Solar Gas Turbine Centaur 40

Pertamina Brandan
Operation and Maintenance Course

Yushup Armansyah
INDOTURBINE
Technical Service
 Operation and Maintenance Class

Course Timings

Morning 08:00 – 11.45

Lunch 11.45 – 13.30
Afternoon 13:30 - 15.00
 INDOTURBINE

General Package Description

 Objectives

• Purpose of the package

• Identify Package Major Element
• Describe the function of the package major
elements
• Identity remote and ancilary equipment
• identify package orientation
 Compressor set Application
A. Transmission
• from gas field to user

B. Storage/Re-injection
• gas injected to a storage site for
pressure maintenance or storage

C. Gathering
• gas collected upstream of the
plant booster

D. High Pressure
• >1500 psi discharge

E. Gas Lift
• gas injected to a well to aerate
Crude
 Purpose

The Gas Turbine and Gas Boost Compressor

Package provides a rise in Gas pressure for Pipeline
Applications. It includes all the necessary equipment
including the following major elements:
• Base frame or skid • All support systems
• Turbine engine – Fuel
• Gas Boost Compressor – Oil
• Interconnect shaft – Start
• Control system • Off-skid ancillary
equipment
– Air Inlet and Exhaust
– Fire system
– Enclosure ventilation
– Battery charger
– MCC, Switchgear, etc >
 Package Orientation

SOLAR PACKAGE ORIENTATION IS TO VIEW

THE PACKAGE FROM THE AFT OR EXHAUST END
 Package Major Element
Compressor Gage Panel Turbine Air Inlet
Compressor
Output Driver Shaft
Exhaust
Gas Turbine Engine

Skid Base Frame

 Package Major Element
Compressor Gage Panel Turbine Air Inlet
TCP

Compressor Output Driver Shaft Exhaust Gas Turbine Engine

Skid Base Frame

Base Frame (Driver Skid)
RIGID WELDED ASSEMBLY
MOUNTING FOR MAJOR
COMPONENTS
MOUNTING FOR ANCILLARIES
INTEGRAL OIL TANK
 Centaur 40 Gas Turbine Engine (2 Shaft)

Exhaust Collector

Accessory Drive

Power
Gas Turbine
Combuster Producer
Section Turbine
Diffuser

Compressor Section
 Centaur 40 Gas Turbine Engine (2 Shaft)

• Axial Compressor - 11 Stages

• Gas Producer Turbine – 2
Stages • Axial Compressor – 15 stages
• Power Turbine – 1 Stages • Fixed Stages – 9
• Combuster – Annular • Variable Stages – 6
• Fuel Injectors – 10 • Gas Producer Turbine – 2 stage
• T5 Thermocouple – 6 • Power Turbine – 2 stages
• Max T5 – 1190F • Combustor – Annular
• Pressure Ratio 11:1 • Fuel Injectors – 14 (SoLoNox)
• Output Power 4427 HP• Fuel Injectors – 21 (Conventiona
• T5 Thermocouples – 17
(4500HP)
• Max T5 – 13600F
• Gas Producer Speed 15000 • Pressure Ratio – 17.4:1
RPM • Output Power – 15000 shp
• Power Turbine Speed 15500 • GP Speed – 11,168 rpm
RPM • PT Speed – 9500 rpm
Oil System Component

Oil Filters
Accesory Gearbox
Starter
Oil Pumps
 Oil Pump Component

Fillers

Filters
AC Pump
DC BU Pump
 Oil Pump Component

AC Pump

DC Backup Pump
 Oil Pump Component

Fillers
AC Starter

Starter Motor
AC Starter

Motor
Starter
Exhaust And Power Turbine
 Ancillary Component

• Air Filters
• Exhaust System
• Oil Cooler
• Battery Charger
• Control Console
• MCC
• Fire System
• Enclosure Ventilation
• Yard Valve
• Anti Surge Valve
• Process Gas Cooling
 Typical Remote And Ancillary Equipment

Vent Silencer Turbine

Exhaust
Battery
Charger

Control
Console

Lube Oil
Cooler

Turbine Air
Intake
Typical Remote And Ancillary Equipment
Component Removal Equipment

Engine Trolley Beam

Extension
 Typical Enclosure and Ancillary
Equipment

Typical Offshore Package shown Self

Cleaning air filter system
Typical Enclosure and Ancillary
Equipment
 Enclosure Set Ancillary Equipment and
Enclosure

• Typical off-shore
package shown
• Enclosed package
• Enclosure ventilation
system
• Integrated fire system
• Gas detection
• Typical off-shore
package shown
• Enclosed package
• Enclosure ventilation
system
• Integrated fire system
• Gas detection
 Air Inlet Filter

Clean air is
essential in
maintaining
engine
performance
and longevity.
 Typical Exhaust Silencer

CAN BE INSTALLED AT 45 OR 90 DEGREE ANGLES

INCORPORATE EXPANSION BELLOWS
 Control Console

• Optional control console in non-

hazardous area
• Control switches and indicators
• Display panel with data logging
capability

• Main control system

components located on-skid
• Basic control switches and
indicators
• Operator Interface Panel
On-Skid Fire Control Panel
 Typical Air-to-Oil Cooler
Air Flow

Fan

Motor
 Typical Water to Oil Cooler

MORE
COMMON FOR
OFFSHORE
PLATFORMS
Typical Exhaust Silincer
Typical Battery Charger, Controls And
Indicator
 Other Ancillary Equipment

• Other equipment that may be installed

includes:
• MCC
– Electrical control of motors

• VFD’s
– Control of starter
Engine Skid – Aft Right
Engine Skid – Forward Right
Engine Skid – Aft Left
Engine Skid – Forward Left
Engine - Left Hand
Engine - Right Hand Side
Question
 CENTAUR 40
TURBINE ENGINE
 Early Gas Turbine

Leonardo da Vinci ingeniously used the hot gases from the fire for driving the spit, thereby cooking
the meat evenly. The conical shape of the chimney made the gases accelerate through the turbine.
Man studied birds and for years and attempted to copy their flight, it was
discovered that the wings of birds had airfoil sections . This airfoil wing section
gives birds lift when passing horizontally through the air. The air travels further
over the upper surface of the airfoil thus causing a loss of some pressure,
consequently permitting the normal pressure under the wing to give the wing
a ‘lift’ upwards. All that was needed now was the forward motion - what man
needed was a means of propulsion.
Thrust and Reaction

Garden water-sprinkler -
rotated by reaction to the water jets.

Artillery Gun -
Shell streaks away, gun leaps back
Hero

Hero made a toy called AEOLOPILE to

show that when steam-jet issues from a
freely-mounted wheel, the wheel is caused
to revolve in the opposite direction to that
of the jet, once again demonstrating
ACTION and the resultant REACTION.
In 1687, Isaac Newton set this fact down
in his ‘Third Law of Motion’, to the effect
that ‘to every ACTION there is an equal
and opposite REACTION’.

Hero’s Aeolopile is reputed to be the first

apparatus converting steam pressure into
mechanical power. It was probably the
earliest demonstration of the principle of
jet reaction.
 Objectives

• State The Purpose of the engine

• Describe the Brayton Cycle
• Identify the different section of the
engine, and describe their purpose
• Describe how the air system is used for surge
avoidance sealing and cooling
• Identify the four engine support system
 Centaur Turbine Engine Purpose

HEAT ENGINE TAKE CHEMICAL

ENERGY AIR AND FUEL

CONVERTS TO MECHANICAL
ENERGY ROTATIONAL TORQUE TO
DRIVE OTHER EQUIPMENT
 Centaur Turbine Engine – Basic Data

• Axial Compressor - 11 Stages

• Gas Producer Turbine – 2
Stages
• Power Turbine – 1 Stages
• Combuster – Annular
• Fuel Injectors – 10
• T5 Thermocouple – 6
• Max T5 – 1190F
• Pressure Ratio 11:1
• Output Power 4427 HP
(4500HP)
• Gas Producer Speed 15000
RPM
• Power Turbine Speed 15500
RPM
OPERATING PRINCIPLES

BRAYTON CYCLE
 Brayton Cycle

• COMPRESSION
- Atmospheric Air Is compressed
• COMBUSTION
- Fuel is added and ignited
• EXPANSION
- The Hot Gases Expand Through a Turbine
• EXHAUST
- The Gases are expelled to atmosphere
Brayton Cycle
 How a Turbine Works

SHAFT
 How a Turbine Works

SHAFT

Air
Inlet

Compressor
 How a Turbine Works

Shaft
Fuel Injector

Air
Inlet

Combustor

Compressor
 How a Turbine Works

Shaft
Fuel Injector

Air
Inlet

Gas Generator
Turbine

Combustor

Compressor
 How a Turbine Works

EXHAUST GAS

Shaft
SHAFT

Fuel
FUELInjector
INJECTOR OUTPUT
SHAFT
Output Shaft
Air
Inlet POWER
AIR INLET PowerTURBINE
Turbine

GasGAS
Generator
GENERATOR
Turbine
TURBINE

Combustor
COMBUSTOR

Compressor
COMPRESSOR
 Simplified gas turbine arrangement

Gas turbine

A
V Compressor Combustion Turbine

The compressor sucks air in and compresses it, the action of compressing the air

O
heats it up and hot, high pressure air is passed into the combustion chamber,
mixed with fuel and ignited. This increases the pressure and temperature further
and the gases are passed to the turbine, which acts like a series of windmills with
the nozzle guide vanes directing the hot gases from the combustion chamber into
the rows of rotating turbine blades. These blades are attached to large discs

N
which are directly connected to the compressor.

main menu
 Brayton Cycle VS OTO Cycle

Simplified gas turbin e arrangement

Working Cycle

Gas Turbine

CONTINOUS AND SIMULTANEOUS CYCLE

A
V Piston Engine

O SUCK SQUEEZE BANG BLOW

N m ain me nu
 Brayton Cycle – Constant Pressure
Cycle
PRESSURE / VOLUME
1. P - Up / V - Down
2. P - Constant / V - Up
3. P - Down / V - Up
4. P - Constant / V – Down

PRESSURE / TEMP
1. P - Up / T - Up
2. P - Constant / T - Up
3. P - Down / T - Down
4. P - Constant / T - Down
 Ducts
Subsonic airflow through DIVERGENT DUCT - as in compressor
PRINCIPLE
Velocity - decreasing
EXAMPLE
Pressure - increasing Typical axial flow compressor outlet
Temperature - increasing casing

Divergent ducts are used in :

1. The passages between rotor blades and between
the vanes of the axial compressor.
2. The passages between the impeller-vanes of
centrifugal compressor, and their discharge diffusers.
3. Compressor delivery casings
 Subsonic airflow through a Convergent Duct - as in a turbine

PRINCIPLE EXAMPLE

Velocity - increasing Flow through turbine nozzle guide vanes

Pressure - decreasing
Temperature - decreasing

Convergent ducts are used in the passages between rotor blades and nozzle guide-vanes in turbine sections

BASICS
 An axial flow compressor consists of one or more rotor assemblies that
carry blades of airfoil section. These assemblies are mounted between bearings
in the casings which incorporate the stator vanes.The passageway between each
blade on the rotor and between each stator vane is made to form a divergent duct.
Moving rotor-blades draw in air at the front of the compressor and force it rearwards,
thereby increasing its velocity and its pressure due to the mechanical force and the
shape of the passageways.

Compressor
In the stator vane passages the velocity is converted into pressure, again
by the divergent form of the passageway, the air is lined up for the next row
of moving blades.This process repeats itself throughout the compressor,
increasing pressure by 10-20% at each stage.

BASICS
 Pressure In An Axial Compressor

BASICS
Pressure and velocity increase in a axial flow compressor
 COMPRESSION

• Great amount of
mass air
• Compression ratio +
10-13
• Axial Compressor
• Rotor
• Stator
• Number of stages
• PCD
 COMBUSTION

• Annular
• Perfect Combustion.
• 15%-20% air enter the
Combustion.
• Initial firing by ignition
torch
• Flame pattern
determined by FGCV,
fuel nozzles, holes
• Mechanically centered
held by fuel injectors
 EXPANSION

• Split or Single shaft power

Turbine
• Newton III Law (Action-
Reaction)
• Impuls Force
• Nozzles and blade
arrangement.
• The highest rotating parts
temperature
• Temperature drops as it
pass the blades.
 Brayton Energy Transfer Cycle

COMPRESSION COMBUSTION EXPANSION Exhaust

AIR IS DRAWN FUEL IS ADDED THE HOT GASES HOT GASES
INTO THE 11 AND IGNITED EXPAND THROUGH EXPELLED TO
STAGE AXIAL CAUSING RAPID A TURBINE AND ATMOSHPHERE
COMPRESSOR EXPANSION ENERGY SOMITIMES
AND COMPRESSED EXTRACTED THROUGH A HEAT
EXCHANGER

IN A 2 SHAFT TURBINE THE TURBINE IS SPLIT INTO 2 – THE FWD STAGES DRIVE
THE GP COMPRESSOR, THE REAR STAGES EXTRACT THE REMAINING ENERGY
TO DRIVE THE OUTPUT SHAFT
 ENGINE CONTROL

• Two shaft engines are used for applications that require

variable speed drive to the driven-equipment
– Compressors and pumps
• During startup the fuel system will be managed to accelerate
the Gas Producer (GP) to idle speed (normally 72% NGP)
• At some point, during acceleration to idle, depending on the
compressor load placed on the Power Turbine (PT), the PT will
breakaway
• Gas Producer speed will then be controlled in order to
maintain a desired PT speed, and therefore Boost Compressor
speed
– This can be managed according to Suction pressure,
Discharge pressure or Flow requirements
 ENGINE CONTROL

• The actual PT speed will depend on two factors:

1. NGP speed and therefore available power
2. Load on the Boost Compressor
• As Boost Compressor load increases, the PT speed would tend
to drop
• The control system will increase the fuel flow, and this will
increase the NGP
• More power is now “left over” to drive the PT, and the NPT will
remain constant (until the setpoint is changed by the operator)
• ALTHOUGH WE ARE DIRECTLY CONTROLLING NGP, THE NET
EFFECT IS TO CONTROL NPT AND THEREFORE THE PROCESS
GAS CONDITIONS
• Maximum load is achieved when one of the following conditions
applies:
– Maximum NGP (100%)
– Maximum NPT (100%)
– Maximum engine temperature (T5 – 1190F) >
 Temperature and Pressure

• We monitor and sometimes control pressure and

temperature at various points in the engine
• The main terms you may hear are:
• T1 – Ambient Temperature
• TPZ – Temperature Primary Zone (Highest Temp)
• T3 – 1st Stage Turbine Rotor Inlet Temperature (Critical)
• T5 – 3rd Stage Rotor Inlet Temperature (Control)
• T7 – Exhaust Temperature (Option)
• P1 – Ambient Pressure
• P2 – Compressor Discharge Pressure (PCD)
(Highest Pressure) >
 Temperature and Pressure Station
T1/P1
Ambient Air Pressure
and Temperature

T2/PCD
Measured at the
diffuser, compressor
discharge pressure
and temperature

TPZ
Temperature of the
Primary Zone
(Fireball)

T3/TRIT
Turbine Rotor Inlet
Temperature

T5
Highest Measured
Temperature on the
Engine
 Surge Control (Engine Compressor Stall)

• During start up the compressor FWD stages

produce more air than the AFT stages can accept
• This would cause a back-pressure and may result
in a damaging condition called ENGINE SURGE
or ENGINE STALL
• To avoid engine stall:
– Excessive air is removed from the engine at low speeds
by opening up a Bleed Valve
– Variable guide vanes on the first 3 stages are partially
closed to limit the airflow entering the engine >
 Engine Surge / Stall Control

• SURGE or STALL = REVERSAL OF AIRFLOW

• SYMPTOMS
– High T5
– Low PCD
– Failure to accelerate
– Axial vibration
• RESULTS IN
– Bearing and seal damage
– Blade damage
• IF YOU SUSPECT ENGINE SURGE / STALL
– Shutdown the engine >
 Effect of Engine Surge

Extreme amounts of force exerted on compressor

rotor
Surge Effect
DIRECT AC START SYSTEM
 LESSON OBJECTIVES

• State the function of the Direct AC Start System

• Identify and state the function of the major
components
• Describe system operation during start and test
crank
• List annunciations and explain possible
conditions for each
 PURPOSE

• Centaur turbine engines are “self-sustaining” at 60%

NGP
• This point is known as “starter drop out”
• They require rotational torque for initial cranking and
up to this speed
• This is provided by the start system
• The start system can also be used to crank the
engine at approximately 20% speed for maintenance
such as engine cleaning
 MAJOR COMPONENT

1. Variable Frequency Drive (VFD)

2. Electric Motor
3. Adapter and clutch assembly
 VFD Controller

• VFD430 works on the principle of

Pulse Width Modulation
• VFD430 communicates with the
Controller via ControlNet
• Start, Stop commands are sent from the
Controller Via this network
• Status information is sent to the
Controller from the VFD
VFD KEYPAD

CONTROLNET
Pulse Width Modulation
 Starter Motor

Low Maintenance
Internal Heaters
Thermal Detectors for motor
protection
 Sprag Clutch

1. Over-Running Clutch
2. Disengages as the turbine
begins to rotate faster than
the starter.
3. Prevents the AC Motor from
rotating at engine speed
4. Allows for easy re-
engagement when the
engine is restarted
Sprag Clutch Operation
DAC Start Schematic