Gas Tubine Generator

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Gas Turbine Generator
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ENGRO ENERGY LIMITED
Page 1 of 14
Revision: 0 Date: June 05,2009
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OPERATING PROCEDURE
EEL Qadir Pur Power Project
217 MW Combined Cycle Power Plant
Qadir Pur, District Ghotki
Sindh, Pakistan
(QFR-135-2)

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1.0 DESCRIPTION OF THE SYSTEM
The Purpose of Gas turbine generator is to convert mechanical energy of gas
turbine into electrical power. The technical data of gas turbine generator is
1. Cold air temperature 40C
2. Active Power 135MW
3. Voltage 13.8KV
4. Current 6644.7A
5. Power Factor (Cos) 0.85
6. Frequency 50Hz
7. Speed 3000 rpm
8. Number of phases 3
9. Excitation current 890A

The Generating Units main components are the generator (stator + rotor), the
Exciter system (a three phase ac machine + single phase PMG + rotating diodes),the
cooler and two bearings. Generator operates on Faradays Law of Electromagnetic
induction.
DC Excitation is supplied to the rotor through brushless excitation system consisting of
rotating diodes to generate the magnetic field. The rotating magnetic field is cut by the
stator conductors and emf (voltage) is induced.

STATOR: Consists of three major components Stator Frame, Stator Core and Stator
windings. Stator frame is a tough and rigid structure and hold the magnetic core and
windings. The core is built into a fabricated steel frame and consists of low loss silicon
steel segmental stampings insulated by a layer of varnish on both sides. The stator
winding is of the two layer diamond type with coils held in open slots by epoxy resin
bake fabric wedges and the insulation is synthetic resin bonded mica glass tape
throughout. The laminations of the stator winding are transposed in a regular pattern to
Minimize circulating currents and losses.
Technical data for the stator is as under
1. Number of slots 66
2. Number of conductors per slot 2
3. Voltage 13.8kV
4. Current 6644.7A
5. Number of terminal outputs 6
6. Temperature rise <80k
9. Phases connection Y

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ROTOR: The rotor main components are the solid rotor shaft, the field winding, the
retaining ring and the fans.
The field winding conductors are made of silver-bearing copper strips. They are
Consolidated together with their insulating material. The rotor windings coil-ends are
secured under the retaining rings to protect the windings against centrifugal forces by
means of laminated glass sheaths insulation. To detect a rotor ground fault in the
generator, a system formed by a brush actuated by a solenoid comes into contact with a
contact ring inside the excitation winding. Rotor is provided with shaft grounding brush
to direct any induced voltages in the rotor shaft to ground.
Technical data for the rotor is as under
1. Number of poles 2
2. Number of slots 28
3. Excitation voltage 400V
4. Excitation current 891A
5. Temperature rise <80k

EXCITATION SYSTEM

The excitation system is a brushless system consisting of a main exciter and a pilot
exciter. The main exciter is a three-phase AC generator. The pilot exciter is a single-
phase permanent magnetic generator. The main exciter is a three-phase synchronous
generator with a static field and rotary armature. The output is rectified into DC by a
rotating rectifier assembled on the exciter rotor. The DC supply is then led to generator
filed winding as excitation supply of generator.
The pilot exciter is a single-phase synchronous generator with magnetic poles.
These magnetic poles are made of permanent steel and mounted on the rotor.
The exciter rotor is coupled with the generator rotor by a flange.

To protect the rotating diodes against over currents, rapid blowout fuse is connected in
series with diode may be blown out in the condition of greater current usually caused by
the fault of one diode during operation. The generator can run in full load continually
while the fault occurs on one diode of the paralleled circuit of one arm.
Diode failure detector in A.V.R (Automatic Voltage Regulator) will give out warning
Signal with light or sound when one arm of the rectifier bridge broken.
.
Technical data for main exciter and pilot exciter is as under

Main exciter Pilot Exciter
- Active power 459 kW Capability 5KVA
- Power factor 0.9 Power Factor 0.9
- Frequency 150 Hz Frequency 400 Hz
- Speed 3000 rpm Speed 3000 rpm

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- Number of poles 6 No. of poles 16
- Voltage (DC) 108 V Number of slots 96
- Current (DC) 7.5 A Voltage 270 V
- Resistance at 75 C 12.197 Ohms Current 18.5A
- Number of slots 54 Number of phases single
- No of conductors per slot 2
- Voltage 435 V
- Current 1055 A
- Number of phases 3
- Number of diodes 12

Exciter cooling is carried out with air circulation by the shaft mounted fan on the exciter
side. The heated air meets the main generator hot air and is get cooled through the
water to air heat exchangers.

GENERATOR COOLING

Gas turbine Generator is air cooled consisting of two axial flow fans mounted on the
shaft , rotating at 3000 rpm and delivering an air flow of 41m
3
/s. Four water to air cooler
are installed to carry out the cooling of hot air when it leaves the generator. The water
used in the coolers is the cooling tower water.
While taking the coolers in service, proper venting and draining should be carried out to
flush out the metal particles and air trapped in the cooler by opening the drains and
vents of the coolers and also visual inspection of water boxes sealing should be carried
out to check for any leakage. Two Coolers water leakage detectors (level detectors
type) are provided to detect any leakage in the coolers at the earliest and to initiate the
alarm accordingly.
GENERATOR BEARINGS

The generator is equipped with two journal bearings to support the shaft.
Bearings are lubricated with lube oil ( pressure 0.8~ 1.5 bars, temperature 40C-55 C
and flow rate is 180 l/min) and at low speeds jacking oil is introduced to the bearings to
lift the shaft in order to provide sufficient clearance between the bearing and the
journals.
Both the bearings are equipped with resistance temperature detectors (RTDs) to
monitor the bearing metal temperature and to initiate an alarm and trip in case of
bearing damage. One Resistance Temperature Detector is installed on the lube oil drain
line to monitor the drain oil temperature.
Generator bearing turbine end is also equipped with two seismic detectors which
monitor the bearing vibration and two proximity detectors to monitor the shaft vibration.

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Generator bearing exciter end is equipped with one seismic vibration detector to monitor
the bearing vibration and two proximity type vibration detectors to monitor the shaft
vibration.
The vibration detectors initiates alarm and trip in case vibrations exceeds the limit
values.
SPACE HEATERS
When the machine shuts down the heating resistors are activated when temperature
inside the generator falls below 25C. The role of the heating resistors is to prevent
internal condensation.
Six sets of three 200 W resistors are mounted on the lower part on each side of the
machine.
SOUND PROOF ENCOSURE AND LIGHTING
The enclosure provides a complete protection for the generator against weather
conditions and thermally and acoustically insulates it.
Four doors with safety locks are provided for access to the enclosure.
The enclosure of the generator unit is lighted by standard 230V A.C incandescent lamps.
Emergency lighting is ensured by protected incandescent lamps supplied with 125V D.C located
in the enclosure.
GENERATOR JACKING OIL SYSTEM
Jacking oil system is provided to lift the generator bearings at low speed (turning gear
operation) in order to maintain a sufficient clearance between the journal and bearings to
prevent metal to metal contact. The system mainly consists of hydraulic oil pump-motor set,
pressure regulation unit, filtration unit, pressure acquisition and control unit.
The system is capable of providing working pressure at max. 20 MPa (200 bars) and flow rate
at max. 36 L/min. Filtration unit of filtration accuracy up to 10m is provided.
System technical data is as under
1. Power supply: three-phase, four-wire, 380V10%V
2. Maximum Working Pressure: 20 MPa
3. Maximum flow rate: 36 L/min2
4. Motor power: 15 kW2
5. Pressure transmitter contact: DC24V4mA~20mA
6. Electric space heater contact: AC220V40 W

The inlet of jacking oil pumps is from the main lubrication system so lubrication system should
be in service before the jacking oil system is taken in operation.

start up of jacking Oil system for flushing and jacking oil pressure adjustment:

1. Check for correct and firm component installation, electric connection and pipe
Connection of the device, e.g. conformity of oil inlet/outlet and blow down port
of valves and pumps with indications.
2. Check that monitoring instruments are installed in easily visible positions.
3. Check and confirm that system valves (#7#10#16 and #31) are fully open;
handle of valve (#14) is fully released (turn anticlockwise to the end position).
4. Loose oil pump blow down pipe connector and fill clean hydraulic oil into pump

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cavity through pump blow down port until it is filled up.
5. Quality of the oil shall be checked and it should be as per OEM recommendations to
ensure the performance and service life of the equipments (Viscosity 20~46 mm2/s).
6. Check and confirm the pressure value at the Pressure gauge # 32 is less than 0.15Mpa.
If its higher adjust valve #16 till the pressure value is below 0.15Mpa.
7. The main lubricating system shall be started before the high pressure shaft raising oil
pump device is started. Operation of pump is forbidden when main lubrication system
is under no flow status. Otherwise, the pump will be damaged.
8. Check for correct motor rotation direction. Correct motor rotation direction shall be
clockwise (viewing from motor tail end).
9. Perform flushing to remove any foreign matters inside before the operation of the
system. For flushing, close main oil outlet stop valves (#12 and #13) to the generator
bearings, run the pump to circulate the oil within the pipeline to perform self circulated
flushing with the two pumps in alternative operation. After flushing, check and replace
filter candle of oil filter (#8) before proceeding further to test run procedure.
10. To carry out the pressure adjustment, start motor and run idly (with overflow valve fully
loose) for 1 minute and observe pressure values (values indicated by three pressure
gages).
11. Adjust overflow valve (#14) to step up pressure by increment of 3~5 MPa/step until
overflow valve reaches preset pressure value, which is preset working pressure of the
device. Working pressure shall be strictly controlled below 20 MPa.
13. After running continuously for a period of time under set working pressure, oil warm
up shall be within allowable range (below 65C).
14. Check the temperature of pump case .Normally it should be 10C~20C higher than oil
temperature at pump inlet.
15. After the device runs for a period of time, adjust overflow valve (#14) to depressurize
the system to no-load operation status, and then stop the motor.
16. Jacking oil system shall be started and stopped under no-load conditions at low speeds.

2. PREREQUISITES FOR START UP OF GENERATOR AND
NO LOAD TESTS

2.1 Lube oil system is in operation and lube oil pressure is normal on pressure
gauges on both generator bearings.
2.2 Pressure switches on generator bearings (63QT-2A & 63QT-2B) are calibrated at
proper value to initiate the trip on low bearing lube oil pressure.
2.3 Site glasses on the lube oil drain lines of each bearing are clear and transparent
and lube oil drain flow is proper.
2.4 Jacking oil system is in operation and jacking oil pressure for each bearing is
normal.
2.5 T/G is in operation.

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2.6 Generator cooling water system is properly ventilated, flushed and cooling water
pressure is normal.
2.7 Water leak detection system installed, checked and normal.
2.8 Proper lighting system in the generator compartment installed and is operational.
2.9 Air filters installed and are clean.
2.10 Hot air and cold air temperature sensors are normal and alarm and trip settings
adjusted, tested and are intact.
2.11 Stator winding temperature and magnetic core temperature sensors are normal
and alarm/trip settings adjusted, tested and are in intact.
2.12 Vibration transducer and normal and alarm and trip settings adjusted, tested and
are intact.
2.13 Generator bearings metal temperatures sensors are normal and
alarm/protections settings adjusted, tested and are intact.
2.14 Operations of the space heaters tested and are normal.
2.15 Rotor ground detection brushes are in proper contact with the slip rings.
2.16 Generator earth switch is in open position.
2.17 Generator 13.8KV isolator is in open position.
2.18 Generator 13.8 KV synchronizing circuit breaker (GCB) is in open position.
2.19 Excitation circuit breaker is on manual mode.
2.20 AVR system installed, contains the diode failure signaling facility, its functioning
tested and is on manual mode.
2.21 Insulation resistance of stator winding (between phases and phases to ground)
measured and is normal (> 11.9M using 2500V megger).
2.22 Insulation resistance of the rotor winding measured and is normal (>1M using
500V megger).
2.23 Insulation resistance of the exciter winding and rectifier rings measured and is
normal ( ).
2.24 Measurement of exciter rotor and stator windings resistance and it is normal.
2.25 Excitation circuit protections like under excitation and over excitation are intact
and are tested.
2.26 All the CTs and PTs for monitoring control and protections are intact and their
circuits are checked.

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2.27 Generator neutral is properly grounded through grounding transformer.
2.28 Shaft grounding brushes are installed on the shaft to drain out the rotor induction.
2.29 Rotating diode fault detection fuses are installed and are of proper rating.
2.30 Generator protections stator earth fault, rotor earth fault, differential protection,
overvoltage, under voltage, unbalance load are intact and are tested.
2.31 Alarms and protections panels are ready to annunciate any alarm and
each alarm/trip indication tested.
2.32 Start up and shut down control panel is ready and tested.
2.33 Emergency trip buttons are installed checked and are normal.
2.34 Sight glasses on drain oil lines should be clear and transparent.
2.35 Both Black Start Diesel Generators are in operation and GT auxiliary bus
bars of 11KV, 415V, DC (110V) power supply and UPS are energized.
2.36 DC batteries of proper rating are installed and are charged properly.
2.37 DC lube oil pump is healthy and is tested normally.
2.38 Starting motor circuit breaker protections for over current, earth fault, short
circuit fault are tested, normal and are intact.
2.39 Starting motor transformer (11KV/6.3KV) ready and its protections are
intact and tested.
2.40 Start/stop push buttons for manual operation of the DC lube oil pump and
Auxiliary lube oil pump provided and tested.
2.41 Emergency Diesel Generator is commissioned and is ready to cut in
operation to energize the emergency bus bar for safe lubrication and
turning gear operation.
2.42 Generator stator voltage monitoring between three lines meters installed
and tested.
2.43 Generator stator current monitoring between the phases installed and
tested.
2.44 Generator excitation voltage and current monitoring meters installed and
tested.
2.45 Generator active power and reactive power monitoring and recording
meters installed and tested.

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2.46 Generator power factor meter installed.
3. INSTRUCTIONS FOR GENERATOR START UP AND NO
LOAD
After fulfilling all the requirements mentioned above, generator can be started
with turbine. During start up following observations should be made very
carefully.
3.1 Vibrations of bearings and shaft displacement.
3.2 Generator bearing metal temperatures.
3.3 Generator bearings drain oil flow should be observed through the sight glass and
drain temperatures should be monitored vigilantly.
3.4 Continuous local monitoring of generator area should be carried out to observe
any abnormal sound, lube oil leakage and drain oil flow from the sight glass.
3.5 Cooling water pressures/ temperatures at the inlet and outlet of generator coolers
should be monitored locally.
3.6 Hot air and cold air temperatures for generator cooling and exciter cooling should
be monitored.
4. TESTS AT FSNL
4.1 Measurement of short-circuit characteristic (Procedure awaited)
A short circuit is placed at the generator terminals. The test consists of
measuring the short-circuit current as a function of the excitation current.
Equipment used:
Adjustable power supply device
A8000/5 A CT and a mill voltmeter class 0.5
5 A AC ammeter class 0.5
4.2 Measurement of no-load characteristic (Procedure awaited)
The test consists of measuring the voltage at the generator terminals as a
function of the excitation current.
Equipments used:
an adjustable power supply device
a 15000/100 A CT or 20000/100 A CT and a mill voltmeter class 0.5
a 150 V AC voltmeter class 0.2

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5. SYNCHRONISATION AND LOADING
In addition to all above requirements following additional measures are required
to be taken to ensure the error free synchronization of the generator.
5.1 Pressure of Hydraulic Oil for the actuation of the Generator circuit breaker
is normal.
5.2 Pressure of SF6 Gas for the Generator circuit breaker is normal.
5.3 Operation of the Generator circuit breaker is checked and is normal.
5.4 Emergency trip of Generator circuit breaker is provided and tested.
5.5 Generator isolator is closed.
5.6 Open/ close status of the circuit breaker provided, checked and is normal.
5.7 Circuit breaker failure for the GCB is intact and tested.
5.8 Main unit step up transformer and auxiliary transformer are in energized
position (if not their Energization tested and all their protections are intact).
5.9 220KV GIS is ready (either energized if dead then its testing would have
completed before the synchronization of the GT generator.
5.10 Operations of the synchronization relays should be checked by manual
injections of electrical signals.
5.11 Following protections for the generators are tested, normal and are intact
Differential protection, Unbalanced load protection, loss of excitation/ over
excitation, overvoltage/under voltage, Reverse power, over frequency/
under frequency, stator earth fault (100%), Rotor earth fault, under
impedance and voltage restrained over current relay.

6. NORMAL OPERATIONS
During normal operations of the generators following parameters should be monitored,
logged, analyzed and controlled within the permissible operating limits to ensure the
safe operation of the unit.
- Stator winding temperatures
-Cooling air, hot air temperatures
-Exciter hot air temperatures
- drive end bearing metal temperatures

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- Non-driven end bearing metal temperatures
- Generator bearings vibrations (seismic and shaft displacement).
- Generator stator voltage
- Generator stator current
- Generator Active power
- Generative reactive power
- Excitation voltage
- Excitation current.
- Power factor.
Operation of the generator should always be carried out within the limits specified by the
Capability curve.
If Generator trips due to any of its protection, then the fault should be thoroughly
investigated in cooperation with the maintenance section and get rectified before
restarting it.

7. SHUT DOWN OF GENERATOR
During deloading and shut down all above parameters should be monitored
carefully for their variation with reference to the load.
During shut down if generator circuit breaker does not open at the set reverse
power load it means that the breaker trip circuit is open. Restart the generator
should be restarted reloaded to minimum load value (~5MW) and manually open
the Generator circuit breaker. If the breaker still refuses to open then attempt
should be made to open the breaker from the local. If there is any problem with
regard to SF6 Gas pressure or Hydraulic Oil pressure then the breaker should be
isolated by opening the relevant 220KV circuit breakers in the GIS.
Under this situation the manual emergency tripping of the m/c is strictly
prohibited as it will result in high levels of reverse power currents while generator
will stay connected to the system.( Reference : GT operation and Maintenance
manual from NSRD).
Monitor and note the run down vibration on generator bearings and also check
for the cut in of jacking oil pump at set low speed ( ). If it did not start
on auto then start it manually.
During shutdown check the correct operation of the space heaters which shall be
switched on when the temperature within generator is below 25C.The space
heaters are used for preventing condensation detrimental to the generator
winding insulation.
If the machine has to be stopped in a cold weather, it is important to empty the
coolers and make sure that they are empty-particularly for the lower tube (open
the air vent-valves and the water drain-valves).if it is possible, blast with
Compressed air to eliminate the eventual water pockets.

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8. INSTRUMENTATION

Measurement Type of sensor Alarm Setting Trip Setting
Stator winding RTD 120C 130C
Magnetic Core RTD 120C 130C
Cold air RTD 60C 65C
Cold air RTD 60C 65C
Hot Air RTD 105C 110C
Hot Air RTD 105C 110C
Exciter Hot air RTD 105C 110C

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Water leakage at DE Water leakage
detector n1
Contact closed Contact closed
Water leakage at NDE Water leakage
detector n2
Contact closed Contact closed
Bearing metal temperature
n1 at DE
RTD 85C 90C
n2 at DE
RTD 85C 90C
n1 at NDE
RTD 85C 90C
n2 at NDE
RTD 85C 90C
Oil outlet temperature at
DE
RTD 70C 75C
Oil outlet temperature at
NDE
RTD 70C 75C
Lube Oil Low pressure

Pressure switch 63QT-
2A
/ 0.0396Mpa
0.069Mpa
Lube Oil Pressure Pressure Switch
63QT-2B
/ 0.0396Mpa
0.069Mpa
Jacking oil pressure low at
inlet of pumps

Pressure switch 0.0396Mpa
0.069Mpa
/
Jacking Oil Pressure low
at the outlet of the pumps
Pressure Switch 8Mpa (turbine not
allowed to start)
/
DE Bearing vibration Seismic sensor 39V-A 7.5mm/s 11.8mm/s
DE Bearing vibration Seismic sensor 39V-B 7.5mm/s 11.8mm/s
NDE Bearing vibration Seismic sensor 39V-5A 7.5mm/s 11.8mm/s
Shaft displacement at DE Sensor 165m (peak to peak) 260m (peak to peak)
Shaft displacement at DE Sensor 165m (peak to peak) 260m (peak to peak)
Shaft displacement at NDE Sensor 165m (peak to peak) 260m (peak to peak)
Shaft displacement at NDE Sensor 165m (peak to peak) 260m (peak to peak)

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9. REFRENCES
Generator manual Operations and maintenance instructions for QFR-135-2
13.8KV Gas turbo generators.
(CONQ.140.409)

Gas Tubine Generator

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