91-461 950 - Design Manual

GE Energy Products - Europe OFF BASE COOLERS
DESIGN MANUAL
CONTENTS
STATE OF MODIFICATIONS ____________________________________________________________2

CHAPTER 1 : SYSTEM FUNCTION_______________________________________________________3
CHAPTER 2 : SYSTEM DESCRIPTION____________________________________________________3
CHAPTER 3 : NORMAL WORKING, STARTING, STOP ______________________________________5
CHAPTER 4 : CONTROL, MONITORING, INSTRUMENTATION, ALARMS LIST________________6
CHAPTER 5 : CONSEQUENCE OF FLUID OR ELECTRICAL POWER SUPPLY FAILURE _______7
CHAPTER 6 : INTERFACES _____________________________________________________________8
CHAPTER 7 : REFERENCE DOCUMENTS ________________________________________________9
Reference : 91-461 950 Rev. : A Section : 01E Page : 1/13

Ce document, propriété exclusive de GE Energy Products France SNC This document, exclusive property of GE Energy Products France SNC
est strictement confidentiel. Il ne peut être communiqué, is strictly confidential. It must not be communicated,
copié ou reproduit sans notre autorisation écrite. copied or reproduced without our prior written consent.
DESIGN MANUAL
STATE OF MODIFICATIONS
INDEX DATE DESCRIPTION
A 18.06.01 First issue

DESIGN MANUAL
CHAPTER 1 : SYSTEM FUNCTION

This specification concerns the Gas Turbine and Generator cooling by water circulation.
The system function is the cooling of :
• GT and Generator bearings lubricating oil
• atomizing air
• GT supporting legs
• Generator cooling air
CHAPTER 2 : SYSTEM DESCRIPTION

See CHAPTER 7 REFERENCE DOCUMENTS
This specification concerns only the off-base cooling system. The GT and Generator base mounted
equipment is described on specific documents.
GT and Generator are cooled in parallel on a common water circulating closed loop.
2.1 Constitution
the fin fan coolers group. It consists of 4 modules installed in parallel water and air side
the pumps skid. It is made up of 2 pumps of 100 % capacity each. It ensures the water circulation
in the complete water loop.
the atmospheric expansion tank, It ensures the minimal pressure in the circuit.
The linking pipes, instrumentation and valves.
2.2 Mechanical characteristics

2.2.1 Fin fan coolers module
Each module is made up of a supporting frame, one heat exchanger, one plenum and four fans.
Framework
- material : carbon steel
Heat exchange battery
- type : tubes brazed on collectors
- tubes material : copper
- tubes diameter : 11.7 mm
- tubes thickness : 0,35 mm
- bundle length and width : according to thermic study
- fins material : aluminium
- fins pitch : 2.12 mm
- fins thickness : mini 0,135 mm
- collectors material : carbon steel
- protective coating : BLYGOLD ( including fins )
Plenum
- material : carbon steel
Fan motor groups
- diameter : 1250 mm, rotation speed : 750 tr/min

DESIGN MANUAL
- electrical power 11 kW,

- driving : direct by electrical motor
- blades material : aluminium
- protection: fan motor guard
2.2.2 Motor pump groups
motor : electrical power 75 kW
pump: type centrifugal, single stage

materials :
- impeller : bronze
- shaft : stainless steel
- casing : cast iron
frame : common to pump and motor, made of carbon steel

2.2.3 Atmospheric expansion tank
3
capacity : 0.75 m
material : carbon steel
2.3 Thermic sizing

cooling fluid : water (See GE Products – Europe specification 91 410 704 "INSTRUCTION
FOR COOLING WATER TREATMENT ") +20% of KEMAZUR 1625 ( anti freeze and corrosion
inhibitor )
flow : 470 m 3/h for all the modules in service
capacity 112 % or two fans in stand by at 51 °C of air ambient temperature

fouling factor
- air side : 10000 kcal/h.m².°C
Fin fan coolers water outlet temperature: maxi. 61 °C for air ambient temperature of 51 °C maxi.
Maxi. calorific losses ( gas turbine + generator ): 3370 kw for g.t. base load

DESIGN MANUAL
CHAPTER 3 : NORMAL WORKING, STARTING, STOP

3.1 Fans motors
The fans motors work in blocks :
Permanent block
Composed of two fans motors of each module, the permanent block is in operation while the
gas turbine is over 10% of nominal speed.
Regulation block
Composed of two fan motors of each module, the regulation block is in operation if the following
conditions are met :
The regulation block is in operation if the following conditions are met :

- {Cooling water pump in operation}
AND
- {oil temperature high (temperature set at 74°C)}
OR
- {fin fan coolers water outlet temperature higher than 48 °C (thermocouple at the outlet of
the fin fan coolers)}
OR
- {Generator stator temperature higher than 100°C}
The regulation block is out of operation if the following conditions are met :
- {Cooling water pump not in operation}
OR
- {normal oil temperature}
AND
- {fin fan cooler water outlet temperature lower than 43°C}
AND
- {Generator stator temperature lower than 90°C}
IMPORTANT:
For all fans block the minimal working time is 30 minutes to prevent frequent motors start and stop.
Motors can be manually controlled from their feeders using a STOP/AUTO/MANU switch for the
commissioning and the maintenance.
3.2 Pump motors

During fin fan coolers working, only one pump is running. This is considered as the principal pump.
A PUMP1/PUMP2 switch located in the Speedtronic enables the principal pump to be selected.
This pump starts if the followings conditions are met :
{ flame detection }
. OR
{ oil temperature tank higher than 74°C }
OR
{ oil pump } AND { oil temperature collector header higher than 45 °C }

DESIGN MANUAL
It is stopped if the following conditions are met :
{ no flame detection }
AND
{stop of oil pump }
AND
{ oil temperature collector header lower than 45 °C }
AND
{ oil temperature tank lower than 74°C }
If the pump discharge pressure is lower than 2.5 bar or if an electrical fault is detected on the principal
pump motor, the stand by pump is started. If a fault is also detected on the stand by pump, it is
stopped and there is no starting order of the principal pump.
The pressure switch at the pump discharge is inhibited during 10 seconds following the principal or
stand by pump starting.
The motor of each pump can be manually started from MCC by a STOP/AUTO/MANU switch for the
commissioning and the maintenance.
CHAPTER 4 : CONTROL, MONITORING, INSTRUMENTATION, ALARMS LIST

4.1 Control, monitoring
See chapter "NORMAL WORKING, STARTING, STOP"
4.2 Instrumentation
pressure gauge measures the water pressure at the inlet part of the fin fan coolers
temperature indicators measures the water temperature at the inlet/ outlet part of the fin fan
coolers
thermocouple type T measures the fin fan coolers outlet temperature. There is an action if the
thermocouple measures a temperature reaching the setting points.
• pressure gauge measures the water pressure at the pump discharge pressure
• pressure switch measures the pump in service discharge pressure. This information is transmitted
to the Speedtronic.
low level switch : installed on the expansion tank. This information is processed by the
Speedtronic.
level indicator installed on the expansion tank.
4.3 Alarms list on GT Control panel ( Speedtronic )

"Cooling water system trouble" :
- low pressure detected ( 10 seconds after the pump starting ) on the pump discharge by
PSL set at 3 bar.
- electrical fault on fan or pump motor : thermic relay action located in MCC
"High cooling water temperature" : if the water temperature measured by thermocouple
is higher than 64°C
"Cooling water temperature sensor in trouble" : if cooling water measurement is out of
range ( 0° < water temperature < 80°C )

DESIGN MANUAL
CHAPTER 5 : CONSEQUENCE OF FLUID OR ELECTRICAL POWER SUPPLY

FAILURE
In case of water temperature increasing, the sequence will be as follow :
alarm due to water temperature high
alarm due to oil temperature high
alarm due to generator stator temperature high
group circuit breaker opening and GT trip due to oil temperature high or/and group circuit
breaker opening due to generator stator temperature high
Power voltage failure

On all the MCC
All the motors feed by the MCC stop and the GT trip
On fan motors block
The concerned motors block alarm will be set off due to electric fault. The water temperature
will increase following the sequence described above.
On one pump motor
The motor alarm will be set off and the stand by pump will start. If this one is also not feed, the
pressure will decrease below the pressure switch setting value and an alarm will be set off.
The oil temperature and the Generator stator temperature will increase until alarm setting value,
group circuit breaker opening and GT stop.
Control voltage failure

On all the MCC
All the motors fed by the MCC stop and the GT trip.
On fan motors permanent block
The block motors alarm will be set on due to lack of control voltage. The water temperature will
increase following the sequence described above.
On the first pump motor
The motor alarm will be set on due to lack of control voltage and the stand by pump will start. If
this one is also not fed, the pressure will decrease below the pressure switch setting value, and
an alarm will be set off.
The oil temperature and the Generator stator temperature will increase until the alarm setting
value, group circuit breaker opening and GT stop.
Fluid failure
In case of water failure, the flow will be too low
alarm due to low pressure at the outlet of the pumps skid,
water temperature increasing following the sequence described above

DESIGN MANUAL
CHAPTER 6 : INTERFACES
6.1 Fluid and voltage requirements
400 VAC voltage for supplying fans and pump motors
230 VAC for pump motors and fan motors anti-condensation heaters
water with corrosion inhibitor for the first filling and the make up
To avoid scaling in the cooling circuit, the first filling and make-up water must be of convenient quality
(pure water ) and it must then be treated against corrosion .
WATER QUALITY
First filling and make-up water quality must be as follows:
_ suspended solids < 50 mg/ l as CaCO3
_ total dissolved salts ( TDS ) < 100 mg/ l as CaCO3
_ total hardness < 150 mg/ l as CaCO3
_ chlorides < 50 mg/ l as CaCO3
_ sulphates < 50 mg/ l as CaCO3
WATER TREATMENT
GE Energy Products –Europe standard anticorrosion system consists of a basic, nitrite based
chemical additional inhibitor to provide a global protection of the circuit.
TREATMENT AGAINST CORROSION
Product is KEMAZUR 1625 ( 20 % of the total cooling water circuit )
Once a year at least send a sample to an analytical laboratory for:
_ pH ( > 8 )
_ TAC (total alcalinity or m-alcalinity) : > 300 ppm CaCO3
_ NaNO2- content > 1 g/l
_ freezing point : < -13 °C
It's important to pay a special attention to TAC because TAC will normally decrease slowly year after
year.
If TAC <30°f (300ppm CaCO3) or/ and pH < 8 remove partially or totally the volume, feed with fresh
KEMAZUR 1625 and soft or demineralized water
KEMAZUR 1625 data sheet and material safety data sheet: see attached
ALTERNATIVE TREATMENTS
Alternative treatments can be acceptable after investigation and approval by GE Energy

Products -Europe
6.2 Limit with other systems

Connecting flanges on the GT and Generator bases, expansion tank filling pipe
Motors electrical power connection in the MCC
Pressure switch connection in the MCC, motors anti-condensation heaters connection in the
MCC
Level switch and thermocouple connection in the Speedtronic

DESIGN MANUAL
CHAPTER 7 : REFERENCE DOCUMENTS

• OFF BASE COOLERS P & I DIAGRAM
Reference number 811 I60 FD 001
Number 91.131.608

DESIGN MANUAL
CENTRIFUGAL PUMP Purchase order N°

Project N°: ABADAN
DATA SHEET
Inquiry N°:
1 Applicable to: Proposal: Purchase: As built: Date :
2 Customer: GEA ERGE SPIRALE Item N° :
3 Site: UAE Unit : FIN FAN COOLERS
4 Service: S1 Driven by: Motor Turbine
5 Type and size : ETA 150.400 Number required : 8
6 MFR Register N° :
7 OPERATING CONDITIONS EACH PUMP PERFORMANCE
8 Liquid : WATER Capacity Nor: Rated: 470 m3/h Proposal curve N°:
9 Disch Press: barg NPSH Required : 4 m
10 PT : 61 °C Suct Press : 0,6 barg N° of stages : 1 Speed : 1475 rpm
11 SPGR at PTR : 1000 kg/m3 Diff Press: bar Des Eff: 82 % Power: 62 kW
12 Vap Press at PT: bara Diff Head: 40 m Max Power rated Impeller : kW
13 Visc at PT : 1 Cst NPSH avail. : 6 m Max Head rated Impel: m
14 Corr/Eros caused by : Min continuous flow: m3/h
15 CONSTRUCTION AND MATERIALS Rotation facing coupling end : CCW
16 Casing mounting: Centerline Foot Bracket Vertical
17 Split: Axial Radial Water cooling:
18 Bearings
19 Type: Single volute Double volute Diffuser Stuff Box
20 Tapped openings: Vents Drains Gage conns Pedestal
21 Nozzles Size ASA Rating Facing Position Gland
22 Suction ND 200 NP 16 Type 01 A Total water req'd : l/mn
23 Discharge ND 150 NP 16 Type 01 A Packing cooling :
24 Impeller Diam: mm Min: 330 Rated: 375 Max: 419 Type: Flushing liquid:
25 Bearings type: ## Radial: Thrust: Cooling piping DWG N° :
26 Coupling type: Spacer Guard Seal flushing DWG N° :
27 Packing type: Size : N° of rings: AUX PIPING BY MFR
28 Mech seal type : Carbure/Carbure Class code: Auxiliary ( Tubing-piping ) :
29 Base plate: Yes No Drain rim type Description :
30 Bed. Plate Yes No Motor bracket
31 PARTS MATERIALS API: ASTM AFNOR DIN
32 Pump casing GJS-400-18 A536 - 60-40-8 SHOP TESTS REQ'D WITNESSED
33 Impeller G-CUSN10 B584 - C90500 Performance test
34 Inner case parts GJS-400-18 A536 - 60-40-8 NPSH
35 Sleeve X19CrNiMoTi17-12-2 316 Ti Disassembly
36 Casing wear ring G-CUPB10SN B584 - C93700 Hydrostatic
37 Impeller wear ring G-CUPB10SN B584 - C93700 Max Allow. casing work. press. : 10 bar
38 Shaft X19CrNi17-2+QT A276 - 431 Weights: kg Pump: Baseplate:
39 Coating Motor: Turbine :
40 Total: 0

DESIGN MANUAL
41 ELECTRIC MOTOR INCLUDED TURBINE INCLUDED MFR FINAL DATA (as built)
42 Item N° : Item N°: Actual Impeller Diam. :
43 Power : 75 kW Power: kW rpm Test curve N° :
44 MFR : ELECTRAMO Outline DWG N° :
45 Type : 280 S Insul : F/B Inlet steam: Temp. : °C Pump sect DWG N° :
46 Exhaust: cw req'd : WR diam. :
47 Volt: 400 Freq: 50 Hz Steam Rate: WR clearance :
48 Bearing: 6316 Lube: Bearings : Lube : Serial N° :
49 Nozzles Size ASA Facing Posit. Seal Device :
50 Inlet Seal : Fitted Boxed separat.
51 Exhaust
52 Exceptions and remarks:
53
54
55
56
57
58 Revisions

DESIGN MANUAL
DATA SHEET - EXPANSION WATER TANK
CLIENT 1
PROJECT NAME ENERGISA 2
MANUFACTURER GEA ERGE SPIRALE & SORAMAT 3
N° OF REQUIRED 4
SITE 5
ERECTED BY OTHERS 6
TYPE CYLINDRICAL - HORIZONTAL 7
APPLIED CODE 8
3
CAPACITY , M NOMINAL: 0.75 STORAGE: / WORKING:/ 9
DIMENSION mm LD: 1000 HEIGHT: 1850 10
11
DESIGN CONDITION 12
FLUID HANDLE WATER + 20% KEMAZUR 1625 13
SPECIFIC GRAVITY 14
TEMPERATURE degree C OPERATING: 60 DESIGN: 15
PRESSURE ( bar g) OPERATING: 0 DESIGN: 0 TEST: WATER FILLING 16
SEISMIC FACTOR: 0.4 g 17
EARTHQUAKE ZONE FACTOR: / SITE COEFFICIENT:/ 18
WIND VELOCITY m/sec 44.5 19
20
JOINT EFFICIENCY : % without 21
CORROSION ALLOW mm 1 22
23
CONSTRUCTION AND MATERIAL 24
MATERIAL SHELL : CC BOTTOM :CC 25
THICKNESS mm SHELL : 3 BOTTOM : 4 25
26
N° OF COURSE 27
SHELL ( HEIGHT , THICKNESS ) 28
COURSE 1 1’’ / 4.55 mm / 29
COURSE 2 1’’ / 4.55 mm / 30
COURSE 3 406 OD / 5 mm / 31
COURSE 4 1’’ / 4.55 mm / 32
COURSE 5 2’’ / 3.91 mm / 33
COURSE 6 ¾’’ / 3.91 mm / 34
INSULATION NO 35
PAINTING INSIDE : YES OUTSIDE: YES 36
WELD EXAMINATION VISUAL : YES RADIOGRAPHIC : NO 37
LIQUID PENETRANT OR ULTRASONIC :NO 38
REMARK 39
SERVICE : L2 DATE: 06/18/01 PAGE : 1/1

DESIGN MANUAL
DATA SHEET - CHEMICAL POT
CLIENT 1
PROJECT NAME ENERGISA 2
MANUFACTURER GEA ERGE SPIRALE & SORAMAT 3
N° OF REQUIRED 4
SITE 5
ERECTED BY OTHERS 6
TYPE CYLINDRICAL - VERTICAL 7
APPLIED CODE B 31-3 8
3
CAPACITY , M NOMINAL: 0.05 STORAGE: WORKING: 9
DIMENSION mm LD: 273 (10 “) HEIGHT: 1381 10
11
DESIGN CONDITION 12
FLUID HANDLE INHIBITOR OF CORROSION 13
SPECIFIC GRAVITY - 14
TEMPERATURE degree C OPERATING: 60 DESIGN: 80 15
PRESSURE ( bar g) OPERATING: 4 DESIGN: 10 TEST: 12.5 16
SEISMIC FACTOR: 0.4 17
EARTHQUAKE ZONE FACTOR: / SITE COEFFICIENT: / 18
WIND VELOCITY m/sec 44.5 19
20
JOINT EFFICIENCY : % 70 21
CORROSION ALLOW mm 1 22
23
CONSTRUCTION AND MATERIAL 24
MATERIAL SHELL : CC BOTTOM : CC 25
THICKNESS SHELL : 9.27 BOTTOM : 9.27 25
26
N° OF COURSE 27
SHELL ( HEIGHT , THICKNESS ) 28
COURSE 1 ( Inlet- Outlet) 2” / 3.91 / 29
COURSE 2 (Vent – Drain ) ½” / 3.73 / 30
COURSE 3 / / 31
COURSE 4 / / 32
INSULATION 33
PAINTING INSIDE : no OUTSIDE: yes 34
WELD EXAMINATION VISUAL : yes RADIOGRAPHIC : no 35
LIQUID PENETRANT OR ULTRASONIC :no 36
REMARK 37
SERVICE : L2 DATE: 06/18/01 PAGE : 1/1


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GE Energy Products - Europe OFF BASE COOLERS

STATE OF MODIFICATIONS ____________________________________________________________2

Reference : 91-461 950 Rev. : A Section : 01E Page : 1/13

INDEX DATE DESCRIPTION

A 18.06.01 First issue

Reference : 91-461 950 Rev. : A Section : 01E Page : 2/13

CHAPTER 1 : SYSTEM FUNCTION

CHAPTER 2 : SYSTEM DESCRIPTION

2.2 Mechanical characteristics

- diameter : 1250 mm, rotation speed : 750 tr/min

Reference : 91-461 950 Rev. : A Section : 01E Page : 3/13

- electrical power 11 kW,

pump: type centrifugal, single stage

frame : common to pump and motor, made of carbon steel

2.3 Thermic sizing

capacity 112 % or two fans in stand by at 51 °C of air ambient temperature

Reference : 91-461 950 Rev. : A Section : 01E Page : 4/13

CHAPTER 3 : NORMAL WORKING, STARTING, STOP

The regulation block is in operation if the following conditions are met :

3.2 Pump motors

This pump starts if the followings conditions are met :

Reference : 91-461 950 Rev. : A Section : 01E Page : 5/13

It is stopped if the following conditions are met :

CHAPTER 4 : CONTROL, MONITORING, INSTRUMENTATION, ALARMS LIST

4.3 Alarms list on GT Control panel ( Speedtronic )

Reference : 91-461 950 Rev. : A Section : 01E Page : 6/13

CHAPTER 5 : CONSEQUENCE OF FLUID OR ELECTRICAL POWER SUPPLY

Power voltage failure

Control voltage failure

Reference : 91-461 950 Rev. : A Section : 01E Page : 7/13

Alternative treatments can be acceptable after investigation and approval by GE Energy

6.2 Limit with other systems

Reference : 91-461 950 Rev. : A Section : 01E Page : 8/13

CHAPTER 7 : REFERENCE DOCUMENTS

Reference : 91-461 950 Rev. : A Section : 01E Page : 9/13

CENTRIFUGAL PUMP Purchase order N°

Reference : 91-461 950 Rev. : A Section : 01E Page : 10/13

Reference : 91-461 950 Rev. : A Section : 01E Page : 11/13

DATA SHEET - EXPANSION WATER TANK

Reference : 91-461 950 Rev. : A Section : 01E Page : 12/13

DATA SHEET - CHEMICAL POT

Reference : 91-461 950 Rev. : A Section : 01E Page : 13/13

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