Part 1 OPERATION AND SERVICE Operation and jaintenance Instructions CENTAUR® Turbine-Driven Generator Set Serial Numbers CG84630, CG84631, CG84632 ESSO PRODUCTION MALAYSIA, INC. Guntong “A” Generator Sets P.O. D43071 SJM30400P Tag No. 7G-510, 7G-511, 7G-512 SOLAR TURBINES INCORPORATEDPROPRIETARY NOTICE The contents of this technical manual are proprietary data of Solar Turbines Incorporated, a subsidiary of Caterpillar Tractor Co. Reproduction or use of any part for other than the operation and maintenance of the Solar Turbine Equipment is permissible only if expressly authorized in writing by Solar Additional copies may be obtained from Solar Turbines Incorporated, 2200 Pacific Highway, P.O. Box 85376, San Diego, California 92138. Address requests for copies to the attention of Sales Department, and refer to the publication number appearing on the title page THE WORDS SOLAR, TITAN, SATURN, CENTAUR AND MARS ARE TRADEMARKS OF SOLAR TURBINES INCORPORATED, A SUBSIDIARY OF CATERPILLAR TRACTOR CO.RECORD OF CHANGES. This page may be used to record changes to the manual made by Publication Changes, Service Bulletin, or local changes and corrections. Change or Service Bulletin Pages Number Description Affected | Datee FOREWORD This manual provides operation and service instructions for Solar Centaur® Turbine-Driven Generator Set, procured by Esso Production Malaysia, Inc. for installation at Guntong "A" Platform, Offshore Malaysia. This equipment was procured under Solar Project Definition No. 3962. Part 1 of this manual is intended as a turbomachinery operator's guide. Part 2 contains systems and major component description and maintenance. The generator set is identified on the package nameplate as follows: Model No. GC1-CB-KATO Assembly No. 39621 Serial Nos. CG84630, CG84631, CGB4632, Drawings applicable to the generator set are enclosed in an envelope furnished with each copy of this manual. These drawings include the followin: 39621-149060 Electrical Schematic 39621-149061 Wiring Diagram e@ 39621-149062 Interconnect Wiring Diagram 39621-149063 Mechanical Installation 39621-84G00060-E3 Enclosure Installation 39621-AN~0001 Inlet System Installation 39621-AN-0002 Exhaust System Installation 149406N/C Pneumatic Start System The other publications applicable to this equipment are the Parts List, PL 84-39621. The List of Equipment, immediately following, defines the components, systems, and special modifications incorporated in the generator set described’ in this manual. 84-39621 int 8/84LIST OF EQUIPMENT Air Inlet Filter, Donaldson AX4001 Filter Malfunction Alarms and Shutdown Air Inlet Ducting and Silencer, Farr AX3262 Ancillary Skid Audible Alarm, First Out and Only Control Console, Local Generator Metering Panel Turbine Control Panel Enclosure Gas Detection Systens Halon Fire Protection High Temperature Switch Lighting Vent Fan Exhaust Bellows and Silencers Fuel System, Dual Fuel Liquid Fuel Boost, Jet Generator Assembly, KATO, 2500 KW Continuous Duty, 4160 Volts, 60 Hz Generator Bearing, Sleeve, Forced Lube Generator Bearing and Winding Temperature Monitor Generator Space Heater, 120 Vac Governor Control System Information Plates and Labels, English Language Oi] Cooler Assembly, Remote, 110°F O11 Filter, Duplex O11 Pump, Pre/Post Lube, 24 Vdc O41 Vent’ Seperator Planetary Gear Box, 1800 rpm Coupling, End Float Start System, Pneumatic Start on Either Fuel Synchroscope Turbine Engine, Dual Fuel Coated Compressor Vibration and Temperature Monitor System Water Wash System 84-39621 iv 8/84TABLE OF CONTENTS FOREWORD. 2... 2 ee eee ed TABLE OF CONTENTS LIST OF ILLUSTRATIONS 2.2... 2.00% LIST OF TABLES... eo SAFETY NOTICES AND PRECAUTIONS... 2... TECHNICAL REQUIREMENTS AND LEADING PARTICULARS . 1.1 STANDARD TECHNICAL REQUIREMENTS . . . 1.1.1 Lubricating O11 we Natural Petroleum Base Oils Synthesized Hydrocarbon Of1s . . Startup Limitations ...... O41 Service Life... 02. Fuel and Service Gas... 2 ta 1.3. Turbine Performance Data... | 1.2 LEADING PARTICULARS . 2.2... -.0. @C1-CB 3.7/2.1 v 2/84TABLE OF CONTENTS, Contd Section Page 2 DESCRIPTIN.. ©. ee boo Gal 2.1 GENERAL DESCRIPTION. ©... 2... rs 2.2 OPERATING SEQUENCE... 2.1 eee ee eee wee 2.5 2.2.1 Start Sequence - Oseration on Gas Fuel - Manual initiation, LOCAL... 2... ae ae 2.7 2.2.2 Temperature Topping Sequence ~ Operating on Gas Fuel ....... 2... ae 2.20 2.2.3 Start Sequence - Overation on Liquid Fuel - OES Chk aE tt al 6 GS 2.21 2.2.4 Temperature Topping Sequence ~ Operating on Liquid Fuel... .... 1... 2 2.2.5 Fuel Transfer Sequence - Liquid Fuel to Gas Fuel. 2.39 2.2.6 Fuel Transfer Sequence - Gas Fuel to Liquid Fuel. 2.42 2.2.7 Stop Sequence, Operation on Gas Fuel = Manual initiation LOCAL... .... . 2.46 2.2.8 Stop Sequence, Operation on Liquid Fuel - Manual initiation LOCAL... .... a 2.49 2.2.9 Malfunction Shutdown Sequence . 1... ++ 2.83 2.2.10 Malfunction Alarm Sequence... 1. 5 2.54 QUOUITe Crankisequanco-a Senet 2.55 2.2.12 Reduced Engine Spead Sequence 2.57 2.3 DESCRIPTION OF CONTROL AND INSTRUMENTATION . . 2.60 2.3.1 Air Systems. - Engine compressor discharge air. . 2.60 2.3.2 O41 Systems Controls and Indicators ....... 2.61 2.3.3 Fuel Systems Controls and Indicators... . 2.62 2.3.4 Gage Panel Control and Indicators... 22... 2.63 2.3.5 Turbine Control Panel Controls and Indicators 2.64 2.3.6 Generator Metering Panel Controls and Indicators . 2.73 2.3.7 Circuit Breaker Panel Controls and Indicators 277 2.4 OPTIONAL CONTROLS AND INSTRUMENTATION . 2... 2. 2.79 G@cl-cB 3.7/2.1 wi 2/84@ TABLE OF CONTENTS, Contd Section Page 3 OPERATING INSTRUCTIONS . . . . ee ec 3.1 3.1 STANDARD OPERATING INSTRUCTIONS .. 2... . ee ora 3.1.1. Prestart Checklist. 2... 2... 0 3.4 3.1.2 Engine Operation... . oe oe oT 3.1.3. Generator Operatior . 2... See BIS 3.1.4 Post-Start Checkout... 2 2. rt) 3.2 SPECIAL EQUIPMENT OPERATING INSTRUCTIONS... . 2... 3.19 3.3. TROUBLESHOOTING INFORMATION . 2... ee oer GC1-CB 3.7/2.1 vii 2/84Section 4 PERIODIC/ROUTINE INSPECTION AND MAINTENANCE... 2... 4.1 PERIODIC/ROUTINE INSPECTION . 2... 2... ee 4.2 ROUTINE INSPECTION. ©. 2... pob0aG 4.3. ROUTINE MAINTENANCE 22... ee ee 4.3.1 Water Wash Operating Procedure... .... « 4.3.2 Battery Care... : 4.4 PERIODIC INSPECTIONS/MAINTENANCE. . . 2. 2... TABLE OF CONTENTS, Contd 4.4.1 Electrical System Inspections ........ 4.4.2 Extended Operation, Service, and Inspection Checklist... 2. 2... GC1-CB 3.7/2.1 vii 4.10 4.12 2/84LIST OF ILLUSTRATIONS Figure Title Page 1,1 Output Power, Flow and Temperature ~ pie Fuel Operation. 2... eee we 1.8 1.2 Output Power, Exhaust Flow and Temperature - Gas Fuel Operation... 0... et ee cee 1.9 1.3 Third stage Turbine Inlet Temperature, TS - Liquid Fuel Operation... 2... ee ee ae eee 1.10 1.4 Third Stage Turbine Inlet Temperature, TS ~ Gas Fuel Operation © 2. ee 1.11 1.5 Compressor Discharge Pressure, PCD. . Se ee ee 1.12 2.1 Centaur® Turbine Generator Set Outline... 2.2... eee 2 2.2 Gage Panel Controls and Indicators... 2.2... ee eee 2.60 2.3 Turbine Control Panel - Controls and Indicators ........ 2.65 2.4 Generator Metering Panel - Controls and Indicators... .... oe 2.5 Circuit Breaker Panel Controls and Indicators ......... 2.77 @C1-CB 3.7/2.1 ix 2/84LIST OF TABLES Table Title Page 1.1 Lubricating Of1 Physical and Chemical Requirements... .. . 12 1.2 Fuel and Service Gas Requirements 2... .....0.0. Ld 1,3 Liquid Fuel Requirements... 2. eee ee 1.6 1.4.1 Installation Data. ee 1.13 1.4.2 Electrical Power Requirements . 2... 0... 0.000 - . 116 1.4.3 Start System. ee ee Lv 1.4.4 Natural Gas Fuel System... . co 1.18 1.4.5 Liquid Fuel System. 2. ee 1.19 1.4.6 Engine Air System oe ee LD 1.4.7 Lubricating and Servo O11 System... 2. eee ee 1.22 1.4.8 Electrical Control System oe Bbooe 1.24 1.4.9 Engine Speed Control Monitor 7283 Setpoints ........ . 1.25 1.4.10 Backup Overspeed Monitor 2353 Setpoints ... 2... 0... 1.25 1.4.11 Engine Temperature Control Monitor 2282 Setpoints ...... 1.26 1.4.12 Miscellaneous System Limits 2.0... ee ee 1.27 4.1 Routine Inspections 2... ee eee 48 4.2 Periodic Inspections... 22. ee ee 4.1 4.3 Extended Operation, Service, and Inspections... 2... 4.12 GC1-CB 3.7/2.1 x 2/84SAFETY NOTICES AND PRECAUTIONS GENERAL Solar turbine-driven packages are designed to provide safe, reliable, operation. The package includes integral features which protect the equipment from damaging malfunctions. Personnel must become thoroughly familiar with the following safety requirements and must observe these requirements throughout all procedures. Maximum safety of personnel is of primary importance followed closely by protection of equipment from damage. Careful observation of the requirements for safe equipment operation will minimize hazards to personnel. Safety requirements include four categories: Warnings, Cautions, Notes, and First Aid. Each category is covered in this section. In addition, many of the Warnings, Cautions, and Notes are given individually where applicable at the various procedures throughout this oubl ication. Safety requirements also include procedures to be observed in the event of certain operating malfunctions and special precautions for explosive atmosphere. First Aid procedures given here are not all-inclusive. They represent only those procedures essential for preservation of life. Additional first aid information, such as provided ina Red Cross First Aid Manual, should be at hand. Standard first aid kits containing basic first aid equipment should be available. A physician must always be summoned in the event of personal injury. Warnings, Cautions, and Notes are intended to emphasize critical and important information. They have the following form and significance. WARNING ‘A WARNING POINTS QUT A PROCEDURE, PRACTICE, CONDITION, OR PRECAUTION WHICH, IF NOT HEEDED, COULD RESULT IN PERSONAL INJURY OR LOSS OF LIFE. CAUTION ‘A CAUTION POINTS OUT A PRECAUTION WHICH, IF NOT OBSERVED, COULD RESULT IN DAMAGE OR DESTRUCTION OF EQUIPMENT. GC1-cB SR crt 5/83Note A Note highlights information essential to understanding or following a procedure, practice, condition, or description PRELIMINARY SAFETY INSPECTION A preliminary walk-around visual safety {inspection of the site shall be performed before beginning any procedures. This inspection shall include applicable items listed below as well as any others which may be peculiar to the installation. Any actual or potential hazard must be corrected before proceeding. + Determine location of emergency shutoff valves, switches, telephones, emergency shutdown provisions, etc. PARTICULARLY note location of remote, hand-operated, quick-closing, emergency shutoff valve that must be provided for safety'in fuel line to package. * Learn special emergency procedures applicable to specific installation. + Observe location and learn operation of fire extinguishers and other emergency and protective equipment. + Look for safety hazards, such as leaking gas, sour gas, condensate in drip pans, drain lines, etc., high voltages, high pressures, other obvious hazards. * Verify that package and vicinity are clean and unobstructed. Check inlet and vent lines for obstructions. + Determine if personnel are working on other equipment in area and whether such work is of hazardous nature that precludes work on Solar equipment. WARNINGS. The following warnings include warnings covering Solar turbine generator packages. Those warnings applicable to the particular package, as well as others not listed which may be applicable to the specific installation, must be scrupulously observed during all service procedures. Failure to observe these warnings could result in personal injury or loss of life. The order of listing here does not indicate the order of importance. ach item is important to overall personnel safety. GC1-cB SR 8.2 5/83| rererreraal e WARNING ENSURE OTHER PERSONNEL ARE IN CLOSE PROXIMITY. NEVER WORK ALONE. NEVER WIRE AROUND AUTOMA"IC SHUTOOWN DEVICES. THIS PROTECTION IS INCORPORATED TO PREVENT PERSONNEL INJURY AND DAMAGE TO EQUIPMENT. WHEN WORKING ON A NON-OPERATING PACKAGE, ALWAYS LOCK QUT START CIRCUIT BY OPENING CONTROL CIRCUIT BREAKER AND MOVING SYSTEMS CONTROL SWITCH TO OFF. ATTACH TEMPORARY DO NOT START TAG TO CONTROL SWITCH TO WARN AGAINST INADVERTENT CLOSING OF SWITCH. VERIFY SATISFACTORY OPERATION OF PERSONAL GAS MONITOR (SNIFFER). USE AS REQUIRED TO ENSURE GAS-FREE ENVIRONMENT. CHECK THAT OPERATION OF SWITCHES AND VALVES CANNOT ENDANGER PERSONNEL AND/OR EQUIPMENT. DO NOT ALLOW ANY BARE WIRING ON OR IN VICINITY OF PACKAGE. DO_NOT STEP ON ELECTRICAL CONDUIT OR JUNCTION BOXES OR USE e THEM AS SUPPORTS. INSERT GROUNDING RODS IN A LOCATION TO PRECLUDE TRIPPING AND RESULTANT INJURY TO PERSONNEL. ALLOW NO SMOKING, OPEN FLAMES, OR SPARK PRODUCING DEVICES IN VICINITY AT ANY TINE. PROTECT EARS AGAINST HIGH NOISE LEVEL DURING OPERATION OF TURBINE WITH INLET —FI'.TRATION/SILENCING — EQUIPMENT DISCONNECTED. HANDLE BATTERY ELECTROLYTE WITH CARE. MAINTAIN BATTERY INSTALLATION IN CLEAN CONDITION. WEAR HARD HATS, SAFETY GOGGLES, EAR PLUGS, PROTECTIVE CLOTHING, ETC., WHERE APPLICAB_E. AVOID PERSONAL CONTACT WITH HOT SECTIONS OF EQUIPMENT. ELIMINATE ANY FUEL OR OIL LEAKS AS SOON AS DETECTED. GC1-CB SR 8.3 5/83WARNING a CHECK FOR ZERO SYSTEM PRESSURE BEFORE DISCONNECTING ANY SYSTEM LINES. HIGH PRESSURE LINES MAY CARRY TO 10 343 KPA (1500 PSI) PRESSURE. HYDRAULIC START SYSTEM OIL LINES MAY CARRY PRESSURE IN EXCESS OF 34 475 KPA (5000 PSI). USE CARE WHEN PERFORMING HIGH VOLTAGE IGNITION SYSTEM CHECKS. USE RUBBER NATS TO STAND ON, USE SHOCKPROOF GLOVES, AND USE PROTECTIVE EYE EQUIPMENT STAND CLEAR OF ALL PRESSURE LINES AND FITTINGS DURING START. WEAR SUITABLE PROTECTIVE EQUIPMENT (MASKS, GOGGLES, GLOVES, ETC. ,) AND OBSERVE FIRE PRECAUTIONS WHEN USING ' CLEANING SOLVENTS OR SOLUTIONS. AVOID SKIN CONTACT WITH SOLVENTS OR SOLUTIONS, OR INHALATION OF FUMES. WHEN PERFORMING’ WELDING OR CUTTING PROCEOURES ON PACKAGE, OBSERVE FIRE PREVENTION REQUIREMENTS STIPULATED IN STANDARD NO. 51B FOR USE OF CUTTINS AND WELDING PROCESSES. THIS STANDARD IS ISSUED BY NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) AND HAS BEEN ADOPTED BY THE OCCUPATIONAL SAFETY AND HEALTH: ADMINISTRATION (OSHA) OF THE UNITED STATES GOVERNMENT AS A NATIONAL CONSENSUS STANDARD. EXERCISE EXCEPTIONAL CARE WHEN HANDLING ASBESTOS MATERIALS. FOR EXAMPLE; WHEN SEALING ELECTRICAL CONOUIT FITTINGS, OBSERVE REQUIREMENTS GIVEN IN SOLAR SERVICE BULLETIN'NO, 5.0CS/103. AVOID INHALATION OF HYDROGEN SULFIDE (H2S). SENSE OF SMELL IS DEADENED IN 2 TO 15 MINUTES; THEREFORE, DETECTION 1S DIFFICULT. EXCESSIVE EXPOSURE CAN CAUSE ACUTE POISONING OR LOSS OF LIFE. USE CARE WHEN TROUBLESHOOTING OR PERFORMING MAINTENANCE PROCEDURES ON GENERATOR PACKAGES. GENERATOR VOLTAGES CAN BE DANGEROUSLY HIGH. NEVER OVERRIDE INTERLOCKS. GC1-CB SR 8.4 5/83L revere} e WARNING Ll DO _NOT APPLY EXTERNAL VOLTAGES TO GENERATOR PACKAGE CONTROL, SYSTEMS. FEEDBACK THROUGH CONTROL TRANSFORMERS TO OUTPUT TERMINALS COULD BE LETHAL. DISCHARGE ALL HIGH VOLTAGE CIRCUITS BY USING A HEAVY INSULATED CABLE. SHORT EACH PHASE TO GROUND BEFORE WORKING ON OR AROUND EQUIPMENT. RESIDJAL VOLTAGES WHICH COULD BE STORED AND MAINTAINED FOR SEVERAL HOURS AFTER SHUTDOWN CAN PROVIDE LETHAL ELECTRIC SHOCK. DO_NOT OPEN CIRCUITS TO CURRENT TRANSFORMERS, AMMETERS, OR WATT-VAR METER CURRENT COILS WITH GENERATOR SET" IN OPERATION. JUMPER SECONDARY TERMINALS OF TRANSFORMER IF GENERATOR IS TO BE OPERATED WITH OPEN CURRENT CIRCUITS. VERIFY CORRECT GENERATOR SYNCHRONIZATION OR PHASE ROTATION WHEN PARALLELING TWO GENERATORS. _GENERATOR=TO-GEARBOX COUPLING DAMAGE COULD RESULT WITH HAZARD TO PERSONNEL AND EQUIPMENT. e CAUTIONS The following includes cautions covering Solar turbine generator packages. These cautions, as well as others not listed which may be applicable, must be observed during all service procedures. Failure to observe these cautions could result in damage to or destruction of equipment. The order of listing here does not indicate the order of importance. Each item is important to overall equipment safety. CAUTION EXERCISE CARE TO PREVENT FOREIGN MATTER OR ICE FROM ENTERING AIR INLET. INGESTION OF SOLID MATTER OR ICE WILL CAUSE SEVERE DAMAGE. PROTECT AIR INLET FROM ENTRY OF CONTAMINANTS SUCH AS MOISTURE, DUST, SAND, AND OIL MIST. GC1-CB SR S.5 5/83CAUTION UNDER SEVERE ENVIRONMENTAL CONDITIONS, ENSURE THAT INLET AIR FILTRATION SYSTEM IS FREE FROM RESTRICTIONS WHICH COULD SIGNIFICANTLY REDUCE INLET AIR PRESSURE. PROVIDE SNOW COVERS, DEICERS, AND SAND AND DUST FILTERS TO PROTECT INLET AIR SYSTEM. BEFORE OPERATING EQUIPMENT, ENSURE THAT COVERS ARE REMOVED FROM AIR INLET, EXHAUST, "AND VENTS. ENSURE THESE OPENINGS REMAIN UNOBSTRUCTED DURING OPERATION. BLEED ALL AIR FROM FUEL SYSTEM PRIOR TO OPERATING EQUIPMENT. AIR IN FUEL SYSTEM COULD CAUSE MALFUNCTION AND/OR SHUTDOWN. WATCH CLOSELY PANEL INSTRUMENTS AND INDICATOR LIGHTS, PARTICULARLY DURING STARTING. ENGINE SPEED AND TURBINE TEMPERATURE ARE BEST INDICATIONS OF PERFORMANCE AND OF IMPENDING MALFUNCTIONS . DURING START CYCLE, WATCH FOR INDICATION OF ENGINE SURGE (RAPID RISE OF TURBINE TEMPERATURE WITH NO CORRESPONDING RISE IN SPEED). IF SURGE OCCURS, SHUT DOWN ENGINE IMMEDIATELY. DO NOT ATTEMPT TO RESTART BEFORE TURBINE HAS COASTED TO A STOP. IN THE EVENT OF MALFUNCTION SHUTDOWN, DO NOT ATTEMPT ANOTHER START UNTIL CAUSE IS DETERMINED AND CORRECTED. DO NOT EXCEED STARTER MOTOR CRANK CYCLE LIMITS. DO NOT ALLOW TURBINE TO BE ROTATED IN A DIRECTION REVERSE FROM NORMAL ROTATION. REVERSE ROTATION CAN CAUSE SERIOUS DAMAGE TO TURBINE. CAP ALL OPEN LINES AND FITTINGS DURING MAINTENANCE TO PREVENT ENTRY OF CONTAMINANTS INTO SYSTEMS. DO NOT USE TAPE. GC1-CB SR 5.6 5/83CAUTION KEEP PACKAGE AND VICINITY CLEAN AND UNOBSTRUCTED. KEEP MAINTENANCE WORK AREAS CLEAN TO ENSURE CLEAN ASSEMBLY. CLEANLINESS IS IMPORTANT DUE TO HIGH SPEEDS AND CLOSE TOLERANCES OF TURBINE PARTS DO NOT OVERFILL OIL TANK. ENSURE THAT OIL TANK VENT CLEARANCE IS MAINTAINED AND VENT EXHAUST IS DIRECTED AWAY FROM ENGINE AIR INLET AND EXHAUST DUCTS. DO NOT FLEX CABLES UNNECESSARILY. REPEATED FLEXING OF WIRING CONNECTIONS WILL CONTRIBUTE TO EARLY FATIGUE FAILURE. KEEP COVERS, DOORS, AND PANELS IN PLACE AND EXPLOSION PROOF ENCLOSURES " CLOSED, WITH ALL FASTENERS INSTALLED AND TIGHTENED WHEN ACCESS IS NOT REQUIRED. WHEN DISCONNECTING ELECTRICAL CABLES, DO NOT EXERT PULLING FORCE ON CABLES. EXERT PULLING FORCE TO BREAK CONNECTIONS BY GRASPING CONNECTORS ONLY. DO NOT ADD WATER TO DISCHARGED BATTERY. ELECTROLYTE LEVEL RISES CONSIDERABLY DURING CHARGE. WHEN CONNECTING GENERATOR PACKAGE HIGH VOLTAGE POWER CABLES, ENSURE THAT ELBOW CONNECTORS ARE PROPERLY SEATED IN SAFE-BREAK BUSHINGS TO AVOID ARCING AND SUBSEQUENT DAMAGE WHEN POWER IS APPLIED. VERIFY THAT EXHAUST COLLECTOR DRAINS ARE NOT CONNECTED TO COMMON DRAIN MANIFOLDS WHICH CAN DRAIN OR VENT FLAMMABLE GASES AND/OR FLUIDS. GC1-CB SR 8.7 5/83OPERATING MALFUNCTIONS Certain operating conditions constitute abnormal turbine engine operation. Identification of the following malfunction symptoms will reveal whether or not corrective action is necessary ENGINE COMPRESSOR SURGE CAUTION IF SURGE OCCURS, DO NOT WAIT FOR CONTROLS TO ACTUATE; PRESS STOP SWITCH IMMEDIATELY. All turbines are subject to engine compressor surge under certain conditions. Transient conditions in fuel or air systems can cause the engine to surge as described by the following sounds and conditions: Surge in the lower speed range may be indicated by failure of the engine to accelerate, coupled with increasing exhaust temperatures, and a sound of buffeting or fluttering air. Surge in the higher speed range may be indicated by a loud roar and/or popping noises plus failure of the engine to accelerate to rated speed. If surge occurs, shut down the engine immediately to prevent the rapid buiTdup of harmful temperatures. After the engine has coasted to a stop, attempt to restart in the usual manner. If surge occurs a second time, refer to Operation and Maintenance manual, Troubleshooting Section. GENERATOR OVERHEATING AND VIBRATION Certain operating conditions may ceuse the generator to overload. Normal temperature rise of the generator windings is given on the generator name plate. Always check temperature with a thermometer or by using the resistance method. Never check temperature by hard. Overheating may be caused by conditions such as excessive ambient temperatures, poor air circulation due to improper or restricted ventilation, overload, excessive field current, contaminated or low lube 011 supply, and worn bearings. If excessive temperature persists, shut down the unit and investigate the cause. GC1-CB SR 8.8 5/83An increase in generator vibration during operation warrants immediate investigation. Shut down the unit and check for misalignment, bent shafts, rubbing between stator and rotating elements, etc. EXPLOSIVE ATMOSPHERE Dangerously explosive accumulations of natural gas, fuel fumes, of] tank vent leakage, or solvent fumes must be avoided at all times by proper ventilation, by elimination of leaks, and by confining use of solvents to appropriate maintenance facilities Relying on sense of smell to determine presence of natural gas can be dangerous since natural gas has no odor unless mercaptan has been added. Pipeline gas usually has no odor because odorizer is not added until gas reaches the distributor. A gas detection device (sniffer) is a more positive approach to determining if and where gas leakage exists. However, the sniffer must be operating properly (refer to manufacturer's operating instructions) before making checks. If there is any doubt at all regarding gas leakage, a sniffer must be used to ensure that there is not leakage. Using a sniffer is the primary method to determine presence of an explosive atmosphere. Determining the source of leakage may be accomplished with the aid of a soap solution (or commercial equivalent). Any condition which may be hazardous must be corrected before continuing with any checkout procedures. This is a mandatory requirement. The following precautions shall be observed at installation and during maintenance of all station equipment: Check all piping for structura’ soundness. Verify that piping is properly supported and all connections made in accordance with best standard practices. Avoid "Jury-rigging" or make-shift plumbing at all times. 2. Prior to admitting gas into lines or systems, make sure that all connections are properly made and all unused ports ‘are plugged. Ensure that all flanged connections include required gaskets and that bolts are tight. Verify blowdown of system before pressurizing. GC1-cB SR 8.9 5/833. Ensure that vent systems which handle natural gas are completed before operation of equipment. Check that vents terminate in an area far enough from equipment or building to prevent any possibility of gas being carried back into work area. Check vent systems to ensure that all unused ports are plugged to prevent possibility of gas escaping into package enclosure or building. Check vent lines for bird nests, insects, ice, or any other obstructions which would impede proper venting. 4. If gas detection equipment fs installed in package or building, confirm Proper operation of this equipment prior to admitting gas into systems. 5. When admitting gas into a system for the first time, be alert for gas Jeaks by listening or by using a gas sniffer. Never attempt to check gas leaks by feeling; this method can be very dangerous as gas pressures can exceed 1034 kPa (150 psig). A pinhole leak of high pressure gas can amputate a finger or hand as ‘t is run around a flange in an effort to feel a leak. In lieu of feeling, use a rag (streamer) on a stick. If, rag flutters, approach area with caution. 6. Once gas has been &dmitted to equ‘pment, always use a gas sniffer to ensure absence of gas prior to opening any explosion proof enclosure for troubleshooting. Battery connections are not enclosed in an explosion-proof housing. Verify that battery, charger, and circuit breakers are loceted in a non-exp'osive environment with exploston- proof, interconnection to package. Take all precautions (testing with gas sniffer) to ensure that an explos‘ve atomsphere does not exist when ac or de connections are made or broken FIRST AID The following instructions for rendering first aid in the event of injury represent a brief outline of basic procedures for first aid assistance in emergencies. The more comprehensive procedures, such as given in a Red Cross First Aid manual or equivalent, should be read and noted before the need for such action occurs. In all cases, medical assistance must be obtained as soon as possible. WARNING a RENDER FIRST AID WITH CARE TO AVOID FURTHER INJURY, AND ONLY TO EXTENT REQUIRED UNTIL ARRIVAL OF MEDICAL ASSISTANCE. GC1-cB SR 5.10 5/83ELECTRICAL SHOCK 1. Turn off electricity source. De not touch victim with bare hands until circuit is de-energized 2. Remove victim from hazard. Use dry insulating material: dry leather, wood, rubber, etc. for protection when removing victim 3. Remove false teeth, chewing gum, etc. from victim's mouth, then perform cardio-pulmonary resuscitation if Ereathing has stopped and no pulse is discernable 4. Obtain medical assistance. INHALATION OF TOXIC GASES, NATURAL GAS, CO2, or HALON 1301 1. Remove victim from hazardous atmosphere. 2. Give artificial respiration 3. Obtain medical assistance EXPLOSION, BURNS, BROKEN BONES, ETC. 1. Hemorrhage and wounds. a. Control bleeding by direct pressure at pressure points. b. Use tourniquet only if other means are unsuccessful. Use with care to avoid further damage. ¢. Treat for shock. Place victim in reclining position and keep warm. d. Obtain medical assistance 2. Broken bones. a. Immobilize break by applying splint before moving. b. Obtain medical assistance. 3. Burns. . Cover lightly with sterile dressing. b. Do not remove charred clothing. c. Obtain medical assistance. GC1-CB SR S.11 5/83SULPHURIC (OR OTHER) ACID 1. Skin, a. Innediately flush with water for 15 minutes. b. Obtain medical assistance. 2. Eyes Inmediately flush with copious amounts of water for at least 15 minutes b. DO NOT attempt to neutralize. c. Obtain medical assistance. PRESERVATIVE POWER (DICYCLOHEXYL AMMONIUM NITRATE) 1, Special Precautions. a. Do not inhale powder dust. b. Avoid repeated or prolonged skin contact. c. Avoid powder contact with foods. 2. Effects of Overexposure. a. Headache, vertigo. b. Lowering of blood pressure. c. Irritation of skin and eyes. 3. First Aid Treatment. a. If ingested, remove from stomach, give activated charcoal, milk. b. If on skin, wash thoroughly to remove. c. If in eyes, flush with copious amounts of water. d, Obtain medical assistance. GC1-CB SR 8.12 5/83SECTION 1 TECHNICAL REQUIREMENTS AND LEADING PARTICULARS, This manual consists of a Part 1 for the generator set operator's manual and a Part 2 for the detailed systems descriptions and the corrective maintenance efforts. The manual does not include the overhaul information for any major assemblies. No attempt to separate or overhaul major assemblies (Reduction Gear Unit, Turbine Engine, or Driven Equipment) should be made without the assistance of a Solar representative 1.1 STANDARD TECHNICAL REQUIREMENTS. This section provides the specifications for lubricating oils and fuels. It enumerates the systems and options included in this particular package. This section also provides operating limits and accessory settings for this package 1.1.1. Lubricating Oil Several types of lubricating oils are suitable for use in the Solar turbine engines, the output drive assemblies, and the driven equipment. The selection of a Satisfactory of] depends on the physical and chemical composition of the ofl and on the ambient temperature surrounding the engine prior to startup. An oil selected to meet the requirements given in this section should ensure the proper lubrication and long life of the engine and components. As a basis for determining oi] degradation during service life, samples should be taken for analysis of new oi] before it is used. Natural Petroleum Base Oils These oi1s consists of refined petroleun based oils with suitable additives to meet the physical and chemical requirements given in table 1.1. The oils shall not contain additives that are degradable below 284°F (140°C) or are water separable. Additives shall remain uniformaly distributed throughout the oi] at all temperatures above the pour point and up to 284°F (140°C) Two ASTM (American Society for Testing Materials) viscosity grades of natural petroleum base oi] are listed in table 1.1. Grade $150 is suitable for use in cold to moderate climates with ambient temperature limits of 11°F (6°C) to 110°F (43°C) above of] pour point. Operating oi] temperature limits out of the oil cooler are between 130°F and 160°F (54°C and 71°C). Grade S215 is suitable for use in warm to hot climates with ambient temperature limits of 11°F (6°C) to 140°F (60°C). Operating oi] temperature limits out of the of] cooler are between 150°F and 180°F (65°C and 82°C). . GCl-cB 3.7 aa 2/84s0:0 60:0, <0-0, ono O° ons 96-0 88°0-98"0 ‘002 Testes) 999 (oss) ee Toss 289 ~ Js OTAUIS-wor-— S110 WN TOMI Ia —nomavaouaxn —— O32 1S3HLNAS usu (sng) s/zua - ago xeH (Sns) $/zum = 350 (32001) 9488 18 AV!soosiA 1912 a sosn a10g9q £4} 11989} 14de 40) 4eLOS WALA 499UD% xea “200/60 “oGueyo 24610n wn} souben xou $ dseosou) £3 {00814 1 s0uOU Ny = Aitisqeis uorrep!xo pue orisosso - 905 pouroH 2801 1e19p04 xen 28 oseos0U! A3y30981A “s01481sBA30 g6s2 a deeg eA 1s0931A “BPEIT ATTSOISTR—BaHE I wats Stuouasinboy 1e0!wou pue 1e9!8AWd 110 SuraeosanT L°L sae, 2/84 GC1-cB 3.7Synthesized Hydrocarbon Oils These are the preferred oils for all applications. They shall conform to the physical and chemical requirements given in table 1.1. The oils shall consist of synthesized hydrocarbons with suitable additions. One ASTM viscosity grade of synthesized hydrocarbon ofl is listed in table 1.1. Grade $150 synthesized hydrocarbon oil is suitable for use in all climates from arctic to tropic with ambient temperature limits of ~65°F to +140°F (-54°C to +60°C). Operating of7 temperature limits out of the oil cooler are between 130°F and 180°F (54°C and 82°C) Startup Limitations The of] selected must have a pour point at least 11°F (6°C) below the expected ambient temperature to ensure flow at startup. Before engine startup, the temperature of all the of] in the entire lubrication system, such as oil tank, lines, cooler, filter, etc., shall be at least 11°F (6°C) above the oil pour point. Suitable heaters and auxiliary oumps may be used to ensure proper of] viscosity in the system prior to startua. Nete For the Centaur@ T-4001, single shaft, sleeve bearing engine, maximum viscosity at startup is 700 SUS. This is equivalent to grade $150 at 52°F (11°C). Oil Service Life The of] should be checked on a regular basis, such as once a month, for contamination and degradation. The degree to which this could occur’ and affect operation varies with each application. The actual limits must be determined by customer experience. The service life of the ofl is limited by the presence of water, viscosity change, and increase in Total Acid Number. The of] must be drained and replaced whenever any of the following conditions are noted. 1. Water content in excess of 2000 pacts per million for all type oils. 2. Viscosity change of +25 to -10% for petroleum based and synthesized hydrocarbon of1s. 3. Increase in Total Acid Number above 4.0 for synthesized hydrocarbon oils and above 1.0 for petroleum based oils. GC1-cB 3.7 13 2/841.1.2 Fuel and Service Gas The selection of a satisfactory fuel depends upon the physical and chemical composition of the fuel, Natural gas fuel and service gas requirements are given in table 1.2 for engine gas fuel and for service gas used for auxiliary gas driven motors and gas driven starter motors Table 1.2 Fuel and Service Gas Requirements Gas Temperature -40°F to +160°F (-40°C to +71.1°C) Lower Heating 800 to 1100 Btu/scf (844 to 1160.5 kJ/nm?). Lower Value of Fuel heating values outside this range are acceptable with the Gas approval of Solar Enginzering. Composition Fuel and Service gas composition shall be such that dew point at maximum engine supply pressure of 205 psi (1413.4 kPa) must be at least 10°F (5.6°C) below gas fuel supply temperature. The dew point of a gas can be calculated from the composition or determined experimentally with an instrument such as the Alnor Dew Pointer, manufactured by Alnor Instrument Company, Chicago, Illinois Contaminants Fuel Gas a. Total contaminants srall not exceed: Jower heating value by weight Btu/1b 30 ppm x: 19 000 Btu/1b ku/kg or 30 ppm x 20.046 kd/kg b. Particles larger thar 10 microns shall not exceed: lower heating value by wetght Btu/Tb 0.3. ppm 19 000 Btu/tb ka/kg or 0.3 ppm x 20 046 kd/kg Gci-cB 3.7 14 2/84Table 1.2 Fuel and Service Gas Requirements, Contd ¢. No entrained water in the gas is allowed: j.e., no water in excess of saturation at 205 psi (1413 kPa) pressure or maximum operating pressure. d. The percent by weight total sulfur, including hydrogen sulfide, shall not exceed: lower heating value by weight Btu/Ib 19 000 Btu/Ib kJ/kg or 1% x— 20 046 kJ/kg Service Gas a. Not more than 0.7 gram of solid contaminants per 1000 cu ft (if separate (28.3 m?) of gas are allowed, 99% of the 0.7 gram/ supply for 1000 cu ft solids shall be smaller than 10 microns. pneumatic e@ starter.) b. No entrained water in the gas is allowed: 1.e., no water in excess of saturation at 205 psi (14.4 kg/cm?) pressure or maximum operating pressure c. Not more than 0.5 pound (0.23 kg) total sulfur per 1000 cu ft (28.3 m) of gas, including hydrogen sulfide. Note Users are urged to consult local authorities for sulphur emission limitations. Limits in this specification are based solely on design considerations, and much lower levels may be required by antipollution regulations. GCl-cB 3.7 15 2/84Table 1.3. Liquid Fuel Requirements ASTM Std Item Limits D1796 ‘Sediment content per gallon (solid or 0.1 gram max (0.09 gram hard contaminants) shall be less than 5 microns) D1796 = Water content per gallon at 80°F, 1 ce max Daas Kinematic viscosity in Centiszokes 12 max 1min at 10°F D287 A.P.I. gravity 30 to 51 degrees 0323 Vapor pressure 3 psia max 02500 Cloud point, °F below ambient, 10°F max p97 Pour point, °F below cloud point 10°F max p93 Flash Point 100°F min (or legal limit) p86 Distillation 90% complete 625°F max Distillation complete 675°F bio Sulfur content by weight (See NOTE on 1% max preceding page) 01319 Aromatics by volume 25% max 01319 Olefins and Diolefins by volune 5% max 0240 Lower heating value 18,000 Btu/Ib min 0524 Carbon residue on 10% residum 0.35% max vag Ash content by weight 0.005% max 0130 Copper corrosion after 3 hours at 122°F, 3 (Dark Tarnish) Class max 02787 Vanadium content by weight 0.5 ppm max 02788 Sodium plus Potassium content by weight 1.0 ppm max 02787 Lead content by weight 2.0 ppm max 02788 Calcium content by weight 1.0 ppm max @cl-cB 3.7 1.6 2/841.1.3 Turbine Performance Data The following curves are provided as a baseline for operator evaluation of turbine engine performance. Comparison with actual performance data, on a periodic basis, should help detect engine degradation and determine frequenc: of corrective maintenance (i.e., compressor cleaning). Part 2 of this manual contains a detailed description of performance criteria and corrective maintenance procedures GC1-cB 3.7 17 2/84CENTAUR T 400s SINGLE-SMAFT TURBINE ENGINE MINIMUM PERFORMANCE - LIQUID FUEL FUEL FLOW. EXHAUST FLOW ANO TEMPERATURE T,. nthonch dS ENS hv = OUTPUT POWER. KILOWATTS y 152 24, = FUEL RATE. MILLIONS Btu/he Blox = EXHAUST FLOW, THOUSANDS OF Ins/ne BE AMBIENT PRESSURE, pia Se 800 3600 400 2200 1000 8 WB 2400 a 2200 2000 0 OUTPUT POWER KW/6; 1600 1400 ve & [ é 800 400 See IN I" 20 «0 0 20 100 120 ENGINE INLET AIR TEMPERATURE, T1"F creo Figure 1.1 Output Power, Flow and Temperature - Liquid Fuel Operation @c1-CB 3.7 18 2/84OUTPUT, POWER, KILOWATTS CEWTAUR T-8001 SINGLE SHAFT UEL RATE, MICLIONS BTU/HR ‘TORBINE ENGINE, MINIMUM PERFORMANCE = EXHAUST FLOW, THOUSANDS OF P.P.HR NATURAL Gas FUEL FUEL FLOW: AMBIENT PRESSURE, PSIA EXHAUST FLOW AND TEMPERATURE Ta? 4000 Tee 328] T leeaT 144 140 3800 T fy TAS 136 a 3600 Won Rea | 3400 3200 ors mt 300 t 4 ‘ 2800 3B (ny/5: 2600 a 2400 34 2000 30 evo OUTPUT POWER, (KW/3) 600 26 3400 1200 2 1000 800 600 1B 400 Seog 200 1 : aL a) Figure 1.2 Output Power, Exhaust Flow and Temperature ~ e Natural Gas Fuel Operation @c1-CB 3.7 19 6/84CENTAUR T-4001 SINGLE-SHAFT TURBINE ENGINE MINIMUM PERFORMANCE - LIQUID FUEL THIRO STAGE TURBINE INLET TEMPERATURE rm 4000 Temi ans 3800 800 400 3200 000 12008 2400 2200 100° 000 ‘OUTPUT POWER HWi5 3 1000 1400 Kt 7 00 = e00F 00 400 200 700 coor 20 0 20 wo 0 ry 100 720 ENGINE INLET AIR TEMPERATURE Ty (°F) cre: Figure 1.3 Third Stage Turbine Inlet Temperature, TS - Liquid Fuel Operation GC1-CB 3.7 1.10 2/844000 ENTAUR T-4001 SINGL TURBINE ENGINE MINIMUM PERFORMANCE - NATURAL GAS FUEL THIRD STAGE TURBINE INLET TEMPERATURE NOTE: SHAFT OUTPUT POWER IS LIMITED ay THE MAXIMUM GENERATOR RATING AT LOWER AIR INLET TEMPERATURES 3800 3600 PM ~ 3400 Loe aie Se 3200 3000 2800 vous 1300F 2600 2400 1200 2200 2000 L00F 1800 ‘OUTPUT POWER, KW/5 1600 1400 2000F 1200 900F 1000 800 600 800F 400 200 700F +20 GC1-cB 3.7 ° #20 40 60 30 ENGINE AIR INLET TEMPERATURE, Ty °F 700 Figure 1.4 Third Stage Turbine Inlet Temperature, T5 - Natural Gas Fuel Operation all 120 creae 6/84pog ‘aunssoug a61e42S1q sossauduoy g*T aunBiy 483 INSSAUd JOUVHOSIO HOSSIUANOD ey tek L dh ji SS tf] | ies cE reece - st oe 4 tS Ft ww J oe Soo w \ \M \ 2/84 1.12 GCl-cB 3.7e 1.2 LEADING PARTICULARS Data applicable to 100% engine speed and rated full load at sea level. All values given are nominal, unless otherw’se specified. Table 1.4.1 Installation Data AIR ASSIST SUPPLY FLOW AND PRESSURE ENGINE AIR INLET FLOW ENGINE AIR INLET DUCT LOSSES ENGINE AIR INLET DUCT ORIENTATION ENGINE EXHAUST FLOW e EXHAUST DUCT LOSSES GAS FUEL SPECIFICATION GAS FUEL SUPPLY FLOW AND PRESSURE GAS FUEL SUPPLY TEMPERATURE LIMITS GENERATOR COOLING AIR FLOW GENERATOR HEAT REJECTION LIQUID FUEL SPECIFICATION LIQUID FUEL DEMANDS 84-39621 15 scfm (0.42 m?/min) of clean, dry air regulated between 70 psi (482.6 kPa) and 200 psi (1378.9 kPa) for 90 seconds per start. 30 000 scfm (850 m?/min). 4.0 inches (102 mn) water gage maximum, Up. 80 000 cfm (2265 m/min) at 910°F (487°C). 6.0 inches (152.4 mm) water gage maximum Refer to Table 1.2. 970 scfm (27.5 m?/min) at 165 to 200 ps’ (1137.6 to 1378.9 kPa). ~40°F to +160°F (-40°C to +71°C). 12 000 cfm (340 m/min) 480 000 Btu/hr (474 775 kJ/hr) Refer to Table 1.3. 7.2 gpm (27.1 1/min) maximum. 1.13 8/84Table 1.4.1 Installation Data, Contd OIL TANK VENT FLOW RATE OIL TANK VENT DUCT Loss OIL COOLER, AIR TO OIL OIL COOLER AIR FLOW OIL COOLER HEAT REJECTION PILOT AIR/GAS SPECIFICATION PILOT AIR/GAS SUPPLY PRESSURE PILOT VALVE VENT PNEUMATIC START INLET SUPPLY WATER WASH SUPPLY AND PRESSURE 84-39621 120 scfm (3.5 m*/min). 1.0 inch (25.4 mm) water gage maximum Renote, blow through, heat exchanger radiator, electric driven. 11 900 emf (337 m?/min) at 110°F (43°C) 45) 000 Btu/hr (474 750 kJ/h) at 80 gpm. Refer to Table 1.2. 165 to 200 psf (1137.6 to 1378.9 kPa). 70 scfm (1.98 m?/min) per 1/2 second. 2600 scfm (73.58 m/min) regulated between 165 and 200 psi (1137.6 and 1378.9 kPa) at package connection. 30 gallons (113.5 liters) at 10 opm (37.8 \/nin) regulated between 20 to 40 psi (137.9 to 275.8 kPa). 1.14 8/84Table 1.4.1 Installation Data, Contd WEIGHTS (Approximate) Base with Accessories and Hardware Turbine Engine with Inlet Duct Enclosure Exhaust Diffuser Generator Reduction Gear Unit Main Control Console oi 011 Cooter (each) DIMENSIONS (Approximate) Generator Set Control Console Length Width Height Depth Width Height Lube 011 Cooler Assembly Depth Width Height 26 12 3750 9000 feet, feet, feet, feet, feet, feet, feet, feet, feet, 12 500 Ibs ibs Ibs Ibs ibs Ibs Ibs Ibs ibs 10 10 0 6 8 6 3 inches inches inches inches inches inches inches inches inches 5670 kg) 1701 kg) 4091 kg) 191 kg) 8163 kg) 1429 kg) 408 kg) 522 kg) 204 kg) oye 3 (1.10 m) (1.06 m) (0.99 m) 84-39621 8/84Table 1.4.2 Electrical Power Requirements ELECTRICAL CONTROL SYSTEM 24 Vde. ENCLOSURE LIGHTS 115 Vac, 60 Hz, single phase, 600 W. ENCLOSURE VENT FAN MOTOR 230/460 Vac, 60 Hz, three phase, 3 hp. GENERATOR SPACE HEATER 115 Vac, 60 Hz, single phase, 1200 W. LIQUID FUEL PUMP MOTOR 230/460 Vac, 60 Hz, three phase, 7.5 hp. LIQUID FUEL PUMP MOTOR 115 Vac, 60 Hz, single phase. SPACE HEATER OIL COOLER FAN MOTOR 230/460 Vac, 60 Hz, three phase, 5 hp. OIL COOLER FAN MOTOR 115 Vac, 60 Hz, single phase. SPACE HEATER PACKAGE AC JUNCTION BOX 115 Vac, 60 Hz, single phase, 30 W. SPACE HEATER PRE/POST LUBE PUMP MOTOR 24 Vde. VALVE JUNCTION BOX 115 Vac, 60 Hz, single phase, 10 W. SPACE HEATER 84-39621 1.16 8/84Table 1.4.3 Start System PNEUMATI STARTING OPERATING PRESSURE TORQUE (each motor, at approximately 30% engine speed) LUBRICATION PILOT AIR/GAS FILTER PILOT RELIEF VALVE AIR/GAS INLET STRAINER GC1-CB 3.7/2.1 Twin pneumatic vane type motors operated from a pneumatic source of clean, dry air or gas 165 psi (1138 kPa) to 200 psi (1379 kPa) 110 ft-1b (149 Ne) Oi] mist. from lubricator in motor pneumatic supply Ine. Turbine of] at approximately 60 drops per minute. Single, pilot operated shutoff valve (normally closed). Controlled by single solenoid operated pilot vaive (normally open) 10 micron nominal, 26 micron absolute. 200 psi (.379 kPa) 100 mesh screen 1.17 2/84Table 1.4.4 Natural Gas Fuel System GAS FUEL INLET STRAINER PILOT VALVE FILTER HIGH GAS FUEL PRESSURE SWITCH (8386-2) PRIMARY/SECONDARY VALVE TEST PRESSURE SWITCH ($342) GAS FUEL THROTTLE VALVE SPARK PLUG Gc1-cB 3.7 100 mesh screen 5 micron nominal psi (1407 + 21 kPa) increasing; 7 psi (1200 # 117 kPa) decreasing 1 psi (310 522. 14 kPa) increasing; 42 = 0.8 psi (290 6 kPa) decreasing Butterfly valve blade opens approximately 40 degrees for acceleration, 10 degrees for deceleration. 0.08 to 0.10 inch (2.03 to 2.54 mm) gap 1.18 2/84Table 1.4.5 LOW PRESSURE DUPLEX FUEL FILTERS, FUEL FILTER SELECTOR VALVES (2) LOW PRESSURE FUEL FILTER ‘AP SWITCH ($343) LOW FUEL PRESSURE ‘SWITCH ($387) HIGH PRESSURE FUEL PUNP (Wotor Driven) HIGH PRESSURE FUEL FILTER HIGH PURGE TANK LEVEL SWITCH ($389) LIQUID FUEL CONTROL VALVE (Univalve) METERED FUEL PRESSURE SWITCH ($344) Gcl-cB 3.7 Liquid Fuel System Two elements each, 10 micron. Two position, manually operated selector valve. Permits {fsolation of either filter for maintenance during operation. Transfers at 15 psi (103 kPa) increasing differential pressure; 10 psi (70 kPa) decreasing. Transfers at 7 psi (48 kPa) increasing; 5.5 psf (38 kPa) decreasing 10 gpm (37.85 1/min) at 2950 rpm and 1000 pst (6895 kPa) Sirgle element, 40 micron, non-bypass fuel filter with 66 gpm (250 1/min) rated flow. Transfers at 5 gallons (19 liters) level in purge tank. Integral Ped bleed valve (L346) admits compressor discharge air pressure when operating on liquid fuel, vents Pcd when operating on gas fuel; integral fuel togping solenoid (L397) decreases fuel flow when energized during start cycle; integral relief valve opens at 800 psi (5816 kPa). Trensfers at 150 £ 3 psi (1034 #1 kPa) increasing, opens at 1257.5 psi (862 4 3 kPa); fuel transfer and operation on licuid fuel possible only when switch is clesed on increasing pressure. 1.19 2/84Table 1.4.5 FUEL VALVE GROUP Reduced Speed Liquid Fuel Bypass Valve (1347-1) Liquid Fuel Valve (1349) Liquid Torch Valve (L348) Air Assist Torch Valve (1348-1) Liquid Purge Valve (1345) Ped Bleed Valve (1346) Relief Valve (Fuel bias to torch) AIR ASSIST METHOD AIR ASSIST STRAINER AIR ASSIST PRESSURE REGULATING VALVE Liquid Fuel System, Contd Normally closed, two way valve. Opens to bypass liquid fuel to the fuel inlet during reduced speed operation. Closes when de-energized for start and normal operation. Normally closed, two way valve. Opens when energized to admit liquid fuel to injectors during operation on liquid fuel. Normally closed, two way valve. Admits liquid fuel to the fgniter torch when energized at start sequence. Closes when de-energized following successful lightoff. Normally closed, two way valve. Admits air to the igniter when energized at start sequence, Closes when de-energized following successful lightoff. Normally closed, two way valve. Opens when energized to drain liquid fuel lines during shutdown on liquid fuel and during liquid fuel to gas fuel transfer operation. Normally open, two way valve. Closes when energized to’ admit Pcd to the acceleration Vimiter and piston assembly. Opens at 10 psi (70 kPa), providing a mininum bias fuel pressure to the liquid fuel torch valve. Shop air, 70 psi (483 kPa) to 200 pst (1379 kPa). "15 scfm (0.42 m/min) for 90 seconds. 100 nesh screen, cleanable. Three port, diaphragm and poppet type. Controls air assist pressure at 5 to 6 pst (34 to 41 kPa) above compressor discharge pressure (Pcd). GC1-cB 3.7 1.20 2/86Table 1.4.6 Engine Air System COMPRESSOR PRESSURE RATIO 8.7 to 9.5:1 (depending on duty cycle) COMPRESSOR DISCHARGE PRESSURE 113 to 125 psi (779 to 862 kPa) (Ped) depending on environment. BLEED AIR VALVE During engine acceleration, the bleed air valve begins to close when Pcd reaches 72 psi (496 kPa) and engine speed of approximately 83% During engine deceleration, the bleed air valye begins to reopen when Ped drops to 38 psi (262 kPa) COMPRESSOR VARTABLE INLET Vanes held in minimum open position GUIDE VANES below 66% engine speed; actuated toward r } maximum open position above 66% speed. At shu:down, vanes return to minimum open position as engine speed decreases below 90%. Required field adjustment to be performed in accordance with maintenance manual procedures. @c1-cB 3.7 1.21 2/84Table 1.4.7 Lubricating and Servo O17 System LUBRICATING AND SERVO OIL Refer to table 1.1. SPECIFICATION LUBE OIL TANK CAPACITY 218 US gallons (825 liters) to gage FULL LEVEL (with unit shut down) LOW OTL LEVEL SHUTOOWN 100 US gallons (379 liters) decreasing SWITCH ($388) LOW OTL LEVEL ALARM 116 US gallons (439 liters) decreasing. SWITCH (S388-1) PRE/POST LUBE OIL PUMP 20 gpm (76 1/min) at 15 psi (103 kPa) and 1725 rpm; 24 Vdc, continuous drive motor. PRELUBE OIL PRESSURE 6 psi (42 kPa) increasing; SWITCH ($322) 4 psi (28 kPa) decreasing: DUPLEX LUBE FILTER 5 micron nominal, 25 micron absolute fi'tration, 2 cases, single element, 150 gon (568 "I/min) rated flow, 2 psi (14 kPa) pressure drop at rated’ flow and : tenperature OIL FILTER HIGH AP ALARM 30 psi (207 kPa) increasing; SWITCH ($397) 25 psi (172 kPa) decreasing. MAIN LUBE OIL PUMP 74 gpm (280 1/min) each at 150 psi (2 elements) (1034 kPa) and 2000 rpm ULTINATE RELIEF VALVE 150 psi (1034 kPa). LUBE OTL THERMAL Conbination temperature and pressure BYPASS VALVES (2) sensing; normally open to bypass most of the oil from the cooler, begins to close at 60°F (15.6°C), fully Closed at 140°F (60°C); reopen if AP exceeds 50 psi (345 kPa). Gci-cB 3.7/4.3 1.22 2/84Table 1.4.7 Lubricating aid Servo O11 System, Contd OTL_TEMPERATURE ALARM SWITCH ($381-1) OTL_TEMPERATURE SHUTDOWN SWITCH (S381-2) LOW OIL PRESSURE SHUTDOWN SWITCH ($380) LOW OTL PRESSURE ALARM SWITCH ($380-2) SERVO PUMP (Fuel actuator supply) SERVO RELIEF VALVE SERVO OIL FILTER 155°F (68.3°C) increasing; 145°F (62.8°C) decreasing. 165°F (73.9°C) increasing; 5°F (68.3°C) decreasing 35 psi (241 kPa) increasing; 25 psi (172 kPa) decreasing. 45 psi (310 kPa) increasing; 42 psi (290 kPa) decreasing 18 gpm (62 1/min) at 500 psi (3147 kPa) and 2000 rpm. 50) psi (3447 kPa). 25 micron absolute. GC1-CB 3.7 1.23 2/84Table 1.4.8 Electrical Control System Governor (Engine Load and Speed Sensing) Control Unit (Z251) Fully electronic governor housed in a single sheet steel chassis containing a single printed circuit board (PCB). Output signals to the main fuel actuator solenoid provides mechanical control of fuel control valves. Provision for selective isochronous (constant speed) or speed droop (speed regulation) mode of operation. Manual speed regulation by means of a remote speed trim potentiometer. For additional information refer to the manufacturer's instructions fn Supplementary Data. GcC1-CB 3.7 1.26 2/84Table 1.4.9 Engine Speed Control Monitor (2283) Setpoints Note: All values are magnetic pickup frequency signals in Hertz + 30 Hertz ‘SPEED METER CALIBRATION SETPOINT 100% speed - 9967 Hz LOW SPEED SWITCH 18% speed - 1495 Hz START SEQUENCE CONTROL SWITCH 66% speed - 6578 Hz (Starter dropout) READY TO LOAD SWITCH 90% speed - 8970 Hz OVERSPEED SHUTDOWN SWITCH 108% speed - 10 764 Hz *Setpoints are marked on control box. Table 1.4.10 Backup Overspeed Monitor (2353) Setpoints Note: All values are magnetic pickup frequency signals in Hertz + 30 Hertz. MONITOR CALIBRATION SETPOINT 100% speed - 8221 Hz START SEQUENCE CONTROL SWITCH 15% speed - 1233 Hz OVERSPEED SHUTDOWN SWITCH 110% speed - 9043 Hz *Setpoints are marked on control box. GC1-cB 3.7/8.1 1.25 2/84Table 1.4.11 Engine Temperature Control Monitor (2282) Setpoints Note: AT] temperatures are in °F = 10°F converted to C® + 5.6° C, and refer to third stage turbine inlet temperature (15). IGNITION FAIL SWITCH 350°F (177°C) IMPENDING HIGH TURBINE TEMPERATURE Shutdown following five seconds SWITCH time delay above 90% engine speed; topping below 90% speed. Normal Operation Setpoint 1155°F (625°C) Start Sequence Offset Setpoint 1200°F (649°C) HIGH TURBINE TEMPERATURE SHUTDOWN Immediate shutdown at any SWITCH time above these temperatures. Normal Operation Setpoint 1220°F (660°C) start Sequence offset Setpoint 1250°F (677%) e *Setpoints are marked on control box. Gcl-cB 3.7 1.26 2/84Table 1.4.12 Miscellaneous Systems Limits COMBUSTIBLE GAS DETECTOR (2199) & (Z199-1) Alarm 20% L.E.L Shutdown 60% L-E.L GOVERNOR (2251) Speed Setpoint 100% - 9967 Hz Reduced Speed Setpoint 62% - 6180 Hz MAIN FUEL ACTUATOR CONTROL UNIT (Z244) Threshold 1140°F (615°C) OVERVOLTAGE (2268) 120% nominal voltage engine shutdown UNDERVOLTAGE (2266) 85% nominal voltage engine shutdown 84-39621 1.27 8/84Table 1.4.12 Miscellaneous Systems Limits, Contd VIBRATION/TEMPERATURE MONITOR (Z184) ITEM MONITORED POSITION CHANNEL ALARM SHUTDOWN UNITS 1 POWER SUPPLY thru 4 Below 90% speed 0.6 1.0 LPS. ENGINE VIBRATION 5 A Above 90% speed 0.4 0.5 LPS. Below 90% speed 0.6 1.0 1.P.s. GEAR BOX VIBRATION 5 B Above 90% speed 0.3 0.5 IPS. DRIVEN END 6 A 82 88 °c GENERATOR BEARING TEMP. EXCITER END 6 8 82 88 °c PHASE A 7 A 150 ie GENERATOR WINDING TEMP. ———— PHASE B. 7 B 150 160 °c PHASE C 8 A 150 160 °c GENERATOR WINDING TEMP. NOT USED 8 8 9 A 68 74 °c LUBE OIL TEMPERATURE 9 8 10 A NOT USED 10 B u A NOT USED 1 B 12 A NOT USED 1 8 84-39621 1.28 8/84SECTION 2 DESCRIPTION 2.1 GENERAL DESCRIPTION Turbine Generator Set The turbine generator set (figure 2.1) consists of a Centaur® single shaft, industrial turbine engine; a two stage reduction gear unit; a generator; an engine and generator control console; and in the case of multiple unit installatations, an automatic synchronizer console for parallel operation. The engine, the reduction gear unit, and the generator constitute the major elements of the generator set. These elements are installed on a heavy steel base frame in an "in line" arrangment. The base frame is a structural steel assembly with beam sections and cross members welded together to form a rigid foundation for the engine assembly, the driven equipent, and major accessories. To facilitate the alignment of major elements of the generator set and for ease of installation, the steel base {incorporates machined mounting surfaces for the reduction gear unit and the generator. The gear unit is installed on the forward end of the turbine engine at the air inlet. The gear unit input shaft is carefully meshed and connected with the engine compressor rotor nose cone hub by means of splined sleeve coupling. A mating flange with pilot surfaces on the gear unit housing, bolted to the engine air inlet housing, holds the assemblies together. reduction gear unit output shaft is aligned with the generator input The two shafts are connected together by means of a flexible shear coupling enclosed in a protective safety cover. The generator set is a fully operational package equipped with all accessories necessary for normal operation when connected to a customer's facilities. It incorporates a full complement of auxiliary systems, including a complete fuel system, an air system with associated pneumatic controls, a lubricating of? system with related subsystems, and an electrical control system. GC1-CB 3.7/2.1 21 6/84GAGE PaNeL OUTPUT ORWE SHAFT ‘AND wan DE. ‘SUNCTION Box GENERATOR SET AIR LET BASE FRAME WN é a TURBINE. i EXHAUST a i I ENGINE suPPORT V ol Tank use ool WssecTion FILL CAP covers POWER LEAD /seseox (CONNECTION Box Courting ‘ANO COVER REDUCTION AC “rn couLector ELANCE, gas tursine — /VANE ENGINE / ASSEneLy [peso yariaeut ‘AG CONNECTION FOR OIL TANK BEATER ‘KID FRAME ou. ourter Tocoder * engine ale ince aver OREM ou mer FROM COOLER cazse Figure 2.1 Centaur® Turbine Generator Set Outline GCl-cB 3.7/2.3 22 2/84Systems The fuel system controls the fuel oressure and automatically regulates the fuel flow according to operating requiranents. The air system pressurizes oi] seals in the turbine engine and the reduction gear unit, cools the turbine rotor, and supplies air to operate the fuel control system and other pneumatic devices in related systems. The lubricating of] system circulates of] under pressure to the various working parts of the turbine engine and the reduction gear unit. In addition, the system supplies oi] at engine inlet pressure to related hydraulic subsystems. The system is supplied from the lube of] tank located in the steel base frame. Proper of] temperatures are maintained by an optional of] tank heater and by an of] cooler and thermostatic oi] valves. The ofl cooler is remotely installed. A number of optional installation plans and cooler types are available, depending on station requirements. The electrical control system, operating on 24 Vde power, provides for automatic starting, acceleration to operating speed, engine and generator monitoring during operation, and normal and emergency (malfunction) shutdown. During operation, the electrical control system, by means of automatic warning and shutdown devices, protects the turbine engine and driven equipment from possible damage resulting from hazads such as an overspeed, a high engine ‘temperature, a low lubricating of] pressure, an excessive oi] temperature, and generator over or undervoltages. Osher’ malfunction shutdown devices are provided. Also, special devices may be added according to application requirements. The electrical control system is operated from a remotely installed control console. A turbine engine control panel and ac generator metering panel, with all necessary switches, pushbuttons, meters, and indicators for engine and generator operational status, are installed on the front of the control console. Reduction Gear Unit The reduction gear unit is bolted to the engine air inlet housing and installed on a raised mounting surface over the of] tank on the steel base. The unit is of a high speed, two stage, star compound, epicyclic design, available with output speeds of 1500 or 1800 rpm (50 or 60 Hz respectively), depending on generator configuration. Rated at 4600 hp (3430 kW), the unit utilizes single helical, hardened and ground gearing capable of sustaining momentary overloads of up'to approximately eight times normal operating rated torque. Lubricating of] for bearings and gear train is supplied from the turbine engine lube 011 system. Bearing of] seals are pressurized with seal ofl from the engine air system. GC1-CB 3.7/2.1 2.3 6/84Generator The generator is installed and bolted to four raised mounting pads on the steel base forward end. It is positioned in accurate alignment with the reduction gear unit by means of shims. Although a variety of generator configurations may be used, the standard turbine generator set normally incorporates a two bearing, revolving field type, three phase, ac generator of drip proof construction equipped with damper winding and direct connected brushless exciter, Voltage regulato~, meters, switches, and other panel mounted equipment are required separately for control of the generator and are located on the control console switchboard. For automatically synchronized parallel operation with other units, an automatic synchronizer is required as a separate console mounted accessory. For additional details peculiar to each individual generator set, refer to the Technical Requirements and Leading Particulars Section 1 and to the component manufacturer's information in Supplementary Data section of this manual. Environment The standard turbine generator set is designed for operation (in “a weather proof enclosure) at sea level and up to 8000 feet (2438 meters) elevation, at temperatures ranging from ~20 to 115°F (-29 to + 46°C). Special accessories are necessary for operation at higher elevations or in extreme temperature, salt, or dust conditions. Lubricating of] used (refer to Subsection 1.1.1) can ‘constrain operation in extreme tenperatures. In particular, the lube oi] in the tank, lines, engine, and of1 cooler should have suitable’ minimum and maximum viscosities for the ambient starting temperature. GC1-CB 3.7/2.1 2.4 6/842.2 OPERATING SEQUENCES General The generator set electrical control system is a closely interrelated combination dc~ac circuit arrangement, consisting basically of the engine dc control system and the generator ac metering system The complete electrical system is shown on the schematic diagram, submitted in a separate envelope together with this manual. The schematic’ depicts the various circuits and identifies components within each circuit. Basic data applicable to the specific electrical components used in this set is provided in Section 1. Descriptions covering the electrical control system are contained in the following paragraphs. Manufacturer's data and additional information are provided in Supplementary Data section. The electrical control system requires 24 volt de power. Customer furnished ac electrical power is required for the options provided. The electrical control system provides for automatic starting and sequencing control as the engine is accelerated to operating speed. During acceleration and operation at rated speed, the system monitors the engine and generator. In the event of an operating malfunction, it activates an electrical circuit to indicate the nature of the trouble, and to cause an emergency engine shutdown. The stop sequence during’ a shutdown cycle is also automatically controlled by the system. The electrical control system is divided into several branch circuits, and is protected against overload by circuit breakers. Transient suppression’ diodes Protect sensitive components from possible damage or malfunction due to switching surges. The electrical circuits incorporate relays, solenoids, and blocking diodes, and speed, pressure, and temperature sensing switches, together with solid state electronic devices, to control the sequence of operation. The system is operated and controlled from the turbine engine control panel which ts the panel on the right of the main control console. GC1-CB 3.7/2.1 2.5 6/84The following sequences describe the function of the electrical control system during normal operation and malfunction shutdown. The sequences may also assist in troubleshooting the generator set. To follow the sequences and for customized features, refer to the electrical system schematic enclosed in an envelope together with this manual. The schematic is necessary to follow each switch, relay, solenoid, and control unit contact transfer as each step is described in the sequence. Relay contacts are located on the schematic by line numbers shown under normally open and/or normally closed symbols to the right of the relay symbols. The line numbers, sequential from "1", are arranged from left to right along the bottom border of each sheet on the schematic. If no Tine numbers are given at the relay symbol, the contacts are not used. A1l contacts are shown in their normal de-energized state without power applied to the component KD (time delay on dropout) timer relay contacts transfer when the relay is energized. Time delay is initiated when the relay is de-energized and the contacts retransfer at the end of the time delay. Z KP (time delay on pickup) relay time delay is initiated when the relay is energized. Contacts transfer at the end of the time delay and retransfer when the relay is de-energized. If the relay is de-energized before it times out, contacts will not transfer. Time delay intervals and the type of time delay relay, KO or KP, are identified on the electrical schematic. Other relays, K, transfer’ when energized and retransfer when the relays are de-energized. Note This dual fuel system is designed for starting on either liquid (diesel) fuel or (natural) gas fuel. If liquid fuel is not selected prior to start, the system will start on gas fuel. The fuel selection cannot be changed between the initiation of the start sequence and the attainment of loading speed. GC1-CB 3.7/2.1 2.6 6/84e 2.2.1 Start Sequence - Operation on Gas Fuel ~ Manual initiation, LOCAL. Prestart conditions: 1. O11 tank is full and low of? level switches are closed. 2. External ac power is applied and all accessories are connected. 3. All fuel and optional service air/gas supply is shut off. 4. All circuit breakers are open (OFF). 5. Systems Control switch S101 is in the OFF position. 6. Fire System Lockout switch $131 is in the ON position. 7. Engine Water Wash switch $190 is in the OFF position. 9. Engine Speed switch $191 and Voltage switch $260 are both positioned to the mode that the generator will te operated (ISOCH or DROOP). 10. Engine Crank switches $193 and $393 are in the OFF position 11, No Gas Fuel Available Bypass switch $259 is in the NO BYPASS position. All system circuit breakers are closed (ON): 1, Circuit breaker C8201 closes. Control Bus power is supplied to the System Control switch S101. Generator space heater interposing relay K891 is energized and contacts transfer. The generator space heater contactor relay k491 is energized to apply utility power to the generator space heater H391. 2. Circuit breaker CB202 closes. Lube System Bus power is supplied. The pre/post lube oi] system is armed at the normally open A contacts of the lube pump relay k221. GC1-CB 3.7/2.1 2.7 6/84. Circuit breaker CB203 closes. Lamp System Bus power is supplied. All malfunction control units 2189 series are armed. Unit alarm relays k274 series and heat sensor switches $399 series are armed. Fire monitor Z198 and gas monitors Z199 and 7199-1 are energized. Fire monitor 7198 internal relay K3 contacts transfer to arm the Fire System Fault alarm circuit (05199) of unit alarm relay k274-2 Gas monitor systems are energized end the gas monitors 7199 and 7199-1 internal switch gates #1 contacts transfer. The intake gas monitor Z199 switch gate #1 contacts arm the Intake Gas Monitor Failure malfunction circuit (DS16) of shutdown nonlockout relay K279. The enclosure gas monitor 2199-1 switch gate #1 contacts arm the Enclosure Gas Monitor Failure malfunction circuit (DS23) of shutdown nonlockout relay K275 Circuit breaker CB204 closes. DC Power Bus power is supplied. Circuit breaker trip control circuit is energized and a trip signal is supplied to the switchgear. Voltage regulator VR260 is armed at the normally open contacts of the field flash relay K260. Circuit breaker CB205 closes. Liquid Fuel Topping Bus power is supplied. Liquid fuel topping valve solenoid L397 is armed at the normally open A contacts of the minimum liquid fuel relay K244. . Circuit breaker CB207 closes. P/P Lube Motor Bus power is supplied. The pre/post lube motor B321 is armed 2t the normally open contacts of the dc pre/post lube of] relay K22l-1. All fuel supply valves are opened manually: 1. Gas fuel is admitted to the pilot branch of the primary gas fuel valve and the secondary gas fuel valve. The primary and secondary gas fuel valves are held closed by the pilot gas pressure until energized to open later in the sequence. . Gas fuel pressure switch $342 will transfer to the closed position as the gas fuel pressure increases above 45 psi (310.2 kPa). When $342 closes the gas fuel pressure (HIGH) relay K238 is armed to energize at application of control power by the Systems Control switch S101. High gas fuel pressure switch $386-2 does not transfer unless gas fuel pressure exceeds 204 psi (1406.5 kPa). High Gas Fuel Pressure malfunction circuit (DS12) of shutdown nonlockout relay K276 is armed. - Low gas fuel pressure switch $386-3 transfers at 175 psf (1206.5 kPa) and unit alarm relay K274-2 is energized. 84-39621 2.8 8/84Systems Control switch S101 is moved to LOCAL: ay 10. ll. The manual systems start, engine crank, and the water wash circuits are armed. . ENGINE STOP indicator light DS112 illuminates. . Liquid fuel pressure timer relay K0286 (6 seconds) is energized in preparation for liquid fuel transfer. Contacts transfer to arm the Low Liquid Fuel Pressure malfunction circuit (DS9) of shutdown nonlockout relay K278. . Circuit breaker OPEN indicator light 0S164 illuminates. . Engine TS temperature monitor 7282 is energized. Contacts J-H-G transfer to arm the ramp topping relay K239, the high temperature hour meter M202, and the Ignition Failure malfunction circuit (DS10) of shutdown nonlockout relay K278. Contacts M-L transfer to arm the Impending High Temperature alarm circuit (DS26) and the high engine temperature relay k282. Contacts S-T-U transfer to arm the High Engine Temperature malfunction circuit (DS4) of shutdown nonTockout relay K277. . Engine speed monitor 2283 is energized and all contacts transfer, except the J-K-L (normally open 15% speed) contacts. The 15%, 66%, and 90% relays and the Overspeed malfunction circuit (DS3) of shutdown nonlockout relay K277 are armed. . Lightoff timer relay 0246 (15 seconds) is energized and contacts transfer in preparation for the ignition sequence. . Start relay K246-1 and start auxiliary relay K246-2 are energized and contacts transfer. Relay k246-1 contacts arm the Ignition Failure malfunction circuit (DS10) of shutdown nonlockout relay K278 and relay K246-2 contacts arm the liquid fuel pressure relay K286-2. - Crank timer relay KD243 (30 seconds) is energized. Contacts transfer and crank timer auxiliary relay Kk243-1 is energized. Fail To Crank malfunction circuit (DS14) of shutdown nonlockout relay K276 is armed. Start timer relay KD285 (9 minutes) is energized. Contacts transfer and start timer auxiliary relay K285 is energized. Fail To Start malfunction circuit (DS13) of shutdown nonlockout relay K276 is armed. Prelube timer relay KD222 (25 seconds) is energized. Prelube relays k222-1 and 222-2 and valve sequence timer relay KD240 (5 seconds) are energized and contacts transfer. Prelube oil pressure switch $322A contacts are bypassed and Low P/P Lube Oil Pressure malfunction circuit (DS2) of shutdown nonlockout relay K277 is disarmed. 84-39621 2.9 8/8412. GAS FUEL SYSTEM ACTIVATE indicator lights DS141-1 illuminates. e 13. If gas fuel inlet supply pressure is normal and the customer furnished gas fuel pressure switch is closed, the gas transfer relay K247 and K247-1, gas transfer timer relay KD247 (1.9 seconds), and gas fuel pressure (HIGH) relay K238 are energized. 14. Contacts transfer to prepare the dual fuel transfer logic for a gas start and to energize the gas fuel relay K248. Relay K248 contacts transfer to Prepare the fuel valve control logic for a start on gas fuel 15. Main fuel actuator control unit (NFCA) 2244 is energized in preparation for a gas fuel start. 16. Backup overspeed monitor Z353 is energized in preparation for a malfunction reset signal. 17. Vibration and temperature monitor Z184 is energized in preparation for a malfunction reset signal. 18. Alarm horn AH172 is energized and horn sounds. Horn Silence switch $172 is pressed. Horn silence relay K272-1 is energized and locked in through normally closed contacts of horn relay K272. Relay K272-1 contacts transfer and AH172 is de-energized. Alarm horn is silent. 19. Low 011 level shutdown relay K288 and low ofl level alarm relay K288-1 e@ are energized. Low Oi] Level malfunction circuit (DS5) of shutdown nonlockout relay K277 and Low Lube Oi] Level alarm circuit (DS30) of unit alarm relay K274 are armed. 20. Temperature shutdown timer KD282 (5 seconds) is energized and High Engine Temperature malfunction circuit (DS4) of shutdown nonlockout relay K277 is armed. 21. High of] temperature relay K281 is energized. Contacts transfer to arm the High O11 Temperature malfunction circuit (DS6) of shutdown nonlockout relay K278 and to energize relay k278. 22. Ramp topping control relay K239 is energized through the closed H-G contacts of engine temperature T5 monitor 2282. Relay K239 contacts transfer and control of the main fuel actuator solenoid L344 is switched from the main fuel actuator control unit 2244 to the ramp generator 2249 which is still de-energized. 23. Battery charger failure relay K295 is armed. 24. Shutdown nonlockout relay k275 is energized. GC1-CB 3.7/2.1 2.10 6/84Malfunction Reset switch S114 is pressed: 1. Engine stop relay K211 is energized and contacts transfer. Relay K211 is Yocked in and shutdown nonlockout velay K276 is armed. 2. All malfunction and alarm indicator lights flluminate (except IMPENDING HIGH ENGINE TEMPERATURE indicator light DS26), providing a test of the malfunction indicator circuits. 3, The vibration and temperature monizor 7184 is reset. Monitor internal relays Kl, k2, and K5 contacts transfer. Monitor relay Kl arms the Summary High Vibration/Temperature alarm circuit (DS33) of unit alarm relay K274-1. Monitor relay K5 arms the Vibration System Fail alarm circuit (DS34) of unit alarm relay K274-1 and relay 274-1 fs energized. Monitor relay k2 arms the Summary High Vibration/Temperature malfunction circuit (DS19) of shutdown nonlockout relay 279 and relay K279 energized. 4, Backup overspeed monitor 2353 is reset to energize the backup overspeed relay K353, Relay K353. contaczs transfer to energize the shutdown nonlockout relay K276 and to arm the liquid fuel purge timer KD245 (20 seconds), liquid fuel valve L349, primary gas fuel valves L341-1 and 1341-2, and secondary gas fuel valve L342, Overspeed backup malfunction circuit (DS11) of shutdown nonlockout relay K276 is armed. 5. Shutdown nonlockout relay K277 is energized. Contacts transfer to lock in relay K277 and to energize the malfunction summary relay K277-1. 6. Relay K277-1 contacts transfer to enable the "first out and only function". 7. ENGINE READY TO RUN indicator ligh: 0S177 illuminates. Malfunction Reset switch $114 is released: 1, Malfunction and alarm indicator lights extinguish. ENGINE STOP indicator light 0S112 extinguishes. ENGINE READY TO RUN indicator light DS177 remains illuminated. Shutdown nonlockout relay K277 is prepared to de-energize upon malfunction and initiate an engine shutdown. 84-39621 24 8/84Systems Start switch S110 is pressed momentarily: 1. 10. Start/run relays 210 series and the pre/post lube timer relay KD220 (55 minutes) are energized, and the EN3INE READY TO RUN indicator light DS130 illuminates. Relay K210 contacts transfer. The start/run circuit is locked-in and the engine crank and water wash Circuits are disabled. Relay K210-1 contacts transfer to arm the lube pump relay K221. . Pre/post lube timer relay K022) (55 minutes) fs energized. Contacts transfer and lube pump relay K221 (controlled by low of] pressure switch contacts $380) is energized. - Relay K221 contacts transfer and the dc pre/post lube oi] relay k221-1, ancillary skid interposing relay 895, and the air/oil cooler fans interposing relay k898 are energized. Relay K221-1 contacts transfer to apply 24 Vdc to the de pre/post Tube motor B321 and the prelube cycle begins. Interposing relays K895 and K898 contacts transfer to apply utility power to the enclosure vent fan motor B336 and the ofl cooler fan motors B598 and 8598-1, Relay K210-2 contacts transfer. Tre liquid purge valve solenoid L345 is energized and the purge valve opens until the turbine engine attains 15% speed. Relay K210-3 contacts transfer to Jockin the fuel selection until the turbine engine attains 90% speed. Relay K210-4 contacts transfer. Prelube timer relay KD222 (25 seconds) is de-energized and begins to time out. The governor control unit 2251 is energized in preparation for load and speed controlled operation when the engine attains 90% speed. The generator circuit breaker trip control circuit is de-energized in prevaration for a circuit breaker close signal. The voltage regulator circuit and the fuel valve contro? logic circuits are armed in preparation for the time out of the prelube timer relay KD222 (25 seconds). The air atomizing air assist valve solenoid 1350-1 fs armed in preparation for a transfer to liquid fuel. @C1-cB_ 3.7/2.1 2.12 6/8411, Relay K210-5 contacts transfer. The liquid fuel pressure relay K286-2 and the ac main fuel pump interposing relay K843 are armed in preparation for a transfer to liquid fuel. 12. Relay K210-7 contacts transfer. The vibration/temperature monitor 7184 is switch to the offset values. The first out and only reset relay k200 is energized and locked-in. 13. At a preset increasing of] pressure, prelube of] pressure switch $3224 contacts transfer. The pneumatic start valve solenoid L355 is armed at the starter relay K230 normally open B contacts. Low P/P Lube Oi] Pressure malfunction circuit (DS2) of shutdown nonlockout relay K277 will be armed upon time out of prelube timer relay KD222 (25 seconds). GCl-CB 3.7/2.1 2.13 6/84Twenty-five seconds after Systems Start switch $110 is pressed: 1. Prelube timer relay KD222 (25 seconds) times out and contacts transfer. Prelube relays K222~1 and K222-2 and the valve sequence timer relay KD240 (5 seconds) are de-energized, . Prelube relay K222-1 contacts transfer. Low P/P Lube Oil Pressure malfunction circuit (DS2) of shutdown nonlockout relay K277 is armed and the prelube of] pressure switch S322A bypass circuit is opened. If 322A has not transferred at this time, relay K277 is de-energized and Low P/P Lube Oi] Pressure malfunction indication and engine shutdown is initiated. . Relay K222-2 contacts transfer and the starter relay K230 is energized and locked in until 66% engine speed. Crank timer relay KD243 (30 seconds) and start timer relay KD285 (9 minutes) are de-energized. . Relay K230 contacts transfer. The Gas Fuel Valve Failure malfunction circuit (DS15) of shutdown nonlockout relay K276 is armed. The pneunatic start valve solenoid L355 is energized and engine cranking begins. With the primary gas fuel pilot valve solenoids L341-1 and L341-2 energized, the pilot gas pressure opens the primary gas fuel valve to begin the valve check sequence. . Gas fuel pressure switch $342 closes at a preset increasing pressure (45 psi) to energize the high gas pressure relay K238. If switch $342 fails to close, a Gas Fuel Valve Failure malfunction (DS15) and an engine shutdown will be initiated at 15% engine speed in shutdown nonlockout. relay K276 circuit. . Five seconds later, valve sequence timer relay KD240 (5 seconds) times out. Contacts transfer and the primary gas fuel pilot valve solenoids 1341-1 and L341-2 are de-energized. Pilot gas pressure closes the primary gas fuel shutoff valve. 84-39621 2.14 8/84Engine speed reaches 15 percent: 1 Engine speed monitor unit 2283 contacts J-K and 2353 (backup overspeed) contacts H-J close to energize the 15% speed relays K242 series and purge timer relay KP241 (7 minutes). - Relay K242 contacts transfer and the 15% speed bypass circuit of the starter relay K230 is opened. The Fail To Crank malfunction circuit (DSi4) of shutdown nonlockout relay K276 is disarmed. Relay K242-1 contacts transfer to de-energize the liquid purge valve solenoid L345 and purge valve closes. The valve check relay K240-1 is energized and locked in. If the gas fuel pressure trapped between the primary and secondary gas fuel shutoff valves has diminished, indicating failure of the secondary valve, gas fuel pressure switch $342 will opene and de-energize the gas fuel pressure (High) relay K238. A Gas Fuel Valve Failure malfunction indication (DS15) and an engine shutdown will be initiated in shutdown nonlockout relay K276 circuit. . Valve check relay K240-1 contacts transfer to energize the secondary gas fuel valve pilot solenoid 1342. Secondary gas fuel valve pilot pressure is vented and the pressure is alloved to open the shutoff valve. The gas fuel pressure on switch $342 diminishes, contacts open at a preset decreasing presure, and gas fuel pressure (Low) relay K237 is energized. If gas fuel pressure (Low) relay k237 fails to energize, a Gas Fuel Valve Failure malfunction indication (DSi5) and an engine shutdown are initiated fn shutdown nonlockout relay K276 circuit. Relay k242-2 contacts transfer but are not functional during a gas fuel start. . Relay K242~3 contacts transfer. The 15% speed bypass in the start/run circuit is opened and the engine crank relays K293 and K293-1 are disarmed. Relay K242-4 contacts transfer. The Tightoff timer relay KD246 (15 seconds) is held energized until the time out of the purge timer relay KP241 (7 minutes). Thirty seconds after starter begins to crank the engine, crank timer relay KO243 (30 seconds) times out. Contacts transfer to de-energize the crank timer auxiliary relay K243-1 and open the bypass in Fail To Crank malfunction circuit (DS14) of shutdown nonlockout relay K276. 84-39621 2.15 8/84Seven minutes after engine speed reaches 15 percent: 1. Purge timer relay KP241 (7 minutes) times out and contacts transfer. Purge timer auxiliary relay K241, ignition exciter relay K245, gas fuel torch valve solenoid L340, primary gas fuel valve solenoids L341-1 and 1341-2, and acceleration control timer KP244 (35 seconds) are energized. Light off timer relay KD246 (15 seconds) is de-energized and begins to time out. GAS FUEL SYSTEM ACTIVATED indicator light DSi41-2 illuminates. 2. Relay K241 contacts transfer and the valve-check sequence in the Gas Fuel Valve Failure malfunction circuit (DS15) of shutdown nonlockout relay K276 is completed. 3. Pilot gas pressure opens the primary gas fuel shutoff valve, increasing gas pressure closes the gas fuel pressure switch $342, and gas fuel pressure (High) relay K238 is energized. Contacts transfer and Gas Fuel Valve Faflure malfunction circuit (DS15) of shutdown nonlockout relay K276 is disarmed. Ignition exciter G340 is energized, gas fuel is admitted to the igniter torch, and the spark plug ignites the torch. 4. Ramp generator 2249 output increases from zero to maximum over a preset time. Main fuel actuator L344 is energized to retract and gradually moves the throttle valve toward maximum fuel position enriching the fuel/air mixture. Lightoff of the mixture in the combustor occurs smoothly at an optimum fuel/air ratio. Engine turbine temperature reaches 350°F: 1, Engine TS temperature monitor unit 2282 contacts G-H-J transfer and disarm the Ignition Failure maifunction circuit (DS10) of shutdown nonlockout relay 278. Simultaneously, ramp control relay K239. is de-energized. Contacts transfer and control of the main fuel actuator L344 is switched from ramp generator 2249 to the main fuel actuator control unit 2244. Maximum 2244 output causes the main fuel actuator L344 to retract fully and move the throttle valve toward full acceleration position. 2. Should the turbine temperature exceed a preset threshold during acceleration to 90% engine speed, the main fuel actuator control unit 7244 output to the main fuel actuactor L344 will decrease and the actuator will extend to reduce fuel flow. Above 90% speed, control of the main fuel actuator L344 is transferred to the governor control unit 2251, 2244 is deactivated, and an overtemperature condition will cause an engine shutdown without any topping action. 84-39621 2.16 8/843, Fifteen seconds after torch is lit, lightoff timer relay KO246 (15 seconds) times out. Valve sequence timer relay KD240 (5 seconds) is de-energized. 4. Five seconds later, valve sequence timer relay KD240 (5 seconds) times out and contacts transfer to de-energize the start relay K246-1. 5. Relay K246-1 contacts transfer. The gas fuel torch valve solenoid L340, ramp generator 2249, ignition exciter relay K245, and ignition exciter G340 are de-energized. Gas fuel torch valve closes and the gas torch extinguishes. Temperature bypass In Ignition Failure malfunction circuit (0810) of shutdown nonlockout relay K278 is opened. If turbine temperature has not reached 350°F prior to the time-out of KO246 (15 seconds), Ignition Failure malfunction (DS10) indication and engine shutdown would have been initiated in shutdown nonlockout relay k278 circuit. Lubricating oil pressure increases: 1. At_ preset increasing pressure, the low of] pressure switch S380 contacts transfer and de-energize the lube pump relay K221. Pre/post lube motor B321 {s de-energized and pre/post lube punps stop 2. Low O11 Pressure malfunction circuit (DS1) of shutdown nonlockout relay k277_ is disarmed. If $380 contacts have not transferred by the time the engine reaches 66% speed, a Low Oi) Pressure malfunction indication and engine shutdown will be initiated in the shutdown nonlockout relay K277 circuit. 3. Low of1 pressure alarm switch S380-2 contacts transfer. The Low Lube 01 Pressure alarm circuit (DS27) of unit alarm relay K274 is disarmed. If switch $380-2 contacts have not transfered by the time the engine reaches 66% speed, a Low Lube O11 Pressure alarm indication will be initiated in unit alarm relay K274 circuit. GC1-CB 3.7/2.1 2.17 6/84Engine speed reaches 66 percent: 1 Engine speed monitor unit 2283 contacts P-R close. The 66% speed relays k251 series are energized. . Relay K251 contacts transfer. The starter relay K230 is de-energized. The field flash relay k260, regulator control relay K261, and the engine start counter M204 are energized. The low oi] pressure switch S380-2 66% speed bypass circuit is opened and the Low Lube Oil Pressure alarm circuit (0827) at unit alarm relay K274 is armed. . Relay K230 contacts transfer. The pneumatic load valve solenoid L355 is de-energized and engine cranking ceases. The Gas Fuel Valve Failure malfunction circuit (DS15) of shutdown nonlockout relay K276 is disabled. Relays 260 and K261 contacts transfer. Voltage regulator control Circuit is activated, generator field is flashed, and controlled generator field excitation begins. The generator space heater interposing relay K891 is de-energ:zed to shutoff the space heater. Relay K251-1 contacts transfer. The low oi] pressure switch $380 66% speed bypass circuit fs opened and the Low Oil Pressure malfunction circuit (DS1) of shutdown nonlockout relay K277 is armed. The hourmeter (elasped time indicator) M200 is energized and begins to log operating time. The guide vane actuator solenoid L339 1s energized and all engine compressor varfable inlet guide vanes begin to move toward the maximum open position. . Relay K251-2 contacts transfer. The low generator bearing pressure switch $398 66% speed bypass circuit is opened and the Low Oil Generator Bearing Pressure malfunction circuit (DS20) of shutdown nonlockout relay k279 is armed. Generator voltage increases: 1 Ata predetermined generator voltage level, the generator undervoltage sensing relay 2266 contacts transfer and ‘disarm the Undervoltage malfunction circuit (DS7) of shutdown nonlockout relay K278 circuit. . If proper voltage level had not been attained by the time the engine reaches 90% speed, an Undervoltage malfunction indication (DS7) and an engine shutdown would have been initiated in shutdown nonlockout relay K278 circuit. GC1-CB 3.7/2.1 2.18 6/84