Starting

System Oil system Fuel System Cooling Water system Cooling and Sealing Air system Fire Protection system Ventilation and heating system Leak Detection system Wet Washing system

GAS TURBINE AT KGPP KAWAS

TECHNICAL

SPECIFICATION VARIOUS SYSTEMS GT STARTUP AND SHUTDOWN

Introduction to Gas Turbine

Introduction to Gas Turbine

Gas Turbine is a heat engine

The Process Includes

Compression :

of working medium (air) taken from atmosphere in a compressor

Combustion

Increase of working medium temperature by constant pressure ignition of fuel in combustion chamber

Expansion

of the product of combustion in a turbine.

Introduction to Gas Turbine

The Ideal Thermodynamic cycle

The working of Gas Turbine is based on Joule Brayton Cycle. A typical cycle consists of two reversible isobars and two reversible adiabatic process Ideal Cycle Efficiency of Brayton Cycle is given below Thermal Efficiency = = 1-1/ (p)v-1/v Where p= Pressure Ratio. v= Adiabatic Constant.

So ideally, Thermal Efficiency of a Brayton Cycle is dependent on Pressure ratio of the cycle.

Introduction to Gas Turbine

The Actual Thermodynamic cycle

For all practical reasons the actual thermal efficiency will depend on

Pressure ratio Turbine inlet Temp Compressor inlet temp Efficiency of Compressor and Turbine

Introduction to Gas Turbine

Applications of Gas Turbine

Conventional applications are

Simple cycle operation. Combined cycle operation. Co-generation.

Electric utility companies use gas turbine predominantly in simple cycle and combined cycle applications. Industrial Company uses them as co-generation power plants

Introduction to Gas Turbine

A Brief History of Gas Turbines

First industrial duty gas turbine of 4 MW was developed by Brown Beaver in 1939 with open cycle efficiency of 18%. The development in the science of aerodynamics and metallurgy significantly contributed to increased compression and expansion efficiency in the recent years.

At Kawas, the Gas Turbine are GE make (Model 9E)

31% open cycle efficiency 49% combined cycle efficiency

Today gas turbine unit sizes with output above 250 MW at ISO conditions have been designed and developed. Thus the advances in metallurgical technology have brought with a good competitive edge over conventional steam cycle power plant.

Introduction to Gas Turbine

Advantages of gas turbine w.r.t steam turbine are:

1. 2.

Fast to start Low Installation Modularization.

cost

due

to

Standardization

and

3.

Low installation cost owing to standardization, factory assembly and test. This makes the installation of the station easy and keeps the cost per installed kilowatt low because the package power station is quickly ready to be put in operation. Due to modular approach they are relatively easy and faster to install. Package concept makes easier shipping, handling, because of its robustness fast start up and shut down reduce conventional stand by cost. The power requirements to keep the plant in standby condition are significantly lower than those for other types of prime movers.

Low standby cost:

Introduction to Gas Turbine

Advantages of gas turbine wrt to steam turbine cont..

4. Low capital cost.
Fewer Auxillaries Benefits of low capital costs were initially offset by higher operating costs when compared with other installed capacities. Therefore earlier gas turbine was strictly for peak load operation. Improvements in efficiency and reliability and application of combined cycle operation have added economic benefits to the gas turbine based power plants.

5.

Maximum application flexibility:

The package plant may be operated either in parallel with existing plants or as a completely isolated station. These units have been used, widely for base, peaking and even emergency service. The station can be equipped with remote control for starting, synchronizing & loading

Introduction to Gas Turbine

Advantages of gas turbine wrt to steam turbine cont..

5.

Control reliability:

the microcomputer based control, with an integrated temperature system (ITS) provides accurate control, quick protection and complete sequential start up & shut down & operation.

Gas Turbine plant Layout

Gas Turbine Auxiallaries Layout

Starting System
Before

the gas turbine can be fired and

started It must be rotated or cranked by the accessory equipment. This is done by an induction motor, operating through torque converter to provide cranking torque and speed required by the turbine for start-up. The starting system consists of an induction motor and torque converter coupled to the accessory gear.

Torque Converter

The starting motor drives the torque converter input through a flexible coupling. The torque converter output is coupled to the accessory gear and provides the required torque multiplication for the starting motor to drive the turbine. The main parts of torque converter are the impeller driven by the input shaft, the turbine wheel, which drives the output shaft, and the stator, which directs fluid from the impeller to the turbine at the correct angle to produce the required output torque.

ACCESSORY DRIVE
The

accessory drive gear, located at the compressor end of the gas turbine, is a gear assembly coupled directly through a flexible coupling to the turbine rotor. function is to drive each gas turbine accessory at its proper speed. In addition, it contains the system main lube oil pumps and the turbine over speed bolt mechanism.

Its

Oil System

Lubricating fluid is circulated to :

Three main turbine bearing Generator bearings, The turbine accessory gears and fuel pumps. The starting means torque converter for use as hydraulic fluid as well as for lubrication. After pressurization oil is diverted and filtered again for use by hydraulic control device as control fluid. The trip circuit as trip oil system

Lub Oil Hydraulic Oil Trip Oil

Lubricating oil system

Major system components include:

Lube reservoir in the accessory base Main lube oil pump (shaft driven from the accessory gear) Auxiliary lube oil pump and emergency lube oil pump Pressure relief valve VR-1 in the main discharge Lube oil heat exchangers Lube oil filters Bearing header pressure regulator VPR-2

Hydraulic oil system

The main hydraulic supply system utilizes turbine lube oil to supply the high-pressure fluid for operating fuel control valves, or other devices
Gas Fuel Stop valve and control valve Liquid fuel stop valve and control valve IGV control

Trip Oil system

Some protections are strictly for abnormal and emergency operating conditions requiring shutdown of the turbine.

The hydraulic trip oil is the primary protection interfacebetween the turbine control protection system circuits (SPEEDTRONIC control system) and the component, which admit or shut off fuel and regulate IGV position.

FUEL SYSTEM

GAS FUEL SYSTEM LIQUID FUEL SYSTEM ATOMISING AIR SYSTEM

Gas Fuel System

The

gas fuel system is designed to deliver gas fuel to the turbine combustion chamber at the proper pressure and flow rates
to meet all of the starting, acceleration and

loading requirements of gas turbine operation

The following major components comprise the gas fuel system:

Strainer Fuel gas supply pressure alarm switch Gas stop ratio valve VSR Gas control valve VGC Stop ratio LVDTS 96GC-1, 2 Stop ratio valve-control servo valve 90SR Gas control valve- control servo valve 65 GC Gas fuel dump valves VH5 and VH12 Gas fuel vent solenoid valve 20 VG-1 and 2 Pressure gauges Lines to the 14 combustion chambers

Liquid Fuel System

This liquid fuel control system is made up of fuel handing components and electrical control components.
It includes
fuel supply strainer SF1, fuel oil stop valve VS1, hydraulic trip valve VH4, fuel pump PFI , fuel bypass assembly, fuel pump pressure relief valve VR4, high and low pressure fuel filters, flow divider FD1, combined selector valve/pressure gauge assembly, check valve VCK1-1 to14, false start drain valve VA17-1, -2, -5.

The electrical control components are:

fuel oil stop valves limit switches 33 FL-1, -2, liquid fuel pump bypass valve servo valve 65 FP, liquid fuel bypass valve position feedback LVDT 96FP-1, -2, flow divider speed pickups 77FD-1, -2

Atomizing Air System

Atomising air system provides sufficient pressure in the air atomising chamber of the fuel nozzle body
to maintain the ratio of atomising air pressure to compressor discharge pressure at approximately 1.2 or greater over the full operating range of the turbine.

Since the output of the main atomising air compressor, driven by the accessory gear, is low at turbine firing speed, during starting, booster atomising air compressor provides a similar pressure ratio during the firing and warm up period of the starting cycle and during a portion of the accelerating cycle

COOLING AND SEALING AIR SYSTEM

The cooling and sealing air system provides the necessary airflow from the gas turbine compressor to other parts of the gas turbine rotor and stator to prevent excessive temperature build-up in these parts during normal operation and sealing of the turbine bearings. Air from two centrifugal type blowers is used to cool the turbine exhaust frame. These two fans are part also the part of cooling system.

COOLING AND SEALING AIR SYSTEM

Cooling and Sealing functions provided by the system are as follows:
Sealing of the turbine bearings Cooling of internal turbine parts subjected to high temperature. Providing an operating air supply for air operated valves.

Bearing cooling and sealing.

Cooling and sealing air is provided from the fifth stage and is piped to each of the three turbine bearings. Orifices in the airlines to the turbine bearing limit the flow of air and the pressure to the proper value. The pressurized air-cools and seals the bearing by containing any lubrication fluid within the bearing housing that otherwise might pass to the mechanical seals. Air is directed to both of each bearing housing for providing a pressure barrier to the lubricating fluid. After performing this function, the air is vented via the oil drain passage from the bearings No.1 and NO.3 while air from the bearing No. 2 is vented to atmosphere.

Exhaust frame and turbine shell cooling

Two electric motor-driven, centrifugal blowers (88 TK-1 and 88 TK-2) are mounted external to the turbine for cooling of the exhaust frame and turbine shell.
The pressure, speed and flow characteristics of the gas turbine compressor are such that air must be extracted from the 11th stage and vented to the atmosphere to prevent pulsation of the compressor during the acceleration period of the turbine starting sequence and during deceleration of the turbine at shutdown. Pneumatically operated 11th stage air extraction valves, controlled by a three-way solenoid valve, are used to accomplish the pulsation function.

Pulsation Protection

GT COOLING WATER SYSTEM

The cooling water system is a pressurised closed system

For heat dissipation requirements of

the lubrication system, the atomising air system and the turbine support legs.

During frost the cooling system must be filled with an aqueous solution of ethylene glycol.

FIRE PROTECTION SYSTEM

The carbon dioxide (CO2) fire protection system
to

extinguish fires by reducing the oxygen content of

the air in the compartment from an atmosphere normal of 21 percent to less than 15 percent which is insufficient concentration to support the combustion of turbine fuel or lubricating oil.
System

design is designed recognizing the reflash

potential of combustibles exposed to high

temperature metal;

it provides an extended discharge to maintain an

extinguishing concentration for a prolonged period to

minimize the likelihood of a reflash condition.

FIRE PROTECTION SYSTEM

Major system components include: Carbon dioxide cylinder, (in and off- base station), discharge pipes and nozzles, pilot valves, fire detectors and pressure switches Zone 1: Turbine accessory compartment and turbine compartment Zone 2: Tunnel of bearing no. 3 Zone 3: Generator Two types of discharge are used: initial discharge and extended discharge

FIRE PROTECTION SYSTEM

The initial discharge must permit a rapid discharge of CO2 to quickly build up an extinguishing concentration.

The extended discharge is smaller and permits a relatively slow discharge rate in order to maintain the extinguishing concentration over a prolonged period of time. By maintaining the extinguishing concentration, the likelihood of a fire reigniting is minimized.

VENTILATION SYSTEM
Ventilating capabilities have been incorporated in the turbine and accessory components (enclosures), by utilizing thermally insulated side panels and roofs The three compartments, accessory, turbine and load shaft are, independently ventilated

Gravity operated dampers are used in the system to automatically provide an enclosure when the protection system is activated

The gravity closing dampers are normally held open by the pressure- operated latches, which must be manually reset after damper release.

GAS TURBINE OPERATIONS

System Line Up
What

is System Lining Up? What if I fail to line up the system ? What are the systems to be lined up ?

System Lining Up
It

is a process of checking
all the auxiliary system along with its equipments
pipings, valves, control instruements , tank levels, Filters , Heat exchangers, pumps, motors etc

Power and control supply

What if I fail to line up the system ?

Failure

to Start Equipment distress Safety Concern Inefficient Operation

What are the systems to be lined up

Starting System Oil system Fuel System Cooling Water system Cooling and Sealing Air system Inlet air Filteration system Fire Protection system Ventilation and heating system Leak Detection system

Starting a Gas Turbine

Turning

Gear Cranking Venting/purging Firing Warm up Acceleration Full speed No Load Synchronization Loading

5 Speed

Torque converter angle 2 0-1 Cranking 1-2 Purging 2-3 Speed down to firing speed 3- Firing 3-4 Warm up 4-5 Acceleration 5-6 Full Speed no load

4 3
Fuel

Time

Turning Gear Operation

In

Turning Gear Operation the whole shaft-line is rotated at 3.3 % speed (100) rpm starting after a long shutdown

During During

Shutdown , to provide uniform and gradual cooling of the rotor,stator and combustion chamber equipment to prevent shaft bowing and decrease thermal stresses

Cranking Operation
In

Cranking Operation the shaftline is rotated at 25% speed (600) rpm starting after a long shutdown

During For

Special Operation like

Wet Washing Heavy Purging

Firing Operation
In

firing Operation shaftline is rotated at firing speed 18% with fuel firing on

During starting after a long shutdown

To Check parameters evolution during startup

AUTO OR REMOTE GAS TURBINE READY TO START PERMISSIVES

Any of the above No

All yes

NOT READY TO START

Ready To Start START ORDER

AUTO VENT CLOSE

AOP START

GT WATER PUMP START

SUPER PACKAGE FAN START 88 BT

LUB OIL PRESSURE NORMAL JACKING OIL PUMP START

1 -No lube Oil pressure low trip 2 -Jacking oil pressure OK 3 -Super package vent complete 4 -Jacking oil pump motor run

All Yes
A

A CRANKING MOTOR START TORQUE CONVERTOR AT MAX 65%

HYD. OIL PUMP START

SPEED DETECTED 14 HR (0.06%)

OIL MIST SEPERATOR START

SPEED INCREASE 14 HT (8.4%)

SPEED INCREASE 14 HM (10%)

EXHAUST COOLING FAN MOTOR START 88 FX

JACKING OIL PUMP STOP

TORQUE CONVERTOR 50%

SPEED INCREASE TO VENT SPEED

TURBINE PURGING (1 min) PURGE TIMER PICK UP

SPEED DECREASES

TORQUE CONVERTOR 15%

SPEED DOWN to FIRING SPEED

FSR FIRING LEVEL (19. 8%) FLAME DETECTION 2 OUT OF 4

SPARK PLUG 1 min

GT COOLER FAN 1-6 START

2 SEC

LOAD COMPT. FAN 88VG EXHAUST FAN 88TK1,2 START

TORQUE CONVERTOR 65%

FSR TO WARM UP LEVEL (9.5%)

FSR & SPEED INCREASE

SPEED 60% 14 HC

CRANKING MOTOR STOP

GEN WATER PUMP START GEN FIN FANS START

SPEED 95% 14 HS

AOP STOP

AUX HYD OIL PUMP STOP

GEN EXCITATION ON

COMPRESSOR BLEED VALVES CLOSE

SPEED SET POINT 100.3%

SYNCRO ON AUTO

Yes
SPEED MATCHING VOLTAGE MATCHING

GEN CIRCUIT BREAKER CLOSE GT COOLING FANS START IF NO LOAD SELECTION BASE OR PEAK LOAD SPINNING RESERVE