Professional Documents
Culture Documents
Part One Gas
Part One Gas
Part One Gas
Mechanical
Engineering
Electrical
Engineering
Petrochemical
Electronic
ICT
Instrumentation
Automation and
Process Control
Data
Communications
& Networking
Cement
Industry
Chemistry &
Laboratory
Project
management
Supply chain
management
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4
Part #4:
Gas Turbine Auxiliary Systems
All rights reserved / Omar Zaareer 2015
Gas Turbine
Topics to be discussed
5) Auxiliary Systems:
Gas Turbine Lubricating Oil System
Hydraulic Supply System and Inlet Guide Vane
Atomizing Air System
Fuel Purge.
Cooling and Sealing Air System.
:
(Compressor bearing)
(Turbine bearing)
(Generator bearing)
Control Oil
:
.
.
All rights reserved / Omar Zaareer 2015
Oil tank
Oil pumps
Oil filters& strainer
Oil cooler
Oil heater
Control valves and protection
devices
) (pretrip
) (Trip
.
.
All rights reserved / Omar Zaareer 2015
.
.
.
.
.
.
:
, Bearing
.
Part #1
Part #1
-1 Common Terms & Abbreviations
-2 (Symbols- Piping) PID
-3 Power Plant History
-4 Power Plant Conception
-5 Power Plant Forms
-1
1- COMMON TERMS AND ABBREVIATIONS
GT - Gas Turbine
CT Combustion Turbine
CTG Combustion Turbine Generator
GTG Gas Turbine Generator
ST - Steam Turbine
STG Steam Turbine Generator
.1939
2
)
, .( ....
Brayton Cycle
Rankine Cycle
Brayton cycle less efficient than Rankine Cycle
Combustion control,
Compressor and turbine blade design,
Metallurgy ) (
Closer tolerances between rotating blades and stationary
parts. ) (
.
) ( %35
.
All rights reserved / Omar Zaareer 2015
Conventional Steam Power Plant
Cooling System
treatment plant)
Simple Cycle Power Plant
Compressor
Combustor
Turbine
Accessory Drive Assembly
COMBUSTION
CHAMBER
WORK
TURBINE
COMPRESSOR
EXHAUST
AIR
All rights reserved / Omar Zaareer 2015
reserved
/ Omar
Zaareer 2015
Brayton Cycle
COMBINED CYCLE
Combined
Part #1 with Part #2
COMBINED CYCLE
EXHAUST
COMBUSTION
CHAMBER
CC
Plant
AIR
+
COMPRESSOR
FUEL
TURBINE
WORK
:
(CTG)
Combined Cycle
Overview the Process
Reduced Maintenance
Reduced Environmental Impact.
Reduced Costs
Less capital equipment than conventional steam power
plants
Significantly reduced construction time
All rights reserved / Omar Zaareer 2015
Reduced Maintenance
Reduced Environmental Impact
Low NOx burners used on modern gas turbines
Further NOx reduction by use of Selective Catalytic Reduction
(SCR) with ammonia injection on HRSG
Part #2:
Gas Turbine Major Components
Gas Turbine
Topics to be discussed
1) Gas Turbine Overview.
2) Major Components
4) Turbine Section
All rights reserved / Omar Zaareer 2015
Gas Turbine
Gas Turbine
2) Major Components
Air Puls
:
)(Supply pipe
) (Shut off Valve
) (Control Valve
:
,
.
Control valve
5+ 5 -
All rights reserved / Omar Zaareer 2015
Gas Turbine
2) Major Components
Compressor Section
Air Compressor
The Role
Air Compressor
Air Compressor
Type of Air Compressors
Centrifugal Compressors
Axial Compressors
Rotor
Blades
Stator
Vanes
Impeller
Diffuser
Manifold
All rights reserved / Omar Zaareer 2015
Air Compressor
Centrifugal Compressors (Principles of Operation)
Centrifugal compressor consists of an impeller, a diffuser and a manifold
Compressor receives air at the center of the impeller in an axial direction
Air is accelerated outward by centrifugal reaction to its rotational speed
Air is then allowed to expand into divergent duct, called a diffuser
According to Bernoullis Principle, as the air spreads, its speed slows and static
pressure builds
The manifold distributes the air in a turbulence free condition to the
combustion section
Advantages: High pressure rise per stage,
Good Efficiency, Simplicity of manufacture,
Low cost, Low weight, Low starting power
requirements
Air Compressor
Air Compressor
Pressure and Velocity Variation in Axial Compressors
Air Compressor
Pressure and Velocity Variation in Axial Compressors
Air Compressor
Air Compressor
Air Compressor
Variable inlet guide vanes (IGV)
1 Pivot pin
2 Airfoil
6 Stationary blade carrier
7 Outer ring
8 Inner ring
All rights reserved / Omar Zaareer 2015
Air Compressor
Surge phenomenon
&
Surge Protection
Air Compressor
Surge
Topics to be discussed:
Air Compressor
What is the surge?
Air Compressor
Surge control
Air Compressor
)Blowoff (Bleed Valves
..
:
.%76
:
.
:
)
(.
:
Blowoff .
) Trip (
Trip
.
All rights reserved / Omar Zaareer 2015
Air Compressor
)Blowoff (Bleed Valves
..
:Compressor Wash Manually
, .
: . Blowoff - Trip .
Air Compressor
Blowoff (Bleed Valves)
Air Compressor
Blowoff (Bleed Valves)
Gas Turbine
2) Major Components
Combustion Chamber
All rights reserved / Omar Zaareer 2015
Combustion Chamber
chamber
basically consists of an
Principles
The combustionof
Operation
outer casing, an inner perforated liner, a fuel
injection system, and a starting ignition system.
The function is to add heat energy to the flowing
gases, thereby expanding and accelerating the
gases into the turbine section
When the fuel heat is added, the volume of the
gas is increased and, with flow area remaining the
same, this causes an acceleration of gases to occur.
Interaction of oxygen molecules and molecules of
fuel which are heated to ignition temperatures
results in combustion
Proper mixing of air and fuel leads to an efficient
functioning of combustion chamber
The combustion chamber must cool hot
combustion products to a temperature which the
turbine section components can withstand
All rights reserved / Omar Zaareer 2015
Combustion Chamber
Flame Tube is
placed inside
the air casing.
consists of
a fuel spray
a combustion
zone.
a spark plug if
necessary
Combustion Chamber
Combustion Chamber
Flame detectors
indicate the
control system
whether or not
flame exists in
the cans they are
mounted on.
In some standard
combustors, spark
plugs are
retractable. They are
pushed outward to
remove the plug
from the flame zone.
This ensures a
longer life for the
spark plug.
Combustion Chamber
Multi-Can Combustor
This older type
combustor consists of
multiple outer housing,
each with its own
perforated inner liner.
Each of the multiple
combustors (cans) is in
effect a separate
burner unit.
Can-Annular Combustor
Annular Combustor
Combustion Chamber
Combustion
Chamber
2*8 Hybrid
Burners
T Bearing
Turbine
C Bearing
Compressor
Combustion Chamber
COMBUSTION CHAMBERS FEATURES
Combustion Chamber
HYBRID BURNER
HYBRID BURNER
Combustion Chamber
HYBRID BURNER
HYBRID BURNER
Combustion Chamber
HYBRID BURNER
Combustion Chamber
HYBRID BURNER
premix burner
) Nox and
(CO
Diffusion
.
Diffusion.
Gas Turbine
2) Major Components
Turbine Section
All rights reserved / Omar Zaareer 2015
Turbine
The Role
The role of the turbine section is
to transform a major portion of
the kinetic energy and heat
energy in the exhaust gases into
mechanical work, thereby
enabling the turbine to drive the
compressor and accessories.
The turbine section is bolted to
the combustion chamber and
contains the turbine wheels and
turbine stators.
Recall that the compressor adds
energy to air by increasing its
pressure. The turbine extracts
energy by reducing pressure of the
flowing gases
Turbine
Gas Flow Through Stator and Rotor
Turbine
The turbine wheels are assembled by
vertically stacking them. This
eliminates sagging. The tie bolts are
weighed, numbered and distributed
to eliminate imbalance.
Turbine
The first stage buckets are
installed initially by inserting
the first bucket into the dovetail
slot made in the wheel.
Turbine
Turbine
Part #3:
Simple Cycle Improvement
Regeneration
9
5.5
Regenerator
3.5
Inlet
Compressor
4.5
Combustor
4
Turbine
Power
Turbine
net
output
work
Intercooling
9
Intercooler
Combustor
4.5
Inlet
1
2
5
3
Compressor 1
Compressor 2
Turbine
Power
Turbine
net
output
work
Reheating
9
Reheater
Combustor
Inlet
1
2
5
3
Compressor
Turbine
Power
Turbine
net
output
work
Single Shaft
9
Combustor
Inlet
1
2
5
3
Compressor
Turbine
net
output
work
Double Shaft
9
Combustor
Inlet
1
2
5
3
Compressor
Turbine
Power
Turbine
net
output
work
Combustor
Inlet
1
2
5
3
net
output
work
Compressor
Turbine
Power
Turbine
Triple Shaft
9
Combustor
Inlet
1
2
5
3
Compressor 1
Compressor 2
Turbine 2
Turbine 1
Power
Turbine
net
output
work
5
Part #5:
Gas Turbine Maintenance
3/2/2015
3/2/2015
Omar Zaareer 2015
Agenda
3/2/2015
GT Maintenance Considerations
Typical Inspection Scopes
Factors That Affect the Maintenance Cycle
Conclusion
Questions
GT Maintenance Considerations
All GTs require regular maintenance.
A typical maintenance regime is given below: Combustion inspection every 8,000 12,000 hrs or
800 starts
Hot gas path inspection every 24,000 hrs or 1200
starts
Major Inspection every 48,000 hrs or 2400 starts
Inspections may have other titles such as A,B or C
inspections, or Level 1,2 or 3 inspections.
The intention is the same.
3/2/2015
GT Maintenance Considerations
Major Inspection
H.G.P.
Inspection
Combustio
n
Inspection
3/2/2015
Inspection Scopes
The combustion inspection
The most frequent inspection, looks at: Fuel nozzles, combustion liners, transition pieces
Hot Gas Path Inspection
Includes a combustion inspection and the following: Turbine stage rotating and stationary parts
Major Inspection
Includes all of the above inspections plus a compressor
and bearing inspection.
3/2/2015
3/2/2015
3/2/2015
Conclusion
Gas turbine fatigue and wear mechanisms are highly
dependant on: Operational duty
Fuel selection
The environment.
3/2/2015
Operating Procedures
Gas Turbine
Cause
Action
L30HRX3
L30AC_ALM
L30AF_ALM
L63CTSL_ALM
(Not Used)
L63ADLA
L63ADL_ALM
L26AAH_ALM
Failure of atomizing
precooler louvers to open
and close.
L86S
Auto Synchronizing
Lockout
Auto synchronizing
self-checking system has
detected a synchronizing
equipment abnormality.
Investigate synchronization
system to determine exact
cause of problem.
L83COMF
L52HQ_ALM
Accessory gear-driven
hydraulic pump has not
supplied sufficient
pressure because of leaks
or failure of pump.
L52QA_ALM
L49X_ALM
L52QS_ALM
ATCMKV-1
Gas Turbine
Operating Procedures
Cause
Action
Battery Charger AC
Undervoltage
Battery charger AC
undervoltage.
Battery DC Undervoltage
Bearing Drain
Temperature High
Bearing Metal
Temperature High
L27VVN_ALM
L27BN_ALM
Bus Undervoltage
No Auto Synch
Bus synchronizing
potential not available.
L28FD_SD
L30SPA
Combustion Trouble
LCOM_B_ALM
Common IO
Communication Loss
<C> processor is no
longer communicating.
L27BLN_ALM
L30LOA
ATCMKV-2
Operating Procedures
Gas Turbine
Cause
Action
L86CB1
L86TCI
Compressor Inlet
Thermocouples Disagree
L26CTH_ALM
L12HF
L12HFD_C
L12HFD_P
L12LF
L30CD
Cooldown Trouble
Unit failed to go on
cooldown, or the
cooldown cycle was
aborted prior to cooldown
timer timeout.
L52FC_ALM
L71WL_ALM
L63QQ3H_ALM
Clogged filter.
Replace filter.
L3CP_ALM
L4CT_ALM
Customer Trip
Customer-Specific
Alarms <C>
ATCMKV-3
Gas Turbine
Operating Procedures
Cause
Action
Customer-Specific
Alarms <Q>
L27QEL_ALM
DC Motor Undervoltage
(Lube Oil)
L30DIAG_C
L30DIAG_Q
The microprocessor
Call up diagnostic display.
self-checking program has
uncovered a control panel
problem.
L26DWH_ALM
L2DWZ2
L48DSX
L4DEY_ALM
L63QDN_ALM
L83DT1
L63LF2H_ALM
Clogged filter.
Replace filter.
L26FD1H_ALM
Distillate Fuel
Temperature High
L12H
Electrical Overspeed
Trip - HP
ATCMKV-4
Operating Procedures
Gas Turbine
Cause
Action
L12L
Electrical Overspeed
Trip - LP
L72QEZ_ALM
L72ES_ALM
L59E_ALM
Exciter Overvoltage
Check exciter.
L94EK
L26SFH_ALM
L86TXT_C
Exhaust Overtemperature
Trip <C>
L86TXT
Exhaust Overtemperature
Trip
L63TK_ALM
L90TKL
L63EAH_ALM
L63ETH
L63ETHX_ALM
ATCMKV-5
Gas Turbine
Operating Procedures
Cause
Action
L30TXA
Exhaust Temperature
High
L30TXA_C
Exhaust Temperature
High <C>
L30SPTA
Exhaust Thermocouple
Trouble
Faulty thermocouple.
Check thermocouples.
L86TFB
Exhaust Thermocouples
Open Trip
Excessive number of
thermocouples not
connected.
L63FLZ_FLT
Failure to Establish
Liquid Fuel Press.
L30FD_ALM
Failure to Ignite
L62TT2_ALM
Failure to Start
L3Z
Failure to Synchronize
L45FTX2_ALM
L45FTX1_ALM
Fire in Zone #1 or
Zone #2 Trip
ATCMKV-6
Operating Procedures
Gas Turbine
Cause
Action
L45FAX_ALM
L28FD_ALM
L60FSRG
L3GCVFLT
Check LVDT.
L63HGL_SENSR
L63HGL_ALM
L3GFIVP
L63PGFT
L94PGT
Either VA13-1 or -2 or
20VG-2 are stuck open
and machine has tripped.
Gas may be backing
through the system.
L33PGFT
VA13-1 or -2 are
obstructed.
L33PGO_ALM
Check valve.
L63FGL_ALM
ATCMKV-7
Gas Turbine
Operating Procedures
Cause
Action
L3GRVFLT
Check LVDT.
L63CA3L_ALM
L43HPA_ALM
L52GA_ALM
L63GFH_ALM
L63BQL_ALM
Generator Bearing
Vacuum Low
L52G_ALM
Generator Breaker
Tripped
L63GKL_ALM
Generator Casing
Hydrogen Press. Low
L71WGH_ALM
L33GCC_ALM
L86TGT_ALM
Generator Differential
Trip
A generator panel
protective device has
tripped the 86G lockout
relay.
L64F_ALM
ATCMKV-8
Operating Procedures
Gas Turbine
Cause
Action
L94H_ALM
Generator Hydrogen
Purge Shutdown
L49GH_ALM
Generator stator
temperature is excessive
caused by lack of cooling
or overload.
L94GEN
Generator Ventilation
Trouble Shutdown
Temperature in generator
compartment exceeds
limits. Vent fans
inoperable or insufficient
to handle ventilation
requirements.
L63FU2LA
L26FU2LA
L3FUZ
L30SPT
L39VA
L39VTX_ALM
L30TNH_DIFF
HP Speed Signal
Differential Alarm
ATCMKV-9
Gas Turbine
Operating Procedures
Cause
Action
L63HF1H_ALM
Hydraulic Filter
Clogged filter.
Differential Pressure High
L86HD
Hydraulic Protective
Trouble
L63HQ1L_ALM
Hydraulic Supply
Pressure Low
L27GHN_ALM
L63GL_GH_AL
L63HHL_ALM
L30HP
LWLX4MIN
LWLXHR
L86GVA
L4IGVT
L3IGVFLT
Check servos.
L30TNI_DIFF
IP Speed Signal
Differential Alarm
ATCMKV-10
Operating Procedures
Gas Turbine
Cause
Action
L71WG_ALM
Liquid Detected in
Generator
L3LFLT
L63LF1H_ALM
L30FQL_DIFF
L63HL_SENSR
L63HLL_ALM
L63FLZ_ALM
L3LFP_FLT
Liquid Fuel Pump Control Problem with one or more Troubleshoot liquid fuel
Trouble
control devices.
pump control components to
determine problem and
correct.
L33FL_ALM
L26FL2LA
L3TFLT
Loss of Compressor
Discharge Pressure Bias
L3DWRF
Determine abnormal
condition by reading signals
(L3LFLT1 to L3LFLT5).
ATCMKV-11
Gas Turbine
Operating Procedures
Cause
Action
L28FDT
L63QTX
L30TNL_DIFF
LP Speed Signal
Differential Alarm
L26QA_ALM
L26QT_ALM
L71QH_ALM
L71QL_ALM
L63QA1L_ALM
L63QT_SENSR
L26QN_ALM
L26QT_SENSR
L63QQ1H_ALM
Clogged filter.
ATCMKV-12
Operating Procedures
Gas Turbine
Cause
Action
L43MAINT
Maintenance - Forcing
Mode Enable
L86MAN_SYNC
Manual Synchronizing
Lockout
L5E_ALM
Manual Trip
L86MP
L27MC1N_ALM
MCC Undervoltage
L30LTA
No. 3 Bearing
Temperature High
L33BS_ALM
Valve incorrectly
positioned.
L3NZFLT
L43DIAG_ALM
Off-Line Diagnostics
Running
Off-line diagnostic
operation has been
selected.
L3WCTIM_ALM
Ambient temperature is
below 50 deg F.
L12HBLT_ALM
L83HOST
L83LOST
ATCMKV-13
Gas Turbine
Operating Procedures
Cause
Action
L30EK
L4ETR_FLT
L12H_P_ALM
Protective Module
Overspeed Trip - HP
<P> module HP
overspeed trip.
Investigate cause of
overspeed.
L12L_P_ALM
Protective Module
Overspeed Trip - LP
L12LF_OS
L30HRX2
L49HR1A_ALM
L30HRX1
Ratchet Trouble
L30RHFLTX
R5E_ALM
L63SAL_ALM
L63ST
L71SDH_ALM
L63STX_ALM
L30WC_LAG
ATCMKV-14
Operating Procedures
Gas Turbine
Cause
Action
L30FD_LAG
L4DT
L3SMT
L4CRT
L49CR_ALM
L86CRTX
L2SFT
L30EKR
L60APHA_ALM
L60APHT
Steam augmentation
Correct problem before
system tripped due to high restarting steam
pressure.
augmentation.
L60ATHT
Steam augmentation
Correct problem before
system tripped due to high restarting steam
temperature.
augmentation.
L60ATHA_ALM
L60APLA_ALM
L60ALPT_ALM
Steam augmentation
system tripped due to low
pressure.
ATCMKV-15
Gas Turbine
Operating Procedures
Cause
Action
L60ATLT_ALM
Steam augmentation
system tripped due to low
temperature.
L60ATLA_ALM
L60WL1_ALM
L60WQPL_ALM
L30SJ
L60SPHA_ALM
L60SPHT_ALM
L60SPLA_ALM
L60SPLT_ALM
L60STHA_ALM
L60STHT_ALM
L60STLA_ALM
L60STLT_ALM
LWLXHR
L63QQ2H_ALM
Clogged filter.
Replace filter.
L63TF1H_ALM
Clogged filter.
Replace filter.
L63TFH_ALM
L63TFH_SENSR
ATCMKV-16
Operating Procedures
Gas Turbine
Cause
Action
L30TFX
L26BT1H_ALM
Turbine Compartment
Temp High
L83KU_ALM
Turbine Compressor
Abrasive Cleaning
Selected
Compressor being
cleaned.
L48
Turbine Incomplete
Sequence
L3A
Turbine Underspeed
L39VD3_ALM
Vibration protection
system problem.
L39VDIFF
Vibration Differential
Trouble
Vibration protection
system problem.
L39VD1
L39VF
Vibration Transducer
Fault
Vibration detector
impedance is not within
normal bounds.
L3WFD_ALM
A disagreement between
Determine failed sensor and
the water flow sensors has replace.
been detected.
L86WN3
L3WFLT_ALM
L86WN1
L86WN2
ATCMKV-17
Gas Turbine
Operating Procedures
Cause
Action
L30WN
L26JS2H_ALM
L26ALL_ALM
Failure of heaters.
L86WN4
L3WSFLT_ALM
L30TWW
L30WSA1
Wheelspace Temp
Differential High
Excessive differential
between wheelspace
thermocouples.
L30WSA2
Wheelspace Temperature
High
ATCMKV-18
Questions
3/2/2015
Part#6
Startup \ Shutdown
3/2/2015
Ensure all permits to work related to GT clear and no any body in the gas turbine and
) (there is no tools in it .
) ( All electrical panels energized & available
( Control cabinets energized and operation
All fluids system available and normal level and temperature
. .
Fire fighting system healthy & energized
No alarms on alarm list.
) Check all doors of the unit in operation position .(filter of air inlet
IGV in auto and remote mode.
Omar Zaareer 2015
3/2/2015
3/2/2015
GT START Up
.
3/2/2015
GT START Up
:
10 %
SFC
350
ESV Pilot line 23 %
.
3/2/2015
GT START Up
RPM 500
RPM 2200 SFC
RPM 2900 1 2 .
RPM 2970 3
RPM3000
526 %100
.
3/2/2015
(A
)
SEQL9ESTD
(B
)
SEQL9ESTD
SEQL9ESTD
(A
)
SEQL9ESTD
(B
)
SEQL9ESTD
3/2/2015
3/2/2015
GT START Up
NG-STOP VALVE
GT START UP
NG CV
GT speed
100
500
OTC
90
450
400
NG stop valve
Speed
controller
active
70
350
60
300
50
250
Start up function active
40
200
SFC OFF
30
20
150
100
First gradient
10
50
Second gradient
0
0
50
100
150
200
250
TIME [s]
3/2/2015
300
350
400
450
0
500
OTC [C]
80
GT START Up
3/2/2015
3/2/2015
GT START Up
3/2/2015
GT START Up
3/2/2015
GT LOADING/UNLOADING GRADIENTS
MW
NORMAL:
11 MW/min
FAST:
15 MW/min
SLOW:
3/2/2015
GT Shutdown
Shutdown
diffusion line pilot line ESV
500 RPM
180RPM
)(Turning gear operation 130
.
3/2/2015
3/2/2015
GT Shutdown
3/2/2015