911 - Chapter 2 - Rev00 PDF

Project : DAWOOD HERCULES
Date : 24.02.2009
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2 DESCRIPTION OF MECHANICAL COMPONENTS AND

SYSTEMS
Chapter: 2 Page - 1 of 1
Title: Mechanical Components 911_Chapter 2_rev00.doc
Date : 24.02.2009
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2 DESCRIPTION OF MECHANICAL COMPONENTS AND

SYSTEMS 1
2.1 Mechanical components 4
2.1.1 Base frame 4
2.1.2 Soundproof enclosure: container 5

2.1.2.1 Container design 5
2.1.2.2 Container lighting 5
2.1.2.3 Container ventilation 6
2.1.2.4 Container temperature 7
2.1.2.5 Fuel gas leak monitoring system 7
2.1.2.6 Fire monitoring system 7
2.1.3 Turbine 8
2.1.3.1 Technical data 8
2.1.3.2 Cutaway a two shaft turbine (Hot End Drive) 9
2.1.3.3 Thermodynamic process 10
2.1.3.4 Turbine design 10
2.1.3.5 Main engine subassemblies similar for single shaft and two shaft turbines 11
2.1.3.6 Internal turbine compressed air system PCD 12
2.1.3.7 Compressor Inlet Guide Vanes = IGV 12
2.1.3.8 Bleed valve 13
2.1.3.9 Fuel supply 14
2.1.3.10 Exhaust system 14
2.1.3.11 Vibrations monitoring system 15
2.1.4 Gear box 16

2.1.4.1 Gear box 16
2.1.5 Generator 17
2.1.5.1 Generator : main components, common to most manufacturers 17
2.1.5.2 Generator design 18
2.1.5.3 Excitation and voltage regulation 19
2.1.5.4 Standard generator data: typical ratings 20
2.2 Mechanical systems 21

2.2.1 Start-up system 21
2.2.1.1 General description 21
2.2.1.2 Functional description 21
2.2.1.3 Typical sprag clutch assembly of a turbine 22
2.2.1.4 Clutch design 23
2.2.1.5 Start-up system of two shaft turbines 24
2.2.2 Fuel systems 26

2.2.2.1 Gas fuel system 26
2.2.3 Lube oil system 30

2.2.3.1 Conception 30
2.2.3.2 Lube oil pumps 31
2.2.3.3 Lube oil cooling system 33
2.2.3.4 Lube oil filter system 33
2.2.3.5 Lube oil temperature and pressure supervision 33
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2.2.3.6 Bearings temperature monitoring 34

2.2.3.7 Lube oil drain system and lube oil tank 34
2.2.3.8 Ventilation and oil vapours extraction 34
2.2.4 Air systems 35

2.2.4.1 Compressed air system 35
2.2.4.2 Container ventilation filter system 35
2.2.4.3 Combustion air filter system 36
2.2.5 Compressor washing system 38

2.2.5.1 Compressor washing with start-up unit (off-line) 39
2.2.5.2 Online compressor washing system (if installed) 39
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2.1 Mechanical components
2.1.1 Base frame

Design
The turbo generator set and its auxiliaries are installed inside of the sound proof container on a
self-supporting frame. The base frame holds the entire mechanical system of the engine,
including the lubricating oil system and the fuel system.
The lubricating oil tank is integrated in the middle of the frame.
The fully welded base frame acts as a tight retention basin which, in case of failure of the lube oil
tank, piping or other piece of equipment, can hold the complete oil filling or all other liquid spills
within the sound proof enclosure.
The base frame bears the entire load of the package on 6 spring units.
The container is complete with lighting and ventilation. Doors on both sides of the container can
be opened to allow its maintenance.
The turbo-generator-set is protected with a fire detection and fire-extinguishing equipment, as
well as with a gas detection system.
The power cables and the low-tension and control wiring connections are brought to the turbine
through cable ducts.
Overall dimensions of the installed TG-sets, complete with frame, container, turbine, generator,
but without filters:
Turbine type Mars

Length 15.3 m
Width 2.9 m
Height 3.14 m
Mass 71 t
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2.1.2 Soundproof enclosure: container

The turbine and driven equipments are housed in a weatherproof, insulated, and sound
attenuated enclosure. The enclosure consists of assembled modules provided with lateral doors
and lifting panels for easy access to internal components for maintenance and for the major
machine overhaul.
The electrical operating and controlled devices installed in the enclosure are wired according to
the standard industrial wiring practices and cables are placed in conduit for physical protection
where necessary.
2.1.2.1 Container design
The panels, roof segments and access doors have a wall thickness of 100 mm and consist of an
outer steel plate with mineral wool packing and 1 mm thick inner plate, made of perforated steel
The outer steel plate of the panels and roof segments is 3 mm thick and the outer plate of the
access doors is 2 mm thick. The casing is sealed against the ground floor.
All unused openings in the soundproof casing are sealed in order to achieve a cladding which is
as soundproof as possible.
2.1.2.2 Container lighting
The internal lighting of the casing, which is supplied with current from the power-supply cabinet,
has explosion proof neon lamps, which are switched on by means of a switch on the access
door.
WARNING
Before repairing or replacing electrical devices such as lamps, terminal wires, etc, turn off the
power supply to prevent injury and exclude the risk of explosion.
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2.1.2.3 Container ventilation
Ventilation of the container is necessary to limit the internal temperature of the casing and to
purge the casing from fuel gas leaks before switching on electrical devices.
The ventilation is carried out by:
2.1.2.3.1. Air intake components
• Cooling air intake filter F5101

• Cooling air intake sound damper S5102,
• Electric motor driven, explosion-proof incoming air blowers M5104
• Incoming air shutters AV5106, powered by pneumatic actuator CYL5106
• Shutter position limit switch GS5106.
• Solenoid valve MV5107 for the pneumatic actuators of the shutters AV5106
2.1.2.3.2. Air exit components
• Sound damper for the outlet cooling air S5112,

• Electric motor M5114 driven, explosion-proof outlet air blowers EV5114
• Outlet air shutters AV5116, powered by pneumatic actuator CYL5106
• Shutter position limit switch GS5116
• Solenoid valve MV5107 for the instrument air to actuator of the shutter AV5116
• The shutters, installed on the entry and exit openings, serve to shut tight the container in
case of fire fighting, to keep the fire extinguish substance inside and to close the container
when the ventilation is turned off.
WARNING
The container ventilation system is part of the explosions proof safety concept and must always be
kept in proper operation conditions.
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2.1.2.4 Container temperature
A PT100 temperature sensor TT0100 is fitted in the top of the soundproof casing, near the
cooling air outlet. From this temperature measure an alarm signal is given if the temperature
exceeds a preset value. This condition usually indicates a failure or fault in the air cooling
system.
The main causes for this may be blower failure, accidental closing of the shutters or an
insufficient air flow caused by clogged pocket filters.
2.1.2.5 Fuel gas leak monitoring system
The gas monitoring system provides a gas leakage detection inside the package in order to
avoid undetected built up of dangerous gas concentration which could lead to explosions.
In case of gas detection the turbo-generator set is stopped and the electrical supply to the
package is interrupted with exception of the explosion-proof ventilation fans which purge the
enclosure, of the explosion proof lube oil pumps and of some other turbo-generator protective
devices like gas detectors, fire detectors, lamps which are all ex-proof.
The gas monitoring system consists of gas detectors DT2050, directly connected to the safety
system.
2.1.2.6 Fire monitoring system
The fire monitoring and extinguishing system detects flames inside the package and, after a pre-
set time delay (typically 30 s) releases extinguishing agent (CO2) which will fill the enclosure.
The fire monitoring and extinguishing system consists of following main components:
• electronic control and monitoring unit with 220V/AC supply,
• 24V/DC internal battery and manual fire alarm button on the front panel in the container
• infrared ray detectors RT0210 and RT0220
outside the container

rack FF0310 containing the following articles:
• manual release push-button SB0302, alongside the enclosure
• warning horn and flashing light signals HAL0305, above the inspection door
• one CO2 bottles set B0312 with sufficient filling for one extinguishing action
• pilot bottle B0311
• weight switches for CO2 bottle leakage monitoring WS0312
• extinguishing agent release solenoid valve MV0311
• distribution piping, and spray nozzles FO0317.
• check valve RV0314
• pressure switch PS0311 to check the pilot bottle pressure level
• B0315 lemon fragrance
• pressure switch PS0316 to check the CO2 release
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2.1.3 Turbine
The main parts of a turbine are the air-intake duct, the start-up unit, the multi-stage air
compressor with variable stator vanes, the distribution ring with fuel nozzles, the annular
combustion chamber, the multi-stage turbine and the exhaust duct.
2.1.3.1 Technical data
2.1.3.1.1. Two shaft turbines
Mars type engines are two shaft turbines.

Two shaft turbines have two separated turbine rotors, mechanically independent: two stages for
the gas producer turbine and two stages for the power turbine.
Turbine type Mars

Compressor type Axial
Compressor no of stages 15
Compression ratio 17: 1
Compr. stages with IGV 5
Combustion chamber type Annular
No of injectors standard 21
No of injectors SoLoNox 14
No of stages gas prod.turbine 2
Gas producer turbine speed 10942 rpm
No of stages power turbine 2
Power turbine speed 8625 rpm
Type of radial bearing Hydrodynam., tilt-pad
Type of axial bearing Hydrodynam., tilt-pad
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2.1.3.2 Cutaway a two shaft turbine (Hot End Drive)
1 compressor rotor 5 exhaust collector 9 compressor case

2 fuel injectors 6 power turbine 10 inlet guide vanes
3 fuel manifold 7 gas producer 11 air inlet
4 exhaust diffuser 8 combustor housing
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2.1.3.3 Thermodynamic process
The compressor draws in ambient air, firstly using the power supply from the start-up system
and, when combustion begins, using energy supplied by the turbine. The compressor diffuser
distributes the compressed air to the combustion chamber. In the combustion chamber, fuel is
injected into the air flow and mixed. During the start-up sequence, the fuel-air mixture is ignited
by the high-voltage spark from a spark plug, and so the continuing burning process starts: it is a
continuous cycle. The combustion hot gasses generated in the combustion chamber drive the
turbine, expanding as they enter it. In this way, the thermal energy generated by the fuel
combustion is transformed into mechanical energy at the turbine shaft. The turbine uses part of
the power for operating the compressor and the turbine accessories. Part of the remaining
energy is used to drive the generator via the gear box and part leaves the turbine as hot
exhaust gas ,which may be recuperated in a boiler: such an arrangement is called co-
generation.
2.1.3.4 Turbine design
The air-intake housing is fitted with a grid to prevent the entry of large foreign objects:
• this screen is not to be considered as an air filtration device.
The compressor housing holds the first turbine-shaft bearing (axial-radial) and the hydraulic
vane control system. The second bearing (radial ) is located behind the compressor. The air
intake end of the compressor shaft is coupled to the start-up motor via gear box. The
combustion-chamber housing holds the third, radial bearing and the exhaust duct. The
combustion chamber is designed as an annular inline construction with a single-component
internal casing and fuel injectors.
The fuel injectors are inserted and flanged from outside the casing.
This arrangement allows easier access for corrective on-the-spot maintenance, when replacing
the fuel nozzles and for inspection of the compressor unit and the front end of the turbine.
The turbine stages consist of discs, which are used to sustain the turbine blades.
The axial thermal extension of the casing is compensated by means of an expansion uni.
The turbine may be equipped with a low-pollution combustion system, called SoLoNOx - system.
This includes two fuel distribution rings and specially developed fuel-injection nozzles.
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2.1.3.5 Main engine subassemblies similar for single shaft and two shaft turbines
1 reduction gear unit 2 air inlet duct

3 air inlet assembly 4 diffuser assembly
5 compressor bearing support housing 6 compressor assembly
7 variable guide vane assemblies 8 compressor 3rd stage
9 compressor 2nd stage 10 compressor 1st stage
11 air inlet 12 exhaust collector
13 turbine rotor assembly 14 Combustor +gas prod. turbine assembly
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2.1.3.6 Internal turbine compressed air system PCD
The compressor air discharge system provides the air under pressure for the turbine oil seal,
cools the components of the hot turbine parts and prevents compressor pumping by means of
diverting an exactly calculated part of the compressor discharge air flow. The system also
supplies the atomization air for units that operate on the liquid-fuel mode.
PCD= Pressure Compressor Discharge
2.1.3.7 Compressor Inlet Guide Vanes = IGV
IGV Inlet Guide Vanes (Variable vane assemblies)
1 vane actuator lever 3 rotor blade

2 compressor housing 4 compressor rotor
5 stator variable vane
Some air intake side stages of the compressor are provided with static vanes of variable angle
type and called IGV (Inlet Guide Vanes).
The IGV’s are in a minimum closing position during engine start-up to avoid compressor surge.
With SoLoNOx turbines, the vanes will be opened according to a schedule designed to reduce
the emissions.
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2.1.3.8 Bleed valve
Bleed valve (bypass) with actuator
1 bleed air butterfly valve 3 bleed air duct and bellow

2 actuator 4 combustor housing
The bleed valve V1020 modulates the amount of air being bled off from the end of the
compressor to the gas turbine exhaust manifold.
To avoid compressor surge during acceleration and at low speed operation the bleed valve will
open in response to command from the turbine control system and bypass part of the air flowing
into the combustion chamber.
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2.1.3.9 Fuel supply
The gas-fuel flow to the turbine is regulated by means of the control valve FCV2021 (SoLoNOx:
main gas valve FCV2021 and pilot gas valve FC2031).
The gas-turbine control logic is based on the control temperature, T5.
The temperature T5 is measured between turbine stages 2 and 3 with the aid of thermocouples
TT1825 .
The mean value for these thermocouples is computed .
This mean temperature, T5, is the calibrated parameter for the regulation (limiting) of the
maximum output power of the gas turbine.
Deviation of one or more thermocouples from the mean value is monitored. If the deviation
exceeds the pre-set limit values, an alarm is set off and, if necessary, the turbine is shut down.
2.1.3.10 Exhaust system
Thermocouples TT5202 located in the exhaust collector measure the exhaust temperature.
If necessary, the exhaust temperature can be limited by means of special control software, to
protect or control the boiler. A back-pressure switch PS5201 on the exhaust collector protects
the gas turbine from excessive back pressure generated by the boiler. In addition, a pressure
transmitter PT5201 calculates the turbine functioning.
CAUTION
The gas turbine cannot be operated with a back pressure of more than 350 mm of head of water.
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2.1.3.11 Vibrations monitoring system
2.1.3.11.1. On gas producer turbine bearings:
• no 1: horizontal proximity sensor ST1715

• no 1: axial proximity sensor ST1716 (option)
2.1.3.11.2. On power turbine bearings:

• no 5: axial proximity sensor ST1756 (option)
2.1.3.11.3. On the gear box casing:
• radial vertical acceleration transducer ST1841
2.1.3.11.4. On non driving end generator bearing:
• radial vertical speed transducer ST4210
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2.1.4 Gear box

On single shaft turbines the reduction gear unit is bolted to the engine air inlet housing .On two
shaft turbines the gear box is flanged on the generator driving end. The unit is a high speed, two
stage, star compound, epicyclical design with output speed of 1500 rpm (50Hz). The unit is able
to sustain momentary overloads of up to approximately eight times normal operating rated
torque. Lubricating oil for the gear box is supplied from the turbine lube oil system.
Technical data
Type: High speed, two stage, star-compound, epicyclical
Rated output speed: 1500 rpm
2.1.4.1 Gear box
1 fixed center 1st stage star gear 3 2nd stage star gear
2 input pinion (sun gear) 4 2nd stage ring gear
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2.1.5 Generator
For details see separated generator manual.
The generator is installed on the base frame on mounting blocks. Its shaft is coupled to the slow-
speed shaft of the gear box.
The generator is air cooled with one or two fans, which draw air in from lateral air intakes.
Although different generator configurations may be used, the standard turbine generator
normally consists of a magnet-wheel three-phase current generator in a drip-proof design with
damper winding and a directly connected brush-free exciter.
The machine consists of a main generator (internal-pole machine) and an exciter (external-pole
machine).
Voltage regulators, generator protection and other instruments are required in addition to the
generator controls. They are located in the control cabinet.
The generator is intended for either isolated or parallel service with the electricity grid or with
other generators.
2.1.5.1 Generator : main components, common to most manufacturers
1 rotor 5 polar wheel

2 drive end bearing 6 exciter
3 fan 7 non drive end bearing
4 stator winding 8 rotating diodes
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2.1.5.2 Generator design
The stator housing, end plates and main terminal box are made of iron plate.
High-quality, low-loss silicon steel with inorganic insulation is mainly used for the stator core
plates. The magnet wheel is built as a solid shaft. The rotor is equipped with a complete damper
winding. All windings are vacuum-impregnated and provided with very stable reinforcement so
that they can withstand all foreseen mechanical demands, including electric shocks and
vibrations.
The rotation direction is clockwise (viewed from the drive side).
The generator is equipped with one or two shaft-mounted fans, which blow cooling air through
the winding and the laminated core.
Air enters from both sides and exits below.
The thermal protection is installed in the stator winding by means of TT4201, TT4202 and
TT4203 sensors for the temperature measurement.
The main terminal box, mounted on top of the generator, contains the winding ends and the
main terminals.
The voltage and current transformers for the control, measurement and protection devices of the
generator are also located within this box.
The power cables are brought to the main terminal box either through a hole in the floor of the
base frame or through special ducts above the control cabinet.
The low tension terminals for the auxiliary devices are in a separate part of the main terminal
box.
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2.1.5.3 Excitation and voltage regulation
The excitation voltage for the brush-free generator is provided by means of an exciter and diode
bridge mounted on the shaft. The excitation voltage for the exciter is supplied by a separate
electronic voltage regulator through a transformer, compound voltage transformer and reactance
coils. The governor is equipped with a surge arrester as reactive-power protection in parallel grid
operation.
The accuracy of the governor is better than +/- 1% for all symmetrical loads.
The voltage setting can be adjusted continuously to +/-10%.
The voltage controller is installed in the control cabinet.
2.1.5.3.1. Principle electrical diagram:
1 Stator 4 Exciter armature

2 Magnet wheel 5 Exiter coil
3 Rectifier bridge 6 Automatic voltage regulator
2.1.5.3.2. Additional equipment:
• 6 Temperature probes (TT4201, TT4202 and TT4203) in the stator winding : 3 used, 3 spare
• 1 Temperature probe (TT4215 and TT4216) in each bearing
• 3 Triple-core current transformers at neutral point: 2 x 20 VA (5 P10) and 1 x 20 VA (0.5 M5)
• 3 Triple-core voltage transformers: 2 for measure and 1 for protection (open triangle)
• different transformers for controller supply and short-circuit correction
• 1 Heater for condensation protection W4100
For further information on the generator, see manufacturer‘s manual.
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2.1.5.4 Standard generator data: typical ratings
Turbine type Mars

Nominal power 12500 kVA
Power factor 0.8
Frequency 50 Hz
Voltage 10500 V
Speed 1500 rpm
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2.2 Mechanical systems
2.2.1 Start-up system
2.2.1.1 General description
The direct start system provides the turbine with starting power. The start system includes the
following:
• starting controller
• starter motor
When the start/crank cycle has initiated, the controller provides the start motor with starting
power.
2.2.1.2 Functional description
The Starter Motor turns the inner race of the clutch assembly and the sprag lock against the
outer race. The torque is transmitted to rotate the engine. After combustion occurs, the engine
turbine begins to support the acceleration. When engine speed exceeds starter motor speed, the
clutch outer race rotates faster than the starter motor-driven inner race and the sprag
disengages, permitting the clutch to overrun or free wheel. When engine speed reaches a pre-
set value, typically 66 percent, the control system de-energizes the starter motor. The starter
clutch disengages and the starter motor stops.
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2.2.1.3 Typical sprag clutch assembly of a turbine
1. quill sleeve 4 starter adapter housing 7 bearings

2. starter splined coupling 5 gear box assembly 8 gear box shaft
3. starter motor 6 starter sprag clutch 9 splined coupling
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2.2.1.4 Clutch design
A sprag clutch engaged B sprag clutch overrunning
1 engine shaft 4 sprag

2 starter drive shaft 5 outer cage
3 inner cage
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2.2.1.5 Start-up system of two shaft turbines
2.2.1.5.1. Start-up motor of two shaft turbines
The starting motor of a two shaft turbine M1200 is a squirrel cage induction motor,4 poles, 400V,
insulation class F. A Static Frequency Converter (SFC) enables the motor to run from
approximately 0% to 100% speed.
The motor is flanged on compressor shaft at the air intake side.
The motor is equipped with:
• a temperature sensor TT1200, which gives the possibility to control its thermal behavior and
to stop the motor in case of overload
2.2.1.5.2. Start-up controller of two shaft turbines
The controller of the starting motor of a two shaft turbine is a static frequency converter (SFC). It
is installed in the SFC cubicle and includes filters and the circuit breaker, which switches on and
off the main power supply.
Starting motor arrangement on two shaft turbines
1 starting motor 2 air inlet duct
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2.2.1.5.3. Start-up motor controller configuration
A keypad/display can be used to program the configuration and the adjustments. This
configuration is only to be modified by Turbomach personnel.
The software configuration is programmed to process a 4-20mA signal transmitted by the turbine
control system. This signal corresponds to 0-100% maximum torque on the starter motor.
The turbine control system schedules the starter motor speeds according to the selected
operating mode start/crank. The speed is controlled with a closed loop controller, implemented in
the software.
CAUTION
Do not modify the starter controller software configuration, modification of the start/crank
schedules can jeopardize the gas turbine plant.
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2.2.2 Fuel systems
2.2.2.1 Gas fuel system
2.2.2.1.1. Description
The gas-fuel system regulates the fuel pressure and automatically controls the fuel supply
according to power requirements.
The system is integrated in the base frame as a pre-assembled module.
Upstream of the control valves, are two quick-action valves, which allow for emergency shut
down and valves tightness check during the start-up phase.
This module is equipped with an electrical terminal box, which contains input and output
components related to the fuel gas system.
All functions are controlled automatically by the field bus.
The gas fuel system has the following functions:

• Controlled fuel gas supply to the gas-turbine nozzles.
• Immediate shut-off of the gas supply to the turbine in emergencies.
Gas fuel is supplied to the gas turbine housing from the existing plant gas pipeline and
regulation station (not supplied by Turbomach).
The standard fuel system is designed for use with natural gas.
CAUTION
The fuel quality must comply with the Solar ES 9-98 Specification.
The customer must ensure that the gas supplied to the turbine contains no liquid or solid foreign
bodies. Nevertheless, a gas filter F2000 is installed in the supply line, which prevents unwanted
pollutants reaching sensitive components like the gas control valve, the gas-fuel nozzles or the
turbine combustion chamber.
A differential pressure switch PDSI2000 on the gas filter sets off an alarm if the pressure drop
exceeds a pre-set value ( typically 1.5 bar ); in this case, the filter cartridge should be replaced.
CAUTION
If the pressure drop on the gas filter reaches the limit value ( typically 1.5 bar ), the filter cartridge
must be replaced.
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The gas fuel system consists of the following components in the soundproof casing:
• Gas-fuel control valve (for SoLoNOx this is the main gas control valve) FCV2021 (Gas fuel
pilot control valve with SoLoNOx turbines FCV2031)
• Secondary gas shut-off valve AV2002 (in standard configuration the primary gas shut-off
valve AV2001 is located outside the container)
• Pressure switch for main gas pressure during ignition sequence PS2022
• Pressure switch for pilot gas pressure during ignition sequence PS2032 in SoLoNOx
• Gas-pressure measuring double transmitter PT2020
• Double pressure transmitter PT2025 downstream the gas-fuel control valve
• Double pressure transmitter PT2035 downstream the gas-fuel control valve in SoLoNox
turbines
• Main gas distributor
• Pilot gas distributor with SoLoNOx turbines
• Ignition gas pressure reducer PC2040
• Solenoid valve ignition gas line MV2041
• Pressure switch 1 for gas-valve tightness control (gas pressure max.) PS2018
• Pressure switch 2 for gas-valve tightness control (gas pressure min.) PS2017
• Solenoid vent valve MV2010
• Piping, manual valves, flexible metal hoses, etc.
The following devices are located outside the soundproof casing:

• Manual shut-off valve HV2011
• Gas Flowmeter FT2091
• Gas filter F2000
• Primary gas shut-off valve AV2001
• Pressure switch for maximum gas pressure PS2008
• Pressure switch for minimum gas pressure PS2007
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2.2.2.1.2. Safety devices of the fuel gas system
At the battery limit the gas line there’s an upstream manual shut-off valve (not supplied by
Turbomach) to interrupt any time the gas supply to the turbine.
Pressure switches PS2007 and PS2008 monitor the maximum and minimum permitted gas fuel
pressures, respectively. If the pressure exceeds or falls below the tolerated range, the gas is
shut off.
CAUTION
The customer must ensure that the natural gas pressure cannot exceed the value given in the
external connection specifications at the package inlet flanges.
In any case, the gas turbine is shut down if a pre-set limit value is reached.
In standard configuration the primary shut-off valve for the gas AV2001 is installed outside the
gas turbine housing and thus guarantees the shut-off function even in the case of fire or
explosion inside the soundproof casing.
This valve can be shut off manually by operating the three-way manual valve HV2001.
By pressing the red cap of HV2001 the instrument air is vented, thus shutting valve AV2001.
The secondary shut-off valve AV2002 serves as a rapid shut-off to interrupt the gas supply
inside the soundproof casing.
NOTA
If the turbine is shut down, both shut-off valves AV2001 and AV2002 are closed.
If the turbine is not running, shut-off valves AV2001 and AV2002 are closed, while the gas fuel
vent valve MV2010 is open and the entire line between AV2001 and AV2002 is vented.
This prevents gas from leaking into the gas turbine.
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2.2.2.1.3. Control and monitoring system of the fuel gas system
The gas-fuel control valve FCV2021 is operated by a stepper-motor with integrated position
feedback. (with SoLoNOx turbines, also pilot gas-fuel control valve FCV2031)
The position control for the gas-fuel control valve provides all necessary logic functions for
opening the control valve according to a required fuel flow for the corresponding turbine
operation, e.g., start-up, acceleration, speed and load regulation.
This gas-fuel control valve is equipped with position feedback.
The control logic gives an alarm if the deviation between the required position and the measured
position exceeds a permitted tolerance range.
The gas pressure is measured by a pressure transmitter PT2020, which sends a 4-20 mA signal
to the turbine control.
The gas-fuel collector distributes the gas fuel to all combustion injectors. A flexible metal hose
EJ2024 (and EJ2034 with SoLoNOx turbines) between the gas fuel control valve and the
collector allows for unhindered heat expansion of the different components and minimizes the
transmission of vibrations of the turbine to the piping.
Only for SoLoNOx turbines:

The gas flow is split between the main gas control valve FCV2021 and the pilot gas control valve
FCV2031, so that the quantity ratio between the main and the pilot gas corresponds to the
needs of SoLoNOx operation.
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2.2.3 Lube oil system
2.2.3.1 Conception
The main function of the lubrication system is the continuous supply of the following parts with
cooled, clean lubricating oil:
• Turbine bearings
• Reduction gear box
• Generator bearings
• Bleed valve and Inlet Guide Vanes actuators, if they are hydraulic.
The oil is fed from the lube oil tank B3400 located in the base frame. The oil is supplied by the
service pumps from the tank, through the double filter F3200, the pressure control valve PC3040
and the temperature control valve TCV3320.
Depending on the need, the oil may pass through the oil cooler module MOD3390.
The valve PC3040 regulates the pressure by returning excess oil back to the tank.
The oil pressure is kept constant by means of a pressure control loop consisting of pneumatic
control valve PC3040 and pressure transmitter PT3030. The pressure control loop is integrated
in the TCS (Turbine Control System).
During operation the oil temperature is controlled by a thermostatic valve TCV3320 and oil
cooler module MOD3390.
At standstill, the oil in the tank is kept warm by means of electrical heater W3420.
In order to guarantee continuous lube oil supply, even in case of a power failure, there is an
emergency lube oil system driven by DC motor, which starts automatically and delivers the
minimal oil flow required for a safe deceleration of the turbine and for post-lubrication of the hot
bearings of the turbine.
The lube oil system is integrated in the base frame as a pre-assembled module.
This module is equipped with an electrical terminal box, containing the lube oil system input and
output components.
All functions are controlled automatically via the field bus.
CAUTION
The lubricant oil used must comply with SOLAR specification ES 9-224, since severe damages to
the turbine may otherwise occur!
Date : 24.02.2009
Rev No :
Rev Date :
2.2.3.2 Lube oil pumps
2.2.3.2.1. Service pumps
The oil is fed by the main pump EP3010 and by the auxiliary pump EP3060.These two pumps
are of centrifugal type and are driven by explosion-proof AC motors.
The pressure switches PS3011 and PS3061, located at the pump outlet constantly supervise
the lube oil pressure and give an alarm, if the pressure drops below the preset value.
WARNING
Even if, because of availability, the operation of the turbine with either the main pump or the
auxiliary pump out of service is permitted, the operator has to be aware of the fact that such a
situation is considered abnormal.
In case of pressure failure during that abnormal operation condition, the emergency lube oil pump
may start and an emergency shut down may occur, caused by the electronic control system or by
the redundant safety backup system.
If, during normal operation, :

• pumps EP3010 and EP3060 have a pressure failure or
• the AC supply is cut or
• the 2 motor overload protections M3010, M3060 activate, the electronic logic control
switches on automatically the DC motor driven emergency pump EP3110.
The non-return valves RV3016, RV3066 and RV3116 installed at the pump outlet, avoid oil
entering into stand-by pumps. For maintenance reasons the shut-off hand valves HV3017and
HV3067 are installed at the pump outlets and, since the pumps are placed below the lube oil
tank level, two hand valves are also installed between pump inlets and tank suction connection.
Closing at the same time the hand valves HV3015, HV3065 and HV3115 immediately causes a
pressure drop in the lube oil system and an emergency turbine shut down. Closing in the same
way the hand valves HV3017 and HV3067 has the same effect.
Date : 24.02.2009
Rev No :
Rev Date :
WARNING
During normal operation, following hand valves must stay open and have to be closed only for
maintenance purposes :
HV3015, HV3065
HV3017, HV3067
HV3115
If the above-mentioned hand valves are closed during operation, the oil flow to the turbine is
jeopardized and a catastrophic failure may occur to the bearings of the turbine gear box or
generator.
Under these circumstances, Turbomach rejects all responsibilities.
2.2.3.2.2. Emergency lube oil pump for two shaft turbines type Mars
The emergency lube oil system is not sized for the supply of all the requested amount of oil to
the bearings during full speed operation.
This system is only operating during deceleration and post-lubrication sequence, if the service
pumps are unable to perform at the nominal pressure.
The emergency lube oil pump EP3110 is a centrifugal pump driven by a DC explosion-proof
motor.
This pump operates when the main pump and the auxiliary pump stop supplying the lube system
because of fault or AC blackout.
In this case the turbine is shut down immediately.
The DC motor is supplied by batteries.
The emergency lube oil piping bypasses the oil cooler and the pressure controller to reduce
pressure loss.
At the outlet of the emergency lube oil pump, no hand valve is fitted in order to avoid
mishandling which may cause components failure.
WARNING
The hand valve HV3115 must always be widely open while the turbine is operating!
Otherwise, in case of emergency shutdown, non full-filling this condition may cause a catastrophic
failure to the bearings of the turbine, gear box or generator.
Under these circumstances, Turbomach rejects all responsibilities.
Date : 24.02.2009
Rev No :
Rev Date :
2.2.3.3 Lube oil cooling system
The lubricating oil cooler module MOD3390 consist of 2 100% oil/water coolers installed in
parallel.
When using standard oil ISO VG32 the lubricating oil is cooled from 65 - 75°C to 54 - 63°C.
A three-way thermostatic valve installed after the lubricating oil cooler maintains the temperature
at the desired value by sending some of the warm oil through the bypass piping to the heat
exchanger.
The temperature after the heat exchanger is measured with the PT100 sensor TT3035.
A safety interlock in the control logic prevents the turbine from start-up if the oil temperature falls
below a specific threshold, usually 15°C.
In continuous operation, the minimum permitted lubricating oil temperature is set at 43°C. If the
temperature falls below this value an alarm is set off indicating low lubricating oil temperature.
At standstill, the oil in the tank is kept warm by means of the thermostat controlled heating
W3420.
2.2.3.4 Lube oil filter system
The double cartridge filter (F3200) allows for uninterrupted operation since, using the manual
valve (HV3200), oil flow can be switched from one filter section to the other.
Drain valves (HV3208) and bleed valves (HV3204) make it possible to change the filter
cartridges.
The filter is fitted with a pressure-differential switch (PDSI3200), which monitors the pressure
drop on the oil filter cartridges. It sends a warning signal, which allows the oil flow to be changed
over from one section to the other if the difference is more than the preset value.
WARNING
From the moment the warning signal is given due to the maximum pressure drop being exceeded,
the operator has 24 hours to switch over to the spare filter section.
If this is not done within 24 hours, a second (and last) alarm is shown which gives the operator 24
more hours to switch over. If this additional time expires and the pressure drop is still higher than
the pre-set threshold value, the turbine undergoes a forced cool down shut down sequence.
2.2.3.5 Lube oil temperature and pressure supervision
The lube oil pressure is measured by transmitter PT3030 and supervised by a hard-wired safety
redundant pressure switch PS3031.
The lubricant temperature is measured using a PT100 sensor TT3035; the redundant
temperature switch TS3036 serves as a safety against over-temperature.
Date : 24.02.2009
Rev No :
Rev Date :
2.2.3.6 Bearings temperature monitoring
Bearing temperatures are measured by means of PT100 sensors.

• turbine bearing no. 1 with sensor TT1710
• coupling and gearbox bearing TT1750 and TT1760
• bearing no.2 and 3 with sensor TT1325 (common drain )
• generator driving end bearing with sensor TT1716
• non driving end bearing with TT4216
2.2.3.7 Lube oil drain system and lube oil tank
The drain lines collect the lube oil into tank B3400.
The lubricant piping between the main components and the lubricant drain lines are equipped
with flexible metal or rubber hoses to compensate for differential heat extension and to prevent
the transfer of vibrations from the main components to the ducting system.
In the event of a leak in the lube oil system, the base frame serves as a retention basin, which
can hold the full amount of oil.
The base frame also serves as a drip tray for liquids, which may be spilled in the soundproof
housing.
The lube oil tank is provided with following instrumentation:
• Level indicator and low level switch: LIS3410
• Lube oil tank under-pressure transmitter: PT3415
• Lube oil tank low level switch: LS3411
2.2.3.8 Ventilation and oil vapours extraction
The lubrication system is ventilated via the oil tank and a negative pressure is maintained of
approximately 50 mm of water column (5 mbar) by means of a fan V3500. This vacuum prevents
leaks from the turbine bearings and leakage of the piping and tank.
The oil vapour is removed from air by means of an electrostatic filter F3500.
Date : 24.02.2009
Rev No :
Rev Date :
2.2.4 Air systems
2.2.4.1 Compressed air system
The package instrument compressed air system is used for the pneumatic actuators and control
valves, purging devices, and for liquid fuel application as atomizing air during start sequences.
The main components are:
• instrument air filter F0420, provided with water separator
• valve MV0405 to cut the compressed-air circuit in case of fire
• hand adjustable pressure reducing regulator PC0401 for air main regulation
• hand adjustable pressure reducing regulator PC1507 for the temporary connection of
sealing air to the bearings during compressor off-line washing
• pressure switch PS0402 for supervision of the minimal air supply pressure
2.2.4.2 Container ventilation filter system
The main function of the container air-filter system is to reduce the amount of solid pollution
entering the soundproof casing.
Because the gas-turbine combustion air and the air for cooling the casing have very different
requirements, different types of filters are used.
The container cooling air system and combustion air system are separated.
The installed container filters F5101 are bag filters made of fiberglass .
When the filter elements become dirty, the severe drop in pressure reduces the air flow through
the soundproof casing and thus increases the outlet air temperature.
The sensor TT0100 measures the cooling air exit temperature. An alarm due to excess
temperature of the casing cooling air, indicates that the inlet and outlet casing fans, the shutters
position and the filter bags must be checked.
Filter bags inspection and replacement, if necessary, is one of the jobs of the planned preventive
maintenance.
Date : 24.02.2009
Rev No :
Rev Date :
2.2.4.3 Combustion air filter system
The main function of the combustion air-filter system is to reduce the amount of solid pollution
entering the gas turbine to the levels established by the turbine manufacturer.
The hot parts of the gas turbine are cooled by air that comes from the compressor section of the
turbine. This air is driven through cooling orifices and channels over the rotating blades and
static guide vanes. If unfiltered air passes through these cooling orifices and channels, they may
become blocked by solid pollutants, which may lead to local overheating and subsequent
damage to the material.
Besides the above-mentioned dangers of dirt and blockage of the cooling channels for the hot
components, operating the turbine with unfiltered air may lead to blockage of the turbine
compressor. The rotating blades and static guide vanes of the first stages of the compressor are
especially prone to the action of precipitates, which can alter the aerodynamic profile of the
blades and vanes; modification of the profile of the vanes deteriorates the performances and can
lead to compressor surge.
CAUTION
The gas turbine must always be operated with all the filter elements in good conditions, not
damaged or missing!
Failure to observe this indication can lead to overheating of the hot parts of the gas turbine or
surging of the compressor and hence to a total failure of the gas turbine!
The combustion air intake system consists of:

• Prefilter stage system F5001
• Main filter stage system F5093
• combustion air silencer S5002
• combustion air duct with expansion compressor EJ5003
• measuring devices PDT5010 and TT5011
A fully welded filter housing in the form of a fixed construction is bolted to the top of the
soundproof casing.
Date : 24.02.2009
Rev No :
Rev Date :
If the plant is equipped with reverse-flow pulse cleaning system, a complete set of solenoid
valves, compressed air tanks and piping are provided.
An electrical terminal box is installed in the filter system and contains the input and output
components for the control system and a complete AC distribution with motor outputs for the air
fans.
All functions are controlled automatically via the field bus.
Before entering the gas-turbine compressor, the combustion air flows through a damper, which
consists of several bafflers, thus ensuring the reduction of noise emissions surrounding the gas
turbine within certain limits. A fabric expansion bellow installed inside the soundproof casing
EJ5003 facilitates the movement between the gas-turbine incoming air distributor and the clean
air duct; this bellow also serves to prevent transmission of vibrations from the gas turbine to the
filter casing, thus avoiding the generation of additional noise.
Adjacent to the air-intake distributor, the temperature indicator TT5011 measures the inlet
temperature of the combustion air. The data are analyzed by the gas-turbine control logic.
In the air distribution duct, a differential pressure transmitter PDT5010 produces a 4-20 mA
signal, which is proportional to the drop in pressure across the filter cartridges.
The drop in pressure is monitored. When the pressure reaches the shut-off limit, the automatic
control system shuts down the turbine. The gas turbine can function without risk to the first alarm
limit, taken from the output of the pressure-drop transmitter. Operation with a high pressure drop
in the filter system leads to reduced power and lower efficiency of the gas turbine.
If the pressure drop in the filter system is too high the filters should be changed or cleaned.
The plant may be equipped with one of these two arrangements:
• with progressive filters
• self-cleaning system
The life of the filter cartridges cannot, in general, be predicted as this depends largely on
impurities in the area of operation and on atmospheric conditions.
CAUTION
Never operate the turbine at a pressure-drop above 150 mm of head of water!
The seal of the filter casing cannot be guaranteed at differential pressures greater than 150 mm of
head of water (tightness value)!
Operating the gas turbine with a pressure drop greater than 150 mm of head of water can lead to
surging of the gas-turbine compressor!
Operation above the nominal tightness value is only allowed with the written permission of
Turbomach.
2.2.4.3.1. Progressive filters
The cartridges of this type of filter have a progressive structure giving a higher life expectancy.
They cannot be used in self-cleaning systems and have to be replaced after service.
Date : 24.02.2009
Rev No :
Rev Date :
2.2.5 Compressor washing system

In normal operation of the gas turbine there will be sedimentation of foreign bodies on the
compressor blades. Matter such as dust, hydrocarbon vapour, oils, soot, etc., reach the air
intake and are deposited on the rotary and static blades of the compressor, primarily on the first
stages of the compressor blades. This sedimentation reduces the air flow of the compressor and
hence the pressure, leading to lower output power and efficiency of the gas turbine.
The normal cleaning process consists of washing the compressor with water, water-based
cleaning product, or, if necessary, solvents. The most effective cleaning solution, the exact
percentage of cleaner in the solution, the duration and frequency of the cleaning cycle can only
be determined by operating experience. The quality of the selected cleaning product should be
so that it does not leave sediment on the blades and does not corrode the machine components.
The cleaning solution is distributed by means of spray nozzles at the air-intake duct.
CAUTION
At temperatures below +7º C the compressor may only be washed if antifreeze agents are added.
The display on the control cabinet indicates the corresponding warning: “The low air temperature
requires the addition of antifreeze”. The operator should ensure before initiating the cleaning
process that the solution of water and cleaning product is correct.
De-mineralized water only should be used for preparing the cleaning solution. Before using other
cleaning products, consult Turbomach.
Washing the compressor, particularly in the online process, is especially dangerous at low
temperatures, as the air entering the compressor may freeze. In this case, severe damage to the
compressor cannot be excluded.
NOTE
The logic control system of the turbine records each washing cycle with water, which is performed
at temperatures below +7ºC and requests confirmation by the operator.
CAUTION
The water quality must comply with Solar Specification ES 9-98.
Date : 24.02.2009
Rev No :
Rev Date :
2.2.5.1 Compressor washing with start-up unit (off-line)
Washing the compressor with the aid of the start-up unit is generally more effective than online
cleaning and should be performed when online cleaning does not completely eliminate blade
contamination. Signs of deterioration may be detected by observing the decrease in the
discharge pressure of the compressor.
In general, a drop of 0.15 bar of compressor discharge pressure at nominal speed and nominal
load, or a reduction in power between 3 and 5 percent, under given environmental conditions,
show possible soiling of the compressor and a washing is needed.
The compressor pressure generally increases again following washing. When the pressure does
not increase or when the improvement in power is not as evident as expected, the unit should be
examined physically to check whether the pressure drop is due to mechanical causes.
The off-line compressor washing system consists of:
• Mobile washing system EP1504
• Tank B1500
• Portable hand lance with spray nozzles FO1504.
An exact description of the washing process can be found in the “Maintenance” chapter of this
documentation.
2.2.5.2 Online compressor washing system (if installed)
When operating in a very dusty atmosphere or where there is a high level of air pollution, it is
advisable to wash the compressor often, in order to obtain a high output of the gas-turbine
generator.
With the off-line washing procedure, the turbine is stopped for a period of several hours, which
could be inconvenient for the customer. There is an alternative process, by which the
compressor is washed while the turbine is operating, using a solution of water and cleaning
product (online washing).
The on-line compressor washing system consists of:
• Mobile washing system EP 1504
• Tank B1500
• Valve AV1515
• Pressure relief valve PC1541
• Fixed installed piping with water spray nozzles FO1539, from the tank to the compressor air
intake.
An exact description of the washing process can be found in the “Maintenance” chapter of this
documentation.

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Project : DAWOOD HERCULES

2 DESCRIPTION OF MECHANICAL COMPONENTS AND

2 DESCRIPTION OF MECHANICAL COMPONENTS AND

2.1.2 Soundproof enclosure: container 5

2.1.4 Gear box 16

2.2 Mechanical systems 21

2.2.2 Fuel systems 26

2.2.3 Lube oil system 30

2.2.3.6 Bearings temperature monitoring 34

2.2.4 Air systems 35

2.2.5 Compressor washing system 38

2.1 Mechanical components

2.1.1 Base frame

Turbine type Mars

2.1.2 Soundproof enclosure: container

2.1.2.1 Container design

2.1.2.2 Container lighting

2.1.2.3 Container ventilation

2.1.2.3.1. Air intake components

• Cooling air intake filter F5101

2.1.2.3.2. Air exit components

• Sound damper for the outlet cooling air S5112,

2.1.2.4 Container temperature

2.1.2.5 Fuel gas leak monitoring system

2.1.2.6 Fire monitoring system

outside the container

2.1.3.1 Technical data

2.1.3.1.1. Two shaft turbines

Mars type engines are two shaft turbines.

Turbine type Mars

2.1.3.2 Cutaway a two shaft turbine (Hot End Drive)

1 compressor rotor 5 exhaust collector 9 compressor case

2.1.3.3 Thermodynamic process

2.1.3.4 Turbine design

1 reduction gear unit 2 air inlet duct

2.1.3.6 Internal turbine compressed air system PCD

2.1.3.7 Compressor Inlet Guide Vanes = IGV

IGV Inlet Guide Vanes (Variable vane assemblies)

1 vane actuator lever 3 rotor blade

2.1.3.8 Bleed valve

Bleed valve (bypass) with actuator

1 bleed air butterfly valve 3 bleed air duct and bellow

2.1.3.9 Fuel supply

2.1.3.10 Exhaust system

2.1.3.11 Vibrations monitoring system

2.1.3.11.1. On gas producer turbine bearings:

• no 1: horizontal proximity sensor ST1715

2.1.3.11.2. On power turbine bearings:

• no 4: horizontal proximity sensor ST1745

2.1.3.11.3. On the gear box casing:

• radial vertical acceleration transducer ST1841

2.1.3.11.4. On non driving end generator bearing:

• radial vertical speed transducer ST4210

2.1.4 Gear box

2.1.4.1 Gear box

2.1.5.1 Generator : main components, common to most manufacturers

1 rotor 5 polar wheel

2.1.5.2 Generator design

2.1.5.3 Excitation and voltage regulation

2.1.5.3.1. Principle electrical diagram:

1 Stator 4 Exciter armature

2.1.5.3.2. Additional equipment:

For further information on the generator, see manufacturer‘s manual.