(GAS TURBINE MS 5001 PA) Volume I

g GE Oil & Gas Nuovo Pignone
INSTRUCTION, OPERATION AND

MAINTENANCE MANUAL
(GAS TURBINE MS 5001 PA)
Volume I
Gas Turbine Starting
NUOVO PIGNONE JOB : 170.5703-04

CUSTOMER : INTERNATIONAL FREE COMPANY
SERVICE : TURBOGENERATOR
PLANT LOCATION : DAURA (IRAQ)
N.P. DOC. No. : MAN 170.5703
MANUFACTURER : GE Oil & Gas

Nuovo Pignone
Via F. Matteucci, 2
50127 Florence - Italy
Telephone (055) 423211
Telefax (055) 4232800
03-09-E 170.5703-04 P. 1-1
MOD. INPR/SVIL/ P.F. 12/00

g GE Oil & Gas Volume I Nuovo Pignone
N.P. Job: 170.5703-04
GENERAL INDEX
The present Instructions Manual concerning the Turbogenerator is subdivided into

five sections, as follows:
System Description Section 1
Installation Section 2
Commissioning Section 3
Initial Start-up Section 4
Technical Documents Section 5
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INDEX
Contents Page
1. INTRODUCTION .......................................................................................................1
2. GAS TURBINE DESCRIPTION ...............................................................................2

2.1 Functional description...........................................................................................2
2.2 Compressor Section ..............................................................................................4
2.3 Combustion Section..............................................................................................5
2.4 Turbine section .....................................................................................................5
2.5 Exhaust section .....................................................................................................6
2.6 Air inlet systems ...................................................................................................6
2.7 Accessory gear box...............................................................................................6
2.8 Starting System (Electric Starting Motor) ............................................................7
2.9 Lubrication system................................................................................................8
2.10 Hydraulic supply system.....................................................................................10
2.11 Liquid fuel system on turbine baseplate .............................................................10
2.12 Cooling and sealing air system ...........................................................................11
2.13 Bearings ..............................................................................................................12
3. GENERATOR DESCRIPTION...............................................................................13
3.1 Stator...................................................................................................................15
3.2 Rotor ...................................................................................................................15
3.3 Bearings ..............................................................................................................15
3.4 Stator winding cooler..........................................................................................15
3.5 Auxiliary equipments..........................................................................................15
4. DESIGN BASE...........................................................................................................16
4.1 Gas Turbine.........................................................................................................16
4.2 Electric Generator ...............................................................................................17
4.3 Reducing Gear Box.............................................................................................17
5. AUXILIARY - FACILITIES....................................................................................18
5.1 Turbine enclosure Ventilation system ................................................................18
5.2 CO2 Fire Fighting system...................................................................................18
5.3 Oil vapour separator............................................................................................19
5.4 Axial compressor washing system......................................................................19
5.5 Atomizing Air System ........................................................................................19
5.6 Diesel Oil Treatment...........................................................................................20
5.7 HFO Filtration and Injection skid.......................................................................20
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The Turbogenerator is part of DAURA plant in Iraq and is designed to provide

the power generation.
This train is composed by a MS5001PA heavy duty Gas Turbine, a reduction
Gear Box and an 25.800 kVA power Generator.
The train is supplied as two baseplates (Gas Turbine baseplate + Gear Box and
Generator baseplate).The Turbogenerator is completed with the auxiliaries
necessary to operate, as: oil vapour separator system, air intake filter, oil cooler,
exhaust system, fuel gas system, turbine package; Turbine & Generator control &
protection system, with detection of vibrations, temperatures, anti-condensating
system, etc. fire detection and fire fighting system, atomizing air system and HFO
1. INTRODUCTION
filtration and inhibitor injection skid.
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2. GAS TURBINE DESCRIPTION
The gas turbine package consists of a two sections, housing the auxiliaries and
the gas turbine.
Both gas turbine and auxiliaries are mounted on a common integral base plate.
On this one is mounted an acoustical enclosure that hold gas turbine and
auxiliaries.
The accessory side of the compartment contains the mechanical auxiliaries, both
mechanically (via accessory gear) and electrically driven, the lube oil system, the
fuel systems and the gas turbine starting means.
The turbine side is separated from the accessory compartment by the combustion
air inlet plenum.
The enclosure is equipped with access doors for inspection and maintenance.
The following code numbers refer to gas turbine model MS5001PA “Turbogroup
General Arrangement”, SOM 5458297
2.1 Functional description

The MS5001PA is a simple-cycle, single shaft gas turbine with a combustor
reverse flow combustion system. The MS5001PA gas turbine assembly contains
five major sections (see Fig. 1.1):
• Air inlet
• Compressor
• Combustion system
• Turbine
• Exhaust
When the starting system is actuated and the clutch is engaged, ambient air is
drawn through the air inlet plenum assembly, filtered and compressed in the
axial-flow compressor.
For pulsation protection during start-up, the air flow coming from the 10th stage
extraction valve is conveyed to the atmosphere through the exhaust duct/stack.
When the starting system has accelerated the rotor to ignition speed, the two
spark plugs are energized and liquid fuel is turned on. The resulting fuel/air
mixture is injected, by means of 10 burners, in the relevant combustion chambers
and ignited by the spark plugs. When the chambers are lit, as indicated by the
flame detectors, the start-up sequence continues.
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When the rotor speed relay actuates at 95% speed, the antisurge valves
downstream the 10th stage extraction are closed. The air extracted from the 10th
stage will be used as cooling and sealing air in the wheel spaces and in the
bearings.
Air from the compressor flows into the annular spaces between the outer
combustion casings and the combustion liners, and enters the combustion zone
through the combustion liner.
The hot gases from the combustion chambers flow through the transition pieces.
The gases then enter the 1st stage fixed nozzles and the 1st stage turbine wheel
buckets and subsequently the 2nd stage nozzles and 2nd stage wheel buckets. In the
nozzle rows, the energy of the jet is increased, with an associated pressure drop
and is absorbed as useful power on the turbine rotor.
After passing through the 2nd stage buckets, the gases are directed into the exhaust
hood and diffuser, which contains a series of turning vanes to turn the gases from
an axial direction to a radial direction, to minimize exhaust hood loses.
The gases then pass into the exhaust plenum and are introduced to atmosphere
through the exhaust stack. Resultant shaft rotation is used to produce electric
power turning the driven Generator.
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Fig. 1.1 - Major sections of the MS5001 PA gas turbine assembly
2.2 Compressor Section

The MS5001 gas turbine has a 17 stages axial-flow compressor. The compressor
is constructed of individual rebadded discs held with through bolts.
The axial flow compressor consists of the compressor rotor and casing, and a
modulating row of stator buckets operated by an hydraulic system as inlet guide
vanes. This system will reduce the air inlet flow during the start up and
acceleration of the unit reducing the enter space section and will be opened when
the provided speed of the unit is reached.
Rotor blades supply the force needed to compress the air in each stage and the
stator blades guide the air so that it enters the following rotor stage at the proper
angle.
The compressed air exits through the compressor discharge casing to the
combustion chamber. Air is also extracted from the compressor 4th and 10th stages
for turbine cooling and for bearings cooling and oil sealing.
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2.3 Combustion Section

The combustion system consists of 10 combustion chambers, with relevant fuel
nozzles (burners), flame detectors, spark plugs, and transition pieces. The
combustion chambers are installed axially to the turbine and are inserted and
bolted to the compressor discharge section combustion casing. Air for
combustion is supplied directly from the axial flow compressor to the combustion
chambers. Fuel is fed into the chambers through fuel nozzles that extend into the
chamber’s liner caps. The air flow through the combustion chambers has three
functions: oxidize the fuel, cool the metal parts, and adjust the extremity hot
combustion products to the desired turbine inlet temperature.
Reverse-flow chambers combustion system is utilized. Combustion of the fuel
and air mixture is initiated by retracting electrode type spark plugs, installed in
two combustion chambers, receiving power from the ignition transformers
installed on the baseplate.
High-pressure air coming from the axial compressor is directed around the
transition pieces. The transition pieces are the hot gas path link between the
combustion liners and the first stage nozzle.
This encounter affords a heat exchange, cooling the transition pieces and
preheating the combustion air.
Transition pieces take the hot gas to the first stage nozzle. The nozzle is air
cooled to reduce metal temperature.
The combustion chambers are equipped with a fuel nozzle that introduces fuel
into the combustion liners. The fuel/air mixture is then introduced into the
combustion zone.
2.4 Turbine section

The two stages of the turbine rotor provide the power required to drive the
Generator. The two wheels, are bolted to the compressor shaft making up a single
shaft driving the load.
Compressor tenth-stage extraction air is piped to cool the turbine wheels and then
discharged at the aft end and also to cool the bearing houses and to seal the oil of
bearing avoiding the oil leakage. The 4th stage extraction air is conveyed to cool
the turbine casing shell.
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2.5 Exhaust section

The exhaust plenum is a rectangular box-like structure into which the turbine
exhaust gases are discharged before being ducted to the silencer and then vented
to atmosphere through the exhaust stack.
It is included and connected to the exhaust duct/stack a continues emission
monitoring system in order to keep the exhaust gases always inside the pollution
clearances recommended by local laws.
Located at the aft end of the turbine base, it encloses the exhaust frame, diffuser,
and turning vanes, with the function to direct the gases from the axial to radial
direction with the minimum loss of energy.
2.6 Air inlet systems

The air inlet system consists of an elevated air inlet compartment and inlet
ducting with silencing provisions connected to the turbine inlet plenum. This
system combines the functions of filtering and silencing the inlet air with the
function of directing the air into the turbine compressor.
Filter House
Turbine combustion air is sucked by the turbine through the air filter system. This
air filter is then cleaned to give the air filter greater cleaning efficiency and
greater life.
The system is single barrier type air filter and is composed mainly by an high
efficiency barrier to separate the small foreign parts of the air.
Upstream the barrier are installed the weather hoods and the droplets catchers.
Downstream the stage is inserted a duct blowing the air to the ventilation system
of the enclosure.
Downstream the filters is installed a silencing system composed by several
silencer panels installed inside the air inlet duct.
2.7 Accessory gear box

The accessory drive gear box, located at the compressor end of the gas turbine, is
a gearing assembly coupled directly through a tooted coupling to the turbine
rotor. Its function is to support and drive each gas turbine accessory at its proper
speed and to connect and disconnect the turbine from its starting device.
Contained within the gear casing are the gear trains, which provide the proper
gear reductions to drive the accessory devices at the required speed, with the
correct torque values. The starting clutch assembly is mounted forward on the
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horizontal joint of the main gear shaft and is used to connect the starting device to
the gas turbine.
Accessories driven by the gear include: the main lube oil pump and the main
hydraulic supply pump.
The gear box transmits a torque from the starting means to the gas turbine during
start up.
2.8 Starting System (Electric Starting Motor)

The starting system includes the driving equipment to bring the unit to self-
sustaining speed during the starting cycle.
The starting system is composed by a Electric starting motor, connected to an
hydraulic torque converter installed on the same supporting base on accessory
compartment, this one gives the motion to the accessory gear box main shaft
through an automatic self synchronizing clutch, the main shaft of gear box is
connected to the turbine shaft by a flexible no lubricated coupling.
When the starting motor is put in operation its output torque starts from zero and
increases as the torque converter is filled with oil by the charge pump.
The torque converter output is directly proportional to the difference between
input and output speeds (maximum slip). When pressurized, the converter
demands power from the motor and supplies power to the gas turbine through the
starting clutch.
The electric starting motor, drives the compressor rotor of the gas turbine through
the starting clutch assembly to bring the gas turbine to the specified self-
sustaining operating speed.
The torque converter transmits the starting motor output torque to the gas turbine
accessory gear through a reversing gear.
A starting clutch connects the output shaft of the torque converter assembly to the
accessory gear. The clutch is automatically engaged and disengaged depending
on the starting means speed and turbine rotor speed. Engagement is maintained
by transmitted torque generated in the torque converter.
The complete starting system is already installed and connected through the oil
supply and discharge piping/hoses to the oil tank in the turbine base, accessory
compartment.
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2.9 Lubrication system

The lubrication system provides an ample supply of filtered lubricant at the
proper temperature and pressure for operation of the turbine and its associated
equipment. Lubricating fluid is circulated to the turbine accessory gear with
starting means, to the turbine bearings, to the load gear box and generator
bearings. A portion of the pressurized fluid is diverted and filtered again for use
by hydraulic control devices as control fluid and as supply to other systems.
Major system components include:
• Lube oil reservoir in the auxiliary side of the base
• Main lube oil gear pump (shaft driven by the accessory gear)
• Pressure safety valve VR-1 in the main pump discharge
• Stand-by oil pump driven by an AC motor
• Emergency lube oil pump driven by a DC motor
• Lube oil heat exchangers
• Main lube oil double filters with replaceable cartridges and transfer valve
• Bearing header pressure regulating valve VPR-2
Lube oil main shaft driven pump, or stand-by and emergency pumps, when
running take their suction from the lube oil tank and discharge into a common
bearing header at a pressure of 1,72 Bar. The lube oil pumped from the lube oil
reservoir to the bearing header flows through an heat exchanger to remove excess
heat and then through the cartridge type filter providing 12 micron filtration.
After lubricating the bearings the oil flows back through various drain lines to the
reservoir. Minimum start up oil temperature is 20°C.
The lube oil filtration system is made out of two parallel filters and one transfer
valve directing the lube oil flow to one or to the other. This allows the
replacement of one filter without stopping the unit. Filter elements should be
changed when the differential pressure transmitter (96QQ-1) gives a differential
pressure of 0,017 Bar.
The preferred oil for the Nuovo Pignone’s gas turbine is the Light Grade oil
having a viscosity of 140 to 170 SUS (Saybolt Universal Seconds) at a
temperature of 38°C (100°F) (Lube oil type ISO VG 32).
The properties of three light grade oils are listed in Table 1 and the lubricated
equipment in Table 2.
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Table 1
Light Light Grade with Light Grade

Property Units
Grade Anti-Wear additives Low Pour Point
Viscosity at 100°F
(37,8°C) SUS
(min.) 140 140 140
(max.) 170 170 170
Viscosity at 210°F
(99°C.) SUS
(min.) 43 43 43
Pour Point (max.) °F (°C) 20 (-6,7) 20 (-6,7) -25 (-31)

Flash Point (min.) °F (°C) 330 (168) 330 (168) 330 (168)
Fire Point °F (°C) 370 (188) 370 (188) 370 (188)
Total Acid Number
mg KOH/g 0.20 1.6 0.20
(TAN) (max.)
Rust Preventing
- Pass Pass Pass
Characteristic
Oxidation Hours to
1000 1000 1000
Characteristic (min.) TAN of 2.0
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Table 2
EQUIPMENT: TURBINE FORCED FEED LUBE OIL

MANUFACTURER: NUOVO PIGNONE
CONSUMPTION
(LITERS/DAY)
FREQUENCY
LUBRICANT
OF CHANGE
Q.TY OF 1ST
EXPECTED
(LITERS)
SAMPLE
FILLING
OIL MAKER
TYPE
LUBRICATED
PART
SHELL
LUBE OIL-ISO VG 32 GT
Any
TURBINE BEARINGS 24 hrs. after
other
TORQUE CONVERTER On the initial
lube oil
MAIN LUBE PUMP…. (1) basis of charge (or
TURBO as per
AUX.LUBE PUMP… (2) 9420 1 the after each
T32 NP
EMERG. LUBE PUMP. (2) analysis charge) then
spec.
MAIN HYDR. OIL PUMP.(1) result every 4000
SOM.
LOAD GEAR BOX hrs.
17366/4
ELECTRIC GENERATOR
(1)-Turbine shaft driven
(2)-Electric motor driven
2.10 Hydraulic supply system

Hydraulic oil at a high pressure (80 Bar) is provided by the hydraulic supply
system, to operate the control components of the gas turbine.
High-pressure hydraulic oil, furnishes the means for operating the fuel gas stop
and control valve assembly and the operating mechanism.
Major system components include the main hydraulic supply pump driven by the
accessory gear box, the system filters (dual filters), a transfer valve, the hydraulic
supply manifold assembly and the IGV control valves and actuator.
2.11 Liquid fuel system on turbine baseplate

The liquid fuel system is designed to delivery liquid fuel to the turbine
combustion chambers at the proper pressure and flow rate, to meet all of the
starting, accelerating and loading requirements for gas turbine operation.
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The following major components:

The liquid fuel system is composed with:
• Pressure transmitter (96FL-1) of liquid fuel supply downstream the filter
• Fuel oil stop valve (VS-1)
• Liquid fuel pump (PF-1)
• Fuel pump discharge relief valve (VR-4)
• Fuel oil by-pass valve (VC-3)
• High-pressure (secondary) fuel filter (FF-3, FF-4)
• Flow divider
Liquid fuel is first cleaned by passing through liquid fuel duplex filter.
A liquid fuel pump permits to supply the required flow to the gas combustion
system by means of 10 combustors.
The fuel control valve is activated by a Speedtronic control signal to admit the
proper amount of fuel required by the turbine for a given load or speed.
Associated with this gas valve are control servo valves, pressure gauges, as above
mentioned, and the distribution piping to the combustion fuel nozzles.
2.12 Cooling and sealing air system

Air obtained from the gas turbine axial flow compressor extracted from the 4th
and 10th stages is used for cooling the various parts of the turbine section and for
pressurizing the bearing oil seals in the gas turbine.
The air flow is divided among the cooling zones of the turbine by means of
calibrated orifices installed on each air ducting pipe.
This cooling and sealing air provides airflow to certain internal and external
turbine parts to prevent excessive temperature build-up in these parts during
normal operation and for sealing the turbine bearings. The parts of the turbine
section which are cooled by air consist of: the first and second stage turbine
wheel forward and afterward faces, the turbine shell and the bearings.
The combustion chambers liners, transition pieces, and the combustion casing,
are designed to utilize compressor discharge air for effective cooling of these
parts.
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2.13 Bearings
The gas turbine unit MS5001PA has two journal bearings to support the rotor,
and one thrust bearing for axial thrust.
The bearing # 1 is located in the compressor inlet casing and the bearing # 2 is
located outside after the discharge casing; the thrust bearing, positioned in the
bearing # 1 casing, is composed by two parts: one positioned in the active side of
the rotor collar to support the active thrust and the other positioned in inactive
side to support the transient thrust.
The bearing assembly consists of oil seal system, an oil ring and the surrounding
housing.
The turbine bearings are pressure-lubricated by the lube oil supplied from the
lube oil header. The drain oil returns through passages in the bearing housing,
then into the drain line to the oil tank. The oil seals control the oil flow along the
shaft. The seals consist of labyrinth packing of teeth assembled at the extremities
of the bearing assemblies.
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3. GENERATOR DESCRIPTION
The Electric Power Generator (brushless type) (see Fig. 1.2) consists of a three
phases alternating current generator and is composed by a static part as stator
(called Armature: the assembly of conductors in which the voltage is inducted)
and a rotor (called Field: consisting of a source of magnetic lines of flux) and the
rotating exciter connected and driven by the rotor, installed in the N.D.E. side of
generator, necessary to produce and supply the power to the rotating field
winding.
The Generator is installed on a baseplate common with the load Gear Box that
reduce the rotating speed from Turbine speed to the Generator speed (rpm 1500).
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Fig. 1.2 - Electric Generator (detail from SOM -/-)
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3.1 Stator
The stator consists of the frame, the core with its thousands of lamination and the
stator winding (armature). The stator winding is provided with the phase
connection rings and bushings, transmitting the electrical power generated.
3.2 Rotor
The rotor is made up of a forging shaft which contains the rotor winding (know as
field). It is also composed by wedges and retaining rings necessary to contain the
rotor winding against the very high centrifugal forces developed during its
rotation. It is supported at the ends by two journal bearings continuously oil
lubricated.
The possible transient axial thrust is supported by the Gear Box thrust bearing.
Being the low shaft of the Gear Box, driving the Generator, rigidly connected to
the Generator.
At the end of the rotor (N.D.E. side) is keyed the exciter current generator
(brushless type with rotating diodes ) to excite the Generator field.
3.3 Bearings
The two Journal bearings, sleeve type, are lubricated by the oil coming from the
turbine bearings header to which the Generator bearings header is connected.
The bearings are grounding insulated to avoid the induction currents through the
shaft and the bearings.
3.4 Stator winding cooler

The stator winding cooling system is composed by an air/water cooler installed
on the top of generator casing. The generator winding air cooler is conveyed to
the cooler, outside the bundles piping, by the blades mounted on the generator
shaft extremities, the water flushes through the piping bundles of the coolers
cooling the air. The water inlet and outlet piping of the coolers are connected with
the Purchaser’s water supply system.
3.5 Auxiliary equipments

he Generator winding for its protection and for produced power distribution
system is connected with the transformer/net by means of connecting point (bus
bars) installed inside the Line and Neutral cubicles, laterally installed and
connected to the Generator structure
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4. DESIGN BASE
4.1 Gas Turbine

The turbine model MS5001PA is a simple-cycle, single-shaft gas turbine with 10
reverse flow combustion chambers, designed for liquid fuel firing. The relevant
characteristics of the turbine are below described.
Turbine rated characteristics with liquid fuel
Turbine model MS5001 PA - Single shaft

Application Generator drive
2
Ambient pressure – kg/cm -/-
Dry Bulb temperature - °C 55
Power - kW 17280
Heat Rate – kJ/kW*HR 15160
Relative Humidity - % 60
For the other different condition see the following specifications:

- SOK 0928964/4 G.T. data sheets
- SOM 6676387/4 G.T. performance curves
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4.2 Electric Generator

The Generator is used for producing Electric power. It is driven by a gas turbine
MS5001 PA and is completed with the relevant accessories necessary for its
operation (as winding cooler, line & neutral cubicles, lubrication system, etc.). It
is planed to reach the following normal conditions provided by the project.
Generator main characteristics
Manufacturer
Generator type
Rated power at 48°C ambient temp. - kVA
Power factor
Rated Voltage - V
Current - A
Number of Poles / Phases
Rated frequency - Herz ± 2%
Rated- rpm
Speed
Overspeed- rpm
4.3 Reducing Gear Box

The load Gear Box has the topic to reduce the Gas Turbine Speed to the
Generator required speed. Is a two parallel wheels (double helical gears),
horizontal offset. It is connected with the Gas Turbine by a dry flexible coupling
and rigidly with the Generator through two flanges. It is manufactured to meet the
required conditions of the project.
Load Gear Box main characteristics:
Manufacturer
Gear Box type
Rated Power
Input speed
Output speed
Type
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5. AUXILIARY - FACILITIES
5.1 Turbine enclosure Ventilation system

The Enclosure is the type installed and fixed on the floor with outside and inside,
around the turbogroup, the walkways and ladders.
The Enclosure needs a ventilation system to cool its internal room divided in
three compartments (Accessory compartment, Turbine, compartment, Coupling &
Gear Box compartment and Generator compartment).
In our case the ventilation system keep the enclosure inlet pressure higher than
the atmospheric pressure.
The ventilation system is realized by two ventilation fans driven by the electric
motors (main and stand-by) sucking the air from the filter house, and blowing it,
through a ducting system, to the enclosure.
The fresh air enters from five openings created in different location of the
enclosure. Each inlet and outlet opening of all compartments are equipped by
manual dampers. Immediately downstream the ventilation fans there is a damper
operated by a solenoid valve installed on the supplying instrument air, driven by
the Turbine Control System in case of fire.
The internal of the enclosure is also protected from explosion risks, provoked by
gas entering with the air, by some gas detectors that give the alarm when the air
become saturated with the explosive gas.
There are the instruments on the dampers (limit switches) inhibiting the
ventilation system starting and other instruments (differential pressure
transmitter) starting the stand-by ventilation fan when necessary.
5.2 CO2 Fire Fighting system

The fire fighting system is projected to protect from the possible fire developing
inside the turbine enclosure during the operation of the Turbogenerator. The
Generator enclosure compartment is not provided with the fire fighting system
In each compartment (Accessory, Turbine and Coupling/Gear) are installed the
fire detector sensors connected to the fire fighting panels in Control Room.
The extinguish means used in our case is CO2; in fact there are, installed outside
of the enclosure, two skids (main and spare) containing the CO2 bottles.
The bottles are connected, by two gas headers, with a certain number of nozzles
installed inside the enclosure: one line of nozzles is used for the first gas
discharge, immediately delivered in case of fire; a second line of nozzles is
necessary to maintain the gas pressurisation inside the enclosure for a long time
in order to avoid an other fire re-kindling.
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5.3 Oil vapour separator

To avoid the oil vapour emission from the gas turbine tank to the atmosphere,
produced by the heating of the oil during the turbine running in order to avoid the
air pollution, has been realized and installed outside the turbine enclosure an oil
vapors/air separation system.
The separation system is installed on one skid composed by a vessel containing
the filtering unit separating the oil vapors from the air and, downstream, by a fan
sucking the air (already separated from the oil vapors) from the filtering unit and
conveying it outside, to the atmosphere.
5.4 Axial compressor washing system

To keep the axial compressor clean during operation for the required efficiency,
the Gas Turbine is provided by a washing system using, as cleaning means, a
mixture of water and detergent to be sprayed into the compressor inlet casing.
The washing Unit will be used to remove the dirt which may accumulate on the
compressor blades (particularly) during normal operation restoring the design
condition.
A very important thing during the compressor cleaning process is to avoid the
blades erosion, damaging of coatings and bearings and closing of the turbine air
cooling holes. These conditions are realized using the before mentioned mixture.
The types of washing system provided is an off-line system to be used with the
Turbogenerator operating at crank speed.
The washing system is composed by a tank installed on a trolley. The tank
contains a mixture of water and additive (see the relevant specification) and this
mixture will be pushed to the sprayers on the compressor mouth by a pump. On
the washing tank is also inserted an electric heater with the relevant on/off control
system for heating the water / additive mixture.
The cleaning sequences will be operated, from the GT control system, by exiting
the solenoid valves installed on each washing line upstream the sprayers,
provided on the turbine baseplate.
5.5 Atomizing Air System

To permit burning of different kind of liquid fuel is present an atomizing air
system. The system is mechanical and driven by the turbine accessory gear. To
cool the compressor is used water from the turbine washing water system.
The system is installed in the turbine package and is composed by:
- Air/liquid separator
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- Main Atomizing air compressor

-Auxiliary Atomizing air compressor
- Air filters
-Starting motor for auxiliary air compressor.
5.6 Diesel Oil Treatment

To purify the diesel oil coming from the tank is installed a treatment system in a
separate skid. The system is composed by:
- Diesel oil Filters
- Regulation valve
- Diesel Metering and deareator ultrasonic type.
5.7 HFO Filtration and Injection skid

To avoid the corrosion and fouling in the gas turbine is supplied a crude oil
system treatment. This oil is treated in order to reduce the various contaminants
coming directly from the well.
The system is composed by two parts, the filtration and the inhibitor injection,
installed on separated skid.
The system main components are the following:
- Self cleaning Filters
- Dosing pumps
- Three way valve
- Safety devices
-Static mixer
-Drain valves
- Recycling valves
- Deareator.
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÷÷INDEX
Contents Page
1. FOREWORD ............................................................................................................... 1
2. SAFETY INSTRUCTIONS (SOM 6607109/4) ......................................................... 2
3. HOW TO USE THE TOOLS ..................................................................................... 3

3.1 Special Tool List....................................................................................................4
4. STANDARD PRACTISES.......................................................................................... 5
4.1 Turbogenerator.......................................................................................................5
5. MATERIAL UNLOADING & STORAGE............................................................... 8

5.1 Equipment arriving at site......................................................................................8
5.2 Storage ...................................................................................................................9
5.3 Reference documents...........................................................................................10
5.4 Decommissioning and Environmental Impact.....................................................11
6. TURBOGENERATOR FOUNDATION AND SKIDS POSITIONING .............. 13

6.1 Turbogenerator foundation checks prior grouting...............................................14
6.2 Turbogenerator sole-plates positioning ...............................................................15
6.3 Turbogenerator Foundation Checks After Grouting............................................15
6.4 Skids Positioning .................................................................................................16
6.5 Equipment required..............................................................................................19
7. PRE-ALIGNMENT ................................................................................................... 20
7.1 General.................................................................................................................20
7.2 Preparation ...........................................................................................................20
7.3 Alignment methodology (example). ....................................................................22
7.4 Alignment execution............................................................................................24
8. ACOUSTICAL ENCLOSURE & VENTILATION SYSTEM.............................. 27

8.1 Enclosure .............................................................................................................27
8.2 Enclosure ventilation ...........................................................................................28
9. MAIN SKID ACTIVITY........................................................................................... 31

9.1 Oil System Activity .............................................................................................31
9.2 Oil System Flushing.............................................................................................35
9.3 Starting System ....................................................................................................42
9.4 Liquid Fuel System (On Base).............................................................................43
9.5 Air Inlet Duct .......................................................................................................45
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Contents Page
9.6 Exhaust System....................................................................................................47

9.7 Generator Activity ...............................................................................................50
9.8 Load Gear Box.....................................................................................................52
9.9 Intake Filter System .............................................................................................53
9.10 Oil Vapour Separator ...........................................................................................55
9.11 Water Washing Skid ............................................................................................56
9.12 Fire Fighting System............................................................................................58
9.13 HFO Filtration and Injection Skid .......................................................................59
9.14 Diesel Oil Treatment............................................................................................60
9.15 Piping Construction in Site ..................................................................................61
10. FINAL ALIGNMENT & COUPLING INSTALLATION .................................... 62

10.1 Baseplate Fixing & Doweling .............................................................................62
10.2 Couplings .............................................................................................................64
11 ELECTRICAL & INSTRUMENTS ........................................................................ 67

11.1 Equipments / Devices Positioning .......................................................................67
11.2 Power-Off checks Initial conditions ....................................................................68
11.3 Turbine, Gear Box & Generator ..........................................................................70
11.4 Auxiliaries Skids..................................................................................................71
11.5 Miscellaneous ......................................................................................................73
03-09-E 170.5703-4 P. 2-2

1. FOREWORD
The present section describes the main erection activities to be carried out in a
Power Generation Station.
Every work shall be carried out according to the Contractor and/or to the Owner
standards and specifications either for the general prescription or for specific
manufacturing standards, norms, special norms of pre-commissioning, execution,
checking, etc..
These instructions, that do not purport to cover all details not to provide for every
possible contingency, are intended to supplement the experience and ability of
qualified personnel who is assumed to be familiar with the installation of turbo-
generator, in general and with the use of tools and commonly used elements,
materials and methods.
Good judgment and proper safe practices to avoid personal injury and property
damage shall be exercised by the personnel who shall not consider the instructions
as relieving him from the responsibility of ensuring a competent care of the
equipment.
! WARNING
THE PERSONNEL ENTRUSTED WITH THE INSTALLATION OF NUOVO

PIGNONE PRODUCTS SHALL HAVE THE NECESSARY TECHNICAL
CHARACTERISTICS AND SUITABLE TECHNICAL TRAINING FOR THE TASK IT
HAS TO ACCOMPLISH.
IN CASE THE INSTALLATION OF NUOVO PIGNONE’S EQUIPMENT IS
PERFORMED BY THIRD PARTIES, NUOVO PIGNONE SHALL HAVE NO
RESPONSIBILITY FOR LOSS OR DAMAGES CAUSED BY IMPROPER
INSTALLATION, UNLESS SUCH THIRD PARTIES HAVE BEEN CERTIFIED AND
TRAINED BY NUOVO PIGNONE.
ANY DAMAGE, EVEN PARTIAL, ASCRIBABLE TO FAILURE TO COMPLY WITH
AFORESAID ESSENTIAL CHARACTERISTICS SHALL BE ATTRIBUTABLE TO
THE PURCHASER AND NUOVO PIGNONE WILL BE DISCHARGED OF ANY
LIABILITY AND INDEMNIFICATION THEREOF.
03-09-E 170.5703-4 P. 2-1

2. SAFETY INSTRUCTIONS (SOM 6607109/4)

(from page no. 211 to page no. 308)
03-09-E 170.5703-4 P. 2-2

3. HOW TO USE THE TOOLS
The standard and special tools listed hereinafter permit to carry out the installation
operations of all component parts of the Turbine.
Before carrying out any operation demanding the use of the following tools, it is
necessary that the installation-men perfectly know how to use the machine, fol-
lowing the instructions supplied by the manufacturer and the indications reported
on the machine itself.
Moreover, the installation-men must be well trained to do their job and to use the
special tools.
! DANGER
BEFORE LIFTING THE DEVICES, VERIFY THEIR POSITION AND THE LIFT-
ING POINT CAPACITIES IN THE LIFTING DRAWINGS.
THEN, CHECK THE SPECIAL TOOLS FOR CORRECT POSITIONING AND
CLAMPING.
DO NOT USE SPECIAL TOOLS FOR OPERATIONS OTHER THAN THOSE
FOR WHICH THEY HAVE BEEN BUILT.
ONLY SPECIALLY TRAINED PERSONNEL MUST CARRY OUT ALL LIFTING
AND HANDLING OPERATIONS.
03-09-E 170.5703-4 P. 2-3

3.1 Special Tool List
3.1.1 Gas Turbine Tools
For details, please refer to “Reference Drawings and Special Tools” Volume of
the Job.
3.1.2 Generator tools
For Electric Generator tools see the relevant “Brush” Generator Manual.
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4. STANDARD PRACTISES
This paragraph contains a series of standard instructions relevant to the equipment

treatment.
! WARNING
FOR ALL THE FOLLOWING INSTRUCTIONS, IT IS IMPORTANT TO PAY

ATTENTION TO THE SAFETY PRESCRIPTIONS DESCRIBED IN SECTION 2.2.
4.1 Turbogenerator
The heavy equipments (as Turbine, Generator), installed directly in the final
location, will be protected by the adverse conditions using suitable coverings.
If the storage time is short it is advisable to keep the equipments temporary
protected by the shipping packing until the beginning of erection activities.
Particularly for the turbine package, the internal parts are already protected in
factory, before shipping. In the mentioned way the turbine is protected for a term
of six months, if the time of storage will be longer is necessary to provide again to
a further protection after an inspection of Nuovo Pignone personnel.
4.1.1 Gas Turbine Inlet System

When the machine is not in place, the inlet plenum opening must be sealed by
means of a nylon cover. The air filter inlet must be sealed to prevent water
ingestion into the filter house and relevant ducts. The filtering elements can be
held in place.
4.1.2 Gas Turbine Exhaust System

The exhaust stack opening must be sealed by means of a bolted cover and a nylon
sheet.
The exhaust plenum has to be covered in order to prevent any incidental ingestion
of foreign objects when the machine is not in place.
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4.1.3 Gas Turbine Lube Oil System

When disconnected, the skid terminal points must be sealed with bolted steel
blanking flanges and oil-tight gaskets.
4.1.4 Electric Equipment

Components such as lock and union joints, bends and nipples, internal and
external explosion proof box lids should be coated with Vaseline.
During non operation periods, the heaters located inside the equipment to preserve
the internal temperature to a minimum acceptable value must be energized;
switches are provided for temperature control.
4.1.5 Control panels

The described preservation in suitable to ensure the material preservation for the
time indicated in the table, in accordance with the storage place. At the expiry
date it will be necessary to check the preservation condition and, if required, to
restore it.
EXPIRY TERM
Storage place Class ITN 54701.00 (months)
with barrier bag
Indoors, in air-conditioned
A 12
shed
4.1.6 Mobile parts and instrumentation

The mobile parts and extractable instrumentation installed on boards or desks
shall be stiffly fastened to the frame.
Should they be damageable during carriage or subject to deterioration during
storage, and if it impossible to meet above instructions, the component must be
dismantled and packed separately.
In this case a proper identification must be used to make its reassembling easier.
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4.1.7 Miscellaneous
A wooden protection must be installed to protect the equipment against possible
damages due to the lifting device slings. For the transoceanic transportation and
once the unit is loaded and firmly secured on the ship, the lifting device shall be
sea fastened to avoid any wear against the unit due to ship motions.
All the instruments which could be damaged during transportation due to the
vibration must be properly supported and / or fixed. All instrumentation with glass
part has to be protected by rigid covers and nylon wrapped-up with plugs and
silicagel bags installed.
All equipment that is supported on antivibration supports shall be blocked to take
the weight off the supports and also secured (air cooler, if applicable, etc.)
The pipework that is supported on spring type supports or resting on guides or
with directional anchors shall be locked in position and secured.
Equipments shall be secured inside panel racks.
The cabinets shall be secured by temporary bracings. They shall be wrapped with
waterproof material.
Vessel internal (KO Pot) shall be checked for rigidity and where necessary
blocked and secured to prevent movements. In this case a notice has to be placed
externally.
All parts of flanges, valves and other parts not coated will be greased, wrapped
with waterproof barrier material and sealed.
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5. MATERIAL UNLOADING & STORAGE
5.1 Equipment arriving at site
Special care will be taken to unloading, handling and storing of all construction
material, arriving in site.
Check carefully the condition and quantity of arriving material, as per packing
list. Notify immediately to the Responsible for everything not conforming to the
packing list or for some damaged material. Take a picture of everything damaged.
File a report with the Shipper for damaged material.
Put the damaged material in a separate place from the right one.
On site must be available the lifting and transport means (cranes, tractors, tracks,
etc.) of adequate characteristic and quantities necessary to unload the arriving
materials and to move the same inside the site and bring them from the storage
area to the erection place.
Ensure all equipment is stored so as to prevent damage from the weather. Place all
ship loose items and control system parts in an area suitable for such equipment.
Electronic components and other sensitive parts should be kept under cover and in
a dry area.
Leave additional supports, bracing, covers etc. installed for shipping, until the
installation.
Reinstall all inspection covers that have been removed for inspection.
Turbine skid and Generator/Load Gear Box skid normally are discharged from the
transport means and immediately installed on proper foundations completed with
the required shim packs.
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5.2 Storage
All material arriving at site will be stored in right condition and in appropriate and
codified place.
The heavy equipments installed directly in the final location will be protected by
the adverse conditions using suitable coverings.
If the storage time is short it is advisable to keep the equipments temporary
protected by the shipping packing until the beginning of erection activities.
Particularly for the turbine packages, the internal parts are already protected in
factory, before shipping. In the mentioned way the turbine is protected for a term
of six months, if the time of storage will be longer is necessary to provide again to
a further protection after an inspection of Nuovo Pignone personnel.
For turbine packaged with the enclosure installed on the base in enough to
maintain the doors closed installing inside some heater to avoid the condensation
formation.
For turbine oil reservoir and internal pipes the protection is performed by oil with
an additive anti rust. Before shipping the reservoir will be filled by an adequate
quantity of oil + additive.
For Generator/Gear Box skid the preservation will be carried out following the
Supplier’s instructions (see the relevant service manual).
The control and electrical boards will be stored in a clean, close and, if possible,
air conditioned ambient, to prevent condensation that may damage the electronic
components and circuits. If not possible the boards will be protected by a
breathable covers.
Piping may be stored externally without specific protection for a period of six
months. If the storage time will be longer is necessary to store them under a shed.
The piping will be normally shipped with the external surface painted and
plugged at the extremities.
! WARNING
IT IS MANDATORY TO MAINTAIN THE MATERIALS IN THE ORIGINAL

PACKING DURING THE WHOLE STORAGE PERIOD. THE ORIGINAL PACKING
MUST BE INTACT AND NOT DAMAGED IN ORDER TO GUARANTEE THE
ORIGINAL SEALING.
03-09-E 170.5703-4 P. 2-9

5.3 Reference documents
N.P. DWG DESCRIPTION
Protection & packing for the shipment of machines,

ITN02175.00
machine components and materials.
ITN02175.04 Preservation for storage & shipment of structural works
Preservation for storage & shipment of commercially

ITN02175.07
available materials
ITN02175.08 Preservation for storage & shipment of electrical materials
Preservation for storage & shipment of Gas Turbine &

ITN02175.12
their auxiliaries
Preservation for storage & shipment of filter house, inlet

ITN02175.21
& exhaust plenum, and other ducts fir gas turbine
ITN54750 Packing specification
These documents are included in Section 5 “Technical Documents” of this Vol-

ume.
03-09-E 170.5703-4 P. 2-10

5.4 Decommissioning and Environmental Impact
Environmental Impact
During operation, the turbine produces a series of exhaust gases due to combus-
tion, approximately: 15% O2, 6% H2O, 2.5% CO2, N2 for the rest; also, minimal
quantities of polluting substances are present due to the type of fuel employed.
When the fuel employed is a natural gas, the main polluting substances are nitric
oxides (NO) and carbon monoxide (CO).
The turbine combustion chambers have been designed to reduce to a minimum the
presence of such oxides by acting on the mixing of fuel and air and by means of
low flame temperatures combustion (weak combustion).
Generally, nitric oxides tend to increase (also in percentage) with the turbine
power, while carbon monoxide (CO) acts in the opposite way. Carbon monoxide,
in fact, is less significant than NO but increases remarkably in low load conditions
(inferior to 30%) and, for this reason, it is necessary, if possible, to avoid running
in such conditions.
Sulphur oxides (SO) derive from the sulphur present in fuel and generally gas oil
contains more sulphur than other fuels.
Besides exhaust gas, other emissions are oil vapours due to the lubricating liquids
employed.
Once the plant is operational and during its whole life, it is the duty of the user to
keep emissions within the levels indicated by the relevant regulations in force and
to follow the instructions below:
- Perform all maintenance operations listed in this manual, according to the
schedule suggested;
- Do not modify the adjustments made by the Manufacturer upon installation;
- Remove any malfunctioning - as soon as possible -, which might cause an
increase in the emission rate (if necessary, refer to GE OIL & GAS Nuovo
Pignone Assistance Service).
Waste, derived from maintenance operations, must be stocked and treated accord-
ing to the local law in force and by referring, if necessary, to the safety data sheet
of the product itself (as concerns lube oils in particular) and the related filters in
order to prevent any risks for people and the environment.
03-09-E 170.5703-4 P. 2-11

Decommissioning
According to the principles of the EN ISO 14000 standard and the ISO EN 14040,
in particular, about Life Cycle Assessment, GE Oil & Gas Nuovo Pignone, in the
planning stage, has perfected a series of devices to facilitate the reutilization and
recycling of the materials and components of the turbine and its auxiliary systems,
and to reduce the environmental impact of the product in each one of its life cy-
cles.
In case of turbine decommissioning, perform the following operations:
Reduce to the minimum the materials to be dumped by their reutilization and re-
cycling (according to the related local law in force). GE Oil & Gas Nuovo Pig-
none is specialized in the recovery, reconditioning and reutilization of machines.
Contact GE Nuovo Pignone qualified technical personnel for turbine disassembly
procedures.
- Recover oils and other liquids from the related tanks and dispose of them
according to the local laws in force.
03-09-E 170.5703-4 P. 2-12

6. TURBOGENERATOR FOUNDATION AND SKIDS POSITIONING
Turbogenerator general arr.gt (detail from SOM 5458297)
03-09-E 170.5703-04 P. 2-13

6.1 Turbogenerator foundation checks prior grouting

In this phase of work the Turbogenerator foundation check is intent to be done
with anchor bolts already installed and without sub-sole plates (see Fig. 2.1).
It is necessary verify foundation, elevations, grout pockets dimensions and
positions, anchor bolts centres distance and all the others dimensions as per
drawings. A useful check is to verify the diagonal distances, this to avoid a
possible error of rhomboidal anchor bolts positioning.
Fig. 2.1
03-09-E 170.5703-04 P. 2-14

6.2 Turbogenerator sole-plates positioning

Sole plates must be positioned, levelled and set as for drawing requirement.
All the components must be cleaned and kept clean from dirty and rust until
grouting activities.
6.3 Turbogenerator Foundation Checks After Grouting

Dimensions checks between anchor bolts centres must be done to be sure that no
change are occur during grouting activities. Others checks needed to verify that
no cavities have been generated under sole-plates after grouting (see Fig. 2.2).
Sole plates and lateral jacking bolts must be kept clean and protect from
atmospheric agents.
Fig. 2.2
03-09-E 170.5703-04 P. 2-15

6.4 Skids Positioning

Prior Turbine and Gear Box / Generator skids positioning it is necessary to clean
the sole-plates from rust and dirty, check integrity of every single shim, shims
cleaning and lubrication, spherical washers (where provided) cleaning and
lubrication, preparation of skid shim packs whit spherical washers according to
drawings elevations requirement.
Main skids must be positioned on foundation keeping anchor bolts well centred
on relative skid holes.
After positioning must be checked the soft-foot and, if occur, correct the gap
adding proper shims.
The positioning includes also, a turbine levelling checks, prior to start the
alignment activities.
The Fig. 2.3 shows the final position of the foundation bolts, tightened and locked
as required. The lifting screw, before tightening the anchor bolts, will be
unscrewed leaving some gap between it and the lifting plate.
Fig. 2.3
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Fig. 2.4 - Gas Turbine base anchoring system (typical)
03-09-E 170.5703-04 P. 2-17

Fig. 2.5 - Devices for horizontal positioning and locking of GT baseplate (typical)
03-09-E 170.5703-04 P. 2-18

6.5 Equipment required
1. Ruler with scraped control plans, length: 5000 mm, thickness admissible
tolerance: ± 0.05 mm.
2. Square level gauge, sensitivity: 0.03 mm per meter; length of sides: 200 ÷
250 mm
3. Template or Harmonic steel wire; length: 3000 x 0.5 mm
4. Outside micrometer 0 to 25 mm
5. Steel metric measuring tape; tape length: 20m
03-09-E 170.5703-04 P. 2-19

7. PRE-ALIGNMENT
7.1 General
On site alignment for turbo groups generally is divided in two phases: pre-
alignment and final alignment. Both alignments use the same philosophy and
same values, however:
Pre-Alignment:
Pre-alignment will permit the start of interconnecting piping and ducts assembly
and installation.
Final Alignment:
This alignment phase is carried out when all major mechanical components have
been installed: ducts, structures, interconnecting piping, gear box, generator, etc.
Temperature has a great impact on alignment readings: see alignment specifica-
tion for temperature impact and/or reference temperature.
7.2 Preparation
Before starting pre-alignment it is necessary to remove transportation devices
from the turbine and generator; these items are located on shaft end for locking.
Remove the turbine from the transportation third point using proper jacking
devices and refer to the turbine documentation.
Then proceed as follows:
• Prepare the shims pack for turbine and generator taken care to clean and
lubricate every single sheet. Prepare the necessary equipment for unit skid
lifting in case jacking bolts are not used. Be sure that no items interfere with
alignment activity in the alignment tools working area.
• Set in axial middle position the drive and the driven shafts and verify their
“face to face” distance respect the alignment specification requirements.
• Install the necessary alignment tool and the proper dial gauges as per the
Fig. 2.6
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Fig. 2.6 - Gas Turbine alignment tool (typical)
03-09-E 170.5703-04 P. 2-21

7.3 Alignment methodology (example).

The axial misalignment value is obtained by subtracting the A gauge value from
the B gauge value and divide the total by 2. This calculation removes the addi-
tional value given by the shaft axial movement and it provides the opening status
on flanges.
Negative values mean that the flanges are more open with respect to the opposite
position.
Example of Axial readings:
On start position, gauge A and B are set at 2.00 mm.
(A – B)/2 = value at position 1, (2.00 mm – 2.00 mm)/2= 0
On Position 2, gauge A sign 2.02 mm and B sign 1.92 mm
(A 2.02 mm – B 1.92 mm)/2 = +0.05 mm
On position 3, gauge A sign 2.04 mm and B sign 1.96 mm
(A 2.04 mm – B 1.96 mm)/2 = +0.04 mm
Considering the starting values, it means that on the bottom position (pos. 3)
flanges are closed (the gauge are charging and so the stroke is shorter respect the
original value)
On position 4, gauge A sign 1.96 mm and B sign 1.98 mm
(A 1.96 mm – B 1.98 mm)/2 = -0.01 mm
Considering the values on pos. 2, it means that flanges are closed on pos. 2 and
more open on pos. 4.
The final misalignment values will be:
Attention: to verify if readings are correct, the sum of misalignment value on
pos. 2 with the value on pos. 4 must be equal with the value on pos. 3.
Position 2 + position 4 = position 3; +0.05 + (-0.01) = +0.04 >>>>
+0.04=+0.04.
Example of Radial readings:

Set the gauge in the starting point and begin to record the values every 90-degree,
rotating both the shafts. The horizontal values provide the exact misalignment val-
ues: The difference between the reading and the specification value is the move-
ment to be done for the radial alignment achievement.
03-09-E 170.5703-04 P. 2-22

The vertical value (pos. 3) provides the misalignment value multiplied for two.
Example: if the specification set the vertical value to –2.00 mm and the reading
shows – 3.00 mm, the driven machine (the machine were has been taken the read-
ing) must drop 0.5 mm (3,00 – 2,00)/2.
Attention: when comparing the reading values with the spec values, remember to
subtract the set value. If in pos. 1 the gauge has been set at 2.00 mm, this quantity
is added to every position.
As explained above for the vertical reading, as soon as a reading turn is finish, the
sum of the horizontal values (pos. 2.& pos. 4) must be equal the vertical value
(pos. 3).
Fig. 2.7 – Example of readings on dials
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7.4 Alignment execution
The following instruction describes how to record the readings using two gauges
for the axial readings and a third gauge for the radial readings; the alignment tools
are usually provided for this kind of alignment.
The readings will be done on four position: at 12:00 hours, 03:00 hours, 06:00
hours, 09:00 hours starting from the top and following the shafts operational rota-
tion sense; the top will be the position 1 and following the rotation sense, position
2,3,4 every 90°.
The alignment tool is fixed on drive shaft and the readings are taken on driven
shaft (in not differently specified on the alignment specification). Sign with a
marker the four reading positions on the reading disc; don’t scratch the surfaces
and don’t use paint that can create a relief, or the reading will be altered by its
thickness. Don’t use solvent-based paint if the reading surface is the hub surface.
Set the gauges on the starting position: radial gauge in position 1, axial gauge A in
position 1 and axial gauge B in position 3. Set a positive reference values to all
the gauges (same value for all of them): If the gauges are set to zero values or to
other values close to the gauge stroke end, in case of excessive negative values,
the gauge will be not in condition to get the reading.
Start to keep alignment readings moving the shaft in the correct rotation sense
every 90°; move both the shafts in position 2 and next to the other positions.
Attention: When the gauges can back in the starting position (pos. 1) they must
show the same values set prior start the readings! Only axial gauges can show an
apparently different values: An axial movement of the shaft due to the rotation ef-
fect can add or remove a value to the original set, but it is the same value for both
the gauges.
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Fig. 2.8 - Dial gauges installation (typical)
Example: axial gauges A and B are set at 2 mm in starting position (see Fig. 3).
After a complete turn, they can back showing a reading of 2,2 mm. This is not an
error because both of them reporting plus 0,2 so the shaft axial movement oc-
curred. The reading errors is a reading shoving different addition values: axial
gauge A 2,2 mm, axial gauge B 2,4 mm. To understand if errors are happening
during the reading on position 2, 3 and 4 , see the alignment methodology expla-
nation in next paragraph.
The reasons whose determinate wrong readings can be several, but the principal
causes are the following:
• The gauges are not properly fixed on alignment tool.
• The alignment tool is not properly fixed on shaft.
• The reading disc shaft has not be stopped in a different position
• Operator did wrong gauges reading.
• A load has been accidentally applied on alignment tool during the readings
recording.
Compare the recorded reading with alignment specification values and correct the
differences using the skid lateral jacking bolts and the jacking devices to add or
remove shims.
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Be sure to use shim pack supplied only. Other shims type with different characteris-
tics and/or different materials can not be used if not authorized by Nuovo Pignone.
Be sure to tight the skid anchor bolts prior to execute a reading.
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8. ACOUSTICAL ENCLOSURE & VENTILATION SYSTEM
The enclosure will be installed on floor therefore it arrives dismounted in many

parts and will be assembled on site.
On the top of the enclosure will be installed the ventilation system with its ducts
and different devices as below described.
8.1 Enclosure
8.1.1 Installation
The main activities to be carried out are as follow:
• Sole plates level checking, before installing the structures.
• Support structures installation, levelling and alignment ready for grouting
• Foundation bolts tightening after grouting as per required torque.
• Erection of enclosure walls and roof panels.
• Erection of gangways, ladders, gratings, etc., inside and outside the
enclosure.
• Installation of doors, windows, gutter pipes, plugging, finishing touches and
accessories.
• Erection of cranes, rail ways and relevant accessories included the ladders,
gratings, protections, etc. for access way;
• Erection of ventilation system as below described.
• Enclosure inside and outside lighting system (AC and DC), construction and
installation.
• Drilling of walls and roof where necessary, in order to install pipes and
electrical cables and conduits or cable trays and relevant restoration.
• Construction and installation of fire fighting and gas and fire detection
systems.
8.1.2 Checks after installation

• Installation of the sealing plates and relevant insulation on enclosure piping
passage.
• Verify the sealing between panels and the opening for ducts.
03-09-E 170.5703-04 P. 2-27

• Verify the correct opening/closing of doors; in case of emergency the

personnel inside the enclosure should be able to open the door easily.
• Verify if gaskets are correctly installed on ports and maintenance doors.
• Verify acoustical panel insulation (Ensure that there is no contamination
caused by flammable liquids or chemicals)
• Verify installation of plugging on pipes, cables and junction boxes crossings
as per connection piping and electrical outline drawings.
• Verify and / or complete the installation of external devices, for example: fire
fighting lights, emergency horn, fire-fighting system operation light,
emergency push button etc.
• Verify and / or complete the installation of the grounding system.
• Check painting.
8.2 Enclosure ventilation
8.2.1 Checks
• Verify the enclosure air ventilation motor/fan skids completion against

packing list. Verify the movement of all the rotating parts, preservation
status, the correct transmission belt tension, alignment between electric motor
and the fan shaft, lubrication of electric motor and fan bearings, correct
anchoring on skid.
• Verify the gravity/manual dampers correct opening and closing prior their
installation.
8.2.2 Installation
Erection of ventilation system including the relevant structures, fans, ducts, filters,
dampers, gangways, ladders, gratings and all accessories, as follows:
• After Structural Platform has been erected, proceed with installation of all
ductwork;
• Install centrifugal ventilation fans [FNVF1 & FNVF2]. Carry out the air
extraction fans skids positioning and levelling on dedicated supporting
structure as per drawings;
• Check the alignment of electric motors with relevant fans. If not differently
specified by the vendor, the alignment is referred to “0”. In this phase, verify
also the cleanliness of shims used;
03-09-E 170.5703-04 P. 2-28

• Tightening the motors & fan anchoring bolts as soon as the alignment has
been completed;
• Check the preservation condition and the correct opening/closing of the
gravity dampers at fans air outlet;
• Verify if transmission belt tension is correct;
• Verify all rotating parts;
• Verify if air extraction group bearings are correctly lubricated;
• Verify if air diffuser is correctly installed and centred;
• Align the fan suction with the relative duct on Air inlet system;
• Install the air ducting starting from the air inlet system side. Verify, during
the installation, the cleanliness of the connecting flange and the correct
application of the gaskets;
• Install the expansion joints avoiding tension and stress on elastic surface and
excessive compression;
• Check the right connection and operation of the inlet and outlet air dampers
operated by the fire fighting system extinguishing gas, on accessory
compartment and turbine compartment.
• Tighten all duct connecting bolts starting from the flange centre.
• Verify if deflectors of ventilation ducting inside the turbogenerator enclosure
are correctly oriented.
• Complete the painting on ventilation system components if/where required.
• Assemble the necessary pneumatic connections to actuate the ventilation
dampers. Install the actuators and the pneumatic tubing line as per
schematics.
• Installation and connection of the instruments for temperature and explosive
gas detection, position limit switches and differential pressure switch to start
the stand-by ventilation fan.
• Install the cable trays/conduits for the ventilation system instrumentation and
motors.
• Execute the limit switches wiring as per schematics and wiring diagrams.
• Execute the fan electric motor wiring as per schematics and wiring diagrams
• Install the grounding system where required.
• Remove anti-rotation sea fastening on all impellers.
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Fig. 2.9 - Ventilation system (detail from SOM 5104280)
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9. MAIN SKID ACTIVITY

In this section are illustrated some operation to be carried out on Gas Turbine &
Gear Box/Generator skids and on related systems during installation on site.
The main reference document is the Schematic Piping Diagram of the Job.
9.1 Oil System Activity
9.1.1 Lube oil system

The lube oil system is installed on the turbine accessory compartment of the
turbine base. The base is also the oil reservoir and the pumps and filters are
installed on the accessory base too.
The more important checks to carry out on the system during installation,
referring to the relevant schematic piping diagram, are as follows:
− Check oil tank cleanliness: to reduce the risk of foreign object or dirty inside
oil tank with possible consequence of extended oil flushing activities or
equipment failure, oil tank must be checked and eventually cleaned prior first
oil filling (oil type ISO VG32).
− Oil Pumps alignment: during skid transportation, alignment could be
changed, for this reason the installer must check and eventually correct
alignment among oil pumps with relevant electric motors (A.C. stand-by
pump [88QA + PL2] and D.C. emergency pump [88QE + PL3]).
− The main oil pump [PL-1] is driven by accessory gear box shaft. It is
important to check, during the Turbogenerator erection, its right connection
and bolting with suction and delivery piping.
− Lube oil filters [FL-1A/B]: it is important to check cleanliness and presence
of cartridges inside lube oil filters on the accessory compartment of the
turbine base prior start any oil circulation.
As soon mechanical installation is completed, it is useful to assure a correct
installation of all the parts.
The lube oil system piping installation consists of:

− Construction and installation of lube oil tank drain on accessory compartment
starting from MP301A÷C maintenance point.
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− Construction and installation of turbine base compartment drains starting

from MP302A/B maintenance points.
− Installation of the interconnecting supply and discharge oil piping with Gear
Box / Generator baseplate.
− The interconnecting lines with oil vapour separator inlet & return lines.
− Verify the installation of Oil Heaters [23QT-1÷4] on the tank with relevant
thermoswitches.
− Verify the installation of space heaters [23QA-E] of the electric motor
[88QA] and of the electric motor [88QE].
− Verify the installation of the Oil tank level gauge and transmitter.
− Verify that all instruments, thermowells, blind flanges, plugs and piping
connected to the oil tank, are correctly installed.
− Verify flow direction on all check valves.
− Verify the installation, orientation and size of lube oil system orifices.
− Execute a visual inspection of pressure control valves and safety valves in
order to detect non-conformity.
− Verify the installation and the cleanness condition of all flow sight glass.
− Verify that the system valves are in correct open/close position.
− Check the instruments correct installation and connection as per required
schematic piping diagram.
− Install or complete the earthing system.
9.1.2 Hydraulic oil and ratchet system

The hydraulic oil system arrives on site already installed on the turbine accessory
compartment, complete of every equipment and instrument; the only thing to
carry out is to verify the correct installation and connection of the system, as fol-
lows:
− The hydraulic oil pump [PH-1] is driven by accessory gear box shaft. Is
important to check, during the installation operation, the right connection and
bolting and interconnecting piping installation (suction and delivery).
− Hydraulic oil filters [FH1-1/2]: it is important to check cleanness and
presence of filters cartridge inside hydraulic oil filters on turbine accessory
base skid prior start any oil circulation.
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− Correct installation of instruments and valves on hydraulic manifold.

− Correct tubing connection of the hydraulic manifold, hydraulic cylinder and
IGV;
− Correct connection to the more important devices of the turbine driving them
by the servovalves as: liquid fuel shut off valve [VS-1] by means of [VC-3]
servovalve.
− Instruments installation and electrical connection.
In the hydraulic oil system is included also the ratchet system, built in the torque
converter, necessary for turning the turbine shaft during the start up of the
Turbogas and during the cool down time after the Unit stop.
− The more important checks to perform are:
− Correct alignment among the ratchet pump [PH-3] with relevant DC electric
motor [88HR].
− Calibration of the control valve, installed on the pump, setting the delivery
pressure as required by the schematic piping diagram and Instrument list..
− Piping/tubing connection with lube oil system.
− Connection of delivery piping with control valve and, downstream it, to the
relevant supply line to the ratchet sequencing system and hydraulic system in
the torque converter.
− Electrical connection of the motor.
− Correct calibration of the safety valve as required by schematic piping
diagram.
9.1.3 Water cooling system

Water Coolers are installed inside the baseplate auxiliary compartment and
consist in two exchangers (main and stand-by) cooled by water circulating inside
a tube bundle. Outside the tubes circulate the oil to be cooled. Before connecting
the inlet and outlet water piping is necessary to install the coolers head, separate
shipping for transport reasons. Opening on Coolers must be keeping close and
sealed until heads installation.
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On the water inlet line will be installed the thermostatic valve reducing or
increasing the cooling water flow as required by the oil temperature. The signal
controlling the valve arrives by means of a capillary tube coming from the oil
supply to the auxiliary gear box.
Correct installation and connection of instruments.
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9.2 Oil System Flushing
9.2.1 General
This paragraph defines the methods to be used to remove all foreign bodies and
ensuring through cleaning of all piping, filter bodies, coolers and other
components which will come in contact with lube oil.
Flushing shall be carried out when all the oil system components have been
completely installed.
After flushing must be certificate the right re-installation of piping and devices as
per relevant drawings.
For more information see the following Oil Flushing description.
9.2.2 Preparation for flushing

1. Empty the tank of protective oil, for shipping applied, and clean it
thoroughly.
2. Check oil tank - baseplate, the inner surfaces and components such as pumps,
filters, piping.
3. Remove “MOOG” servovalves and replace them with the relevant flushing
blocks.
4. Verify that the coolers caps have been cleaned (only for the coolers on base,
where provided).
5. Verify the integrity and exact positioning of filters cartridges.
6. Check the temporary piping cleanness for not contaminates oil flushing.
7. Take out possible leaks.
8. Provide for fire protection means in the oil circulating zone.
9. Check manually the right rotation of oil pumps.
10. Provide the means to transfer the oil from barrels to oil tank.
WORKING ZONE PREPARATION

1. The working zone near oil tank must be kept clean and access allowed only to
the personnel charged of flushing operations.
2. Provide the necessary portable fire extinguishers positioned along the
flushing lines.
3. Drains must be capped to avoid the oil contamination in case of leakage.
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If there are no local pumps operating switches provide for a communication

system between flushing zone and pumps control room in order to operate very
quickly in case of necessity.
SUPPLEMENTARY CRITERIA
1. For a more efficient flushing, oil shall be warmed. If the oil heaters of
machine are not enough for this purpose, will be prepared the adequate
means. During flushing oil temperature will be kept in a range within 60 ÷
80°C.
2. Use [PL-2] (auxiliary pump) to carry out the flushing activities.
MEASUREMENTS
1. Current absorbed by the pump motors should be checked frequently and shall
never exceed the rated values.
2. Oil temperature, during the flushing, shall be kept lower than 80 °C:
3. Flushing oil must not enter in contact with hot parts to not exceed the flame
point (approx. 150°C.).
SAMPLING AND ACCEPTANCE CRITERIA

1. During oil flushing, will be controlled the oil contamination by means of
suitable samples. Type, dimension and quantity of dirt particles will be
checked in laboratory.
The acceptable criterion is defined by the Table 1.
) NOTE
THE FIRST CHECK OF THE SAMPLE WILL BE TAKEN AFTER 24 HOURS OF

FLUSHING
2. To verify the continuous reduction of oil level contamination, carry out
subsequent samples.
3. Oil flushing shall be completed when, the particles contained in the oil will
be lower or equal to the particles shown in the Table 1.
) NOTE
ALL TEMPORARY PIPING WILL BE REMOVED AND FINAL CONNECTIONS

RESTORED TO THE BEARINGS AFTER FLUSHING ACTIVITIES COMPLETION.
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Table 1
Solide contaminant code - Tabular presentation
Number of particles per 100 ml.
CODE Over 5 µ Over 15 µ
Minimum Maximal Minimum Maximal

3 6 3
20/17 500 x 10 1 x 10 64 x 10 130 x 103
20/16 500 x 103 1 x 106 32 x 103 64 x 103
20/15 500 x 103 1 x 106 16 x 103 32 x 103
20/14 500 x 103 1 x 106 8 x 103 16 x 103
19/16 250 x 103 500 x 103 32 x 103 64 x 103

19/15 250 x 103 500 x 103 16 x 103 32 x 103
19/14 250 x 103 500 x 103 8 x 103 16 x 103
19/13 250 x 103 500 x 103 4 x 103 8 x 103
18/15 130 x 103 250 x 103 16 x 103 32 x 103

18/14 130 x 103 250 x 103 8 x 103 16 x 103
18/13 130 x 103 250 x 103 4 x 103 8 x 103
18/12 130 x 103 250 x 103 2 x 103 4 x 103
17/14 64 x 103 130 x 103 8 x 103 16 x 103

17/13 64 x 103 130 x 103 4 x 103 8 x 103
17/12 64 x 103 130 x 103 2 x 103 4 x 103
17/11 64 x 103 130 x 103 1 x 103 2 x 103
16/13 32 x 103 64 x 103 4 x 103 8 x 103

16/12 32 x 103 64 x 103 2 x 103 4 x 103
16/11 32 x 103 64 x 103 1 x 103 2 x 103
16/10 32 x 103 64 x 103 500 1 x 103
15/12 16 x 103 32 x 103 2 x 103 4 x 103

15/11 16 x 103 32 x 103 1 x 103 2 x 103
15/10 16 x 103 32 x 103 500 1 x 103
15/9 16 x 103 32 x 103 250 500
14/11 8 x 103 16 x 103 1 x 103 2 x 103

14/10 8 x 103 16 x 103 500 1 x 103
14/9 8 x 103 16 x 103 250 500
14/8 8 x 103 16 x 103 130 250
13/10 4 x 103 8 x 103 500 1 x 103

13/9 4 x 103 8 x 103 250 500
13/8 4 x 103 8 x 103 130 250
12/9 2 x 103 4 x 103 250 500

12/8 2 x 103 4 x 103 130 250
11/8 1 x 103 2 x 103 130 250
From: Annex “B” of ISO/DIS 4406 standards
03-09-E 170.5703-04 P. 2-37

) NOTE
THE ABOVE TABLE COVERS THE MOST USUAL SERIES OF CODES BETWEEN
RANGES 8 AND 20. OTHER CODES WHICH ARE NOT SHOWN CAN BE
CONSTRUCTED FROM ANNEX “A”.
Table 2
Comparison list - International standards
ISO 4406 of IMPURITY NAS 1638 SAE ACFTD MIL STD
3 (1964) contents 1246 A
CETOP RP 70 H cm - 10 µ (1963) 3
mg/dm (1967)
26/23 140000 1000
25/23 85000 1000
23/20 14000 100 700
21/18 4500 12
20/18 2400 500
20/17 2300 11
20/16 1400 10
19/16 1200 10
18/15 580 9 6
17/14 280 8 5 300
16/13 140 7 4 1
15/12 70 6 3
14/12 40 200
14/11 35 5 2
13/10 14 4 1 0,1
12/9 9 3 0
18/8 5 2
10/8 3 100
10/7 2,3 1
10/6 1,4 0,01
9/6 1,2 0
8/5 0,6 00
7/5 0,3 50
6/3 0,14 0,001
5/2 0,04 25
2/8 0,01 10
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OIL TANK FILLING

1. The oil tank must be filled up to the established level, taking into
consideration that, when the pump start part of oil will fill the piping and the
oil level in the tank will decrease.
2. The oil filling will be carried out through the relevant filter on the oil tank, in
order to avoid the foreign material introduction.
PIPING FLUSHING PROCEDURES
A. Activity
1. Check the correct installation of the oil tank level indicator;
2. Drain the tank protection oil;
3. Clean carefully the oil tank, inside;
4. Check the conditions of the oil tank internal parts;
5. Check the correct installation of the tank oil drain valves;
6. Remove the orifices (in case of regulating orifices, open completely) from the
oil supply pipes to the bearings;
7. Disconnect the oil supply piping to the bearings and install the temporary
piping returning to the oil tank, by-passing the bearings;
8. Fill the tank with flushing oil (see oil specification, normally OTE 32 type);
9. Install a local temporary switch to operate the auxiliary oil pump
[88QA + PL-2];
10. Verify the electrical supply on the MCC (check that the pump & heaters
breakers be extracted);
11. Verify the piping connections of the lines submitted to flushing operation;
12. Check that all interception valves on the local instrument panel be closed;
13. Insert the breakers of the pump & heaters on the MCC;
14. Start up the aux. oil pump [88QA] operating by the local temporary switch;
15. Stop the pump after 30 seconds and verify the oil leakage from the flanged
couplings;
16. Start up again the aux. oil pump;
17. Put in “ON” position the heaters switches;
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18. During the oil flushing operations, keep the temperature within 60° and 80°C;
19. Check the piping oil leakage with the oil at rated temperature;
20. Hammering the discharge pipes with warmed oil, every 30 minutes;
21. The oil flushing activity will be carried out continuously for 48 hours or
alternatively for four days if it will be stopped during the night;
After the mentioned time of oil flushing, will be draw a sample of oil for analysis,
comparing the results to the acceptance criteria mentioned in the table 1.
B. If the acceptance criteria give a positive result will be continued as follows:

1. Shut down the aux. lube oil pump and put in “OFF” position the electrical
heaters switch;
2. Re-install the final oil piping to the bearings and the relevant orifices;
3. Re-start up the oil pump and put in “ON” position the heaters switch;
4. Proceed with the oil flushing operation, continuously, for other 36 hours (or
for three days if the flushing activity will be stopped during the night);
5. Draw an oil sample for analysis and compare the result with the acceptance
criteria shown in table 1.
C. If the oil analysis gives a positive result:

1. Switch off the heaters and shut down the aux. oil pump;
2. Restore the lube oil circuit as requested by the schematic, ready for operation.
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Flushing system general layout (typical)
03-09-E 170.5703-04 P. 2-41

9.3 Starting System
9.3.1 Starting means

The starting system is composed by an electric starting motor [88CR-1],
connected to an hydraulic torque converter installed on Gas Turbine base, this one
gives the motion to the accessory gear box main shaft through an automatic self
synchronising clutch, the main shaft of gear box is connected to the turbine shaft
by a coupling, as shown on the relevant schematic piping diagram.
The complete starting system is already installed and connected through the oil
supply and discharge piping/hoses to the oil tank in the turbine accessory base.
The check to be carried out is the verification of the correct installation and
connection of the torque converter system and the external valves and orifices as
per schematic piping diagram.
9.3.2 Hydraulic ratchet

The hydraulic ratchet system is an important equipment to be used during the
starting phase and the cooling down of the turbine following a shut down.
It is a integral part of the torque converter.
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9.4 Liquid Fuel System (On Base)

The turbine skid arrives on site with the internal piping and gas valves already
installed on the auxiliary compartment. Usually the piping to be installed on the
Fuel Gas system includes the interconnecting vent lines.
9.4.1 Liquid Fuel on turbine base

− Verify the correct installation of the Control Valve [VS-1] combined valves
with respectively proper LVDT’s stroke position and operating system; their
correct connection to the supply and delivery liquid fuel piping.
− Check the correct installation and connection with hydraulic oil of the
servovalves [VC-3] and the [VS-1] shut off solenoid valve.
9.4.2 Piping
− Connection of the turbine liquid fuel line on base with Purchaser’s supply
line.
To perform the interconnecting piping blowing see the relevant procedure.
Blowing operation must involve all piping upstream of the turbine skid
connection limit. Piping installed inside the skid is generally clean and sealed; if
in doubt, contact NP supervisor. Be sure no foreign bodies are left inside the lines.
Restore the Liquid Fuel system after blowing. If necessary remove all parts, and
equipment used and clean the area. A blowing execution certificate must be
issued.
At the end of cleaning procedures restore the pipe lines ready for pressurisation
with gas and install the instruments and control and safety valves (already
calibrated in the instrument calibration room) on the pipes.
Carry out the bandaging of the gas pipe flanges ready for pressurisation test, to be
executed in the following phase of commissioning.
Each pipe and relevant connection, before connecting to the liquid fuel system on
turbine, will be carefully checked for cleanliness and sound conditions.
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9.4.3 Checks
As soon mechanical installation is complete a system check it is useful to assure
installation of all the parts and their correct assembly.
− Check the Liquid Fuel lines supporting system.
− Verify (with schematic diagram) the piping already installed on the package,
in order to determine missing or damaged items or other non-conformity.
− Execute a visual inspection of the Fuel valves installed, looking for damage,
loose connections, and openings and missing connections (tubing & cables).
− Verify if all internal valves/device vent lines are all connected to the vent
header.
− Verify if the fuel lines already installed are connected in the proper ports on
the instrument console. Use schematic (P&ID) and piping route drawing for
verification.
− Execute a fuel line system check to the instrument console; verify if all
instruments and manifolds are correctly installed.
− Check the system for foreign blind flange/disc or inspection screens left
installed.
− Verify and/or complete the wiring and cabling of all instrumentation and
devices on the liquid fuel system.
− Verify that the instruments and devices are provided with identification tags
according to instrument list.
− Verify the whole fuel system is installed according to schematic diagram and
drawing.
− Verify the correct installation of the measuring flow system and the valves
and instruments loosed shipped by Nuovo Pignone.
− Install or complete the earthing system.
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9.5 Air Inlet Duct

The Air Duct, composed by more parts to be assembled in site, connects the filter
house with the Turbine air inlet Plenum.
9.5.1 General
The Air Inlet Duct is composed by (starting from the turbine inlet plenum):
expansion joint, an empty vertical duct, an elbow, a horizontal section duct
containing silencing panels, another horizontal section empty duct and finally an
expansion joint connecting the inlet duct to the filter house.
The cleanliness of Air duct components must be guaranteed.
Part of the Air duct assembly is a silencer. The silencing ducts must have their
silencing panels inserted prior to connect them with the other ducts.
Weld structure support plates only after confirmation of alignment; inlet duct with
the Turbogroup skid.
9.5.2 Checks
− Check the foundations for correct structure locations and potential
interference with other structures and/or equipment.
− Check the diagonal distance between all supporting plate position points.
Subplates are connected to the structure columns.
− Check the anchor bolt holes on the support structure plates to see if they are
compatible with the provided anchor bolts size.
) NOTE
BEFORE STARTING THE ERECTION WORKS WILL BE CHECKED THE

PRESERVATION CONDITION OF ALL COMPONENTS AND WILL BE RESTORED
EVERY PART FOUND NOT IN PERFECT CONDITION; PARTICULARLY THE
COUPLING FLANGES SURFACES, THE THREADED HOLES; MAY BE NECESSARY,
SOME TIME, TO ENLARGE THE NOT THREADED HOLES OR REMAKE SOME OF
THEM.
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9.5.3 Installation
All bolts used inside the Air system must be provided with anti-loosening guards
(system) or be welded.
The threaded bars used to support the expansion joint during transportation and
erection, must be taken out before putting unit into operation.
The ventilation system is connected to the inlet duct. Be sure to close and seal all
the openings until ventilation ducts are installed.
The inlet duct is provided with one or more inspection doors; Verify if inspection
doors are free from obstruction (structures, piping etc.) and if they are installed
with correct gasket and correct bolts.
Then:
− Ensure the air inlet steelwork is correctly erected.
− Lift each section of air inlet ductwork and install them as follows:
a. First expansion joint on the inlet plenum. The expansion joint will be
delivered ‘locked’.
b. Vertical transition duct section on the expansion joint.
c. The elbow connecting the vertical section to the horizontal sections of duct.
a. A section containing Silencers. If not already fitted, insert acoustic panels
into silencer sections in correct position referred to the air flow
d. The horizontal straight transition empty duct.
e. The expansion joint connecting the duct with the filter house.
− Check elevations and level using the adjustable bolts (if any).
− Unlock the expansion joint from they threaded bars after completing the
installation.
− Check the presence of all required gaskets and tighten all bolts on duct’s
connecting flanges.
− Proceed with grounding system installation.
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9.6 Exhaust System

The exhaust system, laterally installed, is composed by: a structure system
supporting the duct, an expansion joint connecting it to the GT exhaust plenum
and an empty duct to be connected with a short straight duct stack (not provided
in our supply).
9.6.1 Checks
Check the foundations for correct structure location and potential interference
with other structures and/or equipment.
Check the diagonal distance between all supporting plate position points. Sub
plates are connected to the structure columns.
Check anchor bolt holes on support structure plates to see if they are compatible
with the provided anchor bolts size. (Where applicable)
) NOTE
BEFORE STARTING THE ERECTION WORKS WILL BE CHECKED THE

PRESERVATION CONDITION OF ALL COMPONENTS AND WILL BE RESTORED
EVERY PART FOUND NOT IN PERFECT CONDITION; PARTICULARLY THE
COUPLING FLANGES SURFACES, THE THREADED HOLES; MAY BE NECESSARY,
SOME TIME, TO ENLARGE THE NOT THREADED HOLES OR REMAKE SOME OF
THEM.
9.6.2 Installation
Tight the baseplate anchor bolts as soon as the alignment of exhaust duct with the
Turbogroup skid is confirmed.
Assemble the exhaust ducts according to assembly drawing and tighten
connecting bolts as per torque value required. Use anti-size compound on exhaust
duct bolts and begin tightening from the flange centre and proceeding
alternatively from the left side to the right side for a better flange distension.
Ensure the exhaust system supports are correctly erected, then lift each section of
exhaust duct / stack and install it as follows:
a. Assembly of the exhaust plenum lateral extension covers.
03-09-E 170.5703-04 P. 2-47

b. Install the short straight duct on the plenum.

c. Install the expansion joint to the exhaust plenum.
d. Install the pyramidal transition duct and straight sections.
e. Installation and fixing of duct sliding equipment for turbine maintenance.
f. Install the silencer duct.
g. Install acoustic pods into silencer section.
h. Install the three sections of vertical empty ducts.
i. Install the duct final section.
The expansion joint threaded bars used to support it, must be taken out before
placing unit into operation. The joint must be fitted correctly avoiding excessive
compression.
As soon as the expansion joint and the other duct parts have been installed,
alignment must be verified between the joint and the transition piece.
9.6.3 Final completion

− Post erect; set a sealing cover (water proof, if provided) on the top of the
exhaust to prevent rain entering until machine commissioning.
− Verify that turbine enclosure panels located close to the exhaust duct are
clean and dry and check the correct installation of the sealing plates.
− Never install short bolts: the nut must cover all its length. Use anti seize
compound on bolts and nuts before installing them.
− Check gaskets during the duct assembly: the gasket must be of the correct
required type, fire proof, and it must be installed to cover all the contact
surface.
− The exhaust duct is provided with one or more inspection doors; verify if
inspection doors are free from obstruction (structures, piping etc.) and if they
are installed with correct fireproof gasket and with correct bolts.
− Install the drain piping under the turbine exhaust plenum.
− Install the false start valve on exhaust plenum drain line, and connect it to the
pneumatic actuation line.
− Depending on project requirements the exhaust duct may be provided with a
connection port for smoke analysis. If necessary, verify if the connection is
03-09-E 170.5703-04 P. 2-48

located at list 10 meters from the exhaust centreline and if these connections
are provided with sealing plugs/blind flanges.
− Verify if inside the exhaust duct, there are no flammable materials.
− Install the cable trays/conduits for the exhaust duct instrumentation.
− Execute the thermocouple wiring as per schematics and wiring diagrams.
− Connect the grounding system.
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9.7 Generator Activity

In this paragraph are illustrated some operation to be carried out on generator
during installation on site.
9.7.1 Checks
Upon receipt, the generator package installed on the skid with a reduction Gear
Box; loose parts have to be checked for damage or loss. A careful visual
inspection will reveal any damage, while missing of any parts can be found by
comparing the received goods with the relative packing list. When any damage is
found, reported immediately to NP representative.
9.7.2 Installation
Maintain cleanliness in all parts of the machine and working area during the
installation activities.
1. During the installation, all openings should be covered as much as possible,
in order to prevent water, dust, dirt or other foreign objects from entering the
machine.
2. It is advisable to connect and switch on the heaters inside the generator as
soon as possible after placing on the machine, to prevent the windings of the
generator becoming damp.
3. Install the air winding cooling system on the generator (water coolers) as per
relevant drawings.
4. Connect the oil piping to the turbine bearing headers (inlet & outlet). Remove
the transportation sealing flanges on the battery limit only during the starting
of interconnecting piping assembly. In case of removal for checks, be sure to
restore the sealing flanges after the inspection.
) NOTE
BE SURE NO FOREIGN BODIES ARE LEFT INSIDE THE LINES OR FOREIGN BLIND
FLANGE/DISC ACCIDENTALLY LEFT INSTALLED IN THE SYSTEM.
5. Verify if all the devices and instrumentals are installed according to the
relevant schematic and drawing.
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6. Install the line & neutral cubicles with the relevant instrument / devices, sent
loose.
7. Install (or verify the installation of) the instruments and devices identification
labels.
8. Proceed with cables wiring according to schematic and wiring diagram.
9. Install or complete the ground system.
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9.8 Load Gear Box

In this paragraph are illustrated some operation to be carried out on gear box
during installation on site.
9.8.1 Checks
Upon arrives the load gear box, installed on common base with the Generator,
loose parts have to be checked for damage or loss. A careful visual inspection will
reveal any damage, while missing of any parts can be found by comparing the
received goods with the relative packing list. When any damage is found, reported
immediately to NP representative. Then proceed as follows:
9.8.2 Installation
Keep the cleanliness on all parts of the gear box and working area during the
installation activities.
a. Verify the alignment with the Gas Turbine and with the Generator.
b. Carry out the bolts tightening as per required torque after alignment
completion.
c. Connection of lube oil piping inlet and outlet to the lube oil headers of the
turbine.
d. Open the visit door and check the contact between the teeth.
e. Install and connect the vent.
f. Verify the correct installation of the instruments and install the instruments
loose shipped, if any.
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9.9 Intake Filter System

The Filter House arrives on site in more then one part to be assembled and it can
present other components and maintenance equipment’s as, for example, cranes
for filters lifting.
9.9.1 Checks
Check the foundations for correct structure locations and potential interference
with other structures and/or equipment.
Check the position of structure journal sub-plates.
It is suggested to check the diagonal distance between plates, in order to discover
eventually rhomboidal errors in previous anchor bolts/subplates positioning
Weld structure foundation pockets after confirmation of the alignment of inlet
duct with the Turbine skid.
9.9.2 Installation
• As soon as the foundations have been verified, the structure installation can
start. Verify the correct structure elevation and the centring with the Air inlet
duct. In the same time can start the assembly of parts of filter house that can
be installed on the ground, as internal walkway, hand rails and ladders.
• Pay attention if during the modules assembly the connection flanges and the
internal surfaces are clean: Also if a final cleaning will be perform prior crank
operations, some internal areas can results impossible to be inspected and
cleaned after the assembly completion. This will elevate the risks of
damaging for the machine.
• Prior the assembly, verified inside the Filter house the components assembled
with bolts. All bolts used inside the Filter House must be provide of anti-
loosening guards (system) or welded.
• After the structure completion, proceed with the filter house connection with
the Air inlet duct, taking care of gasket between flanged connections and their
cleanliness.
• Tight flanged connection bolts as per required torque values and begin the
bolts tightening starting from the flange centre proceeding alternatively from
the left side to the right side for a better flange distension.
• For the expansion joint installed between Filter House and Inlet Duct take in
consideration that the threaded bars used to support it must be taken out
before placing unit into operation. They must be re-installed again for
eventual further disassembly and assembly activities. In a correct installation,
03-09-E 170.5703-04 P. 2-53

in the expansion joint there will be not any tension and there will be not any
presence of torsion on its surface.
• As soon as the journal structure is installed and the filter house positioned on,
it can be installed the provided walkway and ladders; these items can be
previously installed if they don’t obstruct the Filter House positioning.
• Filter House is provided of inspection doors; Verified if inspection doors are
free from obstruction (structures, piping etc.), and if the opening /closing it’s
free from interference. Verify if gaskets are correctly applied.
• Proceed with the installation of rain hoods, inlet protection net, drain piping
and air cooler device as for example piping or ducts.
• Installation of the instruments installed on filter house near the maintenance
door.
Prior start up, the Filter House and all the Air inlet system must be inspect, and
eventually cleaned; an acceptance certification must be issued
For more information’s regarding the installation procedure see the relevant
Manual from filter house Supplier.
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9.10 Oil Vapour Separator

Oil vapour separator skid arrive already assembled on site; it is necessary to in-
stall the separator on relative structure and positioning and levelling it as required
by drawings.
Anchoring bolts with chemical means or expansion bolts can be used for Skid an-
choring on foundations (see the relevant drawing).
It is suggested check internal cartridge condition and oil mist extractor fans
[QV-1] – motors [88QV-1] alignment prior operating oil separator.
Verify the correct connection of the space heaters of the motors.
Piping installation, after initial checks and positioning, will consider on site con-
struction and assembly of:
- Inlet lube oil line (BL209);
- Outlet lube oil line and drain (BL210);
Correct installation and connection of instruments.
The voltage must be checked before feeding the instruments and electrical equip-
ment’s.
Do not forget to remove the vent protection blind flange installed for transport.
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9.11 Water Washing Skid

The purpose of the water wash system is to clean the axial compressor blades of
the gas turbine. The Water Wash system is designed for on-line and off-line
operation.
On/Off-Line Washing skid arrives already assembled on site; it is necessary to
install the skid where required by drawing on relative structure and positioning
and levelling it and to connect the relevant piping/flexible hoses with the Gas
Turbine.
9.11.1 Checks
As soon as the skid has been delivered, check to verify any non-conformity or
damage.
Verify if the hydraulic piping already installed on turbine skid is in accordance
with the drawing and schematics.
Special attention must be given to the connecting union for the flexible piping.
These items must be delivered protected and sealed. Any scratch on the union
contact surface can result in non-repairable leakage.
The interconnection piping/hoses are as follows:
- Installation of the interconnecting piping among the skid and the washing
solenoid valves on turbine baseplate terminal point (TP447) connections.
- Connection with water & chemical additive supply (TP436).
- Connection of the drain valves to the drains system (MP443).
- Connection of the drain valves from inlet plenum (TP448); from the turbine
case (TP450); from the exhaust plenum (TP452).
Make the electrical/instruments connection of the Local control Panel and
motor/pump on the skid, checking the correct voltage before feeding the
instruments and electrical equipments.
It is suggested a spray manifold check from solenoid valves to avoid risk of
nozzle non-conformity or dirty presence inside the lines with possible
consequence of potential machine damage.
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9.11.2 Piping
Water wash piping construction: If some interconnecting piping has to be
assembled on site, take the following steps during the assembly:
• Start fabrication & welding according to welding procedures piping sketches
and line specification requirements.
• Proceed with X-rays & Hydraulic test execution, as per line specification.
• Build (or adjust) piping support.
• Proceed with pipe painting, cleaning and/or piping identification colour/tag
application
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9.12 Fire Fighting System
9.12.1 General
Fire fighting skid (CO2 bottles) arrives on site already assembled except for the
bottles themselves that will be supplied later and assembled on site; it is necessary
to install the skid positioning and levelling it as required by drawing.
damage.
When handling the skid, be careful not to cause collisions and ensure that the
console doors are well locked because they may open during the handling
operations.
Interconnecting piping and material for CO2 fire fighting system is supplied in
commercial lengths and loose fittings and will be fabricated on site.
9.12.2 Installation
Expansion bolts must be used for Skid anchoring on foundations (see the relevant
drawing).
Install and connect (as required by the Schematic Piping) the CO2 bottles inside
the skid.
Restoration of the internal parts of bottles rack to make the system able to operate.
The voltage must be checked before feeding the instruments.
Make the electrical connection to the solenoid valves and the fire fighting system
state signals as: lights, horns and limit switches.
9.12.3 Piping
Piping installation, after initial checks and positioning, will consider on site
construction and assembly of:
- Construction and connection of piping from limit of the CO2 line of the
bottles skid headers to the Gas Turbine fire fighting system quick and slow
discharge lines, and with the ventilation dampers supply tubing.
- Build and install piping support.
- Proceed with pipe painting, cleaning and/or piping identification colour/tag
application
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9.13 HFO Filtration and Injection Skid
9.13.1 General
HFO skid arrives on site already assembled into two parts: the filtration and the
inhibitor injection skid; it is necessary to install the skids positioning and levelling
them as required by drawing.
As soon as the skids have been delivered, check to verify any non-conformity or
damage.
When handling the skid, be careful not to cause collision. Interconnecting pipes
and materials for the skids are supplied in commercial lengths and loose fittings
and will be fabricated on site.
9.13.2 Installation
Expansion bolts must be used for Skid anchoring on foundation (see the relevant
drawing).
Install and connects (as required by Schematic diagram) the inhibitor tank and the
HFO tank to the skids as indicated in the schematic diagram.
Make the electrical connection on the skids.
9.13.3 Piping
- Construction and connection of piping from limit of the HFO fuel and
inhibitor tank to the filtration and inhibitor injection skid respectively.
Connection and construction of instrumental air piping and recycle&drain
piping. Construction and connection of piping from the skid to the three way
valve.
application.
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9.14 Diesel Oil Treatment
9.14.1 General
Diesel Oil Treatment skid arrives on site already assembled into two parts:
damage.
When handling the skids, be careful not to cause collisions.
Interconnecting pipes and material for the skids are supplied in commercial
lengths and loose fittings and will be fabricated on site.
9.14.2 Installation
Expansion bolts must be used for Skid anchoring on foundations (see the relevant
drawing).
Install and connects (as required by the Schematic Diagram) the tank to the skids
as indicated in the schematic diagram. Make the electrical connection on the
skids.
9.14.3 Piping
- Construction and connection of piping from limit of the diesel oil tank to the
treatment skid. Connection and construction of recycle&drain piping.
Construction and connection of piping from the skid to the three way valve.
application
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9.15 Piping Construction in Site
To be applied to every auxiliary skid, if required.

If some interconnecting piping has to be pre-assembled on site, take the following
steps:
− Start piping fabrication and welding according to welding procedures, piping
sketches and line specification requirements.
− If necessary, clean (pickle/acid) pre assembled pipe work prior to installation.
To be at the discretion of NP Engineer
− Proceed with X-ray and hydraulic test execution, as per line specification
requirements.
− Assemble (or adjust) piping support.
− Proceed with pipe painting or piping identification/tag application, according
to identification line procedure (if required).
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10. FINAL ALIGNMENT & COUPLING INSTALLATION

The alignment will be completed only when the reading values respect the
alignment specification requirements considering that all the main items have
been installed.
After turbine inlet and exhaust ducts and piping installation, in case of positive
result, may be certified the final alignment acceptance.
10.1 Baseplate Fixing & Doweling

The operations to carry out after alignment acceptance are the following:
− Tightening of Gas turbine / Gearbox and Generator skids anchor bolts
according to torque value required by the relevant drawings
− Install the anti-loosening means on units anchor bolts (where required).
− After the final alignment completion, execute (where necessary) the units
doweling: items interested can be Gearbox and Generator.
− Regarding the turbine, usually are installed and welded two pair of locking
plate in the exhaust plenum area to avoid expansion toward driven machine
during the running. See Fig. 2.10.
− Couplings and coupling guards’ installation.
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Fig. 2.10 (typical)
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10.2 Couplings
10.2.1 Load coupling installation (flexible type)

Coupling installation will be done only after alignment completion and a previous
coupling dimensional check; main steps are the following:
− Clean coupling flanges and check that no dents or burrs are present.
− Check integrity of coupling.
− Check the correct distance between two coupling flanges of GT and load GB
as required by the Supplier’s instructions.
− Proceed to install the coupling following the Supplier’s Manual instructions,
(do not forget to insert the expansion joint on the coupling before
installation).
10.2.2 Load coupling guard installation

− Coupling Guard bottom side installation and bolting with the joint on turbine
side and the Gear Box flange on the other flange:
− Cover of coupling guard installation and bolting to the joint (turbine side) and
Gear box case and between them.
− Connect the drain and vent piping.
Fig. 2.11 - Load coupling guard (typical)
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10.2.3 Accessory coupling installation (flexible type)

After checking the alignment between accessory gear box and turbine shaft
proceed as follows:
− Clean coupling flanges and check that no dents or burrs are present.
− Check integrity of coupling.
− Check distance between shafts (Turbine & accessory Gear Box) and install
the coupling (do not forget to insert the expansion joint on the coupling)
− Bolts tightening (right torque) on both sides.
10.2.4 Accessory coupling guard installation

− Installation of the lower part of the guard connecting it with the flexible joint;
− Complete the cover installation and bolting as per required torque;
− Install the drain and the vent connecting it to the vent header.
Fig. 2.12 - Accessory coupling guard (Typical)
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10.2.5 Coupling between Gear Box and Generator

There is no separate coupling between the Gear Box and Generator shafts, in this
case the shaft ends are constituted by two flanges integral with the shaft that will
be bolted together, after alignment completion, by the special calibrated bolts.
The coupled flanges protection is supplied by the Generator Supplier.
− Install and tight the bolts as per required torque.
− Install the coupling protection.
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11 ELECTRICAL & INSTRUMENTS

In this paragraph are listed the main electrical & instruments activities to carry out
on Turbogenerator installation.
11.1 Equipments / Devices Positioning

Installer will execute positioning of machine panels only if installation area is
protected from atmospheric agent, humidity, ambient temperature values
acceptable by panels; it’s suggested to restrict the area for authorized personnel
only. The panels/devices will be installed inside the Control Room / Control
Cabin positioning them where provided by the reference drawings.
When the packing containing the panels are delivered to the site and unloaded,
make sure that the panel has not been damaged. Handle the panels with caution
for not damage its internal components. It is advisable to remove the panels
packing on the installation site.
Upon receipt, immediately provide for the panels protection against bad weather
(rain, sand, excessive humidity, heat, etc.) until installation. Generally, the
packing is not suited to the panels’ protection, it is therefore recommended to
store the panels in a closed and possibly air-conditioned location.
In case the panels are not immediately installed upon their delivery or within a
relatively short time after it, and it is not possible to store them in an air-
conditioned location, panels must be protected in accordance with the following
prescriptions:
Transpiring cover able to protect the panels from bad weather and humidity;
Ambient temperature between 0 °C and 45 °C (see panels specification), with
attention to sudden temperature variations that can cause condensation. If
necessary, internally install some heaters. In this case make sure that no
inflammable material is inside the protection;
Humidity between 5% and 95% in order to prevent condensation;
Protection against rodents, dust and corrosive elements and/or atmospheric agents.
For the panels installation it is advisable to keep to the following indications:
Where a floating floor is envisaged, adequate metal supports are to be
contemplated, normally supplied with the panels. These supports shall be fastened
to the reinforced concrete base by means of expansion blocks (Fisher or others).
The same procedure shall be adopted if the panel is fastened directly on the floor.
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For positioning, the panels shall be lifted through hoist or crane by eyebolts that
shall be tightened in the upper part of the frame. In case this operation is not
possible, the panels have to be shifted by rollers, taking all the precautions to
prevent deformation of the metallic structure and consequent damage of internal
components.
Precautions need to be taken in order to prevent damage to the floor in the control
rooms where the panels has already been installed.
11.2 Power-Off checks Initial conditions

Before starting preparation activities, the room where the panels are located must
be closed, clean and free from foreign materials.
Panel general maintenance conditions must be checked, and the panels must be
cleaned internally and externally.
The nameplate data of components inside the panels must be checked in order to
make sure they comply with the project.
11.2.1 Panels internal inspection

Before starting inspections make sure that all power supply circuit breakers are
open.
− Check the distance between power leads and signal leads.
− Visually make sure that internal components are not damaged;
− Make sure that there are no loose connections between cables, leads or relay
anchorage systems both of the panels and of internal sub-racks;
− Check the panels grounding;
− Verify the correct fastening of the sub-racks inside the panel;
− Make sure that electronic boards are in place and fastened;
− Verify the correct connection of flat cables;
− Make sure that wire armours are connected to the required "pin".
11.2.2 Wiring inspection

− Make sure that the panel input leads are correctly and completely connected
in accordance with the panel "Wiring diagram";
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− Make sure that each power connection corresponds to the right power supply;
− Make sure that input leads comply with contractual standards;
− Make sure that terminals are tightly clamped to their terminal boxes;
− Make sure that lead protection sheaths are not damaged; if necessary replace
the leads;
− Check the insulation of power leads;
− Check the interconnection cables with other systems (correct tampering and
numeration).
− Check the licences of the software installed in the interface.
11.2.3 Final Condition

The panels are delivered for commissioning in the following conditions:
− All power leads connected, checked and numbered;
− Control, signal and measurement cables connected, continuity check, and
adequately numbered;
− Internal, mechanical and electrical checks carried out;
− Grounding connections tested and fastened;
− Power supply circuit breakers and breakers for utilities all open;
− Fuse amperage value checked according to specifications;
− The panel and single components clean;
− The installation room clean and free from foreign materials that do not belong
to the fixed installation;
− Cableways clean and closed;
− Internal systems in the distribution panel room (lighting, FM, grounding,
ventilation, etc.) ready for commissioning;
− All knives of terminal boards open in order to isolate panel from the entire
field instrumentation.
Once all the points indicated above have been checked, the panel can be
considered as ready to be powered.
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11.3 Turbine, Gear Box & Generator

All instrumentation and electrical device on skid normally arrive complete
installed (wired to relative JB). Electrical activity will be done from field/off skid
equipment to JB installed on turbine and Gear Box/Generator skids and for
instrumentation sent loose for separated parts installation.
As main reference see “Package electrical outline” and “Field electrical wiring”
drawings.
11.3.1 Instruments, electrical devices & pneumatic connection

For all instrumentation and devices sent loose or partially disconnected (for
transport or installation reasons) by NP as shown on Instrument lists and
schematics to connect electrically and or pneumatically will be necessary
electrical connection and/or tubing connection as for process piping
instrumentation.
As soon skids arrive on site (main skids and auxiliaries) it is important check
completion of electrical and pneumatic connections of all instruments already
installed on skids, this to avoid activities schedule delay in case of repair during
critical phases of installation.
For electrical and pneumatic connection see Electrical and Pneumatic hook up.
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11.4 Auxiliaries Skids
11.4.1 Off-line washing

For Off-line washing skid it is necessary the cables installation and wiring of:
− Remote control unit for motor of washing pump [PW-1] with relevant space
heater [23 TW-5];
− Connection to the electrical heater [23TW-1] into the GT wash water tank;
− Cables laying and connection of the instruments washing skid panel and
instruments on skid.
11.4.2 Oil mist separator

− Cables installation and electrical connection of [88QV-1] fan motors with
relevant space heaters [23QV-1], and emergency stop button.
− Instruments on skid cables laying and connection.
11.4.3 Fire fighting skid

− Cables installation and connection of power supply to the CO2 bottles
pneumatic valves;
− Instruments cables laying and connection.
− Cables laying and connection among the Fire Fighting Panel with the turbine
enclosure Fire Fighting system and with Control Panel.
11.4.4 Filter house

− Supply cables to the instruments laying and connection to the relevant
Junction Box.
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11.4.5 Turbogenerator enclosure and ventilation

− Cables laying for power supply and connection to the ventilation fan motors
[88BA-1/2];
− Cables laying and connection of the instruments inside the enclosure
(temperature detectors, fire & gas detectors, pressure detectors, differential
pressure switch, limit switches position, devices for dampers operating, etc.).
− Connection to the electrical heater [23BA1/2] near the fan motors.
− Power supply cables laying & connection of internal and external lighting
systems (main & emergency).
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11.5 Miscellaneous
11.5.1 Cables & Wiring

Installer will execute cable laying from panel to panel and from control room
panels to turbogenerator, auxiliary’s skids, instrumentation and electrical utilities
involved, taking care to provide sealing for opening on panels.
Wiring (abutment, terminal assembly, cable/wire tagging, etc.) must be execute
for all instrument and devices supplied by NP relevant to turbogenerator unit (and
auxiliaries) erection. This activity include cable continuity check, insulation test
and construction of grounding system for all equipment, auxiliaries, machinery,
etc., belonging to the plant in accordance with the standards.
The cables may undergo damage during transport, handling and in the installation
operations, when mechanical means are used for laying cables.
To avoid the possibility of damage to the insulation at industrial voltage and
frequency, the following preliminary tests are suggested:
− Informal measurement of insulation prior to install the cables (to verify it has
not undergone damage during the transport).
− Informal measurement of insulation after installation of the cables (to check
for possible damage undergone during installation).
The cables are anchored to the gangways and/or to the structures with appropriate
means and materials (designed to avoid formation of magnetic turns for single-
pole cables, and possible dynamic effects deriving from the direct current).
11.5.2 Instruments calibration-setting

On site it is necessary check and perform calibration and setting of all pressure
switches, pressure transmitters, differential pressure transmitters and level
transmitters and other instruments as shown on Schematic Piping diagram and
Instrument list for Turbogenerator.
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INDEX
Contents Page
1. COMMISSIONING OF TURBOGENERATOR ................................................. 3-1

1.2 Oil System Activity .......................................................................................... 3-2
1.3 Starting System ................................................................................................. 3-6
1.4 Fuel Gas System on Base.................................................................................. 3-7
1.5 Load Gear Box.................................................................................................. 3-8
1.6 Electric Synchronous Generator ....................................................................... 3-9
1.7 Enclosure Ventilation ..................................................................................... 3-10
1.8 Fire Protection & Fighting on Base ................................................................ 3-11
1.9 Turbine Control & Protection ......................................................................... 3-12
1.10 Miscellaneous ................................................................................................. 3-14
2. COMMISSIONING OF OFFSITE FACILITIES .............................................. 3-15

2.1 Foreword......................................................................................................... 3-15
2.2 General............................................................................................................ 3-16
2.3 Oil Cooling System......................................................................................... 3-17
2.4 Oil Vapour Separator ...................................................................................... 3-18
2.5 Axial Compressor Washing System ............................................................... 3-19
2.6 Fire Fighting Skid ......................................................................................... 3-200
2.7 Turbine Air Intake Filter............................................................................... 3-211
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1. COMMISSIONING OF TURBOGENERATOR
The gas turbine MS5001 is provided with automatic sequence for “start-up” and
“shutdown” by means of SPEEDTRONICTM Mark VI.
The instructions given hereby are indicative and are referred to the instructions
manual of the gas turbine with the essential reference to the driven machines.
The indicative sequence of the main operation have the same order shown in the
index.
The main reference documents for start-up, operating and shut-down of gas tur-
bine are the following:
• Schematic Piping & Instrument Diagram SOM 5104201
• Field Instrument List SOM 6623063
• Control System Functional Description SOM 6622096
) NOTE
DO NOT ATTEMPT TO OPERATE THE UNIT UNTIL PERSONNEL HAS ACQUIRED A

THOROUGH KNOWLEDGE OF SAFETY DEVICES AND EMERGENCY OPERATION
PROCEDURES AND THE PRE-OPERATION SAFETY AND THE CONTROL FEATURES
HAVE BEEN CHECKED AND VERIFIED
) NOTE
FOR OPERATING ON SPEEDTRONICTM MARK VI PANELS REFER TO “SPEED-

TRONICTM INSTRUCTION MANUALS”.
Following are illustrated the operation to be carried out on gas turbine & Generator
skids and on related systems for their commissioning, after completing the installa-
tion on site.
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1.2 Oil System Activity
1.2.1 Lube oil

The more important checks to carry out for the system commissioning, after com-
pleting the installation and pre-commissioning activities (including the oil system
flushing & system restoring), referring to the relevant schematic piping diagram,
are as follows:
a. Be sure that the oil reservoir is filled with the recommended grade of oil.
b. Verify the oil level in the main reservoir by means of the lube oil tank (on
base) level gauge.
c. A.C. power must be available for: the auxiliary lube oil pump driver [88QA],
lube oil heaters and electric space heater for electric motor by means of the
relevant power indication lamps in the M.C.C.
d. D.C. power must be available for the emergency lube oil pump driver [88QE]
and electric space heater for electric motor, checking the charge of the
accumulator batteries in the D.C. power centre.
e. Verify that the drain valves of the lube oil filters [FL-1A/B] are closed.
f. Verify that all drain valves and test valves of pressure switches and pressure
gauges are closed.
g. Open all isolating valves of pressure transmitters/switches, pressure gauges
and level gauges.
When the mentioned operation are completed, it is possible to proceed with the
starting up of the lube oil system, as follows:
a. Turn the emergency lube oil pump driver [88QE] control switch in “manual”
position and start the emergency lube oil pump [PL-3] checking for direction
of rotation and unusual noise on the motor/pump. Stop the emergency pump.
b. Turn the auxiliary lube oil pump driver [88QA] control switch in “manual”
position and start the auxiliary lube oil pump [PL-2] checking for direction of
rotation and unusual noise on the motor/pump.
c. Turn the auxiliary lube oil pump driver [88QA] control switch in “manual”
position and turn the emergency lube oil pump driver [88QE] control switch
in “auto” position.
d. Put in auto position the electric oil heaters switches, regulating the oil
temperature inside the oil tank by means of the temperature transmitter
[LT-OT-1].
e. Check that the main lube oil filter [FL-1A] is full with oil looking at the
overflow of oil through the sight glass devices.
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f. Open the filling valve of the stand-by lube oil filter [FL-1B] and check when
the filter is full with oil, looking at the overflow of oil through the sigh glass.
g. Leave open the stand-by lube oil filter filling valve.
h. Move the lube oil filters transfer valve and leave it in the position of main
filters [FL-1A] in service.
i. Open the drain valve of the oil lines of the lube oil filter differential pressure
gauge and lube oil filter pressure transmitter, then open first the isolating
valve on the upstream line, and subsequently the isolating valve on the
downstream line.
j. Close finally the drain valve.
k. Check the oil flow from accessory gear, journal and thrust bearings of gas
turbine, by means of the flow sight glass.
l. Check the lube oil pressure in the lube oil header and make sure that it is
according to [VPR-2] pressure control valve setting (1,72 Bar G).
m. Check the lube oil pressure in the lube oil header and make sure that it is
according to [VR-1] pressure control valve setting (8,5 Bar G).
n. Then, stop manually the auxiliary lube oil pump and the emergency lube oil
pump and check the pressure point at which the gas turbine trips because of
lube oil pressure transmitters [96QT-2/A/B/C] installed on the Generator lube
oil bearing header
o. Turn the driver's control switches of the auxiliary lube oil pump and the
emergency lube oil pump in automatic position. The emergency lube oil
pump will stop because of the action of the lube oil pressure transmitter
[96QT-2A/B/C].
p. Verify on the display of the Speedtronic Mark VI that the alarms of the lube
oil system are off, except: auxiliary lube oil pump running.
q. Stop manually the auxiliary lube oil pump leaving the emergency lube oil
pump in automatic position. The emergency lube oil pump will start because
of the action of the lube oil pressure transmitter [96QT-2A/B/C].
The emergency pump starting comes after the turbine stopping.
r. During the normal operation the lube oil flow will be supplied by means of
the lube oil main pump, driven by the accessory gear and the auxiliary lube
oil pump will manually stopped, it will be automatically restart when the oil
pressure decrease under the values provided for restart the auxiliary pump by
acting of pressure transmitter [96QT-2A/B/C].
s. The lube oil temperature is maintained at normal values by means of
thermostatic valve [VTR-1] installed on the water pipe of the lube oil cooling
03-09-E 170.5703-04 P. 3-3

system, providing to cool the oil when the temperature increases. Verify the
normal operating of the system.
t. According to the operating conditions of driven machines, start the hydraulic
ratchet pump [PH-3] and start the ratchet to check if it is working well.
u. Check for any oil leaks of the piping and devices involved in the lube oil
system
v. Verify the indication of oil vapours separator instruments opening the
pressure gauge isolating valves and starting of the extractor fans [FNL-1]
checking for their efficiency.
w. Verify the correct operation of differential pressure transmitter
[96QV-1A÷1C] checking the differential pressure between the oil tank and
atmosphere. These transmitters start the auxiliary extraction motor/fan of the
oil mist separator in case of increasing differential pressure between the tank
and atmosphere, and stop the same motor/fan when the differential pressure is
restored.
1.2.2 Hydraulic oil

The hydraulic oil pump [PH-1] is driven by accessory gear box shaft. Conse-
quently with the turbine at a standstill the pump is motionless. Therefore the sys-
tem commissioning activities will be executed during the turbine first start-up as
follows:
a. When the turbine is running and lube oil pump supply the oil to the hydraulic
oil pump, check for some unusual noise;
b. Open the vent valve of the H.P. hydraulic filters [FH1-1/2] in service and
closed it again as soon as the filter is full;
c. Set the overpressure valve [VR-21], on the hydraulic manifold, at 90 Bar G,
then set, if necessary, the [VPR3-1] pressure regulating valve, on the pump, at
80 Bar G .
d. Open the filling valve of the H.P. hydraulic filter [FH1-2] not in service,
open the vent valve of that filter and closed it again as soon as the filter is
full;
e. Leave the filling valve open;
f. Move the H.P. hydraulic filter transfer valve and leave it in the position of the
main filter [FH1-1] in service;
g. Check if the pressure transmitter [96HF-1] of hydraulic oil filter differential
pressure gives the signal when the differential pressure reaches the setting
value;
03-09-E 170.5703-04 P. 3-4

h. Check if the pressure transmitter [96HQ-1] of hydraulic oil header pressure

gives the signal when pressure reaches the setting value;
i. Reset the trip alarm on the display of the Speedtronic MARK VI;
j. Check for oil leaks of the piping and devices involved in the hydraulic oil
system;
k. Verify on the display of the Speedtronic MARK VI that the alarms of the
hydraulic oil system are off.
1.2.3 Hydraulic ratchet

In the hydraulic oil system is included also the ratchet system, built in the torque
converter and its integral part.
It is necessary for turning the turbine shaft during the start up of the Turbogas and
during its cool down time after the Unit stop.
The more important checks to perform are:
a. Switch on the relevant breaker on the DC panel supplying the necessary
electric power to the electric motor [88HR];
When the lube oil system is running it is possible starting the pump and check
the calibration of the overpressure valve [VRS-1] setting the delivery pressure
at 55 Bar G, as required by the schematic piping diagram.
c. Then, start-up the pump and check the correct motion of the turbine shaft
following the required timing sequences of start and stop.
03-09-E 170.5703-04 P. 3-5

1.3 Starting System

The commissioning of the electric motor requires the following steps:
a. Check the power supply of the electric starting motor [88CR-1].
b. Check the normal engagement of the starting clutch with the relevant signal
given by [33CS-1] limit switch.
c. Check the correct operation of the servovalve for speed changing [20TU-1]
d. Check that all junction boxes are covered, which signifies that all wiring are
completed and correctly connected.
e. Starting motor functional test performing, starting and stop (disconnected
from the turbine shaft, without engaging the clutch.
03-09-E 170.5703-04 P. 3-6

1.4 Liquid Fuel System on Base

It is very important that gas turbine operators always check for liquid fuel leaks,
but the leak test and correcting action required must be performed before gas
turbine preparation for starting.
! WARNING
ELIMINATION OF LIQUID FUEL LEAKS IS OF EXTREME IMPORTANCE AS A

FIRE DANGER PREVENTIVE MEASURE.
a. Check that liquid fuel stop valve is not in closed position [33FL-1].
b. Check that liquid fuel pressure transmitter PT-908 [96FL-1] indicated
pressure fuel is established. It’s used as a permissive to energize fuel pump
clutch solenoid [20CF-1].
c. With the liquid fuel feeding line empty check operating of fuel gas trip
valve [VS-1], with lube oil system and hydraulic oil supply system started,
by opening of solenoid valve and operating the control valve [20LF-1].
! WARNING
REMEMBER THAT AFTER ANY GAS TURBINE SHUTDOWN, ALL VENT

VALVES MUST BE OPEN.
03-09-E 170.5703-04 P. 3-7

1.5 Load Gear Box

For Gear Box commissioning the following activities are required:
a. Open all isolating valves of the instruments closing the relevant vent/drain
valves.
b. Check the oil inlet pressure to the gear box bearings (1,72 Bar G).
c. Verify the correct readings of the four journal bearings (two for each bearing)
and of the thrust bearings (four: two for active side and two for inactive side)
on the low speed shaft, thermoelements.
d. Check the oil flowing through the bearings by means of the flow gauge on the
bearing discharge piping.
e. Vibration no contact probes on gear box # 1 and # 2 journal bearings of high
speed shaft correct positioning and readings.
f. Probes and proximitors for thrust bearing on low speed shaft axial
displacement correct positioning and readings.
g. Vibration no contact probes on the gear box # 3 and # 4 journal bearings with
relevant proximitors correct positioning and readings.
h. Accelerometer for gear box high speed and low speed shafts vibration correct
readings checking.
03-09-E 170.5703-04 P. 3-8

1.6 Electric Synchronous Generator

To prepare the Electric Generator to start-up are to be made the following
commissioning activities:
a. Check the opening of the pressure transmitter [96QT-2A/B/C] isolating
valves ;
b. Check the correct connection and insulation of the generator winding space
heater [23HG-1/2/3/4].
c. Check the correct readings of the thermoelements checking respectively the
ventilation air of the winding cooling (hot and cold).
d. Check the correct readings of the thermoelements of the bearings metal of DE
and NDE sides.
e. Check the correct operation of the vibration sensors on the bearings of DE
and NDE sides.
Electrical:
f. Power cables and bus bars testing (insulation and conductivity).
g. Unit ground connection verification.
h. Excitation system calibration and setting.
i. Protections relays calibration and setting on the relevant protection Panel.
j. Generator neutral point and line star point connection with the power
distribution system completion verification.
03-09-E 170.5703-04 P. 3-9

1.7 Enclosure Ventilation

To prepare this system to start-up, the following commissioning activities are
required:
a. Check that A.C. power be available for main and stand-by electric fans
[FNVF1/2] with relevant space heaters [23BA-1/2] according to
manufacturer’s instructions;
b. Calibration and testing of catalytic gas detectors [45HD-1A÷1C] installed on
the air ventilation outlet duct of the turbine compartment;
c. Verification of accessory compartment inlet damper correct opening and
respectively consequent emission of position switch [33ID-1] signal;
d. Verification of accessory compartment outlet damper correct opening and
closing and respectively consequent emission of position switches [33ID-1]
signal;
e. Calibration and testing of the differential pressure transmitter [96SV-
1A/1B/1C] in the turbine compartment.
f. Calibration and testing of the temperature transmitters [TT-BA-2A÷2C]
installed inside the turbine compartment air ventilation outlet duct
g. Verification of turbine and coupling/gear box compartment outlet damper
correct opening and closing and respectively consequent emission of position
switches [33OD-3] signal;
h. Verification of Generator compartment outlet damper correct opening and
closing and respectively consequent emission of position switches
signal;
i. Calibration and testing of the differential pressure transmitter in the
Generator compartment.
j. Limit switches on access doors [33DT-1÷8] correct setting and operation
checking.
k. Check the correct operation of the manual and gravity dampers on the
ventilation air inlet system;
l. Functional test performing, of motor fans;
m. Turn the control of both fans to automatic position.
03-09-E 170.5703-04 P. 3-10

1.8 Fire Protection & Fighting on Base

To prepare the mentioned system to start-up the following commissioning
activities are required:
a. Verify the correct type installed and functioning of fire detectors [45FA-1,
45FA-2, 45FA-3, 45FA-4] inside the accessory compartment;
b. Verify the correct type installed and functioning of fire detectors [45FT-1,
45FT-2, 45FT-3, 45FT4] inside the turbine compartment;
c. Verify the correct type installed and functioning of fire detectors [45FT-5,
45FT-6, 45FT-7] inside the turbine/coupling compartment;
d. Check the correct installation of CO2 nozzles (slow and quick discharge with
the required release orifice) inside the compartments;
e. Test lighting lamp (visual alarm), buzzer/horns (audible alarm), outside and
inside the enclosure;
f. Being sure that energizing the release solenoid valves CO2 bottles skid, will
not cause the discharge of CO2 from the bottles, activate with a small flame
the fire detector in the different compartments and check the alarm;
g. Reassemble everything as before ready to start-up.
03-09-E 170.5703-04 P. 3-11

1.9 Turbine Control & Protection

For turbogenerator protection and control system commissioning are required the
following activities to carry out on the relevant instruments:
On axial compressor:
a. Verification on the axial compressor air Inlet temperature thermoresistances
[CT-IA-1, CT-IA-2] correct reading.
b. Verify the compressor air discharge temperature thermocouples [CT-DA-1,
CT-DA-2] correct reading.
c. Calibration of discharge pressure transducer [96CD-1÷3].
On turbine:
a. Checking the calibration of the turbine wheel space temperature 1st stage
forward by reading in the MARK VI display the temperature indicated from
[TT-WS1FO-1, TT-WS1FO-2] double thermocouples.
b. Checking the calibration of the turbine wheel space temperature 1st stage
afterward (by reading in the MARK VI display the temperature indicated
from [TT-WS1AO-1, TT-WS1AO-2] double thermocouples.
c. Checking the calibration of the turbine wheel space temperature 2nd stage
forward (by reading in the MARK VI display the temperature indicated from
[TT-WS2FO-1, TT-WS2FO-2] double thermocouples).
Checking the calibration of the turbine wheel space temperature 2nd stage
afterward (by reading in the MARK VI display the temperature indicated
from [TT-WS2AO-1, TT-WS2AO-2] double thermocouples.
The setting values of all wheel space thermocouples are: Alarm: 427°C;
Trip:457°C.
d. Exhaust thermocouples [TT-XD-1 ÷ TT-XD-13] calibration and testing as per
instrument list. Set: Alarm: 574°C; Trip: 582°C..
Check the readings before, at steady state of the turbogenerator.
e. Calibration and testing of the differential pressure transmitters [96EA-1]
between the exhaust duct and atmosphere. Set: Alarm: 5,0 KPa d ; Trip: 6,0
kPa d.
03-09-E 170.5703-04 P. 3-12

Speed, bearings temperature and vibration

a. Speed probes [77NH-1, 77NH-2, 77NH-3] positioning and gap among them
and the turbine shaft verification. Set: Trip: 5610 rpm
b. Temperatures reading verification of thermoelements installed on bearings
metal; thrust bearing active and inactive sides respectively [BT-TA-1A/1B,
BT-TA-2A/2B and BT-TI-1A/1B]; #1 journal bearing [BT-J1-1A/1B and BT-
J1-2A/2B]; #2 journal bearing [BT-J2-1A/1B and BT-J2-2A/2B].
All thermoresistances on the bearings (thrust and journal) are set at 115°C for
alarm only.
c. Seismic probes on the bearings covers [#1 bearing 39V-1A/1B; turbine casing
39V-2A/2B] reading and calibration (setting values on the Control Panel:
High vibration Alarm: 12,7 mm/sec, High-High vibration Trip: 25,4
mm/sec).
d. No contact radial vibration probes on bearings correct readings and
thresholds calibration verification. On journal bearing #1 [XE-1X, XE-1Y];
on journal bearing #2 [XE-2X, XE-2Y], setting values on the Bentley Nevada
rack: 110 micron.
e. Axial displacement probes on thrust bearing [XZ-1 and XZ-2] correct
readings and thresholds calibration verification (setting values on the Bentley
Nevada rack +/- 0,6 mm.
f. Key-phasor [XPH]correct installation and gap checking.
Flame control
a. Flame detectors [28FD-2, 28FD-3, 28FD-7, 28FD-8] testing, exciting them
with a small flame.
b. Transformers [95TR-1, 95TR-10] powering and spark plugs [95SP-1, 95SP-
10] testing, after dismounting them from the combustion chambers.
Reinstalling the sparkplugs on the combustion chambers after completing the
test.
! WARNING
IF A SPARKING TEST OF THE SPARK PLUGS IS NECESSARY, DO NOT TEST

SPARK PLUGS WHERE EXPLOSIVE ATMOSPHERE IS PRESENT. A PERMIT FOR
THIS OPERATION IS REQUIRED.
03-09-E 170.5703-04 P. 3-13

1.10 Miscellaneous
Axial compressor air flow control
Check the operating condition of the antisurge valves [VA2-1, VA2-2] with the
relevant intervention of the limit switches [33CB-1, 33CB-2] inhibiting the
Turbogenerator starting-up when the valves are fully open. Check the correct
operation to the servovalve [20CB-1]
Verify the operation of the IGV control system operating by the servovalve
[90TV-1] and the flow control valve [VC-1]; then living it in correct position to
enable the Turbogenerator start-up.
Check also the correct calibration of the LVDT [96TV-1, 96-TV-2] for IGV
position control.
Washing system on turbine base

Check the correct functioning of the solenoid valves [20TW-2] for off-line water
washing inlet.
Verify the close position of the drain manual valves installed on the inlet plenum,
turbine casing and exhaust plenum drains.
Grounding system
Grounding system of each component of Turbogenerator correct connection and
conductivity checking (Turbine, Gear Box, Generator, Enclosure, etc.).
03-09-E 170.5703-04 P. 3-14

2. COMMISSIONING OF OFFSITE FACILITIES
2.1 Foreword
! WARNING
THE PERSONNEL ENTRUSTED WITH THE OPERATION OF NUOVO PIGNONE

PRODUCTS SHALL HAVE THE NECESSARY TECHNICAL CHARACTERISTICS
AND SUITABLE TECHNICAL TRAINING FOR THE TASK IT HAS TO
ACCOMPLISH.
THESE TECHNICAL CHARATERISTICS SHALL BE IN COMPLIANCE WITH

INTERNATIONAL STANDARD CLASSIFICATION OF OCCUPATIONS.
AFORESAID ESSENTIAL CHARATERISTICS SHALL BE ATTRIBUTABLE TO
These instructions describe a detailed procedure for the operation of the machine.
Since the instructions do not provide for every possible contingency to be met in
connection with operation, slight different procedures can be used.
Regardless of the procedure used, only qualified and experienced personnel shall
be entrusted with this task.
! WARNING
ANY INJURY OR DAMAGE RESULTING FORM OFF DESIGN OR IMPROPER

OPERATION, NEGLIGENT PROCEDURE AND MAINTENANCE DEFICIENCY OR
EFFECT OF CORROSION, EROSION, DEPOSITS OF SCALE AND WEAR AND
TEAR ARE EXCLUDED FROM NUOVO PIGNONE WARRANTY.
03-09-E 170.5703-04 P. 3-15

2.2 General
Here below are described the commissioning activities to be carried out on the
auxiliary equipment of Turbogenerator train positioned outside the main
baseplates. The commissioning activities referred to the Turbogenerator auxiliary
installed on the Turbogenerator base are mentioned on Turbogenerator
commissioning section.
The main reference documents for start-up and operating of gas turbine are the
following:
• Schematic Piping Diagram SOM 5104201
• Field Instrument List SOM 6623063
• Control System Functional Description SOM 6622096
! WARNING
DO NOT ATTEMPT TO OPERATE THE UNIT UNTIL PERSONNEL HAS

ACQUIRED A THOROUGH KNOWLEDGE OF SAFETY DEVICES AND
EMERGENCY OPERATION PROCEDURES AND THE PRE-OPERATION SAFETY
AND THE CONTROL FEATURES HAVE BEEN CHECKED AND VERIFIED
03-09-E 170.5703-04 P. 3-16

2.3 Oil Cooling System

The oil coolers installed inside the turbine baseplate, accessory compartment.
a. Verify the calibration and correct operation of the thermostatic valve
[VTR-1].
b. Check calibration and setting of the safety valves installed on the water outlet
lines from the coolers set at 8,83 Bar G.
03-09-E 170.5703-04 P. 3-17

2.4 Oil Vapour Separator

a. Check external cleaning of vapour separator .
b. Verify of foreign screens and blinds on interconnection lines
c. Instrument calibration, setting, energizing and functional checks performing
d. Check electric motor [88QV-1] with relevant space heaters absorption values
and fan correct operation
e. Check oil tank differential pressure values during machine running with
differential pressure indicators.
03-09-E 170.5703-04 P. 3-18

2.5 Axial Compressor Washing System

a Functional check of valves on drain
b Water / detergent in the reservoir level verification.
c Power supply for motor/pump and heaters checking.
d Heater [23TW-1], in water washing tank, insulation checking & energizing.
e Instruments calibration and testing.
f Electric motor [88TW-1] starting and direction of rotation checking.
g Energizing of the space heater [23TW-5] of the electric motor
h Functional check of ON/OFF washing system.
03-09-E 170.5703-04 P. 3-19

2.6 Fire Fighting Skid

a Connection & operating of discharge solenoid valves.
b Operation of manual discharge actuator.
c Operating of discharge selectors.
d Intervention of discharge stop switch.
e Intervention sequence of fire protection system.
f CO2 bottles used for test re-filled after discharge text execution.
g CO2 bottles restored on the relative racks with relevant piping connected and
tightening.
h Solenoid valve correctly connected to the system after commissioning test

completion.
i Fire fighting system and relative piping checked. No loose components, un-
ions or flanged connections have been detected after commissioning comple-
tion.
03-09-E 170.5703-04 P. 3-20

2.7 Turbine Air Intake Filter

a Setting and testing of limit switch [33AF-1A] on the emergency door.
b Setting and testing of the catalytic gas detectors [45TF-1A/1B/1C].
c Testing of the differential pressure transmitter [96TF-1A/1B/1C] between

downstream filter case and atmosferical pressure.
d Check the correct readings of the differential pressure gauges.
e Inlet plenum instruments setting and testing.
f Ground system testing.
g Duct final internal cleanness condition checking before starting the turbine.
03-09-E 170.5703-04 P. 3-21

Initial Start-Up Section 4
INDEX
Contents Page
1. GENERAL................................................................................................................ 4-1
1.1 General indication............................................................................................. 4-1
1.2 Foreword........................................................................................................... 4-2
2. PREPARATION FOR START-UP........................................................................ 4-3

2.1 General.............................................................................................................. 4-3
2.2 General pre start-up procedure ......................................................................... 4-4
2.3 Introduction....................................................................................................... 4-5
2.4 Lube oil system................................................................................................. 4-6
2.5 Hydraulic oil system ......................................................................................... 4-8
2.6 Lube oil mist separator ..................................................................................... 4-9
2.7 Cooling & sealing air system...................................................................... 4-1010
2.8 Ventilation & gas detection system .............................................................. 4-111
2.9 Starting system.............................................................................................. 4-122
2.10 GT Fire Detection & Fighting System.......................................................... 4-133
2.11 Generator ...................................................................................................... 4-144
2.12 Load Gear Box.............................................................................................. 4-155
3. PROCEDURE OF START-UP........................................................................... 4-166

3.1 Checks Prior to Start-Up............................................................................... 4-166
3.2 Checks During Start-Up And Initial Operation ............................................ 4-188
3.3 Gas Turbine Start-up & Operation ............................................................... 4-200
4. TYPICAL READINGS ....................................................................................... 4-277

4.1 Gas Turbine................................................................................................... 4-277
4.2 Gear Box And Generator .............................................................................. 4-322
03-09-E 170.5703-04 P. 1-1

1. GENERAL
1.1 General indication

The scope of the following instructions is to put in condition the Operators to
prepare the Turbogenerator Unit and relevant auxiliary equipment, through the
commissioning activities carried out in each system involved, at initial start-up.
The activities will be performed by the operating skilled personnel.
The operation are developed as follows:

- Commissioning of Turbogenerator train with the auxiliary equipment
installed on the same baseplate (as starting system, fuel system on base, oil
system, etc.)
- Commissioning of auxiliary equipment installed outside the baseplate and
installed on the different skids.
- Initial startup procedure
- Normal startup procedure.
Therefore will be available in the plant:

- AC and DC electric power, to supply all the electric and control/protection
panels of the GT and Generator.
- The instrument air for the required uses.
- Water for cooling the oil systems.
- The diesel oil and the crude oil for GT operation.
- The fire fighting system of the plant to protect the auxiliary skids.
When the services before mentioned are available and the commissioning
activities referred to all systems involved in Turbogenerator operation are
completed, the Operators may proceed with the initial start activities.
03-09-E 170.5703-04 P. 4-1

1.2 Foreword
! WARNING
THE PERSONNEL ENTRUSTED WITH THE OPERATION OF NUOVO PIGNONE

PRODUCTS SHALL HAVE THE NECESSARY TECHNICAL CHARACTERISTICS
AND SUITABLE TECHNICAL TRAINING FOR THE TASK IT HAS TO
ACCOMPLISH.
THESE TECHNICAL CHARACTERISTICS SHALL BE IN COMPLIANCE WITH

INTERNATIONAL STANDARD CLASSIFICATION OF OCCUPATIONS.
AFORESAID ESSENTIAL CHARACTERISTICS SHALL BE ATTRIBUTABLE TO
These instructions describe a detailed procedure for the operation of the machine.
Since the instructions do not provide for every possible contingency to be met in
connection with operation, slight different procedures can be used.
Regardless of the procedure used, only qualified and experienced personnel shall
be entrusted with this task.
! WARNING
ANY INJURY OR DAMAGE RESULTING FORM OFF DESIGN OR IMPROPER

OPERATION, NEGLIGENT PROCEDURE AND MAINTENANCE DEFICIENCY OR
EFFECT OF CORROSION, EROSION, DEPOSITS OF SCALE AND WEAR AND
TEAR ARE EXCLUDED FROM NUOVO PIGNONE WARRANTY.
03-09-E 170.5703-04 P. 4-2

2. PREPARATION FOR START-UP
2.1 General
The gas turbine MS5001PA is provided with automatic sequence for “start-up” and
“shutdown” by means of SPEEDTRONICTM Mark VI.
The instructions given hereby are indicative and are referred to the instructions ma-
nual of the gas turbine with the essential reference to the driven machines.
The indicative sequence of the main operation have the same order shown in the
index.
The main reference documents for start-up, operating and shut-down of gas turbine
are the following:
Schematic Piping Diagram SOM 5104201
Field Instrument List SOM 6623063
Control System Functional Description SOM 6622096
! WARNING
DO NOT ATTEMPT TO OPERATE THE UNIT PERSONNEL HAS ACQUIRED A

THOROUGH KNOWLEDGE OF SAFETY DEVICES AND EMERGENCY OPERA-
TION PROCEDURES AND THE PRE-OPERATION SAFETY AND THE CONTROL
FEATURES HAVE BEEN CHECKED AND VERIFIED.
) NOTE
FOR OPERATING ON SPEEDTRONICTM MARK VI PANELS “PLS” REFER TO

“SPEEDTRONICTM" INSTRUCTION MANUALS.
03-09-E 170.5703-04 P. 4-3

2.2 General pre start-up procedure

The aim of this paragraph is to briefly remind some of the activities involved in
the initial start-up, especially referring to all the preparation work to be carried out
prior to initial operation.
Technical terms for distinguishing the different phases included in ”Preparation

for start-up” are:
• Pre-commissioning: including all preparatory work
• Commissioning: providing the start-up sequence of the units
The preparatory works includes:

• Systematic conformity checks, carried out on each item of equipment or com-
ponent, visual verification of the condition of equipment, the quality of the
installation, compliance with project drawings and specifications, manufac-
turer’s instruction, safety rules, codes, standards and good construction prac-
tice.
• Completed equipment static/de-energized tests to ensure the quality of equip-
ment installation (”cold tests” – concerns all disciplines):
o Calibration of instruments
o Testing and setting of pressure relief valves
o Machinery alignments
o Hydrostatic pressure testing of piping
o Testing of cables and electric equipments (insulation resistance, continu-
ity, etc), functional tests on all protection relays and interlocks.
• Cleaning and flushing of the unit (air blowing, oil flushing), dry all equip-
ment.
• All initial fill of lubrication oil, grease, chemicals, etc.
Commissioning of the units includes:

• Pre start-up activities such as:
o Dynamic tests: (electrical motors uncoupled runs, instrument loops tests,

electrical breakers operation, energisation of electrical distribution net-
work)
o Mechanical preparation: (running-in and on line tests for a significant pe-
riod of the utilities or of the main process equipment in closed loop).
o Gas-in preparation: (piping drying out, leak tests, inert).
03-09-E 170.5703-04 P. 4-4

2.3 Introduction
The scope of the preparatory works to get the Turbogenerator plant started is:
1) Commissioning and put in service Turbogenerator Fire & Gas detection and
protection System.
2) Commissioning and put in service Fire & Gas Detection System for Control
Cabin (at least) , if any.
3) Commissioning and energize the MCC and all utilities needed for a normal
operation of Turbogenerator plant, such as:
• AC & DC distribution system (MCC, UPS, etc.)
4) Commissioning and starting all the utilities for a gas turbine normal operation
(oil systems, fuel gas, ventilation systems, oil cooling system, GTG fire fight-
ing system, etc.)
03-09-E 170.5703-04 P. 4-5

2.4 Lube oil system
Valves position (opened/closed) for initial start-up and normal operation of lube
oil system is indicated in Schematic Piping Diagram.
The unit is equipped with one mechanical shaft-driven pump [PL-1], an AC auxil-
iary pump [PL-2] and a DC emergency pump [PL-3]. Their purpose is, to lubri-
cate and cooling the GT, as well as the gear box and generator, bearings during
the unit operation.
The lube oil pumps are designed for continuous operation but are not operated af-
ter the gas turbine package is shut down and the cooldown timer has elapsed.
To operate the mineral lube oil pumps, the oil tank level and temperature shall be
between the operation limits; if the level (300÷400 mm. from tank top cover) or
temperature (20°C÷79°C) is not OK before starting, starting will be inhibited and
an alarm will occur. If one of the parameters will be not OK during operation of
the unit an alarm and subsequently a shut down will occur.
oil system is indicated in Schematic Piping Diagram.
Prior to start the gas turbine, the operator selects: ”Auto” control in MCC for
[23QT-1/2/3/4] lube oil heaters and [PL-2] auxiliary lube oil pump, and in DCP
for [PL-3] emergency lube oil pump.
When unit start is selected the lube oil system starts automatically.
When the right pressure is restored permission to continue with starting sequence
is given.
When the gas turbine reaches the ”OPERATING SPEED”, at 95% of the rated
speed, the AC auxiliary lube oil pump will be manually stopped and the accessory
gear driven main lube oil pump guarantees the oil flow amount.
As long as the gas turbine is above the ”OPERATING SPEED”, if the conditions
”LUBE OIL HEADER PRESSURE LOW” (MK VI command name 4QA) will
be detected, the AC auxiliary oil pump will be automatically started. If normal
conditions are restored, the stand by pump can be stopped manually from the HMI
or from the MCC according to the duty/standby philosophy.
The lube oil header pressure low-level threshold [PI-5], installed on the Generator
lube oil header, causes the DC emergency lube oil pump to start if lube oil header
pressure is lower than the shutdown level.
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With such threshold, when the emergency pump comes in operation, the unit is in
shutdown condition.
Once the pump is started, it runs continuously for 15 minutes and then 30 seconds
on, 3 minutes off cycle is started for power supply batteries safeguarding until the
end of cooldown. The DC emergency lube oil pump will be stopped as soon as the
condition ”LUBE OIL HEADER PRESSURE NORMAL” is detected
[96QT-2A÷2C].
During normal GT operation, the operator is normally allowed to manually start

and stop the standby pump, unless it is prevented to run or required on by the con-
trol logic.
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2.5 Hydraulic oil system
Valves position (opened/closed) for initial start-up and normal operation of the
hydraulic system is indicated in Schematic Piping Diagram.
The Gas Turbine is equipped with one mechanical shaft-driven pump installed on
the Accessory gear box. Its purpose is to operate the axial compressor IGV noz-
zles and the GT fuel valves .[SRV-1 and GCV-1].
The H.P oil pump is designed for continuous operation but is not operated after
the gas turbine package is shut down.
To operate the Hydraulic oil pump, the oil pressure shall be inside the operation
limit; if the pressure value is not OK (65 Bar G min.) an alarm will occur. The
maximal pressure admitted for the hydraulic mechanical driven pump delivery is
90 Bar G regulated by a overpressure valve [VR-21]; and is also protected from
overpressure by a pressure regulating valve [VPR3-1] inside the pump body that
will be regulated at 80 Bar G.
If the pressure decrease under the minimal pressure (65 Bar G) during the Unit
operation an alarm is generated by a pressure switch [96HQ-1]
When the hydraulic oil pump driven by accessory gear box reaches the 1500
RPM it guarantees the oil pressure and flow amount during gas turbine operation.
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2.6 Lube oil mist separator
Valves position (opened/closed) for initial start-up and normal operation of oil
vapor separator is indicated in Schematic Piping Diagram.
Prior to starting the GT operator selects ”Auto” control in MCC for [88QV-1]
lube oil vapor separator.
The lube oil vapor separator fans [QV-1] will be started at turbine start-up and
will continue to operate up to the end of cooldown sequence. The stand-by one
will be started, by intervention of differential pressure transmitters, in case of oil
tank pressure increasing over the rated limit. Set: Alarm 20 mm.H2O; Trip 50
mm.H2O.
The fan will be started also in case of pressure detected in the lube oil tank after
cooldown end.
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2.7 Cooling & sealing air system
Valves position (opened/closed) of [VA2-1 and VA2-2] compressor antisurge,

valve vent and instruments condition for initial start-up and normal operation of
cooling & sealing air system is indicated in Schematic Piping Diagram.
The antisurge valves will be checked and will be open to be enable to start the
Unit, the control of opening of the valves will be verified by the signal transmitted
by the positioning micro-switches [33CB-1 and 33CB-2] sending a signal to the
Control Panel.
Check the correct operation of the antisurge valves, before starting the turbine, us-
ing an external source of air, to be able to open them by acting the relevant ser-
vovalve [20CB-1].
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2.8 Ventilation & gas detection system
The gas turbine compartment is equipped with 2×100% duty/standby ventilation

fans [FNVF-1/2].
Before proceeding to first start up of ventilation system operator ensures that all
fire dampers for ventilation air inlet and outlet are opened. Operation with fire
dampers closed is not allowed.
The GT compartment ventilation fans are designed for continuous operation but
are not operated after the gas turbine package is shut down and cooldown timer
has elapsed.
Prior to start the gas turbine, the operator selects: ”Main/Duty” for [FNVF-1] tur-
bine enclosure ventilation fan and ”Standby” for [FNVF-2] turbine enclosure
ventilation fan, in Mark VI software, and ”Auto” control in MCC for [FNVF-1/2]
and for [23BA-1/2] of motors space heaters.
When unit start is selected, the duty fan is started automatically.
After the activation of ”MASTER PROTECTIVE SIGNAL” the fan is not
stopped any more until the end of cooldown, unless emergency conditions such as
fire dampers closed or fire detected in the enclosure: in these cases all fans shall
be immediately cut out.
Fans inhibition for fire dampers closed is not latched and once the dampers are
open again the fans are no more prevented to run.
If there are conditions as ”Compartment temperature high” or ”Gas detected in-
side enclosure”, the stand by fan automatically starts. If normal conditions are re-
stored, the duty fan can be stopped manually from the HMI or from MCC accord-
ing to the duty/standby philosophy.
During normal GT operation, the operator is never allowed to manually stop the
duty fan.
The operator is normally allowed to manually start and stop the standby fan,
unless it is prevented to run or required on by the control logic.
The operator is allowed to initiate any time a duty/standby changeover: the selec-
tion is performed by means of the MK VI <HMI> operator interface software
pushbutton.
Valves position (opened/closed) and instruments condition for initial start-up and
normal operation of ventilation system is indicated in Schematic Piping Diagram .
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2.9 Starting system
normal operation of starting system is indicated in Schematic Piping Diagram.
A visual inspection of the turbine should be performed before attempting to oper-

ate the Turbogenerator.
Prior to starting the gas turbine, the operator will close the switch of [88CR-1]
starting motor in MCC.
After this condition the DCS send a consent to Starting Motor Sequence
(3CZ).putting it in starting condition.
Before starting will be selected the mode of Turbogenerator operation putting the
Main Selector in required condition (CRANK, FIRE, MANUAL, AUTO, RE-
MOTE).
Will be checked the correct operation of the [33CS-1] (starting clutch limit
switch).
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2.10 GT Fire Detection & Fighting System
normal operation of fire fighting system is indicated in Schematic Piping Dia-
gram.
The condition “ready to start” will be given by the limit switches [33ID-1] posi-
tioned on inlet ventilation dampers of the turbine enclosure.
In case of fire the fire detector sensors installed on the accessory compartment
[45FA-1 ÷ 45FA4], on the turbine compartment [45FT-1 ÷ 45FT-4] and on the
load gear compartment [45FT-5 ÷ 45FT-7] send fire signal to UCP and this one
generate a CO2 discharge command.
There are in the system two independent discharge valves operating two different
groups of CO2 bottles (1 for quick discharge and 1 for slow discharge). When the
fire is detected the quick discharge group is put in operation opening the relevant
valves, then, after 30 second, will be put in operation also the second group be-
ginning the slow discharge flow opening the relevant valves.
When is detected the fire signal are activated two alarms signal on the acoustic
enclosure, through the horns [XA] as audible signal and through the flashing lights
[XL] as a visual signal.
The UCP fire fighting system is provided with two “Fire fighting auto-inhibit
switch” to inhibit the discharge phase of CO2. Every inhibit signals from the fire
fighting system send an alarm to the UCP inhibiting the turbine start-up.
The start-up of the turbine will be also inhibited when the signal “System fault”
send an alarm to the UCP.
The “Discharge inhibition” on the fire fighting system is signaled by a green

lamp, lighted with the system in AUTO mode and with a amber light when the
discharge is inhibited. But the inhibition is actuated for CO2 discharge only, while
the detection modules with the relevant indications are operating.
The fire fighting system provides also an input signal “CO2 discharge detected”
from the field. When this signal is detected will be sent to the UCP that will shut-
down the Turbogenerator.
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2.11 Generator
oil system of Generator is indicated in Schematic Piping Diagram.
Prior to starting the gas turbine, the operator shall check the correct oil supply
pressure to the generator bearings by the pressure indicators on the oil header, on
the bearings inlet piping DE and NDE side respectively. Will be checked also the
oil flowing through the discharge oil piping flow gauges (FG 713; FG 714).
The operator will check on the vibration monitor, Generator section, the correct
readings of vibration sensors, the key-phasor values and the bearings temperature
elements, to verify the correct operation.
Will be checked also the stator winding cooling thermoelements readings for cor-
rect operation.
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2.12 Load Gear Box
oil system of Gear Box is indicated in Schematic Piping Diagram.
Prior to starting the Turbogenerator group, the operator shall check the correct oil
supply pressure to the Gear Box bearings by the pressure indicator on the oil hea-
der and the oil flowing through the bearings discharge oil piping flow gauge
(FG 712).
Furthermore will be checked on the vibration monitor, gear box section, the cor-
rect axial positioning of the shaft and the readings of vibration sensors and the
bearings temperature elements, to verify the correct operation.
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3. PROCEDURE OF START-UP
3.1 Checks Prior to Start-Up
3.1.1 Gas Turbine checks
A visual inspection of the turbine should be performed before attempting to oper-

ate a new turbine, with the lube oil pump operating and emphasis on the following
areas:
1) Check that all piping and turbine connections are securely fastened and that
all blinds have been removed.
2) Inlet and exhaust plenums and associated ducting are clean and rid of all for-
eign objects. All access doors are secure.
3) Where fuel, air or lube oil filters have been replaced check that all covers are
intact and tight.
4) Verify that the lube oil tank is within the operating level and if the tank has
been drained that it has been refilled with recommended quality and quantity
of lube oil. If lube oil flushing has been conducted verify that all filters have
been replaced and any blinds if used, removed.
5) Check operation of auxiliary and emergency equipment, such as lube oil
pumps, etc. Check for obvious leakage, abnormal vibration, noise, or over-
heating.
6) Check lube oil piping for obvious leakage. Also using provided oil flow sigh-
ts; check visually that oil is flowing from the bearing drains. The turbine
should not be started unless flow is visible at each flow sight.
7) Check condition of all thermocouples and/or resistance temperature detectors.
Reading should be approximately ambient temperature.
8) Device requiring manual lubrication is to be properly serviced.
9) Check the Cooling and Sealing Air Piping against the assembly drawing and
piping schematic, that all orifice plates between flanges or in orifice unions
are of designated size and in designated positions.
10) At this time all enunciated ground faults should be cleared. It is recom-
mended that units not be operated when a ground fault is indicated. Immedi-
ate action should be taken to locate all grounds and correct the problems.
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3.1.2 Generator/Gear Box checks
1) With turbine oil pumps running check the oil flushing through the generator
bearings and the load gear box.
2) Excitation system in operation
3) Protection system in operation.
3.1.3 General checks by HMI Video Display
The most important controls to be made to verify the Turbogenerator conditions

in real time, during startup or operating sequences, should be executed by the
HMI video display.
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3.2 Checks During Start-Up And Initial Operation
The following checks must be done on a Turbogenerator, these checks should in-
clude: leakage test, vibration unusual noise, overheating, and lubrication.
3.2.1 Listen to noise

1. Start turbine and stop it at around 600 rpm.
2. Listen for rubbing noises in the turbine compartment, load gear and genera-
tor.
3. A sound scope or some other listening type device is suggested.
3.2.2 Crank
1. Listen for rubbing noises in the turbine compartment, load gear and genera-
tor.
2. A sound scope or some other listening type device is suggested. Shutdown
and investigate if unusual noise occurs.
3. Check for unusual vibration
4. Inspect for oil leakage.
3.2.3 Fire
1. Check entire fuel system and the area immediately around the fuel nozzle for
leaks. In particular check for leaks at the following points:
a. Fuel oil piping/tubing to fuel nozzle
b. Fuel gas valves
c. Gas piping to the burner.
2. Monitor the turbine control panel readings for unusual exhaust thermocouple
temperature, wheel-space temperature, lube oil drain temperature, highest to
lowest exhaust temperature spreads and ”hot spots”, combustion chamber
burning hotter than all others.
3. Listen for unusual noises and rubbing.
4. Monitor for excessive vibration.
3.2.4 Manual, Automatic, Remote

1. Continue monitoring for unusual rubbing noises and shutdown immediately if
a noise persists.
2. Monitor lube oil tank, header, white metal bearing and bearing drain tempera-
tures continually during the starting period.
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3. At this time a thorough vibration check is recommended, using portable vi-

bration test equipment with filtered and unfiltered readings.
It is suggested that horizontal, vertical and axial data be recorded for the:
a) Accessory gear forward and after sides.
b) All accessible bearing covers on the turbine.
c) Turbine forward compressor casing.
d) Turbine support legs.
e) Covers on the driven Units.
4. Check and record wheel space, exhaust and control thermocouples for proper
indication on the control display.
5. Check and record electrical characteristics of generator.
6. Monitor control display data for proper operation.
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3.3 Gas Turbine Start-up & Operation
3.3.1 Introduction
This manual provides information needed by an operator to start and operate the
power generation units. This document describes the mode of operation, which
are defined to be:
• OFF
• CRANK
• FIRE
• MANUAL
• AUTO
• REMOTE
3.3.2 References
Reference shall be made to the:
Schematic Piping Diagram SOM 5104201
Instrument List SOM 6623063
Control System Functional Description SOM 6622096
3.3.3 General
The GT Unit Control Panel is equipped with two HMI: one (local) in the Unit
Control Building, for controlling purposes, and the other (remote) in the Main
Control Room for monitoring purposes, as normal options.
Once the main HMI fails, the controlling functionality of the second HMI is en-
abled and the operator can continue to control the unit.
3.3.4 Modes of operation and sequences

There are six operating modes varying from no start acceptance to full automatic
start. Only one mode can be active selecting one mode (position) of MASTER
SELECTOR means disabling all the other modes.
The mode selection can be performed at the local MKVI HMI (PC operator inter-
face) and at the operator back-up panel mounted in the front of the Mark VI panel,
or, if the Main selector is placed on Remote, by putting into action the signal Re-
mote Start-up from the DCS. The back-up feature is required to give the operator
the ability to control the unit (basic function as START, STOP) in case of a fail-
ure of the MKVI HMI or loss of customer UPS power supply. The standard
03-09-E 170.5703-04 P. 4-20

modes OFF, CRANK, FIRE, MANUAL, AUTO and REMOTE are below de-
scribed.
Mode selection can be used to bring in some hold points in the start sequence and
to monitor the process at these stages.
a) Off Mode
When the OFF Mode is selected, the UCP does not accept the START command,
and is thus not possible to start-up the machine. All other functions remain active.
Auxiliaries’ manual control is possible, if the relevant safeties are satisfied.
It shall not be possible to select and initiate the OFF Mode when the Turbogenera-
tor train is running or the COOLDOWN sequence is still in progress.
OFF Mode may be selected and initiated at any other time.
b) Crank Mode
CRANK sequence may only be selected after the gas turbine has stopped rotating.
Starting the turbine with this selection is possible if the unit start permissive is sat-
isfied.
Starting the turbine with this selection will bring the shaft up to crank/purge speed
value of 20% (14HM).
Sequence will precede changing Master Selector position to FIRE, MANUAL,
AUTO, or REMOTE position. The shaft will continue to rotate at 20% of speed
value until the operator initiates a normal STOP, changes the Master Selector po-
sition or a shutdown occurs. Gas turbine shaft can remain at his speed indefinitely
if the operator will not select another command.
For OFF-LINE WATER WASH the selection of CRANK mode is mandatory, and
as long as the wash cycle is enabled the CRANK mode will be locked.
c) Fire Mode
This mode of operation shall primarily be used to verify that the GT start se-
quence functions properly.
Once the start permissive listed in § 3.5 item “a” are valid/healthy, the operator
may initiate start.
Sequence steps § 3.5 “b” to§ 3.5 ”p” are executed, and the turbine will continue
to run at warm-up speed, unless the operator selects another operation mode or
initiates a normal stop or shutdown.
By subsequently selecting MANUAL, AUTO or REMOTE Mode, sequence step
§ 3.5. “q” to 3.5 “t” is executed to accelerate the shaft of the turbine to the prese-
lected speed.
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d) Manual Mode
In the MANUAL Mode a start signal will result in an automatic start-up and load-
ing to the minimum operating speed, then the shaft speed is controlled by raise
and lower commands on HMI.
e) Auto Mode
In the AUTO Mode a start signal will result in an automatic start-up and loading
to the selected value, an external signal from DCS is taken as shaft speed set
point.
f) Remote Mode
In REMOTE Mode position, the set point of load may be varied from outside
through the commands from DCS. The increase and decrease variation speed of
the turbine shaft depends on the value imposed by the automatic ramp and can be
modified through the Operator Interface.
3.3.5 Start-up sequence – AUTO / REMOTE mode

AUTO or REMOTE Mode enables initiation of the complete start sequence, up to
the pre-selected speed of turbine shaft.
a) Prior to start-up permissive must be confirmed; these will include:

• No other modes selected and/or other sequences initiated and/or in pro-
gress (except lube oil pump or enclosure fans post-run sequences)
• Package off mode not selected
• GT speed = 0 RPM
• Package shutdown push buttons reset
• Fuel control valves in correct position (closed)
• Package enclosure doors closed
• Fire dampers open
• Fire alarm cleared
• CO2 discharge not in progress
• CO2 system not in fault
• Battery voltage from DCP above minimum
• Emergency lube oil pump ”Ready to start”
03-09-E 170.5703-04 P. 4-22

• MCC ”Ready to start”

• All parameters that are monitored for alarm and trip purposes are in the
healthy state for start-up (lube oil tank has the correct oil level and tem-
perature, etc.)
• All trip identified in P&I diagrams are cleared
b) When the Shut Down reset and Ready to start – check condition as per (Con-
trol system functional description) are satisfied, the message ”UNIT READY
TO START” will be shown on the MK VI<HMI> operator interface display.
c) The ”START” command can be initiated by the software pushbutton on MK
VI<HMI> and the following actions will be initiated:
d) Start automatically the Gas Turbine Lube Oil auxiliary pump [88QA]. When
the lube oil header pressure is restored, the lube oil system is considered rea-
dy for operation.
e) Start automatically the Lube Oil main Separator fan [88QV-1]
f) Start automatically the Gas Turbine main ventilation fan [88BA-1]. The com-
partment is equipped with 2×100% ventilation fans. Automatic start of
standby fan for the GT is initiated by high temperature and/or high gas con-
centration and/or main fan failure.
g) ”UNIT READY TO START” condition is achieved and if no shutdown con-
dition is present (the ”MASTER PROTECTIVE RELAY (4x)” is still acti-
vated), the MK VI logic will give the command to start the starting motor.
h) The motor starts (4CR) is energized.
i) The turbine will accelerate up to crank speed (20% of shaft speed value -
14HM).
j) Start the turbine purge phase (approximately 2 minutes, to be configured in
field) to purge the turbine, combustion air inlet and exhaust systems, and wait
for purge completion.
k) Open the liquid fuel valve [65FP-1] and when the fuel gas temperature
reaches the set threshold, the liquid fuel valve will be closed.
l) Completed the purge time, is energized the ignition (L2TVX).
m) MKVI will check for excessive fuel flow, if that condition is detected a trip is
initiated.
n) Allow a maximum of 1 minute for light off; activate ”fail to ignite alarm” if
flame is not detected within 2 minutes and continue to rotate at crank speed.
o) The fuel amount is reduced and the warm-up timer is started.
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p) At the end of warm-up period (1 minute), the torque converter raises output
torque unless ”Fire mode” is selected; in this case the turbine shaft will con-
tinue to rotate at warm-up, more than 20% speed.
q) The torque converter is accelerated and fuel is increased to reach the mini-
mum operating speed; during the acceleration sequence, when the turbine
shaft reaches the 60% speed (14HC), the clutch will automatically discon-
nected. The starting system decelerating up to minimum speed, the starting
system is stopped five minutes later (cooling time).
r) At 90% speed of the shaft (14HSX), minimum operative speed, the lube oil
auxiliary pump [88QA] – (PL2) will receive a command to stop. The genera-
tor excitation is enabled.
s) When the turbine shaft reaches 95% of speed (14HS-1) will be closed the ax-
ial compressor bleed valve and the complete sequence flag will be set.
t) After completing the Start up sequence, are enabled the speed set-point varia-
tion and the turbine is ready to synchronize.
3.3.6 Activities on Generator

The following operating activities are only suggested, the real values to operate
are to be taken by the Generator Manual by the Supplier that remains the first do-
cuments to be consulted:
Reached the complete sequence of the turbine shaft, and before synchronizing the
Generator with the network, it will be possible to perform the Generator checks,
as follows:
a) Short circuit checking at Generator terminals.
b) After exciting the Generator at required current, check the stator current mea-
suring circuits.
c) Check, for each protection branch, the differential current protection, follow-
ing the supplier's indication, noting the trip value.
d) Check the unbalance protection increasing the stator current and noting the
trip value.
e) Check the rotor earth protection increasing the current excitation at the re-
quired value.
f) Test of overload protection
g) After the no load test check the Min. and Max. voltage protections.
h) With Generator at the rated voltage, check the frequency protection.
i) Testing of the power protection ( power return, excitation loss, etc.).
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j) Before proceeding with the synchronization check:

- the synchronoscope 0,
- the differential voltage 0,
- the frequency at the coupling switch closing on an out of voltage network.
3.3.7 Synchronization sequences

At minimum operating speed excitation control will be enabled. The Mark VI
checks the synchronization permissive conditions and the speed reference is set at
100.3%. When 100.3% is reached “Unit ready to synchronize” is displayed.
The operator has the opportunity to select in the Mark VI<HMI> “Synchroniza-
tion Mode Selector” the following mode: off, manual, automatic or dead bus.
a) Off mode
Disable all the Mark VI synchronizing functions.
b) Manual mode
The synchronization will be made in manual mode. The panel will send the
raise/lower commands signals to excitation panel for the voltage regulation. When
the unit is synchronized, the operator will close the breaker from the HMI.
c) Auto mode
The Mark VI will adjust the speed the speed and voltage, and will issue the com-
mand for breaker closure when unit is synchronized.
d) Dead bus mode

For this mode, the breaker is closed before to close contactor on ECP. This will
avoid high inrush current due to energization of transformer.
As soon as the breaker is closed, the closing command to excitation contactor on
ECP is given and the generator rise on voltage and energize transformers. Once
the rated voltage is reached the UCP can start to load the machine.
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3.3.8 Load control

Droop or isochronous control is selected on HMI.
Droop mode
When the Turbogenerator unit is connected in parallel to the main grid, the system
frequency is determinated by the grid itself and is maintained constant. The excess
of fuel flow does not result in speed variation, but in augmentation of power ex-
ported to the grid.
The operator can enter a certain MW value as a load control constant. When pre-
selected load is selected the unit will automatically load or unload till the required
value.
The selected mode of control (spinning reserve, preselected) will be reset to man-
ual control when the operator uses the raise/lower commands on HMI or when the
governor control is transferred from droop to isochronous.
The VAR control is based upon the use of voltage raise and lower signals to ECP.
Isochronous
The unit is controlled to maintain a constant speed, regardless of the grid load re-
quest and regardless of the supplier power. When the unit is in this mode, it is not
possible to set a supplied power set point.
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4. TYPICAL READINGS
4.1 Gas Turbine
4.1.1 Lube oil system
• Main lube oil pump:………… speed : 1450 rpm

flow (at P/T) : 1350 l/min
discharge pressure 6 Bar G
operating Pres/Temp 6 Bar/20÷80°C
• Auxiliary lube oil motor:…….. power supply 400 V / 50 Hz / 3Ph
nameplate power 45 kW
“ “ pump: speed: 3000 rpm
flow (at P/T): 1214 l/min
discharge pressure:
operating Pres/Temp: 5,5 Bar/20÷80°C
• Emergency lube oil motor…… power supply 110 Vdc
nameplate power 7,8 kW
“ “ pump: speed: 1870 rpm
flow (at P/T): 708 l/min
operating pressure: 2 Bar G
operating Pres/Temp: 2 Bar/20÷80°C
• Lube oil tank:………………… capacity: 9420 litres
design P/T: atm. / 100°C
operating P/T.: 20÷50 mm.H2O / 80 °C
max oper. level: 300 mm. from tank upper deck
min oper. level: 400 mm. from tank upper deck
• Pressure control valve VR-1:………………………… set at 8,5 Bar G

• Pressure control valve VPR-2:………………………. set at 1,72 Bar G
• Lube oil filters:……………operating press./temp: 5 Bar G / 70°C
filtration degree: 12 micron
max delta P clean/allow. dirty: 1,7 Bar G
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• Service lube oil heaters:….. design duty 5 kW

electric supply 400 V / 50Hz / 3Ph
• Accessory gear box……… operating press./temp.: 1,72 Bar G / 60°C
inlet flow: 520 l/min
• Turbine lube oil supply, bearing. # 1… operating press./temp.: 1,72 Bar G / 60°C
inlet flow: 257 l/min
• Turbine lube oil supply, bearing. # 2… operating press./temp.: 1,72 Bar G / 60°C
inlet flow: 64,3 l./min
• Bearings header temperature….. alarm / trip H 95°C / HH 110°C
• Bearings header pressure……… alarm / trip L: 1,2 Bar G
LL: 0,9 Bar G
H: 1,4 Bar G
• Turbine lube oil bearings drain.. limit temp. value H=100°C
• Bearings metal temperature…… Thrust bearing 1: H=115°C
Journal bearing 1: H=115°C
Journal bearing 2: H=115°C
4.1.2 Oil vapour separator system

• Oil vapour separator:………… inlet flow: up to 900 Nm3/h
operating press. -20 mm. H2O
operating temp. max 75°C
• Service fans………………… power supply 400V / 50Hz / 3Ph
power required 2,2 kW
speed 2850 rpm
• Space heaters………………. design duty 0,1 kW
electric supply 230V / 50Hz / 1Ph
4.1.3 Hydraulic oil and ratchet system

• Hydraulic oil main pump…… speed: 1500 rpm
flow (at P/T): 0÷100 l./m
operating press.: 80 Bar G
operating temp.: 55-70°C
• Pressure relief valve VR-21…. set at : 90 Bar G
• Hydraulic oil filter…... design press./temp.: 100 Bar G / 80°C
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operating press./temp. 80 Bar G / 55÷70°C

filtration degree 5 micron
max delta P clean/allow. dirty 5 Bar G
• Hydraulic ratchet pump……... power supply 110 Vdc
nameplate power 0,56 kW
speed 1770 rpm
flow (at P/T) : 5,38 l/m
discharge pressure: 55 Bar g
operating press./temp.: 55 Bar G / 55÷70°C
• Pressure relief valve VRS-1: set at 55 Bar G
4.1.4 Starting system

• Electric motor: voltage: 6600 V – 3 Ph
frequency: 50 Hz
max absorbed power: 450 kW
speed 3000 rpm
• Torque converter: operating flow: 240 l/m
operating pressure: 3 Bar G
operating/temp.: up to 70 °C
4.1.5 Liquid fuel system

• Liquid fuel system inlet pressure: 0÷5 Bar G
inlet temperature: 70°C
flow: 88÷118 l/min
4.1.6 Turbine control & protection system

• Exhaust duct diff. press. values: H=0,04 Bar G;
HH=0,06 Bar G
• Axial compressor ratio: 10,5 : 1
• Bearing metal temperature value: H=115 °C
Journal bearing 1 H=115 °C
Thrust active side: H=115 °C
Thrust inactive side: H=115 °C
Journal bearing 2 H=115 °C
• Axial compressor inlet temperature: ambient
03-09-E 170.5703-04 P. 4-29

• Axial compressor discharge temperature: # °C
• Wheel space temperature: max values: H: 427°C

HH: 457°C
Wheel space 1 forward: # °C
Wheel space 1 after: # °C
Wheel space 2 forward: # °C
Wheel space 2 after: # °C
• Exhaust temperature: normal H: 574°C
values: HH: 582°C
• Seismic probe: values: H: 12,7 mm/s

HH: 25,4 mm/s
• Vibration probe (no contact) : value: H: 110 µm
• Shaft displacement probe : max values: ± 0,6 mm.
4.1.7 Ventilation & gas detection system

• Accessory compartment gas detectors: H: 5 %
HH: 10 %
• Turbine compartment gas detectors H: 5 %
HH: 10 %
• Hazardous atmosphere exhaust duct H: 5 %
HH: 10 %
• Turbine compartment pressurisation value: L: 5 mm.H2O
• Accessory compartment pressurisation value: L: 5 mm.H2O
• Generator compartment pressurisation value: L: 25 mm.H2O
4.1.8 Enclosure fire detection & suppression

• Accessory compartment fire detector. max value: 160 °C
• Turbine compartment fire detector, max value: 160 °C
4.1.9 Air intake filters

• Filters diff. press. max values: H: 122 mm.H2O
HH: 183 mm.H2O
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• Filter gas detectors max values H: 5%

HH: 10%
• Filters clean pressure loss max. value 55 mm.H20
4.1.10 Compressor washing system

• Water pump motor……… power supply 400 V/50 Hz/3ph.
nameplate power 4 kW
speed: 1438 rpm
pump………. flow (at P/T): 186÷211 l/min
operating pressure: 7,1÷7,7 Bar
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4.2 Gear Box And Generator
4.2.1 Gear box

• Gear box bearing metal temperature: max value: H: 110 °C
Journal bearing 1 HS shaft: # °C
Journal bearing 2 HS shaft: # °C
Journal bearing 1 LS shaft: # °C
Thrust active side LS shaft: # °C
Thrust inactive side LS shaft: # °C
Journal bearing 2 LS shaft: # °C
• Gear box bearing inlet oil: flow: 490 l/m
operating pressure/temperature: 1,72 Bar G / 60°C
• Gear box vibration probe
HS shaft vibration probe (no contact), max values: H: # m.
HH: # m.
LS shaft vibration probe (no contact), max values: H: # m.
HH: # m.
• Gear box displacement probe max value: H: ± 0,2 mm.
HH: ± 0,3 mm.
4.2.2 Generator
• Generator bearing metal temperature: max value H: # °C
Journal bearing DE side 70 °C
Journal bearing NDE side 70 °C
• Generator bearing oil inlet flow: 27 l/m
operating pressure/temperature: 1,72 Bar G / 55°C
• Generator vibration probe (no contact):
Journal bearing DE & NDE sides: max value: H: # µm
HH: # µm
• Winding generator phase U-V-W temperature: H: # °C
HH: # °C
Generator cold air inlet temperature: H: # C
HH: # °C
Generator warm air outlet temperature: H: # C
HH: # °C
(*) All the values flagged ”#” will be supplied after the first Gas Turbine tests.
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INDEX
Contents Page
1. INSTALLATION & ERECTION PROCEDURE.............................................5-1

2. G.T. & AUXILIARY START-UP & SHUT-DOWN PROCEDURE...............5-2
3. FIELD ACTIVITY MISCELLANEOUS ...........................................................5-3
4. PRESERVATION OF GAS TURBINE..............................................................5-4
5. GE REFERENCE DOCUMENTS ......................................................................5-5
03-09-E 170.5703-04 P. 1-1

1. INSTALLATION & ERECTION PROCEDURE
TIL TITLE Sub-Sect.
497C STAND-BY GAS TURBINES ON EXTENDED SHUTDOWN 1
REPAIR CRITERIA FOR ALL GAS TURBINES – CAST SEG-

1108-3 1
MENT TURBINE NOZZLE
VARIABLE INLET GUIDE VANE ASSEMBLY – INNER BUSH-

1068-2R1 1
ING INSPECTION
1069-3 INSTALLATION OF COMBUSTION SYSTEM GASKETS 1
WARREEN LIQUID FUEL PUMP-ADVISORY ON INSTALLA-

1100-3 1
TION AND MAINTENANCE
1237-1 POSSIBLE FLEXIBLE HOSE INSTALLATION ERRORS 1
1295-1 LCI FUSE ASSEMBLY INSTALLATION MODIFICATIONS 1
1137-3 OFF-LINE COMPRESSOR WASH EFFLUENTS 1
1153-3 COLD WEATHER ON-LINE COMPRESSOR WASH 1
PRECAUTIONS FOR WORKING IN/OR NEAR THE TURBINE

1159-2 COMPARTMENT OR FUEL HANDLING SYSTEM OF AN OPER- 1
ATING GAS TURBINE
PROCEDURE FOR REMOVAL OR REPLACEMENT OF

1215-3 1
SHROUDED BUCKETS
03-09-E 170.5703-04 P. 5-1

2. G.T. & AUXILIARY START-UP & SHUT-DOWN PROCEDURE
TIL TITLE Sub-Sect.
F-CLASS ROTOR START-UP/OVERSPEED TRIP TEST REVI-

1345-2R1 2
SION
37 FULL ARC ADMISSION STARTING 2
399B FUEL PURGE OPERATION DURING START-UP 2
509C STARTING TURBINE MAXIMUM EXHAUST PRESSURE 2
513C DRAIN VALVE IN FALSE START DRAIN LINE 2
PROTECTION OF STATIC STARTER EQUIPMENT FROM OVER

1477-1 2
VOLTAGE CONDITION
726-4 CRMOV 1850F GRADE ROTORS 2
968-2 DC EMERGENCY BEARING OIL PUMP STARTER RELIABILITY 2
ADDITIONAL PROTECTION OF STATIC START EQUIPMENT

1351-1 2
DURING DISCONNECT SEQUENCE
1390-3 FSR CLAMP INTERFERENCE WITH LIQUID FUEL STARTS 2
DESIGNE ENHANCEMENT FOR LCI GENERATOR STATIC

1414-3 STARTER COOLANT SYSTEM RESERVOIR LOW-LOW LEVEL 2
FAULT DIAGNOSTIC
DESIGN ENHANCEMENT FOR LCI GENERATOR STATIC

1414-3R1 STARTER COOLANT SYSTEM RESERVOIR LOW-LOW LEVEL 2
FAULT DIAGNOSTIC
03-09-E 170.5703-04 P. 5-2

3. FIELD ACTIVITY MISCELLANEOUS
TIL TITLE Sub-Sect.
591-3 GENERATOR FIELD RETAINING RING INSULATION 3
616-3 GENERATOR FIELD END TURN ELONGATION 3
645-2 GENERATOR FIELD WEDGE SERVICE 3
646-3 NEW GENERATOR FIELD WEDGES 3
800-1 GENERATOR FIELD ALUMINUM WEDGE REPLACEMENT 3
819-2 GENERATOR FIELD FAN BLANDE REPLACEMENT 3
875-3A FIELD REPAIRS OF ASME CODE PRESSURE VESSELS 3
1005-3 FATIGUE CRACKS IN GENERATOR FIELD COILS 3
1010-2 TWISTLOCK INSPECTION, REPLACEMENT & STAKING 3
INSTRUMENTED INACTIVE THRUST BEARING REPLACE-

1028-3A 3
MENT
1181-2 INSTRUMENT AND CONTROL AIR LINE FREEZING 3
03-09-E 170.5703-04 P. 5-3

4. PRESERVATION OF GAS TURBINE
NP CODE TITLE Sub-Sect.
ITN 02175.00
ITN 02175.04
ITN 02175.07
PROTECTION & PRESERVATION SPECIFICATION 4
ITN 02175.08
ITN 02175.12
ITN 02175.21
ITN 54750 PACKING SPECIFICATION 4
SOM 44953 STORAGE INLET SYSTEM COMPONENTS 4
03-09-E 170.5703-04 P. 5-4

5. GE REFERENCE DOCUMENTS
TIL TITLE Sub-Sect.
PROCESS SPECIFICATION FUEL GAS FOR COMBUSTION IN

GEI-41040J 5
HEAVY DUTY GAS TURBINES
GEK-107551A STANDARD FIELD PERFORMANCE TESTING PHILOSOPHY 5
STANDARD FIELD TESTING PROCEDURE FOR NOX EMIS-

GEK-28172F 5
SION COMPLIANCE
GAS TURBINE AND ACCESSORY EQUIPMENT PRESERVA-

GEK-28156H 5
TION
LUBRICATING OIL RECOMMENDATION FOR AS TURBINES

GEK-32568F 5
WITH BEARING AMBIENT ABOVE 500°F/260°C
HEAVY DUTY GAS TURBINES OPERATING AND MAINTE-

GER-3620J 5
NANCE CONSIDERATIONS
03-09-E 170.5703-04 P. 5-5

(GAS TURBINE MS 5001 PA) Volume I

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(GAS TURBINE MS 5001 PA) Volume I

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g GE Oil & Gas Nuovo Pignone

INSTRUCTION, OPERATION AND

NUOVO PIGNONE JOB : 170.5703-04

N.P. DOC. No. : MAN 170.5703

MANUFACTURER : GE Oil & Gas

03-09-E 170.5703-04 P. 1-1

MOD. INPR/SVIL/ P.F. 12/00

N.P. Job: 170.5703-04

The present Instructions Manual concerning the Turbogenerator is subdivided into

System Description Section 1

Initial Start-up Section 4

Technical Documents Section 5

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2. GAS TURBINE DESCRIPTION ...............................................................................2

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The Turbogenerator is part of DAURA plant in Iraq and is designed to provide

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2. GAS TURBINE DESCRIPTION

2.1 Functional description

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Fig. 1.1 - Major sections of the MS5001 PA gas turbine assembly

2.2 Compressor Section

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2.3 Combustion Section

2.4 Turbine section

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2.5 Exhaust section

2.6 Air inlet systems

2.7 Accessory gear box

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2.8 Starting System (Electric Starting Motor)

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2.9 Lubrication system

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Light Light Grade with Light Grade

Pour Point (max.) °F (°C) 20 (-6,7) 20 (-6,7) -25 (-31)

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MOD. INPR/SVIL/ P.F. 12/00

EQUIPMENT: TURBINE FORCED FEED LUBE OIL

2.10 Hydraulic supply system

2.11 Liquid fuel system on turbine baseplate

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The following major components:

2.12 Cooling and sealing air system

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