Gas Turbine Training e we Lesson 6: Starting System System LayoutSystem Layout REDUCTION GEARBOX (RGB) LUBE PUMP. HOUSING The purpose of the the turbine engine and speed |The initial rotation provided by the start system enables the engine to draw in the necessary air for combustion. The Direct-Drive AC Start System uses a Variable Frequency Drive (VFD) working in conjunction with two AC Motors, which in turn, rotates the turbine engine through the accessory drive / reduction gearbox via an overrunning clutch. Once energized, the start system initially provides high torque and low-speed rotational energy to cause the turbine engine to rotate from a standstill. As the start sequence progresses, the VED varies the output voltage and frequency to allow the variable speed AC Motors to rotate the engine on a predefined acceleration schedule.1° Purpose: Start the Gas Turbine Just before the engine ignites its fuel within the combustor, the engine speed will be maintained at a typical value of 15- 22% Ngp for a predefined period to purge the engine, exhaust, and associated waste heat recovery ducting, of any hazardous vapors that may have collected. Once the purge period has expired, the fuel is introduced into the combustor and ignited. The hot gases produced by the combustion begin to drive the gas producer turbine, along with the rotational power provided by the starter motor, to accelerate the engine until it can_ maintain itself without the aid of the start system. This “self-sustaining speed” is often referred to as “Starter Dropout Speed” and is typically between 0 provide a means n) for maintenance purposes. This maintenance-rela e is normally limited to approximately 2 and i is often used to internally clean the engine by spraying water or a cleaning solution directly ito the engine air infet.3° Purpose: Slow Roll Another function of the start system is tofprovide slow roll_] for a predetermined period after non-emergency shutdowns in order to provide a more effective cooldown and thus avoid rotor lock-up. Major Component OverviewMajor Component Overview The simplified system diagram below provides an overview of the major components needed to rotate the engine through its various phases of operation. The Direct-Drive AC Start System consists of the following components: . Variable Frequency Drive (VFD) . VED Monitor & Keypad AC Motors = Clutch Assemblies Major Component Overview Fixed Verable Freqivotage (<} Kemme | EH Freq/Voltage H [Sprag Cth 1 i Co 1 i oO Commercial | starter ‘Accessory a | Motor Drive rion Simplified Direct-Drive AC Start System DiagramVFD (Variable Speed Drive) The Variable Frequency Drive is a solid-state device that converts fixed voltage and frequency AC (input) power into variable voltage and frequency AC (output) power to allow an AC Motor to run at variable speeds. The VFD uses a process called “Pulse Width Modulation” that essentially takes the incoming AC signal and converts it to DC power in the form of pulses that can be controlled for both voltage level and duration. By carefully controlling the DC output pulses, a simulated AC Sine Wave can be produced that can match the energy demands (voltage amplitude and frequency) of the AC start motors to operate at variable speeds and torque requirements. For breakaway rotation, the VFD sends a low frequency, high torque signal for initial engine rotation. The VED then accelerates the starter motors by increasing the frequency and adjusting the voltage of the output power to the AC starter motors. The VFD must be installed in a non-hazardous area, such as the station MCC (Motor Control Center). VFD (Variable Speed Drive) Typical Variable Frequency Drive (VFD) CabinetVFD MONITOR & KEYPAD The typical VFD system is supplied with a LED readout and programming keypad that works in conjunction with the Control System. The operator can scroll through various keypad readouts to monitor output frequency, voltage, amps, and other essential operating parameters. A series of push buttons are positioned on the keypad to enable limited programming changes while at the VFD location. However, the VFD is normally programmed via the RSLogix 5000 programming software that monitors and controls the entire package operation. In addition, a series of status lights are also provided to alert the operator to key start-related events and operational status. VFD MONITOR & KEYPAD Typical Variable Frequency Drive (VFD) CabinetAC Motors The AC motors area standard 3-phase, squirrel-cage, induction type motor. The motors receive the varying frequency and voltage signal from the VFD to develop the appropriate speed and torque required to rotate the turbine engine. The motors are typically furnished with space heaters to prevent condensation from forming internally, as well as employing thermal overload trips to prevent excessive heating during prolonged or repeated Self-Shifting Synchro Clutch (SSS) = ELEMENTS OF 8g8 cLUTCH 5 INPUI 2 StuTon Teen! 8 OUTPUT CLUTCH RING 3 SLOINGCOMPONENT 7 RATCHET TEETH 4 HELICAL SPLINES: A Self-Shifting Synchro clutch is positioned on the interconnect shaft within each of the Starter Adapter Housing to transfer the starter motors torque to the accessory drive gearing. The mechanical clutches will disengage the starter shafts from the accessory drive gearing once the engine speed is self-sustaining, the start system is deactivated, and the turbine engine continues to accelerate on its own.Self-Shifting Synchro Clutch (SSS) How a SSS clutch works? Selr-Shitting Synchro Clutch Self-Shifting Synchro Clutch (SSS) How a SSS clutch engages? Seltshiting Synchro ClutchStart System Sequence of Operation PRE-CRANK PERMISSIVE One of the pre-crank permissives, the] prelube pressure] is verified before the turbine engine is allowed to crank. This crank permissive must be met to ensure the engine and driven equipment bearings have lubricating oil to prevent possible damage from the shafts rolling on dry bearing surfaces. (Refer to corresponding System Sequence Handout)Start Command At the end of the prelube period, as long as all other required permissives have been received, the control system will automatically}turn on the starter motor.|This start command electrically|energizes the VFD} whose varying voltage and frequency output produces the breakaway torque required to rotate the starter motors and consequently, the turbine engine. (Refer to corresponding System Sequence Handout) Cranking Verified and Purge Crank The turbine next reaches the cranking verification setpoint {ypically 15%) within a specified period of time, designating that a successful crank has been achieved. From 15% Ngp, th¢ VED calls for increasing accelerationjuntil the engine crank speed reaches approximately] 15-22% Ngp.JAt this point, the VED modifies its output to the start motors to intain a constant engine speed for the duration of the purge| nk period. The engine purge period is calculated and set during package commissioning and depends upon the volume of the engine exhaust ducting and any additional waste heat recovery ducting or equipment. (Refer to corresponding System Sequence Handout)End of Puge Crank Once the purge timer expires, the ignition sequence begins. When successful ignition has been verified, the VFD is switched back to an acceleration power mode to increase the speed of the engine. The increasing power generated by the combustion process is assisted by the start system and drives the engine to starter dropout speed, typically 60 - 75% Ngp. Once this speed is sensed by the control system, the VFD is deactivated and power to the starter motors shuts down. The overrunning clutches disengage the starter drive from the engine and allows the engine to continue to accelerate under its own power. (Refer to corresponding System Sequence Handout) Operational MonitoringFail to Crank To ensure the start sequence is progressing along properly, the control system monitors the turbine engine cranking speed. If the engine does not achieve the crank verification setpoint listed above (typically 15% Ngp) within the set period also listed above (typically 80 seconds), the system is automatically hut down and a “Fail to Crank” annunciation is provided on he HMI screen. Fail to Start / Accelerate In addition, the control system also verifies that the start system, in conjunction with the combustion process, adequatel accelerates the engine from ignition to starter dropout speed within a predetermined time period (typically 120 seconds). not, a “Fail to Start / Accelerate” malfunction will occur and terminate the start attempt.Slow Roll Speed A “Slow Roll Mode” cranks the engine at a low speed of typically 12 - 15% Ngp once the engine is shutdown and the postlube cycle begins. This slow roll rotates the engine to prevent any shaft distortion due to latent heat and gravitational forces. The slow roll mode typically lasts for three hours. The slow roll mode will be disabled if the backup relay d, the engine shuts down on high vibr: backup postlube cycle is active. The turbine can be restarted while the slow roll timer is timing as long as no shutdown conditions persist. KM As mentioned earlier, the start system has a secondary function of cranking the engine, without combustion, for maintenance needs. This is often referred to as “Test Crank” or “Cold Crank” and is used for washing the engine internals or simply to rotate the engine for other maintenance or diagnostic needs. The Test Crank is still dependent on a prelube pressure permissive and is also monitored by the control system to achieve the “Crank Verification Speed” within the specified time, as detailed above. Once in the Test Crank mode, the engine will continue to rotate at cranking speed (typically 15- 22% Ngp) for as long as the Test Crank remains selected, either from the HMI display or from a switch located at the control console or package.Start System Potential Malfunctions Start System Potential Malfunctions The following table lists potential sequential or operational malfunctions associated with the Direct AC Start System. Although general hints on possible causes have been provided, adherence to a methodical troubleshooting process is strongly recommended when investigating turbomachinery problems.Start System Potential Malfunctions Malfunction Description Typical Causes Fail to Crank The turbine speed did not reach |* \VFD malfunction; VFD the Crank Verification Setpoint programming error (typically 15% Ngp) within the | | designated time (typically 80 Stare; Molymefeinceon seconds) + Clutch failure + Engine or gearbox breakaway torque too high + Exhaust Silencer restricted Start System Potential Malfunctions Malfunction Description Typical Causes Fail to Start The turbine speed did not reach | * ‘VED malfunction Startor Dropout (typically 60— | | 75% Ngp) within the designated ‘VED prograreming err, time (typically 120 seconds) {hor Rls Ikpooe performance + Excessive Engine rotational drag + Engine air system ‘malfunction (variable vanes / bleed valve) + Fuel system malfunction