5.0 Manual - GTGS

Municipality of Bacau, Str. Marasesti Nr.
6, Bacau 600017, Romania
Manual
Gas Turbine Generator Unit

GPB80DD
VOLUME 1
(Gas Turbine & Gear-Box)
First Issue Revision A Revision B Revision C Revision D

Date 15.11.2012
Name O. Frieling
KAWASAKI Gas Turbine Europe GmbH

Nehringstrae 15, D-61352 Bad Homborg
Tel. +49 6172 7363-0
Fax +49 6172 7363-55
Document 1 Page 1 of 208 15.11.2012

TABLE OF CONTENTS
VOLUME 1 ........................................................................................................................... 1
(Gas Turbine & Gear-Box) ................................................................................................... 1
A General ............................................................................................................................. 4
A.1st Abbreviations ........................................................................................................... 5
A.2nd Field of Application/Use ........................................................................................... 6
A.3rd CE Declaration of Conformance .............................................................................. 8
A.4th Standards ................................................................................................................ 9
B Safety ............................................................................................................................. 11
B.1 KAWASAKI safety concept (protection from explosions)......................................... 11
B.2 Safety information.................................................................................................... 12
B.3 Warning systems ..................................................................................................... 13
B.4 Emergency-Off Trigger Criteria................................................................................ 15
B.5 Accident prevention ................................................................................................. 17
B.6 Prohibitions and dangers ......................................................................................... 17
B.7 Special hints ............................................................................................................ 19
C Equipment Description.................................................................................................... 20
C.1 Description............................................................................................................... 20
C.2 Gas turbine .............................................................................................................. 23
C.3 Gear Box ................................................................................................................. 34
VOLUME 2 ......................................................................................................................... 38
(Generator, Base Frame (blue), Speed Measurements, Auxilliaries ) ................................ 38
C.4 Generator ................................................................................................................ 41
C.5 Base frame .............................................................................................................. 43
C.6 Speed measurement ............................................................................................... 44
C.7 Auxiliary System ...................................................................................................... 44
VOLUME 3 ......................................................................................................................... 49
(Lube-Oil System,descriptions, folder 1 of 2 ) .................................................................. 49
VOLUME 4 ......................................................................................................................... 66
(Lube-Oil System, components, folder 2 of 2).................................................................. 66
VOLUME 5 ......................................................................................................................... 67
(Gas- / Liquid-Fuel System) ............................................................................................... 67
C.8 Fuel system ............................................................................................................. 68
VOLUME 6 ......................................................................................................................... 80
(Start-, Purge-, Turn-, Ignition-, BLEED-, VSV-, Seal-Air-, and Drain-system) ................... 80
C.9 Starter motor, purge and turn system ...................................................................... 81
C.10 Ignition system ...................................................................................................... 83
C.11 Bleed Air Ventil / VSV Control System .................................................................. 84
C.12 Seal Air System ..................................................................................................... 89
C.13 Cleaning system compressor ................................................................................ 91
C.14 Drain Tank ............................................................................................................. 93
VOLUME 7 ......................................................................................................................... 94
(Instrument-Air pressure system) ....................................................................................... 94
C.15 Air pressure system ............................................................................................... 95
VOLUME 8 ......................................................................................................................... 97
(Gas-warning & Fire-extinguishing system)........................................................................ 97
C.16 Gas warning and fire extinguishing system ........................................................... 98
VOLUME 9 ....................................................................................................................... 102
(Sound enclosure, filter-house, gas-turbine controls container, cooling-air & exhaust-gas
system )............................................................................................................................ 102
C.17 Noise enclosure, filter house gas turbine control, air duct, cooling air, combustion
air, exhaust gas system.................................................................................................... 103
VOLUME 10 ..................................................................................................................... 111
(Gas Turbine & Gear-Box) ............................................................................................... 111
VOLUME 11 ..................................................................................................................... 162
(Gas Turbine & Gear-Box) ............................................................................................... 162
C.18 Electrical drawings............................................................................................... 163
VOLUME 12 ..................................................................................................................... 164
(Gas Boost Compressor (ELTACON, NL) ........................................................................ 164
C.19 Gas compressor (ELTACON, NL) ....................................................................... 165
C.20 Oils, lubricants and other liquids .......................................................................... 166
C.21 List of manufacturers and suppliers ..................................................................... 167
D Construction and Assembly .......................................................................................... 173
E Commissioning ............................................................................................................. 174
F Operation and Maintenance ......................................................................................... 175
G Maintenance and Repair............................................................................................... 194
H Decommissioning ......................................................................................................... 203
I Disposal ........................................................................................................................ 204
J KGE & KHI Minutes and Reports .................................................................................. 205

A General
The manual is designed to provide the customer with the necessary technical
information for operating a gas turbine. The customer is obliged to store this
documentation in a careful and accessible way. Training documentation and
instructions shall be used in addition to this manual.
The following phases are to be taken into account with ALL inspections.:
Installation and Assembly

Commissioning
Normal Operation
Maintenance, Troubleshooting and Repair
Decommissioning, Dismantling
Disposal
Service Bulletin: This document is issued by KGE and is forwarded to customers.
It is recommended to leave the Service Bulletin at the specified location, so that the
latest status of technical information is always easily accessible to all of those
interested.
The main objective of this manual is to give the operator the necessary information for
operating the GPB80D Gas Turbine Generator Unit. That is:
- to provide the operator with basic information about the gas turbine and its
peripherals.
- to provide the operator with basic instructions for installing and

commissioning the gas turbine and its peripherals.
Should problems occur while operating the gas turbine generator unit, please contact
KGE specialists.

Nehringstr. 15
D-61352 Bad Homburg / Germany
Tel. +49 6172 7363-0
Fax +49 6172 7363-55
www.kawasaki-gasturbine.de

A.1st Abbreviations
BRG Bearing
CDP Compressor Discharge Pressure
CDT Compressor Discharge Temperature
DLE Dry Low Emission
EGT Exhaust Gas Temperature
ELOP Emergency Lube Oil Pump
EOH Equivalent Operation Hours
FOD Foreign Objects Damage
G/B Gear Box
G/T Gas Turbine
HSG Housing
HSI Hot Section Inspection
IGV Inlet Guide Vane
KGE KAWASAKI Gas Turbine Europe GmbH, Germany

KHI KAWASAKI Heavy Industries Ltd., Japan
MFV
MGV
MGCV
MLOP Main Lube Oil Pump
MSV
OGV Outlet Guide Vane
P/S Power Section

P
PGCV
PGSV
PrSV
PPLOP Permanent Relief Pre-Post Lube Oil Pump
RTD Resistance Temperature Sensing Device
TBO Time Between Overhaul

T1 Inlet Air Temperature
TIT Turbine Inlet Temperature
VSV Variable Stator Vane

A.2nd Field of Application/Use
In the use of exhaust gas thermal energy, the gas turbine generator unit
provides economical power supply to the base power range. This type of energy
conversion is known as combined heat and power (CHP). The useful heat is
contained exclusively in the exhaust gas, and namely in that for the waste heat
and reasonably high temperature area. The unit thereby has special
advantages, where, along with electrical energy, a correspondingly high grade
heat requirement is to be covered.
Depending on the utilisation of the exhaust gas temperature and the respective
environmental conditions, electrical efficiency lies in the range of 30%, and fuel
consumption efficiency in the range of 70% to 85%.
Gas turbines work as shown in the following simplified process:
Ambient air is drawn in and compressed in the compressor stages.

Compressed air and fuel are ignited in the combustion chamber.
The resulting volume of hot gas is directed to the turbine stages.

Through the inclination of the turbine blades, the volume of hot gas is
directed in a particular direction, causing the turbine wheel to rotate.
This rotating movement is carried from the turbine rotor to the gear.
With the necessary gear ratio of the gear, a rotational speed is created,
which is converted by the generator into an electrically useful rotational
frequency.
Compressor
stages Combustion
Chamber
Clutch
Generator Gas
turbine
Rough schematic sketches of a gas turbine generator unit
The gas turbine is an industrial gas turbine, built as an single-shaft engine, in

accordance with the open loop principle and a practically constant output
speed. This gas turbine was developed exclusively for the drive mechanism of
power generation.

Power generation:
A KAWASAKI gas turbine generator unit is mainly used for power generation.
Waste heat utilisation
The arising thermal energy of the turbine exhaust gases is used in many
different ways.
This thermal energy is mainly converted into:
Process steam, which is used, for example, in the paper industry for drying
purposes.
Hot water, which is used in heating networks.
Cold water generation through absorption freezing machines.
Operating condition
The normal operating condition of the gas turbine generator unit

is largely network-parallel.
Isolated operation is occasionally possible and in emergency situations.
The gas turbine generator unit is designed for operating in automatic mode.
During normal operation, the gas turbine generator will be remotely

monitored.
Handling of the machine technology within the sound enclosure during

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

A.3rd CE Declaration of Conformance
As the manufacturer of the Gas Turbine Generator Unit, "Kawasaki GP80D",

delivered under project number 3029, KAWASAKI Gas Turbine Europe GmbH
declares conformance with the guidelines and standards in the CE certificate.
For this equipment, a comprehensive risk analysis was carried out by

KAWASAKI Gas Turbine Europe GmbH, and the knowledge flowed into the
design of the equipment from the beginning.
The CE certification for KAWASAKI Gas Turbine Europe GmbH will become
invalid if the following points are not adhered to:
In general, no large changes can be made to the gas turbine generator unit.
The equipment may not be dismantled and installed at another location.

Should this be planned, new acceptance by KAWASAKI Gas Turbine
Europe GmbH is necessary.
With the exception of maintenance work, such as filter changes, all planned
work requires written approval from KAWASAKI Gas Turbine Europe
GmbH.
Spare parts may only be used in accordance with manufacturer guidelines.

A.4th Standards
Standards and guidelines
The following list is not exhaustive, but it lists the main standards and guidelines
related to gas turbine unit machines. This list will be constantly modified and
extended in line with standard-conformance between the national standards
(DIN), European and international standards (EN/CEN/CENELEC/ISO),.
International standards
ISO 12100-1 Security of Machinery

ISO 14121-1 Security of Machinery - Risk Analysis
European standards
90/396/EC Gas Appliances Directive

94/9/EC ATEX equipment and protective systems intended for use in
potentially explosive atmospheres
97/23/EC Pressure Equipment Directive

2006/42/EC Machinery Directive
2006/95/EG Low Voltage Directive with a nominal voltage of
50V - 1000 for alternating current
75V - 1500 for direct current
EN 60204-1 Electrical equipment for machines

General requirements
EN 50156 Electrical equipment for furnaces
German standards
DIN 31051 Fundamentals of maintenance

DIN 51857 Gaseous fuels and other gases
DIN VDE 0100 Erection of electrical power installations with a nominal
voltage of up to 1000V
DIN VDE 0101 Erection of electrical power installations with a nominal

voltage of over 1kV
DIN VDE 0105 Operation of electrical power installations

DIN VDE 0141 Earthing of electrical power installations with a nominal
voltage of over 1kV

TRD 412 Gas firing at steam boilers
Document 1 Page 10 of 208 15.11.2012

B Safety
B.1 KAWASAKI safety concept (protection from explosions)
Due to the high quality and safety standards at KAWASAKI, the concept for the
gas turbine generator unit has been in reliable use for years.
KAWASAKI takes precautions to prevent danger from arising, monitors the

installation constantly and has also installed safety measures to eliminate
danger.
In addition, an inspection was carried out in accordance with the ATEX Directive
94/9EC and concludes with an evaluating description.
This separate safety concept can be seen at KGE on request. (document no.:
EFR3389-091214)
Document 1 Page 11 of 208 15.11.2012

B.2 Safety information
All safety instructions in this manual are to be observed and followed by each
person!
Disregard for these instructions can cause harm to health and life!
Specific instructions about oil, lubricating oil and other liquids can be found under
C 15 of this manual.
Construction and connection, operating, maintenance and dismantling are only to

be carried out by trained personnel.
In this operating and maintenance manual, the following safety instructions are
given.
DANGER
This heading is used when imprecise compliance or non-compliance with the
operating and maintenance manual, working instructions, defined working
procedures etc. can lead to injury or fatal accidents.
CAUTION
This heading is used when imprecise compliance or non-compliance with the
operating and maintenance manual, working instructions, defined working
procedures etc. can cause damage to the machine or connected equipment.
NOTE
This heading is used when special attention should be paid to something.
Document 1 Page 12 of 208 15.11.2012

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

(yellow) (red)
Warning sirens
Image 1
Example
Document 1 Page 13 of 208 15.11.2012

Gas warning
system
Fire detection
system
Image 2
WARNING FIRE ALARM
ACOUSTIC & OPTIC
WARNING FIRE EXTINGUISHING
ACOUSTIC & OPTIC
WARNING GAS ALARM
ACOUSTIC & OPTIC
DANGER
Extinguishing process with CO2 (carbon dioxide). The noise enclosure is to be vacated
immediately and the door to be kept closed. CO2 can be detected by a slight lemon
smell.
Opening the door is then only possible following intensive ventilation and approval by
the fire service.
Document 1 Page 14 of 208 15.11.2012

B.4 Emergency-Off Trigger Criteria
The gas turbine generator has three Emergency Off buttons inside the noise
enclosure.
They are installed in exposed locations to enable a fast reaction when, for
example, controlling running machines and when there are open doors.
It is therefore not necessary to leave the control area to reach one of the
Emergency-Off buttons which are installed on the outside of the noise
enclosure.
Positions of the Emergency -Off buttons in the noise enclosure.
Image 3 Emergency-Off button inside Image 4

the noise enclosure
Image 5
Document 1 Page 15 of 208 15.11.2012

CAUTION
The emergency-stop system only affects the safety shut-off valves (main gas valves) in
the gas compressor and the starter / turn motor.
All other auxiliary drives cannot be stopped via Emergency-Stop.
Therefore, before removing mechanical guards (e.g. safety guards, hood fans), and
before opening pipes, the drives must be switched off using the relevant motor circuit-
breaker and then secured against restarting.
Depending on the operational mode, cyclical control of the drives via the automatic
programme can also occur in error-free operation!
CAUTION
Removing the 400V feeder fuse in field +1N01 is not sufficient for unlocking the
switchgear!
The entire control is fed by a 24V battery, which is located under the floor plates of the
control room.
Likewise, the battery in field 1N01 can be unlocked.
Some users receive additional power via a 230V AC USP, and these must be unlocked
separately.
Attention must also be paid to the control cable of the medium voltage installation,
which is still under 110V DC voltage.
The measuring circuits which are connected to external voltage transformers are also
under voltage.
Document 1 Page 16 of 208 15.11.2012

B.5 Accident prevention
HEARING PROTECTION
Hearing protection is to be worn in the noise enclosure during

operation.
PROTECTIVE GOGGLES
Protective goggles are to be worn in the sound enclosure during

operation.
PROTECTIVE GLOVES
Protective gloves are to be worn in the sound enclosure during

operation.
B.6 Prohibitions and dangers
UNAUTHORISED ACCESS IS FORBIDDEN
During operation, the installation may only be entered with

permission from the manager.
FIRE, NAKED FLAME, SMOKING FORBIDDEN
Fire, naked flames and smoking is forbidden in the installation

and fuel supply control system.
HOT SURFACES
Before starting the turbine, all personnel must leave the danger
zone and surrounding areas.
The high temperature and speed of the exhaust gases, and

obstruction of the suction openings is dangerous.
Document 1 Page 17 of 208 15.11.2012

HAZARDOUS SUBSTANCES
Contact with the specified lube oil over a longer period of time can lead to skin
reactions. Skin and items of clothing which come into contact
with lube oil should be immediately and carefully washed.
Items of clothing which have become completely soaked with
lube oil should be removed immediately. Items of clothing
which have become completely soaked with lube oil should
be removed immediately. Areas where lube oil is used should
be sufficiently ventilated, and vapours and smoke are to be
reduced to a minimum.
DANGER ZONE - HOVERING TRANSPORT
To avoid personal injury and damage to property during

turbine transport, the hoist should be regularly inspected with
1.5 times its permitted load. Faulty parts are to be exchanged.
Repairs can only be carried out by the manufacturer.
DANGEROUS ELECTRICAL VOLTAGE
Parts of the unit are under dangerous voltage both during

operation and in idle mode. Working on or opening of live
parts may only be carried out by trained personnel and in
compliance with the existing rules!
AUTOMATIC EQUIPMENT
In the event of a gas alarm, the ventilators can also start

automatically while in idle mode.
In this case, there is danger from rotating parts or initiating

rotating parts.
HARMFUL / IRRITANT
Due to the toxic and volatilising properties of most cleaning

materials, skin contact and inhalation of vapours is to be
avoided. Protective clothing, such as gloves, boots, overalls
and face shields should be worn during cleaning work.
Document 1 Page 18 of 208 15.11.2012

B.7 Special hints
SPILLED OIL
Spilled oil can damage coating.
Surfaces must be carefully washed. SLIPPERY!
COVERING OF FUEL, OIL AND AIR PIPES.

To avoid soiling or clogging, all exposed openings must be covered immediately.
Cover plates must be kept clean.
Adhesive tape may not be used in place of cover plates.
COVERING OF GEAR AND TURBINE OPENINGS

Both gas ports and air inlets, as well as the gear opening are to be constantly
covered during maintenance to prevent the foreign objects from falling into the
gas turbine.
INSTALLATION AND FITTING OF PARTS

After removal, seal rings, flat seals, packaging, eyebolts, retaining rings, shims,
spring rings, fuse wires etc. should be destroyed and replaced.
COMPONENT MARKING
All parts which are detached or removed from the gas turbine must be marked and
their position must be marked, so that they can be correctly installed again. This
particularly applies to rotating parts, cabling and hoses.
LOG BOOK
It is recommended to keep a log book (maintenance history), in which maintenance
work, operating times and cycles and particulars should be entered, in order to
provide this to operating and maintenance personnel. This document also enables
the gas turbine manufacturer to assess and fix operational problems. The operating time
and starting number - also for exchanged parts, are to be entered.
Document 1 Page 19 of 208 15.11.2012

C Equipment Description
The system description for all components is arranged as follows:
- Description
included in the register:

- Drawing
- Parts list
and finally the manufacturer's documentation:

- Datasheets
C.1 Description
The gas turbine generator described here is a GPB80D unit.

The model GPB80DDual-Fuel (# 3044 Bacau) is described as
follows.
Gas Turbine Power Base

which comprises a complete
gas turbine generator unit.
In this case, no adjacent
exhaust system (vessel) is
delivered by KAWASAKI
Gas Turbine Europe GmbH.
A gas turbine generator unit Is the most modern form of

GPB80 with gas turbine model combustion technology and
M7A-03 and an electrical current means Dry Low Emission. Using
of approx. 7,500 kWe. this technology, the currently
required exhaust gas values for
NOx and CO2 are reached. As
no water or steam spraying is
necessary here, one talks of
"Dry" (dry combustion).
Document 1 Page 20 of 208 15.11.2012

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

1.10 Electrical control system
1.11 Circuit diagrams
III. Filter house and air ducts

1.12 Air ducts
1.13 Filter house (not including technical room)
IV. Gas compressor (ELTACON (NL) (#3044 Bacau)
V. Vessel (this time, not part of KGE delivery)
III
Technical room
Exhaust duct
1.12
1.13 V
1.8 1.9
1.1 1.2 1.4
I II IV
1.3 1.3
1.10
1.11
1.6, 1.7
1.5
Document 1 Page 21 of 208 15.11.2012

In detail, the unit components are fitted with the following subcomponents:
Noise enclosure
This includes the basic frame and its components.
Base frames
with installed components, such as:
Gas turbine
Gear
Generator
Lube oil system
Air pressure system
Fuel system
Filter house
the following components are included in the installation on the
noise enclosure:
Cool air filter for the noise enclosure

Cool air entry ventilators
Cool air entry blinds
Cool air entry sound absorbers
Combustion air filter
Combustion air sound absorbers
Cool air exit blinds
Cool air exit ventilators
Cool air exit sound absorbers
Technical room with:
- CO2 fire extinguishers
- Oil mist separator
- Oil cooler
Control cabinet house

installed on the side of the noise enclosure facing the generator and includes
the following systems:
Turbine control
Feeder
Central fire alarm system with gas warning system
Frequency converter for the starter motor
As a standard, KGE provides the control cabinet house with a control system. There
is, however, the possibility to install individual fields. This mostly occurs for reasons
of space and at the special request of the customer.
Document 1 Page 22 of 208 15.11.2012

C.2 Gas turbine
Description
Manufacturer: KAWASAKI Heavy Industries, Ltd. Japan
Type: M7A-03D
As a heavy duty industrial gas turbine, the gas turbine M7A-03D is specially designed
for continuous use in CHP units and works in a simple open cycle.
As a single-shaft unit for the generator drive, compressors and turbines are fixed to a
common shaft.
Technical data about the Gas Turbine M7A-03D (#3044 Bacau) and its installation
conditions
Installation height: 184 m (Anlage 1 der Generatorbestellung)

Suction pressure loss: 10 mbar,
Exhaust gas pressure loss: 30 mbar,
Suction air temperature 15 C
Generator efficiency: 97%
Fuel: Natural gas H
Heating value: 36,103 kJ / Nm
Terminal power 7,330 kW el, (Cos Phi 0,8)
Consumption: 23.787 kW (+2%)
Air intake: 26.64 kg/s
Exhaust gas temperature EGT approx. 489 C (-20C)
Exhaust mass flow: 25,98 kg/s (-3%)
Compression ratio: 15.9
Rotating speed (gas turbine): 13,790 rpm (50 Hz)
NOTE
The above values are nominal values and are not guaranteed.
Document 1 Page 23 of 208 15.11.2012

The gas turbine-specific description is shown in the following table:
Gas turbine type: Single-shaft machine, open, simple cycle

Compressor Axial compressor, 11 stages
Combustion chambers 6 combustion chambers
Turbine, power section Axial flow through, 4 stages
Bearings Compressor side: No. 1 Axial bearings 2 levels
No. 1 Radial bearings
Turbine side: No. 2 Axial bearings
All bearings are designed as sleeve bearing versions
with external lubrication via the lube oil system.
Coupling to gear Diaphragm coupling
Dimensions L x B x H: 4.780 x 1.460 (1.900 with manifolf ) x
1.702 mm
Weight 6,300 kg
Gas turbine sound level
Frequency, 63 125 250 500 1000 2000 4000 8000

Hz
Sound pressure level dB(A), 2m distance from the suction opening
80 84 92 98 100 104 110 102
Sound pressure level dB(A), 1 m distance from the exhaust flanges
90 102 114 116 114 112 108 104
Sound pressure level dB(A), 1 m distance from the turbine housing
70 86 88 92 96 100 104 98
Document 1 Page 24 of 208 15.11.2012

Main components
Air inlet housing
11-stage axial compressor
with variable stator vane (VSV) of the first 3 stages in the compressor
6 single-pot combustion chambers with primary fuel nozzles, secondary burners

and 2 DLE ignition plugs
DLE ignition plugs
Gas turbine housing
4-stage axial turbine
2 sleeve bearings, 1 thrust bearing
Lube oil system
Fuel system
Compressor washing system
Exhaust gas diffuser
Control system
Monitoring system
Image 6
Example
Document 1 Page 25 of 208 15.11.2012

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

A. Compressor
B. Combustion chamber system
C. Turbine
Image 7
Document 1 Page 26 of 208 15.11.2012

Compressor
The compressor draws in ambient air and compresses it for operating the gas
turbine. To achieve a high level of efficiency, an axial compressor was selected.
The compressor rotor segments consist of several wheels, which are welded
together using an electron beam method.
The compressor has 11 stage rotor blades (on the rotor) and 11 stage guide vanes,
as well as inlet guide vanes (IGV) and outlet guide vanes (OGV).
The suctioned air is accelerated through the Bellmouth and directed to the IGV's. The
first four stages (including IGV) are adjustable (VSV system), in order to achieve a
high level of efficiency and to avoid flow separation during the start-up procedure.
The air is compressed in stages, reaching a pressure of approx 1.2 MPa (12 bar) at a
compression ratio of 15.9: 1 resulting in:
Image 8
Document 1 Page 27 of 208 15.11.2012

Combustion chambers
The 6 combustion chambers are arranged over external, concentric distribution pipes
and supplied with fuel. Each of the six combustion chambers consists of a transition
duct and the actual combustion chamber. The combustion chambers are conical,
point backwards and are arranged on the turbine surface.
A large part of the compressed air is fed between the combustion chamber and the
combustion chamber housing for cooling purposes. The remaining part is fed into
the combustion chamber and burned as a gas mixture. It is then fed into the gas
turbine.
Each combustion chamber has a fuel nozzle system, over which the different load
conditions of the gas turbine can be achieved.
Image 9 shows an example of the nozzle of a combustion chamber.
Image 9
Combustion chambers 2 and 3 are both fitted with an ignition plug, which ignites the
fuel at start-up.
To transfer the flames in the adjacent combustion chambers, they are connected by
a flame transfer tube (not No. 5 and 6). Combustion chambers 5 and 6, which are
last in the firing order, are fitted with flame detectors. The flame detectors inform the
operator about the control of the gas turbine, as to whether ignition is completed.
Document 1 Page 28 of 208 15.11.2012

Turbine
The guide tube directs the hot, high-pressure combustion gases to the first baffle
plate of the first turbine level. In the 4 axial turbine levels, the energy of the gaseous
medium is converted into torque by releasing the approximate ambient pressure.
When leaving the turbine, the gases have significantly lower pressure and a lower
temperature (approx. 550 C, depending on the ambient conditions). The exhaust
gas diffuser stops the flow of exhaust gas, which is then fed over the connected
bellows expansion joint and through the exhaust gas pipe and out of the turbine.
Image 10
Document 1 Page 29 of 208 15.11.2012

Thermal expansion of the gas turbine, Temperature distribution
Image 11 shows the thermal expansion of the gas turbine under nominal conditions.
The vertical movement is very slight (under 0.7 mm) and can be ignored.
On the contrary, the horizontal length variations are not to be ignored. The exhaust
flange shifts about 10.2 mm across the length of the gas turbine. These data are to
be considered when designing exhaust gas expansion joints and other piping. When
using the exhaust gas expansion joints provided by Kawasaki inside the noise
enclosure, these thermal length changes are worked in.
The image also shows the temperature distribution of the gas turbine under the
same conditions. These data are important for the design of cooling, ventilation and
heat protection.
Image 11
Document 1 Page 30 of 208 15.11.2012

Sensors
The gas turbine has several sensors for the following functional areas:
Control:
The sensor signal serves the turbine control.
Safety:
To guarantee safe turbine operation, an alarm and emergency shut-down system is
integrated. The turbine control monitors the sensor signals and triggers an alarm or
shut-down signal if the sensor signal lies outside the intended range.
The layout of the sensors is shown in image 29.
Image 12
2 Vibration pick-up Bearing #1 11 Flame detector

3 Vibration pick-up Bearing #2 12 Revolution
5 Temperature Sleeve bearing #1 13 Revolution
6 Temperature Thrust bearing #1 14 Exhaust gas temperature
8 Delta P measuring device 33 CDP Sensor
9 CDT Sensor 35 VSV-gage
10 Exhaust back pressure
Document 1 Page 31 of 208 15.11.2012

Instrument display:
It is imperative that the operator can visually check the condition of the turbine. The
turbine control cabinet needs display instruments, which measure and show
indicators such as temperatures and vibrations. Image 18 shows the system
structure.
In detail, the sensors provide values for:
EGT (Exhaust Gas Temperature)

The turbine has 2x6 EGT measuring points. From these measuring points an
average of 12 thermal elements, which are mounted on the gas turbine diffuser, are
formed and displayed. Each individual EGT is also used to determine faults, e.g.
misfires or fire extinguishes.
TIT (Turbine Inlet Temperature):

The TIT is a calculated, not a measured, temperature!
Through the TIT (Turbine Inlet Temperature), the turbine output has an upper limit. If
the calculated TIT exceeds the maximum allowed TIT, the turbine output must be
reduced in order to avoid overload. The TIT is calculated from the average EGT of
the T1 and other parameters, among other things.
Suction air temperature

To measure the suction air temperature T1, an RTD (Resistance Temperature
Sensing Device) is mounted on the air inlet boxes of the gas turbine. Its measuring
signal is for turbine control and is also shown in the control unit.
Vibrations.
Bearings No. 1 and 2 each have an X levels and a Y level measuring vibration
sensor, which monitors the main shaft vibrations. The vibrations are displayed over
the display unit in the control cabient.
Document 1 Page 32 of 208 15.11.2012

Instrument structure
Image 13
Document 1 Page 32 of 208 11.02.2010

Gas turbine material
Description Material Specification
1.-7. Compressor blade Ti-6A14V AMS4928
8...12. Compressor blade Custom450 KM-SE410
Compressor wheel FV535 KM-S407
Clutch rotor INCO718 KM-S508
1....3. Turbine blade Rene-80 KM-S513
4. Turbine blade INCO713C KM-S525
1. ..3. Turbine wheel WASPOLY KM-S507
4. Turbine wheel INCO718 KM-S508
2. Bearing shaft 17-22AS AMS6302
1. ..12. Compressor guide 17-4PH KM-S223

vane
Combustion chamber HA188 AMS5608
HASTELLOY-X AMS5536
Transition tee HA188 AMS5608
1. ..2. Turbine guide vane FSX414 KM7020
3. Turbine guide vane X-45 KM-S300
4. Turbine guide vane SCH20 JIS G 5122
Exhaust gas diffuser SCPH21 JIS G 5151
Suction cone SC42 JIS G 5101
Compressor housing SCPH2 JIS G 5151
Turbine housing SCPH21 JIS G 5151
Document 1 Page 33 of 208 11.02.2010

Nozzle guide N-155 KM-S402
C.3 Gear Box
Description
The reduction gear is primarily for reducing the gas turbine wave velocity from 13,790
rpm to the generator-required 1,500 rpm.
In addition, connections for the auxiliary drives, such as lube oil pumps and starter
motors are integrated with relevant overhaul clutches.
Image 14
Document 1 Page 34 of 208 11.02.2010

Technical details
Input speed 13.790 1/min

Output speed 1,500 1/min
Overspeed 111% for 2 minutes
Max. peak torque 400% of constant load
Max. constant load 9,000 KW
Gear type Planetary gear
Operating conditions Continuous operation
Lubrication ~ 2.0 bar under pressure
250 l/min +/- 40 l/min.
30 - 50C oil temperature,
Supply from the gas turbine oil tank
Gas turbine
Lifespan 32.000 hours
Efficiency 98%
Total weight 6,800 kg
Scope of delivery:
Description
Amount
Planetary gear fitted with:
- Lube oil pump (MLOP)
- Starter/Turning unit
Specification:
The generator specification depends on the gas turbine application.

The manufacturer's operating manual of the gear is listed under "Manufacturer and
Supplier Documentation".
Document 1 Page 35 of 208 11.02.2010

Gear installation
Temporary gear installation
1. The gear is temporarily mounted on the base frame. It is then centred to

the marked line on the base frame.
2. The gear is positioned so that the clutch flanged end lies on the turbine
side 650.5 0.5 mm from the screw holes on the base frame, which are
for fixing the front side of the turbine.
3. The tolerance between the gear seat flange and the base frame is
checked with the 0.03 mm gauge. If the bearing gap is 0.03 mm or more,
additional bearing plates are inserted. The following screws are tightened:
6 x M42, torque 2070 Nm.
4. The dimension 650.5 0.5 mm (see above) is re-checked.
Gear installation
1. After the temporary installation of the peripheral device, the alignment of

the gear must be measured and checked.
2. The centring of the turbine low speed coupling and generator are
checked. If centring can only be achieved through height adjustment, the
gear is fixed by tightening the fastening screws on the base frame.
3. The following screws are tightened once again: 6 x M42, torque 2070 Nm.
Temporary gear installation
1. The edges and generator feet and slightly tilted and any foreign objects
and impurities on the generator seat and feet are completely removed.
2. The end plates are fastened to the generator shaft.
3. The generator is positioned on the base frame in a way that positions the
generator axis as parallel as possible to the gear output shaft. Tighten
screws carefully.
Document 1 Page 36 of 208 11.02.2010

Alignment of the gear-box output, low speed coupling, with the generator
CAUTION
The turbines and gears which are fastened to the base frame may not be moved
during alignment of the gear and generator!
CAUTION
If maintenance work is necessary, the necessary space for moving and the crane
must be prepared.
Height of movement: at least 800 mm
Lifting capacity: at least 2,850 kg (gear wheel: 2,740, plus coupling flange).
Document 1 Page 37 of 208 11.02.2010

Municipality of Bacau, Str. Marasesti Nr. 6, Bacau 600017, Romania
Manual

GPB80DD
VOLUME 2
(Generator, Base Frame (blue), Speed Measurements, Auxilliaries )

Date 19.11.2012
Name O. Frieling

Tel. +49 6172 7363-0
Fax +49 6172 7363-55
Document 1 Page 38 of 208 11.02.2010
Couplings
Description
The gear is connected over two diaphragm couplings as torsionally elastic

connections for compensation for misalignment and for torsional damping. As a
diaphragm coupling, the clutch is small and lightweight, which offers advantages in
installation and maintenance work. To avoid risk of accident, both clutches are
equipped with perforated sheeting (see C.7 "speed measurement").
Manufacturer: KAWASAKI Heavy Industries, Ltd. Japan
The high-speed coupling provides a direct connection to the output end of the gas
turbine.
Image 15
Example
The low-speed coupling is between the gear-box and the generator. This clutch is
fitted as a safety clutch for the connection from the gear and generator to the bolts to
protect against overload of the unit, and also against short-circuits during
synchronisation and network failure.
Image 16
Example
Document 1 Page 39 of 208 11.02.2010

High Speed Coupling
Image 17
Low Speed coupling
Image 18
Document 1 Page 40 of 208 11.02.2010

C.4 Generator
Description
The generator has the primary function of power generation.

A further function is the connection of the auxiliary drives, such as the main lube oil
pump, starter / turner motor etc.
Image 19
Technical details (according to Lieferschein)

Type: LSA56 BMBL130 4p
Speed 1,500 1/min
Synchronous Rotary current
Nominal output 10,111 kVA (15C) H/F
Voltage 6,300 V
Frequency 50 Hz
Power factor 0.8
Protection class generator IP23
Protection class terminal boxes IP23
Cooling IC0A1
Stimulation Brushless
Control type: AREP
Heating during stop 1x 500 W under 230 V
Total weight 17.000 kg
Document 1 Page 41 of 208 11.02.2010

Scope of delivery:
Description Amount
Generator fitted with:
- Lube oil pump 1
- Starter/Turning unit (excluding motor)
Specification
The generator specification depends on the gas turbine application.
Document 1 Page 42 of 208 11.02.2010

C.5 Base frame
Description
The machine base is used for integrating and fastening the

gas turbines, gears and required auxiliary systems.
Construction: KAWASAKI Gas Turbine Europe GmbH

Manufacturer: LindenbergAnlagen GmbH
In detail, this consists of:

Rigid hollow-section frame and steel profile
Mounting plates and elements
Elastic turbine connections and tube connections
Oil tank integrated between the side rails
Elastic mounting of the base frame on the foundation
Base frame (blue)
Image 20
Document 1 Page 43 of 208 11.02.2010

C.6 Speed measurement
Description
The speed measurements (three measurements) provide constant control of the

turbine and connection to the generator. Differences in the rotational speed are
registered here and are initiated in the event of a shut-down, in order to avoid
damage. Precisely in the low-speed clutch, the predetermined breaking point (shear
pins) is monitored, in order to shut down in the event of a disconnection between the
generator and turbine.
In detail, this consists of:

Sensors (1x to the low-speed coupling, 2x to the turbine indirectly over the vibration
measurement)
Evaluation (in the control station)
C.7 Auxiliary System
Description
All required auxiliary and monitoring systems are available for operating the gas
turbine generator unit.
RPM-Sensor, installed on the low-

speed coupling (Jaquet)
Image 21
Example
Document 1 Page 44 of 208 11.02.2010
In detail, these are:
Lube oil system
for fully installed gas turbines, gears and generators consists of:
Oil sump, 2,000 l with level monitoring, Pump for filling
Oil - water cooler
Oil mist separators
Oil mist separators separate oil vapours which are in the gear and oil sump, and
return the captured oil.
The fitting of the filter unit guarantees separation of very high concentrations of oil
vapour. Concentrations of oil vapour The relevant negative pressure in the oil tank is
obtained by tuning the device. The exhaust gas flows through the device where dirt
particles are filtered out.
Main oil pump, driven mechanically from the gear.

Pre-/post lube pump, 3 bar, with an AC motor, 400 VAC, 2.2 kW
Emergency oil pump, 1 bar, with DC motor, 24 V DC, 0.4 KW
Double filter, switchable with differential pressure monitoring
Different armature filters
Thermostat/pressure control valves
Pressure and temperature switches
Manometer, thermometer
Hose line, piping for internal distribution in high-grade steel
Technical details of the lube oil system
Lube oil ISO VG 46, mineral oil with additives

Heat removal ~220 kW
Oil amount ca. 2,000 l
Circulation ca. 530 l/min
Oil pressure ca. 1.5 - 2.0 bar (g)
Operating temperature 30 - 50C
Consumption ca. 0.5 l/h
(when using oil mist separator approx. 1.5 l/day)
The corresponding safety data sheet for the above-mentioned lube oil is available
under "oils, lubricants and other liquids".
Document 1 Page 45 of 208 11.02.2010

Fuel system: Gas fuel and Liquid fuel (#3044 Bacau)
The gas turbine is fitted as a DLE variant with a natural gas fuel system.
The fuel control system enables monitoring and control of all required operating
conditions, such as start up, different accelerating and load conditions from zero to
full load
Natural gas fuel and liquid fuel system, consisting of:

Natural gas main filter and Liquid fuel double sided main filter
Gas-fuel:Main shut-off valve combination (2 each valves), with ventilation and
open close feedback-position system, DVGW approved /
Liquid fuel: Main shut-off valve combination with ventilation, (2 each valves) / with
ventilation and open close feedback-position system
Filling gas valve, DVGW permitted
Gas leakage detector, DVGW permitted and Oil leakage detector
Natural gas control valve and DLE control valve and liquid fuel control valves
Natural gas and liquid fuel distributor rings
Multi-burner unit, controlled by air pressure
Safety gas purge valve (NO), (NO = normally open function)
Pressure monitoring with switches and manometers
Flexible tubes
High-grade stainless steel pipings from the base frame connection to the gas
turbine
The approved fuel is natural gas H (with methane as its main component) which is
delivered controlled, filtered, dry and clean and with the necessary supply pressure.
Fuel: Natural gas H (physical properties calculated according to DIN 51817), filtered,
clean and dry
Filtering: < 10 m with steam trap

Temperature: -20....+65C (at least 50C above dew point and free from steam at the
interconnection point
Pressure: 22 bar (g) +/- 0,3 bar (g) (at the interconnection point of the noise
enclosure)
Gas composition (requested min. standard values)

Natural gas H
LHV 10,034 kWh/m
Sulphur content: max. 0.1% wt X LHV (kJ/kg)/43,116
Impurities < 10m, max. 30 ppm x LHV(kJ/kg)/43,116
No liquid components or hydrocarbon which can be condensed
Document 1 Page 46 of 208 11.02.2010

Starter motor
As as starting help for a speed of 0-70%, a three-phase current squirrel cage rotor is
used.
A robust frequency converter for high output drives, which is suitable for different
industrial operating environments, enables the management and control.
IGBT and DTC technology is integrated for low-loss control of the three-phase
current squirrel cage rotor motors.
Turning gear
After shutting down the gas turbine, this must be turned at low speed in order to
avoid warpage of the blade from different cooling in the gas turbine.
For this, the aforementioned starter motor is used.
Air pressure supply
Pressure 6...7 bar (g); min. 5bar (g)

Total air pressure requirement during: ~ 200 Nm/h
of the start/stop procedure
Consumption during: ~ 50 Nm/h
of operation
Quality: Instrument air, oil-free, dried and filtered
Start-bleed system
This system is used during the start up procedure. Here, compressed air is blown
from the gas turbine compressor over a flap valve into the exhaust system, in order
to avoid flow separation in the gas turbine compressor.
Bleed-system to DLE control
During partial load operation of the gas turbine, too much ambient air is drawn in and
compressed by the turbine compressor.
Due to the combustion-related procedures within the gas turbine, and the excess air,
the required exhaust gas values can be exceeded.
For this reason, not only the fuel is regulated during partial load operation, but also
part of the compressor air which is determined in the combustion chamber is fed
directly into the exhaust gas duct.
Document 1 Page 47 of 208 11.02.2010

Electrical components, control and monitoring equipment
To operate the gas turbine and to monitor it during operation, additional sensors are
installed in the gas turbine.
Control and recording of the measuring signals takes place in one of the terminal
boxes which are built into the gas turbine:
Ignition coils, ignition plugs, 2 pcs

Flame detectors with evaluation module, 2 pcs
CDT (Compressor Discharge Temperature) sensor
Outlet temperature sensor
CDP (Compressor Discharge Pressure) sensor
Speed sensors, 3 pcs with monitor
Vibration sensor and monitors, 2 pcs each for the gas turbine, the gear and the
generator.
Thermal elements for monitoring the exhaust gas temperature, 12 pcs with
display
Resistance thermometer PT100
Compressor-cleaning equipment
To maintain the effectiveness of the gas turbine and to avoid erosion/corrosion on the
compressor blades, the gas turbine is fitted with a compressor cleaning device.
This separate component consists of:

a storage tank, a pump unit and a connecting hose to the gas turbine.
The cold wash procedure is carried out when the machine is switched off.
Fluid amount: 19l per wash
Cleaning agent: Clean water/cleaning agent in a ratio of 4:1.
Document 1 Page 48 of 208 11.02.2010

Manual

GPB80DD
VOLUME 3
(Lube-Oil System,descriptions, folder 1 of 2 )

Date 19.11.2012
Name O. Frieling

Tel. +49 6172 7363-0
Fax +49 6172 7363-55
Document 1 Page 49 of 208 11.02.2010
Lube oil system
DANGER
To eliminate the risk of explosion, under NO CIRCUMSTANCE may oil mist be
exposed to a naked flame.
CAUTION
Insufficient or sloppy lubrication can cause bearing damage and thus severe
turbine damage.
The oil pressure and level are always monitored by the turbine control system.
Additional visual inspection must be carried out by the operator and also
directly corrected if necessary.
CAUTION
The key functions of the whole system is electronically monitored and
controlled.
However, the hydraulic control system plays an important role in the system
control.
Thus, the entire lube oil system and all components must be carefully
maintained and continuously observed by the operator.
Document 1 Page 50 of 208 11.02.2010

Description
The lube oil system of the gas turbine generator unit largely consists of the
following main components:
Main lube oil pump (MLOP)
Oil cooler
Thermostatic valve
Main oil filter
Oil pressure controller
Oil mist separator
Oil tank
Lube oil
Pre-/post-lube pump (PPLOP) with AC motor 3 bar,

400 VAC 2.2 kW
Emergency lube oil pump (ELOP) with DC motor 1 bar, 24 V DC
0.25kW
Double filter, switchable with differential pressure monitoring
Oil mist separator with side channel blowers, 400 VAC, 1.5 kW
different armature filters
Pressure and temperature switches
Manometer, thermometer
Hose line, piping for internal distribution in high-grade steel
Tank heating, 400 VAC, 5 kW
The purpose of the lube oil system is the:
Lubrication of the turbine
As the turbine is operated at high speeds and temperatures, a well-functioning

lubrication system is particularly important, in order to ensure correct
functionality of the entire system.
The bearings are lubricated with different parameters, during and after
operation of the gas turbine. The data are summarised in the following table.
Document 1 Page 51 of 208 11.02.2010

Operation Pre-/post-lubrication Emergency Filtering
Post-lubrication
Bearings
Over- Volume Over- Volume Over- Volume
pressure flow pressure flow pressure flow
No. #1 0.98 bar 25 l/min 0.98.. 12 l/min - - 10 m
Axial nom.
2.94 bar
bearings
No. #1 0.98 bar 49 l/min 0.98.. 22 l/min - -

Radial 2.94 bar
bearings
No. #1 0.98 bar 22 l/min 0.98.. 10 l/min - -

Axial 2.94 bar
bearings
No. #2 0.98 bar 35 l/min 0.98.. 16 l/min 0.98 bar 10

Axial l/min
2.94 bar
bearings
All values mentioned above are approximate, and are individually set during
commissioning.
Gear and generator lubrication
The lube oil system supplies the lube oil not only to the gas turbine, but also to
the gear and generator bearings.
The amount of lube oil for the gear is summarised in the following table:
Operation
Reduction gear Overpressure Volume flow Filtering
1.47 bar 214 l/min 10 m nom.
The amount of lube oil for the generator depends on its size and manufacturer.
For this, the lube oil system provides a volume of 50l/min with a positive
pressure of 1.5 bar.
The manufacturer-specific data can be set using a pressure reducer and a

flow metre.
Document 1 Page 52 of 208 11.02.2010

System description
The gas turbine lube oil system consists of the oil tank, pumps, filters, oil
coolers and other devices for controlling the required components.
A good description and presentation of the components is available in the

respective datasheets.
The lube oil is drawn in from the oil tank, over a check valve and dirt trap, and
compressed at a constant pressure of 5 bar. The constant pressure of 5 bar is
set using an internal pressure control valve, in order to protect other
components.
A thermostat regulates the oil feed in accordance with the oil temperature.
Cold lube oil is fed directly in to the circulation, from the lube oil cooler over a
bypass. From a temperature of about 30C, the thermostat valve is activated,
so that a partial flow can first be directed over the oil cooler.
Depending on the temperature, the thermostat opens or closes and maintains

a lube oil temperature of about 40C.
After this, the lube oil is fed from the cooler through a switchable double filter
(10 m), which secures the required oil purity.
After the double filter, the lube oil is distributed in the respective lube oil
volumes and temperatures. A secondary exhaust gas valve regulates the
pressure of the lube oil at 1.5 bar.
A partial flow of 131 l/min is set over an aperture, for lubrication and cooling
bearings #1 and #2.
The remaining lube oil (approx. 398 l/min) is fed to the gear and generator.
The relevant measuring points for the thermometers, pressure sensors and
pressure switches are integrated into the oil system.
The respective data are hereby monitored during the start-up procedure and
operation, and relevant measures are taken.
All feed points for lube oil in the gas turbine generator unit are fitted with a
return pipe. The lube oil is thereby transported back to the tank, where the
flow is steadied and gas bubbles are eliminated.
Similarly, oil mist, which arises from torsion in the bearing seals, is fed over a
pipe in the oil tank and cleaned in an oil mist separator.
Document 1 Page 53 of 208 11.02.2010

The Pre-Post-Lube Oil Pump (PPLOP = Pre/Post-Lube Oil Pump)
works as follows:
1. Pre-lube: At least 20 seconds before turbine start-up, the pump is

automatically switched on and supplies all systems with lube oil.
During the start-up procedure it runs alongside the mechanical main lube
oil pump, providing support.
The PPLOP is switched off when the turbine has reached a speed of
95%.
2. Post-lube: The pump starts working when the turbine speed falls below
95% and supports the mechanical main lube oil pump. It is automatically
switched off after 48 hours turning (shaft rotation).
The Emergency Post-Lube Oil Pump

(ELOP = Emergency Lube Oil Pump) has the following functions:
1. The ELOP (24VDC) serves exclusively to cool the hot bearings No. 2 of
the turbine in case the pre- /post- lube oil pump becomes out of order
due to a power failure. It ensures that the hot bearings are also
sufficiently cooled following shut-down in the event of a power failure.
2. It starts working when the pre- / post-lube oil pump doesn't work (e.g. in
the event of a low-pressure stop, when the turbine speed is below 95%,
power failure).
It is switched off when the above-mentioned conditions no longer prevail.
Document 1 Page 54 of 208 11.02.2010

Main lube oil pump
Main lube oil pump
Image 22
(Example)
Technical details
Type: Gear pump

Output 570 Liters / min
Nominal pressure 0.5 MPa
Speed: 1,141 rpm
Installation location: flange mounted on the gear
Document 1 Page 55 of 208 11.02.2010

Oil cooler
Lube oil outlet

Cool water inlet Lube oil cooler
Image 23
Lube oil inlet Cool water outlet (Example
)
Image 24
(Example)
Document 1 Page 56 of 208 11.02.2010
Technical details
Type: screwed plate heat exchangers

Water volume: 24 m/h
Water temperature on: max. 32 C(# 3044 Bacau)
Water temperature off: approx. 42 C
Pressure loss water 33 kPa
Oil volume: 34.20 m/h
Oil temperature on: 60 C
Oil temperature off: 40 C
Pressure loss oil 46 kPa
Designed heat-power: 324 kW
Installation location: in the technical room of the filter house
NOTE
The power dissipation, which is fed over the lube oil has the following values:
for the gas turbine: approx. 70 kW,

for the gear: approx. 130 kW
Document 1 Page 57 of 208 11.02.2010

Thermostatic valve
Thermostatic valve for regulating the lube oil temperature
Image 25
(Example)
Oil thermostatic valve
Image 26
The thermostatic valve starts to open at approx. 27 - 30 C, and reaches a

mixed oil temperature whereby more and more lube oil is fed over the lube oil
cooler.
Before the automatic thermostatic valve starts opening, the lube oil flows into
the cycle, and thus not over the oil/water cooler.
Should the spring-loaded function be faulty, the thermostatic valve can also be
manually engaged. Options: Completely "open" or completely "closed"
Document 1 Page 58 of 208 11.02.2010

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

lube oil.
Main lube oil filter
Image 27
(Example)
The main lube oil filter is fitted with a double filter and can be switched off
while the turbine is running.
BUT:
It should be noted that the filter which is not yet used must first be slowly filled
with lube-oil and simultaneously ventilated before final switching.
Details can be found in the manufacturer and supplier documentation.
Document 1 Page 59 of 208 11.02.2010

Technical details
Filter class: 7 Micron

Pressure level 2,000 psi, (approx. 207 bar (g))
Switching point: approx. 1.2 bar (g), alarm
Switching point: approx. 1.5 bar (g), stop
Site of assembly: on the basic frames
CAUTION
An absence of the described first pre filling / de ventilation of the second oil-
filter section, can lead to damage, as air pockets can get into the supply pipes
and disrupt lubrication.
Document 1 Page 60 of 208 11.02.2010

Oil pressure controller
Main lube oil pressure controller, adjustable (is adjusted during the IBS)
Controls the main lube oil pressure in the system for the gas turbine, gear and
generator.
Main lube oil pressure controller
Image 28
Technical details
Configured lube oil pressure: approx. 2 bar (g)

Outflow volume in control range: approx. 173 +/- 40 l/min
Site of assembly: on the base frames
Document 1 Page 61 of 208 11.02.2010

Oil mist separator
The oil mist separator is responsible for drawing oil mist out of the lube oil
tank, and separating the air from the oil.
After filtering, the air is directed in this case over the roof and into the open air.
The separated oil is fed back into the lube oil tank.
All oil drains and oil vapour openings are then attached to the gas turbine
using light suction pressure, taken from the negative pressure from the oil mist
separator in the lube oil tank.
In this way, the retention time of the lube oil inside the gas turbine is reduced,
although leakages rarely occur.
Filter housing
Clean air pipe,

(is directed over
the roof)
Bleed air intake
Oil mist -
suction pipe
(from tank)
Image 29
(Example)
Technical details
Residual oil content: approx. 20 mg / Nm

Exhaust air volume: approx. 5 Nm3/min
Negative pressure: approx. 15 mbar
Negative pressure: approx. 10 mbar configured
Vacuum switch: approx. 10 mbar configured
Installation location: In the technical room of the filter house
Document 1 Page 62 of 208 11.02.2010
Principle of the oil mist separator
Image 30
Document 1 Page 63 of 208 11.02.2010
Lube oil
A mineral oil compliant with ISO VG 46 (JIS K2213 or DIN 51515) is used.
The oil temperatures measured at the lubricated parts lie between 10C and
60C.
Lube oil specification, in accordance with ISO VG 46 (JIS K2213 or DIN

51515):
First filling by Kawasaki is: Shell Turbo Oil T32
More specific information can be found in the safety datasheet, which is under
"oils, lubricants and other liquids".
Document 1 Page 64 of 208 11.02.2010

Oil tank
Tank capacity
The internal capacity of the lube oil tank is ~2,2 m,

the filling quantity of the first filling is 2,000 Liters.
Lube oil tank equipment
- Lube oil level display: This enables the lube oil to be checked from outside
the package. The lower limit is the lower part of the suction opening of the
pump. The upper limit is established by the volume of oil.
- Lube oil level switch for external alerts of the oil tank content.
- Suction side dirt traps for the mechanical main lube oil pump, electrical
auxiliary pump and control oil pump.
- Lube oil tank heating and temperature sensor. When the gas turbine is
stopped, the lube oil temperature should be regulated at approx. 10C.
Should the lube oil temperature fall below 10C, the the lube oil tank
heating is switched on via the lube oil temperature switch, so that the lube
oil is warmed up. The heating system is turned off when the oil
temperature has reached ~15C.
- Oil mist separator: This separates the oil vapours in the gear and oil sump,
and feeds the oil which has been captured from the oil mist back into the
tank. This recirculation reduces oil consumption, while the clean air from
the oil can be emitted into the environment. Oil mist is suctioned from the
tank and its connected systems by a ventilator with an air inlet, in order to
establish a certain vacuum in the system.
This vacuum prevents oil leakages into the bearing sealings of the gas
turbine and the gear. Negative pressure inside the oil tank must be kept at
-100 mmWC. At 5m3/min, the ventilator capacity should have a negative
pressure of -100 mmWC.
- A tank filling pump is provided for filling and emptying the lube oil tank; its
relevant function can be selected using a 3-way valve.
Document 1 Page 65 of 208 11.02.2010

Manual

GPB80DD
VOLUME 4
(Lube-Oil System, components, folder 2 of 2)

Date 19.11.2012
Name O. Frieling

Tel. +49 6172 7363-0
Fax +49 6172 7363-55
Document 1 Page 66 of 208 11.02.2010
Manual

GPB80DD
VOLUME 5
(Gas- / Liquid-Fuel System)

Date 29.11.2012
Name O. Frieling

Tel. +49 6172 7363-0
Fax +49 6172 7363-55
Document 1 Page 67 of 208 11.02.2010

C.8 Fuel system
Description
Requirements of gaseous fuels.
1. Gas temperature -20C to +65 C

2. Lower heating value 33,500 to 41,860 kJ/Nm3
(LHV) 9.31 to 11.64 kWh/Nm
3. Sulphur content 0.5% weight x LHV (in kJ/kg)/43,116, only for the
gas turbine
0.1% weight x LHV (in kJ/kg)/43,116, only for gas
turbines with waste heat boilers
4. Foreign objects, total 30 ppm x LHV (in kJ/kg)/43,116,
5. Particle diameter 10 m
6. Water and liquid 0%
hydrocarbon
The gas must be provided dried, filtered and oil-free.
The natural gas system is fully integrated into the base frame of the gas
turbine generator unit and complies with the relevant standards and
regulations.
The natural gas system inside the gas turbine system generator largely
consists of the following main elements:
Natural gas main filter
2x safety shut-down valves 1/2 with interim ventilation
Safety blow-off valve (Start gas)
Natural gas control valve and DLE control valve
Natural gas distributor ring
Natural gas injectors
Document 1 Page 68 of 208 11.02.2010

Image 31 Image 33.1
Example
Natural gas filter
Safety shut-down
valve No. 2 (NC)
Safety shut-down
valve No. 1 (NC)
Start Gas valve

(NC)
Image 32
Safety blow-off
valve (NO)
Image 32
Document 1 Page 69 of 208 11.02.2010

Installation of the Gas-/ & Liquid-fuel system (# 3044 Bacau)
The gas turbine is designed as a DLE variant with a single fuel system.
The fuel control system enables monitoring and control of all required
operating conditions, such as start-up, different accelerating and power
conditions from zero to full power.
(see P&ID E3029 080 102 and E3029 080 103)
Before each start, a control of the leak-tightness is carried out over a valve
combination.
By using the pressure controllers for monitoring the fuel pressure, in the event
of leakage or too low pressure, a start-up is prevented (it is not possible to
operate the gas turbine with gas fuel).
During operation, the configured speed is maintained using a speed control
circuit.
The actual value signal comes from one of the magnetic encoders which are
mounted on the turbine blades.
The main components of the Gas fuel system are:
Switchable double-filter-unit
Safety shut-off valve combination, DVGW permitted,
with position feedback system
Safety ventilation valve, DVGW permitted,
with position feedback system
Gas Leakage detector, DVGW permitted
Gas measurement valve (main gas fuel governor)
Multi-burner unit, air pressure controlled
Parallel ring piping
6 each fuel chambers with nozzles
Gas fuel flexible tubes
Piping from the connecting flanges on the base frame to the gas turbine in
stainless steel.
The approved fuel is natural gas H (with methane as its main component),
which is delivered controlled, dry and clean, and with the necessary supply
pressure.
A main manually operated shut-off valve is fitted in front of the entrance to the
gas turbine generator unit.
Document 1 Page 70 of 208 11.02.2010

The main components of the Liquid Fuel system (# 3044 Bacau) are:
Switchable double-filter-unit
Double Safety shut-off valve combination, with position feedback system
Safety ventilation valve, DVGW permitted, with position feedback system
Liquid fuel Leakage detector
Liquid fuel, high-fuel pressure unit, (installed inside of liquid fuel module)
Liquid fuel ,main- and start-fuel governor unit, (installed inside of liquid fuel
module)
Liquid fuel ,air- / water purge unit (installed inside of liquid fuel module)
Liquid fuel ,drain unit (installed inside of blue GT-base frame)
Multi-burner unit, air pressure controlled
Parallel ring piping
Fuel chamber with nozzles
Liquid fuel flexible tubes
Piping from the liquid fuel module to the connecting flanges on the base
frame to the gas turbine in stainless steel.
k Low pressure water tank
General view: Liquid fuel system
Image 33.2
Image 33.4
Liquid fuel valves, tightness control transmitters
Liquid fuel pressure control transmitters

Image 33.3
Document 1 Page 71 of 208 11.02.2010

Combustion chamber and manifolds
Gas- / Liquid-Fuel 5 x flame-

2x3 = 6-each -
Manifolds transfer tubes
combustion chambers
Image 33.5
Document 1 Page 72 of 208 11.02.2010

Manifolds
The manifolds are responsible for consistently supplying natural gas to the
individual injectors.
This is done in accordance with the respective operating conditions of the gas
turbine.
Combustion chambers
The gas turbine has 6 separate combustion chambers. 3 per side, which are
connected to each other by flexible metal hoses (flame pipes).
The two lower combustion chambers on each side are those which are ignited.
Following ignition, there is a flame rollover to the third/most upper combustion
chamber.
Flame tubes
Following ignition, the flames are fed through the flame tubes to the two lower
combustion chambers and the combustion chambers lying above.
Flame detectors
During the start-up procedure, a flame must be detected in the uppermost

combustion chamber. If this does not happen, start-up is immediately aborted.
Ignition plugs
The two lower combustion chambers are installed with ignition plugs. During
the start up procedure, at approx. 7% of the nominal speed, each of the two
lower combustion chambers on each side is ignited.
Document 1 Page 73 of 208 11.02.2010

Image 35
Example
2x Ignition plug
Document 1 Page 74 of 208 11.02.2010

Overall control of the flow of fuel
The control system consists of three control components.

1. Speed control
2. Control of the start/stop procedure
3. DLE (Dry-Low-Emission) Control
The speed is controlled by controlling the fuel volume.
Activation of the different nozzles and burners depends on the load.
The order of the start-up/stop procedure runs in a linear sequence.
Each combustion chamber is fitted with three different fuel injections.
A Pilot Burner, a Main Burner and a Supplementary Burner.
To achieve combustion with low levels of emissions, the fuel supply to these
burners is regulated over the aperture of the respective burner.
The control valve of the individual burners are located behind the fuel metering
valve.
For the use of liquid fuel, each of the combustion chambers is fitted with a
pilot/primary burner.
The three main components of the fuel system are thus:

- an integral measuring unit, which controls the flow of fuel in the whole
gas turbine
- a unit for the load-dependent control of the different burners, too low-
emission combustion in a load range of 80... 100% load
- a distribution unit in the form of concentrically arranged ring mains, which
distributes fuel to the six combustion chambers.
Speed control
This control unit consists of a speed sensor, a control unit and a fuel metering
valve. Under all operating conditions, the fuel valve which is connected to the
speed sensor doses the flow of fuel to the turbine.
The speed sensor generates an AC signal whose frequency is proportional to
the turbine speed. The signal is transported to the control unit, where it is
converted into a DC signal. The control unit then sends the relevant signal to
the respective device. The fuel metering valve regulates the flow of fuel to the
turbine according to need so that the operating speed remains constant, or is
varied during the start-up procedures.
Document 1 Page 75 of 208 11.02.2010

a) Acceleration to 65% turbine speed.
When the turbine starts, the regulators are responsible for controlling the flow
of fuel so that the the turbine accelerates. This acceleration is a function of
the measured speed and acceleration. When the gas turbine starts
accelerating, the fuel metering valve opens with increasing turbine speed.
This further increases the fuel supply, which in turn means an increase in
turbine speed.
During the acceleration phase, the fuel supply is increased or decreased in
accordance with the acceleration, speed and exhaust gas temperature. This
type of control is continued until the turbine has reached a specified speed
(65% of the nominal speed).
b) Acceleration over 65% of the turbine speed and normal operation with load:
When the turbine speed has reached 65%, a control system is engaged which
controls the turbine at a constant speed. The actual speed is compared with
the target speed; based on this difference, the regulator sends a command to
the fuel metering valve to minimise the difference.
This is how the flow of fuel is controlled in order to maintain the speed at a set
value.
Once the turbine speed has reached 65%, the speed control system increases
the speed automatically until the nominal speed is reached.
Once the nominal value is reached, the control system detects a zero
difference between the actual and target speed, so the speed can be
maintained at a constant level. The control type "constant speed" is used
when the turbine is running in isolated operation under load; the control type
"constant load" is used for network-parallel operation (under load).
Start-up/stop procedure
When the start system brings the turbine to a speed of 5% during the start-up
phase, the starting fuel valve is opened. The starting fuel volume is regulated
by the throttle for primary fuel. With the M7A, the fuel is injected by the pilot
burner and main burner.
The ignition trigger is similarly activated at 5% speed and the fuel is ignited.
When a speed of 25% is reached, the main valve is opened. The fuel then
flows over the main valve to the metering valve and over the nozzles in to the
combustion chamber.
During acceleration, the regulator completely opens the valve and the flow
controller adjusts the volume of fuel to the CDP (compressor discharge
pressure), in order to maintain the acceleration characteristics.
Document 1 Page 76 of 208 11.02.2010

Start Stop Diagram
Do Page 75 of 208 11.02.2010

-
If the exhaust gas temperature does not exceed a temperature of 200 C
within 7 seconds of reaching a required speed, a false start is registered and
shut-down is initiated.
The following procedures are carried out during a start-up/stop procedure.
a) When a start signal is given, the pre-/post-lube pump starts working (pre-
lubrication of the sleeve bearings).
b) About 10 seconds after the start signal, the starter carries out the first pre-
ventilation cycle. This procedure takes approx. two minutes (acceleration to
approx. 24% nominal speed and operation at 24% for approx. one minute).
This pre-ventilation is only carried out with hot machines, and at temperatures
of over 100C.
Three minutes after the turbine speed has fallen to below 5%, the starter
carries out the second purge procedure (again at 24% nominal speed).
After a further three minutes, the start then stops. This time depends on the
volume of the adjacent exhaust gas system and thus be varied.
c) When the turbine speed has reached 5%, the primary/pilot gas supply valve
opens and feeds a low volume of fuel to the combustion chamber.
The ignition is simultaneously activated so that the fuel is ignited and burned.
d) When the turbine speed has reached 18%, the main gas valve (MFV, MSV /
MGV) and the metering valve open for the pilot burner (PLCV / PGCV). The
fuel is supplied to the combustion chamber at a higher level and the turbine is
further accelerated.
When the turbine speed has reached 25%, the ignition is deactivated in order
to avoid electric discharge.
e) When the turbine speed has reached 65%, the starter is switched off.
f) After the switching of the starter, the fuel is further fed into the combustion
chamber to bring the turbine up to the nominal speed. When the turbine
speed has reached 95%, the pre-/post lube oil pump is switched off.
Further lube oil is supplied by the main oil pump only (mechanically-driven
pump, installed in gear).
Document 1 Page 76 of 208 11.02.2010

g) To stop the turbine, a stop signal, which closes all valves in the fuel system,
is given.
h) At below 95% speed, the pre-/post-lube oil pump is re-activated.
i) When the turbine speed is reduced to 4%, the turning and post-lube
procedure is activated.
When the gas turbine safety system is active, all fuel valves are closed, in
order to stop the turbine.
The pre-ventilation procedure
Only the start is run for this procedure; without any fuel supply and without an
ignition. This procedure is carried out three times, whereby the duration is
calculated in accordance with the adjacent, horizontal exhaust gas duct.
The purpose of ventilation is to remove any remaining pockets of gas from the
gas turbine and/or connected horizontal exhaust gas duct before the actual
start, in order to prevent an uncontrolled ignition of the remaining pockets of
gas.
A further purpose is the cooling of the turbine following a stop procedure
(normal stop, not emergency stop!).
In the event of a false start, the fuel supply is immediately discontinued, and
any remaining fuel in the combustion chambers is removed by a ventilation
procedure.
Document 1 Page 77 of 208 11.02.2010

To reach optimum conditions for low-emission combustion, the fuel distribution
to each combustion chamber is regulated in accordance with the turbine load.
The optimum distribution of fuel is regulated over the control valve in the fuel
metering unit, by a regulator using corresponding signals. The control valve of
the individual burners are behind the fuel metering valve.
During DLE operation (only in gas fuel operation)
When the gas turbine starts, the fuel is initially fed to the pilot burner (P). With
increasing power of the turbine, the fuel supply is regulated by the different
ducts of each fuel control valve.
This is how the optimum combustion conditions for fuel distribution are
created.
DLE control in operation with gaseous fuel
A. At increasing load
1. When the load is 75% or lower, the fuel is only fed to the pilot burner.
2. When the power factor has reached 75%, the main control valve
(MGCV) is opened to a pre-set position. At the same time, the pilot burner
regulator (PGCV) is also closed to a pre-set position (see also the time
diagram).
3. Once this switching procedure is complete, the control valves of the

pilot burner (PGCV) and the main burner (MGCV) are maintained at their
respective pre-set positions. These positions are pre-set in accordance
with the power factor.
4. When the power factor has reached 80%, the supplementary burner
starts. The regulator is kept in a position, which is prescribed by the last
factor.
5. When the power factor has reached 90%, the shut-down valve at the
exit closes the pilot gas supply pipes (PGSP). As a result, a small amount
of fuel flows from the main fuel supply over the shut-off valve and on to the
pilot burner. This is how combustion in DLE operating can be kept stable.
6. When the power factor has reached 80%, the DLE operating mode is
automatically established.
Document 1 Page 78 of 208 11.02.2010

B. With reducing load
1. When the power factor falls below 88%, the shut-off valve at the supply
pipe completely opens for the pilot burner (PGSP).
2. When the power factor falls below 77%, the control valve closes for the
supplementary burner (SGCV).
3. When the power factor falls below 72%, the control valve of the pilot
burner (PGCV) opens completely. At the same time, the control valve of
the main burner (MGCV) completely closes.
4. If the power factor is equal to (or less than) the aforementioned value,
fuel is only supplied to the pilot burner.
Document 1 Page 79 of 208 11.02.2010

Manual

GPB80DD
VOLUME 6
(Start-, Purge-, Turn-, Ignition-, BLEED-, VSV-, Seal-Air-, and Drain-system)

Date 01.12.2012
Name O. Frieling

Tel. +49 6172 7363-0
Fax +49 6172 7363-55
Document 1 Page 80 of 208 11.02.2010

C.9 Starter motor, purge and turn system
Description
Starter system
General
The role of the starter, purge and turn motor is to turn the turbine for 48 hours
after shut-down, in order to ensure even cooling of the turbine components. In
this way, bending of the blades from its own weight and resulting rotor grinding
on the stator is avoided. The operation of the starter, purge and turn motor is
monitored and controlled by the gas turbine control system.
The starter system consists of a three-phase asynchronous motor, which is

flange mounted to the gear housing, and a frequency converter, which is in the
control room. It is monitored and controlled by the Engine Controller. The
torque of the starter motor is transferred over the gear to the turbine, so that
they start turning. Once the turbine has reached a nominal speed of 65%, the
starter motor is mechanically decoupled from the gear, using a synchro self-
shifting clutch, and is simultaneously electrically switched off over a shut-down
signal from the control system..
The converter supplies the motor with the variable frequency necessary for
this case. The motor is operated in a closed loop, in order to also bring the
required torque at zero speed. This also enables stable operation with
maximum torque.
The output part of the converter has the classic configuration: network-side
rectifier diode bridge, voltage and current equalisation and IGBT-inverter as a
6-pulse bridge. In addition there are the control circuits. In the engine control,
the DCT technology (direct torque control) is used, in order to ensure low-loss
and stable control.
Document 1 Page 81 of 208 11.02.2010

Starter motor specification
Motor data:
Output 220kW (operating S2: 20 min)

Nominal speed 1,790 1/min
Input voltage 400 V
Thermal class F (used as F)
Protection level IP 55
Weight 1,000 kg
PTC resistor 1 pc per stator phase
Frequency converter data
Output Nominal output 250 kW

Input voltage 380.....415 V 10 %
Short circuit capacity 50 kA/s
Power factor 0.93... 0.95
Efficiency >= 98% at nominal output
Nominal output current max. 500 A (at constant counter-torque)
Frequency control 0.....300 Hz
Control cabinet type Rittal
Protection class IP 21
Coating RAL 7032
Dimensions 2000 x 800 x 600 mm (H x B x T)
Weight approx. 400 kg
Starter purge and turn motor
Purge: The term Purge indicates the procedure before the actual start of
the turbine. The turbine is hereby accelerated to a speed of approx.
25% of the nominal speed. This procedure enables the machine and
connected exhaust gas duct to be freed from gaseous fuel remains.
It also enables the machine to be checked for vibrations before start-
up.
Turning: The role of Turning is to slowly rotate the turbine, for example, one
hour in front of the entire start of the turbine, and for approx..48
hours after shut-down, in order to ensure even cooling of the turbine
components. In this way, bending of the shaft / blades from its own
weight and resulting rotor grinding on the stator is avoided. The
operation of the starter/turning motor is monitored and controlled by
the gas turbine control system.
Document 1 Page 82 of 208 11.02.2010

C.10 Ignition system
Description
CAUTION
The ignition plugs may only be switched on when the ignition cables are
securely fastened in their plugs!
General
This system consists of two electronic ignition triggers with high-voltage calbes
and 2 ignition plugs in each of the two combustion chambers. When the
turbine speed has reached about 5 to 8% of nominal speed, the ignition
impulse is initially transferred to two ignition plugs. The air/fuel mixture is
sparked in the combustion chamber and the flames are carried to the other
combustion chambers over the flame tubes.
When the turbine speed has reached 25% of the nominal speed, the ignition
trigger voltage is switched off and combustion runs independently.
The ignition signal is controlled and monitored by the turbine control system.
Ignition system specification
Ignition trigger Type: Condenser discharging impulse
Nominal data 24 VDC, 1 A

Ignition plugs Type: NGK spark plug
Type GL-501-2
(P/N 00-840-570-02)
Isolation 100 M
resistance
Installation:
The ignition trigger can be installed at a customer-preferred "cold" position, but

the ignition cable should be kept as short as possible.
Document 1 Page 83 of 208 11.02.2010

C.11 Bleed Air Ventil / VSV Control System
Description
DLE Bleed
General
This regulator controls the flow of compressed air pressure from the turbine
main house to the exhaust gas pipe. The measure enables "compressor
pumps" to be avoided during start-up of the turbine. See system diagram (next
page)
Specification
The following table summarises the specification.
Type: Flap valve, from Nippon Keystone Corp.

Nominal 150 mm
diameter
Discharge air Nominal pressure 1.6 MPa
pressure
Electrical data 100 VAC, 50/60Hz (AC)
Nominal pressure 1.55 A / 1.72 A
Control signal 4 mA DC for flap completely closed
20 mA DC for flap completely open
The signals come from the Engine Controller
Document 1 Page 84 of 208 11.02.2010

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

pressure. The measure serves to drive the increasing compression pressure
during the start-up procedure to the exhaust gas pipe, thereby relieving the
starter motor.
At the beginning of the start-up, the valve is completely opened and is slowly
closed when there is increasing speed.
At 70% rpm, the start-bleed valve is completely closed.
Specification
The following table summarises the specification.
Type: Flap valve, from Nippon Keystone Corp.

Nominal 150 mm
diameter
Discharge air Nominal pressure 1.6 MPa
pressure
Electrical data 100 VAC, 50/60Hz (AC)
Nominal pressure 1.55 A / 1.72 A
Control signal 4 mA DC for flap completely closed
20 mA DC for flap completely open
The signals come from the Engine Controller
Document 1 Page 85 of 208 11.02.2010

System diagram
Document 1 Page 87 of 208 11.02.2010

Installation:
A piping example is portrayed in the following illustration: image 36 shows the

position of the "Bleed-Air" flange on the Power Section.
Start Bleed Air

Valve
Image 36
Installation is carried out in the following steps:
1. The piping from the turbine to the drain valve, and from there to the exhaust
gas pipe is prepared. The drain valve can be installed in any place. The
compressed air outlet flange can be installed in the exhaust gas pipe
without any special positioning requirements.
2. The electrical cable between the Engine Controller and the drain valve are
installed.
3. The drain duct is installed at the lowest point of the pipe, which is connected
to the gas turbine. This drain duct is connected with a drain tank over a
pipe and manual shut-off valve.
Document 1 Page 87 of 208 11.02.2010

VSV control system
General
The variable guide vanes of the compressor consist of the inlet guide vanes,
the guide vanes of the first, second and third compressor stages. The aim of
the VSV control system is to set the inflow angle of the guide vanes so that the
quantitative air flow varies and can be optimised, and also so that "compressor
pumps" can be avoided during start-up of the turbine.
The control system consists of the following components:
1) Differential transformer
2) Electrical cylinder
3) VSV control unit
The VSV control unit is controlled over a signal from the gas turbine control It
activates the cylinder rod. The differential transformer transports the cylinder
movement to the angle of the guide vanes. Its output signal is transferred to
the VSV control unit and to the gas turbine control system.
Specification
The VSV control system specification is summarised in the following table.
Electrical cylinder Type: Thrust: 2,200 N

Actuating speed: 0.55/25 mm
Actuating speed: 50 mm
Power consumption 700 W
Manufacturer: KOSO
Type: 3800-L-500-2-C-P
VSV control unit Type: Elektro- Servo, from REXA
Type: 500-2-C-P
Current 4 - 20 mA (DC)
signal
Document 1 Page 88 of 208 11.02.2010

C.12 Seal Air System
Description
General
The purpose of this system is to prevent lube oil leakages from bearings No. 1
and No. 2 into the compressor and turbine during the start-up procedures. Air
pressure is directed to the lube oil pressure in the bearings side opposite. In
this way, during the start phase, lacking compressor pressure is used to press
on the labyrinth seal.
Document 1 Page 89 of 208 11.02.2010

The details are summarised in the following table.
Turbine speed "Seal-Air" System

(as a percentage
of the nominal
speed)
0 to 25 In this speed range the compressor input pressure is
about the same as the ambient pressure. Seal air is
not required.
25 to 85 In this speed range the compressor pressure is low
and unstable. The external source of compressed air
is therefore used.
85 to 100 Pressure level of the compressed air after the fifth
stage is sufficient for pressing on the seal.
Specification
The specification for seal air is as follows:
Seal air 1) Instrument air, oil-free and filtered

2) Pressure: 0.13 bis 0.14 MPa
3) Volume flow 2,0 Nm3/min instrument air,
4) through a command from the turbine control
centre:
- Solenoid valve open at 25%N85%
- Solenoid valve closed at N25%, or N85%,
where N = turbine speed.
Seal air system components
1. Air pressure shut-off valve

2. Air pressure control valve
Document 1 Page 90 of 208 11.02.2010

C.13 Cleaning system compressor
Description
General
The aim of the compressor cleaning is to maintain a high level of efficiency

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

Cleaning system compressor storage
tank
Image 37
Document 1 Page 91 of 208 11.02.2010

Washing water storage tank
Capacity: approx. 75 litres

Filling: Manual shut-off valve in the supply pipe
Water quality VE water
Washing water driver motor
Output: 0.75 kw
Voltage: 400 VAC 50Hz
Washing water pump
Output 10 litre / min

Pressure level: 1.0 mP
Specification:
Cleaning Specification Mixture of cleaning agent (1 part) and water

fluid (4 parts)
Cleaning agent: ZOK27 or similar
Total volume: Hot wash: (optional)
Cold wash: approx. 19 l per wash procedure
Cleaning Type: Portable pump (KYC-300, from Kyowa)
pump
Nominal 0.3 MPa
pressure 6 l/min
Mass flow 220/110/100 VAC, 0.75 kW
Supply:
Tank for cleaning agent Volume approx. 100 l
Drain tank see section "Drain Tank"
Document 1 Page 92 of 208 11.02.2010

C.14 Drain Tank
Description
To drain off condensation or other liquids in the turbine, a collecting tank is

fastened to the base frame. The outflow is cleaning agent.
The following pipes are necessary for the connections to the collecting tank
and are turned off using a manual shut-off valve.
Pipe Pipe position

No.
1 Suction collector
2 Compressor housing (discharge "seal air")
3 Compressor housing (discharge "turbine cool air")
4 Air discharge, elbow pipe
5 Main housing
6 Lowest combustion chamber (only for liquid fuel)
The tank can be emptied into a collection container using a manual valve.
Document 1 Page 93 of 208 11.02.2010

Manual

GPB80DD
VOLUME 7
(Instrument-Air pressure system)

Date 01.12.2012
Name O. Frieling

Tel. +49 6172 7363-0
Document 1 Page 94 of 208 11.02.2010
Fax +49 6172 7363-55
C.15 Air pressure system
Description
The air pressure system for this gas turbine generator unit is supplied by the
customer, and connected in accordance with the scheme (E3029 080 102)
coordinate G/3, and the following information:
Extract from drawing E3029 080 013
Technical details
Pressure: 10 bar (g)

Air pressure requirement: approx. 4 Nm/min
Air pressure tank Steel, sunk, stationary
Air pressure tank volume: 1,500 litres
Control: none
Document 1 Page 95 of 208 11.02.2010
Document 1 Page 96 of 208 11.02.2010
Manual

GPB80DD
VOLUME 8
(Gas-warning & Fire-extinguishing system)

Date 01.12.2012
Name O. Frieling

Tel. +49 6172 7363-0
Fax +49 6172 7363-55
Document 1 Page 97 of 208 11.02.2010
C.16 Gas warning and fire extinguishing system
Description
The Gas Turbine Generator Unit GPB80D has its own gas warning and fire
detection system.
Gas warning
system
Fire detection
system
Image 38
Gas warning system
The gas warning system consists of 2 gas sensors, which are installed in the
noise enclosure in the area of the gas injection (1 at the front at the gas inlet,
and 1 above the gas supply in the ceiling area).
The evaluation system is installed in the control cabinet.
Both sensors have the following switching thresholds:
20% LFL (LFL = lower flammability limit) pre-alarm

40% LFL (LFL = lower flammability limit) pre-alarm
with shut-down of the gas turbine
and closure of the main gas
valve
Document 1 Page 98 of 208 11.02.2010

In the event of one of the two gas detectors sounding, an alarm message is
triggered if there is a threshold of 20% LFL (lower flammability limit).
If a threshold of 40% LFL is reached, an emergency shut-down of the gas
turbine is initiated. The gas valve inside the noise enclosure is closed and the
gas ventilation opened.
The noise enclosure ventilation remains on, in order to lead the escaped gas
over the sound enclosure ventilation system, out of the sound enclosure and
into the open air.
Further users are switched without voltage.
An optical and acoustic notification of a gas alarm is given by one of the yellow
flashing lights installed at the front exterior wall of the sound enclosure, and by
an alarm sound apparatus installed int he same place.
Image 39
Example
2. Gas sensor 1. Gas sensor
Image 40 Image 41
Example Example
3. Gas sensor
Image 41.1
Example
Document 1 Page 99 of 208 11.02.2010
Fire detection and extinguishing system
The fire detection unit consists of 2 automatic fire detectors, which are installed
above the gas turbine combustion chamber, and 2 manual triggers, which are
installed at the front and back of the gas turbine generator unit.
The evaluation system is installed in the control cabinet.
Both automatic sensors are temperature-dependent sensors.

At the end of the sensors, there is a glass ball, which breaks at 110C and
releases a pre-stressed spring, which then closes contact.
If one of the two fire detector sounds, an emergency shut-down of the gas
turbine is initiated at the same time as the alarm.
The gas valve inside the noise enclosure is closed and the gas ventilation
opened. The noise enclosure ventilation system is switched off, the channel
flaps closed, and the noise enclosure is flooded with CO2.
Manual triggering of this procedure is also possible by pressing one of the two
manual trigger buttons which are installed in the noise enclosure.
An optical and acoustic notification of a fire alarm is given by one of the flashing
red lights installed on the exterior wall of the gas turbine control system, and by
an alarm sound.
Image 43.1
Image 42 Image 43.2
Example Example
Example
Fire alarm Nr 1
& Nr. 2
Trigger point:
110C
Document 1 Page 100 of 208 11.02.2010

CO2 Cylinders
Fire extinguishing units,
installed next to the booth under the filter house.
(example installation only)
CO2 Cylinders
(shortage monitoring)
Trigger solenoid valve
3 pieces CO2 cylinders
Image 44
Example
Document 1 Page 101 of 208 11.02.2010

Manual

GPB80DD
VOLUME 9
(Sound enclosure, filter-house, gas-turbine controls container, cooling-air & exhaust-
gas system )

Date 01.12.2012
Name O. Frieling

Tel. +49 6172 7363-0
Fax +49 6172 7363-55
Document 1 Page 102 of 208 11.02.2010
C.17 Noise enclosure, filter house gas turbine control, air duct, cooling air,
combustion air, exhaust gas system
Description
Noise enclosure
with 16 doors and 12 windows, contains
Base frame with installed gas turbine, gear, generator and all supply and
control systems
Ventilation with flaps
Monitoring system for gas leakages and fire
Filter house Sound -

Enclosure
Image 45
Example
Document 1 Page 103 of 208 11.02.2010

Filter house
Filter house with platform, contains (details can be found in the manufacturer
and supplier documentation):
Weather protection grid with bird screen
Filter of the filter stages 1 (combustion air) and 2 (cooling air)
Coalescer-Filter stage 1: Rough filter of grade G2

Filter stage 2: Pre-filter of grade G4
Filter of filter stages 3 and 4 (only for combustion air)
Filter stage 3: Fine filter of grade F7

Filter stage 4: Hepa-filter of grade H10
Cool air inlet channel with sound absorber
(bottom 1/3, front of filter house)
Combustion air channel to the gas turbine with sound absorber (the upper
2/3 of the filter house front)
Platform with steps (outside)
External crane for lifting the filter cassettes during maintenance.
Gas turbine control system
From installation on, the gas turbine control system is described in the
manufacturers documents; the functions are described under "Electrical Control
Systems".
Air ducts
Air ducts inside and outside the building, which are responsible for air (supply,
exhaust) will be supported by the ventilators.
A detailed description of this component can be found in the manufacturer's
documentation.
Document 1 Page 104 of 208 11.02.2010

Cooling air system
If the turbine generator unit is placed in a closed room, it is important that the
heat loss radiation does not lead to too high temperatures inside.
The thermal output values, which are transferred to the housing surfaces via
radiation are as follows:
for the gas turbine: approx. 48 kW

for the gear: approx. 3 kW
for the generator: approx. 100 kW
To keep the internal temperature to acceptable levels, a cool air system is

planned in. As described above, it consists of electrically operated ventilators,
filters and sound absorbers.
The nominal volume flow of a cooling fan is designed so that the air
temperature inside the noise enclosure remains under 70C (at max. 35C
intake air temperature).
Dimensioning: 2 x 100%
Volume flow supply air: 2 x 25,000 m/h
Volume flow exhaust air: 2 x 27,000 m/h
Combustion- Cooling-Air
and Cooling- Outlet-Duct
Air Inlet Duct
Image 47 Image 47
Example Example
Document 1 Page 105 of 208 11.02.2010

Combustion air
The gas turbine generator unit has an air inlet

In this air inlet housing, which is protected against weather and birds, the first
two filter levels of class G2 droplet separator (coalescer) and G4 (pre-filter) are
installed.
Using an air duct, all the air, cool air to the package and combustion air is then
directed to the gas turbine over separate sound absorbers in the actual filter
house above the package.
The two main filter stages for the combustion air are in the filter house - F7 (fine
filter) and H10 (Hepa-filter). Using these filters, the combustion air required for
operating the gas turbine is cleaned.
The combustion air reaches the gas turbine over a connected redirection with
flow metal sheets, via a connected sound absorber, a transmission channel and
expansion joint.
The cool air for the package is blown out of the air ducts, without further
filtering, directly into the sound enclosure, through two ventilators which are
installed in two separate areas of the filter house. It is then drawn in again by
two ventilators located on the opposite side.
On the exhaust gas side, the gas turbine is connected, via the exhaust gas
expansion joint and the exhaust gas pipe, with the exhaust gas flange which is
installed on the sound enclosure.
Pressure loss
The specific values of suction loss are described in the following section.
Suction pressure loss indicates the difference between the ambient pressure
and the pressure at the upper air inlet of the turbine.
This difference must be under 20 mbar.
Exhaust gas back pressure indicates the difference between the pressure at the
exhaust gas flange of the turbine and the ambient pressure.
This difference must be under 40 mbar.
These differences in pressure reduce the turbine output and can lead to
damage to the turbine when exceeded. They are therefore important criteria
when designing gas turbine generator units. Furthermore, when the suction
pressure loss exceeds the design values, countermeasures must be taken (e.g.
exchange the filter).
Document 1 Page 106 of 208 11.02.2010

CAUTION
The combustion air of the gas turbine must be completely free of foreign objects
so that the compressor and turbine blades are not damaged.
CAUTION
In addition, the air flow must be consistent. Turbulence in the air flow can lead
to flow separation and "compressor pumps".
Installation of the combustion air system
1. Common air inlet duct in the external wall with weather protection blinds
and bird screen for combustion and cool air.
2. 2-stage pre-filter consisting of G2, Coalescer and G4 Filter
3. Separate air ducts for combustion air and cooling air
4. Sound absorbers in the combustion and cooling air ducts
5. Main filter with F7 and H10 (Hepa-Filter) for combustion air
6. Transition duct to the air inlet in the turbine housing
7. Expansion joint to the decoupling
8. Suction chamber with Bellmouth (as part of the Power Section)
Permitted load for air entry in the turbine housing
Each component of the suction system component is to be laid out so that it

does not transfer its own weight on to the suction chamber of the turbine.
The suction chamber is designed for the following maximum allowed load
values:
vertical: 686 N
horizontal: 0N
Document 1 Page 107 of 208 11.02.2010

Combustion air filter
The ambient conditions largely depend on the installation site of the turbine, but
it must always be ensured that the pre-combustion air is free from foreign
objects and corrosive material.
The following measures are intended in this regard:
1. Intake port for external air: Here a safety measure in the form of a weather
protection grill with a bird screen is provided.
There is an air velocity of 2.8 m/s inside the weather protection grill and bird
screen.
2. The actual fine filtration of air into combustion air for the gas turbine takes
place in the "filter house". The load limit of the filter is typically approx.
3.300 m/h. The lower the inflow, the longer the downtime of the individual
filters and the risk of icing.
The following table summarises the filter specification.
Efficiency >99.97% at 0,3 with the DOP method

in accordance with the standard MIL-STD-282
Pressure loss Starting conditions: approx. 500 Pascal, or less
Limit for exchange
Filter 1 (PDT 3122) approx. 300 Pascal
Filter 2 (PDT 3104) approx. 800 Pascal
Filter 1+2 (PDT 3126) approx. 1200 Pascal
Recommended values. Dependent on the filter strength

and the previous system in terms of pressure loss.
Document 1 Page 108 of 208 11.02.2010

Exhaust gas system
Exhaust gas
system
CAUTION Image 46
Example
The exhaust gas has a high temperature (over 500 C). Relevant measures for
thermal isolation and expansion compensation must be taken, e.g. with the
connection to the Power Section.
Installation of the exhaust gas system
1. Gas turbine diffuser (as part of the Power Section).

2. Bellow expansion joint (before handing over to the customer exhaust gas
duct)
3. Exhaust gas pipe as connection to the noise enclosure
4. Further exhaust gas pipes and flaps
(customer side)
5. Thermal insulation
6. Exhaust gas sound absorber (customer side)
7. Thermal recovery system (e.g. an exhaust heat vapour vessel, customer
side).
Document 1 Page 109 of 208 11.02.2010

The exhaust gas expansion joint serves as an interconnection between the
exhaust gas diffuser of the tas turbine and the exhaust gas duct integrated in
the noise enclosure. It takes on approx. 10.2 mm of the thermal expansion of
the gas turbine between cold status and full load operation. To protect the
exhaust gas compensator against accidental contact, it is installed inside the
noise enclosure with an isolation.
Permitted forces on the exhaust gas diffuser
The components of the exhaust gas system are to be arranged so that they do
not transfer their own weight on to the exhaust gas diffuser of the turbine.
The exhaust gas diffuser is designed for the following maximum allowed load
values:
vertical: 2,900 N
horizontal: 1471 N
CAUTION
The exhaust gas flange at the customer must be connected with absolutely no
load.
Document 1 Page 110 of 208 11.02.2010

Manual

GPB80DD
VOLUME 10

Date 01.12.2012
Name O. Frieling

Tel. +49 6172 7363-0
Fax +49 6172 7363-55
Document 1 Page 111 of 208 11.02.2010

Electrical control system
Description
Gas turbine control, includes
in the model with individual control cabinets, or as a control cabinet connected

with the sound enclosure:
Control cabinets with power supply, security and all necessary switching
devices
Control system for the Gas Turbine Generator Unit GBP80D
Visualisation system
Frequency converter for the start, purge and turn motor
Gas warning and fire detecting unit
Air conditioning unit UPS to buffer the control system.
Batteries for the ELOP (Emergency Lube Oil Pump), which are located in
the battery cupboard
Turbine control Turbine control 400 VAC power feed

Control cabinet +1U01, Control cabinet +1U01, and distribution +1N01
Document 1 Page 112 of 208 11.02.2010
Image 48
Example
All security devices, switching, monitoring and control devices necessary for
operating the gas turbine generator control unit, as well as the visualisation are
built into the control cabinet.
The most important operating and monitoring systems are in the control
cupboard opposite the entry door of the electrical switching house.
These three control cupboards are assembled and fulfil the following individual
functions (list from left to right):
+1U01 Turbine control Field 1
+1U01 Turbine control Field 2
+1N03 400VAC feeding and distribution
Operating hours
counter gear box +
gas turbine
Network (customer side)

and generator guard
Synchronisation device
Overspeed monitoring
Vibration monitoring gear
Image 49
Example
Document 1 Page 113 of 208 11.02.2010
Turbine control Field 2, +1U01
Buzzer
Failure Shut-down
GT-start
GT - speed counter
GT exhaust
gas
temperatur
e
GT - peak load
counter
Image 50
WINNCC
touchscreen
Control panel
Release turbine
PP17 II
Manual EMERGENCY
Synchronisation SHUT-DOWN
Wash turbine Control

location - remote
Automatic Failure
Synchronisation Acknowledgement
Synchronisation Lamp test

Hand - Automatic
Synchronisation Acknowledgement
Geno network beep
Image
51
Document 1 Page 114 of 208 11.02.2010
Turbine control Field 3, 400 VAC - Feeding field, +1N01
Shows voltage and power

of battery system
Shows charging current

of battery system
Shows 400,VAC network

and auxiliary power
requirement
Selector switch for volt

meter
Image 52
Example
CAUTION
As a general rule, full load drops over the 60kV switch are to be reported
to KAWASAKI Gas Turbine Europe!
Document 1 Page 115 of 208 11.02.2010

INHALTSVERZEICHNIS DER GASTURBINENSTEUERUNG
1.) bersicht ber das Automatisierungssystem: 77
2.) Bedeutung der Farbanzeigen der Flchen LEDs des Tastenfeldes: 80
2.1) Hilfsantriebe (LED 1-9): 80
2.2) Zu- / Abluftjalousie 1+2 (LED 10+11): 80
2.3) Kesselklappe (LED 12): 80
2.4) Bypassklappe (LED 13): 81
2.5) Gasventil-berwachung Startfreigabe (LED 14): 81
2.6) Reserve (LED 15): 81
2.7) Gasventil (LED 16): 81
2.8) Starter schneller (LED 17): 81
2.9) Starter langsamer (LED 18): 81
2.10) Starter Hand / Automatik (LED 19): 81
2.11) Hilfsantriebe Hand / Automatik (LED 20): 82
2.12) Insel / Netzparallelbetrieb (LED 21): 82
2.13) Gasventilberwachung (LED 22): 82
2.14) Reserve (LED 23): 82
2.15) Reserve (LED 24): 82
2.16) Spannung / Drehzahl hher (LED 25): 82
2.17) Spannung / Drehzahl niedriger (LED 26): 83
2.18) Verstellung Spannung / Drehzahl (LED 27): 83
2.19) Generatorschalter EIN (LED 28): 83
2.20) Generatorschalter AUS (LED 29): 83
2.21) Turbine Start (LED 30): 84
2.22) Turbine Purgen (LED 31): 84
2.23) Turbine Stop (LED 32): 84
3.) Handfunktion Hilfsantriebe ber das Tastenfeld: 85
4.) Serviceschnittstelle der Turbine in WINCC: 88
4.1) Parameterverstellung DB11 + DB15: 88
4.2) Ansteuerung der Ventile: 89
4.3) Rcksetzen der Sperren des Turnsystems: 90
4.4) Sonderbetriebsarten: 91
4.5) Verstellung von Einstellwerten ausserhalb des DB11 + DB15: 91
5.) Handbetrieb Starter: 92
6.) Verstellungen der Hilfsantriebe bei Gasalarm Stop: 93
7.) Verstellung der Hilfsantriebe bei Feueralerm Stop: 94
8.) Gasverdichter: nicht vorhanden! 95
9.) Automatikfunktion der Ventilatoren: 95
10.) Purgen im Automatikbetrieb: 96
11.) Turbine Start: 97
12.) Grundstzliches zur Benutzung der beiden Synchronisierstellen: 99
13.) Handsynchronisierung Generatorschalter: 99
14.) Automatiksynchronisierung Generatorschalter: 100
15.) Handsynchronisierung Netzschalter: 101
16.) Automatiksynchronisierung Netzschalter: 102
17.) Sonderfunktion Rckspeisung auf die schwarze Fabrikinsel: 102
18.) Turbine Stop: 103
19.) Automatischer Turnmodus: 104
20.) Einstellung des Reglermodus bei Netzparallelbetrieb: 105
Document 1 Page 116 of 208 11.02.2010
21.) Automatischer cos-phi Steller: 106
22.) Stndererdschlussschutz Generator und Schaltung Erdwiderstand: 106
23.) Inselbetrieb: 108
24.) Bilderbaum WINCC: 109
25.) Bilder WINCC: 110
25.1) Startbild mit Hauptmen: 110
25.2) Meldearchiv: 110
25.3) Startbild mit Untermen: 110
25.4) Bild Allgemein: 111
25.5) Bild Luftsystem: 111
25.6) Bild Treibstoff: 112
25.7) Bild Schmierl: 113
25.8) Bild ltemperatur: 113
25.9) Bild Generator: 114
25.10) Bild Regler: 114
25.11) Bild Reglermodus: 115
25.12) Unterbild Synchronisierung Turbine: 115
25.13) Bild Vibrationsmessung: 116
25.14) Startbild mit Untermen 2 (Kurven): 116
25.15) Kurvenbild Abgas (als Beispiel): 117
25.16) Startbild mit Untermen 3 (Kurven 2): 117
25.17) Kurvenbild Ventile (als Beispiel): 118
26.) Datenschnittstelle S7 <-> WINCC: 118
27.) Datenschnittstelle S7-315F <-> S7: 118
28.) Einstellwerte (nur Servicepersonal): 118
Document 1 Page 117 of 208 11.02.2010

1.) bersicht ber das Automatisierungssystem:
PC677 Touch 15
- Meldesystem und Meldearchiv ISDN-Modem
- Prozessbilder
- Kurvendarstellung und Archive
- Serviceschnittstelle Ind.Ethernet
CPU S7-412-2DP MPI KAWASAKI Service Center

Bad Homburg
-Zentrale Steuereinheit L2-Bus
CP441-1 Ind.Ethernet
- Ind. Ethernet zu WINCC Leit-

technik
Kunde
CP441-1 Ind.Ethernet
PP17II
- Ind. Ethernet zur Kundenleittech.
- 32 frei programmierbare Taster /
Meldelampen
E/A-EBENE
- Digitale Ein - und Ausgnge
- Analoge Ein - und Ausgnge ET200S/L
- Signalschnittstelle Turbine
FM458
Schneller Rechner fr die
Drehzahlregelung der Turbine SYNAMICS (Umrichter Starter)
- Signalschnittstelle Umrichter
E/A-EBENE REGLER
- Digitale Ein - und Ausgnge SIPROTEC (Generatorschutz)
- Analoge Ein - und Ausgnge - Signalschnittstelle Generatorschutz
S7-315F (CPU) Zhlerbaugruppe

Steuerung fr sicherheitsrelevante Drehzahlsignal 4 Kupplung
Programmteile
Sicherheitsgerichtete E/A-
EBENE
- Digitale Ein - und Ausgnge
- Analoge Ein - und Ausgnge
Document 1 Page 118 of 208 11.02.2010

Dieses Symbol warnt vor Gefahren, die zu Verletzungen von Personen, auch mit
tdlichen Folgen, und / oder zu Schden an der Maschine und ihrer Steuerung fhren
knnen.
Vor der Inbetriebsetzung der Anlage oder der Ausfhrung von Reinigungs-, Service
oder Instandsetzungsarbeiten an der Steuerung oder der Maschine muss diese
Beschreibung gelesen werden.
Achtung: Alle Arbeiten an der Maschine und der Steuerung drfen nur durch
qualifiziertes und eingewiesenes Personal ausgefhrt werden. Insbesondere drfen
Arbeiten an der elektrischen Ausrstung nur durch Elektrofachkrfte ausgefhrt
werden.
Achtung: Bei allen Arbeiten an, bzw. im Bereich von drehenden Teilen der Turbine
im Innen- und Auenbereich, sowie bei Arbeiten im Zu- und Abluftsystem der Turbine,
muss die Maschine stillgesetzt und der Einspeisetrenner des Starterfeldes geffnet
und gegen Wiedereinschalten gesichert werden.
Das Ausschalten ber die Softwaretaster ist kein Schutz vor gefhrlichen
Betriebszustnden.
Der Startermotor / Turnmotor wird ber eine speicherprogrammierbare Steuerung
direkt ein und ausgeschaltet.
Auch im fehlerfreien Betrieb kann es, je nach Betriebsweise, zum zyklischen Ansteuern des
Starters ber das Automatikprogramm kommen.
Achtung: Bei allen Arbeiten am VSV (Schaufelverstellung) der Turbine, muss die
Maschine stillgesetzt und die Stromversorgung der beiden Treiberboxen der VSV-
Antriebe mit den zugehrigen Sicherungen ausgeschaltet und gegen
Wiedereinschalten gesichert werden.
Massive Quetschgefahr !
Document 1 Page 119 of 208 11.02.2010
Achtung: Der Anlagen Not-Aus wirkt nur auf die Gashauptventile, den
Gaskompressor und den Starter / Turnmotor.
Alle anderen Hilfsantriebe knnen nicht ber Not-Aus gestoppt werden.
Deshalb mssen vor dem Entfernen von mechanischen Schutzeinrichtungen (z.B.
Schutzgitter Haubenventilatoren), bzw. vor dem ffnen von Rohrleitungen, die
Antriebe ber die zugehrigen Motorschutzschalter abgeschaltet und gegen
Wiedereinschalten gesichert werden.
Auch im fehlerfreien Betrieb kann es je nach Betriebsweise zum zyklischen Ansteuern der
Antriebe ber das Automatikprogramm kommen!
Achtung: Zum Freischalten der Schaltanlage reicht es nicht den 400V-Einspeisetrenner

im Feld +1N01 zu ziehen!
Die gesamte Steuerung wird von einer 24V-Batterie gespeist, die sich unter den
Bodenplatten des Schaltraumes befindet. Die Batterie lsst sich ebenfalls im Feld
+1N01 freischalten.
Einige wenige Verbraucher werden zustzlich ber eine 230V AC USV versorgt
und mssen separat freigeschaltet werden.
Zustzlich muss beachtet werden, das Steuerleitungen der
Mittelspannungsanlage 110V DC weiterhin unter Spannung stehen. Ebenfalls unter
Spannung stehen die Messkreise, die an externen Spannungswandlern angeschlossen
sind.
Document 1 Page 120 of 208 11.02.2010

2.) Bedeutung der Farbanzeigen der Flchen LED`s des Tastenfeldes:
Taste:8 Taste:7 Taste:6 Taste:5 Taste:4 Taste:3 Taste:2 Taste:1

Turnmotor AC DC Hauben- Haubenventil Haubenventil Haubenventil
Vor/Nach- Vor/Nach- ventilator ator ator ator
schmierpum schmier- Zuluft 1 Zuluft 2 Abluft 1 Abluft 2
pe pumpe

Gasventile Gasventil- Bypass- Kessel- Zu / Abluft- Zu / Abluft- Oeldunst-
berwach. klappe klappe jalousie 1 jalousie 2 abscheider
Startfreigabe
auf / zu zu / auf auf / zu auf / zu
Gasventil- Insel/ Hilfsantriebe Starter Starter Starterschn
berwachun Netzparallel- Hand / langsamer eller
g
betrieb Automatik
Turbine Purgen Turbine Generatorsc Generatorsc Verstellung Spannung / Spannung /
Stop Start halter halter Spannung / Drehzahl Drehzahl
Aus Ein Drehzahl tiefer hher
2.1) Hilfsantriebe (LED 1-9):
LED Grau Antrieb ist ausgeschaltet

LED Grn Antrieb ist eingeschaltet
LED Rot Antrieb ist gestrt
2.2) Zu- / Abluftjalousie 1+2 (LED 10+11):
LED Grau Klappe verfhrt

LED Grn Klappe ist geffnet
LED Gelb Klappe ist geschlossen
2.3) Kesselklappe (LED 12):
LED gelb Kesselklappe ist geffnet

LED Grn Kesselklappe ist geschlossen (Startbedingung)
2.4) Bypassklappe (LED 13):
LED gelb Bypassklappe ist geschlossen

LED Grn Bypassklappe ist geffnet (Startbedingung)
Document 1 Page 121 of 208 11.02.2010

2.5) Gasventil-berwachung Startfreigabe (LED 14):
LED Grau Keine Startfreigabe durch Gasdichtheitskontrollsystem

LED Grn Startfreigabe durch Gasdichtheitskontrollsystem
2.6) Reserve (LED 15):
2.7) Gasventile (LED 16):
LED Grau Ventile geschlossen

LED Grn Ventile offen
LED Rot Ventile gestrt
2.8) Starter schneller (LED 17):
LED Grau Taster 19 (Starter Ein/Aus) in Stellung Aus oder maximale

Drehzahl erreicht.
LED Grn Drehzahl in Richtung maximaler Drehzahl verstellbar.
2.9) Starter langsamer (LED 18):
LED Grau Taster 19 (Starter Ein/Aus) in Stellung Aus oder minimale

Drehzahl erreicht.
LED Grn Drehzahl in Richtung minimaler Drehzahl verstellbar.
2.10) Starter Hand / Automatik (LED 19):
LED Grau Antrieb ist ausgeschaltet

LED Grn Antrieb ist eingeschaltet
LED Rot Antrieb ist gestrt oder nicht freigegeben
Achtung: Da der Umrichter bei stehenden Motor bereits einen hohen Strom
durch den Motor treibt, sollte mglichst schnell die Drehzahl aus
dem Stillstand heraus erhht werden (Bereits 0,1% Drehzahl reicht
aus).
2.11) Hilfsantriebe Hand / Automatik (LED 20):
LED Grau Hilfsantriebe im Modus Automatik

LED Grn Hilfsbetriebe im Modus Hand
Document 1 Page 122 of 208 11.02.2010

Der Handbetrieb ist nur unter bestimmten Bedingungen mglich (siehe zustzlichen
Punkt der Beschreibung)
2.12) Insel / Netzparallelbetrieb (LED 21):
LED Grau Der Generatorschalter ist offen

LED Grn Der Generator wird im Modus Netzparallelbetrieb gefahren
LED Gelb Der Generator wird im Modus Inselbetrieb gefahren
2.13) Gasventilberwachung (LED 22):
LED Grau Gasdichtheitskontrollsystem ist gesperrt

LED Grn Gasdichtheitskontrollsystem ist freigegeben
2.16) Spannung / Drehzahl hher (LED 25):
LED Grau Verstellung nicht mglich

LED Grn Bei offenen Leistungsschalter -> Verstellung der Drehzahl in
Richtung hher mglich // Bei geschlossenem Leistungsschalter
und Leistungsregelung in der Betriebsart Hand -> Verstellung
der Leistung in Richtung hher mglich // Bei geschlossenem
Leistungsschalter und Inselbetrieb -> Verstellung der Frequenz in
Richtung hher mglich.
LED Gelb Bei offenen Leistungsschalter -> Verstellung der Spannung in
Richtung hher mglich // Bei geschlossenem Leistungsschalter
und Inselbetrieb -> Verstellung der Spannung in Richtung hher
mglich // Bei geschlossenen Leistungsschaltern und
Netzparallelbetrieb -> Verstellung des cos in Richtung 0,8 ind.
Caution: When the automatic cos control is running (see also 2.21), the
buttons in the cos-phi settings of the regulator are overridden.
2.17) Spannung / Drehzahl niedriger (LED 26):
LED Grau Verstellung nicht mglich

LED Grn Bei offenen Leistungsschalter -> Verstellung der Drehzahl in
Richtung niedriger mglich // Bei geschlossenem
Leistungsschalter und Leistungsregelung in der Betriebsart Hand
-> Verstellung der Leistung in Richtung niedriger mglich // Bei
Document 1 Page 123 of 208 11.02.2010
geschlossenem Leistungsschalter und Inselbetrieb -> Verstellung
der Frequenz in Richtung niedriger mglich.
LED Gelb Bei offenen Leistungsschalter -> Verstellung der Spannung in

Richtung niedriger mglich // Bei geschlossenem
Leistungsschalter und Inselbetrieb -> Verstellung der Spannung in
Richtung niedriger mglich // Bei Geschlossenen
Leistungsschaltern und Netzparallelbetrieb -> Verstellung des cos
in Richtung 1.
Achtung: When the automatic cos control is running (see also 2.21), the
buttons in the cos-phi settings of the regulator are overridden.
2.18) Verstellung Spannung / Drehzahl (LED 27):
LED Grn Verstellung der Drehzahl ber die Tasten 25 und 26

LED Gelb Verstellung der Spannung ber die Tasten 25 und 26
2.19) Generatorschalter EIN (LED 28):
LED Grau Leistungsschalter ist ausgeschaltet

LED Grn Leistungsschalter ist eingeschaltet
2.20) Generatorschalter AUS (LED 29):
LED Grau Leistungsschalter ist eingeschaltet

LED Rot Leistungsschalter ist ausgeschaltet
2.21) Turbine Start (LED 30):
LED Grau Turbine startbereit

LED Grn blinkend Turbine started
LED Grn Turbine luft
LED Rot Turbine nicht startbereit
2.22) Turbine Purgen (LED 31):
LED Grau Bereit zum Purgen

LED Grn Starter ist eingeschaltet
LED Rot Nicht bereit zum Purgen
2.23) Turbine Stop (LED 32):
Document 1 Page 124 of 208 11.02.2010

LED Grau Turbine klar zum stoppen
LED Rot blinkend Turbine stopped
LED Rot Turbine steht
3.) Handfunktion Hilfsantriebe ber das Tastenfeld:
Achtung: Jegliches Arbeiten an den Hilfsantrieben und den Klappen ist nur erlaubt, wenn
vorher der zugehrige Motorschutzschalter bzw. die zugehrige Sicherung
ausgeschaltet und gegen Wiedereinschalten gesichert worden ist.
Das Ausschalten ber die Softwaretaster ist kein Schutz vor gefhrlichen
Betriebszustnden.
Die Hilfsantriebe werden ber eine speicherprogrammierbare Steuerung direkt
ein und ausgeschaltet.
Ebenfalls ist zu beachten, das die Zu- und Abluftklappen sowie der
Haubenventilator jederzeit durch das Automatikprogramm geschaltet
werden knnen (siehe Schalthandlungen bei Gasalarm Stop und
Feueralarm Stop) auch wenn Handbetrieb angewhlt ist.
Um bei der Inbetriebnahme bzw. bei Wartungsarbeiten bestimmte Antriebe ein bzw.
ausschalten und einige Klappen auf und zufahren zu knnen, befindet sich auf dem
Tastenfeld die Taste 20 (Hilfsantriebe Hand / Automatik). Ein Umschalten auf die
Handfunktion ist nur mglich, wenn folgende Bedingungen erfllt sind:
Turbine steht
Startprogramm nicht aktiviert
Kein Stop von der Feuerwarnanlage
Kein Stop von der Gaswarnanlage
Turneinrichtung nicht vom Automatikprogramm aktiviert
Sind diese Bedingungen erfllt, kann durch Bettigen der Taste 20 ( Hilfsantriebe Hand /
Automatik ) von Automatik (grn) nach Hand (gelb) umgeschaltet werden.
Achtung: Bei den Signalen Feueralarm Stop und Gasalarm Stop wird
zwangsweise auf Automatik zurckgeschaltet, damit die Zu-/
Abluftklappen und die Haubenventilator entsprechend automatisch
geschaltet werden knnen.
Document 1 Page 125 of 208 11.02.2010

Nun knnen die Hilfsantriebe wie folgt gesteuert werden:
Haubenventilator Abl. 2: Ein-Ausschalten ber die Taste 2 (Haubenventilator Abluft

2). Achtung: Der Haubenventilator Abluft 2 kann nur
eingeschaltet werden, wenn vorher die Zu / Abluftjalousien
2 in Stellung offen gefahren wurden.
Haubenventilator Abl. 1: Ein-Ausschalten ber die Taste 3 (Haubenventilator Abluft

1). Achtung: Der Haubenventilator Abluft 1 kann nur
Haubenventilator Zul. 2: Ein-Ausschalten ber die Taste 4 (Haubenventilator Zul. 2).

Achtung: Der Haubenventilator Zul. 2 kann nur
Haubenventilator Zul. 1: Ein-Ausschalten ber die Taste 5 (Haubenventilator Zul. 1).

Achtung: Der Haubenventilator Zul. 1 kann nur
DC-Vor- /Nachschmierpumpe: Ein-Ausschalten ber die Taste 6 (DC- Vor-/

Nachschmierpumpe).
Die DC-Vor- / Nachschmierpumpe ist kein vollstndiger
Ersatz fr die AC-Vor- / Nachschmierpumpe, da sie nur
das Heilager der Turbine versorgt.
Achtung: Die DC-Vor- / Nachschmierpumpe kann nur
eingeschaltet werden, wenn vorher der ldunstabscheider
eingeschaltet wurde.
AC-Vor- /Nachschmierpumpe: Ein-Ausschalten ber die Taste 7 (AC-Vor-/

Nachschmierpumpe).
Achtung: Die AC-Vor / Nachschmierpumpe kann nur
eingeschaltet werden, wenn vorher der ldunstabscheider
eingeschaltet wurde.
Die AC-Vor/Nachschmierpumpe kann nur ausgeschaltet
werden, wenn vorher der Turnmotor ausgeschaltet wurde.
Turnmotor: Ein-Ausschalten ber die Taste 8 (Turnmotor).

Achtung: Der Turnmotor kann nur eingeschaltet werden,
wenn vorher der ldunstabscheider und die AC-Vor /
Document 1 Page 126 of 208 11.02.2010

Nachschmierpumpe (Mindestlaufzeit 10 sek.) eingeschaltet
worden sind.
ldunstabscheider: Ein-Ausschalten ber die Taste 9 (ldunstabscheider).

Achtung: Der ldunstabscheider kann nur abgeschaltet
werden, wenn vorher Turnmotor und Schmierlpumpe
abgestellt wurden.
Zu / Abluftjalousie 2: Auf-/Zufahren ber die Taste 10 (Zu / Abluftjalousie 2 auf

/zu). Das Auffahren dauert cirka 3 Minuten. Das Zufahren
cirka 10 Sekunden.
Achtung: Die Zu / Abluftjalousie kann nur geschlossen
werden, wenn vorher der Haubenventilator Zul. 2 und Abb.
2 ausgeschaltet wurden.
Zu / Abluftjalousie 1: Auf-/Zufahren ber die Taste 11 (Zu / Abluftjalousie 1 auf

/zu). Das Auffahren dauert cirka 3 Minuten. Das Zufahren
cirka 10 Sekunden.
Achtung: Die Zu / Abluftjalousie kann nur geschlossen
werden, wenn vorher der Haubenventilator Zul. 1 und Abb.
1 ausgeschaltet wurden
Document 1 Page 127 of 208 11.02.2010

4.) Serviceschnittstelle der Turbine in WINCC:
Diese Funktionen sind Mitarbeitern der Firma KAWASAKI vorbehalten. Der Zugang zu
diesen Steuermasken ist Passwortgeschtzt.
Der Zugang erfolgt ber die Bettigung der Softwaretaste Login im Startbild und der
Eingabe des Login und des Passwortes.
Login: XXXXXX (Nur Servicepersonal)

Passwort: XXXXXX (Nur Servicepersonal)
Achtung:
Es erfolgt ein zeitlich unbegrenzter Zugang. Deshalb unbedingt, nach dem Verlassen der
Servicemasken den Zugang durch die Bettigung des Tasters Logout im Startbild
abschalten.
Fehlbedienungen knnen zur Zerstrung der Turbine und zu Personenschaden fhren!
4.1) Parameterverstellung DB11 + DB15:
Es knnen Verstellungen am DB11 (Regler) und am DB15 (Zeiten)

vorgenommen werden. Die dunkelgrau hinterlegten Felder dienen zur
Dateneingabe. Die weien nur zur Anzeige. Grundvorraussetzung fr die
Verstellung ist der Besitz der zugehrigen Schlsselliste, die den Einzelnen
Datenpunkten eine konkrete Funktion zuordnet.
Zum Ansehen der Speicherstelle wird im Block des jeweiligen Datenbausteins

(DB11 / DB15) die Adresse im Datenbaustein im gleichlautenden Eingabefeld
eingegeben. Das System warnt durch ein rotes blinken der Anzeige
Unzulssige Adresse automatisch vor der Anwahl von Zwischenadressen.
ber die Tasten Adresse +x bzw. Adresse x kann man hinter einander
liegende Adressen anwhlen. Bestimmte Speicherstellen, die der
Systemsicherheit dienen, werden dabei automatisch bersprungen. Im Feld
Istwert der Adresse kann nun der momentan eingestellte Wert abgelesen
werden.
Zum Verstellen wird nun im Eingabefeld Sollwert der Adresse ein neuer Wert
eingetragen und dann mit der Softwaretaste Adresse bernehmen bertragen.
Bei Eingaben im Block Zeiten (DB15) sind die angegebenen Restriktionen zu

beachten !
Document 1 Page 128 of 208 11.02.2010

4.2) Ansteuerung der Ventile:
Diese Steuerfunktionen sind nur mglich, wenn folgende Grundbedingungen

erfllt sind:
kein Start angewhlt

kein Stop angewhlt
Schlsselschalter Turbine freigegeben in Position nicht freigegeben
Drehzahl <1%
Hilfsantriebe in der Betriebsart Hand
Kein manueller Not-Stop
Sind diese Bedingungen erfllt, knnen Binre und Analoge Ventile wie folgt
verstellt werden :
- Schalter Handbetrieb Ventile freigeben

- Taster des entsprechenden Ventils bettigen bzw. Sollwert des Ventils
eingeben.
Fr die Hauptgasventile muss zustzlich die Bedingung erfllt sein, das der
Mittelwert der Abgastemperatur kleiner 50C ist.
Document 1 Page 129 of 208 11.02.2010

Vor der Bettigung der Hauptgasventile unbedingt die Gaszuleitung drucklos
machen und ein Wiedereinschalten des Gaskompressors blockieren !
Ist eine der oben genannten Grundbedingungen nicht mehr erfllt, schalten alle
Ventile und Antriebe automatisch wieder aus, bzw. in den vom
Automatikprogramm vorgegebenen Zustand!
4.3) Rcksetzen der Sperren des Turnsystems:
Eine unsachgeme Nutzung dieser Funktion fhrt zwangslufig zur Zerstrung

der Turbine!
Document 1 Page 130 of 208 11.02.2010

4.4) Sonderbetriebsarten:
Durch das Einschalten des Schalters Freigabe Sonderbetriebsarten, wird die

Berechtigung zum Ein-und Ausschalten der Sonderbetriebsarten freigegeben.
Die Funktionen werden dann durch die Bettigung des jeweiligen Ein-
Ausschalters aktiviert.
Umschalten der Regelung des Multiburners auf Inselbetrieb:

Durch die Bettigung des Schalters, kann man fr Servicezwecke den
Multiburner hndisch in die Betriebsart Inselbetrieb umschalten obwohl die
Maschine Netzparallel luft. Die Ventile verfahren dann so, wie sie auch im
echten Inselbetrieb verfahren wrden. Auch die Kennlinien wechseln auf
Inselbetrieb.
4.5) Verstellung von Einstellwerten ausserhalb des DB11 und DB15:
Hier kann man einige ausgewhlte zustzliche Parameter des Systems

verstellen.
Document 1 Page 131 of 208 11.02.2010

Document 1 Page 132 of 208 11.02.2010
5.) Handbetrieb Starter:
Achtung: Vor dem Purgen der Turbine mssen alle Erdungsseile in der
Mittelspannungsanlage entfernt sein, alle Erdungsschalter geffnet sein, der
Leistungsschalter in Betriebsstellung stehen und alle Personen den Gefahrenbereich der
Mittelspannungsanlage verlassen haben. Bereits bei geringen Drehzahlen treten erhebliche
Spannungen durch die Remanenz des Generators auf.
Achtung: Jegliches Arbeiten am Startermotor und dem zugehrigen Umrichter ist nur
erlaubt, wenn vorher der zugehrige NH-Lasttrenner des Starterfeldes geffnet und gegen
Wiedereinschalten gesichert wurde (Wartezeit fr das entladen der Kondensatoren
beachten).
Das Ausschalten ber die Softwaretaster ist kein Schutz vor gefhrlichen Betriebszustnden.
Der Startermotor wird ber eine speicherprogrammierbare Steuerung direkt ein und
ausgeschaltet.
Achtung: Ebenfalls zu beachten sind die Sicherheitsanweisungen des

Umrichterherstellers.
Trotz geffnetem Einspeisetrenners kann noch eine hohe Gleichspannung an einigen Teilen
des Umrichters anliegen (Kondensatoren im Gleichstromzwischenkreis).
Fr die Inbetriebnahme und fr Servicearbeiten gibt es die Mglichkeit den Starter per Hand
zu betreiben. Zu diesem Zweck, wird ber den Taster 19 (Starter) der Starter eingeschaltet.
Dieses ist nur mglich, wenn:
keine Turnanforderung anliegt
keine Startanforderung anliegt
die Drehzahl < 1% ist
die Kesselklappe geschlossen und die Bypassklappe offen ist
der lnebelabscheider eingeschaltet wurde
die AC-Vor / Nachschmierpumpe eingeschaltet wurde
der Turnmotor eingeschaltet wurde
Document 1 Page 133 of 208 11.02.2010

kein relevanter Not-Stop anliegt
Nach dem Bettigen des Tasters wechselt die Farbe von grau nach grn. Ebenfalls grn wird
der Taster 17.
ber den Taster 17 kann die Geschwindigkeit erhht werden, bis die Farbe des Tasters von
grn nach grau wechselt (Grenzwert max erreicht).
ber den Taster 18 kann die Geschwindigkeit gesenkt werden, bis die Farbe des Tasters von
grn nach grau wechselt (Grenzwert min erreicht).
Wird der Taster 19 (Starter) erneut bettigt, schaltet der Starter aus und der Taster wechselt
von grn nach rot . Ein erneutes Einschalten ist erst mglich wenn die Maschine wieder
steht. Der Taster wechselt dann von rot nach grau.
6.) Verstellungen der Hilfsantriebe bei Gasalarm Stop:

Wenn das Signal Gasalarm Stop von der Gaswarnanlage durchgeschaltet wird, werden
folgende Schalthandlungen automatisch durchgefhrt:
1 Umschalten von Handbetrieb in den Automatikbetrieb (falls Handbetrieb

aktiv)
2 ffnen der Zu-und Abluftjalousien 1+2 (falls nicht bereits offen)
3 Not-Stop Turbine (falls diese luft)
4 Einschalten der Haubenventilatoren (Die Einschaltung erfolgt

abweichend vom Normalbetrieb sofort, ohne die komplette ffnung der
Luftklappen abzuwarten).
5 Not-Aus Gasverdichter
Nach dem Rcksetzen des Gasalarm Stop an der Gaswarnanlage und der Turbine (durch
den Taster Stoerungsentriegelung , wird der Haubenventilator ausgeschaltet und die Zu-und
Abluftjalousien geschlossen (falls keine Nachlaufzeit aktiv ist). Danach ist die Anlage wieder
betriebsbereit.
Document 1 Page 134 of 208 11.02.2010

7.) Verstellungen der Hilfsantriebe bei Feueralarm Stop:
Wenn das Signal Feuerarm Stop von der Feuerwarnanlage durchgeschaltet wird, werden
folgende Schalthandlungen automatisch durchgefhrt:
1 Umschalten von Handbetrieb in den Automatikbetrieb (falls Handbetrieb aktiv)
2 Verzgertes (30sek.) Schlieen der Zu- und Abluftjalousien (falls offen) bzw.
kurzzeitiges ffnen der Zu-und Abluftjalousien (falls geschlossen).
3 Not-Stopp Turbine (falls diese luft)
4 Ausschalten der Haubenventilatoren (Falls in Betrieb)
5 Not-Aus Gasverdichter
6 Auslsung der CO2-Lschung (Falls nicht blockiert)
Nach dem Rcksetzen des Feueralarm Stop an der Feuerwarnanlage und der Turbine
(durch den Taster Strungsentriegelung ist die Anlage wieder betriebsbereit.
Achtung: Bei jeder Auslsung der Feuerlschanlage sollte grundstzlich die Feuerwehr
gerufen werden.
Das gesamte Anlagenpersonal muss sofort das direkte Umfeld der Anlage verlassen.
Keinesfalls darf das Personal im Schalthaus der Turbine bleiben, bzw. das Filterhaus oder
sogar das Turbinenpackage betreten.
Es besteht Lebensgefahr durch ersticken!

Eine Freigabe der Anlage darf nur durch die Feuerwehr erfolgen!
Achtung: Die Eindsung von CO2 erfolgt bei Feueralarm, ohne Vorwarnung und
Wartezeit.
Document 1 Page 135 of 208 11.02.2010

Es besteht Lebensgefahr durch ersticken!
Aus diesem Grund muss, vor dem Betreten der Gasturbinenhaube oder des
Filterhauses, die CO2-Lschanlage durch die Bettigung eines Ventils am CO2-
Flaschenschrank blockiert werden.
Abschlieen nicht vergessen!
8.) Gasverdichter: nicht vorhanden!

Wird einer der Not-Aus Taster an der Turbine, den Schaltschrnken oder der Gebude
Not-Aus bettigt oder laufen die Signale Feueralarm Stop / Gasalarm Stop auf,
geht der Gasverdichter ebenfalls in den Not-Stop.
Beim Gaskompressor bedeutet dieser sofortige Stop ohne stufenweise
Druckentlastung, da mehrere Liter Schmierl in das Gas hineingerissen werden.
Nach einem derartigen Not-Stop muss der Gaskompressor mindestens 30

Minuten ohne Gasabnahme betrieben werden, um das l wieder aus dem Gas
heraus zu bringen. Ansonsten wird das Schmierl mit in den Gasfilter und die
Maschine gefrdert, was zu Ausfllen der Maschine fhren kann.
9.) Automatikfunktion der Ventilatoren:

Nach dem Stop der Turbine laufen die Ventilatoren fr eine Stunde nach.
bersteigt nach dem Ausschalten die Temperatur in der Haube 35C starten die
Ventilatoren erneut fr eine Stunde.
Document 1 Page 136 of 208 11.02.2010

10.) Purgen im Automatikbetrieb:
Achtung: Vor dem Purgen der Turbine mssen alle Erdungsseile in der
Mittelspannungsanlage verlassen haben. Bereits bei geringen Drehzahlen treten erhebliche
Spannungen durch die Remanenz des Generators auf.
Achtung: Beim manuellen Purgen mssen unbedingt die Schwingungen beobachtet

werden. Bei ungewhnlich hohen Schwingungen oder ungewhnlichen Geruschen muss
der Purgevorgang sofort unterbrochen werden.
Ein erneutes purgen ist erst erlaubt, wenn die Maschine in der Zwischenzeit
mindestens 1Stunde lang geturnt hat. Sollte die Maschine sich bereits auerhalb der Turnzeit
befinden, muss die Maschine im Handmodus mindestens 1 Std. geturnt werden.
Sollte das Problem erneut auftreten, unbedingt Rcksprache mit der Firma
KAWASAKI halten.
Achtung: Die Schmierltemperatur muss > 18C betragen. Ansonsten warten, bis die
Schmierlheizung das l aufgewrmt hat. Dieser Fall tritt nur auf, wenn die 400V Anlage
lngere Zeit auer Betrieb war. Ansonsten erfolgt die Erwrmung automatisch.
Das Purgen im Automatikbetrieb ist nur mglich, wenn:
keine Startanforderung anliegt

die Hilfsantriebe im Automatikmodus stehen
die Drehzahl < 1% ist
die Kesselklappe geschlossen und die Bypassklappe offen ist
kein relevanter Not-Stop anliegt
Document 1 Page 137 of 208 11.02.2010

In diesem Fall ist der Taster 31 (Purgen) grau. Bettigt man nun den Taster 31 dauernd
(Purgen), so erfolgen folgende Schritte automatisch:
Einschalten des lnebelabscheiders

Einschalten der AC-Vor/Nachschmierpumpe
Einschalten des Turnmotors ( 10 sek. nach AC-Vor/Nachschmierpumpe )
Wenn alle Bedingungen erfllt sind, wechselt der Taster von grau nach grn. cirka 10 sek.
spter beginnt die Turbine zu beschleunigen, bis sie 24% der Nenndrehzahl erreicht. Nach
Erreichen der 24% Drehzahlschwelle luft die Maschine mit konstanter Drehzahl weiter.
Wird der Taster 31 (Purgen) losgelassen, wird der Starter abgeschaltet und die Maschine
luft aus. Der Taster wechselt von grn nach rot. Erst wenn die Maschine die 1%
Drehzahlschwelle deutlich unterschritten hat, ist ein erneutes purgen mglich. Sichtbar wird
dies durch den Wechsel des Tasters von rot nach grau.
11.) Turbine Start:
Achtung: Vor dem Starten der Turbine mssen alle Erdungsseile in der
Mittelspannungsanlage verlassen haben. Der Generator erregt sich automatisch bei 95% der
Nenndrehzahl. Bereits vorher treten erhebliche Spannungen durch die Remanenz des
Generators auf.
Achtung: Der Start der Turbine sollte grundstzlich vor Ort erfolgen. Whrend des
eigendlichen Startvorgangs mssen dabei immer die Abgastemperatur, die Drehzahl und die
Schwingungswerte im Auge behalten werden. Obwohl die Steuerung alle Punkte selbstndig
berwacht, erkennt der Mensch oftmals schneller ein ungewhnliches Verhalten und kann
damit den Schaden verhindern, bzw. begrenzen.
Document 1 Page 138 of 208 11.02.2010

berprfen, ob noch eine Stop oder Not-Stop-Meldung aktiv ist ( Rote Lampe
oben am Feld +1U02. Clarify any existing notifications.
Check that the manual gas valve is in the open position.
Rohrleitungen im Package auf Undichtigkeiten berprfen.
Stellung der Abgasklappen berprfen (Kesselklappe zu und Bypassklappe offen).
Schlsselschalter Freigabe Turbine in Stellung Freigabe schalten. Nun msste
die LED 30 (Turbine Start) grau sein.
Nun kann durch das Bettigen des Tasters 30 (Turbine Start) der automatische Start in Gang
gesetzt werden. Der Startvorgang, wird durch ein blinken der LED 30 (Turbine Start)
angezeigt und luft wie folgt ab:
Einschalten der Schmierlpumpe und des ldunstabscheiders

Einschalten des Turnmotors
ffnen der Zu-und Abluftklappen der Haube
Starten der Haubenventilatoren
Befindet sich die Abgastemperatur zwischen 400 und 120C beschleunigt der
Starter zu einem oder mehreren Vor-Purgezyklen bis auf 24% der Nenndrehzahl
fr 1 Sekunden. Danach luft die Maschine aus und wartet 5 min bis zum nchsten
Schritt. Befindet sich die Abgastemperatur unter 100C beginnt der eigentliche
Startvorgang.
Durchfahren des Gasdichtheitskontrollzyklus bei Gasbetrieb
Der Starter beschleunigt zum Hauptpurge bis auf 24% der Nenndrehzahl.
Belften des Abgassystems bei 24% Nenndrehzahl
Abfahren der Turbine auf kleiner 3% der Nenndrehzahl
Beschleunigen der Turbine, Einschalten des Hauptgasventils 1, des Zndventils
und der Zndung bei 8% der Nenndrehzahl
Further acceleration of the turbine and switching on of the main gas valve 2 at 25%
of nominal speed.
Further acceleration of the turbine to 100% of nominal speed.
Freigabe der Erregung des Generators bei 95% Drehzahl.
Nun wird die LED 30 (Turbine Start) grn und die Maschine ist klar zum
synchronisieren.
Document 1 Page 139 of 208 11.02.2010
12.) Grundstzliches zur Benutzung der beiden Synchronisier-stellen:
Eine Synchronisierung des Netzleistungsschalters ist erst mglich, wenn der
Generatorschalter bereits eingeschaltet ist.
Lsst man den Schlsselschalter Hand / 0 / Automatik auf Automatik stehen, wird der
jeweils angewhlte Leistungsschalter nach einer Sicherheitsheitszeit von 2 min (Frequenz
und Spannung O.K. und kein Vektorsprung ) wieder automatisch zusynchronisiert und die
Maschine auf die voreingestellt Leistung hochgefahren.
Sinnvoll ist dieser Betrieb aber nur fr die Synchronisierung des Netzschalters, da dieser
ber die Netzentkopplung abgeschaltet wird.
Achtung: Diese Funktion ist in der Steuerung vorhanden, sollte aber nicht
genutzt werden, da auf der Netzseite kein berwachungsgert eingebaut ist. Die
Netzentkopplungsgerte sitzen alle auf der Sammelschienenseite bzw. der
Generatorseite.
13.) Handsynchronisierung Generatorschalter:
Vor dem Synchronisieren bitte folgende Schritte durchfhren:
Generatorspannung kontrollieren (Generator erregt, Spannung stabil und zwischen

10 und 12KV)
Generatorfrequenz kontrollieren ( Frequenz stabil und zwischen 49 und 51Hz)
Netzspannung kontrollieren (Generator erregt, Spannung stabil und zwischen 10
und 12KV)
Netzfrequenz kontrollieren ( Frequenz stabil und zwischen 49 und 51Hz)
Nun muss der Vorwahlschalter Synchronisierung Generatorleistungsschalter /

Netzleistungsschalter in die Position Generatorleistungsschalter gebracht werden und
der Synchronisierwahlschlsselschalter in die Position Hand gestellt werden. Danach
bitte folgende Schritte ausfhren:
Mit dem Taster 27 ( Verstellung Spannung / Frequenz ) auf Spannungsverstellung

umschalten (LED 27 wird gelb).
Mit Hilfe der Taster 25 (Spannung hher) und 26 (Spannung tiefer) und der
Spannungsanzeige auf dem Synchronisiergert die Spannungen abgleichen.
Danach mit dem Taster 27 ( Verstellung Spannung / Frequenz ) auf
Frequenzverstellung umschalten (LED 27 wird grn).
Document 1 Page 140 of 208 11.02.2010
Mit Hilfe der Taster 25 (Frequenz hher) und 26 (Frequenz tiefer) und der
Frequenzanzeige, sowie der LED-Kette (Synchronoskop) auf dem
Synchronisiergert die Frequenz bzw. den Winkel abgleichen.
Beim Erreichen der mittleren grnen LED in der LED-Kette des

Synchronisiergertes, den Taster 28 (Leistungsschalter ein) bettigen und bis zur
Einschaltung des Leistungsschalters gedrckt halten (LED 28 wird grn) . Kommt
es nicht zur Einschaltung, Taster loslassen und Einstellung der Frequenz und des
Winkels wiederholen.
Nach erfolgter Zuschaltung den Synchronisierwahlschalter wieder in Position Aus
bringen.
Fehlschaltungen sind durch ein Impulssperrrelais ausgeschlossen!
Trotzdem Eintaster nur beim erreichen der grnen LED (Synchronoskop-Anzeige

wechselt sehr langsam), bzw. bei langsamer Durchlaufsgeschwindigkeit beim Wechsel
von gelb auf grn bettigen.
Keine Synchronisierversuche bei hoher Durchlaufsgeschwindigkeit des

Synchronoskopes!
14.) Automatiksynchronisierung Generatorschalter:


10 und 12KV)
und 12KV)

Netzleistungsschalter in die Position Generatorleistungsschalter gebracht werden und
der Synchronisierwahlschlsselschalter in die Position Automatik gestellt werden.
Danach erfolgt der Abgleich von Frequenz und Spannung, sowie die Zuschaltung des
Leistungsschalters automatisch.
Nach erfolgter Zuschaltung gibt es nun zwei Mglichkeiten:
Der Synchronisierschalter wird in Stellung Aus gebracht. Nach einem Abschalten

des Leistungsschalters muss nun der Synchronisiermodus wiederholt werden.
Der Synchronisierschalter verbleibt in der Stellung Automatik. Nach einer
betriebsmssigen Abschaltung des Leistungsschalters (Leistungsschalter ber
Taster Aus geffnet kommt es nach 5 Minuten zu einer automatischen
Rcksynchronisierung der Turbine.
Document 1 Page 141 of 208 11.02.2010
15.) Handsynchronisierung Netzschalter:

10 und 12KV)
und 12KV)

Netzleistungsschalter in die Position Netzleistungsschalter gebracht werden und der
Synchronisierwahlschlsselschalter in die Position Hand gestellt werden. Danach bitte
folgende Schritte ausfhren:
Mit dem Taster 27 ( Verstellung Spannung / Frequenz ) auf Spannungsverstellung

umschalten (LED 27 wird gelb).
Mit Hilfe der Taster 25 (Spannung hher) und 26 (Spannung tiefer) und der
Spannungsanzeige auf dem Synchronisiergert die Spannungen abgleichen.
Danach mit dem Taster 27 ( Verstellung Spannung / Frequenz ) auf
Frequenzverstellung umschalten (LED 27 wird grn).
Mit Hilfe der Taster 25 (Frequenz hher) und 26 (Frequenz tiefer) und der
Frequenzanzeige, sowie der LED-Kette (Synchronoskop) auf dem
Synchronisiergert die Frequenz bzw. den Winkel abgleichen.
Beim Erreichen der mittleren grnen LED in der LED-Kette des
Synchronisiergertes, den Taster 28 (Leistungsschalter ein) bettigen und bis zur
Einschaltung des Leistungsschalters gedrckt halten (LED 28 wird grn) . Kommt
es nicht zur Einschaltung, Taster loslassen und Einstellung der Frequenz und des
Winkels wiederholen.
Nach erfolgter Zuschaltung den Synchronisierwahlschalter wieder in Position Aus
bringen.
Fehlschaltungen sind durch ein Impulssperrrelais ausgeschlossen!
Trotzdem Eintaster nur beim erreichen der grnen LED (Synchronoskop-Anzeige

wechselt sehr langsam), bzw. bei langsamer Durchlaufsgeschwindigkeit beim Wechsel
von gelb auf grn bettigen.
Keine Synchronisierversuche bei hoher Durchlaufsgeschwindigkeit des

Synchronoskopes!
16.) Automatiksynchronisierung Netzschalter:

Document 1 Page 142 of 208 11.02.2010
10 und 12KV)
und 12KV)

Netzleistungsschalter in die Position Netzleistungsschalter gebracht werden und der
Synchronisierwahlschlsselschalter in die Position Automatik gestellt werden.
Danach erfolgt der Abgleich von Frequenz und Spannung, sowie die Zuschaltung des
Leistungsschalters automatisch.
Nach erfolgter Zuschaltung gibt es nun zwei Mglichkeiten:
Der Synchronisierschalter wird in Stellung Aus gebracht. Nach einem Abschalten

des Leistungsschalters muss nun der Synchronisiermodus wiederholt werden.
Der Synchronisierschalter verbleibt in der Stellung Automatik. Nach einer
betriebsmigen Abschaltung des Netzleistungsschalters (Leistungsschalter ber
Taster Aus geffnet oder Auslsung ber den Netzschutz) kommt es nach 5
Minuten zu einer automatischen Rcksynchronisierung der Turbine.
17.) Sonderfunktion Rckspeisung auf die schwarze Fabrikinsel:

Sollte einmal die Notwendigkeit bestehen, die Fabrik ohne Netz wieder in Betrieb zu
setzen (Sammelschiene Fabrik ist spannungslos (schwarz)), kann dieses wie folgt
durchgefhrt werden:
Sammelschiene Fabrik lastlos schalten / Alle Leistungsschalter Richtung Betrieb

ausschalten.

Schlsselschalter Schwarzzuschaltung auf 1 stellen. Mit diesem Signal wird der
Synchronisierer so umgeschaltet, das er eine Zuschaltung auf ein schwarzes Netz
freigibt. Diese Funktion ist nur bei Automatiksynchronisierung und nur fr den
Generatorleistungsschalter freigegeben. Der Schlsselschalter hat eine
Sonderschlieung und darf nur fr diesen Betriebsfall benutzt werden.
Die Zuschaltung der Verbraucher muss in Stufen erfolgen. Der maximale Wert fr
eine Laststufe errechnet sich mit der Formel:
Psmax = 0,20 x Maximal zur Zeit fahrbare Turbinenleistung
18.) Turbine Stop:
Document 1 Page 143 of 208 11.02.2010

Durch das Bettigen der Taste 32 (Turbine Stop), wird der automatische Abfahrmodus
der Turbine, wie folgt in Gang gesetzt. Die LED 32 blinkt (rot) whrend dieser Zeit.
Die Turbine entlastet automatisch bis auf eine Leistung von 500KW
Der Leistungsschalter ffnet
Die Turbine luft 5 min nach
Die Turbine stoppt und luft aus
Der Dichtheitskontrollzyklus wird durchfahren (falls Gasdruck anliegt)

Bei Erreichen einer Drehzahl <5% beginnt der Nach-Purge-Modus
Dabei beschleunigt die Maschine bis auf 24% der Nenndrehzahl fr 1 Minute und
luft danach aus.
Bei 5% Drehzahl schaltet der Turnmotor ein
Bei 1% Drehzahl und Ablauf einer Sicherheitszeit ist der Stopmodus
abgeschlossen
Die LED 32 geht in Ruhelicht (rot)

Die Haubenventilatoren laufen 1 Stunde nach. Wird eine Haubentemperatur von
35C berschritten, startet der Nachlaufmodus erneut fr eine weitere Stunde (
Achtung: Der Haubenventilator ber dem Startermotor luft whrend der gesamten
Turnzeit).
Die Klappen schlieen nach 2 Stunden und 45 Minuten. Auch diese Nachlaufzeit
wird erneut gestartet, wenn eine Haubentemperatur von 35C berschritten wird.
Die Schmierlpumpe und der Turnmotor laufen 48 Stunden nach.
Whrend der Entlastung des Generators und whrend der Nachlaufzeit der Turbine kann
jederzeit der Stopvorgang durch die Taste 30 (Turbine Start) wieder Rckgesetzt
werden.
Ein Neustart nach dem Abfahren der Turbine ist erst mglich, wenn die Turbine eine
Drehzahl <1% erreicht hat. Erkennbar durch den Farbwechsel der LED 30 (Turbine Start)
von rot nach grau.
19.) Automatischer Turnmodus:

Sobald die Maschine mit Kraftstoff betrieben wird, initialisiert sich automatisch ein 48
Stunden langer, berwachter Turnvorgang. Dieser automatische Vorgang lsst sich auch
durch einen Neuanlauf der CPU nicht zurcksetzen. Auch eine eventuelle Blockierung der
Turbine wird gefangen und ist ebenfalls nicht durch einen Neuanlauf der CPU quittier-
oder rcksetzbar.
Wird ein Neuanlauf der CPU gestartet, wenn die Turnzeit bereits abgelaufen ist, startet
automatisch eine neue 48 Stunden lange Turnzeit.
Document 1 Page 144 of 208 11.02.2010
a) Wird durch einen Fehler der Turnvorgang fr eine Zeit von 1-5 Minuten unterbrochen,
ist ein Neustart der Turbine erst nach Ablauf einer Stunde mglich (Zeit ist im OP
ablesbar).
b) Wird der Turnvorgang fr lnger als 5 Minuten unterbrochen, so unterbricht die

Steuerung den Turnvorgang fr die Zeit:
X = 15 Stunden bereits geturnte Zeit vor dem Fehler (Zeit ist im OP ablesbar)
Danach wird der Turnmotor automatisch gestartet und muss nun mindestens 1 Stunde
lang laufen, bis der Start der Turbine wieder freigegeben wird.
c) Wie aus der Formel bereits ersichtlich, wird eine Unterbrechung des Turnvorgangs fr
mehr als 5 Minuten, nach einer bereits abgelaufenen Turnzeit von mehr als 15 Stunden,
wie im Fall a) behandelt.
Grundstzlich gilt, steht die Maschine fr eine lngere Zeit, mehrere Tage bis einige
Wochen, so muss die Maschine vor dem Starten fr mindestens eine Stunde im
Handmodus geturnt werden (ldunstabscheider einschalten, AC-Vor /
Nachschmierpumpe einschalten und Turnmotor einschalten). Neben dem Effekt, das alle
Lager wieder geschmiert werden, wird zustzlich das Schmierl ber eine Tankheizung
aufgeheizt.
Document 1 Page 145 of 208 11.02.2010

20.) Einstellung des Reglermodus bei Netzparallelbetrieb:
Die Einstellung des Regelungsmodus im Netzparallebetrieb erfolgt in WINCC.
Der Wechsel der Betriebsart erfolgt durch Eingabe der Betriebsartenziffer in der obersten
Zeile, vor der Beschriftung Reglermodus. Nach der bergabe der Ziffer durch Return
wechselt die Angabe hinter der Beschriftung Reglermodus auf die entsprechende
Betriebsart.
Betriebsarten:
0 = Hand: Verstellung der Leistung ber die Taster 25 (Frequenz hher) und 26
(Frequenz tiefer) .
1 = 0-Leistungs- / Cos-Phi-Regelung zum Netz: nicht installiert!
2 = Sollwertregelung Kessel: Die Turbine regelt nach dem vorgegebenen Sollwert
vom Kessel (4-20mA = 0-100% der zur Zeit mglichen Leistung)
3 = Sollwertregelung: Die Turbine regelt nach dem im Bild angegebenen
Wirkleistungssollwert in KW.
4 = Sollwertregelung: Die Turbine regelt nach der im Bild angegebenen
prozentualen maximal mglichen Wirkleistung in
Bei Ausfall der Datenverbindung zur Warte, wechselt der Reglermodus automatisch nach
Hand. Das bedeutet, der letzte gltige Leistungswert bleibt bestehen.
Document 1 Page 146 of 208 11.02.2010

21.) Automatischer cos-phi Steller:
21.1) Schalterposition 0
Der cos phi Sollwert wird ber die Tasten an PP17II, auf den gewnschten Wert,
verstellt (siehe auch 2.16 und 2.17)
21.2) Schalterposition 1
Der cos phi Sollwert wird automatisch auf den Wert verstellt, der im Eingabefenster
eingetragen ist. Parallel kann von Seiten der Leittechnik der cos phi, z.B. getseuert,
verndert werden.
22.) Stndererdschlussschutz Generator und Schaltung Erdwiderstand:

Wenn die Maschine startet, ist der Erdungswiderstand nicht mit dem
Generatorsternpunktverbunden. In dieser Phase wird der Stndererdschluss ber die
Messung der Verlagerungsspannung erfasst.
Document 1 Page 147 of 208 11.02.2010

Ist die Maschine die Erste im Kraftwerk, die startet, schaltet der Erdungswiderstand mit
dem Einschalten des Generatorschalters ein. Bei der zweiten Maschine die im Kraftwerk
an das Netz geht, bleibt der Erdungswiderstand ausgeschaltet.
Die erste Maschine, die an das Netz synchronisiert, ist automatisch der Master: Die
zweite Maschine ist automatisch der Slave. Im Generatorbild des Masters ist es
mglich, ber den Taster Wechsle Master nach Slave, zu jedem Zeitpunkt den Master
auf die andere Maschine zu wechseln. Mit dem Wechsel von Master nach Slave
schaltet der Erdungswiderstand zuerst im ursprnglichen Master aus und dann, nach
einer Sicherheitszeit, im neuen Master ein (Wechsel mit Unterbrechung).
Wird der Master betriebsmig oder per Not-Stopp abgeschaltet, wechselt der Master
automatisch auf die zweite Maschine. Der Wechsel der Zuschaltung des
Erdungswiderstandes folgt dann analog zum gewollten Wechsel des
Erdungswiderstandes.
Wenn beim Wechsel von Master nach Slave der Automat des Antriebsmotors des
ehemaligen Masters fllt, bzw. der Trenner des ehemaligen Masters nicht ffnet, wird
eine Strmeldung ausgelst und es erfolgt keine Einschaltung des zweiten
Erdungswiderstandes.
Wird die Automatik durch Abschalten der Versorgungssicherung der Stellmotoren der
Erdungswiderstnde bei beiden Maschinen auer Betrieb gesetzt, wre ein manuelles
Schalten durch Schaltstangen in den Zellen mglich.
Document 1 Page 148 of 208 11.02.2010

Achtung: Dieses darf aber nur durch ausgewhltes und geschultes Personal
erfolgen, da die Spannung am offenen Schalter des Erdungswiderstandes, bei
Strungen bis zu 6,4kV betragen kann. Damit drfen hier nur Personen eingesetzt
werden, denen das direkte Schalten von Mittelspannungsanlagen erlaubt wurde und
die entsprechend geschult wurden.
Achtung: Sollten die Erdungswiderstnde manuell geschaltet werden, ist unbedingt

darauf zu achten, dass niemals beide Erdungswiderstnde gleichzeitig eingeschaltet
werden. Ansonsten wird mindestens eine Maschine wegen
Stndererdschlussauslsung abstellen.
23.) Inselbetrieb:
Erfolgt eine Abschaltung des 60kV Schalters wechselt der Master automatisch in den
Inselbetrieb. Beim Slave erfolgt eine automatische Abschaltung.
Document 1 Page 149 of 208 11.02.2010

24.) Bilderbaum WINCC:
Startbild
Menue Meldearchiv Exit Login Logout
Generator Regler
Allg.Werte Luft Treibstoff Schmierl ltemp.
Reglermo Vibration Kurven Zurck Service 1

dus
Service 2
Synchroni
sierung
Generator
Abgasdru Schmier Multiburn Drehzahl P/Q/U/f P/Q/I/f

ck ldruck er (6,3KV) (6,3KV)
Gasdruck Kurven 2 Zurck
Abgas- Brennka Zulufttem Schmier- Vibr. Vibr. Vibr.

temp. mmer p. ltemp. Turbine Getriebe Geno
Ventile zurck Zurck
Zutritt nur fr Servicepersonal Passwortschutz
Document 1 Page 150 of 208 11.02.2010

25.) Bilder WINCC:
25.1) Startbild mit Hauptmenu:
25.2) Meldearchiv:
Document 1 Page 151 of 208 11.02.2010

25.3) Startbild mit Untermenu 1:
25.4) Bild Allgemein:
Document 1 Page 152 of 208 11.02.2010

25.5) Bild Luftsystem:
Document 1 Page 153 of 208 11.02.2010

25.6) Bild Treibstoff:
25.7) Bild Schmierl:
Document 1 Page 154 of 208 11.02.2010

25.8) Bild ltemperatur:
25.9) Bild Generator:
Document 1 Page 155 of 208 11.02.2010

25.10) Bild Regler:
Document 1 Page 156 of 208 11.02.2010

25.11) Bild Reglermodus:
25.12) Unterbild Synchronisierung Turbine:
Document 1 Page 157 of 208 11.02.2010

25.13) Bild Vibrationsmessung:
25.14) Startbild mit Untermenu 2 (Kurven):
Document 1 Page 158 of 208 11.02.2010

25.15) Kurvenbild Abgas (Als Beispiel):
25.16) Startbild mit Untermenu 3 (Kurven 2):
Document 1 Page 159 of 208 11.02.2010

25.17) Kurvenbild Ventile (Als Beispiel):
Document 1 Page 160 of 208 11.02.2010

26.) Datenschnittstelle S7 <-> WINCC:
siehe Verbindungsliste S7 <-> WINCC
27.) Datenschnittstelle S7-315F <-> S7:

Siehe Verbindungsliste S7-315F <-> S7
28.) Einstellwerte (Nur Servicepersonal):

siehe Liste der Einstellwerte
Document 1 Page 161 of 208 11.02.2010

Manual

GPB80DD
VOLUME 11

Date
Name

Tel. +49 6172 7363-0
Fax +49 6172 7363-55
Document 1 Page 162 of 208 11.02.2010
C.18 Electrical drawings
Document 1 Page 163 of 208 11.02.2010

Manual

GPB80DD
VOLUME 12
(Gas Boost Compressor (ELTACON, NL)

Date
Name

Tel. +49 6172 7363-0
Fax +49 6172 7363-55
Document 1 Page 164 of 208 11.02.2010
C.19 Gas compressor (ELTACON, NL)
Document 1 Page 165 of 208 11.02.2010

C.20 Oils, lubricants and other liquids
Description
Lube oil (see description on C.8.1)
Lube oil specification, in accordance with ISO VG 46 (#3044 Bacau) bzw VG 32

(JIS K2213 or DIN 51515):
First filling by Kawasaki is:

Shell Turbo Oil T32
Cooling water
is delivered by the customer and circulated in the oil cooling system.
Compressor washing fluid
ZOK 27
NOTE
Liquid run off from old lube oil and compressor wash is handled as waste
material. The customer is responsible for proper disposal.
Document 1 Page 166 of 208 11.02.2010

C.21 List of manufacturers and suppliers
KAWASAKI Heavy Industries, Ltd.

Gas Turbine Division
Industrial G/T Center
1-1 Kawasaki-Cho
623-8666, Akashi
JAPAN
Tel.: + 81 / 28 / 9 21 - 15 25
Fax: + 81 / 28 / 9 13 - 33 44
AKO Regelungstechnik GmbH & Co. KG

Proschestr. 16
D-51381 Leverkusen
Allweiler AG
Allweilerstrae1
28315 Radolfzell
Tel.: 02232/86-0
Fax: 02232/86-436
Altmann GmbH
Oberdieberg 12
83544 Albaching
ANIKON GmbH
Rudolf Diesel Strae 8
D 53859 Niederkassel
BOLL & KIRCH GmbH

Postfach 14 20
50143 Kerpen
Tel.: 02223-562-0
Fax: 02223-562-223
Brush HMA B.V.

P.O. Box 3007
2980 DA Ridderkerk
The Netherlands
DeKomTe de Temple
Kompensator Technik GmbH
Walinussstrae 13
63500 Klein Welzheim, Seligenstadt
Easy Energy Companies & Consulting SA, (EECC)

Via Cantonale 7
6805 Mezzovico / Switzerland
Document 1 Page 167 of 208 11.02.2010

Edelstahlservice GmbH
Voltenseestr. 6
D-60388 Frankfurt / Main
Tel.: +49 (0) 61 09 / 23 22 - 50
Fax: +49 (0) 61 09 / 34 62 3
Emerson Process Management GmbH & Co. OHG

Argelsrieder Feld 3
82234 Wessling
ERMO Industriemontagen Reuner GmbH

Jahnstrasse 25
D-63533 Mainhausen
Tel.: 06182-939-0
FEMA Regelgerte
Honeywell AG
Bblinger Strae 12
21101 Schnaich
Tel.: 02031/632-02
Fax: 02031/632-850
FRANKE-Filter GmbH
Wiedhof 9
D-31162 Bad Salzdetfurth
Tel.: 05064-904-0
Fax: 05064-904-18
Friedrich Krombach GmbH & Co. KG Armaturen

Marburger Strae 364
57223 Kreuztal-Kredenbach
Tel.: +49 (0) 2732/520-00
Fax: +49 (0) 2732/520-100
G & S Brandschutz GmbH

Westerwaldstrae
56424 Mogendorf
GMB
GETTORFER METALLBAU GmbH
Starkenbrook 7 - 10
D - 24214 Gettorf
Document 1 Page 168 of 208 11.02.2010

halstrup-walcher GmbH
Stegener Strasse 10
D-79199 Kirchzarten
Tel.: 07661-3963-0
Fax: 07661-396399
e-mail: info@halstrup-walcher.de
Internet: www.halstrup.de
Hansa Flex
Rathenaustrae 35
63263 Neu-Isenburg
Tel.: 0 61 02 / 24 86 23
Fax: 0 61 02 / 24 86 25
Herbst Beheizungs-Technik
Postfach 12 25
58804 Neuenrade
Tel.: 02394/911136
Fax: 02394/911137
hpTechnik GmbH Industriepumpen-

Frderaggregate und Anlagenbau
Gablonzer Strae 21
26185 Karlsruhe
Tel.: 0221 9 56 18-0
Fax: 0221 9 56 18-22
HYDAC
INTERNATIONAL GmbH, VB Mitte
Dieselstrae 9
D 64293 Darmstadt
INTERNORMEN Technology GmbH

Friedensstrae 41
D-68804 Altluheim
Deutschland
Tel.: +49 (0)6205 - 2094-0
Fax: +49 (0)6205 - 2094-40
Email: info@internormen.com
Internet: www.internormen.com
Intra-Automation GmbH
Otto-Hahn-Strae 20
41515 Grevenbroich
Tel.: 02181-75665-0
Document 1 Page 169 of 208 11.02.2010

J. Helmke & Co.
Elektrische Maschinen und Antriebe
Ludwig - Erhard-Ring 7 - 9
31157 Sarstedt - Germany
JAQUET AG
Thannerstrasse 15
CH-4009 Basel
Jumo
Moltkestrae 13
36039 Fulda
Tel.: 0661/8003-224
Fax: 0661/8003-801
Kobold Messring GmbH

Nordring22 - 24
65719 Hofheim / Ts.
Kromschrder Elster GmbH

Postfach 2809
D-49018 Osnabrck
Tel.: 0541-1214-365
Fax: 0541-1214-547
Leroy Somer
Eschborner Landstrae 166
D-60489 Frankfurt / Main
Tel.: 069/280208-0
Fax: 069/28020851
LESER GmbH & Co. KG

Wendenstrasse 133-135
20537 Hamburg
Germany
www.leser.com
+49 40 25 165 - 100
+49 40 25 165 500
Lindenberg-Anlagen GmbH
Auf der Grefenfurth 25-27
51503 Rsrath
Telephone: +49 (0) 2205 8009-0
Telefax: +49 (0) 2205 8009-109
Document 1 Page 170 of 208 11.02.2010

MIT Moderne IndustrieTechnik GmbH
Industriestr. 9
32602 Vlotho-Exter
Telephone: +49 5228 952-0
MTB Sensor Technik GmbH

Temperaturmesstechnik
Echternacher Str. 5
D 53842 Troisdorf
Munters Euroform GmbH

Division GTEC
Philipsstr. 8
52068 Aachen
PALL Corporation
PALL Filtersystems GmbH
Werk Schumacher Crailsheim
Zum Flgelau 70
D-74564 Crailsheim
PKP Prozessmesstechnik GmbH

Siemensstr. 7
D-65205 Wiesbaden
Tel: 06122-9937-23
Fax: 06122-9937-25
Internet: www.pkp.de
RBG Strder
Hauptstrae 66
D-56271 Kleinmaischeid
Tel.: 0049-2689-9276-0
Fax: 0049-2689-9276-59
Riegler & Co. KG

Schtzenstrae 27
D-72574 Bad Urach
Tel.: 0049-7125-9497-0
Fax: 0049-7125-9497-97
info@riegler.de
http://www.riegler.de
Reger GmbH
Plieninger Str.58
Postfach 81 04 67
D 70567 Stuttgart
Document 1 Page 171 of 208 11.02.2010

Schubert & Salzer
Control Systems GmbH
Bunsenstrae 38,85053 Ingolstadt
Postfach 10 09 07, 85009 Ingolstadt
Telephone: 0049/841/965 40
Telefax: 0049/841/965 45 90
E-Mail: info.cs@schubert-salzer.com
Schulz GmbH
Wikingerstr. 70
51107 Kln
Stahlcon GmbH
Kringstrae 13
D 71144 Steinebronn
SWD A. Hock GmbH

Mainzer Strasse 116
64293 Darmstadt
Tranter International AB,

D-31137 Hildesheim
www.tranter.com
info@de.tranter.com
Uni Gerte
Holtumsweg 13
D-47652 Weeze
Tel.: 0049-2827-9134-0
Fax: 0049-2827-1444
WENDT SIT GmbH & Co. KG

Beindersheimer Strasse 79
D-67227 Frankenthal
Werner Bhmer GmbH

Gedulderweg 95
D-45549 Sprockhvel
Tel.: 0049-2324-70010
Fax: 0049-2324-700179
Document 1 Page 172 of 208 11.02.2010

D Construction and Assembly
Described here are particular notes from KAWASAKI about constructing and assembling
components of the gas turbine generator unit. Manufacturer-specific descriptions for the
construction and assembly of the individual components can be found in the individual
operation and maintenance guides (see manufacturer documentation in the C sub-points
in the contents list).
Is carried out exclusively by KAWASAKI Gas Turbine Europe
Gas turbine
The table shows the standard values for the tightening torque for the screw categories
4.6 and 9.8.
Bolts- Screw category 4.6 Screw category 8.8

size nominal max. min. nominal max. min.
M6 4.9 5.9 3.9 8.8 10.8 7.1

M8 11.8 13.7 9.4 20.6 24.5 16.7
M10 24.5 29.4 19.6 44.0 53.0 35.0
M12 41.0 39.0 32.0 74.0 88.0 59.0
M14 68.0 80.0 54.0 122.0 145.0 97.0
M16 106.0 127.0 84.0 190.0 228.0 152.0
M20 210.0 251.0 168.0 378.0 453.0 302.0
M22 289.0 347.0 231.0 521.0 625.0 416.0
M24 366.0 438.0 292.0 658.0 789.0 526.0
M30 734.0 880.0 586.0 132.0 1584.0 1055.0
M36 1290.0 1548.0 1032.0 2314.0 2777.0 1852.0
NOTE
- The screw class is defined as follows (see also JIS B 1051 or ISO 281):
(yield strength/tensile strength) X 10; tensile strength (in N/mm2) /100
- The material of screw class 4.6 comprises SS41 (according to

JIS G 3101) or S20C (according to JIS G 4051). The material of screw class 8.8
comprises SCM435 (according to JIS G 4105).
Document 1 Page 173 of 208 11.02.2010

E Commissioning
CAUTION
As a precaution, the gas and flame detectors should be checked before starting the unit.
A check for possible fuel leakages should also be carried out. A check for gas leakages
by the operator's trained personnel should also be carried out continuously during
operation.
Checklist before 1st Commissioning
The following checks are to be made before the 1st commissioning the unit.
1. Was the installation of the unit and switching system properly carried out (floor plan
etc.)?
2. Were the commissioning requirements of the gas turbine manufacturer noted?
3. Were the commissioning requirements of the generator manufacturer noted?
4. Were the auxiliary drives checked for connectivity and functionality?
5. Were the safety measures (earthing, potential equalisation connections etc.) of the
responsible EVU or the customer noted?
6. Were the commissioning requirements of the battery manufacturer noted?
7. Were the proper functions of all fuses checked and were the circuit breakers and
thermal tripping devices switched to the "ON" position?
8. If available, were the shut-down functions of the switching system ("EMERGENCY

OFF" button, door contact etc.) opened and checked for proper functioning?
9. Was the connection of all pipes and cables checked according to the schematic
(correct connection of the +/- potential for direct current, rotary field for alternating
current etc.)?
10. Were the lamps and horn controls checked?
11. Was the ventilation in the unit room checked?
NOTE
With automatic units, commissioning is to be first carried out in manual/maintenance
mode.
Document 1 Page 174 of 208 11.02.2010

F Operation and Maintenance
OPERATION
CAUTION
As a precaution, the gas and flame detectors should be checked before starting the unit.
A check for possible fuel leakages should also be carried out. The last check by the
operator's trained personnel should also be carried out continuously during operation.
Inspection measures before starting
1. The lube oil in the tank should always be kept at a specified level higher.
2. Check the air intake route (intake flaps open) and the exhaust gas route (exhaust gas
flaps in bypass position). No foreign objects may be present in the intake or exhaust
ducts.
3. Check that all cables and plugs on the sensors are properly connected.
4. Check that no cables and/or plugs are hanging loose.
5. Check that all fuel pipes and other piping are securely connected and that there are no
leakages at the connection points.
6. Check that all screws, nuts and bolts on the turbine are properly tightened.
7. Check that all auxiliary properties (power supply, auxiliary drivers, compressed air,
cooling water, fuel etc.) is available in the necessary quantity and quality.
8. Turn the turbine over the turning apparatus and check the following characteristics:
- Uniformity of rotation
- Abnormal noises
- Oil leakage
Inspections during the purge process
1. Uniformity of the turbine acceleration and deceleration (coast down time)

2. If one or more of the following phenomena occur, the purge process must be stopped
immediately:
- Abnormal noises
- Oil leakage
- Abnormal vibrations of the turbine blades.
3. Manual purging may only be carried out at a turbine speed of below 25%. If the
turbine speed goes beyond the 25% mark, purging must be interrupted.
4. Follow the precautions and instructions given on the following pages.
Document 1 Page 175 of 208 11.02.2010

I. Start preparations
1. Check for failure signals from other operators on the customer side. Visual control
inside and outside the noise enclosure for fuel and lube oil leakages.
2. Ensure free air supply for combustion and cooling of the unit.
3. Control lube oil status of the turbine.
4. Ensure fuel supply to the turbine. Check for availability of control air to the valve
control, seal air, cooling air and flame detectors.
5. Check that the shut-down valve for the cooling water of the lube oil cooling is open.
6. Check the operational readiness of the power supply.
7. Ensure operational readiness of the gas warning, fire detection and fire extinguishing
systems.
8. Check the operational readiness of the vessel.
9. Ensure that the bypass flap is open.
II. Start the gas turbine generator unit

Set the switch to "local/remote" to position "local". (with the first start)
Set the switch "start approved" to position "I".
Set the switch "synchronisation" to position "0".
Delete any remaining notifications with the key "Fault reset", "Acknowledgement Stop" or
"Acknowledgement Warning".
Notifications only delete themselves after the removal of fault causes.
Otherwise, the alarm buzzer sounds.
To start the unit, press the green "start" button.
The automatic start-up procedure, including the leak test, runs.
During the start-up phase of the turbine of ~5% to 100% speed, the start-up time is to be
registered with a stopwatch and entered in the operating handbook.
Determine the start-up time using a stopwatch and enter it in the operating handbook.
The same must be be carried out with the coast-down-time.
III. Network-parallel operation

The turbine is constantly monitored by the control system and is immediately shut down
by an emergency stop function if a failure requires this.
After approx. 1 minute in idle mode at 100% speed, synchronisation occurs by switching
the key switch to the position "automatic". The turbine automatically runs up to the
minimum power level and then continuously increases in power. After synchronisation,
the key switch is to be reset to position "0".
If manual synchronisation is selected, the synchronisation settings of the generator
switch are set in zero-crossing of the synchronoscope using the button "Generator switch
On". The synchronisation conditions are to be noted (same voltage, same frequency).
The key "speed higher/lower" is for synchronising the frequency.
Once the unit has reached minimum performance, the desired level can be set using the
key "Power higher/lower". This can also be done using the vessel control It is not
possible for the operator to overload the turbine.
Document 1 Page 176 of 208 11.02.2010

The turbine can only be operated with a fault-free vessel and over a bypass chimney.
Otherwise the turbine is immediately switched off.
IV. Switching off the turbine
In dangerous situations, the gas turbine can always be immediately shut down using the
key "Emergency-Off".
Should the turbine be shut down, the switch "local/remote" must be switched to "local".
The stop command can come from the control room.
The turbine is stopped normally by pressing the red key "Turbine Stop".
The turbine is automatically shut down.
The generator switch is automatically opened. The run-down time after which the
generator switch is opened is approx. 10 minutes. The gas turbine is then automatically
switched off (all power supply valves close).
The time it takes the turbine to shut down from 100% speed to 0% is established with the
stopwatch during shut-down. (0% speed is established by observing the clutch rotation).
After falling below 5% speed, the turning motor is activated, in order to prevent the
turbine rotors from sagging (see variant 1-2). Should this turning gear fail, the required
measures from the operating handbook are to be taken (variants 1-1 & 1-2).
With longer-term standstill of the unit, the manual fuel valves can be closed.
It is important to note that the introduction of a "Stop" of the turbine cannot be reversed
by pressing "Start".
A typical start-up/stop operating procedure, such as that described under C.10 is shown
using a gas turbine fired with natural gas.
Modifications due to project-specific reasons is possible.
Before start-up, the following steps should be taken.:
Check if a "Stop or "Emergency-Stop notification is still active (red light at the top in field
+1U02). Clarify any existing notifications.
Check that the manual gas valve is in the open position.
Check the piping in the package for leakages.
Check the exhaust gas flap (vessel flap closed and bypass flap open).
Set the key switch Release Turbine to the position Release. The LED 30 (Turbine
Start) should now be grey.
Now the automatic start-up can be set in motion by pressing the key 30 (Turbine Start).
The start-up procedure is indicated by a flashing LED 30 (Turbine Start) and proceeds as
follows::
The lube oil pump and oil mist separator switches on

The turn motor switches on
Opening of the supply and exhaust gas flaps of the enclosure
Start of the enclosure ventilators
If the exhaust gas temperature is between 400 and 120c, the starter acclerates to one or
more pre-purge cycles to 24% of nominal speed for 1 second. The machine then runs
Document 1 Page 177 of 208 11.02.2010
and waits 5 minutes before moving on to the next step. If the exhaust gas temperature is
under 100C, the actual start-up procedure begins.
Running of the gas tightness check cycle in gas operation
The starter accelerates to the main purge to 24% of nominal speed.
Ventilation of the exhaust gas system at 24% of nominal speed.
Shut-down of the turbine at less than 3% of nominal speed.
Acceleration of the turbine, switching on of the main gas valve 1, of the ignition valve,
and ignition at 8% of nominal speed.
Further acceleration of the turbine and switching on of the main gas valve 2 at 25% of
nominal speed.
Further acceleration of the turbine to 100% of nominal speed.
Release of the generator trigger at 95% of nominal speed.
The LED 30 (Turbine Start) is now green adn the machine is ready to be synchronised.
Document 1 Page 178 of 208 11.02.2010

During operation the following points must be strictly adhered to.
DANGER
During operation, the housing, flanges, exhaust gas ducts and pipes close to the gas
turbine are very hot. One should never get too close to these parts.
The gas turbine rotates at high speed. One should never allow their face or hands to
come too close to the rotating blades, even if the clutch is fitted with safety guards.
The piping and turbine package operate under high pressure and at high temperatures.
During operation, the pipe connections may not be tightened or dismantled.
CAUTION
Precautions when charging
1. The power should always be gradually increased, in order to prevent the hot parts
from overheating.
2. During the power increase, check that all sections are in the specified ranges of
temperature, pressure and vibration (WinCC).
Precautions during nominal load
1. Check that the temperature, pressure and vibration are normal in all areas.
2. Check that there are no oil, mist or gas leakages inside the sound enclosure. Also
check the lube oil level on the tank display.
3. Check the vibrations; watch out for abnormal smells and noises.
Document 1 Page 179 of 208 11.02.2010

CAUTION
Precautions during power cut-off
1. The power should always be reduced over at least 3 minutes. Under no

circumstances reduce the power suddenly.
Precautions and inspections after the turbine stops
G Check that there is no fuel or oil leakage in the noise enclosure.
H It must be ensured that the turning procedure is carried out for at least 48 hours after the
stopping of the turbine. The post-lube pump must be in continuous operation. The
turning procedure is fully explained in the following pages.
Precautions for a hot start of the gas turbine (exhaust gas temperature >100C,
strict monitoring)
1. Purging of the gas turbine may not be started before the signal "Rotor Stop" is
identified, and before the turbine speed has fallen to below 5%.
2. Purging is carried out at a maximum turbine speed of 25%. When the turbine speed
has reached 25 %, purging is immediately stopped. Purging may not be continuously
carried out, otherwise severe damage can arise in the turbine.
3. The time period between two consecutive purge procedures must be at least 5
minutes (measured from the time when the turbine speed reached 0.3%).
4. While purging, the vibrations in the turbine blades are continuously monitored. If the
vibrations in bearings 1 or bearings 2 exceed a value of 35 mp-p, purging is
immediately stopped. These requirements also apply to cold starts (exhaust gas
temperature <100C).
5. The gas turbine is not started as long as the blade vibrations lie above 35 m during
purging.
Document 1 Page 180 of 208 11.02.2010

CAUTION
Measures for incomplete turning
Although the turbine is stopped, the gas turbine rotor could experience temporary thermal
distortion, if the turning procedure is not started.
The same can happen if the turning procedure is interrupted. If the turning procedure is
carried out and the gas turbine is started before the distortion disappears, blade
vibrations can occur and strike or grind on the rotor housing. This causes severe
damage to the gas turbine.
The procedure is described in these instructions, in order to bring the the turning
procedure to an end and to restart the turbine without causing any damage. The cases
which are described in this manual also apply to standard use of the gas turbine
generator unit. When using the gas turbine at high temperatures (e.g. because the
exhaust gas vessel is too close to the turbine), the turning time must be extended in
accordance with the local conditions, if necessary.
Before the turbine is restarted, it must be ensured that "manual purging" has been carried
out, and also that all of the precautions described in this chapter have been correctly
carried out.
NOTE
All measures described here must be carried out:
1) Check the turning procedure after shutting down the gas turbine. The check is carried
out by observing the rotor turning over the clutch between the gear and generator.
2) Check the blade vibrations. Before restarting, the gas turbine must be checked with
purging, that the blade vibrations lie in the normal range ( < 35 m). This is done by
rotating the turbine in manual purge mode. In this operating mode, the turbine speed
should be at max. 25% of the nominal speed. If the turbine vibration is > 35 m, the
purge procedure is immediately stopped. Finally, the turning procedure must be
carried out for at least 1 hour. After that, manual purging is carried out again, to check
again for blade vibration.
Document 1 Page 181 of 208 11.02.2010

3) Special precautions apply for "hot" restarts of the gas turbine. This is the case when
the exhaust gas temperature is 100 C or more. The standards must be applied here:
A. Before purging, check the rotor stop signal (speed should be at maximum 5% of
nominal speed).
B. In purging mode, the turbine speed should be below 25%. If the turbine has
reached this value, purgine should be immediately stopped. Purging should not
be restarted.
C. In purge mode, the blade vibration must be constantly monitored. If the blade
vibration shows 50 mp-p or more on display No. 1 or No. 2, the purge procedure
must be immediately stopped.
D. The gas turbine may only be restarted when the blade vibration in purge mode is
max. 35 m P-P.
4) Check that the 400 VAC supply for the auxiliary drives is available, and also that the
pre-/post lube oil pump (PPLOP) works.
A. If this pump does not work, it must be checked that the emergency lube oil pump
(ELOP) is in operation. This is one with a direct current-driven pump, which
supplies lube oil to the gas turbine bearings No. 2 in order to cool it down.
B. If the pre-/post-lube oil pump is in operation, it is a sign of availability of the 400V

supply for the auxiliary drive. Incidentally: In all of the cases described in this
manual, the pre-/post-lube oil pump (PPLOP) should always be in working order
and in operation.
Document 1 Page 182 of 208 11.02.2010

Manual for restarting the gas turbine
Variant No. 1
Turning doesn't start although the gas turbine has come to a stop.
Variant 1-1: If the time in which the turning still hasn't started, although the turbine
has come to a stop, is not longer than 5 minutes (Ts < 5 min), the
procedure is as follows:
A. Turing is carried out for at least 1 hour.

B. Check the vibration in "manual purge mode" of the gas turbine. If the
vibrations lie within the normal range, the turbine can be restarted.
Document 1 Page 183 of 208 11.02.2010

Variant 1-2: If the time between the turbine stopping and the start of the turning
procedure is more than 5 minutes (Ts > 5 min), the procedure is as
follows:
A. The gas turbine is kept in an idle state for a minimum of 15 hours,

without carrying out the turning procedure. The 15 hours are
calculated from the stopping of the turbine.
B. Next, the turning procedure is carried out for at least 1 hour.
C. Check the vibration in "manual purge mode" of the gas turbine. If the
Document 1 Page 184 of 208 11.02.2010

Variant No. 2
The turning procedure is interrupted
Variant 2-1: The turning time is less than 15 hours (T0 < 15 hours) after the stopping
of the gas turbine and the time of the interruption is less than 5 minutes
(Ts < 15 min) (also, when it is necessary to abort the turning procedure
because of an emergency inspection, the turning time should last at least
6 hours in order to avoid warpage of the rotor).
A. Turing is carried out for at least 1 hour.

B. Check the vibration in "manual purge mode" of the gas turbine. If the
Document 1 Page 185 of 208 11.02.2010

Variant 2-2: The turning time is less than 15 hours (T0 < 15 hours) after the stopping
of the gas turbine and the time of the interruption is greater than 5
minutes (Ts > 15 min).
A. The gas turbine is kept in an idle state for a minimum of 15 hours,

without carrying out the turning procedure. The 15 hours are
calculated from the stopping of the turbine.
B. Next, the turning procedure is carried out for at least 1 hour.
Document 1 Page 186 of 208 11.02.2010

Variant 2-3: The turning time is between 15 hours and 48 hours (15 hours T0 48
hours) from the stopping of the gas turbine.
A. The turning procedure can be resumed at any time.

B. The turning procedure is carried out for at least 1 hour.
Document 1 Page 187 of 208 11.02.2010

Variant No. 3: (Standard)
The turning of procedure runs 48 hours after the stopping of the gas turbine without
interruption.
The procedure can be restarted during 48 hours after the stopping of the turbine,
provided that the vibrations measured in "manual purge mode" lie within the permitted
range.
NOTE
Operating conditions and start-up situations which deviate from the above descriptions
must be agreed with KAWASAKI!
Document 1 Page 188 of 208 11.02.2010

Manual for compressor wash
A. Hot Wash
Is carried out during operation of the gas turbine.
B. Cold Wash
The cold wash is carried out as follows:
The turbine is switched off

Turning is carried out for at least 12 hours (the turbine must be completely
cooled down)
Connect the compressor cleaning pump to the ring main (see the following
sketch).
Connect the compressor cleaning pump electrically.
Prepare cleaning agent in accordance with C.23.
Set the pump pressure to 0.2 MPa (spray method).
Carry out the cold wash five times.
Carry out purging twice (without spraying).
Open the five drain valve for 10 minutes and empty the washing liquid from the
turbine.
Completely close every single drain valve, including the ball valve of the seal air
drain pipe.
DANGER
Before the purge or start-up procedure, every single valve (including the ball valve of the
seal air drain pipe) must be closed, otherwise the hot compressor air will blow out
through the drain pipe. This can be dangerous.
Start the turbine and operate for five minutes at approx. 1,500 kW (turbine
drying).
Document 1 Page 189 of 208 11.02.2010

Document 1 Page 190 of 208 11.02.2010
MAINTENANCE
Oils, lubricants and other liquids are described in C. 15!

Daily maintenance
The daily records of the operating data also include the daily maintenance activities.
Such activities could include, for example:
Records of the values at the gas turbine control cabinet,

Monitoring of operating noises,
Measurements of the start-up/stop times
Visual inspections of the external turbine parts.
A typical daily inspection is compiled in G MAINTENANCE (table 1/table 2). These

operating and commissioning records must be filed.
Inspections for M7A-03 Gas Turbines
The inspection intervals for the basic load units (units which are not intended for peak
load) are calculated as follows:
TE = TR + 10xTH + CxS,
where:
TE = the equivalent operating time

TR = the real operating time (including idle time)
TH = time of overload operation
S = number of start procedures
C = 15
Gaseous fuel
First inspection 500 h
Inspection of the Every 8,000 h
suction/exhaust gas parts;
Inspection of the combustion
chamber and
Endoscopy inspection
Hot section inspection Every 16,000 h
Overhaul Every 32,000 hours
Document 1 Page 191 of 208 11.02.2010

NOTE
If fuel lines are dismantled in the context of maintenance work or special cases, they are
to be checked for contamination and cleaned, if necessary, before reinstalling.
The values given in the table are measured with respect to the mode of operation and
last overhaul. Following an overhaul, all inspections must be repeated, with the
exception of the first inspection.
If abnormal operating conditions are found during the inspections, the relevant corrective
and preventative measure must be carried out immediately. To ensure the effectiveness
of these measures, the inspection plan must be carried out in advance.
All inspection intervals (except the first inspection) can be changed by 1000 hours,
depending on the result of the last inspection and condition of the unit and components.
The overhaul interval may not exceed the values which are given in the table.
If "8000 hour non-stop operation" is a requirement, the installation conditions and fuel
must be checked in advance. Only then can continuous operation be gradually started.
This means that all inspections to the first HSI will be carried out as planned and the
8000-hour non-stop operation can be started, assuming that all conditions are fulfilled.
Content of inspection
Details for each inspection are given in G MAINTENANCE (table 2).

Gear overhaul
1. Operating time
This is based on the equivalent operating time (TE = Time Equivalent)
2. Overhaul intervals and operating time of the high-speed bearings.

The following table shows the overhaul intervals and operation times of the high-speed
bearings.
Turbine- Gear Box

Turbine Overhaul
generator type Operating Type: High- interval
unit mode speed (hours)
bearings
GPB 80/80 M7A-03 Continuous Planetary Sleeve 32,000
operation gear bearings
#3044
Hitachi /
Nico (Allen
gears)
Document 1 Page 192 of 208 11.02.2010

Periodic inspection of the dirt traps in the air-lock system (seal air)
Procedure
Visual inspection of the the dirt trap tray (see following illustration) during each
periodic inspection. Thorough cleaning with a brush or similar tool, if necessary. If
the tray cannot be properly cleaned in this way, or if it is very dirty, then change it.
Inspection intervals: as with the periodic inspections, i.e. 8,000 hours in natural gas
operation.
Strainer
Filter screen
Seal
Document 1 Page 193 of 208 11.02.2010

G Maintenance and Repair
The chapter describes how causes of fault are communicated and how errors can be
eliminated. If the operating staff cannot eliminate the fault, immediate contact is to be
made with KAWASAKI.
For faults which are not in the turbine area, the respective user handbook should be
referred to. In emergencies, experts from the affected suppliers should also be
contacted.
If one of the faults mentioned below occurs, a warning signal sounds over the turbine
monitoring system and the warning light flashes. If the fault is serious, the turbine is
immediately stopped.
Turbine does not start
This section will be covered in the final documentation with regard as well to the liquid
fuel system related details. ( # 3044 Bacau)
NOTE
If fuel lines are dismantled in the context of maintenance work or special cases, they are
to be checked for contamination and cleaned, if necessary, before reinstalling.
NOTE
The gas turbine generator unit installed here is a fully automatically running unit, which
controls itself.
Although expensive and very good sensors are included in the monitoring software, the
feelings and hunches of humans cannot be replaced.
The unit must be inspected and monitored from time to time.

Visible damage or abnormal sounds are to be taken seriously and must be further
inspected, even if no alarms have been triggered.
CAUTION
If in doubt, shut down the unit in order to avoid further damage.
In any case, Service from KAWASAKI Gas Turbine Europe GmbH is to be informed.
Document 1 Page 194 of 208 11.02.2010
Document 1 Page 195 of 208 11.02.2010
To maintain the performance of the gas turbine generator unit at a high level over the
planned lifetime, maintenance work must be carried out at regular intervals.
The schedule of maintenance work on the gas turbine and supply systems, along with
information about the tasks, is described in the following table.
To discuss maintenance work or faults, Service at KAWASAKI Gas Turbine Europe

GmbH can be reached as follows:
During office hours:

Nehringstasse. 15
D-61352 Bad Homburg, Germany
Contact person Representative

Mr Axel Knirsch Hans Brck
Tel: +49 (0)6172-7363-35 +49 (0)6172-7363-45
Fax +49 (0)6172-7363-55 +49 (0)6172-7363-55
e-mail knirsch@kge-gmbh.com brueck@kge-gmbh.com
Document 1 Page 196 of 208 11.02.2010

Table 1
Daily check by the operator
Checkpoint Place/measure Before & During During &

during operation after
start-up shut-down
Lube oil sump Oil level display x x x
Turbine outside All connections x x x
Turbine speed Revolution counter x x x
Exhaust gas Instrument EGT x x x

temperature
Oil supply Oil thermometer x x x
temperature
Oil supply pressure Oil manometer x x x
Compressor pressure CDP manometer x x x
Oil return Oil thermometer - x -

temperature
Vibration Vibration counter x x x
Output: kW-meter x x -
Start-up time with stopwatch x - x
Shut-down time with stopwatch - - x
Shut-down noise Listen - - x
Pre-/post-lubrication Noises and control x - x

pump light
Turning motor after Visual check - - x
shut-down
Operating hours Bh counter x - x
Start number Start counter x - x
Generated output kWh counter x - x
p Lube oil filter Difference pressure x x x

display lube oil
p fuel filter Difference pressure x x x
display fuel filter
p gas filter Difference pressure x x x
display gas filter
Document 1 Page 197 of 208 11.02.2010

Table 2
KAWASAKI Gas
Turbine Europe
KGE No. GmbH
Gas LAST START

turbine M7A-03 DD TIME
[SEC]:
SERIAL LAST STOP

NO. TIME
[SEC]:
LOCATIO
N # 3044, CET Bacau, Romania
DATE
OPERATION HOURS [hrs] Hrs Hrs Hrs Hrs
START Qty pcs pcs pcs pcs
SUCTION
TEMPERATURE T1
[C] TE3150
PRESSURE LOSS PDT310

TURBINE FILTER
[Pa] 4
COMPRESSOR
DIFF PRESSURE [bar] PT9208
CPD
EGTav1 / EGTav2 TE3306
(mean value)
[C] TE3308 ---------------- --------------- ---------------- --------------------
TE3302
.1
EGT #1 [C] TE3304 ---------------- --------------- ---------------- --------------------
.1
TE3302
Gas turbine
.2
#2 [C] TE3304 ---------------- --------------- ---------------- --------------------
.2
TE3302
.3
#3 [C] TE3304 ---------------- --------------- ---------------- --------------------
.3
TE3302
.4
#4 [C] TE3304 ---------------- --------------- ---------------- --------------------
.4
TE3302
.5
#5 [C] TE3304 ---------------- --------------- ---------------- --------------------
.5
TE3302
.6
#6 [C] TE3304 ---------------- --------------- ---------------- --------------------
.6
POWER [kW]
PERC. RATED
POWER
[%]
Document 1 Page 198 of 208 11.02.2010

SPEED [%]
LE9225
VSV-ANGLe /mm LE9226 ---------------- ---------------- -------------------- --------------------
BLEED-VALVE DLE
/mm LE3404
FUEL Nm/h
CONSUMPTION r.
VIBRATIONS VIBRATIONS
XE
BEARING #1 9201
(y)
[m] XE ---------------- ---------------- -------------------- --------------------
9202
XE
BEARING #2 9203
(y)
[m] XE ---------------- ---------------- -------------------- --------------------
9204
TEMPERA-
BEARING #1 [C] TE2171

TURE
BEARING TE2170
#1/#2
[C] TE2172 ---------------- ---------------- -------------------- --------------------
PRESSURE [bar] PT2124

Lube Oil
TEMPER-
ATURE
[C] TE2125
[mm/s XE9301
VIBRATIONS
Gear Box
]
TEMPERATURE
ON
[C] TE9304
TEMPERATURE
OFF
[C] TE9305
POWER L1/L2/L3 [A]
COS PHI/
-/[Hz]
GENERATOR
FREQUENCY
TE9109
BEARINGS (A)
[C] ---------------- ---------------- -------------------- --------------------
TEMPERA-
#A/#B TE9110
TURE
(B)
TE9101
COIL [C] TE9102 ----------------- ----------------- --------------------- ---------------------------
TE9103
XE9113
VIBRA-
BEARINGS [mm/s
TIONS
(A)
XE9112 ---------------- ---------------- -------------------- --------------------
#A/#B ]
(B)
Document 1 Page 199 of 208 11.02.2010

PLANNED COMMISSIONING TABLE FOR M7A-03 -TURBINE
EOH Working range Standstill (after

cooling)
(Days)
Y
500 h - Endoscopic inspection (LEVEL 0) 4
800 h Inspection of the combustion chambers, compressors,
turbine blades and stator rings.
Check the previous problem
Y
8,000 h Endoscopic inspection (LEVEL A) 4
Inspection of the combustion chambers, compressors,
turbine blades and stator rings
Inspection of all filters in the systems
Compressor washes with cold gas turbines
16,000 h Inspection of intake/exhaust gas system, hot part (LEVEL B) 12
Dismantling of the above turbine housing
Inspection of the 1st stage compressor turbine blades
and guide vanes with exchanges if necessary
32,000 h Basic overhaul (LEVEL 14
C)
Exchange of the turbine with a basic overhauled
Exchange of the gear with a basic overhauled
Change lube oil (oil on-site) if necessary
Y ySub-total 1 y y 38
32,500 h - Endoscopic inspection (LEVEL 0) 4

32,800 h Inspection of the combustion chambers, compressors,
Y
Document 1 Page 200 of 208 11.02.2010

EOH Working range Standstill (after cooling)
(Days)

Inspection of the 1st stage compressor turbine blades and
guide vanes with exchanges if necessary
64,000 h Basic overhaul (LEVEL C) 14
Sub-total 2 76

Y
Inspection of the 1st stage compressor turbine blades and
guide vanes with exchanges if necessary
96,800 h Basic overhaul (LEVEL C) 14
Document 1 Page 201 of 208 11.02.2010

Sub-total 3 114
EOH Working range Standstill (after

cooling)
(Days)
Y


Inspection of the 1st stage compressor turbine blades
and guide vanes with exchanges if necessary
127,999 EOH or 15 years; end of maintenance contract
Should irregularities be established during a regular inspection, interim inspections could be

required.
Notes
EOH = OH + 10x OOH + 15x NS
EOH = Equivalent operating hours
OH = Operating hours
OOH = Overload operating hours
NS = Normal start
Tolerance band for all inspections +/- 500 EOH
Document 1 Page 202 of 208 11.02.2010

H Decommissioning
To avoid damage to the gas turbine generator unit and connected parts (vessel, chimney
etc.) KAWASAKI specialist staff are to be used.
KAWASAKI is not liable for any improper decommissioning!
The gas turbine generator unit is to be brought to a standstill (see F. Operation, stop
procedure).
The gas pressure, air pressure and fluid intake is to be adjusted and switched off.
The power supply is to be adjusted and switched off, to secure against any re-starting.
All liquids are to be disposed of in an ecologically, environmentally friendly and

professional manner. The same applies to batteries and similar hazardous materials.
The gas turbine generator unit is to conserved for future re-commissioning (close
connections etc.)! The customer is obliged to deliver all necessary preserving material,
at his own cost, to the installation location of the gas turbine generator unit.
Document 1 Page 203 of 208 11.02.2010

I Disposal
To avoid damage to the gas turbine generator unit and possible connected parts (vessel,
chimney etc.) KAWASAKI specialist staff are to be used.
KAWASAKI is not liable for any improper decommissioning!
Document 1 Page 204 of 208 11.02.2010

J KGE & KHI Minutes and Reports
Project-specific certificates, minutes and test results of KAWASAKI Gas Turbine Europe
(KGE) and KAWASAKI Heavy Industries Japan (KHI) are listed at the end.
Document 1 Page 205 of 208 11.02.2010

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Municipality of Bacau, Str. Marasesti Nr.

6, Bacau 600017, Romania

Gas Turbine Generator Unit

First Issue Revision A Revision B Revision C Revision D

KAWASAKI Gas Turbine Europe GmbH

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Installation and Assembly

Service Bulletin: This document is issued by KGE and is forwarded to customers.

- to provide the operator with basic instructions for installing and

KAWASAKI Gas Turbine Europe GmbH

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KGE KAWASAKI Gas Turbine Europe GmbH, Germany

P/S Power Section

RTD Resistance Temperature Sensing Device

TBO Time Between Overhaul

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Gas turbines work as shown in the following simplified process:

Ambient air is drawn in and compressed in the compressor stages.

The resulting volume of hot gas is directed to the turbine stages.

Rough schematic sketches of a gas turbine generator unit

The gas turbine is an industrial gas turbine, built as an single-shaft engine, in

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Waste heat utilisation

This thermal energy is mainly converted into:

Hot water, which is used in heating networks.

Cold water generation through absorption freezing machines.

The normal operating condition of the gas turbine generator unit

During normal operation, the gas turbine generator will be remotely

Handling of the machine technology within the sound enclosure during

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As the manufacturer of the Gas Turbine Generator Unit, "Kawasaki GP80D",

For this equipment, a comprehensive risk analysis was carried out by

The equipment may not be dismantled and installed at another location.

Spare parts may only be used in accordance with manufacturer guidelines.

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Standards and guidelines

ISO 12100-1 Security of Machinery

90/396/EC Gas Appliances Directive

97/23/EC Pressure Equipment Directive

EN 60204-1 Electrical equipment for machines

EN 50156 Electrical equipment for furnaces

DIN 31051 Fundamentals of maintenance

DIN VDE 0101 Erection of electrical power installations with a nominal

DIN VDE 0105 Operation of electrical power installations

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KAWASAKI takes precautions to prevent danger from arising, monitors the

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Construction and connection, operating, maintenance and dismantling are only to

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Rotating beacon gas Rotating beacon fire

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WARNING FIRE ALARM

ACOUSTIC & OPTIC

WARNING FIRE EXTINGUISHING

ACOUSTIC & OPTIC

WARNING GAS ALARM

ACOUSTIC & OPTIC

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Positions of the Emergency -Off buttons in the noise enclosure.

Image 3 Emergency-Off button inside Image 4

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