Cooling and Sealing Air System Table of Contents O41 ‘Schematic Diagram 356 B 2925, Rev A, Approved 2001-01-30... 9.2 Device Summary ... 9.3 Brief Description 94 Functional Description ... 9.4.4 9.4.2 9.4.3 9.4.4 9.4.5 9.4.6 Bearing seal air Compressor Bleed Subsystem For Pulsation Protection, Turbine Nozzle Cooling Air Supply Subsystem.. Exhaust Frame and No. 2 Bearing Area Cooling Fan Module Subsystem. 7 Pressurized Air Supply... Water Wash Provisions...9.2 Device Summary Device 2008-1 33CB-1 33CB-2 63TK-1 63TK-2 B8TK-1 B8TK-2 96CD-1 VA2-1 VA2-2 VCK7-4 VCK7-2 Description ‘Compressor Bleed Solenoid 3 Way Valve Normal: 8 to Open; A Closed ‘Compressor Bleed Valve Limit Switch 11 TH Stago Valve Opon: Switch Actuatad and Contact Ciosed Compressor Bleed Valve Limit Switch 1TH Stage Valve Open: Switch Actuatod and Contact Closed Turbine Shell and Exhaust Frame Blower Discharge Pressure SW Close: above 381 = 78 mm H.0 Normal=NO CEC Turbine Shell and Exhaust Frame Blower Discharge Pressure SW Close: above 381 = 78 mm H.0 NormalsNO CEC ‘Turbine Shell and Exhaust Frame Blower Motor Power: 34,5 KW; 3600 RPM; 480 V; 3 PH: 60 Hz Turbine Shell and Exhaust Frame Blower Motor Power: 34,5 KW; 3800 RPM; 480 V; 8 PH; 60 Hz ‘Compressor Discharge Pressure Transmitter Rango 0-13,7 Bar ~ Adustement ON Condition Pressure Output Transducer. Zo10 0 Bar 4 mA Zorot ‘Maxi 19,7 Bar 20 mA GAIN Compressor Bleed Valve "Normal: Open Compressor Bleed Valve Norma: Open Turbine Shell and Exhaust Frame Blower Check Valve ‘Turbine Shell and Exhaust Frame Blower Check Valve9.3 Brief Description The cooling and sealing air system provides the necessary air flow from the gas turbine compressor to other parts of the gas turbine rotor and stator to cool these parts during normal operation. When the gas turbine is operating, air is extracted from two stages of the axial flow compressor as well as from the compressor discharge. It is used to pro- vide the following cooling and sealing functions: = Seal the turbine bearings. = Cool the internat parts. - Cool the turbine outer shell and exhaust frame. - Provide an operating air supply for the air-operated valves. - Compressor pulsation protection. ‘Specially designed air passages are fabricated in the turbine casing, turbine nozzles and rotating wheels. ‘The schematic diagram shows the external flow of cooling and sealing air. The cooling and sealing air system consists of specially designed air passages in the turbine casing, turbine nozzles and rotating wheels, piping for the com- pressor extraction air, and associated components. Associated components used in the system include: 4. Turbine Exhaust Frame And No. 2 Bearing Area Cooling Blowers 2. Motors 88TK~1 and B8TK-2 8. Diverter Type Check Valve VCK7—1 and VCK7-2 4. Air Filter with poro-stone element 5. Compressor Bleed Valve VA2-1 and V2-2 6. Solenoid Valve 20CB-1 7. Compressor Discharge Pressure Transmitter, 96CD-19.4 9.4.1 Functional Description The cooling air system is composed of three major subsystems: 1. Compressor bleed subsystem for pulsation protection 2, Turbine nozzle cooling air supply subsystem 3. Exhaust frame and No. 2 bearing area cooling fan module subsystem Bearing seal air Sealing air for the bearings is provided from the fifth-stage air. Fifth-stage compressor extraction air is taken from a connection on the compressor casing and flows through two centrifugal separators to the bearings. Sealing air discharge from the compressor 5" stage is piped externally to each of the ‘two turbine bearings. Orifices in the air lines to the turbine bearings limit the flow of air and the pressure to the proper value. The centrifugal separators located in the fifth- stage piping upstream of the valve remove any particles of dirt or for matter that might be injurious to the bearings. Such matter is vented to the turbine exhaust through continuous separator blowdowns. ‘The pressurized air seals the bearings and contains any lubricating fluid within the bearing housing that otherwise might seep past the mechanical seals. Airis directed to both ends of each bearing housing providing a pressure barrier to the lubricating fluid. After performing this function, the air is vented via the oil drain passage of the bearing. Compressor Bleed Subsystem For Pulsation Protection The pressure, speed, and flow characteristics of the gas turbine axial flow compressor are such that special equipment and sequencing of the gas turbine components are re- quired to prevent pulsation of the compressor when the turbine is fired and when ac- celerating to speed in the starting sequence. Pulsation protection is also required in the shutdown and decelerating sequence when the turbine is tripped. The equipment re- quired to provide this protection is the compressor bleed valve subsystem and the vari- able inlet guide vane subsystem. The operation of the inlet guide vane subsystem is covered elsewhere in this manual. ‘The MS-6581B is fitted with pneumatically actuated compressor bleed valves (VA2—1 and VA2-2) to bleed the compressor eleventh stage. The valves are designed to be selt—opening on the loss of actuation air supply pressure from the electrically ac- tuated solenoid 3-way valve, 20CB-1. The 20CB-1 three way valve is designed such that the supply port for the VA2—1 and VA2-2 valve is vented to atmosphere through the 20CB-1 valve when the 20CB-1 valve is in the normal deenergized position. Only when the 20CB-+1 valve is energized, is the actuation air source connected to the sup- ply port for the VA2—1 and VA2-2 valves. This feature is considered to be fail-safe with respect to the protection of the compressor.9.4.3 ‘Compressor discharge air (controlled by the solenoid valve 20CB-1) is used to close the compressor bleed valves VA2~1 and VA2-2. Air from the compressor discharge is routed to a porous air filter, which removes dirt and water from the compressor dis- charge air, by means of a continuous blowdown orifice, before the air enters solenoid valve 20CB-1. The filter is also fitted with a normally closed manual blowdown needle valve that can be used to manually drain the filter shell. From the solenoid valve, the air is routed to the piston cylinder of the bleed valve. During turbine startup the 20CB-1 valve is deenergized and the compressor bleed valves VA2-1 and VA2-2 are open. This allows eleventh stage air to be discharged into the turbine exhaust diffuser, thereby eliminating the possibility of compressor pulsation. Limit switches, 33CB—1 and 33CB-2, on the bleed valves provides permissive logic in the starting sequence and ensures that the bleed valves are fully opened before the turbine is fired. This switches also provides an alarm if the valve opens when it should be closed. When the turbine accelerates to full speed, the 20CB-1 solenoid valve is, energized to close the bleed valve and allow normal running operation of the turbine. When a turbine shutdown signal is initiated and the 20CB-1 valve is deenergized, eleventh stage air is again discharged into the exhaust diffuser to prevent compressor pulsation during the turbine deceleration period, CAUTION ‘Under no circumstances should attempts be made to start the turbine if all extraction valves are not fully opened. Serious damage to the gas turbine may occur if all the valves are not opened during the acceleration and deceleration cycle of the turbine. Turbine Nozzie Cooling Air Supply Subsystem The cooling circuit for the turbine components consists of both internal and external cir- cuits. The first and second stage buckets, the first stage nozzle, and the first stage shroud are cooled by an internal cooling air circuit, while the second and third stage nozzles are cooled by an external cooling air circuit. The internal circuit is supplied by the seventeenth stage and by compressor discharge air, and the external circuits by the thirteenth stage with extraction air. The first stage nozzle and shroud cooling air is supplied from the compressor discharge plenum housing into the combustion transition pieces. The bucket cooling is supplied by air flowing radially inward at the seventeenth stage compressor wheel, then through holes drilled axially through the distance piece, and then over the forward face of the first stage turbine wheel. The bucket cooling air then flows through the bore of the first stage turbine wheel into the chamber between the first and second stage buckets. This Circuit also provides air to heat the bores of the second and third stage wheels and to purge the wheelspaces. The external circuit consists of piping between the thirteenth stage bleed piping and the turbine shell. A two-branch piping system is used to pipe the cooling air from the thir- teenth stage to the turbine shell for third stage nozzle cooling. This subsystem is, shared with the compressor bleed subsystem to minimize the quantity of piping. Orifice plates are installed in this piping subsystem to timit the pressure and flow of the cooling air and compressor bleed to the proper values.9.4.4 Four individual pipe runs are used to lead the cooling air from the thirteenth stage to the turbine shell for second and third stage nozzle cooling. Orifice plates are installed in this piping subsystem to regulate the pressure and flow of the cooling air to the proper values. Exhaust Frame and No. 2 Bearing Area Cooling Fan Module Subsystem A cooling fan module consisting of two centrifugal blowers driven by two motors, 88TK- 1 and 88TK-2, provides air to the exhaust frame cooling manifold and the No. 2 bear- ing area. Each blower is sized to provide 100 percent of the required flow for its re- spective cooling requirement. The motors are controlled to operate in a lead-lag ar- rangement so that only one blower is operating when the gas turbine is running. The ‘output of each blower flows through a single diverter type check valve VCK7—1 and VCKT-2 before splitting into the exhaust frame cooling manifold and the No. 2 bearing area, This valve is required for lead-lag operation; otherwise the air from the operating biower would escape through the non-operating blower bypassing the cooling circuit. The air flowing into the exhaust frame cooling manifold enters the exhaust frame through four radial nozzles on the outer annulus of the frame where it cools the exhaust frame and third aft wheel space. The air cools the outer diameter of the outer exhaust frame. Some of the cooling air exits the frame at the forward joint with the third stage bucket shroud, The remainder flows aft, then turns, flowing through and cooling the ra~ dial support struts. The air cools the inner diameter of the exhaust frame inner barrel and exits the exhaust frame by being dumped into the third stage bucket aft whee! space. The cooling air also prevents exhaust gas from being aspirated into the No. 2 bearing sump. The air flowing to the No. 2 bearing area enters the bearing area through one of the three exhaust diffuser struts. Some of this cooling air is aspirated by the No. 2 bearing through the bearing seal. This air flow is used as sealing air and is drawn into the bearing sealing air cavity by the vacuum created in the bearing drain system. The air entering the No. 2 bearing area is filtered to remove dirt particles that would be injuri- ‘ous to the journal bearing. The remainder of the air entering the No. 2 bearing area cools the ten exhaust frame struts before exiting into the turbine compartment, Pressure switches 63TK-1 and 63TK-2 on the exhaust frame and No. 2 bearing area blowers are used to sense the blower discharge pressure. If the operating blower or motor should fail, the loss of discharge pressure will cause the contacts of the respec- tive 63TK pressure switch to close, sending a signal to the control panel to start the other motor. If a second failure should occur, the turbine will shut down in a normal shutdown sequence.9.4.5 9.4.6 NOTE TT one blower Fails, it should be repaired or replaced as soon as possible 10 preclude tho possibilty of shutting down the turbine by failure of the remaining blower. Pressurized Air Supply Compressor discharge air is used as a source of air for operating various alr-operated valves in other systems. Air for this purpose is taken at the discharge of the compres- sor and is then piped to the various air-operated valves. The compressor discharge pressure is monitored by an pressure transducer, 96CD-1, as usefull help in controling of the gas turbine. Water Wash Provisions When water washing the gas turbine’s compressor or turbine section, itis important to keep water out of the components that are actuated by compressor discharge air. To prevent water from entering these components, isolation valves are provided in the lines to the 20CB-1, the 96CD pressure transmitter, and in lines used by other sys~ tems. During normal operation of the gas turbine, all isolation valves are open. Before initiating water wash, the isolation valves must be closed and the drain valves opened. At the conclusion of water wash, the isolation valves must be opened and the drain valves closed to allow normal operation of the turbine.