CX501KB Series

TRAINING GAS TURBINES

ROLLS-ROYCE 501KB7
GAS TURBINE

MLN BLOCK 405, ALGERIA

OPERATOR TRAINING

CX501KB Series
TRAINING GAS TURBINES

TURBINE DESCRIPTION

Rolls-Royce Allison 501 KB7

Simple cycle, single shaft engine
Speed = 14571 rpm
Weight = 767kg
Nominal Power = 7500hp
Electrical Output = 5100kW (installed)
Exhaust Temperature = 518°C
Exhaust Gas Mass Flow = 20.6kg/sec
Typical Steam Flow = 12T/h

TURBINE SECTION 2 PAGE 1-2

 CX501KB Series
TRAINING GAS TURBINES

Engine looking from the compressor intake end

CX501KB Series
TRAINING GAS TURBINES

ROLLS-ROYCE 501KB7 GAS TURBINE

BOOST MODULE

COMPRESSOR COMBUSTION TURBINE

PTO SHAFT
1 2 3 4 5 6

ACCESSORY ENGINE
DRIVE MOUNT

TOTAL COMPRESSION RATIO APPROX 13.5:1

TURBINE SECTION 2 PAGE 3-4

 CX501KB Series
TRAINING GAS TURBINES

KB7 SCHEMATIC

BOOST
MODULE COMPRESSOR FUEL COMBUSTORS TURBINE
OUTPUT
SHAFT

AIR
EXHAUST
GASES
AIR

USABLE COMPRESSOR ENERGY FUEL TURBINE ENERGY

ENERGY

CX501KB Series
TRAINING GAS TURBINES
WORKING CYCLE COMPARISON

AIR INTAKE COMPRESSION COMBUSTION EXHAUST

Continuous

Intermittent

AIR/FUEL INTAKE COMPRESSION COMBUSTION EXHAUST

TURBINE SECTION 2 PAGE 5-6

 CX501KB Series
TRAINING GAS TURBINES

PRESSURE,TEMPERATURE & VELOCITY

CX501KB Series
TRAINING GAS TURBINES

ASSEMBLIES

Built up of five major assemblies:

Boost compressor module;
Core compressor module;
Combustion module;
Turbine module;
and the Accessory Drive.
The rotating assemblies of the engine are bolted
and splined together to form a single shaft which is supported by the
transition sections on six main bearings.
A pressure pump within the accessory drive
provides lubrication to the bearings. Scavenge pumps return the oil from
sumps within the engine to the accessory drive.

TURBINE SECTION 2 PAGE 7-8

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TRAINING GAS TURBINES

MATERIALS

Air Intake and Bearing Support - aluminium casting

Accessory Drive Gear Casing - magnesium
Compressor Casing - cast steel
Compressor Rotor - forged stainless steel
Compressor Blades and Vanes - stainless nickel alloy
Diffuser Casing and Bearing Support - stainless steel
Combustion Casing - titanium
Combustion Inner Casing - stainless steel
Combustion Liners - hastalloy
Turbine Inlet Casing and Bearing Support - hastalloy
Turbine and Rear Bearing Support Casings - steel alloy
Turbine Rotor - stainless steel
Turbine Blades and Vanes - high temperature nickel alloys with electro
phosphoric aluminised coatings and ceramic coating to the first stage vanes

CX501KB Series
TRAINING GAS TURBINES

QUANTITIES

Boost Module Blades:

Zero Stage = 29
Compressor Rotor Blades:
1st Stage = 33 8th Stage = 91
2nd Stage = 33 9th Stage = 95
3rd Stage = 37 10th Stage = 95
4th Stage = 39 11th Stage = 95
5th Stage = 41 12th Stage = 95
6th Stage = 89 13th Stage = 95
7th Stage = 91 14th Stage = 91
Turbine Rotor Blades:
1st Stage = 102 3rd Stage = 89
2nd Stage = 89 4th Stage = 69

TURBINE SECTION 2 PAGE 9-10

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TRAINING GAS TURBINES

BEARINGS

The 6 bearings provide support for the rotor assembly and are mounted in
the transition sections. All the bearings are sprayed with oil for cooling and
lubrication.
No 1 Boost Compressor Front Bearing - roller bearing to allow axial
expansion;
No 2 Boost Compressor Thrust Bearing - ball bearing to anchor the zero
stage compressor
No 3 Core Compressor Front Bearing - roller
No 4 Turbine and Compressor Thrust Bearing - anchors both compressor
and turbine.
No 5 Front Turbine Bearing - roller
No 6 Rear Turbine Bearing - roller
Thrust for the compressors is towards the inlet and for the turbine is towards
the exhaust
Thermal expansion is approximately 7mm

CX501KB Series
TRAINING GAS TURBINES

Engine Shutdowns

C.I.T. SENSOR FAULT Open or short circuit of either CIT sensors Check
and replace sensors - inspect for cause of damage
THERMOCOUPLE FAULT Open or short circuit of thermocouple sensors .
Check and replace sensors - inspect engine internally for cause of
damage.
Open circuit = High reading
Short circuit = Low reading
SPEED SENSOR FAULT Failure of either speed sensors while the
engine is running - auto shutdown as Underspeed. Check and replace
sensors - inspect engine internally for cause of damage.
TURBINE FAILED TO LIGHT CTIT temp. < 316°C or TOT <180°C at
turbine speed <13000 during accelerative schedule. Check for igniter
fault; - Insufficient fuel :Fuel supply fault; gas-regulator or valve fault.;
Compressor bleed valve position.
TURBINE STAGNATION Turbine acceleration < 40rpm/sec
speed<13000rpm.- insufficient fuel. Check:Gas regulator; Hydraulic start
system; Compressor bleed valve position

TURBINE SECTION 2 PAGE 11-12

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TRAINING GAS TURBINES

Engine Shutdowns

AUX.GEARBOX CHIP DETECTED Metallic debris on magnetic plug in

turbine auxiliary gearbox - Turbine gear or bearing damage. Check and
retain debris and refer to Centrax before restarting the turbine.
TURBINE OIL PRESSURE LOW Turbine oil pressure < 1.38 bar g whilst
running at > 13000rpm . Check turbine auxiliary gearbox oil
pump;regulator fault or oil leaks.
TURBINE VIBRATION HIGH Turbine vibration >31µm peak to peak
running or >62µm starting - operation of this channel indicates a turbine
rotor imbalance, this may be bearing failure or blade damage. Refer to
Centrax before restarting the turbine

CX501KB Series
TRAINING COMPRESSOR SECTIONS GAS TURBINES

Boost
Compressor
Blow Off Valve
Boost (duct) Core
Diffuser
Compressor Compressor

5th & 10th

Stage Blow Off
Valves (8)

Magnetic Chip Accessory

Detectors (2) Drive

TURBINE SECTION 2 PAGE 13-14

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TRAINING GAS TURBINES

KB7 BOOST MODULE

SINGLE STAGE,
AXIAL FLOW BOOST BLOW OFF VALVE: PREVENTS
COMPRESSOR SURGING DURING THE STARTING
DIRECTLY AND STOPPING SEQUENCES:
CONNECTED TO THE CLOSES AT APPROX 12,500 RPM
CORE COMPRESSOR.
PRESSURE RATIO
1.464:1.0

Boost compressor
thrust (ball) bearing

PTO SHAFT rear shaft CORE COMPRESSOR

Boost compressor
front (roller) bearing

CX501KB Series
TRAINING GAS TURBINES

CORE COMPRESSOR

14 STAGE, AXIAL FLOW CORE COMPRESSOR HAS A COMPRESSION RATIO OF 9.175:1.0 .

EIGHT BLOW OF VALVES RELEASE PRESSURE DURING THE START AND SHUT DOWN
SEQUENCES. THE VALVES ARE CLOSED DURING COMPRESSOR CLEANING. ACCESSORY
DRIVE RUNS THE TURBINE'S INTERNAL LUBE OIL SYSTEM. COMPRESSOR DRUM DIRECTLY
CONNECTED TO THE TURBINE SECTION.

Boost compressor Compressor and turbine

thrust (ball) bearing thrust (ball) bearing

BOOST COMBUSTION
compressor tie bolt SECTION
MODULE

compressor front
(roller) bearing

ACCESSORY BLOW OFF VALVES

DRIVE

TURBINE SECTION 2 PAGE 15-16

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TRAINING GAS TURBINES

COMPRESSOR ROTOR ASSEMBLY

TURBINE SECTION 2 PAGE 17-18

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TRAINING GAS TURBINES

COMBUSTION SECTION

COMPRESSOR AIR PASSES THROUGH A DIFFUSER TO SIX CANNULAR COMBUSTION

CHAMBERS WHERE FUEL IS ADDED THROUGH SIX GASEOUS FUEL NOZZLES.
THE MIXTURE IS IGNITED BY TWO IGNITER PLUGS DURING THE START SEQUENCE AND IS
SELF SUSTAINING WHILST RUNNING.
THE FUEL/AIR MIXTURE BURNS AND THE RESULTING GASES DRIVE THE TURBINE.

Igniter plug
Fuel nozzle

Compressor and turbine front

turbine thrust (roller) bearing
(ball) bearing
COMPRESSOR turbine and compressor tie bolt POWER TURBINE

Combustion can

TURBINE SECTION 2 PAGE 19-20

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TRAINING GAS TURBINES

COMBUSTION LINERS

LE1 LE2 LE3 LE4

LE = Low Emission

CX501KB Series
TRAINING GAS TURBINES

COMBUSTION LINER

72% SECONDARY COOLING AIR FORMS A CUSHION

TO KEEP THE LINERS AND CASING AS COOL AS POSSIBLE - 200 TO
320°C
FUEL

1057°C
1775 - 2000°C 1100°C

25% PRIMARY 3% FOR TUBINE BLADE AND VANE

COMBUSTION AIR - COOLING -
290 TO 320°C APPROX 200 °C

TURBINE SECTION 2 PAGE 21-22

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TRAINING GAS TURBINES

COMBUSTION AND TURBINE ASSEMBLY

Combustion Turbine
Section Section

Turbine
Exhaust

Turbine to
Compressor
Shaft

Turbine front
bearing oil
supply

Turbine Outlet
Temperature
Thermocouples
Bearing oil (12)
return Liner Supports
or Turbine Inlet
Temperature
Combustion 4 Liner Thermocouples
Liner (6) Supports and 2 (18) when fitted
Ignitors

CX501KB Series
TRAINING GAS TURBINES

TURBINE SECTION

4 STAGE TURBINE EXPANDS THE GASES, CONVERTING THE THERMAL ENERGY INTO
KINETIC ENERGY TO DRIVE THE COMPRESSOR AND THE PTO SHAFT. THE GASES THEN
EXIT THROUGH THE EXHAUST SYSTEM AT APPROX 518°C WHERE HEAT IS NORMALLY
EXTRACTED FOR AN INDUSTRIAL PROCESS (TYPICALLY THROUGH A BOILER TO
PROVIDE 12t/h OF STEAM AT 10 barg) .

turbine front
(roller) bearing turbine rear
(roller) bearing
COMBUSTION
SECTION EXHAUST

TURBINE SECTION 2 PAGE 23-24

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TRAINING GAS TURBINES
TURBINE ROTOR ASSEMBLY

Labyrinth Seal

Turbine Rear
Bearing
Support
Turbine Rear
Bearing
Assembly

Turbine Rotor

CX501KB Series
TRAINING GAS TURBINES

INTERNAL LUBRICATION

The turbine oil pump is mounted on the front of the

Accessory Drive Housing and is supplied with oil from the common genset
lubrication system.
Internal filtration and regulation is provided at 3.8bar.
Oil passes through grooves and ducts within the shaftsand casings and is
sprayed onto the six main bearings and splined couplings.
Sumps are provided in the lower casing beneath the bearings and a
scavenge pump returns the oil to the Accessory Drive Housing and pump
feed.
Two metallic chip detectors wired in parallel are mounted in the turbine, one
in the scavenge outlet and one in the Accessory Drive Housing.
The system is vented to prevent a build up of pressure in the oil.

TURBINE SECTION 2 PAGE 25-26

 CX501KB Series LUBE SYSTEM BLOCK DIAGRAM
TRAINING GAS TURBINES

CX501KB Series
TRAINING
ACCESSORY DRIVE HOUSING GAS TURBINES

TURBINE SECTION 2 PAGE 27-28

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TRAINING GAS TURBINES

ENGINE CONTROL

Turbine temperature control is based on Control Temperature (CT) which is

determined by obtaining the Turbine Outlet Temperature (TOT) with 12
thermocouples connected in parallel and converting this average
temperature to an equivalent Turbine Inlet Temperature (TIT).
During starting, fuel and ignition are programmed automatically by the
digital control via the open loopstart schedule as a function of compressor
inlet temperature (CIT), engine speed, control temperature(CT), and
closed-loop control via the CT.

CX501KB Series
TRAINING GAS TURBINES

ENGINE CONTROL UNIT (ECU)

The HSDE ECU is mounted within the Turbine Control Panel and incorporates
all the functions necessary to start and operate the engine. The ECU
provides the following functions:
Start logic
Start Sequencing
Fuel flow control during starting
Monitoring of engine speed and temperature
Fault detection and protection logic to prevent engine damage
Indication signals for engine speed, turbine temperature, fault detection and
status.

TURBINE SECTION 2 PAGE 29-30

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TRAINING GAS TURBINES

OPERATING PARAMETERS

CX501KB Series
TRAINING GAS TURBINES

OPERATING LIMITS

Notes:
1. Turbine outlet temperature (TOT)
over-temperature backup is >1400°F (760°C) and
N1 is <13,000 rpm.
2. TOT run-over temperature backup when N1 is
>13,000 rpm.
3. The symbol > means more than
and the symbol < means less than.

TURBINE SECTION 2 PAGE 31-32

 CX501KB Series
TRAINING GAS TURBINES

OPERATING THEORY

CX501KB Series DIGITAL ENGINE CONTROL

TRAINING SYSTEM SCHEMATIC GAS TURBINES

TURBINE SECTION 2 PAGE 33-34

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TRAINING GAS TURBINES

FUEL CONTROL VALVE (FCV)

The Fuel Control Valve position is dictated by the output signal from the ECU
The FCV's electronics provide a position feeback signal to the ECU which will
initiate an engine shutdown if the valve position signal does not track the
demand signal.

TURBINE SECTION 2 PAGE 35-36