Professional Documents
Culture Documents
Warning: The purpose of this training is to provide basic information and principles of
Gas Turbine Generator (GTG) and its components. Under no circumstances, this
note is to be used as a reference during GTG maintenance or operation.
CONTENT
SYSTEM:
a.
GTG in General
b.
Enclosure and Inlet/Exhaust System
c.
Fuel System
d.
Lube Oil System
e.
Instrument Air System
f.
Electrical System
g.
Control System
OPERATING INSTRUCTION
a.
Pre-operation Check
b.
Starting Procedure
c.
Load Transfer Procedure
d.
Stopping Procedure
e.
Cranking
f.
Log and Operating Condition
TROUBLESHOOTING
POWER SECTION
Called Gas Turbine or GT
Consists of:- Two stages of CENTRIFUGAL Compressors
- Three stages of AXIAL Turbine
- Single CAN type combustor
- Double end supported BEARINGS
Speed: 21870 rpm
Weight: 1.19 ton
Accessory Gearbox
- Mounted to main reduction gearbox
GENERATOR
Type: Synchronous AC generator type
Capacity: 2812.5 kVA
Voltage: 6.6 kV
Frequency: 50 Hz
Number of poles: 4 poles
FUEL SYSTEM
Engine Gas Fuel System
PT, FT, TE
Temperatur/Presure
compensation
PA
To Gas Exhaust
KHI/PLC
KHI/PLC
PT
FT
EOV
PGV
TE
SSV1
SSV2
MGV
Gas Control
Valve
Gas Filter
SGV
FUEL SYSTEM
Engine Diesel Fuel System
PASSING
Pressurizing
Valve
Supply Fuel
Shutoff
Valve
Start Fuel
Pump
Main Fuel
Pump
Start Fuel
Valve
Fuel Control
Valve
Bypass Fuel
Valve
Main Fuel
Valve
Return to
service tank
DIESEL FUEL
LEAK
Vent
Manifold
Gas Turbine
Generator
Gearbox
LO Tank
160L
Main LO Pump
M
Pre Post
Pump
P
G
P
G
Pressure
Control
Valve
Air for Starting
Pressure
Control
Valve
M
Instrumen
t Air Tank
Instrumen
t Air Tank
EOV
Intake Filter
JB Pressurizing
Gas Pressure Regulating
Valve
ELECTRICAL SYSTEM
Engine Electrical System
1. Ignition System
2. EGT Hardness
3. Speed Pick Up (Pulse)
4. Turning Motor
1. Ignition System
Ignition system is required to ignite the mixture of fuel and air inside the combustor during start up.
Ignition Plug:
Ignition Exciter:
4. Turning Motor
Turning motor is required to rotate the turbine shaft slowly after shutdown to allow uniform cooling to
the turbine shaft.
The turning duration is controlled automatically by the gas turbine control panel.
CONTROL SYSTEM
Engine Control System
1. Timing Schedule (Gas)
2. Timing Schedule (Diesel)
3. Alarm and Interlock
4. Operation Display Panel
TIMING CHART
Start
com
Gas Pressure
Established
Voltage
establish
Loading
completed
CB
close
95%
Stop
com
Stop
CB
open
95%
GTG cooling 5 min
55%
Fuel Changing
Unloading
4%
Loading
22%
3 min
Synchronizing
2 sec
Pre-excite
Fuel Changing
Pre Purge
Pre Purge
On
Off
55%
22%
4%
Starter Motor
Aux Machine
cooling 30 min
Ignition Exciter
Oil Cooler Fan
Encl Vent Fan
Turning Motor
Liquid Fuel Cooler Fan
Turning 10 hours
1 sec
1 sec
1 sec
30 sec
10 sec
TIMING CHART
Start
com
Gas Pressure
Established
Voltage
establish
Loading
completed
CB
close
95%
Stop
com
Stop
CB
open
95%
GTG cooling 5 min
55%
Fuel Changing
Unloading
Loading
22%
3 min
Synchronizing
4%
2 sec
Pre-excite
Fuel Changing
Pre Purge
Pre Purge
On
Off
55%
22%
4%
Starter Motor
Aux Machine
cooling 30 min
Ignition Exciter
Oil Cooler Fan
Encl Vent Fan
Turning Motor
Liquid Fuel Cooler Fan
Turning 10 hours
1 sec
1 sec
1 sec
10 sec
Voltage
establish
Loading
completed
CB
close
95%
Stop
com
Stop
CB
open
95%
GTG cooling 5 min
55%
55%
Unloading
22%
Loading
5%
Pre-excite
22%
Synchronizing
2 sec
4%
Starter Motor
Ignition Exciter
Aux Machine
cooling 30 min
Turning 10 hours
30 sec
Voltage
establish
Loading
completed
CB
close
95%
Stop
com
Stop
CB
open
95%
GTG cooling 5 min
55%
55%
Unloading
22%
Loading
5%
Pre-excite
22%
Synchronizing
2 sec
4%
Starter Motor
Ignition Exciter
Aux Machine
cooling 30 min
Turning 10 hours
30 sec
Set Point
Major Fault
1.1
352 seconds
1.2
202 seconds
1.3
Over Speed
110+0, -2%
1.4
54+0, -4%
1.5
94+0, -4%
1.6
LO Supply Temperature HH
905C
1.7
0.1+0.05, -0 MPa
1.8
0.2+0.05, -0 MPa
1.9
700+0, -40C
1.10
58010C
1.11
Emergency Shutdown
Push Button
1.12
2D3m
1.13
Gearbox Vibration HH
2D0.5 mm/s
1.14
Flame Out
20010C
1.15
Miss Fire
1.16
10000 ppm
1.17
1502C
1.18
952C
1.19
85V, 2 seconds
1.20
130V, 2 seconds
1.21
2 seconds
1.22
Set Point
1.23
1.24
1.25
1.26
1.27
1.28
1.29
1.30
1.31
1.32
1.33
Middle Fault
2.1
111%, M:1
2.2
10%, 10 seconds
2.3
M:10, 30%
2.4
2.5
2.6
2.7
AVR Failure
0.0150.0013 MPa
0.35 MPa
Set Point
Light Fault
3.1
1.5D3 m
3.2
Gearbox Vibration H
1.5D0.5 mm/s
3.3
2500 ppm
3.4
56010C
3.5
LO Supply Temperature H
805C
3.6
LO Tank Level L
12010 L
3.7
0.240.04 MPa
3.8
LO Supply Pressure L
0.260.02 MPa
3.9
Sensor Failure
3.10
3.11
3.12
3.13
3.14
3.15
3.16
1352C
3.17
852C
3.18
3.19
Fail to Syncoro
3.20
3.21
Display Failure
3.22
0.7 kPa
2 minutes
Set Point
3.23
0.3 MPa
3.24
3.25
3.26
3.27
DC Battery Failure
3.28
3.29
3.30
3.31
3.32
0.24 MPa
0.880.025 MPa
500 Pa
OPERATION INSTRUCTION
a.
b.
c.
d.
e.
f.
Pre-operation Check
Starting Procedure
Load Transfer Procedure
Stopping Procedure
Cranking
Log and Operating Condition
DESCRIPTION
CRITERIA
GTG
Area
Open
Open
Open
Open
Open
Confirm Full
Instrument Air
Supply
Open
Confirm >120
Visual Inspection
No Leak
Confirm no obstruction
Power Supply
confirm energize
JUDGEMENT
DESCRIPTION
CRITERIA
GTG
a
Area
Open
Valve Open
Open
Open
Open
Open
Open
Instrument Air
A
Supply
Open
Confirm >120
Visual Inspection
No Leak
Confirm no obstruction
Power Supply
a
confirm energize
JUDGEMENT
b. STARTING PROCEDURE
Starting and Loading in Manual Mode
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
b. STARTING PROCEDURE
Starting and Loading in Semi Auto Mode
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
b. STARTING PROCEDURE
Starting and Loading in Auto Mode
1.
2.
3.
4.
5.
6.
7.
8.
9.
After GTG cooling sequence completed, select the STOP on the Operation page and execute.
After GTG completely stopped, carry out inspection and verify for pre-post pump and turning motor operation.
Stopping in Semi Auto Mode:
GTG will auto fuel change to DIESEL mode after 3 minutes of cooling and resume another 2 minutes cooling
on DIESEL mode.
After GTG cooling sequence completed, select the STOP on the Operation page and execute.
After GTG completely stopped, carry out inspection and verify for pre-post pump and turning motor operation.
Stopping in Auto Mode:
After GTG completely stopped, carry out inspection and verify for pre-post pump and turning motor operation.
Unit
Criteria
#1 Engine Speed
95~108
#2 Engine Speed
95~108
Gearbox Speed
95~108
<560
<560
<560
<560
#1 LO Supply Temp
<80
#2 LO Supply Temp
<80
<1.5D
<1.5D
Gearbox Vibration
mm/s
<1.5D
MPa
MPa
MPa
MPa
MPa
MPa
Time
Time
Time
Time
Time
Unit
Criteria
MPa
>0.015
MPa
>0.015
MPa
kPa
<0.7
Hr
#1 LO Supply Pressure
MPa
>0.26
#2 LO Supply Pressure
MPa
>0.26
MPa
MPa
MPa
MPa
MPa
MPa
<0.3
<0.3
Time
Time
Time
Time
Time
Unit
Criteria
400
400
400
Hz
50
Generator kWh
kWh
Generator kW
kW
Generator kVar
kVar
Excitation Voltage
Excitation Current
<135
<135
<135
<85
<85
Time
Time
Time
Time
Time
Unit
Bus Voltage
400
Bus Frequency
Hz
50
Nm3/h
MPa
Nm3
MPa
MPa
MMSC
FD
Remarks
Criteria
Time
Time
Time
Time
Time
TROUBLESHOOTING
1.
2.
3.
4.
5.
6.
Large Vibration
High Exhaust Gas Temperature
Overspeed
Startup Failure
Low Lubrication Oil Pressure
High Lubrication Oil Temperature
1. Large Vibration
Vibration of gas turbine shaft is monitored to
detect Large Vibration. Specific alarm
value and trip value has been set in the
PLC.
1. Large Vibration
Possible causes of this problem are as
follows:
1. Defect of gas turbine itself: Abnormal
bearing or rotary part, etc.
2. External factor: Rubbing with foreign
matters entering through intake port.
3. Defect of control system: Abnormal
vibration system, etc.
1. Large Vibration
1.1 Simplified Inspection of Equipment
Gas Turbine
Inspection item 1
Visually check that engine (output shaft) is rotating smoothly as driven by turning motor
Objective
To confirm that rotor system is not on contact with stationary part and that foreign matter has not been
caught. If there is such abnormality, engine rotation is not smooth and generating friction sound.
Inspection item 2
Manually rotate engine by hand to check for abnormal rotation or abnormal rotating sound
Objective
This method is to be conducted if above inspection item 1 cannot be done by turning motor.
Inspection item 3
Study of data before occurrence of problem
Change in gas turbine shaft vibration value or reduction gear vibration value
Generator output
Lubrication oil temperature and pressure
Change in temperature for No.1, No.2 lube oil drain.
Objective
To obtain data useful to determine whether vibration increase is sudden or gradual as the result of
aged deterioration or false meter indication
To confirm that load is normal
To confirm that bearings are lubricated properly.
1. Large Vibration
1.2 Inspection of Individual Control Devices
Vibration System
Inspection item 1
Check monitor cable connection for looseness. If connection is loose or disconnect then connect cable
properly.
Objective
To confirm that signal is input properly to monitor
Inspection item 2
Check sensor wiring connection for looseness
Objective
To confirm that signal is output properly from sensor
Inspection item 3
Disconnect wire from sensor and measure DC resistance. Normal value is between 2.5-3.0 ohm
Objective
To confirm that wire is not broken
3. Overspeed
Rotation of gas turbine power section is
monitored to detect Overspeed. Specific
trip value has been set in the sensor.
3. Overspeed
Possible causes of this problem are as
follows:
1. Defect of gas turbine itself: Broken
coupling of output shaft of power section
rotor system, etc.
2. External factor: Sticking fuel control
valve, etc.
3. Defect of control system: Abnormal
rotation pickup, etc.
3. Overspeed
3.1 Simplified Inspection of Equipment
Gas Turbine
Inspection item 1
Visually check that engine (output shaft) is rotating smoothly as driven by turning motor.
Objective
To confirm that gas turbine itself and reduction gear are normal
Inspection item 2
Manually rotate engine by hand to check for abnormal rotation or abnormal rotating sound
Objective
This method is to be conducted if above inspection item 1 cannot be done by turning motor.
Inspection item 3
Study of data before occurrence of problem
Gas turbine shaft vibration
Gas turbine speed
Whether any problem occurred at startup or during operation
If problem occurred during operation, check generator output for change
Operation mode: island or parallel with other GTG or Diesel Gen set.
Objective
To confirm that gas turbine itself is normal
To clarify the time of problem occurrence
3. Overspeed
3.2 Inspection of Individual Control Devices
Instrumentation Devices
Inspection item 1
Inspection of rotation pickup connector for looseness
Objective
To confirm the connector or pickup is not loose
Inspection item 2
Measure resistance for rotation pickup. Normal value is 30050 ohm at 25 degC
Objective
To confirm that sensor is normal
4. Startup Failure
Rotation and exhaust gas temperature of
gas turbine are monitored to detect
Startup Failure. Alarm signal is output
when specified conditions are not met.
4. Startup Failure
Possible causes of this problem are as
follows:
1. Defect of gas turbine itself: Defective fuel
nozzle, etc.
2. External factor: Abnormal starter
equipment, abnormal ignition system,
etc.
3. Defect of control system: Defective
rotation pickup, defective controller, etc.
4. Startup Failure
4.1 Simplified Inspection of Equipment
Gas Turbine
Inspection item 1
Visual check that engine (output shaft) is rotating smoothly as driven by turning motor.
Objective
To confirm that gas turbine itself and reduction gear are normal.
Inspection item 2
Manually rotate engine by hand to check for abnormal rotation or abnormal rotating sound
Objective
This method is to be conducted if above inspection item 1 cannot be done by turning motor.
Inspection item 3
Study of data before occurrence of problemIncrease in turbine speed
Increase in exhaust gas
Instrument air pressure 0.45MPa or higher
Fuel filter differential pressure indication
Objective
To confirm that gas turbine itself and reduction gear are normal
To confirm that fuel system is normal
To confirm that shutoff valve opening air pressure is normal
4. Startup Failure
4.1 Inspection of Individual Control Devices
Instrumentation Devices
Inspection item 1
Inspection of solenoid valve operation of starter valve unit
Objection
To confirm the integrity of starter air supply equipment
Inspection item 2
Inspection of exciter and ignition plug. Visual check for damage
Objective
To confirm that ignition system is normal
Inspection item 3
Inspection of exhaust gas temperature thermocouple for broken wire. Measure insulation resistance. Normal value is
1.5Mohm or higher as measured with a 500V megohmmeter at ordinary temperature
Objective
To confirm that thermocouple is not damaged
Inspection item 4
Inspection of rotation pickup for looseness. Disconnect cable from pickup and measure resistance. Normal value is
30050 ohm at 25 degC.
Objective
To confirm that pickup is not loose and wire is not broken.
Gas Turbine
Inspection item 1
Visually check that engine (output shaft) is rotating smoothly as driven by turning motor.
Objective
To confirm that gas turbine itself and reduction gear are normal
Inspection item 2
Manually rotate engine by hand to check for abnormal rotation or abnormal rotating sound
Objective
This method is to be conducted if above inspection item 1 cannot be done by turning motor.
Inspection item 3
Check piping for any lubrication oil leakage.
Objective
To confirm that there is no oil leakage which can cause low oil pressure
Inspection item 4
Check oil level of lubrication oil tank.
Objective
To confirm that there is no oil level drop which can cause low oil pressure
Inspection item 5
Study of data before occurrence of problem
Lubrication oil temperature at bearing outlet.
Interval between alarm and trip.
Indication of clogged lubrication oil filter
Objective
To confirm that bearing are normal
To confirm that filter is free of foreign matters