Professional Documents
Culture Documents
GT 5-8
Compressor and Turbine Design
Frame MS 9001 E
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After passing through the third stage buckets, the exhaust gases are directed into the
exhaust hood and diffuser which contains a series of turning vanes to turn the gases from
the axial direction to a radial direction, thereby minimizing exhaust hood losses. Then, the
gases pass into the exhaust plenum. The resultant shaft rotation is used to turn the
generator rotor, compressor rotor and to drive certain accessories through accessory gear
at various speeds.
NOTE: By definition, the air inlet of the gas turbine is the forward end, while the exhaust end is
the aft end. The forward and aft ends of each component are determined in like manner
with respect to its orientation within the complete unit. The RIGHT and LEFT sides of the
turbine or of a particular component are determined by standing forward and looking aft.
2. COMPRESSOR
The axial-flow compressor consists of the rotor and the enclosing casing. Included within
the compressor casing are the inlet guide vanes, the 17 stages of rotor and stator blades
and the exit guide vanes. In the compressor, air is confined to the space between the rotor
and stator blades where it is compressed in stages by a series of alternate rotating and
stationary airfoil-shaped blades.
The rotor blades supply the force needed to compress the air in each stage and the stator
blades guide the air so that it enters in the following rotor stage at the proper angle. The
compressed air exits through the compressor discharge casing to the combustion
chambers. Air is extracted from the compressor 5 th stage for bearing sealing and from 11th
stage for pulsation control. Since minimum clearance between rotor and stator provides
best performance in a compressor, parts have to be made and assembled very accurately.
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inlet casing
forward compressor casing
aft compressor casing
compressor discharge casing
These sections, in conjunction with the turbine shell and exhaust frame form the primary
structure of the gas turbine. They support the rotor at the bearing points and constitute the
outer wall of the gas-path annulus.
2.2.1 I n le t C a s i n g
The inlet casing is located at the forward end of the gas turbine. Its prime function is to
uniformly direct air into the compressor. The inlet casing also supports the no.1 bearing
housing; a separate casing that contains the 1 bearing.
2.2.3 F o r w a r d C a s i n g
The forward compressor casing contains the first four compressor stator stages.
2.2.4 A f t C a s i n g
The aft compressor casing contains the 5th through 10th compressor stages. Extraction
ports in the casing permit removal of 5th and 11th stage compressor air. This air from 5 th
stage is used for cooling and sealing functions and 11th stage air is extracted for starting
and shutdown surge and pulsation control.
2.2.5 D i s c h a rge C a s in g
The compressor discharge casing is the final portion of the compressor section. It is the
longest single casting consists of two cylinders. It contains the final seven compressor
stages, to form both the inner and outer walls of the compressor diffuser and to join the
compressor and turbine stators. They also provide support for bearing 2, the forward
end of the combustion wrapper and the inner support of the first-stage turbine nozzle.
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2.4
C OMPRESSOR S URGE
Operating speed of the gas turbine is held constant and very little deviation takes place.
The blades of the axial compressor are designed to achieve optimum efficiency at the
synchronous speed. To achieve a good performance, the angle and aerofoil shape of the
rotor and stator blades are precisely machined and set in place such that the compression
of air through the compressor is smooth and efficient.
During startup and shutdown of a gas turbine, the rotor and stator blades do not deliver a
smooth progression of air through the compressor. This occurs, simply because the shape
and position of the blades is not conducive to low speed and low flow conditions. Speeds
less than the permissible range would exert strain on the front stages of the compressor
that the result would be separation of the flow at the airfoils, this is, the air is not
smoothly compressed. Such separation will cause the delivery to become unstable. The
compressor will begin to surge. This is characterised by rapid fluctuations of the
compressor discharge pressure combined with heavy vibration of the unit and surging
noise in rhythm with the pressure fluctuations with the compressor blades being
endangered by the resulting high alternating bending stresses and high temperatures.
Figure illustrates the effects of air flow through a gas turbine compressor during a
compressor surge.
Since on start-up and shut-down of the gas turbine and under-frequency operation, the
compressor is bound to run at speeds below the permissible value, air will have to be
blown off at specific parts of the compressor as a result of which the volume flow is
matched to the blade case cross-sections.
2 . 4 . 1 C o n t r o l t h r o u g h I n l e t G u i d e Van e s
Variable inlet guide vanes (VIGV) are installed on the compressor to provide compressor
pulsation protection during start-up and shutdown and also to be used during operation
under partial load conditions. The variable inlet guide vane actuator is a hydraulically
actuated assembly having a closed feedback control loop to control the guide vanes angle.
The vanes are automatically positioned within their operating range in response either to
the control system exhaust temperature limits for normal loaded operation, or to the
control system pulsation protection limits during the start-up and shut-down sequences.
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2.4.2 S u r ge C o n t r o l t h r o u g h B l e e d Val v e s
The pressure, speed and flow characteristics of the gas turbine compressor are such that
air must be extracted from the 11th stage and vented to atmosphere to prevent pulsation of
the compressor during the acceleration period of the turbine starting sequence and during
deceleration of the turbine at shut-down.
Pneumatically operated air extraction bleed valves, controlled by a three-way solenoid
valve, are used to accomplish the pulsation protection. Eleventh stage air is extracted
from the compressor at four flanged connections on the compressor casing. Each of these
connections is piped through a normally open (by spring force), piston-operated, butterfly
valve, VA 2-1, -2, -3 and -4 to the turbine exhaust plenum. Limit switches 33 CB-1, -2, -3
and -4 are mounted on the valves to give an indication of valve position.
Compressor discharge air controlled by solenoid valve 20 CB is used to close the
compressor bleed valves. Air from compressor discharge is piped to a porous air filter
which removes dirt and water from the compressor discharge air, by means of a
continuous blow-down orifice, before the air enters solenoid valve 20 CB. From the
solenoid valve, the air is piped to the piston housings of the four extraction valves.
During turbine start-up, 20 CB is de-energized and the 11th stage extraction valves are
open allowing 11th stage air to be discharged into the exhaust plenum thereby eliminating
the possibility of compressor pulsation. Limit switches, 33 CB-1 through -4, on the valves
provide permissive logic in the starting sequence and ensure that the extraction valves are
fully opened before the turbine is fired. The turbine accelerates to 95% speed and then the
20CB solenoid valve is energized to close the extraction valves and allow normal running
operation of the turbine. When a turbine shut-down signal is initiated and the generator
circuit breaker is opened, 20CB is de-energized and 11th stage air is again discharged into
the exhaust plenum to prevent compressor pulsation during the turbine shut-down period.
CAUTION: Under no circumstances should attempts be made to start the turbine if all
four extraction bleed valves are not fully opened. Serious damage to the compressor
blades may occur if all the valves are not opened during the accelerating and decelerating
cycle of the gas turbine.
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3. COMBUSTION SECTION
The combustion system is of the reverse-flow type
with 14 combustors arranged around the periphery
of the compressor discharge casing. This system
also includes fuel nozzles, spark plug ignition
system, flame detectors and crossfire tubes. Hot
gases, generated from burning fuel in the
combustors, are used to drive the turbine.
High pressure air from the compressor discharge is
directed around the transition pieces and into the
combustor liners. This air enters the combustion
zone through metering holes for proper fuel
combustion and through slots to cool the
combustor liner. Fuel is supplied to each combustor
through a nozzle designed to disperse and mix the
fuel with the proper amount of combustion air. Combustors are numbered counterclockwise when viewed looking down-stream and starting from the top of the machine.
1-
Combustion Wrapper:
The combustion wrapper forms a plenum in which the compressor discharge air flow is
directed to the combustors. Its secondary purpose is to act as a support for the
combustors assemblies. In turn, the wrapper is supported by the compressor discharge
casing and the turbine shell.
2-
Combustors:
Discharge air from the axial-flow compressor flows into each combustion flow sleeve
from the combustion wrapper (see figure). The air flows upstream along the outside of the
combustion liner toward the liner cap. This air enters the combustors reaction zone
through the fuel nozzle swirl tip, through metering holes in both the cap and liner and
through combustion holes in the forward half of the liner.
The hot combustion gases from the reaction zone pass through a thermal soaking zone
and then into a dilution zone where additional air is mixed with the combustion gases.
Metering holes in the dilution zone allow the correct amount of air to enter and cool the
gases to desired temperature. Along the length of the combustion liner and in the liner cap
are openings whose function is to provide a film of air for cooling the walls of the liner
and cap as shown in figure. Transition pieces direct the hot gases from the liners to the
turbine nozzles. All 14 combustion liners, flow sleeves and transition pieces are identical.
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3-
Crossfire Tubes:
Spark Plugs:
Retaining Nut
Lock Plate
Insulator
Gasket
Top Cover
Tie Bolt
Terminal
Extension
Spring
Cylinder
Core Assembly
Equal Gaps
within 0.01"
(0.25 mm)
Figure CI-40
Spark Plug Assembly
5-
Flame Detectors:
During the starting sequence, it is essential that an indication of the presence or absence
of flame be transmitted to the control system. For this reason, a flame monitoring system
is used consisting of four sensors which are installed on four combustors no. 3, 4, 5 and
11, and an electronic amplifier which is mounted in the turbine control panel.
The ultraviolet flame sensor consists of a flame sensor, containing a gas filled detector.
The gas within this flame sensor detector is sensitive to the presence of ultraviolet
radiation which is emitted by a hydrocarbon flame. A dc voltage, supplied by the
amplifier, is impressed across the detector terminals. If flame is present, the ionization of
the gas in the detector allows conduction of current in the circuit which activates the
electronics to give an output defining flame. Conversely, the absence of flame will
generate an opposite output defining "no flame".
After the establishment of flame, if voltage is re-established to the sensors defining the
loss (or lack) of flame a signal is sent to a relay panel in the turbine electronic control
circuitry where auxiliary relays in the turbine firing trip circuit, starting means circuit, etc.
shut down the turbine. The Failure to Fire or Loss of Flame is also indicated on the
annunciator. If a loss of flame is sensed by two flame detector sensor, the control circuitry
will cause an annunciation only of this condition.
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6-
Fuel Nozzles:
Each combustor is equipped with a fuel nozzle that emits the metered amount of the
required fuel into the combustion liner. The fuel nozzle functions to distribute the liquid
fuel into the reaction zone of the combustion liner, in a manner which promotes uniform,
rapid and complete combustion.
Purge Air
Fuel Gas
GCV Gas
Control Valve
SRV Speed
Ratio Valve
Combustion Air
Gas outlet
Purge air
VCK-2
Atomizing Air
HSD or Furnace Oil
VCK-1
Liquid Fuel
Drain
Liquid Fuel
Inlet
To Sump
Tank
Combustion Air
Atomizing air
Atomizing air is utilized with liquid fuel to assist in the formation of a finely divided
spray. The liquid fuel and atomizing air enter the fuel nozzle assembly through separate
connections. Then, they are introduced through separate but concentric passages in the
nozzle body. Fuel enters the inner passage. Atomizing air enters around the fuel nozzle
and split fuel into very fine particles. In this way fuel ignites easily and burns completely.
Fuel burning process completes within combustor liner zone and flame finishes after the
liner. Therefore, only flue gas enters into the transition piece.
7-
Transition Pieces
Transition pieces direct the hot gases from the liners to the turbine
first stage nozzle. Thus, the first nozzle area is divided into 14 equal
areas receiving the hot gas flow. The transition pieces are sealed to
both the outer and inner sidewalls on the entrance side of the nozzle,
so minimizing leakage of compressor discharge air into the nozzles.
8-
From turbine
drains
Compressor
discharge air
Oil to sump
tank
Water to
washing pit
The false start drain valves, normally open, are closed during start-up when the turbine
speed reaches a sufficient value. Air pressure from the axial-flow compressor discharge is
used to actuate these valves. During the turbine shut-down sequence, the valves open as
compressor speed drops (compressor discharge pressure is reduced).
When GT is started, these valve are opened at start and closed at about 35-40% speed.
False start drain valve is a three way valve. Normally its position is towards sump tank
and any leakage of liquid fuel oil goes towards sump tank. During turbine washing their
position is changed towards washing pit and water goes to washing pit. After completion
of washing three way valves position is again changed towards sump tank.
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4. TURBINE SECTION
The three stage turbine section (Fig-2) is the area in
which energy in the form of high pressurized gas,
produced by the compressor and combustion sections, is
converted to mechanical energy.
Each turbine stage is comprised of a nozzle and the
corresponding wheel with its buckets. Turbine section
components include;
turbine rotor
turbine shell
nozzles
shrouds
exhaust frame
exhaust diffuser
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Temperature at first stage nozzle is controlled by the gas turbine control system by means
of controlling the hot gas temperature in the exhaust casing. This is important for the
turbine life because of thermal stresses.
At base load operation, temperature on turbine first nozzle must not exceed 1004 C. The
hot gas stream expands through the first stage nozzle and it leaves with a whirl to attack
the first stage turbine wheel, where kinetic energy is converted to mechanical energy. This
process is repeated in the other turbine stages.
Turbine Rotor Cooling:
The first-stage buckets are the first rotating surfaces encountered by the
extremely hot gases leaving the first-stage nozzle. Each first-stage
bucket contains a series of longitudinal air passages for bucket cooling.
Air is introduced into each first-stage bucket through a plenum at the
base of the bucket dovetail. It flows through cooling holes extending the
length of the bucket and exits at the recessed bucket tip. The holes are
spaced and sized to obtain optimum cooling of the airfoil with minimum
compressor extraction air.
Like the first-stage buckets, the second-stage buckets are cooled by
spanwise air passages the length of the airfoil. Since the lower
temperatures surrounding the bucket shanks do not require shank
cooling, the second-stage cooling holes are fed by a plenum cast into the
bucket shank. Spanwise holes provide cooling air to the airfoil at a
higher pressure than a design with shank holes. This increases the
cooling effectiveness in the airfoil so airfoil cooling is accomplished
with minimum penalty to the thermodynamic cycle.
The third-stage buckets are not internally air cooled; the tips of these buckets, like the
second-stage buckets, are enclosed by a shroud which is a part of the tip seal. These
shrouds interlock from bucket to bucket to provide vibration damping.
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The turbine rotor must be cooled to maintain reasonable operating temperatures and,
therefore, assure a longer turbine service life. Cooling is accomplished by means of a
positive flow of cool air radially outward through a space between the turbine wheel with
buckets and the stator, into the main gas stream. This area is called the wheel-space.
There are 14 thermocouples before and after the nozzles to measure the wheel-space
temperature. Six thermocouples are at stage-1, four are at stage-2 and four are at stage-3.
Following wheel-space reading are taken from log sheet of GT-5, 14:00 hrs, dt. 05/02/08.
Compressor inlet temperature 14 C and Compressor discharge temperature 330C.
Thermocouple No.
st
Temp
Thermocouple No.
nd
350 C
391 C
341 C
356 C
400 C
369 C
Temp
Thermocouple No.
rd
Temp
397 C
366 C
352 C
386 C
rd
360 C
292 C
356 C
338 C
The turbine rotor is cooled by means of a positive flow of relatively cool air (300 C,
relative to hot gas path air) extracted from the compressor. Air extracted through the rotor,
ahead of the compressor 17th stage, is used for cooling the 1st and 2nd stage buckets and
the 2nd stage aft and 3rd stage forward rotor wheel spaces. This air also maintains the
turbine wheels, turbine spacers and wheel shaft at approximately compressor discharge
temperature to assure low steady state thermal gradients thus ensuring long wheel life.
The 1st stage forward wheel-space is cooled by air that passes through the high pressure
packing seal at the aft end of the compressor rotor. The 1st stage aft and 2nd stage
forward wheel spaces are cooled by compressor discharge air that passes through the first
stage shrouds and then radially inward through the stage 2 nozzle vanes. The 3rd aft
wheel-space is cooled by cooling air that exits from the exhaust frame cooling circuit.
Turbine Shell
The turbine shell controls the axial and radial positions of the shrouds and nozzles. It
determines turbine clearances and the relative positions of the nozzles to the turbine
buckets. This positioning is critical to gas turbine performance.
Hot gases contained by the turbine shell are a source of heat flow into the shell. To
control the shell diameter, it is important that shell design reduces the heat flow into shell
and limits its temperature. Heat flow limitations incorporate insulation, cooling and multilayered structures. The external surface of the shell incorporates cooling air passages.
Flow through these passages is generated by frame blower cooling fans 88 TK 1, 2.
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Turbine Nozzles
In the turbine section there are three stages of stationary nozzles (see figure), which direct
the high-velocity flow of the expanded hot combustion gas against the turbine buckets
causing the turbine rotor to rotate. Because of the high pressure drop across these nozzles,
there are seals at both the inside and the outside diameters to prevent loss of system
energy by leakage. Since these nozzles operate, in the hot combustion gas flow, they are
subjected to thermal stresses in addition to gas pressure loadings.
18 Segments, 2 airfoils
16 Segments, 3 airfoils
16 Segments, 4 airfoils
First-Stage Nozzles
The first-stage nozzle receives the hot combustion gases from the combustion system via
the transition pieces. The transition pieces are sealed to both the outer and inner sidewalls
on the entrance side of the nozzle; this minimizes leakage of compressor discharge air
into the nozzles. The 18 cast nozzle segments, each with two partitions of airfoils, are
contained by a horizontally split retaining ring which is centreline supported to the
turbine shell on lugs at the sides and guided by pins at the top and bottom vertical
centrelines. This permits radial growth of the retaining ring, resulting from changes in
temperature while the ring remains centred in the shell.
The aft outer diameter of the retaining ring is loaded against the forward face of the firststage turbine shroud and acts as the air seal to prevent leakage of compressor discharge
air between the nozzle and shell. First-stage nozzle is cooled with compressor discharge
air.
Second-Stage Nozzle
Combustion air exiting from the first-stage buckets is again expanded and redirected
against the second-stage turbine buckets by the second-stage nozzle. This nozzle is made
of 16 cast segments, each with three partitions or airfoils. The male hooks on the entrance
and exit sides of the outer sidewall fit into female grooves on the aft side of the first-stage
shrouds and on the forward side of the second-stage shroud, to maintain the nozzle
concentric with the turbine shell and rotor. This close fitting tongue-and-groove fit
between nozzle and shrouds acts as an outside diameter air seal. The nozzle segments are
held in a circumferential position by radial pins from the shell into axial slots in the
nozzle outer sidewall. Second-stage nozzle is cooled with compressor discharge air.
Third-Stage Nozzles
The third-stage nozzle receives the hot gas as it leaves the second-stage buckets, increases
its velocity by pressure drop, and directs this flow against the third-stage buckets. The
nozzle consists of 16 cast segments, each with four partitions or airfoils. It is held at the
outer sidewall forward and aft sides in grooves in the turbine shrouds in a manner
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Diaphragms
Attached to the inside diameters of both the second and third-stage nozzle segments are
the nozzle diaphragms (see figure at previous page). These diaphragms prevent air
leakage past the inner sidewall of the nozzles and the turbine rotor. The high/low,
labyrinth seal teeth are machined into the inside diameter of the diaphragm. They mate
with opposing sealing lands on the turbine rotor. Minimal radial clearance between
stationary parts of diaphragm and nozzles and the moving rotor are essential for
maintaining low interstage leakage; this results in higher turbine efficiency, due to which
it can take more load.
Shrouds
Unlike the compressor blading, the turbine bucket tips do not run directly against an
integral machined surface of the casing but against annular curved segments called
turbine shrouds. The shrouds' primary function is to provide a cylindrical surface for
minimizing bucket tip clearance leakage.
The turbine shrouds' secondary function is to provide a high thermal resistance between
the hot gases and the comparatively cool shell. By accomplishing this function, the shell
cooling load is drastically reduced, the shell diameter is controlled, the shell roundness is
maintained and important turbine clearances are assured. The shroud segments are
maintained in the circumferential position by radial pins from the shell. Joints between
shroud segments are sealed by interconnecting tongues and grooves.
4.3
R OTOR A LIGNMENT
Generator rotor is 1.25 mm above than turbine rotor. After GT start, when turbine rotor
becomes hot then it becomes high. To compensate this misalignment bearing no. 3 has
special arrangement of tilting pads.
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The exhaust diffuser, located at the extreme aft end of the gas turbine, bolts to, and is
supported by, the exhaust frame. The exhaust frame is a fabricated assembly consisting of
an inner cylinder and an outer divergent cylinder that flares at the exit end at a right angle
to the turbine centreline. At the exit end of the diffuser between the two cylinders are five
turning vanes mounted at the bend. Gases exhausted from the third turbine stage enter the
diffuser where velocity is reduced by diffusion and pressure is recovered. At the exit of
the diffuser, turning vanes direct the gases into the exhaust plenum.
Exhaust frame radial struts cross the exhaust gas stream. These struts position the inner
cylinder and bearing 3 in relation to the outer casing of the gas turbine. The struts must
be maintained at a uniform temperature in order to control the centre position of the rotor
in relation to the stator. This temperature stabilization is accomplished by protecting the
struts from exhaust gases with a metal fairing fabricated into the diffuser and then forcing
cooling air from 88 TK 1,2 into this space around the struts.
Turbine shell cooling air enters the space between the exhaust frame and diffuser and
flows in two directions. The air flows in one direction into the turbine shell cooling
annulus and also down through the space between the struts and the airfoil fairings
surrounding the struts and subsequently into the load shaft tunnel and turbine third-stage
aft wheel-space.
5. BEARINGS
The MS 9001 E gas turbine unit 5-8 contain three main journal bearings used to support
the compressor-turbine rotor. The unit also includes thrust bearings to maintain the rotorto- stator axial position. These bearing assemblies are located in three housings:
one at the air inlet,
one in the compressor discharge casing, and
one in the exhaust frame.
Bearing metal temperature detectors have been installed on all bearings. High temperature
alarm limit is 130 C.
All bearings are pressure-lubricated by oil supplied from the main lubricating oil system.
The oil flows through branch lines to an inlet in each bearing housing.
BEARINGS
No.
Class
Type
Vibration Pick-ups
Journal
Elliptical
BB-1 / BB-2
Loaded Thrust
Self-Aligned
(Equalized)
Unloaded Thrust
Tilting Pad
Journal
Elliptical
BB-3
Journal
Tilting Pad
BB-4 / BB-5
Journal
BB-7 / BB-8
Journal
BB-9
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Lubrication
The three main turbine bearings are pressure-lubricated with oil supplied by the 12,540
litres capacity lubricating oil reservoir. Oil feed piping, where practical, is run within the
lube oil reservoir drain line, or drain channels, as a protective measure. This procedure is
referred to as double piping and its rationale is that in the event of a pipe-line leak, oil
will not be lost or sprayed on nearby equipment, thus eliminating a potential safety
hazard. When the oil enters the bearing housing inlet, it flows into an annulus around the
bearing liner. From the annulus the oil flows through machined slots in the liner to the
bearing surface. Oil is prevented from escaping along the turbine shaft by labyrinth seals.
Oil Seals
Oil on the surface of the turbine shaft is prevented from being spun along the shaft by oi1
seals in each of the three bearing housings. These labyrinth packings and oil deflectors
(teeth type) are assembled on both sides of the bearing assemblies where oil control is
required. A smooth surface is machined on the shaft and the seals are assembled so that
only a small clearance exists between the oil and seal deflector and the shaft. The oil seals
are designed with two rows of packing and an annular space between them. Pressurized
sealing air is admitted into this space and prevents lubricating oil from spreading along
the shaft.
Oil Vent
Some of the sealing air returns with the oil to the main lubricating oil reservoir and is
vented through a lube oil vent. A vent pipe takes air from the tank and an air nozzle or
venturi sucks air from the lube oil tank. Blower fan 88FX-1 provides air to the venturi.
(3)
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Air flows through this seal into the drain space of the housing and is vented outside the
machine via the inner pipe connecting to the bottom of the housing. This drain space vent
piping continues to the lubricating oil tank. The middle labyrinth prevents the hot air
leakage from mixing with the oil. The mixture of hot air and cool air is vented outside the
unit via the outer pipe connected at the top of the bearing housing.
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The tilting pad journal bearing comprises two major components pads and a retainer ring.
The retainer ring serves to locate and support the pads. It is a horizontally split member
that contains the pad support pins, adjusting shims, oil feed orifice and oil discharge seals.
The support pins and shims transmit the loads generated at the pad surfaces and are used
to set the bearing clearance. An anti rotation pin extends from one edge of the lower half
of the rectangular ring. This pin locates the bearing within its housing and serves to
prevent the bearing from rotating with the shaft.
Bearing No. 3,
Upper half with
tilting pads
6. COUPLINGS
Couplings are used to transmit starting torque from the accessory gear to the gas turbine
axial compressor and to transmit shaft horsepower from the turbine to the driven
generator. Couplings are of two types; rigid and flexible.
7. STARTING SYSTEM
Before the gas turbine can be fired and started it must be rotated or cranked by accessory
equipment. This is accomplished by an induction motor, operating through a torque
converter to provide the cranking torque for speed required by the turbine for start-up.
The starting system consists of:
Starting motor induction type
Torque Converter: Voith Germany
Torque Adjusting Motor
Turning Gear Motor
88 CR
Voith
88 TM
88 TG
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After a shut down order, when speed decreases to 99 rpm, the torque converter motor sets
it to 11 turns and a turning motor 88 TG specially provided to rotate the turbine for cooldown purpose starts. Then speed is increased and turning speed value is about 120 rpm.
The main parts of the torque converter are the impeller
driven by the input shaft, the turbine wheel which drives
the output shaft and the stator which directs fluid from
the impeller to the turbine at the correct angle to produce
the required output torque.
Starting motor is linked to an impeller called pumpwheel. The turbine shaft is linked to a turbine-wheel. The
pump-wheel and turbine-wheel do not have any
mechanical contact. Two seconds after the start up of
cranking motor, the torque converter is filled with oil,
extracted from lube oil circuit at 6.9 bar by energizing
solenoid valve 20 TU-1. Pump-wheel transforms the
power of the cranking motor into a manometric lift (i.e.
increase in pressure) of oil.
The turbine-wheel transforms this manometric lift into a
rotating power and transmits it to the turbine shaft. That means, the oil transmits the
power. Due to great difference of speeds at the beginning of the start up sequence
(Cranking motor 2975 rpm, turbine shaft 120 rpm) torque converter transmits a very high
torque to the turbine shaft and thus breaks it away.
To adjust various speed limits for turning, start up, warm up, acceleration, washing etc.
the torque converter is equipped with a range of variable vanes, automatically operated by
the torque adjusting motor or manually by a hand-wheel drive. These vanes, installed in
converter housing, admit circulation of certain oil flow corresponding to their position.
That means, output speed is limited by reducing the output power through variable vanes.
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The torque adjustor drive 88 TM rotates the blades of the impeller. When the impeller
blades are fully closed there is no transfer of torque and when blades are fully open
maximum torque is transferred. The number of turns, as it can be seen from the top of
torque converter, depends on the operation of limit switch. Six switches are provided for
torque adjustment;
33 TM-1
33 TM-2
33 TM-3
33 TM-4
Adjusted at 6 turns
Adjusted at 3 turns
Adjusted at 11 turns
Adjusted at 22 turns
33 TM-5
Adjusted at 0 turns
33 TM-6
Adjusted at 30 turns
Washing speed
Minimum firing torque for warm up
Turning gear operation
To obtain the maximum torque; during accelerating
phase upto 60 % speed
For minimum torque limit; to limit the torque in case of
malfunction of the system
For high torque limit
7.1.1 F u n c ti o n a l De s c r ip ti o n o f Tor q u e C o n ve r t e r
1.
Start-up
In the normal starting sequence, fluid is admitted into the torque converter hydraulic
circuit from the lubrication system by the integral valve 20 TU-1 two seconds after the
starting motor 88 CR is energized. Torque converter is adjusted at 22 turns to achieve
maximum torque of the starting motor. The turbine begins to increase in speed and
continues to accelerate until firing speed is attained and relay 14 HM picks up. When the
turbine has reached this speed (14 HM setpoint), the internal geometry of the torque
converter is adjusted to 3 turns by the torque adjustor drive 88 TM to hold firing speed
constant throughout the firing and warm-up cycle.
Readjustment of the converter geometry (torque adjustment) at the end of warm-up
allows the torque converter to assist in accelerating the unit up to self sustaining speed. At
this speed, (about 60 % speed), the torque converter hydraulic circuit is drained, by
deenergizing solenoid valve 20 TU-1, at the same time cranking motor 88 CR is
deenergized, which effects disconnect. A crank and restart can be initiated at any time
below 14 HT speed (at turning gear).
2.
Shut-down
The shut-down order is given and the turbine speed slows down. When relay 14 HP drops
out (at about 99 rpm), the turning motor 88 TG starts. Solenoid valve 20 TU-1 is
energized and the torque is adjusted to 11 turns allowing to turn the turbine at a speed of
about 120 rpm for cool down purposes after shut down.
3.
Turning
The turbine is at standstill and all circuits are ready for turning. The operator turns the
operation selector switch 43 of the turbine control panel to position TURNING, then
gives a START order. The starting motor 88 CR starts, 20 TU-1 is energized and torque
converter is adjusted to 22 turns. When the speed reaches about 120 rpm, motor 88 CR is
stopped. The speed decreases a little and at about 99 rpm, turning motor 88 TG starts.
Torque converter is readjusted at 11 turns and it allows a turning speed of about 120 rpm.
NOTE: Torque Converter is drained at 60 % speed by opening the 20 TU-1 solenoid valve, but
if does not drained then indication Torque Converter drain valve trouble is appeared on
the screen and the m/c would take shut down command.
GT 5-8
46
8. ACCESSORY DRIVE
The function of the accessory gear in this system is to drive a number of the control
components and to provide connection between the starting motor and the gas turbine
compressor. It is permanently coupled to the turbine compressor shaft by a flexible
coupling.
Location of
air ejector
Automizing air
compressor shaft
TURBINE SIDE
Main Oil Pump
Fuel Pump
Driving
shaft
Mechanical
Overspeed
Main HP
Oil Pump
The accessory drive gear, located at the compressor end of the gas turbine, is a gearing
assembly. Contained within the gear casing are the gear trains which provide the proper
gear reductions to drive the accessory devices at the required speed, with the correct
torque values. Its functions are to:
3000 rpm
3424.2 rpm
1554.2 rpm
6607.2 rpm
1421.9 rpm
Driving shaft
A tachometer on turbine side
Fuel pump through electromagnetic clutch
It drives atomizing air compressor
HP hydraulic oil pump on starting motor side and Lube oil
pump on turbine side
GT 5-8
47
A high-pressure turbine overspeed trip, capable of mechanically dumping the oil in the
trip circuits, is mounted on the exterior casing of the gear. This device can shut the turbine
down when the speed exceeds the design speed. The overspeed bolt which actuates the
trip upon overspeed is installed in the main shaft. Lubrication of the gear is from the
turbines pressurized bearing header supply.
9. COMPARTMENTS / ENCLOSURES
Gas Turbine 5-8 is a package type unit; it is divided into various compartments/
enclosures. Gas turbine enclosures, referred to as compartments, are those partitioned
areas in which specific components of the overall power plant are contained. These
compartments are built for all weather conditions and designed for accessibility when
performing maintenance. They are provided with thermal and acoustical insulation and
lighted for convenience.
Compartment construction includes removable panels, hinged doors and a thermally
insulated roof section with welded frame structuring providing the support for these parts.
The panels are thermally insulated and held in place with bolts. Doors are kept tightly
closed by sturdy latches. Gaskets between panels and framing maintain a weather-tight
condition. Inspection and maintenance are facilitated as the door panels allow easy access
for station personnel and the removable panels provide greater accessibility for major
inspections and overhauling.
There is an inlet plenum between the accessory and the turbine compartments and an
exhaust plenum between the turbine and generator compartments. Thus, in the compact
integrated gas turbine-generator design, there is an in-line sequence of lagged
compartments, the sequence being broken by the inlet plenum and the exhaust plenum.
These compartments are named as:
12345-
Accessory compartment
Turbine compartment
Exhaust compartment
Load coupling compartment
Generator compartment
Exhaust
Compartment
Load
Coupling
Compartme
nt
Generator
Compartment
Turbine
Compartment
Accessory
Compartment
GT 5-8
48
Gas system,
Hydraulic system,
On-base portion of the turbine cooling water system
starting motor,
accessory drive gear
Besides being the main link between the starting system drive components and the gas
turbine, the accessory drive gear is the gear reduction unit connected directly to the
turbine for driving several of the accessory devices of the gas turbine support systems. A
pressure gauge and switch cabinet located on the left side of the accessory compartment
(looking downstream), contains panel mounted gauges and switches used with the
systems mentioned above.
GT 5-8
49
GT 5-8
50
GT 5-8
COMPRESSOR
1 Inlet plenum assembly
2 Inlet casing
3 Magnetic pickup arrangement
4 Thrust bearing
5 No 1 bearing
6 Variable inlet guide vane arrangement
7 Compressor blading
8 Compressor rotor assembly
9 Forward compressor casing
10 After compressor casing
11 Compressor discharge casing
12 Inner compressor discharge casing
13 Turbine forward support
14 Turbine base
COMBUSTION
15 Combustion wrapper
16 Fuel nozzle assembly
17 Combustion liner
18 Transition piece
19 Combustion chamber arrangement
20 Spark plug
21 Flame detector
TURBINE
22 Turbine casing & shrouds
23 First stage nozzle
24 Second stage nozzle & diaphragm
25 Turbine stage nozzle & diaphragm
26 Turbine rotor assembly
-
Forward shaft
First stage turbine wheel & bucket assembly
Second stage turbine wheel & bucket assembly
Third stage turbine wheel & bucket assembly
Spacer wheels
After shaft
27 No 2 bearing
28 No 3 bearing
29 Turbine after supports
AIR INLET
50
COMPRESSOR
COMBUSTOR
TURBINE
EXHAUST
EXHAUST
30 Exhaust hood
31 Exhaust diffuser
32 Load coupling
33 Turbine vanes
34 Control & regulation thermocouples
35 Exhaust plenum assembly
51
AIR INLET
51
COMPRESSOR
COMBUSTOR
TURBINE
EXHAUST