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OJT for Premier Oil Natuna Sea Ltd Sec. 1
Anoa AGX Project Rev. 0
There are many different types of turbines in use in the world today. Some forms are old, like the Waterwheel
(hydraulic turbine) and Windmill. Others are of more recent origin, Steam Turbines date from the 19th century
while Gas Turbines date from the 20th century. Gas Turbines were originally conceived as a means of aircraft
propulsion and were not developed for industrial use until 1947. Since then they have undergone significant
changes in design to become more powerful and efficient and capable of operation in a wide variety of
environments and applications.
Operating Principles
All turbines are basically engines that convert the energy of a moving stream of fluid (liquid / water,
steam or gas) into mechanical energy. The essential element of all turbines is a shaft with blades or
buckets arranged radially around the shaft in such a fashion that the fluid stream imparts a force to
the blades or buckets to cause the shaft to rotate. The rotational torque imparted to the shaft is then
used to provide useable power;
Note: The rotating shaft on a Turbo-jet (aircraft engine) drives a compressor and other auxiliary
drives and uses the exhaust gases to provide thrust to push the aircraft forward.
There are numerous variants to the basic operating concept of an engine that converts the energy of a
moving fluid stream into mechanical energy. What is common to all Gas Turbines is the Driving fluid which
is Gas. An aircraft Turbo-jet may use liquid fuel, but it is still a Gas Turbine because it is driven by gas, just
as the Turbo-charger is driven by the exhaust gas of a reciprocating engine and an Expander / Compressor
is driven by the gas of the process it is operating on.
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Energy Services International Doc. Turbo. M/c
OJT for Premier Oil Natuna Sea Ltd Sec. 1
Anoa AGX Project Rev. 0
There are numerous designs and configurations of Industrial Gas Turbines, but they all operate in
essentially the same basic manner. They are heat engines and use the expanding gases of
combustion to drive the turbine shaft. They operate under what is called the Brayton Cycle. Unlike the
reciprocating Internal Combustion engine which also uses the expanding combustion gases to drive
its pistons and operates under the Otto Cycle; the Gas Turbine has continuous combustion to
provide continuous torque to the turbine shaft. They do not need a flywheel to dampen the intermittent
cylinder combustion of the Internal Combustion engine and do not develop the high internal pressures
encountered in the cylinders of a reciprocating engine.
The Brayton Cycle
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Energy Services International Doc. Turbo. M/c
OJT for Premier Oil Natuna Sea Ltd Sec. 1
Anoa AGX Project Rev. 0
Principle to Practice
As the thermodynamic principle on which Gas Turbines operate has been mentioned, how this is
achieved in practice can now be considered. On Anoa AGX, Premier have Solar Saturn 20
Generator and Mars 100 Compressor sets. While other manufacturers use different arrangements
these two machines are typical of the most common internal mechanical arrangements generally
used.
The Saturn 20 is referred to as a Single Shaft while the Mars 100 configuration used on Anoa is
referred to as a Split or Two Shaft arrangement. The Single Shaft configuration is the least
complicated arrangement and will be considered first.
T5
P5
T3 T7
Data Points T1, etc P3 P7
T1 T2
P1 P2
The drawing above shows the engine internal arrangement and the Data Points in the gas path. Air
from the atmosphere is drawn in through the Air Inlet (T1, P1) by the Compressor Rotor Assembly,
which is mounted on a common shaft connected to the Turbine Rotor Assembly at the RH end and
the Engine Output Shaft at the LH end. As the Engine Output Shaft is at the cooler Air Inlet end and
not at the hotter Turbine Exhaust end it is referred to as Cold End Drive.
The compressed air leaves the compressor and enters the Diffuser (T2,P2) where its pressure(P2) is
greatest and the temperature (T2) has also increased about 260C [@ 500F] above T1. Fuel Gas from
the Fuel Gas Manifold is mixed with air from the Air Manifold and injected into the Combustion
Chamber through Fuel Injectors where it is burnt after having been initially ignited by the Igniter Torch
at the start. Combustion causes the temperature to increase to about 2800F and the volume to also
increase greatly. The Combustion Chamber is constructed to allow cooler air to enter and direct the
hot gases away from the Combustion Chamber liners (to minimise heat damage and to cool the hot
gas) and into the Turbine assembly without increasing the pressure. The temperature at the inlet of
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Energy Services International Doc. Turbo. M/c
OJT for Premier Oil Natuna Sea Ltd Sec. 1
Anoa AGX Project Rev. 0
the Turbine (T3) sometimes referred to as TRIT (Turbine Rotor Inlet Temperature) is generally not
monitored, but the temperature at the inlet of the last stage (T5) invariably is and can be used as an
indication of the heat energy in the engine. After exiting the turbine section the gases are directed
away to atmosphere through the Turbine Exhaust (T7) and any external ducting.
In the single shaft arrangement the rotational speed of the output shaft (load) will always be directly
related to the speed of the turbine shaft, even if a gearbox is used to alter the ratio from 1:1. The
speed of the turbine shaft will largely determine how much air is compressed by the compressor,
(essentially the faster it rotates the more air mass it can compress) and consequently at what speed
and how much load the engine can tolerate before the driving gases become too hot for it to operate.
This fixed ratio is normally suitable where the speed is constant and the load varies, in generator
applications for instance. It can be a disadvantage in some applications, especially where the load is
required to operate over a wide speed range, for example Compressors and other Mechanical Drives.
To overcome this, the split shaft machine is designed so that on one shaft the turbine rotor and the
compressor are mounted (as per the single shaft arrangement) and on a second shaft which is
mechanically independent from the first, another turbine rotor is mounted and this shaft is connected
to the load . Both shafts are driven by the same expanding gas path imparting kinetic energy to their
rotors from the velocity energy of the gas. The diagram below shows the gas path and data points.
The first shaft which drives the compressor is known variously as the CT (Compressor Turbine),
GG (Gas Generator) or as Solar usually refer to it as GP (Gas Producer). The second shaft is
invariably known as the PT (Power Turbine) as it provides the useful power to drive the load.
A split shaft machine operates in essentially the same way as a single shaft arrangement, but is
controlled such that the fuel and air input into the machine are regulated to produce enough gas to
firstly drive the GP (compressor) to provide Primary Air for combustion and Secondary Air for
cooling, etc, and also enough to rotate the PT and thus the load. As the 2 shafts are both driven
(rotated) by a common gas path produced by the same combustion system, the amount of gas
produced will determine how quickly they will each rotate.
FUEL EXHAUST
T5
P5
AIR
IN COMBUSTOR T7
T1 AIR P7
P1 OUT
T2
P2
AIR
COMPRESSOR
LOAD
T3
P3
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Energy Services International Doc. Turbo. M/c
OJT for Premier Oil Natuna Sea Ltd Sec. 1
Anoa AGX Project Rev. 0
GAS
PRODUCER
DATA POINTS T1, etc
POWER
TYPICAL SPLIT SHAFT GAS FLOW WITH DATA POINTS
TURBINE
T2
P2
T1
P1
T7
P7
T3 T5
P3 P5
COMPRESSOR ROTOR
The drawing above shows the engine internal arrangement and the Data Points in the gas path. Air
from the atmosphere is drawn in through the Air Inlet (T1, P1) by the Compressor Rotor Assembly,
which is mounted on a shaft connected to the Gas Producer Turbine Rotor.
Compressed air leaves the compressor and enters the Diffuser (T2,P2) where its pressure(P2) is
greatest and the temperature (T2) has also increased about 260C [@ 500F] above T1. From the Fuel
Gas Manifold it is mixed with air from the Air Manifold and injected into the Combustion Chamber
through Fuel Injectors where it is burnt after having been initially ignited by the Igniter Torch at the
start. Combustion causes the temperature to increase to about 2800F and the gas volume increases
greatly. The Combustion Chamber is constructed to allow cooler air to enter and direct the hot gases
away from the Combustion Chamber liners (to minimise heat damage and to cool the hot gas) and into
the Turbine assembly without increasing the pressure. The temperature at the inlet of the Gas
Producer Turbine Rotor (T3) sometimes referred to as TRIT (Turbine Rotor Inlet Temperature) will
have decreased to @1900F and is generally not monitored, but the temperature at the inlet of the
Power Turbine Rotor (T5 @1300F) invariably is and can be used as an indication of the heat energy
in the engine. After exiting the turbine section the gases are directed away to atmosphere through the
Turbine Exhaust (T7) and any external ducting.
As mentioned earlier (Page 1.2) about 2/3 of the total power produced is used to drive the compressor
through the first shaft arrangement (Gas Producer = GP) and the remainder is available to drive the
connected load through the Power Turbine (PT).
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Energy Services International Doc. Turbo. M/c
OJT for Premier Oil Natuna Sea Ltd Sec. 1
Anoa AGX Project Rev. 0
Ancillary Systems
In order to support the processes described in outline above, obviously several support systems have
to be available and integrated into an overall control scheme to allow the engine to function correctly
and for the load parameters to be controlled safely. For example the fuel and air to the engine are
critical and as these engines are High Speed Rotating Heat Engines lubricating oil will be required to
help lubricate and cool the bearings which support the shafts and the other rotating components. Also
the engine must initially be started to allow the power generation processes described above to be
self-sustaining. These topics will be examined in the sections that follow.
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Energy Services International Doc. Turbo. M/c
OJT for Premier Oil Natuna Sea Ltd Sec. 1
Anoa AGX Project Rev. 0
Premier currently have the following machine packages installed on Anoa AGX:-
GT 7300 Solar Saturn 20 Generator Natural Gas Fuel
GT 7400 Solar Saturn 20 Generator Natural Gas Fuel / Liquid Fuel
CT 2500 Solar Mars 100 Gas Compression 1 or 3 stages (Export / Boost modes)
CT 2600 Solar Mars 100 Gas Compression 1 stage Export
Note: GT 7400 has Liquid Fuel capability, but no supply is currently available.
CT 2500 can be configured as a single stage Export or triple stage Boost Compressor. Premiers
design intention at some future date is to re-configure CT 2500 to a 2 stage arrangement to be
capable of operating in parallel with CT 2600 which will then also be re-configured to a 2 stage
compression package.
These engines were mentioned earlier (Page 1.3) and will now be described in more detail, with
material
largely quoted from the Solar Manuals available on site.
SAFETY
Industrial Gas Turbines are high speed rotating heat engines which can present many
potential hazards and caution must be exercised at all times, not only when in the vicinity of
the Turbine package, but also when operating remotely. The following WARNING should be
understood and heeded at all times. Appendix A of these notes contains the Solar Operations
Manual Safety Guides which must be understood and should be used as a guide to the safe
operation and maintenance of the packages.
WARNING
1. Operation of the unit may be performed only when conditions indicate it is safe to
proceed. Dangerously explosive accumulations of natural gas, fuel fumes, oil tank vent
leakage, or solvent fumes must be avoided at all times. This is done by proper
ventilation, elimination of leaks, and by confining the use of solvents to appropriate
maintenance facilities.
2. Appropriate hearing and eye protection must be used by operating and maintenance
personnel in the vicinity of the operating machine.
3. Turn off electrical power. Tag control devices to prevent electrical shock and starting
of unit while unit is shut down.
4. Allow sufficient time for piping and system components to cool. Components can
become extremely hot and cause burns if touched with unprotected hands.
5. Do not allow fluids to come in contact with hot surfaces. Fluids discharged from lines
or fittings may be flammable and could cause a fire hazard.
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Energy Services International Doc. Turbo. M/c
OJT for Premier Oil Natuna Sea Ltd Sec. 1
Anoa AGX Project Rev. 0
YOU MUST HAVE A PERMIT TO WORK ON ANY PART OF THE TURBINE PACKAGE
NOTE - ORIENTATION
Directional references on the unit (right side, left side, forward, and aft) are
established by viewing the unit facing the engine exhaust (aft) end and looking
forward.
LEFT
RIGHT
FORWARD
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Energy Services International Doc. Turbo. M/c
OJT for Premier Oil Natuna Sea Ltd Sec. 1
Anoa AGX Project Rev. 0
The Saturn 20 Gas Turbine-Driven Generator Set consists of an axial-flow turbine engine, a
generator, and gear unit. These elements are installed in-line on a steel base frame, a structural
weldment with beam sections and cross members forming a rigid foundation. Machined mounting
surfaces on the base facilitate alignment of major components. The gear unit input shaft is connected
with the engine compressor rotor nose cone hub with a splined sleeve coupling. A mating flange
bolted to the engine air inlet housing attaches the assemblies.
The generator input shaft is aligned with the gear unit output shaft, and the shafts are connected with
a flexible shear coupling in a protective cover.
Components
The generator sets accessories include the start, fuel, electrical control, lube oil, pneumatically
controlled air systems, and a governor.
Air Inlet
Gauge Panel Assembly
Generator
Coupling
Starter
Motor
Gear Unit
Exhaust
(hidden by
Assembly
Package Air Inlet
Turbine Assembly)
Base
Engine
Saturn 20 Gas Fuel Generator Set Frame
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Energy Services International Doc. Turbo. M/c
OJT for Premier Oil Natuna Sea Ltd Sec. 1
Anoa AGX Project Rev. 0
Compressor Compressor
Exhaust Diffuser Turbine Assembly Combustor Assembly Diffuser Assembly
T5 Thermocouples Gas Fuel Manifold Air Manifold Liquid Fuel Manifold Fuel Injectors
The turbine engine is the package power plant. Air is drawn into the compressor section through the
air inlet and is compressed. Fuel is added to the compressed air in the combustor and is ignited. After
combustion, hot gases expand through turbine nozzles and drive the turbine rotor. The turbine drives
the engine compressor, accessories, and generator. Air and combustion gases are discharged to the
atmosphere through the exhaust system. Major components include air inlet, engine compressor,
compressor diffuser, combustor, turbines, exhaust diffuser and exhaust collector.
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Energy Services International Doc. Turbo. M/c
OJT for Premier Oil Natuna Sea Ltd Sec. 1
Anoa AGX Project Rev. 0
Generator
Drive End Non-Drive End
The genator, the driven equipment, transforms
Mechanical energy to electrical energy. The
Generator is bolted to the raised mounting pads on
The base, in alignment with thegear unit. The
Standard generator ste has a two-bearing, revolving
field-type, three-phase, ac generator, of dripproof
construction, with damper windings and a direct-
connected brushless exciter,controlled by an Electrical Generator
Automatic Voltage Regulator (AVR).
AVR
Coupling Guard
Coupling Guard
Main Lube
Oil Pump
Gear Unit
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Energy Services International Doc. Turbo. M/c
OJT for Premier Oil Natuna Sea Ltd Sec. 1
Anoa AGX Project Rev. 0
Start System
Actuator
Fuel System
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Energy Services International Doc. Turbo. M/c
OJT for Premier Oil Natuna Sea Ltd Sec. 1
Anoa AGX Project Rev. 0
Air/Oil Cooler
Filter Selector
Filler Cap
Level Gauge Crossfeed Hand Valve
Electrical System
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Energy Services International Doc. Turbo. M/c
OJT for Premier Oil Natuna Sea Ltd Sec. 1
Anoa AGX Project Rev. 0
package skid to the Turbotronics panel located in the MCC. Display of engine and generator
operational conditions is available on theTurbotronics panel , along with indicator lights and
pushbutton and other switches to display and control operational status. A gauge panel is also
installed on the engine package to show some engine operating conditions.
The Mars 100 gas turbine-driven compressor set consists of an axial-flow engine and the driven
compressor(s). Engine and compressor(s) are mounted on a heavy steel base frame in an in-line
arrangement. The base frame is a structural steel weldment, forming a rigid foundation. To facilitate
alignment of major package elements the steel base may include a machined mounting surface for
the driven equipment.The engine power turbine output shaft is aligned with the driven equipment input
shaft, and the shafts are connected with a splined interconnecting drive shaft enclosed in a cover.
The turbine engine is the prime mover. Air is drawn into the compressor section through the air inlet
and is compressed. Fuel is added to the compressed air in the combustor and the mixture is ignited.
After combustion, hot gases expand through turbine nozzles and drive both the gas producer and
power turbine rotors. The two-stage gas producer turbine drives the engine compressor and
accessories. The two-stage power turbine powers driven equipment. Air and combustion gases are
discharged into the atmosphere through the exhaust system. Major components include air inlet,
multistage compressor, compressor diffuser, annular combustor, gas producer and power turbine
assemblies and an exhaust diffuser, and exhaust collector.
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Energy Services International Doc. Turbo. M/c
OJT for Premier Oil Natuna Sea Ltd Sec. 1
Anoa AGX Project Rev. 0
Compressor Skid
Gear Unit
Gauge & Instrument Panel
Base Frame
The dry gas seal system consists of filters, regulators, pressure-sensitive devices, and valves to
supply regulated buffer air or nitrogen and seal gas to the gas compressor suction and discharge
seals. The system prevents contamination of process gas with bearing lubricating oil and prevents
process gas from entering the lubricating oil drain lines.
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Energy Services International Doc. Turbo. M/c
OJT for Premier Oil Natuna Sea Ltd Sec. 1
Anoa AGX Project Rev. 0
Start System
Starter Motor
The start system includes starter and control
devices. The starter rotates the engine to self-
sustaining speed, where the starter shuts
down, the starter clutch overruns, and the
engine accelerates under its own power to
loading speed.
Fuel System
Fuel Valves Gas Fuel Loader Valve
The fuel system controls the fuel pressure
and flow to the engine.
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Energy Services International Doc. Turbo. M/c
OJT for Premier Oil Natuna Sea Ltd Sec. 1
Anoa AGX Project Rev. 0
Combustor
Assembly
Combustor
Compressor
Diffuser
Compressor
Air Inlet Muff
Exhaust Collector
Exhaust Diffuser
Fuel Manifold
Compressor Case
Page 1.17