Solar Saturn gas turbine continuous duty generator set Solar Gas TurbinesENGLISH TO METRIC MEASURES CONVERSION CHART Te convert from English To Metric Multiply by inches tin} centimeter (em) inches tin) rillimesers (rm) Feet (ft) meters tm) 0.3048 yards (yd) meters th ond ‘eubie feet (eu ft) ‘eubie meters (m3), 0.0283 square feet (sq f0) square meters (m2) xallons (al) Titers tb pounds (lb) Btu/Ib} kilograms tke British Thermal Unit/pound (Btu/Ib) | kilogram ealorie,kilogram (ky-cal/kg) British Thermal Unit Btu) kilo ealories (keal)| 0252 ceubie feet/min (efm) cubic meters min (m3/min) 0.0288 std. cubie feet/min (sefm) normal cubie meters hr (nm /he} 161 pounds/sq in gage (psig) atmospheres abs tata) o.orus pounds/sq in absolute (psia) bars o.o7164 horsepower (hp) kilowatts (kw) 0.7457 Pahrenheit (°F) Centigrade (°C) Ax 5) “The wordsSolr Centaur and Saturn appearing horn ar trademarks of Interetionl Harvester All ghia teorved. Copyright 107 by Salar Division of Inertial Har ester Company. The contents of tus publction may not be reproduced ether fe ‘ae ot in par witout consent of the eopymghe omer, Cover Photo: Saturn Generator Set Before Shipment From the Solar Plant at San Diego, California OLAR » rs7a/s75INTRODUCTION ‘This proposal describes the Saturn gas turbine generator set manufactured for continuous duty power applications by the Solar Division of International Harvester Company. ‘Major emphasis has been placed on application flexibility in design and packaging of the generator set. The basie set, with its wide range of available voltages and control system. arrangements, satisfies the majority of eustomer installation tnd operating requirements. ‘The system desig, based on ‘years of experience, is produced with standard components manufactured for industrial service. Prime consideration has been given to reliability of the set and to simplicity of ‘operation and maintenance, In comparing the Saturn gas turbine generator set with ‘generator sets of comparable rating, the following factors should be considered: Weight of the Saturn gas turbine generator set is approximately 17,00) pounds (7711 kg) and it ean be installed in a 120 f (11 m2) area. The compact size and lightweight features permit more efficient. use of available space and a considerable reduction in instal- lation eost. ‘The continuous-burning combustion eycle and the eon- tinuous rotary motion of the turbine virtually eliminate the need for vibration absorption equipment. ‘The package configuration, operating characteristics, and flexibility keep overall costs of installation to a ‘minimum (ie. transportation; rigging; foundation, platform, or building requirements; support equipment: Piping and dueting connections). ‘Turbine lubricating oil does not enter the combustion area and, therefore, is not subject. to contamination. Lubrieation oil replacement is required only at suit cient intervals (o prevent chemical breakdown eaused by aging. The quantity of oi] consumed during opera tion is negligible. Performance of the gas turbine generator set is supe rior to most diesel engine generator sets in frequency control, voltage regulation, transient response, and behavior in parallel operation as established by existing. test data. Motor starting characteristies are excellent, Starting time is fast and warmup is not required. The gas Uurbine-driven generator set ean aeeept full load immediately upon reaching rated speed Sound emitted from the set during: operation may be reduced Lo comfortable levels through proper selection of standard silencing components, ‘The turbine exhausts at a rate of approximately 28,000 ‘fm(792 m/min). The exhaust gas is elean,dry, and con tains 17 to 18 percent oxygen by volume. These com: bined characteristies create ideal circumstances for recovery of exhaust heat, The exhaust is relatively free of pollutants because of the continuous-burning ‘combustion eyee. ‘The generator set is a completely packaged and factory tested system, requiring only fuel, starting and eontrol power, and component interconnection to make it ‘operative. It requires no eooling water. ‘The set is offered with a variety of proven control systems to meet specifie customer requirements, ‘The produet is designed and applied by engineers spe- cifically trained and experienced in gas turbines, power gonoration, and eleetrieal systems. It is manufactured in accordance with the best industrial standards and is thoroughly tested in modera facilites. Personnel, specializing in equipment installation, re: view customer plans and specifications to ensure proper system integration. Qualified Power Support personnel are available throughout the world to pro: vide startup supervision, maintenance assistance, and ‘operator training ‘This proposal deseribes the basie configuration, avail able modifications, ancillary equipment, system perfor ‘mance, installation requirements, and power support forth Saturn Gas Torbie Continuous Duty Generator et.CONTENTS: SECTION 1 GAS TURBINE GENERATOR SET General Description Modifications Generator Liquid Fuel System Laubrieation Oil System Electrical System Control System Package 2 POWER SUPPORT Worldwide Techaieal Support Operation and Technical Manuals Replacement Parts Contract Maintenance Overhaul Overhaul Warranty ‘Training 8 SATURN GAS TURBINE ENGINE, Design Concept ‘Mechanical Features Saturn Gas Turbine Specifications 4 GENERATOR AND ASSOCIATED EQUIPMENT Generator Deseription Generator Construction Rating, General Selection Performance Characteristies Voltage Regulator Exciter 5 STANDARD OPERATING SYSTEM Starting Systems Gas/Air Starting System DC Electrie Disengaying Start System Fuel Systems ‘Natural Gas Fuel System Requirements Gas Fuel System Components Liquid Fuel System Dual Fuel Systems Governor Systems ‘Model PSG Governor Model EGB-2C Governor Lube Oil and Hydraulie System Standard System “Available System Modifications Air System Engine Seal Pressurization Turbine Cooling Air Compressor Bleed AirCONTENTS Continued CONTROLS AND INSTRUMENTATION Package Control System Start Sequence Running Sequence Stop Sequence Control System Components Control System Modifieations Control Console Automatic Control Systems PERFORMANCE CALCULATIONS: Performance ‘Typical Performance Curve Performance Correction for Altitude Effect of Inlet and Exhaust Pressure Loss Curve Available Exhaust Heat Motor Starting Capability “Approximate Exhaust Gas Composition Examples Of Use Of Curves INSTALLATION Installation Advantages ‘Mounting ‘Turbine Air Intake System Inlet Air Cooling. Exhaust System Ventil Electrical Interconnect AC Power System Additional Services ‘TESTING AND QUALITY CONTROL Testing Standard Testing Certified Test Reports Quality Control Product Improvement ProgramFIGURE Sefeer ILLUSTRATIONS, ‘Major Components Included With Basie Sot Basie Generator Set With Optional Enclosure Solar’s Power Support Facilities Saturn Single-Shatt Gas Turbine Reduction Gear Cross Section of Solar Saturn Gas Turhine Voltage Regulator Sehematie Exciter System Gas Start System Schematic DC Blectrie Starting System Natural Gas Fuel System Schematic Liquid Fuel System Schematic ‘Typical Start Air Assist Systems Dual Fuel System — Natural Gas/Distillate ‘Woodward Model PSG Governor Schematic BGB-2C Governor System Schematic Lube Oil and Hydraulic System Schematic Lube System Components Relay Panel Turhine Control Panel — Local ‘Turbine Control Panel — Remote Electrical Metering Panel Control Console ‘Output (KW) Versus Engine Inlet Air Temperature Altitude Correction Factor Inlet and Exhaust Pressure Loss Available Exhaust Heat Voltage Transients for Starting Lange Motors Approximate Exhaust Gas Composition Generator Set Components Generator Set Details Saturn Generator Ser With Optional Enelosure Exhaust Heat Recovery Diagram Gas Turbine Energy Systems ‘Typical Electrical interconnection Requirements ‘Typieal AC Power System PAGE ELELSSSSSHLERLLE RELL SE® GENERAL DESCRIPTION ‘The basie gonerator set consists of a Solar Saturn indus: ‘rial gas (urbine engine and reduetion gearbox mounted on a rigid base with the generator and operating systems. ‘Additional system components are identified in Figure -1. Depending on the final configuration selected, some of these components may requive separate mounting. ae e@ | | | | | stagr Couracto oc i eeu ESusroaner GENERATOR GEARBOX ASSEMBLY. 1 Gas Turbine Generator Set ‘The set is a compact, lightweight unit requiring minimum floor space and installation effort. Overall dimensions and component weights are shown in Figure 1-2, ‘The Saturn Gas Turbine Generator Set is a standard pro: duction unit designed for continuous duty power applica- tions. A wide ehoice of standard and optional equipment is available to meet varying installation and operating require TURBINE RELAY PANEL, TURBINE CONTROL, PANEL — Figure 1-1. Major Components Included With Basic Setgas will start system all skid-mounted electrical components meet the national electrical ende for Class 1, Division 2, Group D locations. A description of the basie set equipment is presented in subsequent parageaphs. Power Plant. & Solar Saturn 1200, single-shaft indus- ‘ial gas turbine engine with sleeve bearings and an integral, speed-redueiny geurbox to 1800 rpm. (A 1500 rpm gearbox is supplied with 0-H sets.) The nominal engine rating is 1200 horsepower, based on standard conditions of 59°F (15°C) at sea level, with zero inlet and exhaust losses, (Power available under other con- ditions is shown in Section 6.) A flexible-drive coupling feonneets the output shaft of the gearbox to the generator shaft Generator. A standard performance, 800 kw, 1000-kva, 480 volt, three phase, 60-H2, open-type generator with static voltage regulator. Fuil-load voltage transient is| 25 percent (15 percont for high porformance generator) with a maximum telephone influence factor (TIF) of 125 (50 for high performance), Other generators are available with the following frequencies and voltages. 60 Hz 50 Halt) Frequeney (1800 rpm) (1500 rpm) Voltage 4160 380 2400 415 600 240 3300 208 1. Specifications for 50 hertz may vary from the 60 hertz application. 2. Available as basic modifications. Additional rating will be provided on request. Governor. A Woodward Model PSG, speed-sensing, hydraulic governor with speed:trim motor. The Wood. ward Model EG-B2C electric load-sensing governor with mechanical backup is also available, Fuel System, Natural gas fuel system with all eompo- nenls necessary to meter and control fuel according to 12 aut, Turane exnaust veut GENERATOR 2b0LeR AW NET patel pa ier ale u\_/U U fue ] Flow as => “{8 A I Se I O | 9 oh aS sees WEIGHT, 17,000 LB G7L8 Ke) 12FTe Im, 86,1 cm [rrr ain, (225,50M—+| Figure 1-2. Basic Generator Set With Optional Enclosure ments, By speciying the natural gas fuel system and the load requirements, Solar Speciation ES 121 contains specific requirements for natural gas. fuel optional systems are available: Liquid fuel system. Complete with all necessary ‘metering and control instrumentation. A duplex filter arrangement is available to permit. changeout while the set is operating. Simplex is standard, Refer to Solar Specification ES 1224 for specific liquid hydrocarbon fuel requirements. Several Dual fuel system. Suitable for operation on either natural gas or liquid fuel. Includes eapabilty of start- 1g on either fuel and changing over during opera: tion. A system for operating on natural gas and wide-range liquid fuels is also available. Laubrication System. Complete lubrication system, including a storage tank with sight level indicator, zeardriven main lubrication oil pump, de pre/post lube oil pump, filter, temperature and pressure gages (set mounted); and an air-to-oll heat exchanger ‘with a hydraulic motor-driven draw-through eooling fan, (Solar Specification ES 9.224 contains specific Iube oil requirements}. Other available items include a three-phase, 480/240-volt ae, motor-driven cooling fan with an air-to-oil heat exchanger for remote mounting. ‘Starting System. (Paoumatie start system operating, fn 150 psig (10.5 kg/em® gage) natural gas or eom pressed air; ineiudes the lubricator, filter, and con- trols, A 24-volt de, disengaging-type starter, includ ing the main start contactor, is also available. Base. A struetural steel base supporting the turbine power plant, generator and standard operating systems, The base is treated with an inorganic zine coating to inhibit corrosion and is suitable for sup- porting an enclosure. All. electrical components ‘mounted on the base are designed to meet the National Blectrical Code requirements for Class 1, Group D, Division 2 locations. (Exclusive of de starter.) %Control System. A 24-volt, de turbine relay control system operates on either of the starting and/or control battery systems. The basie control system includes: ‘Turbine relay panel including all starting, operating, and protective relays; speed and temperature monitoring devices; and hourmeter DC cireuit breaker assombly and start contactor assembly, Voltage adjust reheostat Cross-current-compensating transformer ‘Turbine contro! panel with the following turbine instruments and controls: Exhaust temperature meter ‘Turbine temperature meter Pereent speed meter Off/Loeal/Auto-Remote switeh Reset button Start button Stop button Speed adjust switeh High turbine temperature light High oll temperature light, Low oil pressure light Overspeed light Start failure light Roady-to-load light Pre/Post lubrieation light MODIFICATIONS “The Saturn Continuous Duty Generator Set is a complete init in its. basic configuration; however, preengineered ‘Standard modifications are available to make the set adapt able to existing systems and to meet special installation requirements GENERATOR Gulf Coast Treatment, Protects internal components of the generator against humid environment. Generator Space Heaters, Protects the generator against condensation when unit is not operating. LIQUID FUEL SYSTEM Fuel Boost Pemp. Supplies fuel to the filter inlet at g rate of 2.5 gpm (8.5 liters/min) and 20 psig (1.4 kg/cm zzage! (minimum). The purap is driven by a 24-volt, de notor and has an equivalent lift capacity (head) of 20 feet (6 meters). Supplied with a T5-mieron strainer. 13 LUBRICATION OIL SYSTEM Immersion Oil Heater. A 3-kw, 110- oF 220-vot, ae, 50: fo 60-Hlz, single-phase oil tank immersion heater for installations where the oil temperature may fall below 40°F 14°C). High Ambient Oil Cooler, A high ambient air-to-oil cooler, furnished in liew of the standard cooler, for in ‘Stallations where ambient ir inlet temperatures between 15°F and 140°F (46° and 60°C) are common. Remote Oil Cooler, The oil cooler assembly, with hhydraulie motor-driven fan, furnished separately for remote offskid mounting by others. Coupling connec: tions on both the package and the cooler are included; interconnecting piping is to be supplied by others. Since the cooler fan also provides package ventilation, this modification is not available on enclosed units. ELECTRICAL SYSTEM DC Power Supply. Two de power supply systems are available for the generator set. One supplies power for both start and control systems; the other supplies power for the control system when the pneumatic start system is used, Starting and control battery system, Lead-acid bat teries of adequate capacity for five consecutive starts, battery charger with a S0-ampere charge rate, and a battery rack, Starting and control battery syetem. Nickel-eadmium batteries of adequate capacity for five consecutive starts, battery charger with a 20-ampere charge rale, and a battery rack. CONTROL SYSTEM Remote Turbine Control Panel. Used in addition to the standard turbine panel to provide remote capability and consisting of Exhaust temperature meter Percent speed meter Control power on/off switeh Speed adjust switeh Reset button Start button Stop button ‘Turbine melfuetion light Ready toload light Remote-status light Deluxe Electrical Metering Panel Monitors the gen: ‘erator output and has synchronizing lights and controls for paralleling with other units. The panel consists of Voltmeter and a six position selector switch “Ammeter and a three-position selector switch Frequeney meter KW-KVAR meter with selector switeh Voltage adjusting rheostat Cireuit breaker control switch and position lights ‘Synchronizing lights with switeh