas generator turbine
Pressure curve
Power turbine
Calculation of equivalent operating hours

Calculation of the equivalent operating hours (EOH) in the course of
determination of service and maintenance intervals or service lives is
necessary for the consideration of factors which have a major influence on
the condition of the base engine parts. Calculation is based on the
following formula:
EOH = operating hours A 1 A 2 A 3 + 10 number of starts
Factors for calculation of the equivalent operating hours
Factor
A1
Operating conditions
Weighting factor for load stage
Base load (operation at nGG or T4 limitation)
1.0
Operation predominantly below 80% base load
0.9
Base load operation with recurring, short-term overload

above the T4 limitation for base load
2.0
Version 02.2008
Base engine
2 | 2 - 22
Value
MAN TURBO AG
Factor
Operating conditions
A2
Value
Weighting factor for fuel

Low-sulphur fuel gas
1.0
High-sulphur fuel gas
1.3
Fuel oil EL, Diesel
1.3
Other fuels
A3
2.1.4
on request
Weighting factor for suction air

Low-pollutant suction air
1.0
Corrosive suction air, e.g. off-shore operation
1.3
Safety information
WARNING
Hazard of personal injury and damage to property.
Work on base engine components may only be carried out
during standstill and after a cool-down period of several
hours. Prior to performance of service and maintenance
measures the following Sections shall be observed.
2.1.5
Inspection measures V1, V2, V3, and V4

Inspection measures V1, V2, V3, and V4 are aimed at assessing the
condition of the internal base engine components.
The following tables provide an overview of the times for performance of
these measures and of the scope of components to be inspected.
At the time of inspection of the base engine, the component parts and
protective equipment which are relevant for proper functioning may be
checked.
Inspection times for base engine
Equival. OH*
10
20
30
40
50
60
70
80
90
...
Measure
V1
V2
V2
V3
V1
V2
V2
V4
V1
...
* OH = Operating Hours. The values are to be multiplied by 1,000.

Scope of base engine parts to be inspected
Inspection measure
V1
V2
V3
V4
Flame tubes
Compressor
Gas collector
Combustion chambers
HP1/HP2 stator blades
Gas collector
Version 02.2008
Base engine
MAN TURBO AG
2 | 3 - 22

Inspection measure
V1
V2
V3
V4
HP1/HP2 rotor blades
HP turbine
LP1 stator blades
LP turbine
Flame tubes
Compressor
Checking of major functional component parts and protective
equipment [J 1 | 19]
2.1.6
Maintenance
Maintenance work (cleaning, readjustment) on the base engine is limited
to keeping the outer area and/or the surroundings of the base engine
clean and to condition-dependent cleaning of the compressor.
2.1.7
General repair information

Repair of the components of the base engine depends on the respective
condition, which means that fixed dates and/or regular intervals for repair
measures are not specified. Relevant information provided by MAN
TURBO AG shall only be regarded as reference values for planning
purposes. Point in time and scope of necessary repairs depend on the
operating conditions and on the state and/or operating behaviour of the
plant unit. Assessment of the actual condition is made by the timedependent repair measures V1, V2, V3 and V4 as well as based on the
evaluation of operating data.
2.1.8
Spare parts catalogue

Data of spare parts for the base engine are listed in an electronic spare
parts catalogue which will be found on the electronic documentation data
carrier included in the supply. This catalogue which is structured according
to subassemblies covers all component parts of the base engine which are
indicated in parts lists and explosion drawings. A search function is
available for finding parts e.g. by means of the part no. or part designation.
Above that, a facility is provided for generating spare parts enquiries or
purchase orders. If requested, the EPOS Electronic Parts Ordering
System can be set up; this system makes it possible - via the internet - to
look e.g. for spare parts prices, delivery times, and parts available from
stock. Furthermore, enquiries or purchase orders for spare parts can be
submitted to MAN TURBO AG via the internet.
Version 02.2008
Base engine
2 | 4 - 22
MAN TURBO AG
2.2
Gas generator
2.2.1
Design and function of gas generator

The compressor, the combustion chamber section, and the HP turbine are
the main components of the gas generator and are shown along with other
components in the following figure.
The gas generator generates the energy required for drive of the power
turbine.
Having passed through the compressor, the air drawn in enters the Vshaped combustion chambers where it is mixed and burnt with the fuel.
Via a gas collector the hot exhaust gases reach the two-stage HP turbine
which drives the compressor of the gas generator. The surplus exhaust
gas energy is transferred further to the power turbine (LP turbine). Part of
the air from the compressor is also used for cooling the combustion
chambers and turbines.
Ignition is made by two igniters operating independently from each other.
Subsequently, combustion is self-sustaining.
Fuel supply to the gas generator is adjusted by means of a control valve
with reference to the power requirement.
2.2.2
Modular design of gas generator

The following figure illustrates the modular design of the gas generator of
a THM 1304 gas turbine unit with standard combustion chambers. The
modular design of a THM permits the exchange of all modules inside the
acoustic enclosure with only few equipment needed.
Modular design of gas generator
Version 02.2008
Base engine
MAN TURBO AG
2 | 5 - 22

1
Gas generator
Upper half compressor stator blade

carrier
Combustion chamber
10
Planetary gear unit*
Flame tube
11
Planetary gear unit connecting

shaft*
HP1 stator blade carrier
12
GG front bearing
HP turbine rotor
13
Compressor inlet casing
HP2 turbine ring
14
Compressor rotor
Upper half GG main casing
15
Upper half GG rear bearing
Gas collector
16
Lower half GG main casing
These parts are only installed in units with a starter system equipped with an
auxiliary gearbox.
Compressor inlet casing [J 2 | 6]

Combustion chambers [J 2 | 11]
Gas collector [J 2 | 10]
HP turbine [J 2 | 11]
Support of the GG rotor [J 2 | 13]
Compressor [J 2 | 8]
2.2.3
Modules of gas generator
2.2.3.1

The compressor inlet casing is a single-part casing with four hollow struts
which interconnect the inner and outer casings. The inlet casing
accommodates the GG front bearing for supporting the rotor. Further
components of the inlet casing are 18 inlet guide vanes (IGV's) with an
associated adjusting mechanism / actuator (see figure below).
The first stator blade / guide vane row of the GG compressor on the THM
1304 is of adjustable design in order to allow control of the air flow rate
(especially during start-up and rundown as well as during turndown). This
control feature makes it possible to achieve an optimum GG compressor
efficiency throughout the total speed range.
Actuation of the adjusting mechanism by means of an electrically operated
stepping motor is initiated by the GT control system as a function of the
GG speed.
Version 02.2008
Base engine
2 | 6 - 22
MAN TURBO AG
The description of the guide vane positioning system includes a diagram

which illustrates the speed-dependent guide vane position as well as the
other components of the guide vane positioning system.
Strut
Variable inlet guide vane
Guide vane positioning mechanism
Front GG bearing
Bore for instrument cable
Version 02.2008
Base engine
MAN TURBO AG
2 | 7 - 22
ATTENTION
Risk of machine damage!
The linkage of the guide vane positioning mechanism has
been set and tested at works. This setting must only be
changed by MAN TURBO AG.
Guide vane positioning
2.2.3.2
Actuating ring
Lifting rod
Inlet casing
Vane closing direction
Compressor
The compressor of the THM 1304 which supplies the air required for
combustion and/or cooling is a 10-stage axial compressor with one
centrifugal stage and consists of the following major components:
Main casing (2 parts),
Stator blade carrier (2 parts),
Axial rotor.
The air flows through the individual stages of the axial compressor and is
compressed accordingly. This compression also results in an increases in
the air temperature. The radial flow impeller of the compressor rotor
subsequently deflects the air flow by 90 and directs it into the smoothing
chamber via a diffuser which effects a reduction of the flow velocity (see
figure below). The smoothing chamber consists of the compressor stator
blade carrier casing and the GG main casing. Subsequently, the major
Version 02.2008
Base engine
2 | 8 - 22
MAN TURBO AG
part of the air present there is routed through two elbows into the
combustion chambers. The residual air is passed on via ducts and bores
for cooling of the HP turbine which serves as driver for the compressor
rotor.
Compressor design and numbering of stages
Annular duct stage 3
Stator blades
Annular duct stage 6
Smoothing chamber
Rotor blades
Axial compressor
GG rotor
Radial stage
HP turbine
Version 02.2008
Base engine
MAN TURBO AG
2 | 9 - 22
Blading
Identification of the compressor stages had to be adapted in the course of
further development of the THM 1304 as the compressor capacity was
continuously increased by adding stages 000, 00 and 0. All compressor
blades are provided with an anti-corrosion coating. Teflon segments are
screwed to the tips of the stator blades of stages 000, 00, 0, 1 and 2. The
labyrinth strips at the rotor discs of the compressor rotor work into the
Teflon in the course of the first operating hours.
This kind of sealing makes it possible to minimize clearances and thus to
keep the performance and/or efficiency losses low. The discs (into which
the blades are inserted in dovetail grooves), the radial flow impeller and
the shaft ends of the rotorare held together by 13 tie bolts.
Blow-off and cooling system
Under certain operating conditions compressor air has to be removed via
blow-off valves in order to prevent surging of the compressor. For this
purpose, the compressor stator blade carrier is fitted with radially running
grooves between the 2nd and 3rd as well as between the 5th and 6th
stages, via which the compressor air is routed into two annular ducts.
Depending on the type of machine, the drawn-off air is discharged via two
or three blow-off valves installed on top of the GG main casing. The blowoff valves installed on the bottom GG main casing half (one or two,
depending on the machine type) serve to remove the compressor air from
the last stage. For further information about the arrangement and purpose
of the blow-off valves please refer to the description of the blow-off and
instrument air system.
2.2.3.3
Gas collector
The gas collector guides the hot exhaust gases from the combustion
chamber into the HP turbine. The gas collector is cooled from outside with
the air that has been routed before via the smoothing chamber into the
combustion chambers for cooling of the flame tubes. The lower section of
the gas collector accommodates a drain connection.
Version 02.2008
Base engine
2 | 10 - 22
MAN TURBO AG
Gas collector
Gas collector
2.2.3.4
Combustion chambers
2.2.3.5
HP turbine
Drain connection
The HP turbine of the gas generator (an axial-flow two-stage backpressure

turbine) consists of the following components:
HP1 stator blade carrier,
HP turbine rotor,
HP2 stator blade carrier (2-part, vertical split joint).
Version 02.2008
Base engine
MAN TURBO AG
2 | 11 - 22
HP turbine
HP turbine rotor
HP2 stator blade carrier casing
HP1 stator blade carrier
HP2 stator blade
The single-part HP1 stator blade carrier which is centred by eight pins on
the GG main casing consists of one inner and one outer support ring as
well as the HP1 stator blades. The inner ring is bolted to the gas collector
and the outer ring to the GG main casing.
The HP turbine rotor consists of two discs and the HP1 and HP2 rotor
blades, inserted in fir-tree-shaped grooves. The pair of discs is connected
to the rear shaft end of the compressor rotor by four centring pins and four
Version 02.2008
Base engine
2 | 12 - 22
MAN TURBO AG
bolts.Sealing of the HP turbine rotor is by honeycomb seals. In the course

of the first operating hours, the labyrinth strips mounted on the rotor
blades and on the turbine disc work into the honeycomb seals. This kind of
sealing keeps the clearances and as such the performance and efficiency
losses very low.
For inspection of the hot gas parts, one carrier half can be removed (after
having shifted apart the gas generator and the power turbine).
2.2.3.6
Support of the GG rotor

The GG rotor is supported by two hydrodynamic tilting pad sleeve
bearings. With this bearing type, the lube oil pressure required for
supporting the shaft is generated by the rotary movement of the GG rotor.
With increasing speed, more and more oil is transferred from the contact
surface of the shaft into the lubricating gap. As a result, the oil pressure in
the lubricating gap increases until the shaft floats on the lube oil film.
The GG front bearing comprises one axial thrust, axial backpressure and
sleeve-type radial bearing each. During start-up the backpressure bearing
absorbs the axial force acting opposite to the direction of flow. At higher
speeds, the conditions of the axially acting forces change and the rotor is
pressed against the thrust bearing in the direction of flow.
Sealing towards the compressor space at the rear end of the GG front
bearing is made via a floating ring sliding on the shaft end of the GG rotor
and via a labyrinth seal. The required seal air is routed from the inner area
of the compressor rotor to the labyrinth seal through bores.
Thrust and backpressure bearings are formed by 12 ball-supported tilting
pads each. The sleeve bearing which serves for absorption of the radially
acting forces consists of five tilting pads.
The GG rear bearing like the GG front bearing is of two-part design, but
consists of one sleeve bearing only, the design of which is similar to that of
the GG front bearing. Contrary to the GG front bearing, sealing at both
ends of the bearing is made via floating rings and labyrinth seals. The seal
air is routed through the inner area of the compressor rotor and through
bores to the labyrinth seals.
Supply of lube oil to the GG front bearing is made through a line
connected to the GG inlet casing. Through internal ducts and lines, the oil
is fed into the annulus of the bearing and injected there through five bores
located between the tilting pads of the sleeve-type radial bearing. The oil
then gravitates from the bearing over the lower strut of the GG inlet casing
into the lube oil tank.
The line for lube oil supply to the GG rear bearing is connected to the
lower GG main casing half in the rear area. The oil is injected in the same
way as on the GG front bearing through a hose and internal ducts inside
the gas generator. By gravitational force the oil flows into a collecting
chamber and from there through a hose that is also inside the gas
generator back into the lube oil tank. Details about the instruments on the
GG bearings and on the rear GG bearing housing will be found in the
description of the base engine instrumentation.
Version 02.2008
Base engine
MAN TURBO AG
2 | 13 - 22
Lube oil connections on the gas generator
Oil feed
Oil return
Front bearing gas generator
Version 02.2008
Base engine
2 | 14 - 22
MAN TURBO AG
2.2.4
Oil feed
Oil return
Carrier for labyrinth / floating ring

seal
GG shaft
Backpressure bearing
Thrust collar
Sleeve bearing
Thrust bearing
Bearing support

The gas generator components to be inspected during the scheduled
inspection measures V1, V2, V3, and V4 are listed in the following table.
For determination of the times of implementation, the equivalent operating
hours shall be calculated according to Section 2.1.3 Calculation of
equivalent operating hours [J 2 | 2] .
Inspection measures for gas generator (part 1 of 2)
Components to be checked
Point in time
V1
V2
V3
V4
- front gearbox or inner shaft
- front bearing
- oil sealing ring and labyrinth seal
- inlet guide vanes
- upper main casing half
- upper stator blade carrier half
- clearances between rotor/stator blade carrier
- compressor rotor
Disconnection of the gas generator from the power turbine

Air inlet elbow
External inspection
Disassembly, inspection, and assembly

Air inlet casing of compressor
External inspection
Internal inspection
Disassembly, inspection, and assembly of
Compressor
Borescopic examination of stages 000 and 00
Axial displacement measurement of stages 000 and 00
Version 02.2008
Base engine
MAN TURBO AG
2 | 15 - 22

Point in time
- rear bearing
Inspection measures for gas generator (part 2 of 2)

Point in time
V1
V2
V3
V4
Combustion chambers
External inspection
Borescopic and visual inspection
- flame tubes
- slide rings
- fuel nozzles
- igniters
- slide rings
- air manifold
- main casing, top part
- gas collector
- HP1 stator blades
- HP rotor
- HP2 stator blades
- replacement of HP1/HP2 honeycomb seals
Gas collector
Borescopic and visual inspection
HP turbine
Borescopic examination of HP1 stator blades
Borescopic examination of HP rotor
Checking of clearances between rotor and stator blade carrier
x
x
2.3
Power turbine
2.3.1
Design and function of power turbine

The LP turbine consists of one each
LP1 stator blade carrier,
LP2 stator blade carrier,
Version 02.2008
Base engine
2 | 16 - 22
MAN TURBO AG
LP turbine rotor,
Main casing,
Exhaust elbow.
The LP turbine is an axial-flow two-stage backpressure turbine which
converts the energy contained in the exhaust gas from the gas generator
into rotary movement and transfers it to the processing machine via the
output coupling.
2.3.2
Modular design
The following figure illustrates the modular structure of the LP turbine of a
THM 1304 gas turbine unit with standard combustion chambers. The
modular design of a THM permits the exchange of all modules inside the
acoustic enclosure with only few equipment needed.
Modular design of the power turbine
2.3.3
LP1 stator blade carrier
LP turbine shaft
LP main casing
LP turbine rotor
LP1 stator blade carrier casing

The gas generator is connected to the power turbine via the inlet flange of
the single-part LP1 stator blade carrier. Eight thermocouples (T4) for
monitoring the PT inlet temperature and the LP1 stator blades are
arranged in the LP1 carrier.
Version 02.2008
Base engine
MAN TURBO AG
2 | 17 - 22
LP1 stator blade carrier casing
2.3.4
T4 thermocouple
LP1 stator blade
LP turbine rotor / LP2 stator blade carrier

The LP2 stator blades are inserted in the two-part LP2 stator blade carrier.
For inspection of the hot gas parts, one carrier half can be removed (after
having shifted apart the gas generator and the LP turbine).
The LP turbine rotor consists of two discs with the LP1 and LP2 rotor
blades, inserted in fir-tree-shaped grooves. The pair of discs is connected
to the LP shaft via four body-bound studs and four bolts. The shaft is
connected to the output coupling which transmits the torque to the driven
machine. Sealing of the LP turbine rotor is made by honeycomb seals. In
the course of the first operating hours, the labyrinth strips mounted on the
rotor blades and on the turbine disc work into the honeycomb seals. This
Version 02.2008
Base engine
2 | 18 - 22
MAN TURBO AG
kind of sealing keeps the clearances and as such the performance and
efficiency losses very low.
LP turbine rotor / LP2 stator blade carrier
2.3.5
LP turbine rotor with shaft
LP2 stator blade
Borescope port
Support of LP turbine rotor

The LP turbine rotor is supported by two hydrodynamic tilting pad sleeve
bearings the design and function of which is similar to that of the GG
bearings. Contrary to the GG rotor, the axial thrust, axial backpressure
and sleeve-type radial bearings are arranged at the rear shaft end.
Version 02.2008
Base engine
MAN TURBO AG
2 | 19 - 22
Sealing towards the LP turbine at the front end of the LP front bearing is
effected via a floating ring which slides on the shaft end of the LP rotor
and via a labyrinth seal. There is no sealing at the rear end of the LP front
bearing. The cooling air from the space between the two LP turbine discs
is used as seal air for the labyrinth seal. On the LP rear bearing a floating
ring and/or labyrinth seal is not installed.
Supply of lube oil to the two LP bearings is made through a line connected
to the LP rear bearing housing. Part of the oil flows directly into the LP rear
bearing while the remaining oil flows to the LP front bearing through an
internal line connecting the two bearings. Oil injection in the bearing is
made in the same way as on the GG bearings. The oil from the LP front
bearing then gravitates into the internal casing of the LP main casing.
Approximately half of the oil from the LP rear bearing also flows into the
internal casing while the remaining oil flows into the coupling guard. The
oil then returns through the line connected to the internal casing and/or to
the coupling guard into the lube oil tank.
The description of the base engine instrumentation includes information on
the instruments that are installed on the bearings and/or the rear bearing
housing.
Lube oil connections on the LP turbine
Oil feed
Version 02.2008
Base engine
2 | 20 - 22
Oil return
MAN TURBO AG
Rear bearing power turbine
2.3.6
Bearing support
Sleeve-type radial bearing
Oil feed
LP shaft
Thrust bearing
Oil supply connection
Backpressure bearing
Oil supply line to the LP front

bearing

The LP turbine components to be inspected during the scheduled
inspection measures V1, V2, V3, and V4 are listed in the following table.
For determination of the times of implementation, the equivalent operating
Version 02.2008
Base engine
MAN TURBO AG
2 | 21 - 22
hours shall be calculated according to Section 2.1.3 Calculation of

equivalent operating hours [J 2 | 2] .
Inspection measures for power turbine
Point in time
V1
V2
V3
V4
Measurement of axial displacement
Checking of clearances between rotor and stator blade carrier
- oil sealing ring and labyrinth seal
- LP turbine shaft
- front and rear bearing
LP1 stator blades

LP2 stator blades
LP turbine rotor
LP turbine shaft and bearings
Plate lining of LP casing

Visual inspection
Exhaust elbow
External inspection
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2 | 22 - 22
MAN TURBO AG
Instrumentation base engine
3.1
3.1.1
Design and function

The instrumentation of the base engine mainly comprises the speed,
pressure, vibration, bearing wear, and temperature measuring devices
which are installed on gas generator and power turbine and which are
required on the one hand for control purposes and on the other hand for
monitoring of the gas turbine.
Location of base engine measuring devices*
Drive coupling with gear wheel for speed measurement of GG rotor

(in the case of units with mechanically driven main lube oil pump the GG speed
sensors are located on the auxiliary gearbox.)
Front GG bearing with vibration measurement, keyphasor, bearing monitoring

(temperature, wear)
Rear GG bearing with bearing temperature monitoring
PT inlet temperature measurement
Front PT bearing with bearing temperature monitoring
Rear PT bearing with vibration measurement, keyphasor, bearing monitoring

(temperature, wear), speed measurement
The Figure shows a gas generator with standard combustion chambers. In the
case of gas generators with DLN combustion chambers the measuring locations
are the same as shown in the illustration.
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Instrumentation front GG bearing
Bearing wear sensors
Keyphasor
Instrumentation rear PT bearing
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3.1.2
Cables of vibration sensors arranged directly

behind the speed sensors.
Speed sensors
Keyphasor
Bearing wear sensors
Safety information
WARNING
Work on base engine components may only be carried out
during standstill and after a cool-down period of several
hours. Prior to performance of service and maintenance
measures the following Sections shall be observed.
3.1.3
Inspection
Routine inspections and walk-around checks have to be carried out
regularly. Additionally, an annual major inspection of the described system
is recommended.
Routine inspections / walk-around checks [J 1 | 19]
3.2
Speed measurement (nGG, nPT)
3.2.1
Design and function

The main components for speed measurement are 4 inductive speed
sensors, and 2 overspeed protection relays installed in the GT control
cabinet.
The two speed sensors envisaged for monitoring the GG rotor are
installed on the auxiliary gearbox. The two speed sensors envisaged for
monitoring the PT rotor are installed in the rear PT bearing location.
The speed sensors generate a frequency proportional to the number of
impulses. In the case of the gas generator the impulses are generated by
means of a gear wheel (number of teeth = 50) which is fixed to the
auxiliary gearbox. In the case of the power turbine the impulses are
generated by means of a shaft toothing (number of teeth = 60).
Two speed signals are picked up for each rotor (GG, PT); one of these
signals is processed by the GT control system and the other one by the
overspeed protection relay. The sensor cabling is routed through a rib of
the GG inlet casing or the PT main casing via a terminal box installed on
the GT base frame to the GT control panel.
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Arrangement of GG speed sensors
Auxiliary gearbox
Cardan shaft
Fitting plates for GG speed sensors
Gas generator connecting flange
3.3
Inlet temperature measurement on power turbine (T4)
3.3.1
Design and function

The main component parts of PT inlet temperature measurement are 8
double thermocouples, 10 temperature measuring transducers and one
evaluation unit (component part of the GT controller).
Measurement serves amongst others for monitoring the ignition process,
for protecting the gas turbine unit against overfiring and for measuring
individual and averaged values which are necessary for control of the gas
turbine unit.
Two thermal e.m.f's are generated for each thermocouple, one serves for
determining the individual values and the other for average value
generation. Average value generation is made by means of the
temperature measuring transducers.
Arrangement of the thermocouples in the LP1 stator blade carrier casing
of the power turbine is shown in the figure below. There is a total of 12
ports in the LP1 casing; 4 of these are closed by blind flanges and are not
identified by a number in the figure below.
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Arrangement of the T4 thermocouples (shown in the direction of flow)
Assembly location of a T4 thermocouple
T4 cable
LP1 casing
Thermocouple element
HP2 casing
Protection sleeve
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3.3.2
Exchange of T4 thermocouple
NOTE
Note concerning installation.
When installing the T4 thermocouple take special notice of the groove
in the thermocouple cartridge and the tongue of the T4 thermocouple
which is visible when looking into the cap nut. The tongue and groove
ensure that the openings in the area of the thermocouple tip point in
the direction of flow and the T4 temperature can thus be measured
correctly.
1. Loosen the cable ends of the T4 thermocouples to be exchanged in the

terminal box.
2. Loosen the cap nut of the T4 thermocouple on the LP1 stator blade
carrier casing.
Note: The screws of the T4 protection sleeve need not be loosened.
3. Install the T4 thermocouple.
4. Tighten the cap nut.
Note: Observe the tightening torque in Chapter General service and
maintenance information.
5. Connect the cable ends of the T4 thermocouple in the terminal box.
Tightening torques for base engine connections [J 1 | 15]
3.4
Vibration measurement
3.4.1
Design and function

4 inductive proximity sensors (vibration pick-ups), 4 signal transducers and
electronic cards are installed to monitor the vibrations of the GG and PT
rotors.
The two sensors for monitoring the GG rotor vibration are installed in the
front GG bearing section and the PT vibration sensors in the rear PT
bearing section (see figures in Section 3.1.1 Design and function [J 3 | 1]
). The sensor cabling is routed through a rib of the GG inlet casing and the
PT main casing to the signal transducers.
Due to the radial movement of the rotor the oscillating circuit created by
the sensor coil is dampened considerably, i.e. the cyclic stress is greatly
reduced. The generated negative voltage signal is proportional to the
distance between sensor and shaft.
The measured signals are transmitted by the signal transducers to the
vibration monitor in the GT control cabinet where they are evaluated and
indicated. If a limit value is exceeded, either an alarm is issued or tripping
initiated.
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3.5
Phase angle measurement
3.5.1
Design and function

Phase angle measurement comprises 2 keyphasor sensors, 2 signal
transducers and, depending on the design, either 1 or 2 electronic card(s).
One keyphasor each is located in the front GG bearing section and one in
the rear PT bearing section (see figures in Section 3.1.1 Design and
function [J 3 | 1] ). The sensor cabling is routed through a rib of the GG
inlet casing and the PT main casing to the signal transducers. The
electronic cards for evaluation are a component part of the vibration
monitor which is installed in the GT control cabinet.
The keyphasor is a position transducer or a capacitive proximity sensor
which once every revolution generates a voltage signal via a square bar or
pin fastened on the GG or PT shaft; this signal is transmitted to the
vibration monitor via a signal transducer. The keyphasor signal serves for
illustrating the relation between speed and vibration frequency.
3.6
Bearing temperature measurement
3.6.1
Design and function

Bearing temperature measurement comprises 12 thermocouples and 6
temperature transducers.
Each bearing is provided with 2 thermocouples; one of these is connected
to a temperature transducer and the other - which is routed to the
measuring transducer - serves as standby and is connected only in the
event of failure of a thermocouple.
The thermocouple is passed through a bore in the tilting pad of the
bearing. Cabling of the thermocouples is routed through a rib of the GG
inlet casing or the PT main casing to the GT control panel via terminal
boxes.
3.7
Wear measurement on thrust bearing
3.7.1
Design and function

Wear measurement on the thrust bearing comprises 4 capacitive proximity
sensors and 4 signal amplifiers (proximitors).
Two sensors each for monitoring axial wear on the thrust bearing are
arranged in the front GG bearing section and in the rear PT bearing
section (see figures in Section 3.1.1 Design and function [J 3 | 1] ).
The sensor cabling is routed through a rib of the GG inlet casing and the
PT main casing to the signal transducers.
The electronic cards for evaluation are a component part of the vibration
monitor which is installed in the GT control cabinet.
Due to the axial movement of the rotor the oscillating circuit created by the
sensor coil is dampened considerably, i.e. the cyclic stress is greatly
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reduced. The generated negative voltage signal is proportional to the

distance between sensor and shaft.
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Fuel gas system
4.1
4.1.1
Design and function

The fuel gas system mainly comprises: trip and vent valves; fuel gas filter;
monitoring instruments (e.g. for pressure, temperature, etc.) as well as one
fuel gas metering valve.
The fuel gas system operating in conjunction with the GT control system
supplies the gas turbine with fuel gas during start-up and subsequent
operation. Further, it warrants immediate isolation of fuel gas feed
especially in the case of a trip (e.g. due to overtemperature and overspeed
conditions or component malfunctions).
The fuel gas flows through a fuel gas filter and trip valve(s) to the fuel gas
metering valve. The fuel gas flow rate is regulated in line with the
operating condition and the gas turbine power setting and routed to the
two combustion chambers.
In the event of a gas turbine unit trip, the fuel gas trip valve is closed, the
vent valve is opened and the fuel gas present in the pipes is discharged
through vent pipes.
4.1.2
Fuel gas specification
4.1.2.1
General
This fuel gas specification defines the requirements for gaseous fuels to
be used in THM gas turbines. Natural gases with a methane content of
more than 80% by volume are used by preference. Generally, the limit
values for physical and chemical properties listed in the table below have
to be adhered to.
Gaseous fuels which do not correspond to the limit values given in the
table may possibly be approved for THM gas turbines nonetheless. For
this, however, the technical department of MAN TURBO AG has to make a
detailed assessment of these values. By special protective measures
carried out on gas turbine components it may become permissible to
exceed individual limits. In the case of gas turbines which are equipped
with Dry-Low-NOx (DLN) combustion chambers further limit values have to
be observed to ensure trouble-free operation.
When assessing the gas analysis especially those substances have to be
considered which can lead to corrosion, e.g. alkaline metals (sodium,
potassium, etc.) or sulphur compounds so that adequate steps can be
taken for minimising corrosion in the gas turbine or the fuel system.
In addition to assessment of the gas analysis and of impurities contained
in the fuel gas envisaged for operation customer is urgently recommended
to set up a suitable system for fuel supply and conditioning as well as for
monitoring the fuel gas quality.
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The table specifies limit values for the concentration of various impurities.
Further possible sources of impurities are the inlet air, and, if applicable,
the water which is injected into the combustion chamber. The limit values
in the table are valid on the assumption that additional impurities will not
be added through air or water. If, however, this should be the case, the
limit values for fuel gas have to be reduced for each component as shown
in the following formula:
Cmax,corrected = Cmax, table - AFR x Cair - WFR x Cwater
4.1.2.2
Cmax,corrected
Corrected max. permissible concentration
Cmax, table
Maximum permissible concentration from the table
Cair
Expected concentration in the air
Cwater
Expected concentration in the injection water
AFR
Mass flow ratio air to fuel (typically approx. 60 : 1)
WFR
Mass flow ratio injection water to fuel (typically 0.5 - 1.0 : 1)
Minimum physical and chemical properties profile of gaseous fuels

Fuel gas properties
Property
Limit value
Lower heating value (LHV)
31 - 48 MJ/mN3 *)
Wobbe Index (Note 1)
40 - 53 MJ/mN3 *)
Admissible fluctuation of heating

value and Wobbe Index with set
control
Test method
10%
Methane content (CH4)
min. 80% by vol. (only DLN)
Content of hydrocarbons C3 or
heavier
max. 4.0 vol.-% (only DLN)
Hydrogen content (H2)
max. 1.0 vol.-% (only DLN)

max. 60 vol.-%
(standard combustion chamber)
Ratio between upper and lower

quenching limit
(at 101.3 kPa, 25C)
min. 2.2 (only DLN)
Water content (H2O)
(Note 2)
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Property
Dust particle impurities:
Limit value
Test method
max. 20 ppm wt
ISO 3735
Particle diameter > 10mm

Particle diameter 2 - 10mm
0 vol.-%
10 vol.-%
Impurities with corrosive effect :

Total sulphur content
max. 100 ppm vol. (without

special coating)
ISO 8754
max. 1.5 vol.-%

(with special coating in the
turbine section)
(Note 3)
Sodium + potassium
max. 0.5 ppm wt
DIN 51797
*) mN referred to standard conditions (0C, 101.3 kPa)
Note 1
Wobbe Index (corrected to 15C) =
T = Fuel gas temperature [C]

d = ratio of standard density of fuel gas to standard density of air
Hu = lower heating value [MJ/Nm]
Note 2
The water content must not exceed a max. concentration during which gas
hydrates might develop immediately upstream the fuel gas control valve,
taking into consideration the fuel gas temperatures, pressures, and
compositions which are possible during operation. Gas hydrates are not
allowed. Heating up of the fuel is permissible.
Note 3
Sulphur dioxide (SO2) develops through combustion of sulphur
compounds in the fuel gas. The total sulphur content must therefore be
limited to such an extent that compliance with the emission limit values
specified by the local approval authorities is ensured.
Among other elements, the total sulphur contains hydrogen sulphide
(H2S), mercaptan, carbon disulphide (CS2), carbonyl sulphide (COS),
thiopenes and sulphur oxides.
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4.1.2.3
Fuel gas pressure

The following table contains limit values which have to be maintained at
the inlet of the fuel gas control valve, i.e., downstream of the gas pressure
control unit.
Fuel gas pressure at the inlet to the fuel gas control valve
Property
Limit value
Test method
Minimum fuel gas inlet pressure

(Note 4) :
THM 1203
approx. 1.5 MPa (absolute)
THM 1304-10
THM 1304-11
Maximum admissible fuel gas inlet

pressure
3.1 MPa (absolute)
Acceptable pressure variation
2,5%
DIN 3380
Acceptable hysteresis of fuel gas

pressure
4%
DIN 3380
Admissible deviation of fuel gas

pressure from set-point value at
minimum flowrate
15%
Admissible transient pressure

change
max. 0.2 bar/s
Note 4
The minimum fuel gas inlet pressure given in the table refers to ISO
conditions (15C air inlet temperature, sea level, no pressure losses).
The fuel gas inlet pressure required in each respective case depends on
the installation and operating conditions and also on the fuel gas
composition. Calculation for a specific project can be made by MAN
TURBO AG.
4.1.2.4
Fuel gas temperature (gas turbine inlet)

Liquid constituents in the fuel gas are not allowed. The min. temperature
must be 20 K above the dew point of heavy hydrocarbons and 20 K above
the dew point of water.
Limit values for the fuel gas temperature
Property
Limit value
Minimum fuel gas temperature
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0C
MAN TURBO AG
Property
Limit value
Maximum dew point temperature
50C
Maximum fuel gas temperature
70C *)
Admissible transient temperature change
max. 4 K/min
*) With minor modifications to the fuel gas system 90C are also acceptable.
4.1.3
Safety information
WARNING
The service and maintenance work described for the fuel
gas system can only be carried out with the gas turbine unit
at standstill and cooled down. Where work can be carried
out during ongoing operation (e.g. work on a change-over
type filter) a note is added under the relevant component
description.
For safety reasons the components of the fuel gas system
must not be dismantled and repaired at site but only in an
authorized workshop.
Prior to performance of service and maintenance measures
the following Sections shall be observed.
4.1.4
Service and maintenance

The service and maintenance intervals have to be determined by the
Operator / User by reference to the operating conditions such as medium /
temperature / degree of fouling / environmental effects / operating cycle,
etc. MAN TURBO AG recommend a 2-year interval for the performance of
inspection, maintenance, and possibly repair work.
U CAUTION
Warning of pressurized media!
Before start of work make sure that the operating system is
isolated and that the section to be inspected has been
drained, or, in the case of gas systems, has been
adequately inertized.
The safety shut-off facilities with bellows seal on the spindle or automatic
sealing set with subsequent additional O-ring or grooved ring seal are
designed for maintenance-free operation.
Owing to the encapsulated design there is no access from the spindle
guide towards the outside, so that readjustment (such as in the case of
stuffing box packings) is excluded and constant frictional forces are
maintained for a safe operating mode.
Checking of the spindle seal for external tightness (bellows or automatic
sealing set) can be made at the test connection provided for this purpose
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(see following figure) by brushing with Nekal; this should be done at

specified time intervals during the walk-around checks.
In case of even minor leakage the damage must be eliminated at the
earliest possible opportunity by personnel at site or by the manufacturer.
Operation can be maintained for a short period only by plugging the test
connection (G1/8).
Any sealing of the guides of movable parts through stuffing boxes
adjustable by hand is not permitted for safety shut-off facilities according
to the applicable standards for component testing.
Testing of internal tightness valve seal on the seat of a single trip valve
can be made based on the pressure drop or pressure rise method. For
this, appropriate shut-off valves and measuring connections must be
available.
Testing of internal tightness valve seal on the seat, in the case of gas trip
combinations on the burner can be made as follows after venting the
space between the two valves:
a) By means of an optical leakage check facility downstream of the
intermediate vent valve (float or bubble vessel with water fill). During
this test with gas pressure applied, only the first valve in flow direction is
checked for leak proofness.
b) By an automatic leakage check facility (interrogated via pressure
monitor). During this test with gas pressure applied, both valves are
checked for leak proofness according to the pressure rise / pressure
drop method. In case of a leakage, start-up of the burner is prevented
by the electric interlock in the safety chain. In such a case the damage
has to be corrected immediately by the maintenance personnel or by
the manufacturer.
On safety shut-off facilities service and maintenance has to be carried out
by the manufacturer after an operating period of 2 3 years at the latest.
In the course of this work damaged parts are replaced and signs of wear
are assessed for determining whether continued use of the safety shut-off
facilities is possible.
All elastomers must be replaced after 5 years at the latest (limited by the
manufacturer guarantee for elastomers). This is also necessary if the
safety facility was not actually used in operation.
The same conditions apply to mounted control parts especially the
solenoid control valves. During revision of the solenoid valves,
disassembly shall be carried out on a spot-check basis so that wear parts
and cleanliness of the control air system can be assessed.
During maintenance of the valve actuators the cylinder tube and the
spindle guides/seals shall be lightly greased prior to assembly. The
recommended lubricant is silicone paste, e.g. Gleitmo 750.
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ATTENTION
Risk of malfunctions!
Following the performance of service and maintenance
measures, proper functioning has to be rechecked as
described above prior to re-starting; component parts
designed for signalling (e.g. limit switches) may have to be
readjusted.
Test connection on trip / vent valve
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4.1.5
Venting
Instrument air connection
Test connection
Inspection
is recommended.
4.1.6
Repair
General information relating to the replacement of components (e.g.
pressure switches, pressure sensors, limit switches, thermometers,
pressure gauges, valves, etc.) not included in the present system
description will be found in Chapter "General service and maintenance
information". Should any further information be required, please contact
the MAN TURBO AG After Sales Service.
General notes on the exchange of component parts [J 1 | 5]
4.2
Job-specific and system-related documents
4.2.1
Drawings
Drawings (as far as listed in the following) are filed in the printed
documentation in folder Drawings.
4.3
Fuel gas metering valve
4.3.1
Design and function

The fuel gas metering valve (see illustration below) installed inside the
acoustic enclosure serves on the one hand for the supply of ignition gas to
the igniters and on the other hand for control of the fuel gas mass flow
during load operation of the gas turbine. With reference to the GT
performance set by the operator a stepping motor is actuated amongst
others by the GT control system and the fuel gas metering valve is
adjusted accordingly.
The fuel gas metering valve is a compact unit comprising the actual
metering valve, a stepping motor, limit switches, solenoid valves and a
pressure limiting and trip valve.
During the ignition cycle, the fuel gas flows into the fuel gas metering
valve, and then via the ignition gas pressure limiting valve and the ignition
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MAN TURBO AG
gas solenoid valve to the two igniters in the combustion chambers. In

order to prevent the fuel gas from flowing to the fuel nozzles during
initiation of the ignition cycle, the metering valve, the solenoid valve and
the trip valve are closed.
The spark plugs ignite the air/fuel gas mixture flowing out of the igniters.
The solenoid valve is then energised to open. This causes the trip valve
located downstream of the metering valve to also open. If the trip valve
has not opened, the limit switch initiates tripping of the gas turbine.
Actuation of the stepping motor opens the fuel gas metering valve,
allowing fuel gas to flow to the two fuel nozzles of the combustion
chambers where it is mixed with compressor air and ignited.
Following successful completion of the ignition cycle, the ignition gas
solenoid valve is closed. The actual position of the metering valve
detected by the repeater is processed by the GT control system. Under
certain operating conditions a limit switch initiates an alarm if the metering
valve is not closed.
During the purging process or following a trip, the fuel gas remaining in the
fuel gas metering valve is discharged through a vent line into the
atmosphere via the solenoid valves and a pipe connected to the trip valve.
For calibration, switches are provided on the GT control panel for manual
actuation of the fuel gas metering valve. During calibration, the position of
the valve can be read from a scale directly fitted on the valve.
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Fuel gas metering valve
Terminal box
Solenoid pilot valve for trip valve
Repeater
Stepping motor
Ignition gas release valve

connection *
Terminal box
Vent port
Trip valve
Vent valve
10
Compensation connection
The Figure shows a dummy flange instead of the ignition gas release valve.
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4.4
Fuel gas filter
4.4.1
Subcontractor documentation
The subcontractor documents are filed in the printed documentation in
folder Operating Instructions for Components.
4.4.2
Drawings
Drawings (as far as listed in the following) are filed in the printed
documentation in folder Drawings.
4.5
Trip valve
4.5.1
Design and function

The fuel gas system of the gas turbine is equipped with a pneumatically
operated trip valve (for number of installed trip valves refer to the
instrument list and to the P&I diagrams). In the event of a trip of the gas
turbine unit, it immediately shuts off the fuel gas supply to the fuel gas
metering valve and thus to the combustion chambers of the gas turbine.
The valve position is monitored by limit switch. The trip valve is actuated
by instrument air. For safety reasons failure of the instrument air supply
results in immediate closing of the trip valve with simultaneous opening of
the fuel gas vent valve as well as tripping of the gas turbine unit. A
solenoid valve is provided for trip valve activation.
4.6
Vent valve
4.6.1
Design and function

The fuel gas accumulating during depressurisation of the fuel gas system
on shutdown of the gas turbine is conveyed to the atmosphere via a
pneumatically operated vent valve (for the number of installed vent valves
refer to the instrument list and to the P&I diagrams) and the associated
piping. The valve position is monitored by limit switch. A solenoid valve is
provided for actuation of each vent valve.
4.7
Pressure transducer
4.7.1
Subcontractor documentation
The subcontractor documents are filed in the printed documentation in
folder Operating Instructions for Components.
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Ignition system
5.1
5.1.1
Design and function

The main components of the ignition system comprise two igniters and two
high-voltage ignition transformers. One igniter each is fitted laterally in the
combustion chamber casing. The ignition transformers are installed in a
casing which is located to the right of the gas generator (view in direction
of flow).
The ignition system is designed for igniting the fuel/air mixture in the two
combustion chambers during the start-up process of the gas turbine.
5.1.2
Safety information
WARNING
The service and maintenance measures described in the
following must only be performed with the gas turbine unit at
standstill and cooled down.
Prior to the exchange of any components, the ignition
system must be safely isolated from the supply voltage. If
this is not observed, there is the risk of an electric shock
owing to the extremely high voltage. Work on the ignition
system may be carried out at the earliest 30 minutes after
voltage supply has been discontinued to permit the stored
charge to decay.
the following Sections shall be observed.
5.1.3
Inspection
is recommended.
5.1.4
Ignition test
For checking proper functioning of the ignition system a program
sequence is envisaged which can be selected via button "ignition test" on
the GT control panel. The following sequence description is based on a
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fuel gas system with two vent and trip valves. The sequence is identical for
plant units with just one vent and trip valve.
For initiating the sequence the following steps have to be carried out:
1. Observe the general safety information given in the system description.
2. Actuate button "ignition test".
3. Actuate button "... start-up preparation".
4. Actuate button " pressurization" (only for plant units with compressor).
5. Actuate button " start".
Note: When purging for the removal of gas residues from the gas
turbine interior has been carried out, the following sequence steps are
initiated for checking proper functioning of the ignition system.
6. The instrument air solenoid valves are changed over and the vent and
trip valves opened. For approx. 10 to 30 seconds gas flows through the
vent valves for purging impurities (especially condensate) from the fuel
gas piping.
7. The instrument air solenoid valves for activation of the two vent valves
are changed over and the vent valves are closed.
8. The ignition transformers for supply of the ignition electrodes are cut in.
9. The fuel gas control valve is opened. The fuel gas flows to the ignition
electrodes. In the area of the ignition electrodes the fuel gas is mixed
with compressor air and ignited.
10.
Proper functioning of the ignition system can be assessed by
reference to the slight rise in the T4 temperature (approx. 5 to 8C / 41
to 46.4F) or to the noise developed by the ignition transformers.
11.
The ignition test is complete when the fuel gas trip valves close,
the fuel gas vent valves open, and the ignition transformers are cut out.
12.
Unless the gas turbine is then stopped and button "ignition test"
actuated once more, the start-up procedure is continued with repetition
of the purging operation.
13.
If ignition problems should still occur, please contact the Service
Department of MAN TURBO AG.
5.1.5
Repair
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5.2
Ignition transformer
5.2.1
Design and function

The two ignition transformers are installed in a casing next to the gas
generator. The ignition transformers are connected to the igniter spark
plugs through the ignition cables and supply the spark plugs with a voltage
of approx. 2,000 V.
Design of ignition transformers
5.2.2
Replacement
Z Observe the general safety information given in the system description.
1. Open the ignition transformer casing.

2. Disconnect the wiring from the ignition transformer to be replaced and
mark the cables, if necessary.
3. Exchange the ignition transformer.
4. Connect the cables.
5. Tighten the screw fitting on the ignition transformer casing.
6. Carry out an ignition test.
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5|3-4
5.3
Igniters
5.3.1
Design and function

The igniters which are fitted laterally into the combustion chamber casings
consist of a double-wall casing with screwed-in fuel nozzle and spark plug.
The casing is equipped with a connection for supply of the fuel nozzle with
fuel gas. Compressor air and fuel gas enter the interior of the igniter
casing through bores and slots. It is here that mixing and ignition take
place.
Location and design of the igniter
Spark plug
Compressor air supply
Liquid fuel supply*
Fuel gas supply
Igniter
In units operated on fuel gas, the liquid fuel supply connection is closed by
means of a plug screw.
Version 02.2008
Ignition system
5|4-4
MAN TURBO AG
Guide vane actuator
6.1
System information
6.1.1
Design and function

The main components of the guide vane positioning system include the
GG compressor inlet casing with 18 movable inlet guide vanes, a
positioning mechanism and an electrically driven servo motor as well as a
positioner.
The first stator blade / guide vane row of the GG compressor on the THM
1304 is of adjustable design in order to allow control of the air flow rate
(especially during start-up and rundown as well as during turndown). This
control feature makes it possible to achieve an optimum GG compressor
efficiency throughout the total speed range. Above that, a favourable
air/fuel ratio is ensured and compressor surging avoided. Positioning of
the guide vanes is made as a function of the GG speed via the gas turbine
control system. The actual position of the inlet guide vanes detected by a
position sensor is processed in the GT control system.
Guide vane positioning mechanism
Limit switch
Protective sheathing
GG compressor inlet casing
Actuator
Version 02.2008
Guide vane actuator

MAN TURBO AG
6|1-5
6.1.2
Diagram guide vane angle vs. GG speed
Diagram guide vane angle vs. GG speed
Guide vane angle
Version 02.2008
Guide vane actuator

6|2-5
ISO corrected GG speed
MAN TURBO AG
6.1.3
Safety information
WARNING
standstill and cooled down. Prior to performance of service
and maintenance measures the following Sections must be
observed.
6.1.4
Maintenance
Service and maintenance work on the guide vane positioning system must
only be carried out by appropriately trained and authorized personnel.
Following exchange of the servo motor, the guide vane positioning system
has to be calibrated.
6.1.5
Inspection
is recommended.
6.2
Position sensor
6.2.1
Design and function

The position sensor installed on the GG compressor inlet casing (in 1
oclock position) serves for detection of the actual position of the inlet
guide vanes. The stem of the electromechanical position sensor is directly
connected to one of the inlet guide vanes. Movement of the inlet guide
vane simultaneously initiates rotation of the stem. On the one hand, the
position of the guide vane is locally indicated on a scale and on the other
hand transmitted to the GT control system via the measuring sensor
installed in the head of the position sensor.
The position sensor is equipped with a heat shield to protect it from heat
radiation. In addition, an instrument air line is directed to the position
sensor for cooling.
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Guide vane actuator

MAN TURBO AG
6|3-5
Location and design of position sensor
Measuring value sensor
Inlet guide vane
Heat radiation shield
mech. position indicator
GG compressor inlet casing
6.3
Switch - Calibration of guide vane positioning system
6.3.1
Design and function

By means of a switch which is installed on the GT control panel, the guide
vane positioner can be switched over from automatic to manual mode for
calibration of the system and for cleaning the GG compressor. Two other
switches are provided on the GT control panel for fully opening or fully
closing the inlet guide vanes after change-over to manual mode.
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6|4-5
MAN TURBO AG
ATTENTION
Risk of damage to the gas turbine unit!
Change-over to the manual mode may only be performed
with the plant unit at standstill and exclusively for test and
calibration purposes. This work may only be carried out by
appropriately trained and authorised personnel.
Version 02.2008
Guide vane actuator

MAN TURBO AG
6|5-5
Blow-off and instrument air system
7.1
7.1.1
Design and function
7.1.1.1
Blow-off system
The blow-off system prevents surging of the compressor such that
particularly during start-up, shut-down and part-load operations
compressor air is discharged via blow-off valves from the third, sixth and
last (radial) compressor stages into the atmosphere via headers
connected to the exhaust duct.
In addition, two pressure sensors are dedicated to the blow-off system for
monitoring the compressor discharge pressure and the PT inlet pressure.
A total of five blow-off valves (1 x 3rd stage, 2 x 6th stage, 2 x radial stage)
is fitted to the front of the GG main casing.
During normal GT operation, compressor air is taken from the radial stage
and routed through pipes into the control chamber of the blow-off valves in
order to keep them closed.
One solenoid valve each is provided for activating each blow-off valve. If
the GG rotor reaches the (ISO-corrected) speeds indicated in the following
Table, power supply to the solenoid valve is switched on or off as required,
thus adjusting the air supply to the valve control chamber.
The gas turbine is monitored for surges by means of a differential pressure
sensor. The two measuring lines are installed at two different locations on
the intake elbow. Further information relating to this measurement is
provided in the description of the intake air filter system.
ATTENTION
Risk of damage to the gas turbine!
If a surge is detected, the gas turbine is tripped for safety
reasons. The gas turbine may only be started up again after
the cause of the surge has been investigated and remedied.
Position of blow-off valves
Valve
Blocked position
Flow position
rpm (GG speed, ISO-corrected)

3. stage
10,100
10,100
6. stage
10,100
10,700
10,000
10,600
Radial stage
9,500
9,750
9,400
9,650
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MAN TURBO AG
7|1-6
Arrangement of the blow-off valves*
7.1.1.2
Blow-off valve, stage 3
Blow-off valves, radial stage
Blow-off valves, stage 6
The Figure shows a gas generator with standard combustion chambers. The
arrangement of the blow-off valves is identical for gas generators with DLN
combustion chambers.
Instrument air system

The instrument air system supplies the necessary compressed air for
closing the blow-off valves during GT compressor cleaning and in this way
prevents draining of cleaning fluid via the blow-off valves.
Before the GT compressor cleaning operation is carried out, the
instrument air system must be connected to the piping of the blow-off
system by using hoses. Further information relating to these measures
and to the cleaning operation will be found in the description of the
cleaning system.
Version 02.2008

7|2-6
MAN TURBO AG
7.1.2
Safety information
WARNING
standstill and cooled down. Prior to performance of service
and maintenance measures the following Sections must be
observed.
7.1.3
Inspection
is recommended.
7.1.4
Repair
7.2
Blow-off valves
7.2.1
Design and function

The five blow-off valves are almost identical in design. Some of the valves
are, however, additionally equipped with a spring ( 4 ) or with different
valve plugs ( 5 ). The spring which is installed in the blow-off valves of
stages 3 and 6 supports complete opening of the valve. A shoulder on the
valve plug of the blow-off valves of stage 6 and of the radial stage reduces
the cross-section of the valve and as such the outgoing air flow (stage 6 to
50% and radial stage to 60% for each valve).
The compressor air taken from the radial stage is routed via a port ( 1 )
into the control chamber of the blow-off valves. The valve stem which is
connected to a rubber diaphragm is forced down keeping the valve closed.
If air supply to the control chamber is interrupted by closing of the
associated solenoid valve, the valve is opened by the compressor air
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MAN TURBO AG
7|3-6
acting on the valve plug. When the gas turbine is at a standstill, the valve
is kept open by the diaphragm (with some support by the spring).
Design of blow-off valve
7.2.2
Compressor air (radial stage)
Spring
Diaphragm
Valve plug
to the atmosphere
from the compressor
Replacement
ATTENTION
Risk of damage to the gas turbine!
As the blow-off valves are of identical appearance on the
outside, special care must be taken to ensure that the
correct valve is installed. Refer to the spare parts catalogue
for unambiguous identification. Installation of a blow-off
valve at the wrong location can lead to gas turbine damage.
Z Observe the general safety information given in the system description.
1. In view of its weight, the blow-off valve to be removed must be

suspended from the acoustic enclosure crane using a suitable hemp
rope.
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7|4-6
MAN TURBO AG
2. Loosen the screw connections on the blow-off valve (piping, GG main

casing).
3. Use the enclosure crane to handle the defective and the new valve.
4. Apply graphite paste Never-Seez to the blow-off valve fastening bolts.
5. Use new seals when screwing down the blow-off valve.
6. Note: Observe the "Tightening torques for base engine connections" in
Chapter General service and maintenance information.
7.3
Solenoid valves (for activation of blow-off valves)
7.3.1
Design and function

The electrically actuated and directly controlled 3/2-way solenoid valves
are provided for activating the blow-off valves. Activation of the solenoid
valves is made as a function of the GG speed.
The solenoid valves are mounted on a rack inside the acoustic enclosure
on the right-hand side (view in direction of flow) next to the GG inlet
casing.
Ports on the solenoid valve
Port 1: Control chamber vent
Port 2: To control chamber of blow-off valve
Port 3: From compressor (radial stage)
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MAN TURBO AG
7|5-6
7.4
Pressure sensors compressor discharge pressure / PT inlet pressure
7.4.1
Design and function

The pressure sensors for measuring and monitoring the compressor
discharge pressure (P2) and the PT inlet pressure (P4) are dedicated to
the blow-off and instrument air system.
The pressure sensors are mounted on the instrument rack which is
located in the right-hand front area of the acoustic enclosure (view in
direction of flow).
For further details refer to the instrument list.
Version 02.2008

7|6-6
MAN TURBO AG
Drainage system
8.1
8.1.1
Design and function

The drainage system mainly consists of three pneumatically operated
drain valves and a drainage vessel. The valves are connected to the
intake elbow, to the GG main casing, and to the exhaust elbow.
The drain valves are kept in closed position during GT operation by GG
compressor air. The valves are open during start-up, post-lubrication,
standstill and/or the cleaning process. The lube oil or waste water drained
through the valves is routed to a drainage vessel. Disposal of the liquid
accumulating there must be carried out properly in compliance with the
laws applicable at the site location.
U CAUTION
Fire hazard!
Should lube oil escape during start-up or post-lubrication
from one of the drain valves connected to the inlet bend and
to the GG main casing, the gas turbine unit must not be
started until this malfunction has been eliminated. While the
oil mist separator is not in operation during the start-up
process or during the post-lubrication phase or if the
separator is not functioning properly there is an increased
risk of lube oil penetrating through the bearings into the gas
turbine and being ignited there. Oil residues outside the
bearing locations must therefore be carefully removed and
proper functioning of the oil mist separator ensured at all
times.
8.1.2
Safety information
U CAUTION
Hazard of injuries!
Except for evacuation of the drainage vessel or of the
foundation pit, work on the drainage system can only be
carried out with the gas turbine at standstill. Work inside the
acoustic enclosure may only be carried out after an
adequate cooling-down period.
the following Sections must be observed.
8.1.3
Inspection
is recommended.
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Drainage system
MAN TURBO AG
8|1-2

8.1.4
Repair
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Drainage system
8|2-2
MAN TURBO AG
Cleaning system
9.1
9.1.1
Design and function

The main components of the cleaning system include the offline cleaning
nozzles (4 off) located in the GT intake elbow which are interconnected
through a ring line, and a mobile cleaning unit.
In addition to the cleaning nozzles, two nozzles for the injection of a
preservation fluid are installed in the intake elbow. Since dry air
preservation is preferable to wet preservation, the preservation nozzles
are not used any longer.
The cleaning system serves to clean the gas generator interior. Impurities
deposited on the blades are removed by regular cleaning, counteracting
deteriorations in the performance and efficiency of the gas turbine unit.
Above that, frequent compressor cleaning reduces the risk of corrosion
damage and also the fuel consumption.
The performance level and the efficiency of a gas turbine unit in the asnew state can, however, not be regained by cleaning because of the
normal wear resulting from operation (e.g. in the area of seals and
blades). The original level can only be restored by extensive works repair
measures. For information about the expected course of deterioration of
efficiency and performance refer to the diagrams / curves in the Operating
Instructions.
9.1.2
Time of cleaning
The time of cleaning depends on the site conditions and the associated
soiling as well as on the operational experience. Above that, the time of
cleaning depends on the extent of performance deviation which, as a rule,
is indicative of soiling of the gas generator compressor.
We recommend to initially clean the gas generator at least once a month.
For determination of the site-specific cleaning interval, the performance
shall be recorded before and after cleaning at comparable suction
temperature and comparable suction pressure. If the improvement in
performance after cleaning should only be slight, the cleaning interval may
be extended. If the improvement in performance is significant, the cleaning
interval has to be shortened appropriately.
With a high salt content in the intake air, daily cleaning is recommended. If
continuous operation does not allow this, cleaning is required at least once
per week. This also applies if the unit has not been in operation before.
Cleaning of the gas generator compressor is also required prior to long
standstill periods for removing corrosive deposits.
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Cleaning system
MAN TURBO AG
9|1-1
9.1.3
Use of cleaning additives

Cleaning additives have to be used for improving the cleaning efficiency,
especially in the case of oily deposits and deposits insoluble in water.
No other than the cleaning additives approved by MAN TURBO AG may
be used (see Section 9.1.6.3 Approved cleaning additives [J 9 | 4] ).
U CAUTION
Hazard to health from cleaning additives!
In order to avoid hazards to the health of personnel, the
safety instructions by the respective cleaning additive
supplier must be observed.
For preparation and processing of the cleaning solution, the information
provided by the supplier of the cleaning additive shall be observed.
9.1.4
Use of antifreeze
9.1.4.1
Risk of frost during cleaning

In order to avoid freezing of the pumps and lines during cleaning when
there is a risk of frost, isopropyl alcohol (IPA) or ethylene glycol shall be
added to the cleaning solution or to the wash water. The following table is
based on a mixing ratio of 1 : 4 (cleaning additive / water).
Mixing ratios
Cleaning additive
% vol
above +5
above 41
20
80 / 0
80 / 0
+5 to -5
41 to 23
20
60 / 20
60 / 20
-5 to -20
23 to -4
20
30 / 50
40 / 40
-20 to -30
-4 to -22
20
10 / 70
30 / 50
-30 to -40
-22 to -40
20
---
20 / 60
Ambient temperature
Water/IPA
% vol
Water/glycol
% vol
ATTENTION
Performance losses and damage to the blading!
Icing on the blades from frozen cleaning solution or wash
water may result in performance losses and damage to the
blading!
9.1.4.2
Risk of frost after cleaning

In order to avoid freezing of the cleaning system after cleaning, all water
lines and components of the cleaning system have to be drained. For this,
the hand shut-off valves which must be kept closed during the cleaning
phase have to be opened. During standstill of the cleaning system the
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Cleaning system
9|2-8
MAN TURBO AG
valves of this system must be kept open, to ensure that water which might
possibly freeze does not remain in the system.
9.1.5
Cleaning sequence
After the gas turbine has cooled down (PT inlet temperature T4 < 65C)
and the preparatory measures have been completed, the following
cleaning sequence steps may be initiated via the control panel on the GT
control cabinet.
Step 1:
Injection of cleaning solution with subsequent soaking.
Step 2:
Injection of clear water for flushing out the cleaning solution.
Step 3:
Ventilation of gas turbine for drying the internals.
Step 4:
15-minute load operation for drying the internals.
The cleaning sequence (steps 1 to 3) is basically a start-up process, but

without the ignition being cut in and with the inlet guide vanes fully open.
Above that, the blow-off valves are kept closed by instrument air instead of
GG compressor air. Depending on the degree of soiling, steps 1 and 2
have to be repeated several times.
9.1.6
Wash water specification / approved cleaning additives
9.1.6.1
Scope
This specification stipulates the approved cleaning additives and the
requirements concerning the minimum properties profile of the wash water
used for cleaning the gas generator compressor in gas turbine units of
MAN TURBO AG.
9.1.6.2
Minimum properties profile of wash water

Fully demineralized water (deionate) of high-purity should be used for
cleaning the gas generator compressor in order to avoid corrosion and
erosion.
Since full compliance with these stringent quality requirements is often
difficult to achieve at the installation site, the following water parameters
are regarded as being still tolerable.
Physical and chemical minimum properties profile of the wash water
Property
Limit value
Unit
pH value at 20C
6.5 to 8.5
pH
Conductivity at 20C
50
S/cm
Chlorides
10
mg/l
Sulphates
10
mg/l
Total hardness
mg CaO/l
SiO2 content
mg/l
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Cleaning system
MAN TURBO AG
9|3-1
9.1.6.3
Property
Limit value
Unit
Total dissolved solids
30
mg/l
Solid foreign matter
mg/l
Approved cleaning additives

The following cleaning additives may be used for online as well as offline
cleaning:
Turbo-K
ZOK 27
Information about procurement of these products is available from the
competent After Sales Service department of MAN TURBO AG.
Version 02.2008
Cleaning system
9|4-8
MAN TURBO AG
9.1.7
Safety information
WARNING
Cleaning of the gas generator compressor may be carried
out only with the gas turbine unit cooled down.
safety instructions by the respective cleaning additive
supplier must be observed.
At ambient temperatures below +5C (41F) an antifreeze
must be used.
The pump of the mobile cleaning unit must not on any
account be run without water - not even for checking.
standstill and cooled down. Prior to the performance of
service and maintenance work observe the following
Sections.
9.1.8
Measures to be taken before initiating the cleaning sequence

U CAUTION
Warning of hazard to health!
Cleaning of the gas generator compressor may be carried
out only with the gas turbine unit cooled down. Hazard of
burns!
relevant safety information by the respective cleaning
additive supplier and the references included in Chapter
"General safety information" shall be observed.
ATTENTION
Risk of damage to plant unit components!
At ambient temperatures below +5C (41F) an antifreeze
must be used.
Before starting up the cleaning unit, the pump has to be
vented (see Service and Maintenance Instructions for Gas
Turbine Cleaning System Mobile Cleaning Unit). The
pump of the mobile cleaning unit must not on any account
be run without water - not even for checking.
Z For carrying out the following tasks, P&I diagram "Auxiliary air /
Cleaning" and/or "Draining" (if available) may have to be consulted.

Approx. 50 l (13 gallons) of cleaning solution are required for one
cleaning operation.
1. Remove the plugs from the header of the instrument air system.
2. Flexible hoses for compressor cleaning were included in the scope of
supply. They have to be connected to the instrument air header and to
the solenoid valves provided for activation of the blow-off valves (see
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Cleaning system
MAN TURBO AG
9|5-1
P&I diagram Auxiliary air / Cleaning).

Note: Since during standstill of the gas turbine GT compressor air is not
available, the blow-off valves have to be kept closed by instrument air
from an outside supply source to prevent a major portion of the cleaning
solution escaping via the blow-off valves.
3. Open the instrument air supply.
4. For draining the GT compressor open ball cock V141.1 (see P&I
diagram Draining or Auxiliary air / Cleaning).
5. Connect the hose of the mobile cleaning unit to port Q1 of the ring line
on the GT compressor inlet casing.
6. Verify that the drain valve of the mobile cleaning unit is closed and that
the mobile cleaning unit is in safe condition. Clean the tank, if
necessary.
7. Check further that the vent screw in the pump head and the drain plug
in the lower pump section are screwed in.
8. Fill the cleaning unit mixing vessel with the required amount of water.
Note: At an ambient temperature below +5C (41F) the amount of
water to be filled in is less, since antifreeze has to be added (see
Service and Maintenance Instructions for Gas Turbine - Cleaning
System - Use of Antifreeze).
9. Add the cleaning additive.
Note: Observe the mixing ratio specified by the supplier.
9.1.9
Performance of cleaning
The cleaning procedure is described in the Operating Instructions.
9.1.10
Measures after cleaning

1. Remove the cleaning unit connections from the gas turbine.
2. If there is the risk of frost, the cleaning unit must be drained thoroughly
by opening the drain valve in order to avoid damage to components.
3. Shut off instrument air supply.
4. Close ball cock V141.1 (see P&I diagram Draining or Auxiliary air /
Cleaning).
5. Remove the hoses installed on the instrumentation and blow-off system
for the cleaning process and close the openings at the instrument air
end with the corresponding plugs.
Note: The lines of the blow-off system shall not be closed in order to
ensure ventilation of the control chamber of the blow-off valves and as
such proper functioning of the blow-off system.
6. Empty the drainage vessel. Disposal of the accumulated liquid must be
carried out properly in compliance with the laws applicable at the site
location.
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Cleaning system
9|6-8
MAN TURBO AG
9.1.11
Examination of cleaning result

The cleaning result can be checked using the following methods:
Visual inspection of the blades with a boroscope.
Analysis of fouled cleaning water for non-water-soluble substances
and/or analysis of conductivity.
If the result is not satisfactory, clean the gas generator compressor once
again.
9.1.12
Repair
9.2
Cleaning nozzles
9.2.1
Design and function

The ring line with 6 nozzles (4 for cleaning and 2 for preservation) installed
on the intake elbow serves for offline cleaning. Although the preservation
nozzles originally envisaged for wet preservation of the base engine are
installed, they must not be used, since dry preservation is preferable to
wet preservation.
Design and location of cleaning nozzles
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Cleaning system
MAN TURBO AG
9|7-1

1
Intake elbow
9.3
Mobile cleaning unit
9.3.1
Design and function
Cleaning nozzle
The following illustration shows the components of the mobile cleaning

unit and their arrangement.
For carrying out a cleaning process, the hose of the cleaning unit must be
connected to port Q1. A corresponding socket is installed on the acoustic
enclosure for power supply.
A pressure reducing valve and a pressure gauge are provided for pressure
adjustment to 5 6 bar.
Design of the mobile cleaning unit
Electric motor
Pump
Supply hose
Filling nozzle
Pressure reducing valve / pressure

gauge
Containers
Terminal box with switch
Drain/shut-off valve
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Cleaning system
9|8-8
MAN TURBO AG
10
Annex
10.1
Spare Parts Catalog
10.2
Curves
Version 02.2008
Annex
MAN TURBO AG
10 | 1 - 1

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Service and Maintenance Instructions for Gas Turbine

Hompu 1/2 - H.2100002.21

General service and maintenance information .................................... 1

Performance of service and maintenance measures.................3

Impact of adhesive tape.............................................................3

Examination of component parts ...............................................4

Identification of component parts...............................................4

Storage of spare parts ...............................................................4

Performance of welding work ....................................................4

Use of graphite pastes...............................................................5

General notes on the exchange of component parts .................5

Use of SWAGELOK adapters....................................................7

Use of thread sealing tape and thread sealant ..........................8

Thread sealing tape ....................................................8

Storage and installation of hoses...............................................9

Installation of locking plates.....................................................10

Snap rings ...............................................................................11

Use of lockwire ........................................................................11

Safety information .......................................................5

Tightening torques for pipe flanged connections ......15

General service and maintenance information

Service and Maintenance Instructions for Gas Turbine

Service and maintenance Definition of terms and

System-related information ....................................................... 1

Design and function of base engine ........................... 1

Gas generator ........................................................................... 5

Design and function of gas generator......................... 5

Design and function of power turbine ....................... 16

Instrumentation base engine...............................................................1

System-related information ....................................................... 1

Speed measurement (nGG, nPT) ............................................. 3

Design and function.................................................... 4

Vibration measurement ............................................................. 6

Design and function.................................................... 3

Inlet temperature measurement on power turbine (T4) ............. 4

Design and function.................................................... 1

Design and function.................................................... 6

Phase angle measurement ....................................................... 7

General service and maintenance information

Bearing temperature measurement ...........................................7

Design and function ..................................................11

Subcontractor documentation ................................... 11

Trip valve .................................................................................11

Design and function ....................................................8

Fuel gas filter ...........................................................................11

Fuel gas metering valve.............................................................8

Design and function ....................................................1

Job-specific and system-related documents..............................8

Design and function ..................................................11

Pressure transducer ................................................................11

Subcontractor documentation ................................... 11

Ignition system ................................................................................... 1

Design and function ....................................................1

Design and function ....................................................7

Fuel gas system ................................................................................. 1

Design and function ....................................................7

Wear measurement on thrust bearing .......................................7

Design and function ....................................................7

Design and function ....................................................3

General service and maintenance information

Service and Maintenance Instructions for Gas Turbine

Guide vane actuator............................................................................1

System information ................................................................... 1

Design and function.................................................... 4