Академический Документы
Профессиональный Документы
Культура Документы
01/02
SERVICE INSTRUCTIONS
(ELECTRICALLY STARTED)
CR054.01/02
CODE
REPLACE
SH. 1
PREPARED
CHECKED
DISK
PAGE
2013.4
2013.5
APPROVED
QUAN.
OF 149
2013.5
EXAMINED
LABEL
CR053.01/02
FILE CODE
BRIEF ELUCIDATION
2013.5
SIGNATURE
CASE
CR054.01/02
CONTENTS
1. GENERAL
1 .1 General descrip tion o f th e un it
1.2 Main tech nical performance indices of the unit
1.3 Requirements fo r fuel, cooling water an d po wer su pply u sed b y the unit
1 .4 Brief description of the unit con figu ration
2. GAS TURBINE
2 .1 General
2.2 Inlet plenum
2.3 Comp ressor casing
2 .4 Tu rbine sh ell
2.5 Turbine exhaust frame
2 .6 Exhaust plenum
2 .7 Comp resso r blade
2.8 Turbine blade and flo w path section
2.9 Rotor assemb ly
2.10 Bearings
2.11 Co mbustion system
2 .12 Gas turbine sup ports
CR054.01/02
4. GENERATOR PACKAGE
4.1 Generato r
4.2 Electrical equipment
5. LOAD GEAR
5.1 Main structure of the gear
5.2 main tech nical capab ility d ata
CR054.01/02
1. GENERAL
The unit has a small volume, taking a small area of land and having fewer accessories.
Both the programmed control and the detecting protection are carried out completely by
means of electronic circuits, and the automation level of operation is high, and thus the
required operating personnel are less.
Base load
Fuel
Output
34800 kW
Heat rate
12231 kJ/kWh
425.6410 6 kJ/h
Heat consumption
CR054.01/02
564.7
Exhaust temperature
489.510 3 kg/h
The measurement tolerances of the output and heat rate of the unit are specified in GEK
28106A "Standard Field Performance Testing Procedure".
1.2.2 Correction for the Performance of the unit under off design conditions
When the unit is not operating under design conditions, the correction for the
performance data will be carried out by using the following curves:
Rev B
Rev2
Rev1
Rev2
Rev1
CR054.01/02
CR054.01/02
CR054.01/02
CR054.01/02
CR054.01/02
10
CR054.01/02
1.2.3 Effects of additional inlet and exhaust pressure drops on the unit performance
The output power of the unit performance is given on the assumption that the inlet and
exhaust pressure drops are 101.6mmH2O and 350mmH2O respectively. The effects caused
by additional inlet and exhaust pressure drops are as follows:
% EFFECT ON
% EFFECT ON
EFFECT ON
OUTPUT
HEAT RATE
EXHAUST TEMPERATURE
inlet
-1.45
+0.45
+1.1
exhaust
-0.45
+0.45
+1.1
1.3 Requirements for fuel, cooling water and power supply used by the unit
1.3.1 Fuel
1.3.1.1 NGnatural gas
The gas fuel shall have the physical and chemical characteristics required in the attached
specification GEI 41040 and in the Design Basis.
Allowable gas fuel supply conditions at the inlet flange of the unit
Pressure range: 20.35 to 22.1 barg
Temperature
Minimum: 28C superheat above the hydrocarbon and the water dew point
additional super heat could be applied to comply with maximum Wobbe index
requirement
11
CR054.01/02
The distillate oil supplied for the unit shall be consistent with the requirements as
specified in the GE specification GEI41047.
The parameters of the distillate oil at the inlet flange of the unit are as follows:
Pressure:
0.210.59MPa (gauge)
Volume flow:
6220L/min
Temperature:
Filtering accuracy: 5m
145
GENERATOR
150
0.15
0.08
0.46
0.4
0.40
MPa
TEMPERATURE
35
35
12
CR054.01/02
The customer is required to provide the following four alternating-current power sources
for the unit.
No.1 alternating-current source is for duty use in MCC with voltage 415/240V10%
three-phasefour-wire50Hz, capacity 250kW. Its power will be sent to A column in MCC.
No.2 alternating-current source is for backup use in MCC with voltage 415/240V10%
three-phasefour-wire, 50Hz, capacity 250kW. Its power will be sent to A column in MCC.
No.3 alternating-current source is for water washing equipment with voltage 415/240V
10%, three-phase, four-wire, 50Hz,capacity 120kW. Its power will be sent to the control
panel of water wash skid.
No.4 alternating-current source is for the starting motor with voltage 6600V 5%,
three-phase, 50Hz, capacity 450kW. Its power will be sent to the connection box of the
starting motor in the accessory compartment of the unit.
CR054.01/02
synchronous generator and the related equipment. Such equipment is also equipped with
the weather protection enclosures in order to adapt it to outdoor installation.
In addition to the above-mentioned main body sections, the unit also includes:
a. An inlet system which mainly includes an inlet air filter house, an inlet silencer
and inlet ducting;
b. An exhaust system;
c. An automatic fire protection equipment which is placed outside the unit;
d. An air processing skid (a self-cleaning pressurized air source for the inlet air
filters) which is placed outside the unit;
e. A compressor water wash skid placed outside the unit;
f. Two off-base blowers for cooling the turbine shell and the turbine exhaust frame;
14
CR054.01/02
2. GAS TURBINE
2.1 General
The chapter will describe the gas turbine section of the power generating unit, i.e. the
main body and its related assemblies, which includes the individual assemblies of the
axial compressor, combustion chamber, turbine, etc from the inlet flange of the inlet
plenum to the outlet flange of the exhaust plenum and the related cooling and sealing
arrangement, No.1 bearing, No.2 bearing, etc. All the above-mentioned assemblies are
mounted on a common base.
CR054.01/02
respectively mounted. In the forward cavity of the inlet casing there is No.1 bearing
housing that contains No.1 journal bearing and thrust bearings, which are used to
support the journal of the low pressure end stub and bear the total thrust of the gas
turbine. The inlet casing is horizontally split and is connected with the compressor
casing through the vertical flange.
CR054.01/02
isolation valve, a porous filter and the solenoid valve 20CB-1 to the lower end of the
air bleed valve, and the spring acts on the upper end. If the spring force is greater than
the action of the compressor discharge air pressure (in the case no compressor
discharged air enters the air bleed valve or the compressor discharge air pressure is
relatively low), the air bleed valves will open. If the action of the compressor
discharge air pressure is able to overcome the spring force, the air bleed valves will
close and stop bleeding. When the unit reaches its rated speed, the compressor
discharge pressure reaches its design value. Thereby the action of the compressor
discharge air which passes through the solenoid valve 20CB-1 and then enters the
lower end of the air bleed valve is greater than the spring force, which will cause the
air bleed valves to close and stop bleeding. During the complete operation period the
air bleed valves remain close without bleeding.
CR054.01/02
In the rear area of the compressor discharge casing there are ten rigid struts that
support the ring support inner barrel and the inner cylinder of the discharge casing.
The ring support inner barrel is bolted to the support ring for the first-stage turbine
nozzle, which will separate the gas from the cooling air leakage passing through the
channel between the ring support inner barrel and distance piece of the rotor.
On the outer wall of the outer cylinder of the diffuser of the compressor discharge
casing there are circumferentially distributed bosses used to support and mount the
transition pieces of the combustion chambers.
18
CR054.01/02
At the bottom of the turbine lower half casing a gib key for limiting the centerline of
the gas turbine is machined, and on the two upper sides of the turbine lower half casing
a pair of blind holes are respectively machined for mounting the turbine support legs.
At the two ends of the turbine shell there are vertical flanges which are respectively
connected with the vertical flanges of the compressor discharge casing and the exhaust
frame by bolts.
On the outer wall of the turbine some appropriate points are selected to machine the
measuring holes, through which some necessary instruments including the borescope
can be inserted to view and inspect the operation conditions and measure some
parameters of the gas flow.
On both the upper half and the lower half of the turbine shell there are trunnions for
lifting. The trunnions are used to lift the turbine shell during installation or inspection
maintenance of the unit.
CR054.01/02
In order to extend the service life of the inner and outer cylinders of the exhaust frame
and improve the ambient working temperature, lagging is filled in their inner space for
thermal insulation.
The exhaust plenum is a welded structural frame made of steel plates. It is directly
welded onto the turbine base. The forward side of the exhaust plenum is connected
with the forward flange of the turbine exhaust frame through a flexible sealing plate,
and the aft side is a sealed blocking plate. There is an inner cylinder, the forward
vertical flange of which is tightly bolted to the inner cylinder of the exhaust frame.
On the aft end wall of the exhaust plenum there are eighteen thermo-coupes as
mounted for measuring the exhaust temperature of the turbine. Moreover, in order to
extend the service life of the exhaust plenum and reduce the heat emission to the load
gear compartment, the inner walls are covered with lagging.
CR054.01/02
mounted, which is fitted with a ring gear. When the ring gear is turned, it will drive the
engaging pinion and in turn, the pinion will turn the inlet guide vane by means of a
fastening bolt. The ring gear is mounted on a control ring which is driven by the
actuator. When the piston of the actuator does the straight reciprocating motion, the
control ring is driven, which will cause the ring gear to be turned, and finally the inlet
guide vane can be turned to the required angle position.
CR054.01/02
chamber via the transition pieces. The hot gases expand in the first-stage nozzle
passage and then enter first-stage buckets.
The first-stage nozzle assembly consists of airfoil-shaped partitions between an inner
sidewall and an outer sidewall. The nozzle assembly is divided into 18 segments, each
with two partitions or airfoils. The first-stage nozzle assembly has totally 36
partitions.
The nozzle segments are machined to have a dual inverted T-shaped base, by means of
which they are inserted into the matched circumferential groove in the retaining ring.
The retaining ring has a horizontal split and is centerline supported to the turbine shell
on lugs held down with strips at both sides and guided by eccentric pins at the top and
bottom vertical centerlines because the position of the nozzle assembly in the hot flow
path section is very important. This permits radial growth of the retaining ring,
resulting from changes in temperature while the ring remains centered in the shell. The
inner sidewalls of the nozzle assembly are tightly bolted to the outside end surface of
the support ring of the first-stage nozzle assembly with gaskets so as to prevent the
compressor discharge air from leaking into the hot gas path.
In order to maintain a certain service life of the first-stage nozzle assembly in the hot
gas flow, the nozzle partitions are designed to be hollow so as to use the compressor
discharge air to cool them.
22
CR054.01/02
In order to have as more as possible amount of gas expanding in the nozzle channels,
the inner sidewall of the turbine second-stage nozzle segment is designed to have a
diaphragm attached to its inside diameter. The diaphragm acts as a seal to prevent air
leakage past the inner sidewall of the nozzle and the turbine rotor. The high/low teeth
are machined into the inside diameter surface of the diaphragm. They mate with the
opposite lands on the outside diameter surface of the spacer of the rotor to form a
labyrinth-type seal. Moreover, on the two sides of each diaphragm segment there is an
arc respectively, which combines with the sharp shoulders on the shanks of the
first-stage buckets or the second-stage buckets to form a seal. This is also used to
restrict the leakage.
In the areas of the entrance side and exit side of the lower half nozzle diaphragms, two
thermocouples are placed respectively on either the left side or the right side to
measure the temperatures in the first-stage aft wheelspace and second-stage forward
wheelspace.
CR054.01/02
Like the diaphragm for the second-stage nozzle, the high/low teeth are machined into
the inside diameter surface of the third-stage diaphragm. They mate with the opposite
lands on the outside diameter surface of the spacer of the rotor to form another
labyrinth-type seal. On the entrance side and exit side of the diaphragm there are also
axially fitted sealing arcs. Each diaphragm segment is positioned by a locating pin.
24
CR054.01/02
The tips of both the second-stage buckets and the third-stage buckets are respectively
enclosed by a shroud which has teeth. These teeth combine with the teeth on the inside
diameter surfaces of the second-stage shroud and the third-stage shroud respectively to
form a labyrinth-type seal to restrict the leakage at the bucket tip.
The assembly or disassembly of the three stages of buckets does not need the whole
turbine rotor to be dismantled.
CR054.01/02
The rim of each stage wheel is broached to have the firtree grooves. The rotor blades
of each stage are axially fitted into the matched grooves of the corresponding stage
wheel and are locked in place with the fitting pins to prevent axial movement. The
turbine rotor is not required to be disassembled for the assembly and disassembly of
each stage of buckets.
The outside diameter surfaces of the two spacers of the turbine rotor are machined to
have concave and convex lands, which combine with the teeth of the second-stage
nozzle diaphragm and the third-stage nozzle diaphragm respectively to form the
labyrinth-type seals so as to reduce the leakage.
The stub shaft of the turbine rotor is machined to have the No.2 journal which
combines with the No.1 journal together to provide the supporting surfaces for the
rotor. The output end of the stub shaft is a flange, for which a rabbet is provided.
Through such structure the stub shaft is connected with the rigid load coupling to make
the rotor system on the load side have proper alignment.
The assembled compressor rotor and the assembled turbine rotor are closely jointed
together through the mating rabbet joint between the compressor 17th stage wheel and
the distance piece to achieve a proper alignment and are tightly bolted with short bolts
of high strength.
2.10 Bearings
The gas turbine has two journal bearings and one thrust bearing. The No.1 bearing
including the thrust bearing is located at the journal of the forward stub shaft and is
contained in the bearing housing inside the compressor inlet casing. The No.2 bearing
is contained in the bearing housing inside the exhaust frame inner tunnel. The No.1
bearing and No.2 bearing have the function of supporting the rotor assembly of the gas
turbine.
CR054.01/02
rotation. In order to prevent the lube oil from spreading along the shaft the labyrinth
seal with three rows of packing is used.
CR054.01/02
On the entrance side and exit side of the No.2 bearing there is a labyrinth-type oil seal
respectively to prevent the lube oil from spraying outwards. Moreover, on the outside
of the oil seal for the entrance side there is another labyrinth-type seal which is used to
completely separate the gas from the lube oil. For improving the sealing effect the
compressor fifth-stage extraction air is directed to the two labyrinth-type oil seals.
Such pressurized air is sent to the air passage of the lower half bearing housing
through piping and then flows through two branch lines to the forward and aft oil seals
respectively.
chambers,
transition
pieces,
fuel
nozzles,
crossfire
tubes,
CR054.01/02
highly pressurized air from the diffuser of the compressor discharge casing is directed
in reverse around the transition pieces and into the annuluses between the liner outside
surfaces and the inside surfaces of the forward and aft flow sleeves and then flows into
the forward caps attached to the liners and the liner bodies.
After being diluted with the cold air the generated gas reaches its design temperature
and then flows through the transition pieces, entering the flow path annulus of turbine
to expand and do work.
The transition pieces are the hot gas passages which serve to direct the hot gas from
the combustion chambers to the turbine first-stage nozzle. The entrance side of each
transition piece is attached to the liner and the exit side is fitted into the
circumferential grooves on the end surfaces of the inner sidewall and the outer
sidewall of the first-stage nozzle assembly. There are totally ten transition pieces
corresponding to the ten liners in a one-to-one manner around a circle. At the exit of
the transition pieces an annulus adaptable to the annular blading of the first-stage
nozzle is formed. As for the shape of each transition piece, it is transited from the
circular entrance at the liner end to the sectorial exit at the first-stage nozzle end.
The liner is contained in the casing of the combustion chamber and is fixed through the
cap, the flow sleeves and the transition piece. The casing of the combustion chamber is
mounted onto the aft vertical flange of the compressor discharge casing by means of its
aft flange. Between the casing and the liner there are two sections of flow sleeve, i.e.
the forward and aft sections, which are attached together. The forward and aft flow
sleeves are fixed on the forward flange and the aft flange of the combustion chamber
casing respectively through their individual flanges.
CR054.01/02
After the No.1 and No.10 combustion chambers which have spark plugs have achieved
firing, the remaining chambers without spark plugs will be fired by means of crossfire
tubes.
In order to achieve safe and continuous operation of the unit,there is eight ultraviolet
flame detector on the combustion chambers . During startup and operation of the unit it
is possible to monitor whether the combustion chamber is in flame out state at any time.
If failure to fire or flame out state happens, the turbine control system will cause the
unit to shut down.
CR054.01/02
order to reduce the unfavorable effect on the alignment of the unit due to such action, a
cooling arrangement is applied to the flexible support plates. On the inner surface of
each flexible support plate a water jacket is welded, and meanwhile, on the outer
surface of the flexible plate an inlet flange and an outlet flange are welded and
machined so as to connect the water feed pipe and the water return pipe respectively.
The circulating water will absorb the heat from the support legs to minimize thermal
expansion and assist in maintaining alignment between the turbine and the generator.
31
CR054.01/02
32
CR054.01/02
The accessory gear is a multi-shaft drive mechanism. There are five parallel shafts. As
for the No.1 shaft, its one side is linked with the starting equipment through the
starting clutch, and the other side is linked with the rotor of the unit through the
accessory coupling. The rest shafts are used to drive the above-mentioned pumps after
using the gear trains to change the speed. On the No.1 shaft there is an overspeed bolt,
which is set for the mechanical overspeed protection of the unit.
For the details of the accessory gear see the related service instructions provided by
the manufacturer.
3.3.1 Function
The main function of the starting system is providing the necessary power for the gas
turbine generator unit during its starting process which starts from zero speed state
through purging, firing, self-sustain to reach disengaging state. In order to obtain the
optimum power characteristics, the hydraulic torque converter is used to be combined
with the starting motor, which converts the external characteristic of the motor torque
into the optimum output characteristic adaptable to the start-up of the gas turbine.
Besides, the starting system is also used to achieve the "cranking" operation mode of
the unit, i.e. the high speed turning.
3.3.2 Combination
3.3.2.1 Starting motor
Use an asynchronous motor for continuous duty:
V H =6600V5%,
I H =46.0A,
n H =2970rpm,
33
N H =450kW,
N MAX =540kW
CR054.01/02
f H =50H Z 5%
CR054.01/02
no mechanical link between the input and output shafts, so the two shafts may have
different speeds. Assuming the working cavity of the torque converter is fully filled
with oil, the oil liquid will increase its energy when the pump impeller is driven by the
motor and rotates at a high speed. Then the oil of high energy impinges against the
turbine impeller to cause it to rotate. Through this process the potential energy
obtained in the pump impeller will be converted into the output power of the turbine
impeller. The output power of the converter is transmitted to the gas turbine unit
through a pair of gears, thus driving it to start.
35
CR054.01/02
under low speed is less, the working cavity of the torque converter is not fully filled.
So the power consumption for torque converter startup is less. Consequently the
startup of the motor becomes faster and its temperature rise is smaller.
The basic pressure of the torque converter is not allowed to be too low, otherwise this
will result in the cavitation to take place or cause the output torque to significantly
drop and the temperature of the drain oil to rise. The purpose of placing the 20TU
unloading valve in the piping is to decrease the speed after the purging cycle in the
turbine startup sequence is finished, so as to achieve firing at a relatively lower speed.
The flow rate of the oil fed to the torque converter is 160L/min. Selecting a small flow
rate is not appropriate, because it is necessary not only to ensure that the working
cavity is fully filled, but also to bypass a large amount of oil to oil sump for taking
away the heat generating in the operating process of the impellers. Therefore a
compensation system for the circulating oil is provided (see the system schematic
diagram).
Since the starting current of the motor is 6.5 times as great as its rated current, the
starting time of the motor should be limited (10 15 seconds) and the overload
protection must be provided.
CR054.01/02
Before the motor is stared, the oil is provided through OL-6 line (a small amount of
lube oil coming from the lube oil pump of the unit). Its pressure is controlled by
VPR-38 (the pressure setting value is about 0.035MPa). After the motor is stared, the
charge pump draws oil from the unit tank. In the suction line a bottom valve and a
strainer are provided. When the solenoid valve 20TU is energized, the "adjustable
orifice" is open and thus the amount of drained oil is greater. But when the solenoid
valve is deenergized, the adjustable orifice is closed and so the amount of drained oil is
smaller, which causes the basic pressure to increase and insures that the circulating
loop of the torque converter is filled up with oil. As a result the output power increases.
If firing is successful, the fuel stroke reference value FSR will decrease to the warm up
value. After the warm up period ends, the speed of the unit will continuously increase
to full speed.
As soon as the unit is disengaged from the starting system, the starting motor will stop.
CR054.01/02
b. Check and clear off the foreign objects within the motor. The environment of
the motor should be cleaned to avoid any foreign objects to be drawn in.
c. Turn the motor rotor with hands (one turn forward and backward respectively)
by using the two hand-holes on the transition envelope of the torque converter,
and the movement should be smooth without seizing.
d. Check the rotational direction of the motor. Before the initial startup of the
unit the piping between the charge pump of the torque converter and the tank
should be disconnected in order to check the rotational direction of the motor by
means of jogging operation. The motor is not allowed to run for long time
(because the auxiliary lube oil pump of the unit is switched off).
e. Switch the auxiliary lube oil pump 88QA on and check whether the oil enters
the working cavity of the torque converter and whether there is drain oil. If there
is no oil, check whether the pressure regulator valve VPR 38 and the bottom
valve are inversely installed or seized. (Before switching 88QA on, the piping
to the charge pump of the torque converter should be connected again.)
f. Check whether the unloading valve 20TU operates properly (including open
and close actions) and whether there is any leakage with it.
g. Before starting the motor, switch its heater on at first (check whether the
heater is working properly) to dry the inner windings of the motor (the heater is
automatically switched off when the motor starts.)
h. If the unit is to be started after a long time of standby, it is necessary to check
the insulation of the motor stator and the heater, the direct-current leakage of the
38
CR054.01/02
i. Check whether the starting clutch and the limit switch 33CS-l are operating
properly. Check whether the jaws of the clutch actuated by the oil cylinders are
engaged properly and whether the strokes are proper.
j. With the starting clutch disengaged, turn the output shaft of the torque
converter two turns with two hands. The movement should be smooth without
seizing and the force acting on the hands is felt equal.
T h e f l o w r a t e o f t h e c h a rg e p u m p o f t h e t o r q u e c o n v e r t e r : a b o u t 160L/min.
The discharge pressure of the charge pump of the torque converter: not greater
than 0.7MPa.
Motor Startup time 15s 0 to 3000r/min
When the torque converter is working under spoiled operating condition (i.e.
20TU is energized and the torque converter drains a large amount of oil), it is
only allowed to operate for 60 seconds.
b. Assuming a shutdown is performed after the unit has continuously run at the
cranking speed for more than 30 minutes and then another startup attempt is
made, there should be an interval of 90 minutes for the motor between the
subsequent starts.
c. Assuming the starting motor has stopped after finishing its operating cycle
during a normal startup and another startup attempt is made, there should be an
interval of 15 minutes for the motor between the subsequent starts.
39
CR054.01/02
d. Check carefully for the abn o rmal noise from th e bearing s and th e p rop er
temp eratu re rise o f the bearings within 30 minutes of the initial on-load
operation of the starting motor.
e. Check the transient temperature at the place close to the cover of the bearing.
It should not be higher than 60 .
f. The temperature at the bearings of the starting motor should not be higher than
100 , and the oil temperature at the drain port of the torque converter should not
be higher than 110 (check it during the initial startup).
g. Check for the switching-off of the motor heater after the motor starts.
3.3.7.2 Control and measurement for the power distribution system for the starting
motor
a. Control
The start and stop of the starting motor can be automatically controlled, as well
as manually controlled.
The automatic control is achieved by means of the turbine control panel, which
will automatically control the start and stop of the starting motor in
accordance the startup sequence of the unit.
In the motor control center (MCC) there is a control unit, which is used to
manually control the start and stop of the starting motor.
The panel of the control unit in MCC is equipped with:
Control switch HK: It is used to manually control closing or opening of the
vacuum breaker 52CR (i.e. the start or stop of the starting motor).
40
CR054.01/02
The HK switch has three positions, i.e. CLOSE, AUTO and OPEN. The turbine
control panel can achieve its automatic control for the start and stop of the
starting motor only when HK switch is set in AUTO position.
Control switch HK1: It is used to switch the heater of the motor on or off.
Control switch HK2: It is used to switch the energy storage circuit of the circuit
breaker 52CR on or off.
On the panel of the 88CR control unit in MCC there is an ammeter indicating the
current of the motor.
For the electrical connections for control and measurement, see the 88CR
control unit of ML Q9623 MCC.
CR054.01/02
During the startup of the unit, the two cylinders are fed with the hydraulic oil supplied
by the hydraulic ratchet pump 88HR through the P-B path in the solenoid valve 20CS-1
after it is energized. Under the action of the hydraulic oil the pistons in the cylinders
will carry the sliding jaw clutch hub to move axially and engage with the stationary
jaw clutch hub, and thus it enables the torque converter to carry the gas turbine to start.
It should be noted that the starting motor could only be started when the limit switch
33CS-1 is closed, which will occur after the starting clutch completes its engagement
action.
The speed of the unit begins to rise due to the crank of the motor, and 20CS-1 will be
deenergized when the speed reaches 14HM pickup value. At this time the hydraulic oil
in the cylinders will be gradually drained through the B-T path in the solenoid valve.
However, it is not possible for this action to cause the starting clutch out of
engagement. When the gas turbine reaches approximately 60% rated speed
(self-sustain), the torque at the driving jaws then reverses. As a result, the sliding
clutch hub is forced to be automatically disengaged by the force of internal springs and
the gradual slope of the backside of the clutch jaws.
42
CR054.01/02
88HR
PH3
hydraulic ratchet pump (for supplying the system with hydraulic oil);
43HR
VR5
ratchet pump pressure relief valve (for relieving any overpressure of the
ratchet pump output);
VH14
Fig. 3-3
43
CR054.01/02
HM2 ratchet mechanism is the rotary actuator of the ratchet system. It is attached to
the outboard end of the gear shaft of the turbine impeller of the torque converter by
means of a one-way ratchet clutch and consists of two piston rods with double-ended
hydraulic cylinders. The piston rods are attached to the outer race of the ratchet clutch
with teeth. The ratchet clutch is a caged-roller type overrunning device which slides on
rotation in one direction and locks in the other. As shown in Fig. 3-3, the left piston
rod moves downwards while the right one moves upwards. When the left piston rod
reaches the end of the stroke, the port FS in the left cylinder is uncovered to allow the
high pressure oil to flow off to the command mechanism of the first 4-way valve, by
the action of which the flow paths in this valve are shifted and in turn the high
pressure oil will act on the command mechanism of the second 4-way valve and thus
the flow paths in this valve are shifted. As a result, the high pressure oil enter the
port R of the left cylinder and meanwhile the limit switch is actuated, which informs
the automatism loop that the ratcheting stroke is completed forward. Then the return
sequence is initiated.
Since the high pressure oil only enters the port R of the left cylinder of the ratchet
device, the piston rods move in reverse directions respectively to achieve the reset
stroke.
FH5 and FH1 oil filters: the filtering accuracy of the two oil filters is 40 m.
The primary operating principle of the ratchet system is as follows:
During turbine startup 88HR and 20CS-1 are simultaneously energized. The hydraulic
oil discharged from the hydraulic ratchet pump PH3 is divided in two ways: one way
towards the control valve module (i.e. the hydraulic self-sequencing valve); the other
way through 20CS-1 towards the starting clutch hydraulic cylinders, causing them to
pull the sliding clutch hub to engage with the stationary clutch hub. When the clutch is
closed, the oil pressure increases in this circuit and thus actuates the sequence valve
VPR, causing it to establish a hydraulic oil flow of definite pressure. Then the oil
flows through the first four-way valve and actuates the second four-way valve, causing
the second four-way valve to establish the flow which is directed to the entrance ports
F of the ratchet mechanism. In such a way, under the action of the hydraulic oil the left
and right piston rods will move upwards and downwards respectively and thus drive
the ratchet to rotate, achieving the forward stroke ratcheting.
CR054.01/02
Lube oil system is an important operation system absolutely necessary for any gas
turbine. Its function is supplying the individual bearings of the operating gas turbine
generator unit and the its transmission gear and accessories with clean lube oil of
sufficient amount and proper temperature and pressure during startup, normal
operation and shutdown of the unit, so as to ensure safe and reliable operation of the
unit and prevent the accidents of bearing burn-out, rotor journal bowing due to
overheat and deformation of high-speed gear coupling flange. For the equipment
configuration and supplying conditions of the lube oil system see ML416 "Lube Oil
System Schematic Diagram".
a. Main lube oil pump pressure relief valve VR-1, of which the setting pressure is
0.480.014MPa;
b. Hydraulic trip pressure regulator valve VPR-1, of which the setting pressure is
0.4550.007MPa;
c. Lube oil header pressure regulator valve VPR-2, of which the setting pressure
is 0.1720.007MPa;
d. Dual heat exchangers (oil coolers) of U-tube bundle structure in the lube oil
tank and the associated transfer valve;
e. Dual lube oil filters with removable cartridges and the associated transfer
valve;
f. Lube oil tank immersion heater 23QT-1: 10.2kW, 415V, 3-phase;
g. Dual filters for trip oil and the associated transfer valve.
3.4.2.2 One main lube oil pump shaft-driven from the accessory gear: outlet flow
45
CR054.01/02
3.4.2.3 One auxiliary lube oil pump 88QA driven by a AC motor: outlet flow
1741L/min (460GPM), outlet pressure 0.45MPa (65PSIG), 30kW, 3000rpm, 415V, 3Ph,
50Hz.
3.4.2.4 One emergency lube oil pump 88QE driven by a DC motor, outlet flow
946L/min, outlet pressure 0.21MPa (30PSIG), 7.5kW, 1750rpm, 120V, DC.
CR054.01/02
When the oil temperature in the lube oil tank is above 102.7 , the temperature
switch 26QN-1 will close, and thus the unit is permitted to be started. However, when
the oil temperature is below 102.7 , the setting value of 26QN-1, even if the master
control switch "START" position is selected, the startup sequence will not be initiated.
When the oil temperature is below 152.7 , the setting value of 26QL-1,
The heater 23QT-1 will start into operation and at the same time the AC auxiliary lube
oil pump 88QA will automatically start to circulate the system lubricating fluid. When
the oil temperature increases to the setting value of 26QL-1for 23QT-1 stopping, the
heater 23QT-1 will stop operation.
When AC power is available for the turbine startup sequence, the system lube oil
pressure is supplied by the AC auxiliary lube oil pump during the time that the main
shaft-driven pump is at too low speed to develop sufficient pressure. It will not stop
unit the turbine speed reaches approximately 95% rated speed. At this point, because
the main lube oil pump driven by the accessory gear is able to establish sufficient
discharge pressure, the AC auxiliary pump shuts down and since then system lube oil
pressure is supplied by the main shaft-driven pump.
During the shutdown sequence of the unit the system oil pressure continues to drop.
When it reaches 0.082MPa (gauge), the AC auxiliary pump 88QA will automatically
start. After this, the pump will continue to run throughout the shutdown and cooldown
period and will stop only when the operator takes the unit out of cooldown by moving
the cursor to point at the "COOLDOWN OFF" target on the cooldown control page on
MARK e and clicking on it.
If AC power is not available during the turbine startup sequence, the system lube oil
pressure will be supplied by the emergency lube oil pump driven by a DC motor as a
change. The pump runs until the unit reaches approximately 40% rated speed. However,
it will continue to run after 40% rated speed if the system pressure has not reached the
pressure setting value of the pressure switch 63QL at this time. During the turbine
shut-down sequence the emergency lube oil pump will automatically start into
operation only when the system lube oil pressure decreases to 0.041MPa (gauge),
which will occur at approximately 25% rated speed of the unit.
The normal temperature of the lube oil fed to the bearings should be in the range of
48.9~54.4 . When the unit is operating at very high ambient temperature, the highest
temperature of the lube oil fed to the bearings is allowed to reach as high as 71 .
However, when the oil temperature in the lube oil header reaches 73.881.6 , the
temperature switch 26QA for lube oil header high temperature alarm will open and
47
CR054.01/02
annunciate an alarm. If the lube oil temperature continues to increase and reaches
79.441.6 , the temperature switch 26QT will open, which causes the unit to trip
and shut down.
Generally the lube oil temperature rise from inlet to outlet of the bearing varies in the
range of 13.9~27.8 . For the load gear box the lube oil temperature rise may reach
33.3 .
The pressure in the lube oil header should be above 0.13780.0138MPa (gauge). The
pressure switch 63QA for bearing low lube oil pressure alarm will open and annunciate
an alarm when the lube oil header pressure decreases to 82.76.89KPa (gauge). In
addition, the pressure switch 63QT for low lube oil pressure trip will open to cause the
unit to trip and shut down immediately when the lube oil header pressure decreases to
0.0550.0021MPa (gauge) due to trouble. If the lube oil header pressure continues to
decrease and reaches 0.04140.00689MPa, the pressure switch 63QL will close,
which causes the emergency lube oil pump 88QE driven by a DC motor to
automatically start. The emergency lube oil pump will not stop until the header
pressure restores rise and reaches 0.13780.0138MPa (gauge), which will cause the
lube oil pressure switch 63QL to open.
A test valve is installed in the line of the lube oil header. It is used to verify the
accuracy of the setting of the operation of the pressure switches 63QA and 63QL
under no load operation. This valve is normally closed and is opened only when
performing tests. The valve should be gradually opened in order to cause the
indicated lube oil header pressure to drop smoothly. The variation of the oil pressure
is indicated by the lube oil header pressure gauge installed in the gauge cabinet.
When the pressure in the header is below 8.276.89kPa (gauge) by opening the test
valve, the AC auxiliary lube oil pump 88QA should automatically start, and
meanwhile the condition of low lube oil pressure is indicated on CRT. Further
opening of the test valve will cause the oil pressure to decrease to 0.0414
0.00689MPa (gauge), and on this occasion the DC emergency lube oil pump 88QE
should automatically start into operation, whereas the AC auxiliary lube oil pump
should be prohibited to start somehow. On the other hand, when the oil pressure in
the header restores rise and reaches the normal setting value 0.13780.0138MPa
(gauge) by gradually closing the test valve, the pressure switch 63QL should operate
again, which will automatically stop the operation of the emergency lube oil pump.
The manual operated test of the emergency lube oil pump can be carried out by
turning the switch 43QE in MCC. After the test is completed, the signals on CRT
should be cleared by operating the master reset switch.
48
CR054.01/02
The flow condition and temperature variation of the lube oil in the bearings may be
viewed from the sight ports and the thermocouple reading display. Beside that a large
portion of oil in the lube oil system is supplied to the bearings and the gearboxes, there
is a small portion being supplied to the trip oil system and the hydraulic supply system.
It may be seen from ML 416 drawing that the hydraulic operation oil used in the trip
oil system is extracted from the branch line between the main lube oil pump and the
pressure regulation valve VPR-1. The pressure setting value of VPR-1 is 0.455
0.00689MPa (gauge) in order to ensure a relatively high pressure for the trip oil
system. The lube oil is filtered by the dual filters of 5 m filtering accuracy before it
enters the trip oil system.
The oil used in the hydraulic supply system is extracted from the branch lines of the
lube oil header. The OR-1 circuit (see ML 434) is used to actuate the control ring of the
variable inlet guide vane of the compressor, and the other circuit OR-2 is used to
actuate the ratchet mechanism and the starting clutch (see ML 421). Besides, the OR-1
circuit also supplies power fluid for the fuel system. The quality of the lube oil used in
the lube oil system shall be in accordance with the specifications in GEK-28143A.
49
CR054.01/02
CR054.01/02
A differential pressure gauge is provided to indicate the oil pressure across the filters.
When the gauge indicates a pressure difference of P 0.4MPa, the filter cartridge
should be renewed.
Now the high-pressure oil coming from the filters has been consistent with the
requirements and will flow into the fuel system and the variable inlet guide vane
system respectively, which is shown on the diagrams of the individual systems.
CR054.01/02
the oil pressure from the system either directly or indirectly through the solenoid valve
20FL-1. When the oil pressure in the trip oil line is relieved, the liquid oil stop valve
or the gas fuel speed ratio/stop valve closes by spring return action.
When the unit is started, the solenoid valve 20FL-1 is energized to shift its position to
"close", causing the system to establish the required pressure and thus open the fuel
stop valve. The fuel stop valve remains open until some trip action occurs or until the
unit is in shutdown sequence.
The group of pressure switches 63HG-1, -2, -3are all installed in the trip and fuel
control systems to provide redundant pressure monitoring and feed back to the turbine
control system and relevant electrical circuits, insuring the required trip oil pressure
level for turbine operations. A direct reading pressure gauge and three test valves for
the group of the pressure switches are installed to facilitate required inspection and
maintenance.
solenoid-operated spring-return spool valve that relieves the control pressure going to
the fuel stop valve trip oil or hydraulic oil . By dumping the low pressure oil to the
52
CR054.01/02
deenergized to trip and energized to reset from the SPEEDTRONIC control panel. This
solenoid valve is spring biased to trip and, therefore, protects the turbine during all
normal conditions as well as at any time that a loss of DC power may occur. 20FL-1 or
20FG-1 are shown in the deenergized state in the schematic diagram.
CR054.01/02
The gasfuel stop/speed ratio valve and the gas fuel control valve is the most critical
component in the gas fuel system. The fuel gas first passes through the stop/speed ratio
valve and then through the control valve prior to entering the combustion chamber. The
ratio function of the stop/speed ratio valve is to provide a regulated inlet pressure for
the control valve which is proportional to the turbine speed, i.e. a definite intervalve
pressure (behind the stop/speed ratio valve and ahead of the control valve) responding
to a turbine speed. A pressure transducer senses the intervalve pressure, which
provides a feedback signal to compare with the pressure control signal to reposition the
valve if there is an error between the speed and the pressure. There is also a close loop
functioning as position control. The position transducer (LVDT) senses the actual
position of the stop/speed ratio valve which provides the feedback signal of the
position control loop. This feedback signal is compared with the pressure control
signal. The difference between them is amplified and sent to the elector-hydraulic
servo valve to displace the cylinder piston and thus change the opening of the valve.
Both the stop/speed ratio valve and the control valve are stroked by elector-hydraulic
servo actuators. The actuators are of signal action type. This means the valves are
opened by feeding the lower part of the servo valve-controlled cylinder with hydraulic
oil to push the piston against the upper spring and they are closed by the top return
spring while dumping the hydraulic oil in the lower part of the servo valve-controlled
cylinder. When a an emergency stop is initiated, the hydraulic oil pressure suddenly
drops and the hydraulic oil in the lower part of the trip valve is rapidly dumped
through the inner path of the trip valve. In this case, the stop/speed ratio valve
immediately closes under the action of the top return spring to shut off the fuel gas
supply, which causes the unit to shut down.
The fuel gas control valve is controlled by a position loop. The master control signal
determining the stroke of the valve is the fuel reference stroke signal FSR from the
turbine control panel. The FSR signal is compared with the position feedback signal.
The difference between them is sent to the electro-hydraulic servo valve after being
amplified to displace the cylinder piston and thus change the opening of the control
valve. This action will continue until the error vanishes. From the above description it
is known that the flow of the fuel gas passing through the control valve depends on the
turbine speed and the fuel reference stroke.
For the setting of the primary transducersee DEVICE SUMMARY (ML 0414).
54
CR054.01/02
The liquid fuel system is used to equally distribute and deliver the liquid fuel of a
certain pressure and flow to the individual combustion chambers of the gas turbine so
as to meet the necessity of unit startup, accelerating and loading.
For
the
details
of
the
liquid
fuel
see
"GAS
TURBINE
LIQUID
FUEL
SPECIFICATIONS" (GEI-41047). For the details of the liquid fuel system see "Liquid
Fuel Piping Schematic Diagram". ML0424
The fuel oil first enters the low pressure fuel oil filter FF1 which is comprised of a
case and six cartridges with filtering accuracy of 5 m. The maximum working
pressure of the filter is designed to be 1.03MPa (gauge). The pressure drop for a clean
cartridge is 0.0103MPa. When the pressure differential reaches 0.118MPa, which
indicates the cartridges are very dirty, the cartridges have to be replaced. The pressure
differential value can be directly read out from the pressure differential gauge.
After passing through the low pressure filter the fuel oil enters the fuel stop valve VS1
that is a hydraulically controlled valve. In the lower part of the valve there is a
cylinder containing a piston, beneath which the control oil is passed in and controls the
opening of the stop valve. But its closing is accomplished by means of the action of a
compression spring in the upper part of the valve. The fuel stop valve only has two
positions: fully open and fully close. When the control oil is passed into the cylinder
section beneath the piston, the stop valve will be fully opened. However, if the unit is
required to shut down in case of emergency, the control oil is dumped, which results in
the fuel stop valve to be immediately closed under the action of the upper spring and
thus the fuel oil supply is cut off. The fuel oil stop valve is equipped with a limit
switch 33FL-1 that sends the open or close position signal of the fuel oil stop valve to
the turbine control panel.
The fuel oil discharged from the fuel stop valve enters the fuel oil pump PF1. The fuel
oil pump is a triple screw pump of high accuracy and is driven by he accessory gear.
Between the accessory gear and the fuel oil pump there is a solenoid clutch for
connection. If the fuel oil pump is not operating, it is detached from the accessory gear
through the action of the solenoid clutch.
The fuel oil flow discharged from the fuel oil pump is divided into two ways: one way
of oil flow returns to the inlet side of the fuel oil pump via the fuel oil bypass valve,
and the other way of oil flow goes to the combustion chamber of the gas turbine.
The fuel oil bypass valve VC3 is a hydraulically actuating valve controlled by a
55
CR054.01/02
CR054.01/02
flow divider can be read out by turning the handle to the position No.11 or No.12.
After passing through the selector valve the fuel oil enters the ten combustion
chambers primary liquid fuel nozzle via the check valves VCK-1~10. The other way of
fuel oil pass through the liquid fuel system nozzle isolation valve secondary
VH9-1,then the fuel oil enters the ten combustion chambers secondary liquid fuel
nozzle via the check valves VCK-11~20.Each fuel oil passage has a check valve. The
opening pressure of the check valve is 0.6960.007MPa.
CR054.01/02
limitation to the temperature of the incoming air of the atomizing air compressor,
in the inlet piping of the main atomizing air compressor the temperature switch
26AA-1 is provided, which will annunciate an alarm when the inlet air
temperature increases to 135 . In order to make the atomizing air compressor
operate properly to provide atomizing air the differential switch 63AD-1 is installed
between the inlet side and outlet side of the main atomizing air compressor to sense
the pressure differential between the inlet and outlet of the main atomizing air
compressor. If such pressure differential decreases to the setting, an alarm or
turbine trip will be initiated.
Since the speed during unit startup is relatively low, the axial compressor is unable to
provide proper air for the main atomizing air compressor. In order to achieve firing and
maintain combustion, the unit is equipped with a starting booster compressor to supply
the atomizing air for the combustion system. The booster compressor is driven by a
special motor that is matched with the compressor. The atomizing air exiting from the
starting booster compressor flows through the main atomizing air compressor to the
individual fuel nozzles. When the starting device stops, the starting booster
compressor accordingly stops. Since then, the total atomizing air will be completely
supplied by the main atomizing air compressor.
It has been mentioned that this gas turbine unit can burn liquid fuel or gas fuel. The
gas fuel for this unit is natural gas. The changeover between two fuels can be
performed. The purging system of this unit is definitely different with the normally
used system due to the properties of natural gas. When the unit is burning gas fuel, the
atomizing air is not needed. By using the solenoid valve 20AA to open the
pneumatically operated bypass valve VA18 the atomizing air can return to the inlet
piping of the precooler, i.e. the atomizing air circulates in closed loop. Although the
atomizing air is not needed now, there is a problem necessary to be considered. After
the fuel changeover from liquid fuel to gas fuel the nozzle oil passage may have
residual fuel oil (previously burning fuel oil). In order to remove the residual fuel oil
and prevent the nozzle components from depositing carbon or distorting due to being
overheated and in turn reducing their service lives, it is necessary to adopt the purge
air piping system that will ensure the cleanness of the fuel nozzle and remove the
troubles when burning fuel oil is resumed. So the purge air piping system creates a
good condition for the subsequent burning fuel oil.
The purging system for the fuel oil passages of the dual fuel nozzles is comprised of
the filter FA3, the pneumatic purge valve VA19-1 and the associated piping. When the
unit is burning gas fuel, the compressor discharge air goes sequentially through the
58
CR054.01/02
filter FA4, the pressure regulated valve VPR54 and the energized solenoid valve
20PL-1 to cause the purge air valve VA19-1 to open, which results in a portion of the
air in the atomizing air manifold to flow into the purge air branches via the purge air
manifold and purge the fuel oil passages of the fuel nozzles.
3.10.2 Cooling of the turbine 2nd stage nozzle by using the extraction air from the
compressor 13th stage
In order to insure steady operation of the turbine 2nd stage nozzle over a long period,
it needs to be cooled by using the extraction air from the compressor 13th stage. Four
pipelines are used to direct the extraction air. For each pipeline an orifice plate is
installed to adjust the air flow in normal operation. Besides, for the lower two lines an
isolation valve is separately provided for blocking the water flow during water wash.
For the composition of such piping system see ML0417.
CR054.01/02
the compressor rotor flows through the center bore of the turbine rotor and the gaps
between the turbine 1st stage and 2nd stage wheels and the forward spacer wheel and
then enters the radial holes of the turbine 1st stage and 2nd stage buckets from their
base and finally flows off from the tips of the buckets, entering the main gas flow in
the turbine flow path annulus. Such air flow cools the 1st stage wheel aft-face, the 2nd
stage wheel forward-face and the 1st stage and 2nd stage buckets. A portion of the
above-mentioned extraction air continues to flow downstream through the center bore
of the turbine rotor and then through the gap between the 2nd stage wheel and the aft
spacer wheel to cool the 2nd stage wheel aft-face. On the way such air flow is divided
into two ways: one way for cooling the 2nd stage wheel outer aft-face, the other way
for cooling the 3rd stage wheel forward-face after passing through the seal packing of
the 3rd stage nozzle. Finally the two air streams exit into the main gas flow.
The leakage air at the extraction gap between the 17th stage wheel of the compressor
rotor and the seal packing of the inner cylinder of the compressor discharge casing
flows through the annulus between the inner cylinder plus inner barrel and the distance
piece and then through the gap between the support ring and the turbine 1st stage
wheel forward face. Such air flow cools the 1st stage wheel forward-face including its
rim and 1st stage bucket base. Finally the stream exits into the main hot gas flow after
the 1st stage nozzle.
The turbine 1st stage nozzle is cooled by the compressor discharge air which flows
through the designed gap and is directed to the nozzle hollow partitions. The concave
surface of each 1st stage nozzle partition is machined to have a number of small holes
along its longitudinal direction. The cooling air exits from these holes with the heat
taken away and enters the main hot gas flow, having a perfect cooling effect. The
turbine 1st stage shroud is cooled by the compressor discharge air which is directed
through the small holes on the forward side face of such shroud to come in. After
absorbing the heat this air stream exits into the hot gas passage and mixes with the hot
gas flowing downstream.
CR054.01/02
circumferentially distributed in the turbine shell, entering the space between the outer
cylinder of the exhaust frame and the outer barrel of the exhaust diffuser and in turn
the space between the struts and their envelopes. The air exiting from here is divided
into two ways. One way air goes along the outer wall of the inner cylinder to cool the
turbine 3rd stage wheel aft-face and then exits into the gas flow. The other way air
passes through the space between the inner cylinder of the exhaust frame and the inner
barrel of the exhaust diffuser and then through the two pipes which are located at the
aft end of the diffuser and run through the enclosure roof of the unit, entering the
atmosphere. Such cooling air flow will insure that the temperature of the space, in
which the No.2 gearing is located, is not too high and thus provide a fairly good
working environment.
CR054.01/02
coolant to exit from both the oil cooler connection and the bypass connection. If the oil
temperature continues rising, the valve VTR1 will further open up to fully opening.
The total flowrate coming from the outlet of the oil cooler and the bypass port of the
valve VTR1 is 134 m 3 /h. A portion of such cooling water flow that is approximately 75
m 3 /h will pass through the orifice plate to the drain water header and the rest part that
is approximately 59 m 3 /h will flow towards the temperature regulating valve VTR2
installed in the feed water piping of the atomizing air precooler. A thermo-sensor
senses the atomizing air temperature from the outlet air piping of the atomizing air
precooler. Such signal is used to adjust the temperature regulating valve VTR2 for
controlling the amount of the cooling water entering the atomizing air precooler so as
to insure the atomizing air temperature at the inlet of the main atomizing air
compressor is limited to be not higher than 107 . The remaining cooling water will
flow towards the drain water header via the bypass port of the temperature regulating
valve VTR2.
The above-said two temperature regulating valves have the manual operated device
which can override the thermal element. When the automatic control is not working
properly, the manual operated device should be used to control the opening of the
valve.
All the water drain lines including the drain lines from the turbine legs, the oil coolers
and the atomizing air precooler and the bypass lines will join the drain header, through
which the cooling water leaves the unit.
CR054.01/02
CR054.01/02
opening the nitrogen cylinder. After the device is installed in place on site, the stopper
on the solenoid valve must be removed to allow the solenoid valve going into service.
If necessary to use emergency manual mode to extinguish the fire, it is only necessary
to pull out the retaining spring and press the handle, causing the solenoid valve to open
to release the nitrogen and thus release the extinguishing agent. The gauge is provided
for measuring the pressure inside the cylinder. If it indicates the pressure decrease, fill
the cylinder in time. For filling operation it is only necessary to remove the end cover
and connect the nitrogen source. After filling nitrogen is finished, remount the end
cover and make it tightened. After the actuation of the solenoid valve replace the
working diaphragm.
3.12.2.4 The pressure switch is installed in the manifold and is actuated when the
extinguishing agent is released, which functions as a feedback signal sent to the
alarming and extinguishing controller. The pressure switch must be reset after its
actuation.
3.12.2.5 The safety relief valve is installed in the manifold. Its safety diaphragm will
burst when the pressure in the manifold exceeds 15MPa, which provides protection
for the system. The specifications, material and burst pressure of the replacing
diaphragm should be consistent with the original one when replacing the bursted
diaphragm.
3.12.2.7 A manual control box (red) is located in the central control room. The box is
64
CR054.01/02
equipped with two buttons. One is the emergency electrical extinguishing button for
releasing carbon dioxide in case of emergency. The other is the "cancel" button that is
used to cancel the extinguishing command issued by the alarming and extinguishing
controller within 30 second extinguishing alarm time.
3.12.3 Operation
and
the solenoid valve on the nitrogen cylinder to operate and jab the working diaphragm
to release nitrogen gas.
3.12.3.2 Emergency electrical extinguishing
After the fire alarm signal is annunciated due to that the fire detector senses fire, the
solenoid valve is actuated to release carbon dioxide with 30 second extending alarm
time by operating the release switch on the alarming and extinguishing controller or by
operating the emergency electrical extinguishing button on the manual control box in
the central control room.
for
initial
discharge.
Then
open
the
rest
cylinders
CAUTION
Since there is no 30 second extending time for such
emergency extinguishing, it is emphasized that such
65
for
extended
CR054.01/02
3.12.4.1 Check the pressure of the nitrogen cylinders for release-initiating. If the
pressure is below 90% nominal value (6MPa), refill the cylinders.
3.12.4.2 The weight of the extinguishing agent in the carbon dioxide cylinder should
be annually weighed by using a weighing device. If it is below 90% nominal value
(38.5kg), refill the cylinder.
3.12.4.3 Inspect the cylinder support, piping hangers, hooks or press plates for
stableness and secureness every three months.
3.12.4.4 Inspect and maintain the various valves of the equipment annually to insure
there is any abnormal sign, otherwise they can not be used.The whole piping and
nozzles should be purged once every years by using compressed air (or nitrogen).
3.12.4.5 Perform the following items in accordance with this instruction and relevant
specifications once every three years:
Check the corrosion and mechanical damage of the storage cylinders
and the cylinder head valves and carry out the hydraulic test for them;
Carry out the hydraulic test and gas-tightness test for the equipment and
the valves;
Carry out the hydraulic test and gas-tightness test for the hoses;
66
CR054.01/02
3.12.4.6 The requirements of the hydraulic test and the gas-tightness test for various
sections are as follows:
The gas-tightness test is carried out at the pressure of 15MPa for the
extending time of 3 minutes. The pressure loss is not greater than 10%
under the condition of no supplementary gas.
For piping:
The hydraulic test is carried out at the pressure of 15MPa for the
extending time of 5 minutes. No leakage should be found.
The gas-tightness test is carried out at the pressure of 10MPa for the
extending time of 3 minutes. The pressure loss is not greater than 10%
under the condition of no supplementary gas.
3.12.4.7 After the extinguishing operation of the equipment, the alarming and
extinguishing controller (for details see the Electrical Operation Instructions), pressure
switch, check valves, cylinder head valves should be restored to the normal working
state or position. The knife type solenoid valves should be reset after their working
diaphragms are replaced. Besides, the nitrogen cylinders and carbon dioxide cylinders
should be refilled.
CR054.01/02
turbine compartment through the ventilation openings in the side walls of the
accessory compartment and the turbine compartment and intensify the air convection
in the turbine compartment. As a result, the space temperature in the turbine
compartment is reduced during normal operation and meanwhile the combustible
gaseous mixture is not easy to build up.
The ventilating fan 88VL-1 is mounted on the enclosure roof of the DLN module. The
external air is drawn in through the vent on the enclosure roof of the DLN module and
is exhausted out of the enclosure by 88VL-1 mounted on the roof after circulating
through the module. Thus the concentration of combustible gas in the compartment is
reduced to minimum.
For the unit, of which the load gear box is equipped with an enclosure, two ventilation
fans are mounted on the enclosure roof of the load gear box compartment, by which the
pressurized fresh air is sent in for dissipating heat and ventilating.
3.13.2 Lighting
The accessory compartment, the load gear box compartment and the generator
compartment are all equipped with AC 220V and DC 120V lighting lamps. During
normal operation or maintenance the AC lighting lamps are on duty, and the DC
lighting lamps are for backup. The DC lighting lamps will automatically be on when
there is failure of AC power source.
For the schematic circuits of the lighting facility and receptacles of the unit see ML
Q9623 Motor Control Center.
60m 3 /h
0.96 m 3 /h
Electrical heaters:
40kW3, 415VAC
68
0.75MPa,
0.80MPa,
CR054.01/02
Water tank:
8 m3 ,
Detergent tank:
0.2 m 3 ,
There are two types of nozzle for washing: portable and fixed. The former type is used
to clean the inlet plenum and the compressor inlet bell mouth in order to prevent those
foul contaminants from entering the compressor. Such facility will be provided by the
customer according to its necessity.
In order to remove oil soluble deposits, the compressor should be soaked in the water
containing detergent. Then it should be rinsed with pure water to remove the remaining
detergent and finally dried, in order to avoid the corrosion of the flow path section
caused by the detergent.
The washing efficiency can be evaluated by visual inspection or measuring the electric
conductivity of the drained water or inspecting the contents of the trace metals by
optical spectrum analysis.
CR054.01/02
on-line cleaning. For the detailed operating principle of the system see ML 0419
"CONTROL GAS PIPING SCHEMATIC DIAGRAM".
CR054.01/02
The main function of the system is to eliminate the oil mist contained in the oil drain
lines from the generator and the load gear and in the unit oil tank. The oil vapor mixed
with air after being processed is vented to the atmosphere, and the oil eliminated from
the mist flows back to the oil tank. For the detailed working process see ML Q05-3
DIRGRAM SCHEM. PP-OIL-AIR SEPERATOR (i.e. OIL MIST ELIMINATOR
PIPING SCHEMATIC DIAGRAM).
The core component of the system is the oil mist eliminator. The following description
will be focused on it.
3.16.1 Configuration of the oil mist eliminator and its working principle
The oil mist eliminator includes a shell, a stainless steel mist eliminator, a gas
distributor, a coarse-grained polymerization and elimination element assembly, a fan,
automatic control instrumentation, a supplementary gas regulation device, a negative
pressure protection valve, bypass piping and its automatic open and close device and
various valves. They are integrated and assembled on a base to form an integral set-up.
The shell of the equipment, all the piping valves connected with the shell, and all the
parts inside the shell are all made of stainless steel. They have comparatively strong
anti-corrosion capability that will completely insure their service in open air and make
them be applicable to the treatment or elimination of various corrosive gaseous mists.
The stainless mist eliminator and the gas distributor are made of a special stainless
71
CR054.01/02
steel mesh and are manufactured through a precision finishing process. They are used
to remove the entrained mist foam in the gas and equally distribute the oil vapor to be
processed in the shell so as to insure the effective elimination of oil mist.
The coarse-grained polymerization and elimination element is made of a high
molecular substance and is produced through a special technological process. This
element has a good capability to adhere, capture and polymerize the oil particles in the
oil mist and to eliminate the oil beads. It can capture the oil beads greater than 2 m
and various mist contaminants.
The fan for this equipment is a centrifugal fan of large flowrate and high pressure head
(the discharge pressure may reach 0.007MPa). It is specially designed and
manufactured in accordance with the design requirements of the general arrangement
by the specialized factory.
The oil mist eliminator uses a specially made centrifugal fan which operates in
negative pressure draught, that is to say, the fan is installed in the gas vent piping of
the oil mist eliminator. Depending on the action of negative pressure, the oil mist to be
processed is drawn from the oil tank and the other places into the oil mist eliminator
where it will be processed and eliminated.
The oil mist from the generator, the load gear and the unit lube oil tank automatically
enters the oil mist eliminator under the drawing action of negative pressure. First the
oil mist passes through the capturer to cause most part of the oil foam to be removed
and then passes through the gas distributor to enter the coarse-grained polymerization
and elimination elements for carrying out the oil mist elimination. Here, the oil beads
greater than 2 microns and contaminants are completely captured, polymerized and
eliminated. After passing through the secondary mist elimination device the purified
gas enters the inlet of the fan, by which it is vented to the atmosphere. The captured oil
beads and contaminants are getting larger and larger due to polymerization. When their
gravitation force is greater than the adherent force, they will drop and then flow to the
oil collection chamber at the bottom of the mist eliminator. In the outlet piping of the
oil collection chamber there is a valve that directs the oil back to the oil tank.
In order to ensure the normal reliable operation of the system, negative pressure
indicators, a differential pressure indicator under automatic control, a supplementary
gas regulation device and an overload protection device due to negative pressure are
installed for the mist inlet chamber and the gas outlet chamber of the equipment
respectively.
72
CR054.01/02
KYF-20D
2 m
-2000Pa
80
auto/manual
auto/manual
7.5kW
3000rpm
CR054.01/02
7. After the above checks are completed, start the fan. If the fan is operating
properly, check for the proper function of the gauges in the equipment.
8. Adjust the valve in the inlet piping to cause the inlet flowrate of the equipment
to meet the operation requirement. The general way for making such
adjustment is slowly reducing the valve opening until the required inlet gas
flowrate is reached. (A flowrate of approximately 600m 3 /h is available when
the valve is one third opened.)
9. After the flowrate regulation is finished, check whether the indicated negative
pressure in the inlet chamber is 0.002MPa. If the required negative pressure is
not reached, close the supplementary gas valve to achieve that.
10. After the above procedures are completed, the system is ready for normal
operation.
11. If the system is required to be out of service, it only requires stopping the fan.
At this time, do not operate any valves and touch any gauges in the system as
they have been ready for next start.
3.16.3.2 For normal service it is only required to start the fan. If the equipment is not
operated by a special person, it is necessary for the other person to check all the
gauges in the equipment and check for the normal operation position of the valves.
3.16.3.4 Maintenance
1. Regularly check for the normal operation indication of the various gauges in
the equipment.
2. When the negative differential pressure between the inlet and the outlet of the
equipment reaches 0.004MPa, the coarse-grained polymerization and
74
CR054.01/02
For the dual fuel system an air stream is branched off from the atomizing air system for
75
CR054.01/02
purging. The purge air system is to purge the liquid passages of the fuel nozzles when
use fuel gas. And purge gas fuel pipe & gas fuel nozzles when use fuel liquid. The
detailed control of purge air system see the control specification (A010)
76
CR054.01/02
4. GENERATOR PACKAGE
4.1 Generator
For the detailed description of the generator see QFR-42-2.
"INSTALLATION, OPEERATION & MAINTENANCE INSTRUCTION FOR GAS
TURBO-GENERATOR".
42MW
Nominal voltage:
10500V
Nominal current:
2886.8A
Frequency:
50Hz
Power factor:
0.8
Efficiency:
98.2%
0.51
Connection:
Protective type:
IP54
Rotation direction:
77
CR054.01/02
78
CR054.01/02
5. LOAD GEAR
The load gear is located between the gas turbine and the generator, and its function is
to transmit the torque of the turbine shaft to the generator shaft through speed
reduction.
For the detailed description of the load gear see the relevant instruction provided by
the manufacturer. The load gear is made by France Flender company.
The gear shafts are laid out in the longitudinal vertical plane, and the drive shaft
(pinion shaft) is above. The casing is divided into three parts: upper, middle and lower.
They are bolted on the horizontal joints to be an integral. The whole gear box is
installed on a specially designed base plate.
54000kW
3000rpm
5163rpm
Center-to-center:
660mm
2320mm
Efficiency:
79
CR054.01/02
CR054.01/02
The standard MK VIe control panel is provided with DC 120V source by means of
batteries. The ignition transformers and the primary operator interface <HMI> use AC
240V 50Hz source respectively. The typical power consumption of the standard panel is
DC 900W and AC 300W. The power distribution core inside the panel is used to safely
send the input power to the individual cores and cards through different branches. For
the detailed information of the turbine control panel see manuals of MARK VIe
control panel provided with the unit.
CR054.01/02
2.
82
CR054.01/02
The excitation system of the generator is provided with output ammeters, output
voltmeters.
The system is provided with voltmeter, frequency meter and synchroscope (It indicates
whether
the
synchronization
conditions
are
reached
when
performing
the
synchronization of the generator with the system, it also indicates the voltage
difference and the frequency difference between the generator and the system).
CR054.01/02
The mainframe includes the following main plug-in items: power supply board
1(PWR1),
power
supply
board2(PWR2),CPU
board(CPU),
digital
input-output
The equipment may operate using constant power factor control mode.
The equipment has the functions of over excitation limit and under excitation limit and
V/Hz limit.
The equipment has the functions of system checkout itself include RAM checkout,
power control, silicon control failure etc. When the equipment has same trouble, it will
send out hardware failure single, at the same time this channel will quit, and the
standby channel will run automatically.
The equipment has the protection functions of PT open. Pulse fault detection, over
excitation, under excitation, V/Hz, etc.
For the detailed operation principal and service of the equipment see "DVR-2000R
EXCITATION REGULATOR USER GUIDE
relay
and
synchroscope.
It
is
used
to
accomplish
the
manual
CR054.01/02
system.
The annuaciator consists of power supply unit, alarm unit, operation unit and audible
unit.
Each alarm unit is an independent module. The number of the alarm units for an
acousto-optic annunciator is determined by the quantity of the alarm signals.
The primary functions of an alarm unit are as follows:
(1) It provides four independent alarm circuits. The number of alarm circuits
for each unit is selected according to the level of importance of the alarm
signal.
(2) One to four light indicator windows are provided on the front of the unit.
The number of the windows should be matched with the number of the
alarm circuits. The dimension of the window may be 1/4, 1/3, 1/2 and 1
unit size. Each window may have four colors, i. e. red, yellow, white and
green. The selection of the different colors is depended on the character
of the alarm.
(3) It provides nine annunciating programs, two input modes and two kinds
of alarm status. They can be selected according to the needs on site.
The acousto-optic annunciator for this panel provides the following alarm
signals:
85
CR054.01/02
earth;
over
voltage;
field-loss;
Generator
reverse
power;
Generator
3. Operation unit
Four buttons are available on the panel of the operation unit, Their names and
functions are as follows:
SILENCE: It is used to silence the present alarm, but does not have any effects on
the light indicators and the alarm acknowledgement status, The sequence is still
in alarm status. If there are any inputs of new alarm messages, the annunciator
will sound again.
ACK: It is used to perform the status conversion from "ALARM" to
"ACKNOWLEDGEMENT".
RESET: If the "manual reset" is selected by the program, this button can be used
to perform the status conversion from "ACKNOWLEDGEMENT" to "NORMAL"
when the normal state of the process has been restored. It can also be used for
status restoring from "ACKNOWLEDGEMENT" to "NORMAL" if the backward
signaling sequence is selected by the program.
TEST: It is used to simulate the instantaneous abnormal status for all alarm
points, activating the indicating lamps to blink and the sounder to sound (except
the back signaling sequence). During the test new alarm messages can be stored
for display after the test is finished.
The operation unit can be installed together with the alarm unit as well as
separately on the panel or the operator console.
86
CR054.01/02
4. Audible unit
The audible unit provides three kinds of sound of different tunes when the system
is annunciating alarms: normal alarm sound, emergency alarm sound and
backward signaling alarm sound. (This is depended on the configuration of the
programs for the system).
The audible unit can be installed together with the alarm unit as well as
separately on the back face of the panel.
87
CR054.01/02
It is used to adjust the frequency of the generator (by means of the coordination
of the turbine control panel) when the generator is operating in single unit mode
or regulate the active power output (by means of the coordination of the turbine
control panel) when the generator is operating in parallel with the grid;
43PF "POWER FACTOR" control switch
It is used to control the operation status of the power factor card. During unit
operation turn the switch to "ON" if the card is needed to go into operation or
turn the switch to "OFF" if it is needed to be out of operation;
43VS "VOLTMETER SWITCHING" selector switch
It is used to measure each phase-to- phase voltage of the system by switching the
voltmeter to the individual corresponding position;
43S "SYNCHRONIZING MODE" selector switch
It is used to select "MANUAL" or "AUTO" operation of the synchronization
device. The "TEST" position is used to check whether the synchronization device
sends "circuit breaker close" signal.
43ST "SYNCHRONIZING OPERATION POSITION" selector switch
It is used to select "LOCAL" or "REMOTE" synchronizing operation.
43EF "EXCITATION SOURCE" control switch
It is used to switch on or off the excitation source.
43ECS "EXCITATION CHANNEL" select switch
It is used to exchange between A channel and B channel while running.
88
CR054.01/02
2. Test buttons
89
CR054.01/02
2. Indicating lamps
52Z-1, 52Z-1X
52Z-2
52Z-3
52GX-1, 52GX-2
6.3.4 Instruction for the service and operation of the generator control panel
6.3.4.1 The following items of work should be carried out before initially going into
service of the generator control panel:
1. Calibrate the measurement instruments for all the operating parameters;
2. Calibrate the active and reactive power transmitters;
3. Inspect and commission the automatic voltage regulator (DVR-2000R) and set
90
CR054.01/02
4. Inspect and commission the synchronization device and set the operating
values of various parameters;
5. Check for the correct connection inside the panel according to the electrical
elementary circuit diagram;
6.3.4.2 The generator control panel is allowed to go into normal service only after
finishing the above check and commissioning items.
CR054.01/02
The control objectives for the operation of various protective devices are dependent on
the character and options of the protective devices and the actions taken for faults. For
the gas turbine generator unit the following several kinds of actions are taken:
Completely stop: turbine shutdown, circuit breaker 52G trip field suppression and
annunciating alarms;
The overcurrent protection under the presence of the composite voltage refers to the
generator overcurrent protection due to the external fault of the generator, as well as
the backup protection of the longitudinal differential protection due to the internal
fault of the generator.
CR054.01/02
In order to prevent the malfunction of the stator ground protection due to the
high-tension side earth of the generator transformer, the earth protection blocking on
high-tension side is used. When the generator stator earths and the first harmonic
zero-sequence voltage at the generator outlet or the triple-frequency harmonic voltage
at the neutral exceeds the setting value, the protective device operates with a time
delay.
CR054.01/02
transmission power of the load gear box, and thereby will cause the serious damage of
the gas turbine and generator. In order to avoid such damage, the reverse power
protection is provided. When the active power absorbed from the system exceeds the
sum of copper loss, windage loss and friction loss of the generator, the reverse power
relay will actuate 52G to trip with a time delay.
Overvoltage protection:
This protection is the stator overvoltage protection due to the generator load rejection
The power source for the operation of the protective devices is DC 120V. On the panel
94
CR054.01/02
When any group of protective devices operates, there will be the indicator light display
on the front panel, indicating the fault has occurred and sending the signals to the
acousto-optic annunciator.
The protective device is designed to accept the signals of differential CT circuit break,
PT circuit break on generator side VT. There will be the indicator light display on the
panel when any circuit break signal occurs and the signal is sent to the acousto-optic
annunciator.
The top wall of the panel is equipped with a lighting lamp for convenience of
maintenance. When the door is open, the lamp is automatically on.
95
CR054.01/02
AC/DC
CODE
UNIT NAME
CAPACITY
(kW)
AC
AC
AC POWER-SWITCHING
AC
88CR
AC
88TK-1
CRANKING MOTOR
450
37
FRAME BLOWER
5
AC
88BT-1
22
AC
88BT-2
22
AC
88VL-1
VENTILATION
FAN
8
AC
88TK-2
37
FRAME BLOWER
9
AC
88VG
7.5
10
AC
88QV
7.5
11
AC
88VL-2
VENTILATION
FAN
12
AC
88QA
13
AC
88HQ
AUXILIARY
HYDRAULIC
30
SUPPLY
6kw
PUMP
14
AC
AC415V
15
AC
23QT
16
AC
23HG
415V
SWITCHGEAR
10.2
AC
TP1
AC 415/220V SWITCHGEAR
2kVA
18
AC
AC220/110V
AC 220/110V SWITCHGEAR
19
DC
88QE
7.5
20
DC
88HR
0.6
21
DC
DC120V
22
AC
88AB
30
23
AC
23HA
15
24
AC
23HT
15
25
AC
TP2
DC 120V SWITCHGEAR
415/220V-110V-0
96
SWITCHGEAR
40kVA
CR054.01/02
RESISTANCE
26
AC
23HA-11
3.9
27
AC
23HA-12
15
28
AC
23HA-13
15
29
AC
23HA-14
15
30
AC
88SP-1
STANDBY UNIT
37
31
AC
88SP-2
STANDBY UNIT
7.5
32
AC
88SP-3
STANDBY UNIT
30
33
AC
88SP-4
STANDBY UNIT
22
34
AC
88SP-5
STANDBY UNIT
35
DC
88FM
0.37
97
CR054.01/02
The DC control units adopt automatic operation mode and have the protection
functions of short circuit and overload. On the front panel of each unit there are "RUN",
"STOP", and "OVERLOAD" indicator lights. The front panel of emergency lube oil
pump control unit is provided with a test button which is used to check the actuation
conditions of the components inside the control unit and manually start this pump
under emergency conditions.
6.6.2 Receptacles
For the elementary circuit diagrams of the unit lighting equipment see ML Q9623
MCC.
98
CR054.01/02
99
CR054.01/02
Fig 7 -1 Working schema tic diagra m of the inlet air filter house
7.2.1 Installation , op eration and maintenance
7.2.1.1 In stallatio n
a. The installation of the inlet filter house is carried out on site. For the
installation dimensions of various components and the foundation requirements
see the relevant drawings.
b. All the ducts should be carefully cleaned to be rid of any foreign objects before
installation.
c. Inspect the operating conditions in accordance with the following procedures
after finishing the installation:
Check for the proper and secure electrical connection of all instruments and the
backup air compressor motor.
Open all valves in the pressurized air piping to make the outlet of the air
compressor open to the pressurized air manifold.
Start the air compressor and observe whether the air compressor is operating
properly. The compressor should automatically stop when the air pressure in the
storage tank reaches 810 5 Pa.
By pressing the proper buttons on the instrument cabinet the back-blowing
100
CR054.01/02
system will initiate the back-blowing operation according to the sequence of row
by row scanning.
The air compressor will automatically start when the pressure in the storage tank
is lower than 610 5 Pa.
The ambient air penetrates the filter elements to flow to the compressor inlet under the
action of the negative pressure in the filter house. The dust particles and corrosive
liquid drops in the air are blocked by the paper cartridges of the filter elements and
adsorbed by the filter paper. With the increasing accumulation of the dust particles the
resistance of the filter cartridges is increasing, which will cause the inlet air pressure
drop to increase. After a certain time it is necessary to blow the dust down by operating
the back-blowing system. As to the back-blowing of the filters there are two operation
modes, i.e. auto and manual operation.
Auto mode: After finishing the installation and commissioning of the complete filter
system turn the operation switch on the control panel to "AUTO" position. When the
pressure differential reaches the setting value of "on" status (650Pa), the back-blowing
system will operate automatically. But when the pressure differential decreases to
reach the setting value of "off" status (450Pa), the back-blowing system will stop
operation automatically.
Manual mode: The manual mode has the priority over the auto mode. After finishing
the installation and commissioning of the complete filter system turn the operation
switch on the control panel to "MANAUL" position, which will cause the
back-blowing system to start operation. It will not stop operation until the operation
switch is transferred to "AUTO" position.
It is suggested to perform the back-blowing once everyday by using the manual mode
in the initial operation period of the unit when the inlet pressure differential is
101
CR054.01/02
relatively small, not reaching the setting value of the auto back-blowing and so the
auto mode will not work in that period. This will prevent the dust accumulated on the
filter from hardening and being difficult later to be blown down to cause the operation
life of the filter to be reduced. After performing the back-blowing periodically by
using the manual mode in a certain operation period of the unit, it is allowed to shift to
the auto mode for automatically performing the back-blowing when the pressure
differential reaches 650Pa.
Because the effect of the back-blowing performed during shutdown of the unit is best,
the back-blowing of the filters should be performed by using the manual mode after the
unit has shut down whenever the condition is allowable.
Notes:
1. The back-blowing system for the inlet filter house must be put into operation
simultaneously with the unit, i.e. after the unit has started operation, the back-blowing
system should be immediately put into periodical operation by using the manual mode
to prevent the dust from being accumulated on the filter paper of the filter elements for
long time to form "dust cake".
2. If the weather is bad, such as strongly foggy, snowing or meeting with ambient
temperature below 0 , it may be necessary to perform the back-blowing under the
manual mode once or multi-times each day depending on the resistance increase of the
inlet air.
The pressurized air for back-blowing can be provided in two ways. One is using the
compressor extraction air of the turbine as the main air supply, and the other is using
the pressurized air of a back air compressor as the backup air supply. When the unit is
under operating status, the air for back-blowing is provided by the main air supply.
When the unit is under shutdown status, however, the air for back-blowing is provided
by the backup air supply. The air compressor is provided with an air reservoir.
Assuming the unit is running, when the pressure in the air reservoir reaches 810 5 Pa,
the air compressor will stop running automatically. But when the pressure in the air
reservoir decreases to 610 5 Pa, the air compressor will start automatically.
The operation life of the filter element of the air filter is dependant on the operating
environment. When the pressure differential of the filter reaches 1000Pa and it is
impossible to return to the operational condition through cleaning, the filter elements
should be replaced. Alternatively, replace the filter elements after the unit has operated
102
CR054.01/02
for 18 24 months.
As to the operation and maintenance of the air compressor, follow the regulations as
specified in the document provided by the manufacturer.
103
CR054.01/02
104
CR054.01/02
ML 0414
DEVICE SUMMARY
ML A010
CONTROL SPECIFICATIONS-SETTINGS
MARK e Turbine Control System Manual
9.2.1 Lube oil system and hydraulic supply system and trip oil system
The inlet strainers for all the pumps should be flushed to be clean.
The filters in the lube oil piping, hydraulic supply piping and trip oil piping should be
cleaned or renewed if necessary.
The transfer valves for the various oil filters and the oil coolers should be turned to an
105
CR054.01/02
extreme position (No.1 or No.2) and are not allowed to stay in any intermediate
position between the two extreme positions.
Set the level indicator of the lube oil tank properly according to the specification, i. e.
manually adjust the indicator float to make the distance from the float center to the top
of the tank meet the requirement. The specification for the lube oil level is 432mm low
level alarm, 406mm empty, 305mm full, and 254mm high alarm.
Fill the lube oil tank with oil to "FULL" level. Inspect the leakage of the piping and
view the flow conditions at the various sight ports by starting the emergency lube oil
pump to fill the lube oil system. Then stop the emergency lube oil pump and refill the
tank to "FULL" level after the lube oil drains to the tank from the individual feed
points.
Manually start the auxiliary lube oil pump and view whether the readings of the
various pressure gauges are consistent with the requirements. Otherwise adjust the
VR-1, VPR-1 or VRR-2 valves according to the conditions.
For the newly installed or major-overhauled unit the lube oil system should be flushed.
For the flushing procedures see ML A125 (NO SITE LUBE OIL FLUSH PIPING).
Check whether the manual emergency trip valve is set in the normal operation position.
CR054.01/02
Look up the function of the individual accessory systems and the settings of the system
components
from
"DEVICE
SUMMARY"
and
"PIPING
SCHEMATIC
DIAGRAMS".
Clearly know the location and function of the various hardwares inside the turbine
SPEEDTRONIC control panel.
The operational personnel are also required to be aware of the power plant equipment
either mechanically or electrically linked with the gas turbine and their effects on the
normal operation of the unit.
Do not make an attempt to start the unit, either newly installed or major-overhauled,
until the following conditions are met:
1. The requirements listed in "Checks Prior to Operation" have been met.
2. Perform the function inspection for the control system before starting the unit
and confirm the capability of proper operation.
3. The "General Operating Precautions" described in 9.4 paragraph have been
taken seriously.
Especially the operational personnel should cultivate good operation style. Here the
following important points should be emphasized:
a. Response to annunciator indicators-Once the alarm information is displayed on
the screen, investigate the cause and take correct actions particularly for the
alarms
from
the
protection
systems;
such
as
low
lube
oil
pressure,
107
CR054.01/02
CAUTION
Overtemperature can damage the turbine hot gas path parts.
CR054.01/02
temperatures and making plots. For the PG6581B turbine, the expected average spread
is 45F35F (2519). If the exhaust temperature spread exceeds 80F (44)
Or deviates 35F (19) from the baseline value, the correction measures should be
accordingly taken.
The permitted maximum values of the turbine wheel-space temperatures during unit
operation is given below: (to review)
First stage
TT-WS1FI-1 & 2
800F (427)
TT-WS1AO-1 & 2
950F (510)
Second stage
TT-WS2FO-1 & 2
950F (510)
TT-WS2AO-1 & 2
950F (510)
Third stage
The
TT-WS3FO-1 & 2
900F (482)
TT-WS3AO-1 & 2
800F (427)
wheelspace
temperature
thermocouples,
identified
together
with
their
CR054.01/02
an orifice should be
increased.
After a major overhaul of turbine, all orifices should be changed back to their original
size, assuming that all turbine clearances are returned to normal and all leakage paths
are corrected.
CAUTION
Wheelspace temperatures are read on the CRT of <HMI> .
Temperatures exceeding the maximum are potentially harmful to
turbine hot-gas-path parts over a prolonged period of time.
Excessive temperatures will annunciate alarms, but will not trip
the turbine. High wheelspace temperature readings must be
reported to the technical representative of the manufacturer as
soon as possible.
110
CR054.01/02
If there is any doubt about the accuracy of the reading or if more accurate and specific
vibration readings are desired, a vibration check is recommended by using vibration
test instrument. If the measurement is carried out by using a displacement type
vibration meter, the reading obtained at a given speed (or frequency) should be
converted into the vibration velocity value by using a special vibration analysis chart.
In the following the factors and policy related to the overloading of gas turbine are
described.
The unit is manufactured in accordance with GE technology. It is GE practice to design
gas turbines with margins of safety to meet the contract commitments and to secure
long life and trouble-free operation.
CR054.01/02
CR054.01/02
The ventilation dampers are automatically closed by a signal received from the fire
protection system, but they must be manually reopened in all compartments before
restarting the unit.
CAUTION
Failure to reopen compartment ventilation dampers
w i l l s e v e re l y s h o r t e n t h e s e r v i c e l i f e o f m a j o r
accessory equipment. Failure to reopen the load gear
compartment dampers will materially reduce the
performance of the generator.
WARNING
Sudden emission of black smoke may indicate a
possibility of combustion chamber outer casing
failure or other serious combustion problems.
In such an event ought to perform the
following:
113
CR054.01/02
b. After a trip from 75% load or above, observe the exhaust on startup for black
or abnormal smoke and scan the exhaust thermocouples for unusually high
spreads. Record temperature spread during a normal startup to obtain base line
signature for comparison. Excessive tripping should be investigated and
eliminated.
CAUTION
Operation of the gas turbine with a single faulty
thermo co uple sho uld not be neglected, beca use
even one faulty thermocouple will increase the
risk of an invalid "combustion alarm" and/or
"trip". The unit should not be shut down just
for replacement of a single faulty thermocouple.
H o w e v e r, e v e r y e f f o r t s h o u l d b e m a d e t o
replace the faulty thermocouples when the
machine is down for any reason.
Adherence to the above criteria and early preventive maintenance should reduce
distortions of the control and protection functions and the number of unnecessary
turbine trips.
114
CR054.01/02
CAUTION
It the event of an emergency shutdown in which internal
damage of any rotating equipment is suspected, do not
turn the rotor after shutdown. Maintain lube oil pump
operation, since starvation of circulating lube oil following a
hot shutdown will cause rising bearing temperatures
which ca n result in damaged bearing surfaces. If the
malfunction that caused the unit to shut down can be
quickly repaired, or if a check reveals no internal damage
affecting the rotating parts, reinstate the cooldown cycle.
If there is an emergency shutdown and the turbine is not turned with the rotor turning
device, the following factors should be noted:
a. Within 15 minutes, maximum, following turbine shutdown, the gas turbine may
be started without cooldown rotation, using the normal starting procedure.
b. After a shutdown of between 15 minutes and 48 hours, a restart should not be
attempted unless the gas turbine rotor has been turned from one to two hours
prior to the startup attempt.
c. If the unit has been shut down and not turned at all, it must remain shutdown
for approximately 48 hours before it can be started without risk of shaft bow.
115
CR054.01/02
CAUTION
Where the gas turbine rotor has not turned after
shutdown and a restart attempt is made, as under the
above conditions (a) and (c), the operator should
maintain a continuous check on vibration velocity
during the process of bring up the unit to its rated
speed. If the vibration velocity exceeds 25.4 mm/s at
any speed, the unit should be shut down and the rotor
should be turned for at least one hour before a second
starting attempt is made. If any seizure occurs during
the turning operation of the gas turbine, the turning
operation should be stopped and the gas turbine
should remain idle for at least 30 hours, or until the
rotor is free. The turbine may be turned at any time
during the 30-hour period if it is free, however,
audible checks should be made for rubs.
NOTE
The vibration velocity must be measured at the points near
the gas turbine bearing caps.
CR054.01/02
4. Lube oil pumps. The auxiliary pump should run at regular intervals to prevent rust
formation in the lube oil system.
5. Operation of air conditioner at control equipment area during periods of high
ambient temperature to maintain electrical equipment insulation within design
temperature range.
6. Battery charger.
9.5.2.1 Check that all piping and turbine connections are securely fastened and all blinds
have been removed.
9.5.2.2 Inlet and exhaust plenums and associated ducting are clean and rid of all foreign
objects. All access doors are secure.
9.5.2.3 Where fuel, air or lube oil filters have been replaced, check that all covers are
intact and tight.
9.5.2.4 Verify that the lube oil tank is within the operating level and the tank has been
refilled with the recommended quality and quantity of lube oil if it has been drained. If
lube oil flushing has been conducted, verify that all filters have been replaced and any
blinds if used, removed.
9.5.2.5 Check operation of auxiliary and emergency equipment, such as lube oil pumps,
water pumps, fuel forwarding pumps, etc. Check for obvious leakage, abnormal vibration
(maximum 0.076mm), noise or overheating.
9.5.2.6 Check lube oil piping for obvious leakage. Also using provided oil flow sights,
check visually that oil is flowing from the bearing drains. The turbine should not be
117
CR054.01/02
WARNING
Do not test spark plugs where explosive atmosphere is present.
If the arc occurs anywhere other than directly across the gap at the tips of the electrodes,
or if by blowing on the arc it can be moved from this point, the plug should be cleaned and
the tip clearance adjusted.
If necessary, the plug should be replaced. Verify the retracting piston for free operation.
9.5.2.10 Determine that the cooling water system has been properly flushed and filled with
the recommended coolant. Any fine powdery rust, which might form in the piping during
short time exposure to atmosphere, can be tolerated. If there is evidence of scaly rust, the
cooling system should be power flushed until all scale is removed. If it is necessary to use
a chemical cleaner, most automobile cooling system cleaners are acceptable and will not
damage the carbon and rubber parts of the pump mechanical seals or rubber parts in the
piping.
Refer to GEI-41004 "cooling water recommendations for combustion gas turbine closed
cooling systems".
Following the water system refill ensure that the water system piping do not leak by
inspecting.
9.5.2.11 The use of radio transmitting equipment in the vicinity of open control panels is
not recommended. Prohibiting such use will insure that no extraneous signals are
introduced into the control system, which might influence the normal operation of the
equipment.
9.5.2.12 Check the Cooling and Sealing Air Piping against the assembly drawing and
118
CR054.01/02
piping schematic diagram to ensure that all orifice plates between flanges or in orifice
unions are of designated size and in designated positions.
9.5.2.13 At this time all annunciated ground faults should be cleared. It is recommended
that the unit not be operated when any ground fault is indicated.
Immediate action should be taken to locate all grounds and correct the problems.
9.5.3.1 Crank
1. Listen for rubbing noises in the turbine compartment and in the load gear
compartment, especially in the load tunnel area. A soundscope or some other
listening type device is suggested to be used. Shut down the unit and
investigate the cause if unusual noise occurs.
2. Check for unusual vibration.
3. Inspect for any water system leakage.
9.5.3.2 Fire
1. If the air in the fuel oil filters has been bled and they are in normal condition,
inspect for the leakage of the whole fuel system and the area in close vicinity
of the fuel nozzles. Especially inspect the leakage for the following places:
Turbine compartment:
a. The fuel piping to fuel nozzles;
b. The fuel oil check valve
119
CR054.01/02
Auxiliary compartment:
a. The fuel oil flow divider
b. The fuel oil pump
c. The cover of filter & drain piping
d. The fuel piping;
CAUTION
Elimination of fuel leakage in the turbine compartment
is of extreme importance as a fire and explosion
preventive measure.
2. Monitor the turbine control panel readings on the CRT for unusual exhaust
thermocouple temperature, wheelspace temperature, lube oil drain temperature,
highest to lowest exhaust temperature spreads and "hot spots", i.e. combustion
chamber(s) burning hotter than all the others.
3. Listen for unusual noises and rubbing.
4. Monitor for excessive vibration.
CR054.01/02
2. Monitor lube oil tank, header and bearing drain temperature continually during the
heating period. Refer to the Piping Schematic Diagram and DEVICE SUMMARY
for temperature guidelines.
121
CR054.01/02
These instructions are based on use of MARK e EDTRONEC turbine control panel.
It is assumed that initial startup, calibration and checkouts have been completed. The
turbine is in the cool down or standby mode ready for normal operation with AC and
DC power available for all pumps, motors, heaters and controls and all annunciator
drops are cleared.
9.6.2 Startup
9.6.2.1 General
Operation of a single gas turbine generator unit may be accomplished either locally or
remotely.
The following description lists operator, control system and machine actions or events
in starting the gas turbine.
The following description assumes that the unit is off cooldown and in a ready to start
condition.
122
CR054.01/02
b. Unit accessories will be started, including a motor-driven lube oil pump used
to establish lube oil pressure.
c. If the starting clutch is not engaged, the ratchet mechanism will operate until
the clutch engages. With the clutch engaged, the lube oil pressure and all other
qualification satisfied, the master protective logic (L4) will be satisfied.
d. The cranking motor will start immediately and the hydraulic torque converter
will be filled with oil.
e. The turbine shaft will begin to rotate and accelerate. When the unit speed
reaches approximately 16 rpm, the ratchet mechanism will be turned off. The
zero speed signal "14HR" will be displayed.
f. When the unit reaches approximately 19% speed, the minimum speed signal
"14HM" will be displayed.
g. The unit enters purging period and the purge timer is initialized to begin
timing.
h. After the timeout of purging the solenoid valve 20TU is reenergized to cause
the decreasing unit speed. When the unit speed decreases to approximately 18%
speed, "14HM" reaches its drop value.
i. At this time 20TU is deenergized again, which causes the unit speed to
gradually increase. When the unit reaches the pick-up value of 14HM (about
19% speed) again, the igniter is energized.
j. FSR will be set to firing value (FSR, Fuel Stroke Reference, is the electrical
signal that determines the amount of fuel delivered to the turbine combustion
system.) Ignition sequence is initiated.
123
CR054.01/02
k. When flame is established, the CRT display will indicate flame in No.2,3,7
and 8 combustion chambers.
l. FSR is set back to warm-up value. If the flame goes out during the 60 second
firing period, FSR will be reset to firing value. (At the end of the ignition period,
if flame has not been established, the unit will remain at firing speed.) At this time
the operator may shut the unit down or attempt to fire again. To fire again select
CRANK in the MODE SELECT frame on the Main Display. The purge timer and
firing timer are reinitialized. The purge timer will begin to time. Reselecting
AUTO will cause the ignition sequence to repeat itself after the purge timer has
timed out. If flame is not established at this time, the starting sequence will be
terminated and the unit will shut down. At the end of the warm-up period, with
flame established, FSR will begin increasing. The turbine speed will in turn
increase. At approximately 50% speed, the accelerating speed signal "14HA"
will be displayed on the CRT.
m. The unit will continue to accelerate. When it reaches approximately 60%
speed, the starting means will disengage and then shut down.
n. When the unit reaches operating speed, the operating speed signal "14HS" will
be displayed on the CRT. The motor-driven auxiliary lube oil pump will shut
down, since lube oil is being supplied by the shaft-driven main pump. If the
synchronizing mode selector switch on the generator control panel is in the OFF
position and REMOTE is not selected on the CRT, as the turbine reaches
operating speed, the CRT will now display the proper information.
If the synchronizing mode selector switch and "EXCITATION MODE" selector
switch on the generator control panel are in the AUTO position, and the
"EXCITAATION SOURCE" control switch is on and AUTO is also selected on
the turbine control panel, automatic synchronizing will be initiated.
The turbine speed is matched to the system frequency and when the proper phase
relationship is achieved, the generator circuit breaker will close. The unit will be
loaded to Spinning Reserve unless a load control point BASE, PEAK or
PRESELECTED LOAD has been selected.
9.6.3 Synchronizing
124
CR054.01/02
125
CR054.01/02
CAUTION
Before initiating synchronization procedures, be sure
that
all
synchronization
equipment
is
functioning
Initial
synchronization
and
checkout
after
NOTE
Synchronizing can not take place unless AUTO has been selected on the CRT Main
Display and the turbine has reached full speed.
Generator synchronization can be accomplished either automatically or manually.
Manual synchronization is accomplished by the following procedures:
Make
any
necessary
voltage
adjustment
by
operating
the
"AUTO
EXCITATION" control switch (90 R4) on the generator control panel until the
generator voltage is approximately equal to the system voltage.
6. Compare the generator and system frequency on the synchroscope (placed on
the generator control panel). The brightness of the synchronizing lights will
change with the rotation of the needle of the synchroscope. When the lights are
their dullest, the needle of the synchroscope will be at the 12 oclock position.
126
CR054.01/02
The lights should not be used to synchronize but only to verify proper
operation of the synchroscope.
7. Make the unit frequency basically equal to the system frequency by operating
the governor control switch (70 R4/CS).
8. The generator circuit breaker "close" signal should be given when the needle
of the synchroscope reaches a point approximately one minute before the 12
oclock position. This allows for a time lag for the breaker contacts to close
after receiving the close signal.
This procedure will start the unit, synchronize the generator with the system and load
the generator to the pre value. A "breaker closed" indicator will be actuated when the
generator circuit breaker has closed, placing the synchronized unit on-line.
Once the generator has been paralleled to the power system, the turbine fuel flow may
be increased to pick up load, and the generator excitation may be adjusted to obtain the
desired KVAR value.
WARNING
Failure to synchronize properly may result in
equipment damage and/or failure, even system
disruption.
In those cases where out-of-phase breaker closures are not so serious as to cause
immediate equipment failure or system disruption, cumulative damage may result to
the on-coming generator. Repeated occurrences of out-of-phase breaker closures can
eventually result in generator failure because of the stresses created at the time of
closure. Gear damage may result on load packages with a reduction gear in the gas
127
CR054.01/02
turbine generator train. Such damage may occur separately or in conjunction with
generator damage from out-of-phase breaker closure. Damage may be to the gear teeth
or to the quill shaft.
Out-of-phase breaker closure of a magnitude sufficient to cause either immediate or
cumulative equipment damage mentioned above will usually result in annunciator
drops to notify the operator of the problem. The following alarms have been displayed
at various occurrences of known generator breaker malclosures:
2. Loss of excitation;
3. Various AC under voltage drops.
Out-of-phase breaker closure will result in a abnormal generator noise and vibration at
the time of closure. If there is some reason to suspect such breaker malclosure, the
equipment should be immediately inspected to determine the cause of the malclosure
and for any damage to the generator and/or reduction gear.
NOTE
When manually loading with the governor control switch
(70 R4/CS) for load changes greater than 25% of full load,
the operator should not change more than 25% of full load
in one minute.
128
CR054.01/02
On the startup if no load point is selected, the unit will load to the Spinning Reserve
load point. The Spinning Reserve load point is slightly greater than no load, typically
4MW.
An intermediate load point (Preselected load) or the temperature control load point
(Base load) can be selected any time after a start signal has been given. The selection
will be display on the CRT and the unit will load to the selected load point. Preselected
load is a load point greater than Spinning Reserve and less than Base load. The auto
loading rate is 25% nominal load per minute.
or
stopping
the
whole
power
plant
refer
to
CONTROL
9.6.5.3 Cooldown
Immediately following a shutdown, after the turbine has been in the fire mode, the
rotor is turned to provide uniform cooling. Uniform cooling of the turbine rotor
prevents rotor bowing, resultant rubbing and unbalance and related damage that might
otherwise occur when subsequent starts are attempted without cooldown. The turbine
can be started and loaded at any time during the cooldown cycle.
129
CR054.01/02
The cooldown cycle may be accelerated using the starting means, in which case the
unit will run at cranking speed. After furnishing crank operation, ratcheting should be
initiated immediately.
The device furnished for cooldown turning is the hydraulic ratchet mechanism which is
mounted as part of the torque converter. The ratchet mechanism cycles once every 3.0
minutes to turn the rotor 47. A description of rotor turning operation and servicing
can be found in the Starting System paragraph.
The minimum time required for turbine cooldown depends mainly on the turbine
ambient temperature. Other factors, such as wind direction and velocity, can have an
effect on the time required for cooldown. The cooldown times recommended in the
following sections are the result of GE company operating experience in both factory
and field testing of GE gas turbine. The customer may find that these times can be
modified as experience is obtained in operation of the gas turbine under his particular
site conditions.
Cooldown times should not be accelerated by opening up the turbine compartment
doors or the lagging panels since uneven cooling of the outer casings may result in
excessive stress.
The unit must be on rotor ratcheting operation immediately following a shutdown for
at least 24 hours to ensure minimum protection against rubbing and unbalance on a
subsequent staring attempt. However, the GE company recommends that the rotor
ratcheting operation continue for 48 hours following a shutdown to ensure uniform
rotor cooling.
In order to end ratcheting sequence during cooldown period, in the User-Defined
Display Menu successively select "AUXILAARY CONTROL" and the command target
"COOLDOWN OFF" and then point and click on "OK" PUSH BOTTON to make
MK VIe acknowledge this selection. Similarity, the cooldown sequence can be
restarted by selecting "COOLDOWN ON" command target.
CR054.01/02
out
the
overspeed
trip
test
in
accordance
with
the
CONTROL
SPECIFICATIONS.
Overspeed trip system testing should be performed on an annual basis on peaking and
intermittently used gas turbine. On continuously operated units, the test should be
performed at each planned shutdown and after each major overhaul. All units should be
tested after an extended shutdown period of two or more months unless otherwise
specified in the CONTROL SPECIFICATIONS.
The turbine should be operated for at least 30 minutes at rated speed before checking
the overspeed settings. This will allow determining the actual speed setting.
NOTE
A l a r m m e s s a g e m a y b e c l a s s i f i e d a s " t r i p " a n d " a l a r m " . A n y t r i p message
contains "TRIP" word, but the alarm message does not indicate "TRIP". Those alarms
related to the startup permissives and trips will be latched up by the function of
"MASTER RESET". In order to unlatch and clear these alarms, th e Master Reset
must be executed on Main Display.
131
CR054.01/02
132
CR054.01/02
10. E M E R G E N C Y
SHUTDOWN
OF
THE
CORRECTIVE ACTIONS FOR TROUBLES
UNIT
AND
CR054.01/02
accident is not possible to be found out in a short time, the unit will not be
attempted to start and the ratcheting operation of the unit should be initiated.
10.1.3 The unit should be shut down immediately by depressing the EMERGENCY
STOP pushbutton or pushing the manual button for emergency trip on the side of the
accessory gearbox if any of the following conditions occurs:
Thick smoke emits from any bearing liner;
Metal collision sound is heard from the rotating components of the unit;
The protection device does not operate when the trouble occurs;
Black smoke is seen in the flue gas of the turbine and the temperature differential
of the exhaust thermocouples is great;
Smoke emits from the generator or exciter;
Any explosion occurs to the cable heads of the generator outgoing lines, the
circuit breaker or the arrester;
Smoke emits from the current transformer of the generator;
Any occurred trouble that may be harmful to the safety of the personnel or the
equipment.
10.2.2 If the unit speed rise is slow or the speed does not rise, check that the oil
pressure in the torque converter is proper and the oil temperature is not too high.
134
CR054.01/02
10.2.3 If the hydraulic ratchet mechanism does not operate properly, check the
following:
10.2.4 When the starting clutch does not engage, check the following:
The gap between the two clutch hubs is proper;
The connection nuts between the moving clutch hub and the actuators are
securely tightened:
The clutch solenoid valve (20 CS-1) operates when energized.
135
CR054.01/02
The LVDT linear displacement transducers (96 GC-1,2 and 96 SR-1,2) of the fuel
gas combination valve are set properly in consistency with the requirement;
The flow of the fuel for firing is not too small;
10.2.6 If the exhaust temperature is high after firing and black smoke is seen, check
the following:
The pressure in the fuel system is proper.
The pressure readings in the outlet tube of the flow divider are approximately
equal and the conditions of the atomizing air are proper when burning liquid fuel.
10.2.7 If the vibration level of the unit is comparatively high, but lower than the trip
setting, ought to perform the following:
Check the temperature and oil drain condition for the individual bearings and the
bearing header pressure;
Check the vibration detector functions properly;
Carefully increase and decrease the load to observe the variation of the vibration.
If the problem of comparatively high vibration level can not be settled, shut down
the unit and check the alignment of the unit, bearing liner top clearance, liner (or
journal) wear and whether there are any rubs in the flow path section.
CR054.01/02
The fuel oil bypass valve and the electro-hydraulic servo-valve are operating
properly;
The combination valve for delivering the fuel gas is operating properly.
10.2.9 Underloaded
10.2.9.1 If the unit is unable to enter the temperature control operation phase, check
the following:
The exhaust thermocouples are functioning properly;
The operating pressure in the fuel system is proper;
The various electro-hydraulic servo-valves in the fuel system operate properly.
10.2.9.2 If the unit is operating under the temperature control, compare the actual load
with the estimated load that can be reached under the present ambient temperature. If
the actual load is lower that the estimated value, it indicates the unit is underloaded.
The very possible cause is the deposit formation in the compressor flow path section
and thus the compressor water wash is needed.
137
CR054.01/02
Fig.11-1
138
CR054.01/02
In Fig.11-1 the accumulated operating hours reach the specified value for an inspection
interval first when the unit operates in accordance with line A whereas the accumulated
fired starts reach the specified value for the same type of inspection interval first when
the unit operates in accordance with line B. For both cases the appropriate inspection
is required to be performed.
The recommended inspection intervals for the unit operating under ideal conditions are
shown in GER3620. The so-called ideal operating conditions refer to using natural gas
as fuel, performing normal startup, operating on base load and without steam or water
injection and using non Dry Low NO X combustor.
Actually, the unit operating conditions can not be ideal. A lot of factors such as fuel
type, load setting, water or steam injection, peak load operation, unit trips, startup
mode, design of hot gas path components, etc will have effects on the inspection
intervals. Therefore, for the recommended inspection intervals given in Table 11-1 it is
necessary to do correction according to the actual operating conditions, so as to obtain
the possibly actual inspection intervals. For the contractual unit the following
corrections should be carried out.
CR054.01/02
servicing the unit individual systems, changing filters, checking water and oil levels,
checking the calibration of all sorts of measurement devices, etc. A periodic startup
test run is an essential part of such inspection.
Running inspections
The principal contents of running inspections consist of the general and continual
observations of the unit operating data. This starts by establishing baseline operating
data during initial startup of a new unit and after any major disassembly work. This
baseline then serves as a reference from which various signs of subsequent unit
deterioration can be found through comparative analysis of the operating data. The
baseline data should include the parameters of normal startup and steady state
operating of the unit. The so-called steady state is defined as conditions at which no
more than 5F/3 change in wheelspace temperature occurs over a period of 15
minutes. In the subsequent operation process such data should be observed at regular
intervals and recorded for evaluating the unit performance and maintenance
requirements that should vary with the operating time. The principal data required to
be recorded in running inspections are listed in Table 11-2.
Rotate Speed
Load
Fired starts
Fired hours
Barometric pressure at site
Temperatures:
Inlet ambient air
Compressor discharge air
Turbine exhaust
Turbine wheelspace
Lube oil header
Lube oil tank
Bearing drains
Exhaust spread
Pressures:
Compressor discharge air
Lube oil pump(s)
Lube oil header
Cooling water
Fuel
Filters (fuel, lube oil, inlet air)
Vibration data under various load levels
Generator:
Output voltage
Phase current
Active power
Reactive power
Excitation voltage
Excitation current
Stator temperature
Vibration value
Startup time
Coast-down time
It is preferable to plot some of them in curves, such as the curves of startup parameters
(speed, exhaust temperature and vibration value) against time, load against exhaust
temperature, vibration value against load , etc. The abnormality of parameters will
necessarily relate to the damage of the internal parts of the unit or the faults of its
140
CR054.01/02
systems. Therefore, the running inspections are the most effective measures to identify
the performance and status of the unit, and are also the keys to judge whether a certain
disassembly inspection of the unit can be performed in accordance with the scheduled
inspection interval.
Combustion inspection
The combustion inspection is a disassembly inspection performed in short shutdown
period. The inspection scope includes all parts of the combustion system from the front
of combustion chambers to the exit of transition pieces, and may also include the rest
parts that can be accessed due to performing the combustion inspection. The main parts
that need to be inspected are fuel nozzles, combustion liners, transition pieces,
crossfire tubes and retainers, spark plugs, flame detectors and flow sleeves. The
inspection will be focused on combustion liners, transition pieces and fuel nozzles.
Generally speaking, it is very usual to replace or repair these parts first during
maintenance to keep them in good condition, which will ensure the life of downstream
parts, e.g. turbine nozzles and buckets.
The specific requirements of the inspection are as follows:
CR054.01/02
Perform the observation of the condition of rotating blades in the aft end of the
compressor with a borescope;
Visually inspect the compressor inlet and turbine exhaust areas, examining the
condition of IGV and their bushings, last-stage buckets and exhaust system
components;
Verify proper operation of purge and check valves.
CR054.01/02
Inspect and record the condition of 1st, 2nd- and 3rd-stage turbine nozzles;
Inspect and record the condition of later-stage nozzle diaphragm packing. Check seals
for rubs and deterioration of clearance;
Record the bucket tip clearance. Inspect bucket shank seals for clearance, rubs and
deterioration;
Inspect the turbine stationary shrouds for clearance, cracking, rubbing and build-up;
Visually inspect the turbine exhaust area for any signs of cracking and deterioration.
CR054.01/02
Inspect compressor rotating and stationary blades for tip clearance, rubs, impact
damage, corrosion pitting, bowing and cracking;
Inspect turbine stationary shoulders for clearance, erosion, rubbing, cracking and
build-up;
Inspect seals and hook fits of turbine nozzles and diaphragms for rubs, erosion and
thermal deterioration;
Remove turbine buckets and perform a non-destructive inspection of buckets and
wheel dovetails. Make evaluation for the remaining life of the 1st-stage bucket
protective coating. The 1st-stage buckets that were not recoated at the hot gas path
inspection should be replaced;
Inspect bearing liners and seals for clearance and wear;
Inspect inlet system for corrosion, loose parts and cracked silencers;
Inspect exhaust system for cracks, broken silencer panels and insulation panels;
Inspect the alignment of gas turbine to generator and gas turbine to accessory gear.
Borescope inspection
The casing (or shells) of gas turbine are provided with optical borescope access holes
for inspecting compressor rotor some intermediate stages and turbine 1st-, 2nd- and
3rd-stage nozzles and buckets. The location of such holes can be found from relevant
drawings. The borescope inspection interval is scheduled as follows:
The borescope inspection interval may be adjusted as based on the unit operating
experience, the fuels used and the result of previous inspections.
144
CR054.01/02
Concluding remarks
1. The inspection intervals given in Table 11-1 are the maximums corresponding
to ideal operating conditions.
145