Professional Documents
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P9005
CUSSONS TWO SHAFT GAS
TURBINE UNIT
P9008
DATA LOGGING OPTION
ISSUE 15
January, 2004
TABLE OF CONTENTS
1 RECEIPT AND UNPACKING ......................................................................................6
3 INTRODUCTION......................................................................................................10
5 DESCRIPTION.........................................................................................................13
5.1 General..............................................................................................................13
5.2 Gas Generator...................................................................................................13
5.2.1 Compressor. .................................................................................................. 13
5.2.2 Combustion Chamber. .................................................................................... 13
5.2.3 Turbine. ........................................................................................................ 13
5.3 Power Turbine. .................................................................................................14
5.4 Loading System for Power Turbine..................................................................14
5.5 Starting System. ...............................................................................................14
5.6 Ignition System. ...............................................................................................14
5.7 Lubrication System...........................................................................................14
5.8 Instrumentation. ..............................................................................................15
5.8.1 Temperature.................................................................................................. 15
7 OPERATING INSTRUCTIONS.................................................................................. 25
7.1 General..............................................................................................................25
7.2 Starting. ............................................................................................................25
APPENDICES
App. I A First Course In Gas Turbine Technology – T.H. Frost
Section 1 Fundamental Concepts
Section 2 Types and Arrangements of Engine Components
Section 3 Test Techniques
Section 4 A Complete Test and Analysis Programme
App. II Power Turbine
App. III Gas Generator
App. IV Loading Unit
2.2 Safety.
Before proceeding to install, commission or operate this equipment you are directed to read the
following safety notes. The notes are intended to help you to be aware of potential hazards and
thereby avoid accidents. Where appropriate, further information and recommendations are
incorporated in the main body of this manual. In all cases the requirements of relevant local
health and safety regulations should be complied with.
2.2.1 Electrical Equipment.
This equipment operates from a mains voltage electrical supply. Electrical installation
and maintenance must therefore only be carried out by a competent electrical engineer in
accordance with local regulations and the following notes.
a) Installation.
Ensure that the electrical supply voltage, frequency and configuration are compatible
with this equipment, which requires a single/three phase supply and a reliable protective
earth or ground connection.
To minimise danger, as the supply is connected by a trailing lead**, it is recommended
that a high sensitivity (30mA) residual current device which is designed for personnel
protection, should be incorporated in the supply.
The electrical supply and connecting cable should be suitably rated with respect to
current, temperature and physical protection for the conditions of use. The supply outlet
should be suitably labelled and must incorporate an independent means of isolating the
supply and be fitted with a suitable over-current protection device.
b) Maintenance.
Always isolate the equipment from the electrical supply when the equipment is not in
use.
Always isolate the equipment from the electrical supply before removing the front or
rear panels to expose any part that in operation, carries a potential in excess of 30V dc.
or 50V ac.
The equipment should be periodically inspected and tested to ensure continued safety.
2.2.2 Rotating Equipment.
This equipment contains rotating parts, which rotate at very high rotational speeds. The
equipment is provided with guards and the equipment must therefore only be operated
with the guards in position. If for any reason the guards are removed then there is a
serious risk of the rotating parts causing the entrapment of loose clothing, hair, items of
jewellery or parts of the body etc. Consequently the equipment must not be operated
without the guards being properly fitted.
2.2.3 High Temperature Equipment
During operation this equipment contains parts and water/air at high temperature. To
minimise associated hazards the following precautions must be taken:
a) The equipment must be installed and maintained by a competent engineer in
accordance with local regulations and codes of practice.
b) Before operating read and understand the instructions given. Avoid the dangerous
release of hot fluids, e.g. by opening the wrong valves. Leakage’s from valves and
joints should be investigated and rectified as soon as possible.
c) Avoid contact with hot surfaces as serious burns can result. If necessary the
operator should wear protective gloves.
3 INTRODUCTION
The P9005 Cussons Gas Turbine Unit is a full two shaft machine with built in air starting system
and electrical loading unit. All operational instrumentation and controls are to be found on the
large coloured schematic diagram panel mounted at a convenient operating height. Light
indicators and clear reading instruments enable the operator to be aware of circuit conditions at a
glance.
The equipment employs an automotive turbocharger together with a gaseous fuelled combustion
chamber to form the gas generator section of the engine. The exhaust from the gas generator is
directed through a radial power turbine which drives a variable frequency alternator which
disipates the generated power in a resistive load bank. From the power turbine the gases pass
through a silencer to be discharged into the atmosphere.
Since the unit is mobile it can easily be sited adjacent to its required electrical, fuel, water and
exhaust facilities, and even when operating at high speed it has only a relatively low noise level.
Signal conditioning for data logging purposes can be provided as an optional extra by the factory
fitted P9008 Data Logging Option available from serial number 206 onwards. The P9008 option
provides 0-10V dc analogue signals for all measured parameters.
4 GENERAL SPECIFICATION
4.1 General.
Note that from Serial No. 167 onwards, the Gas Turbine Unit has been tropicalised and is
generally suitable for use in ambient temperatures of up to 40ºC and ambient conditions of up to
80% relative humidity.
4.5 Instrumentation.
4.5.1 Pressure Measurement.
0 – 1600 KPa (0 – 16 bar) Gas Bottle supply indicator
0 – 400 KPa (0 – 4 bar) Combustion chamber inlet gas pressure
0 – 250 KPa (0 – 2 bar) Combustion chamber pressure p3
0 – 40 KPa (0 – 0.4 bar) Power Turbine inlet pressure p4
0 – 10 cmHg Combustion chamber pressure loss p2 - p3
(p2 is compressor outlet pressure)
0 – 1000 KPa (0 – 10 bar) Lubricating oil pressure
4.5.2 Flow Measurement.
0.4 – 3.3 g/s Fuel flow (propane 15°C, 1.5 bar g)
0 – 200 mmH2O Inlet air flow
5 DESCRIPTION
5.1 General.
Cussons P9005 Two Shaft Gas Turbine Unit is a self contained equipment with the gas generator,
power turbine, loading unit, instrumentation and controls all housed on a castor mounted
framework, giving a degree of mobility. Thus the Unit can be tidily stored when not in use and
then readily positioned near the required services, when it is required to be run. The services
required are :
a) The Unit requires to be positioned under an exhaust duct so that the gas turbine exhaust
products can be extracted if prolonged running is contemplated.
b) A cooling water supply is required for the oil cooler.
c) A drain is required to cater for the oil cooling water.
d) A single phase electrical power supply.
e) A suitable gaseous fuel supply.
The instrumentation and controls for the Unit are incorporated in a large coloured schematic
diagram of the system - see Fig. 1 Front Panel Layout of Gas Turbine Unit. This diagram is
invaluable as an aid to understanding the complete functioning of the Gas Turbine Unit. Fig. 2
Rear View of Gas Turbine Unit illustrates the physical disposition of all the major components.
with turbocharged Diesel engines. The normal operating pressure of the lubrication system is 400
to 450 Kpa (4 – 4.5 bar) on starting from cold with the pressure dropping towards 200 Kpa (2
bar) as the working temperature in the oil tank rises. The oil cooler ensures that the temperature
of the oil fed to the bearings is maintained at approx. 80ºC.
5.8 Instrumentation.
Instrumentation for both operational and experimental measurement is integrated into the
coloured schematic diagram on the instrument and control panel.
5.8.1 Temperature.
From serial number 206 all seven temperatures are measured using type K NiCr/NiAl
thermocouples, whereas previous models used diodes for low temperatures and thermocouples
for high temperatures. The seven temperature channels are :
T1 Air inlet temperature
T2 Gas generator compressor exit temperature
T3 Gas generators turbine inlet temperature
T4 Power turbine inlet temperature
T5 Power turbine exit temperature
Tg Gas (fuel) temperature
To Oil (lubricant) temperature
All the thermocouples are connected via a cold junction compensation unit and break-out unit to
Cussons eight channel thermocouple printed circuit board CBA 219. For each channel there are
two independent outputs, one is for the front panel instrumentation while the other is a 0 - 10V dc
analogue output available for input to a data logger, computer input or chart recorder. Three front
panel analogue temperature indicators are provided. The three high temperatures T3, T4 and T5
are connected to a 1000°C meter, via cascaded push buttons to read T4 and T5. With neither
button depressed the meter reads T3. Similarly T1, T2 and Tg are connected to a 120°C meter
which normally reads T2 unless either the T1 or Tg button is pressed. The oil thermocouple is
permanently connected to the 120°C oil meter.
5.8.2 Pressure.
Conventional Bourdon tube pressure gauges are used to measure all pressures other than the
combustion chamber pressure loss (p2 – p3) which is obtained from a differential mercury
manometer. Snubbers are fitted in the P2, P3 and P4 pressure lines.
5.8.3 Air Flow Rate.
The air flow is measured at the inlet to the gas generator compressor by a pitot-reverse pitot tube
connected to a differential manometer on the front panel. The air mass flow rate is given by :
m& = k √∆h g/sec
where k = calibration constant (determined by Cussons and engraved on the unit)
∆h = differential pressure mmH2O
The pitot-reverse pitot method is used as it is not so sensitive as a pitot-static tube to flow pattern
distortion effects.
ρ propane
m& mixture = m& reading
ρ mixture
If the readings are taken at a pressure of 150 Kpa (1.5 bar) and a temperature of 15°C (which are
the calibration conditions for the flow meter) then the multiplicative correction factor is
ρ propane 44
= 44Ρ + 58Β
ρ mixture
where P = fraction of propane in mixture
B = fraction of butane in mixture
P B Correction Factor
1.0 0.0 1.000
0.9 0.1 0.984
0.8 0.2 0.970
0.7 0.3 0.955
0.6 0.4 0.942
0.5 0.5 0.929
0.4 0.6 0.916
0.3 0.7 0.904
0.2 0.8 0.893
0.1 0.9 0.882
0.0 1.0 0.871
5.8.5 Rotational Speeds.
The gas generator speed and free power turbine speed are both measured using two channels of a
four channel frequency to dc conversion printed circuit board CBA 216. The signal for the gas
generator is provided by an inductive pick up sensing a magnetic nut at the compressor eye,
whilst the power turbine speed is obtained by sensing the ac voltage output of the alternator.
5.8.6 Power Output.
The turbine power output can be calculated from the dc voltage applied and current flowing to the
resistive load bank, together with the curve Fig. 5 giving the relationship between dc power
measured and an efficiency factor which takes into account belt, alternator and rectifying circuit
efficiencies.
momentary switch which will self latch only if the interlocks associated with the oil pressure
switch, the over temperature cut-out and the starter blower motor thermal trip are correctly
positioned.
5.9.1 Turbine Over Temperature.
A comparator circuit contained within the eight channel temperature printed circuit board
continuously monitors the turbine inlet temperature T3. In the event of T3 exceeding the limit set
by the comparator circuit, relay R1 will be unlatched thus switching off the ignition system and
starting blower. The fuel shut-off solenoid valve will also be de-energised.
5.9.2 Loss of Oil Pressure.
An oil pressure switch monitors the pressure of the oil used to supply the oil circuit and if its
pressure falls too low the oil pressure switch opens and unlatches the relay R1, thus shutting
down the engine.
5.9.3 Starter Blower Motor.
The induction motor which drives the starter blower is protected by a thermal trip in the blower
motor contactor. Auxiliary contacts on the contactor are used to enable relay R1 thus providing
protection should the motor trip during operation.
5.9.4 Oil Pump Motor.
The induction motor which drives the oil pump is protected by a thermal trip in the oil pump
motor contactor.
5.9.5 Electrical Power Failure.
The system is designed to fail safe in that should electrical power be lost in any part of the
protection system or to the unit as a whole, then relay R1 will unlatch and the fuel solenoid valve
will close, thus causing the shut down of the equipment.
Mne-
Pin Channel Description Range
monic
Apart from air flow and fuel flow the analogue outputs are all linear and correspond to the
appropriate front panel display.
6.1 Installation.
When the unit is required to be operational it should be wheeled into a position where all the
necessary ancillary requirements for electrical, fuel and water supplies, together with provisions
for the exhaust, are met. (See Fig. 13).
6.1.1 Electrical Supply.
A single phase ac supply of approximately 3.5 KVA is required for normal operation, e.g. 240V
50 Hz. Equipment may be supplied suitable for alternative supply specifications to order. Check
rating plate at rear of unit for correct supply specification. The blower motor, used for starting
purposes, can take initially high starting currents and hence the supply fuses should be such as to
cater for these transient starting conditions. A separate earth lead is also required.
6.1.2 Fuel Supply.
The fuel to be used is Propane (C3H8) a gas in standard gas take-off bottles for which suitable
fittings are provided. Short period running is possible from 11 kg (24 lb) net bottles but 45 kg
(100 lb) bottles are recommended for normal use. Providing that the ambient temperature is not
too low, one of these latter bottles will allow adequate operating periods at full power. Where it is
essential to site the propane bottles outside in cold conditions, it may be necessary to couple two
bottles in parallel to maintain an adequate supply. Consumption at full load is approximately 7 kg
(15 lb) per hour and at no load (idling) 2 kg (5 lb) per hour. Note that the level of liquid
remaining in the bottle during running can often be seen from the dew condensing on the outside
of the bottle, but for an accurate check on fuel available the bottle must be weighed by weighing
platform or spring balance.
6.1.3 Water Supply.
An oil to water heat exchanger is included in the oil circuit and the cooling water should be
connected to the at the inlet to the heat exchanger. The cooling water outlet should be connected
to waste. The water supply required should be made with a 9 mm (⅜") bore flexible hose and
have a minimum flow rate of 10 litres (2 gals) per minute.
6.1.4 Exhaust Provisions.
The exhaust is non-toxic and clean but for extended running, provision should be made for the
discharge to take place into a duct leading into the open air. However, there must be a break in
the exhaust system, usually in the form of a conical entry, with the turbine exhaust discharging
into the centre of the cone. This then ensures that the exhaust gas is diluted and reduces the
possibility of the final exhaust gas mixture being inflammable. Incorrect starting procedure can
produce inflammable exhaust mixtures and hence the above precautions should be taken.
6.1.5 Lubrication System.
The turbine’s lubricating oil is normally drained before shipment, it is therefore necessary to fill
the system with the CRH10 oil supplied.
6.2 Commissioning.
It is important that the operator should familiarise himself with the operating procedure before
attempting to run the unit (see section 7).
6.3 Calibration.
6.3.1 Speed Measurement.
The speed measurement circuits on printed circuit board CBA 216 are calibrated prior to
dispatch, however, if necessary they can be adjusted without running the gas turbine as follows :
a) Preparatory Work.
Disconnect printed circuit board CBA 216 from its edge connector and re-connect it via a DIN
41612 64 way (rows a and c) extender card. Disconnect the two input co-axial cables from the
gas generator and power turbine by unplugging them at the rear of the control box.
b) Gas Generator.
Connect the output from a signal generator to the gas generator speed input socket on the rear of
the control box. Adjust the signal generator to produce a sine wave output of one volt peak to
peak at a frequency of 2000 Hz. Connect a digital voltmeter between test points TP8 and TP1 and
adjust VR10 to give a 10V output signal. Adjust VR11 to span the front panel gas generator
speed meter to 2000 rev/sec.
c) Power Turbine.
Connect the signal generator to the power turbine speed input socket on the rear of the control
box. Adjust the signal generator to produce a sine wave output of one volt peak to peak at a
frequency of 6400 Hz. Connect a digital voltmeter between test points TP4 and TP1 and adjust
VR3 to give a 10V output signal. Adjust VR4 to span the front panel gas generator speed meter to
800 rev/sec.
6.3.2 Temperature Measurement.
All the temperature channels are adjusted prior to dispatch and should not require further
attention. However, if any channel is found to need to be checked or adjusted the following
procedure, which refers to figure 14, should be followed.
a) Preparatory Work.
Disconnect the thermocouple plugs at the rear of the control cubicle. Open the hinge down lid of
the control cubicle and pull out the thermocouple printed circuit board CBA 219 from its edge
connector and re-connect it via a DIN 41612 64 way (rows a and c) extender card. A calibrated
millivolt source will be required to simulate the e.m.f. normally produced by the thermocouple
hot junction. A calibrated digital voltmeter will also be required.
b) Pre-amplifier Zero Adjustment.
Set jumpers J1 to J9 on the printed circuit board to position B and adjust the variable resistors, as
listed in column 2 of the following table, to give a reading of zero volts at the test points shown in
column 3 of the table with respect to test point TP1.
1 (T2) VR1 TP 3
2 (T1) VRS TP 5
3 (Tg) VR9 TP 7
4 (T3) VR13 TP 9
5 (T4) VR22 TP 11
6 (T5) VR26 TP 13
7 (TOil) VR30 TP 15
8 (spare) VR34 TP 17
T/C
Channel mV inject Adjust Reading Test Point
Socket
T/C
Channel mV inject Adjust Reading
Socket
T/C
Channel mV inject Adjust Reading
Socket
8 (spare) H 8.14 mV - -
6.4 Maintenance.
a) Lubricating Oil.
The oil in this system undergoes little deterioration and is only changed if the system has to be
dismantled for any reason. Always use the oil specified - oils of higher viscosity, such as normal
motor oils, make starting difficult and reduce the turbine’s overall performance. The oil level
should only be half way up the oil tank as gas blow-by may cause overflowing if the tank is too
full. After initial filling, run the oil pump for a minute to fill the oil filter etc., and then ensure that
the correct oil level in the tank is obtained by adding oil if required.
b) Toothed Turbine-Generator Driving Belt.
The tension of this belt is automatically controlled by a hydraulic ram fed from the lubricating oil
circuit.
7 OPERATING INSTRUCTIONS
7.1 General.
The Cussons Gas Turbine Unit incorporates a gas generator driving a free power turbine which
drives an alternator. The gas generator consists of a centrifugal compressor, a single gas fuelled
tubular combustion chamber and a radial turbine. The free power turbine is also of radial design,
with a belt drive to the alternator. The unit is designed to permit analysis of the performance
characteristics of the gas generator, power turbine and combustion chamber using the
instrumentation displayed on the front panel. Operation over a wide range of speed and load is
possible which, together with the facility for varying the speed ratio between the gas generator
and the power turbine, means that a test programme on the Two Shaft Gas Turbine system can be
carried out. By carefully controlling the speed ratio of the gas generator and free power turbine to
a constant value, a coupled power turbine can be simulated, whereas if the free power turbine
speed is held constant, then the gas generator simulates a single spool turbo jet.
7.2 Starting.
1. Connect the cooling water supply and drain.
2. Connect the gas bottle.
3. Connect the electrical supply.
4. Set the air inlet control to the start position.
5. Close the gas valve and open the valve on the gas bottle.
6. Set the dynamometer excitation to maximum.
7. Start the oil pump.
8. Press the reset button.
9. Start the blower.
10. Set the gas pressure to 200 Kpa (2.0 bar) with the reducing valve.
11. Press the ignition button and hold it in whilst opening the gas valve to give a gas flow of
0.5 g/s.
12. If ignition, as shown by an increase in T3, does not occur within 5 seconds of gas flow
commencing, close the gas valve to allow unburnt gas to clear the system before
continuing from item 11.
13. Release the ignition button.
14. Open the gas valve slowly to give a gas generator speed of 1000 rev/s taking care to keep
combustion chamber temperature below 900°C (this operation may take some minutes
depending on the oil temperature).
15. Turn the air inlet control to the run position.
16. Switch off the blower.
7.4 Stopping.
1. Close the valve on the gas bottle.
2. Close the gas valve.
3. Once the turbines have stopped reset the air inlet control to the start position.
4. Re-start the blower.
5. When T4 has dropped below 80°C and the oil temperatuer drops below 40°C :
i) Switch off the blower.
ii) Switch off the oil pump.
iii) Turn off the gas supply.
iv) Turn off the water supply.
v) Turn off and disconnect the electrical supply.
7.5.3 Stopping.
When the turbine has been stopped and the system is being cooled by operating the blower, it is
essential to leave the blower running until the temperature of T4 has dropped to less than 80°C
and the oil temperature to less than 40°C.
(P9005/245 ONWARDS)
LUBRICATION SYSTEM
FIG. 6
(UPTO P9005/244)
FIG. 6 LUBRICATION SYSTEM
m& C CORRECTED AIR FLOW @ 288 K and 1.01325 bar (kg√K/s bar)
1.5
Tt3 = Total Turbine Inlet Temp (K)
1.3
1.25
1.2
1.15
2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9
Semi-dimensional Mass Flow Paramater
1.16
1.12 Pt 4
= Turbine Expansion Ratio
P5
1.11
& Tt 4
m
= Semi Dimensional Mass Flow Parameter (kg√K/s)
1.1 Pt 4
1.09
1.08
1.07
1.06
1.05
2 2.2 2.4 2.6 2.8 3 3.2 3.4 3.6 3.8 4
Semi-dimensional Mass Flow Parameter
FUEL FLOW AIR FLOW OIL PRESSURES TEMPERATURES SPEEDS POWER OUTPUT
Mf Tg Pg g/sec P-RP Toil P3 P4 P2-P3 T1 T2 T3 T4 T5 G.G P.T Voltage Current Correct Power
2.34 18.26 154 148.72 64.40 0.69 0.15 18.99 93.98 726.07 624.76 501.95 1514.16 612.11 64.50 29.80 1922.0
2.12 18.47 148 134.45 65.63 0.58 0.13 18.77 83.59 713.38 622.31 505.86 1398.44 608.59 54.69 25.62 1401.2
1.87 19.06 150 120.53 62.89 0.48 0.10 19.17 74.45 699.71 615.97 500.73 1281.25 602.73 44.78 21.28 952.7
1.69 19.56 152 107.92 60.50 0.40 0.09 19.31 67.07 700.20 618.65 501.95 1179.69 611.33 35.84 17.26 618.6
1.54 19.92 154 96.51 58.64 0.33 0.08 19.25 60.94 712.16 630.13 511.23 1085.45 608.01 27.42 13.35 366.1
1.43 21.09 150 83.91 56.45 0.27 0.06 19.54 55.27 747.31 656.25 529.05 977.05 608.59 14.92 7.30 108.9
T3 OVER TEMPERATURE SETTING 900ºC PITOT - REVERSE PITOT CONSTANT DATE TEST COMPLETED
BELT TENSIONING RAM PRESSURE KPa AIR FLOW CALIBRATION EQUATION:- TEST ENGINEERS SIGNATURE
M air = 11.51{h} 0.5
Remarks
SERIAL NUMBER
FUEL FLOW AIR FLOW OIL PRESSURES TEMPERATURES SPEEDS POWER OUTPUT
Mf Tg Pg g/sec P-RP Toil P3 P4 P2-P3 T1 T2 T3 T4 T5 G.G P.T Voltage Current Correct Power
T3 OVER TEMPERATURE SETTING ºC PITOT - REVERSE PITOT CONSTANT DATE TEST COMPLETED
WATER THERMOSTAT SETTING ºC AIR FLOW CALIBRATION EQUATION:- TEST ENGINEERS SIGNATURE
0.5
BELT TENSIONING RAM PRESSURE KPa M air = {h} TEST SUPERVISORS SIGNATURE
Remarks
FIGURE 13
FIGURE 15 PRINTED CIRCUIT BOARD 220 (ANALOGUE COMPUTING) P9008 OPTIONAL EXTRA