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Turbina Gaz
Turbina Gaz
With the necessary gear ratio of the gear, a rotational speed is created,
which is converted by the generator into an electrically useful rotational
frequency.
r"
Operating condition
The normal operating condition of the gas turbine generator unit is largely
network-parallel.
Isolated operation is occasionally possible and in emergency situations.
The gas turbine generator unit is designed for operating in automatic mode.
During normal operation, the gas turbine generator will be remotely monitored.
Handling of the machine technology within the sound enclosure during normal operation
of the gas turbine generator unit is not necessary.
All other or abnormal application and use of the gas turbine generator unit is not permitted.
Kawasaki Gas Turbine Europe GmbH accepts no liability for damage to persons or material!
B Safety
B. 1 KAWASAKI safety concept (protection from explosions)
Due to the high quality and safety standards at KAWASAKI, the concept for
the gas turbine generator unit has been in reliable use for years.
KAWASAKI takes precautions to prevent danger from arising, monitors
the installationconstantly and has also installed safety measures to
eliminate danger.
>
In addition, an inspection was carried out in accordance with the ATEX
Directive 94/9EC and concludes with an evaluating description.
This separate safety concept can be seen at KGE on request, (document no.:
EFR3389-091214)
B. 3 Warning systems
The gas turbine generator
unit GPB80D has its own
gas warning and fire
detection system.The Gas
Turbine Generator Unit
GPB80D has its own gas
warning and fire detection
system.
Rotating beacon gas
(yellow)
(red)
Image 1
Exampl
e
Gas
warning
system
Fire
detection
system
Image
2
&
OPTIC
&
OPTIC
\I/
n'
%
i
n
WARNING GAS ALARM
ACOUSTIC
&
DANGER
Extinguishing process with C02 (carbon dioxide).
The noise enclosure is to be vacated immediately
and the door to be kept closed. C02 can be detected
by a slight lemon smell.
Opening the door is then only possible following
intensive ventilation and approval by the fire service.
OPTIC
C Equipment Description
-
Datasheets
C.1 Description
The gas turbine generator described here is a GPB80D unit.
The model
GPB80DDual-Fuel (# 3044 Bacau) is described as
follows.
The Gas Turbine Generator Unit GPB80 consists of the following main components (unit
parts which are not included in the standard configuration will be marked as "part of
delivery" or "not part of delivery"!)
I. Noise enclosure
1.1 Gas turbine
1.2 Gear
1.3 Coupling
1.4 Generator
1.5 Base frames
1.6 Auxiliary system
1.7 Air pressure system, exhaust system, motors
1.8 Gas warning and fire extinguishing systems
1.9 Noise enclosure, cooling and combustion air system
II. Power house (sound enclosure)
1.10
Electrical control system
1.11
Circuit diagrams
III. Filter house and air ducts
1.12
Air ducts
1.13
Filter house (not including technical room)
IV. Gas compressor (ELTACON (NL) (#3044 Bacau)
V. Vessel (this time, not part of KGE delivery)
In detail, the unit components are fitted with the following subcomponents:
Noise enclosure
This includes the basic frame and its components.
Base frames
with installed components, such as:
Gas turbine
Gear*
Generator
Lube oil system
Air pressure system
Fuel system
Filter house
the following components are included in the installation on
the noise enclosure:
Turbine control
Feeder
Central fire alarm system with gas warning system
Frequency converter for the starter motor
As a standard, KGE provides the control cabinet house with a control system. There
is, however, the possibility to install individual fields. This mostly occurs for reasons
of space'and at the special request of the customer.
C.2 Gas
turbine
Description
Manufacturer: KAWASAKI Heavy Industries, Ltd. Japan
Type: M7A-03D
As a heavy duty industrial gas turbine, the gas turbine M7A-03D is specially
designed for continuous use in CHP units and works in a simple open cycle.
As a single-shaft unit for the generator drive, compressors and turbines are fixed to
a common shaft.
Technical data about the Gas Turbine M7A-Q3D (#3044 Bacau) and its installation
conditions
Installation height:
Suction pressure loss: Exhaust
gas pressure loss: Suction air
temperature Generator
efficiency:
Fuel:
Heating value:
Terminal power Fuel
Consumption:
Air intake:
Compressor
Combustion chambers
6 combustion chambers
Bearings
Coupling to gear
Diaphragm coupling
Dimensions
Weight
6,300 kg
125
250
500
1000
2000
4000
8000
84
92
98
100
104
110
102
102
114
116
114
112
108
104
86
88
92
96
100
104
98
Main components
Air inlet housing
11 -stage axial compressor
with variable stator vane (VSV) of
the first 3 stages in the compressor
Image 6 Example
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
Image
7
Image 8
Combustion chambers
The 6 combustion chambers are
arranged over external, concentric
distribution pipes and supplied with fuel.
Each of the six combustion chambers
consists of a transition duct and the
actual combustion chamber. The
combustion chambers are conical, point
Turbine
The guide tube directs the hot, highpressure 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.
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.
11
Flame detector
3
5
6
8
9
10
12
13
14
33
35
Revolution
Revolution
Exhaust gas temperature
CDP Sensor
VSV-gage
15.11.2012
Nozzle guide
N-155
KM-S402
Technical details
.
I
p
n
e
p
a
u
k
t
to
rq
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e
e
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e
a
d
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o
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a
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ty
O
p
v
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e
Ope
r
ratin
s
g
p
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e
e
ditio
d
ns
M
Lubr
a
icati
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on
L
i
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a
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E
f
f
i
c
i
e
n
c
y
T
o
t
a
l
w
e
i
g
h
t
13.790
1/min
1,500
1/min
1
1
1
%
f
o
r
2
m
i
n
u
t
e
s
4
0
0
%
o
f
c
o
n
s
t
a
n
t
l
o
a
d
9,1
KW
P
l
a
n
e
t
a
r
y
g
e
a
r
C
o
n
t
i
n
u
o
u
s
o
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e
r
a
t
i
o
n
~
2
.
0
b
a
r
u
n
d
e
r
p
r
e
s
s
u
oil
tem
per
atur
e,
Sup
ply
fro
m
the
gas
turbi
ne
oil
tank
Gas
turbi
ne
r
e
2
5
0
l
/
m
i
n
+
/
4
0
l
/
m
i
n
.
3
0
5
0
3
2
.
0
0
0
h
o
u
r
s
8
%
6,80
0 kg
Scope of delivery:
Description
Amount
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 highspeed
coupling
provides a
direct
connection to
the output end
of the gas
turbine.
The iow-speed
coupling is
between the
gear-box and
the generator.
This clutch is
fitted as a
safety clutch for
the connection
from the gear
and generator
to the bolts to
protect against
overload of the
unit, and also
against shortcircuits during
synchronisation
and network
failure.
Image
16
Image 19
Technical details
(according to
Lieferschein)
Type:
cy
Speed
Power
Synchro
factor
nous
Prote
Nominal
ction
output
class
Voltage
gener
Frequen
ator
Protectio
10,11
n class
1 kVA
terminal
(15C
boxes
) H/F
Cooling 6,300
V
Stimulati
50 Hz
on
0.8
Control
IP23
type:
IP23
Heating
IC0A1
during
Brushl
stop
ess
Total
AREP
weight
1x
LSA56
500
BMBL13
W
0 4p
under
1,500
1/
230 V
min
17.1
k
Rotary
g
current
C.5 Base
frame
Descripti
on
T
h
e
m
a
c
h
i
n
e
b
a
s
e
i
s
u
s
e
d
f
o
r
i
n
t
e
g
r
a
t
i
n
g
a
n
d
f
a
s
t
e
n
i
n
g
t
h
e
g
a
s
t
u
r
b
i
n
e
s
,
g
e
a
r
s
a
n
d
r
e
q
u
i
r
e
d
a
u
x
i
l
i
a
r
y
s
y
s
t
e
m
s
.
C
o
n
s
t
r
u
c
t
i
o
n
:
K
A
W
A
S
A
K
I
G
a
s
T
u
r
b
i
n
e
E
u
r
o
p
e
G
m
b
H
M
a
n
u
f
a
c
t
u
r
e
r
:
L
i
n
d
e
n
b
e
r
g
A
n
l
a
g
e
n
G
m
b
H
In detail,
this
consists
of:
Rigid
hollowsection
frame
and steel
profile
Mounting
plates
and
elements
Elastic
turbine
connectio
ns
tube
and
connectio
ns
Oil
tank
integrate
d
between
the
side
rails
Elastic
mounting
of
the
base
frame on
the
foundatio
n
Image 20
C.6 Speed
measurement
Description
The speed
measurem
ents (three
measurem
ents)
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 shutdown, in
order to
avoid
damage.
Precisely in
the lowspeed
clutch, the
predetermi
ned
breaking
point
(shear
pins) is
monitored,
in order to
shut down
in the event
of a
disconnecti
on 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
measurem
ent)
Evaluation (in
the
control
station)
C.7 Auxiliary
System
Description
All
required
auxiliary
and
monitoring systems
are available for
operating the gas
turbine generator
unit.
Image 21
Example
generators
consists of:
Oil sump, 2,000 I
with
level
monitoring, Pump
for filling
Oil - water cooler
Oil mist separators
Oil mist
separators
separate oil
vapours which
are in the gear
and oil sump,
and return the
captured oil.
The fitting of the
filter unit
guarantees
separation of
very high
concentrations of
oil vapour.
Concentrations
of oil vapour The
relevant negative
pressure in the
oil tank is
obtained by
tuning the
device. The
exhaust gas
flows through the
device where dirt
particles are
filtered out.
Main oil pump,
driven
mechanically
from the gear.
Pre-/post lube
pump, 3 bar,
with an AC
motor, 400
VAC, 2.2 kW
Emergency oil
pump, 1 bar,
with DC motor,
24 V DC, 0.4
KW
Double filter,
switchable with
differential
pressure
monitoring
Different
armature filters
Thermostat/pre
ssure control
valves
Pressure and
temperature
switches
Manometer,
thermometer
Hose line,
piping for
internal
distribution in
high-grade
steel
Technical details of
the lube oil system
Lube oil
Heat removal
Oil amount
Circulation
Oil pressure
Operating temperature
Consumption
ISO VG
46,
mineral
oil with
additive
s
-220 kW
ca.
2,000 I
ca. 530
l/min
ca. 1.5 2.0 bar
(g)
30
50C
ca. 0.5
l/h
(when
using oil
mist
separat
or
approx.
1.5
l/day)
The
corresponding
safety data sheet
for the abovementioned lube
oil is available
under "oils,
lubricants and
other liquids".
(2 each
valves), with
ventilation
and open
close
feedbackposition
system,
DVGW
approved /
Liquid fuel:
Main shutoff valve
combination
with
ventilation,
(2 each
valves) /
with
ventilation
and open
close
feedbackposition
system
Filling gas valve,
DVGW permitted
Gas
leakage
detector,
DVGW
permitted and Oil
leakage detector
Natural gas control
valve and DLE
main
component)
which is
delivered
controlled,
filtered, dry and
clean and with
the necessary
supply
pressure.
Fuel: Natural
gas H (physical
properties
calculated
according to
DIN 51817),
filtered, clean
and dry
Filtering: < 10 |jm
with steam trap
Temperature:
-20....+65C (at
least 50C
above dew
point and free
from steam at
the
interconnection
point
Pressure: 22
bar (g) +/- 0,3
bar (g) (at the
interconnection
point of the
noise
enclosure)
Gas composition
(requested
min.
standard values)
Natural gas H
LHV 10,034
kWh/m3
S
u
l
p
h
u
r
c
o
n
t
e
n
t
:
m
a
x
.
0
.
1
%
w
t
X
L
H
V
(
k
J
/
k
g
)
/
4
3
,
1
1
6
I
m
p
u
r
i
t
i
e
s
<
1
0
p
m
,
m
a
x
.
3
0
p
p
m
x
L
H
V
(
k
J
/
k
g
)
/
4
3
,
1
1
6
N
o
l
i
q
u
i
d
c
o
m
p
o
n
e
n
t
s
o
r
h
y
d
r
o
c
a
r
b
o
n
w
h
i
c
h
c
a
n
b
e
c
o
n
d
e
n
s
e
d
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 threephase current
squirrel cage
rotor motors.
Turning gear
After shutting
down the gas
turbine, this
must be turned
at low speed in
order to avoid
warpage of the
blade from
different cooling
in the gas
turbine.
For this, the
aforementioned
starter motor is
used.
Air pressure
supply
Pressure 6...7 bar
(g); min. 5bar (g)
Total air
pressure
requirement
during: ~ 200
Nm3/h of the
start/stop
procedure
Consumption
during: ~ 50
Nm3/h of
operation
Quality:
Instrument air,
oil-free, dried
and filtered
Start-bleed
system
This system is
used during the
start up
procedure.
Here,
compressed air
is blown from
the gas turbine
compressor
over a flap valve
into the exhaust
system, in order
to avoid flow
separation in the
gas turbine
compressor.
Bleed-system to
DLE control
During partial
load operation
of the gas
turbine, too
much ambient
air is drawn in
and compressed
by the turbine
compressor.
Due to the
combustionrelated
procedures
within the gas
turbine, and the
excess air, the
required
exhaust gas
values can be
exceeded.
For
this
reason,
not
only the fuel
is regulated
during partial
load
operation, but
also part of
the
compressor
air which is
determined in
the
combustion
chamber
is
fed
directly
into
the
exhaust gas
duct.
Electrical
components,
control and
monitoring
equipment
To operate the
gas turbine and
to monitor it
during
operation,
additional
sensors are
installed in the
gas turbine.
Control and
recording of the
measuring
signals takes
place in one of
the terminal
boxes which
are built into the
gas turbine:
Ignition
coils,
ignition plugs, 2
pcs
Flame
detectors with
evaluation
module, 2 pcs
CDT
(Compressor
Discharge
Temperature)
sensor
Outlet
temperature
sensor
CDP
(Compressor
Discharge
Pressure)
sensor
Speed sensors,
3
pcs
with
monitor
Vibration
sensor and
monitors, 2 pcs
each for the gas
turbine, the
gear and the
generator.
Thermal
elements
for
monitoring the
exhaust
gas
temperature, 12
pcs with
display
Resistance
thermometer
PT100
Compressorcleaning
equipment
To maintain the
effectiveness of
the gas turbine
and to avoid
erosion/corrosio
n on the
compressor
blades, the gas
turbine is fitted
with a
compressor
cleaning device.
This separate
component
consists of:
a storage tank, a
pump unit and a
connecting hose to
the gas turbine.
The cold wash
procedure is
carried out when
the machine is
switched off.
Fluid amount: 191
per wash
Cleaning agent:
Clean
water/cleaning
agent in a ratio of
4:1.
Description
The lube oil
system of the
gas turbine
generator unit
largely consists
of the following
main
components:
Oil cooler
Thermostatic valve
Oil
pressure
controller
Oil tank
Lube oil
Pre-/post-lube
pump
(PPLOP)
with AC motor 3
bar,
functionality of
the entire
system.
The bearings are
lubricated with
different
parameters,
during and after
operation of the
gas turbine. The
data are
summarised in
the following
table.
Bearings
Operation
Pre-/post-lubri cation
Emergency
Filtering
Post-lubrication
No. #1
Over
Volume
pressure
flow
0.98 bar 25 l/min
Axial
bearings
No. #1
0.98 bar
> 49 l/min
Volume
flow
10 pm
nom.
0.98..
> 22 l/min
2.94 bar
0.98 bar
22 l/min
Axial
bearings
No. #2
0.98..
Volume
Over
flow
pressure
12 l/min
2.94 bar
Radial
bearings
No. #1
Over
pressure
0.98..
> 10 l/min
2.94 bar
0.98 bar
> 35 l/min
Axial
bearings
0.98..
2.94 bar
ividually
se
10
l/min
during
e
oi
l
s
y
st
e
m
s
u
p
pl
ie
s
th
e
lu
b
e
oi
l
n
ot
o
nl
y
to
th
e
g
a
s
tu
rb
in
e,
b
ut
al
s
o
to
th
e
g
e
ar
a
n
d
g
e
n
er
at
or
b
e
ar
in
g
s.
The
amo
unt
of
lube
oil
for
the
gear
is
sum
mari
sed
in
the
follo
win
g
tabl
e:
gear
Operation
Overpressure
Volume flow
Filtering
1.47 bar
>214 l/min
10 pm nom.
T
h
e
a
m
o
u
nt
of
lu
b
e
oi
l
fo
r
th
e
g
e
n
er
at
or
d
e
p
e
n
d
s
o
n
it
s
si
z
e
a
n
d
m
a
n
uf
a
ct
ur
er
.
F
or
th
is
,
th
e
lu
b
e
oi
l
s
y
st
e
m
pr
o
vi
d
e
s
a
v
ol
u
m
e
of
5
0
1/
m
in
w
it
h
a
p
o
si
ti
v
e
pr
e
s
s
ur
e
of
1.
5
b
ar
.
T
h
e
m
a
n
uf
a
ct
ur
er
s
p
e
ci
fi
c
d
at
a
System
description
c
a
n
b
e
s
et
u
si
n
g
a
pr
e
s
s
ur
e
re
d
u
c
er
a
n
d
a
fl
o
w
m
et
re
.
The gas
turbine lube oil
system
consists of the
oil tank,
pumps, filters,
oil coolers and
other devices
for controlling
the required
components.
A good
description
and
presentation of
the
components is
available in
the respective
datasheets.
The lube oil is
drawn in from
the oil tank,
over a check
valve and dirt
trap, and
compressed at
a constant
pressure of 5
bar. The
constant
pressure of 5
bar is set
using an
internal
pressure
control valve,
in order to
protect other
components.
A thermostat
regulates the oil
feed in accordance
with the oil
temperature.
Cold lube oil is
fed directly in
to
the
circulation,
from the lube
oil cooler over
a
bypass.
From
a
temperature of
about
30C,
the thermostat
valve
is
activated, so
that a partial
flow can first
be
directed
over the oil
cooler.
Depending on
the
temperature,
the thermostat
opens or
closes and
maintains a
lube oil
temperature of
about 40C.
After this, the
lube oil is fed
from the
cooler through
a switchable
double filter *
(10 pm), which
secures the
required oil
purity.
After the
double
filter, the
lube oil is
distributed
in
the
respective
lube
oil
volumes
and
temperatu
res.
A
secondary
exhaust
gas valve
regulates
the
pressure
of the lube
oil at 1.5
bar.
A partial flow
of 131 l/min is
set over an
aperture, for
lubrication and
cooling
bearings #1
and #2.
The remaining lube
oil (approx. 398
l/min) is fed to the
gear and
generator.
The relevant
measuring
points for the
thermometers,
pressure
sensors and
pressure
switches are
integrated into
the oil system.
The respective
data are
hereby
monitored
during the
start-up
procedure and
operation, and
relevant
measures are
taken.
All feed points
for lube oil in
the gas turbine
generator unit
are fitted with
a return pipe.
The lube oil is
thereby
transported
back to the
tank, where
the flow is
steadied and
gas bubbles
are eliminated.
Similarly, oil
mist, which
arises from
torsion in the
bearing seals,
is fed over a
pipe in the oil
tank and
cleaned in an
oil mist
separator.
Image 22
Techni
cal
details
Typ
e:
Gea
r
pum
p
Out
put
570
Liter
s/
min
(imiti
No
min
al
pres
sure
0.5
MPa
Spe
ed:
1,14
1
rpm
Install
ation
locatio
n:
flange
mount
ed on
the
gear
Image
23
(Exampl
e
Image
24
niiHi)
Technical
details
Type:
screwed
plate heat
exchange
rs Water
volume:
24 m3/h
Water
temperatu
re on:
max. 32
C(# 3044
Bacau)
Water
temperatu
re off:
approx.
42 C
Pressure
loss water
33 kPa Oil
volume:
34.20
m3/h Oil
temperatu
re on: 60
C
Oil
temperatu
re off: 40
C
Pressure
loss oil 46
kPa
Designed
heatpower:
324 kW
Installatio
n location:
in the
technical
room of
the filter
house
NOTE
The
power
dissipatio
n, which
is fed over
the lube
oil has the
following
values:
for the
gas
turbine:
approx.
70 kW, for
the gear:
approx.
130 kW
Therm
ostatic
valve
for
regulat
ing the
lube
oil
temper
ature
The
thermo
static
valve
starts
to
open
at
approx
. 27 30 C,
and
reache
sa
mixed
oil
temper
ature Thermostatic valve
where
by
more
and
more
lube oil
is fed
over
the
lube oil
cooler.
Before
the
autom
atic
thermo
static
valve
starts
openin
g, the
lube oil
flows
into
the
cycle,
and
thus
not
over
the
oil/wat
er
cooler.
Should
the
springloaded
functio
n be
faulty,
the
thermo
static
valve
can
also be
manua
lly
engag
ed.
Option
s:
Compl
etely
"open"
or
comple
tely
"closed
"
Main
oil
filter
M
a
i
n
l
u
b
e
o
i
l
f
i
l
t
e
r
,
s
w
i
t
c
h
a
b
l
e
,
f
o
r
p
e
r
m
a
n
e
n
t
f
i
l
t
e
r
i
n
g
o
f
t
h
e
l
u
b
e
o
i
l
.
Main
lube
oil
filter
(Exam
ple)
The
mai
n
lube
oil
filter
is
fitte
d
with
a
dou
ble
filter
and
can
be
swit
che
d off
whil
e
the
turbi
ne
is
run
ning
.
BUT:
It
sho
uld
be
note
d
that
the
filter
whi
ch
is
not
yet
use
d
mus
t
first
be
slo
wly
fille
d
with
lube
-oil
and
sim
ulta
neo
usly
vent
ilate
d
bef
ore
final
swit
chin
g.
Detail
s can
be
found
in the
manuf
acture
r and
suppli
er
docum
entatio
n.
Main lube oil pressure controller, adjustable (is adjusted during the IBS)
Controls the main lube oil pressure in the system for the gas turbine, gear and
generator.
Image 28
Technical details
Configured lube oil pressure: approx. 2 bar (g)
Outflow volume in control range: approx. 173 +/- 40 l/min Site of assembly: on
the base frames
approx.
approx.
Vacuum
Tank capacity
the
filter
The internal capacity of the lube oil tank is ~2,2 m 3, the filling
quantity of the first filling is 2,000 Liters.
Lube oil tank equipment
Lube oil level display: This enables the lube oil to be checked from outside the
package. The lower limit is the lower part of the suction opening of the pump. The
upper limit is established by the volume of oil.
Lube oil level switch for external alerts of the oil tank content.
Suction side dirt traps for the mechanical main lube oil pump, electrical auxiliary pump
and control oil pump.
Lube oil tank heating and temperature sensor. When the gas turbine is stopped, the
lube oil temperature should be regulated at approx. 10C. Should the lube oil
temperature fall below 10C, the the lube oil tank heating is switched on via the lube oil
temperature switch, so that the lube oil is warmed up. The heating system is turned off
when the oil temperature has reached ~15C.
Oil mist separator: This separates the oil vapours in the gear and oil sump, and feeds
the oil which has been captured from the oil mist back into the tank. This recirculation
reduces oil consumption, while the clean air from the oil can be emitted into the
environment. Oil mist is suctioned from the tank and its connected systems by a
ventilator with an air inlet, in order to establish a certain vacuum in the system.
This vacuum prevents oil leakages into the bearing sealings of the gas turbine and the
gear. Negative pressure inside the oil tank must be kept at -100 mmWC. At 5m3/min,
the ventilator capacity should have a negative pressure of -100 mmWC.
A tank filling pump is provided for filling and emptying the lube oil tank; its relevant
function can be selected using a 3-way valve.
C.8 Fuel system
Description
Requirements of gaseous fuels.
1. Gas temperature
-20C to +65 C
3. Sulphur content
5. Particle diameter
10 pm
0%
HK Kawasaki
Installation of the Gas-/ & Liquid-fuel system (# 3044 Bacau)
The gas turbine is designed as a DLE variant with a single fuel system.
The fuel control system enables monitoring and control of all required
operating conditions, such as start-up, different accelerating and power
conditions from zero to full power.
(see P&ID E3029 080 102 and E3029 080 103)
Before each start, a control of the leak-tightness is carried out over a valve
combination.
By using the pressure controllers for monitoring the fuel pressure, in the event of
leakage or too low pressure, a start-up is prevented (it is not possible to operate
the gas turbine with gas fuel).
During operation, the configured speed is maintained using a speed control circuit.
The actual value signal comes from one of the magnetic encoders which are
mounted on the turbine blades.
The main components of the Gas fuel system are:
Switchable double-filter-unit
Safety shut-off valve combination, DVGW permitted,
with position feedback system
Safety ventilation valve, DVGW permitted, with
position feedback system
Gas Leakage detector, DVGW permitted
Gas measurement valve (main gas fuel governor)
Multi-burner unit, air pressure controlled
Parallel ring piping
6 each fuel chambers with nozzles
Pressure monitoring with switches and manometers
Gas fuel flexible tubes
Piping from the connecting flanges on the base frame to the gas turbine in
stainless steel.
The approved fuel is natural gas H (with methane as its main component),
which is delivered controlled, dry and clean, and with the necessary supply
pressure.
A main manually operated shut-off valve is fitted in front of the entrance to the gas
turbine generator unit.
The main components of the Liquid Fuel system (# 3044 Bacau) are:
Switchable double-filter-unit
Double Safety shut-off valve combination, with position feedback system
Safety ventilation valve, DVGW permitted, with position feedback system
Liquid fuel Leakage detector
Liquid fuel, high-fuel pressure unit, (installed inside of liquid fuel module)
Liquid fuel ,main- and start-fuel governor unit, (installed inside of liquid fuel module)
Liquid fuel ,air- / water purge unit (installed inside of liquid fuel module)
Liquid fuel .drain unit (installed inside of blue GT-base frame)
Multi-burner unit, air pressure controlled
Parallel ring piping
Fuel chamber with nozzles
Pressure monitoring with switches and manometers
Liquid fuel flexible tubes
Piping from the liquid fuel module to the
connecting flanges on the base ^
frame to the gas turbine in stainless steel.
Image
33.2
Image 33.4
Image
33.3
5 x flametransfer tubes
Image 33.5
Manifolds
The manifolds are responsible for consistently supplying natural gas to
the individual injectors.
This is done in accordance with the respective operating conditions of the
gas turbine.
Combustion chambers
The gas turbine has 6 separate combustion chambers. 3 per side, which are
connected to each other by flexible metal hoses (flame pipes).
The two lower combustion chambers on each side are those which are
ignited. Following ignition, there is a flame rollover to the third/most upper
combustion chamber.
Flame tubes
Following ignition, the flames are fed through the flame tubes to the two
lower combustion chambers and the combustion chambers lying above.
Flame detectors
During the start-up procedure, a flame must be detected in the uppermost
combustion chamber. If this does not happen, start-up is immediately
aborted.
Ignition plugs
The two lower combustion chambers are installed with ignition plugs.
During the start up procedure, at approx. 7% of the nominal speed, each of
the two lower combustion chambers on each side is ignited.
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:
Type:
Isolation
resistance
100 MQ
Installation:
The ignition trigger can be installed at a customer-preferred "cold" position, but the ignition
cable should be kept as short as possible.
150 mm
Discharge air
pressure
Electrical data
Control signal
Start Bleed
This controls the increasing compression pressure of the combustion air pressure. The
measure serves to drive the increasing compression pressure during the start-up procedure
to the exhaust gas pipe, thereby relieving the starter motor.
At the beginning of the start-up, the valve is completely opened and is slowly closed when
there is increasing speed.
At 70% rpm, the start-bleed valve is completely closed.
Specification
The following table summarises the specification.
Type:
Flap valve, from Nippon Keystone Corp.
Nominal
diameter
150 mm
Discharge air
pressure
Electrical data
Control signal
25 to 85
85 to 100
Specification
The specification for seal air is as follows:
Seal air
1) Instrument air, oil-free and filtered
2) Pressure: 0.13 bis 0.14 MPa
3) Volume flow > 2,0 Nm3/min instrument air,
4) through a command from the turbine control
centre:
- Solenoid valve open at 25%^N^85%
- Solenoid valve closed at N^25%, or N85%,
where N = turbine speed.
Seal air system components
1. Air pressure shut-off valve
2. Air pressure control valve
C. 13 Cleaning system compressor
Description
General
Image 37
Specification:
Cleaning
fluid
Specification
Total volume:
Cleaning
pump
Type:
Nominal
pressure
Mass flow
Supply:
Tank for cleaning agent
Drain tank
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
No.
Pipe position
1
2
Suction collector
Compressor housing (discharge "seal air")
Main housing
Image
38
pre-alarm
pre-alarm
with shut-down of the gas
turbine and closure of the
main gas valve
In the event of one of the two gas detectors sounding, an alarm message is
triggered if there is a threshold of 20% LFL (lower flammability limit).
If a threshold of 40% LFL is reached, an emergency shut-down of the gas
turbine is initiated. The gas valve inside the noise enclosure is closed and the
gas ventilation opened.
The noise enclosure ventilation remains on, in order to lead the escaped
gas over the sound enclosure ventilation system, out of the sound
enclosure and into the open air.
Further users are switched without voltage.
An optical and acoustic notification of a gas alarm is given by one of the
yellow flashing lights installed at the front exterior wall of the sound
enclosure, and by an alarm sound apparatus installed int he same place.
Image 41.1
Example
Filter
house
Filter house with platform, contains (details can be found in the manufacturer and
supplier documentation):
Combustion air channel to the gas turbine with sound absorber (the upper 2/3 of the filter
house front)
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).
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
m3/h. The lower the inflow, the longer the downtime of the individual filters and the
risk of icing.
The following table summarises the filter specification.
Efficiency
>99.97% at 0,3p with the DOP method in accordance with
the standard MIL-STD-282
Pressure loss
Visualisation system
Batteries for the ELOP (Emergency Lube Oil Pump), which are
located in the battery cupboard
Image 48
MiHli
All security devices, switching, monitoring and control devices necessary for
operating the gas turbine generator control unit, as well as the visualisation
are built into the control cabinet.
The most important operating and monitoring systems are in the
control cupboard opposite the entry door of the electrical switching
house.
These three control cupboards are assembled and fulfil the following
individual functions (list from left to right):
+1U01
+1U01
+1N03
Failur
e
GT-start
counter
GT speed
GT
exhaust
gas
temperatur
GT - peak
load counter
Image
50
WINNCC
touchscree
n
Control
panel PP17II
Manual
Synchronisatio
n
Wash
turbine
Automatic
Synchronisatio
n
Synchronisation
Hand
Automatic
Synchronisati
on
Geno
network
Release
turbine
EMERGENC
Y
SHUT-DOWN
Control
location remote
Failure
Acknowledgemen
t
Image 52
Example
CAUTION
As a general rule, full load drops over the 60kV switch are to be
reported to KAWASAKI Gas Turbine Europe!