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General Electric LM6000PC
For a
detailed description of the basic and optional scope of supply please refer to
the accompanying Product Specification manual.
THE FOLLOWING EQUIPMENT AND SERVICES ARE INCLUDED
IN THE BASIC SCOPE OF SUPPLY:
- LM6000PC
gas turbine engine equipped with bellmouth and screen.
-
Natural gas
fuel, water injected combustion system, complete and self –contained on the
unit, with connection on the baseplate for customers filtered, regulated fuel
supply at 675 psig +/- 20 psig.
-
Generator,
13,800 Volt, 60 Hz, 3600RPM, 71.176 MVA @ 0.85 pf, 59 Deg F cooling air. Low
maintenance brushless excitation system suitable for Class I, Group D, Div 2
areas. Neutral and line cubicles with CTs, surge protectors and lightning
arrestors.
-
I-beam
baseplates for turbine, generator and unit mounted accessories.
-
Acoustic
enclosure for gas turbine, generator and unit mounted accessories.
-
Multi stage
air inlet filtration system for both gas turbine and generator, including
weather hoods, inlet screen, pre-filter, final barrier filter, intake silencer,
and standard ducting to plenum chamber. Filter house ladders and platforms are
included.
-
Electro-hydraulic
starting system
-
Separate oil
systems for gas turbine and generator, including duplex filters, shell and tube
coolers, stainless steel piping and stainless steel reservoirs.
-
Axial-exhaust
system with discharge flange for customer connection.
-
Unit control
panel for indoor mounting in a controlled environment, including microprocessor
fuel management and sequencing system, generator metering.
-
Bently
Nevada vibration monitoring, CRT annunciation of alarms and shutdowns,
-
RS232, LAN
or Modbus ports for data output to customers control systems.
-
I/O cubicle
mounted on gas turbine enclosure.
-
24VDC
Control system. Battery with dual battery chargers.
-
Fire and gas
detection and extinguishing system, serving both turbine and generator
compartments, complete with 24VDC battery and charger.
-
“On-line”
water wash system and “soak wash” system
-
Generator
factory testing to IEEE or IEC standards. Gas turbine performance test by GE.;
full load string test and performance verification of turbine.
-
Six sets of
drawings and data packages, O&M manuals.
-
Training
course for up to 10 customer personnel.
1.2
Equipment and Services by Seller
1.2.1
Transport to
the job site (all logistics)
1.2.2
Complete
Engineering, Procurement and Construction Services (the EPC)
1.2.3
Simple cycle
exhaust stack with EPA ports, platforms and ladders
1.2.4
35’ X
14’ Modular Control Room
1.2.5
Inlet air
chilling module
1.2.6
Fired, fuel
gas, heating module
1.2.7
Unit 480 V
Motor Control Center
1.2.8
NEMA 3R 15
kV Switchgear
1.2.9
Dual Fuel
Option (transfer fuels at reduced load, non-cooled CDP)
1.2.10
O&M
Manuals on CD ROM
1.2.11
Low ambient
temperature anti-icing system
1.2.12
Generator
inlet air cooling system
1.3
Equipment and Services by Purchaser
The Purchaser will
provide the following equipment, materials, and services unless otherwise noted:
1.3.1
Unloading, indoor and outdoor storage (as required) and installation
labor.
1.3.2
Foundations, anchor bolt hardware, grouting forms, and grouting.
1.3.3
Fuel and water forwarding systems including piping to flange connections
at Vendor's baseplate.
1.3.4
Lubricants and fluids (Operating and Commissioning)
1.3.5
High voltage cables and/or bus duct from the generator terminals.
1.3.6
Electric utility interconnect including the required circuit breakers and
protective devices.
1.3.7
Interconnection piping, conduit, and wiring between the unit control
panel, main unit termination boxes, auxiliary system modules, and motor control
center.
1.3.8 Bolts, nuts, washers, and gaskets required at terminal points.
2.0
REFERENCED DOCUMENTS
The
applicable sections of the following US and ISO Codes and Standards will be
considered as relevant Standards for gas turbine equipment. The designs and
procedures will be compliant with applicable sections of the following:
AGMA 421
Standard
Practice for High Speed Helical and Herringbone Gear Units (Used for the
accessory gear except for service factor.)
ANSI/AFBMA
Std 9
Loading Ratings and Fatigue Life for Ball Bearings.
Std 11
Load Ratings and Fatigue Life for Roller Bearings.
ASCE-7
Minimum Design Loads for Buildings and Other Structures
(Used for Snow Loads)
ANSI B1.1
Unified Inch Screw Threads (S&S Energy Products complies at the
customer's connection)
ANSI
B1.20.1
Pipe Threads
ANSI
B16.5
Steel Pipe Flanges and Flanged Fittings
ANSI
B16.9
Factory - Made Wrought Steel Butt Welding Fittings
ANSI B16.21
Non-metallic Flat Gaskets for Pipe Flanges.
(Spiral-wound gaskets per API 601 may be used, particularly in turbine
compartment piping.)
ANSI B31.1
Pressure Piping and gas turbine piping systems comply.
ANSI B133.2
Basic Gas Turbine. Complies, with the exception of paragraph:
8.5
Loose items such as jackscrews and eyebolts are not furnished.
Provisions for use of such items are not included in the design.
ANSI B133.3
Gas Turbine Auxiliary Equipment. Auxiliary
equipment will fully comply with design portions only.
The Seller’s recommended lube oil flushing procedure will be
implemented. Atomizing air receiver
is not applicable.
ANSI B133.4
Gas Turbine Controls and Protection Systems
ANSI B133.5
Gas Turbine Electrical Equipment
ANSI
B133.8
Gas Turbine Installation Sound Emissions
ANSI
C37.90
Relays Associated with Electric Power Apparatus
ANSI
C37.90.1
Guide for Surge Withstand Capability (SWS) Tests
ANSI
C50.10
General Requirements for Synchronous Machines
ANSI
C50.13
Requirements for Cylindrical Rotor Synchronous Generators
ANSI C50.14
Requirements for Combustion Gas Turbine Driven Cylindrical Rotor
Synchronous Generators (The GTG does not provide a peak reserve rating.
Not all of the prototype tests indicated in Table 2 have necessarily been
conducted.)
ANSI C57.94
American Standard, Guide for Installation and Maintenance of Dry Type
Transformers
ANSI
C83.16
Relays
ANSI
S1.2
Method for the Physical Measurement of Sound
ANSI
S1.4
Specification for Sound Level Meters
ANSI
S1.13
Method for the Measurement of Sound Pressure Levels
ANSI/ASHRAE 52.1-1992
Gravimetric and Dust Spot Procedures for Testing Air-cleaning Devices
Used in General Ventilation for Removing Particulate Matter
ANSI/IEEE
C37.2
Electrical Power System Device Function Numbers (The Unit complies with
respect to device designations except that in a few cases device numbers had to
be modified or added for this application.)
ANSI/IEEE
100
IEEE Standard Dictionary of Electrical and Electronics Terms
ANSI/NEMA
MG1
Motors and Generators
ANSI/NEMA
MG2
Safety Standard for Construction and Guide for Selection, Installation
and Use of Electric Motor and Generators
ANSI/NFPA
12
Carbon Dioxide Extinguishing Systems
ANSI/NFPA 70
National Electrical Code (Electrical components will be designed to meet
the intent of this Code for Class 1, Group D, Div. 2, Hazardous area
classification where appropriate.).
API 614
Lubrication, Shaft-Sealing, and Control - Oil Systems for Special -
Purpose Applications
API 616
Gas Turbine for Refinery Services
API 650
Storage Tanks
API
670
Vibration Monitoring Systems
API
678
Accelerometer - Based Vibration Monitoring System
API
RP11PGT
Packaged Combustion Gas Turbines
ASME
PTC22
Gas Turbine Power Plants - Performance Test Codes
ASME
Section VIII
ASME Boiler and Pressure Vessel Code
ASME
Section IX
ASME Boiler and Pressure Vessel Code
AWS
D1.1
American Welding Specification
EIA RS-232
Interface between Data Terminal Equipment and Data Communication
Equipment Employing Serial Binary Interchange
IEC
34.1
Rotating Electrical Machines - Rating and Performance
IEC
34.3
Rotating Electrical Machines - Turbine Type Synchronous Machines
IEEE Std.
421
IEEE Standard Criteria and Definitions for Excitation Systems for
Synchronous Machines
JIC
Hydraulic Standards for Industrial Equipment
UBC
Uniform Building Code (Used for wind loads and seismic design)
3.0
TECHNICAL REQUIREMENTS
3.1
Operation
The Unit shall be capable of satisfactory operation
from 0% load to 100% load at the Site Design Conditions. During startup, the turbine shall be capable of idling
unsynchronized for up to 60 minutes. The
UNIT shall be capable of starting, synchronizing and loading within 10 minutes
of dispatch from a ready to start condition.
3.2
Performance Data and Guarantees
The Seller guarantees the kW output, heat rate, NOx,
CO, PM10 and UHC emissions, and noise emissions of the Unit according to the
Contract.
Seller shall provide additional performance data to
show how changes in ambient temperature and inlet/exhaust losses affect heat
rate, power output, exhaust mass flow, and exhaust gas temperature.
3.3
Site Design Conditions
3.3.1
Climatic Conditions
The Unit and related equipment furnished by the
Seller shall be designed for proper operation with the following climatic
conditions:
-
Maximum wind
velocity of 100 mph
-
Ambient
temperature range of 44 to +105°F*
-
Relative
humidity of 15% to 100%
*Lower-operating temperatures can be realized with
the addition of an anti-ice system
3.3.2
Seismic Conditions
The gas turbine structure and attachments shall be
designed in accordance with UBC 1997, Seismic Zone 4.
3.4
Surface Temperatures
Surface temperature of components that can be
readily accessed during normal operation shall not exceed 140°F without a
barrier to protect personnel. The
engine compartment interior and roof are excluded from this requirement.
4.0
LM6000PC Uprated GAS TURBINE GENERATOR SET
4.1
Gas Turbine
Major Components of the LM6000 turbine are:
-
5-stage
low pressure compressor (LPC)
-
14-stage
variable geometry high pressure compressor (HPC)
-
Annular
combustor
-
2-stage
air cooled high pressure turbine (HPT)
-
5-stage
low pressure turbine (LPT)
-
Accessory
Drive Gear Box
The LPC
will be driven through a concentric drive shaft by the 5-stage LPT, forming the
low-pressure rotor. The
high-pressure rotor will be formed by the 14-stage HPC, driven by the 2-stage
HPT. The high pressure
"core" will be formed by the HPC, combustor and HPT section.
The Unit
uses the Low-Pressure Turbine (LPT) powers the output shaft. Driving with the LPT improves fuel efficiency and allows the
turbine to be directly coupled to the electrical generator rotating at 3600 RPM.
The gas turbine drives the generator through a flexible dry type coupling
connected to the front, or "cold", end of the LPC shaft.
4.2
Turbine Cycle
The gas turbine cycle begins with air entering the inlet plenum, where it
is directed through inlet guide vanes into the LPC. The LPC compresses the air by a ratio of approximately 2.4:1.
Air leaving the LPC is directed into the HPC.
Variable bleed valves (VBV) in the flow passage between the two
compressors regulate the airflow entering the HPC during idle, low power
operation, and transient load conditions. To
further control the airflow, the HPC will be also equipped with variable pitch
inlet guide vanes and stator vanes.
The HPC compresses the air by a ratio of approximately 12:1. The HPC discharge will then be directed into the annular
combustor section where it mixes with the fuel from the 30 fuel nozzles.
One igniter initially ignites the fuel/air mixture.
When combustion is self-sustaining, the igniter will then be turned off. The hot combustion gases will then be directed into the HPT,
which consequently drives the HPC. The
gas then expands further through the LPT, which drives the LPC.
The flanged LPC shaft drives the electric generator.
4.3
Inlet Section
The air intake section of the
gas turbine consists of an annular flow section to direct the air stream into
the low-pressure compressor.
4.4
Low Pressure Compressor
The low-pressure compressor (LPC) will be a 5-stage axial flow compressor
with 2.4:1 pressure ratio. At
low power settings and during large power reduction transients modulating bleed
ports control LPC bypass flow to assure adequate LPC stall margins.
4.5
High Pressure Compressor
The high-pressure compressor (HPC) will be a 14-stage design. Variable
stators in stages 1 through 5 provide stall-free operation and high efficiency
throughout the starting and operating range.
The stator geometry of stages 6-14 will be fixed.
The HP compressor casing will be split horizontally to allow ready access
to the stator vanes and rotor blades for inspection or replacement.
4.6
Combustion System
The gas generator will be furnished with 30 externally mounted fuel
nozzles for the natural gas fuel system requirements.
For NOx reduction, water will also be injected into the fuel nozzles
through a separate manifold.
The Unit uses a high performance annular combustor with low exit
temperature pattern, low-pressure loss and high combustion efficiency at all
operating conditions.
4.7
High Pressure Turbine
The high-pressure turbine (HPT) will be an air cooled, 2-stage design
with demonstrated high efficiency.
The HPT will be designed to be easily maintainable in service.
Significant maintainability features include:
- Stage 1
nozzle assembly will be removable as a unit.
- Stage 2
nozzle assembly will be removable as a unit.
- Turbine
blades will be individually replaceable.
- Stage 1
and 2 shrouds will be segmented and designed for removal and replacement in the
stator assembly.
The 2-stage high-pressure turbine will be assembled on the same shaft as
the 14-stage high-pressure compressor.
Compressor discharge air will be used to cool the rotor structure and
both blade stages. The cooling air
flows through the shaft and the bore of the stage 1 disk, where it separates to
supply stage 1 and 2 blades. Compressor
discharge air and bleed air will be used to cool the HPT stator.
4.8
Low Pressure Turbine
A 5-stage low-pressure turbine receives the outlet flow from the HP
turbine. The LP turbine will be
mounted on a common shaft with the 5-stage LP compressor.
This shaft will be concentric to the HP rotor.
4.9 Gas
Turbine Support Structures
Three frames provide support for the LP and HP rotors.
-
Front
Frame
The front frame will be a major engine structure that provides support
for the LPC rotor and the forward end of the HPC rotor.
The frame also forms an airflow path between the outlet of the LPC and
the inlet of the HPC. Engine front
mount provisions will be made off the front frame.
The front frame contains the engine "A" sump that includes a
thrust and a radial bearing for support of the LPC rotor and a radial bearing
which supports the forward end of the HPC rotor.
Lubrication oil, supply and scavenge, lines for the "A" sump
will be routed inside the frame struts. The
engine inlet gearbox will be located in the "A" sump, with the radial
drive shaft extending out through the strut located at the six o'clock position.
-
Compressor
Rear Frame
The compressor rear frame consists of an outer case, 10 struts and the
"B-C" sump housing. The
outer case supports the combustor and 30 fuel nozzles.
The hub provides support for both a thrust bearing and a radial bearing
to support the mid section of the HP rotor system.
-
Turbine
Rear Frame
The turbine rear frame provides the aft connection of the gas turbine to
the base through the rear engine mounts and is the structure supporting the
"D-E" sump, and the LPT stator case.
4.10
Accessory Drive System
The hydraulic starter, lube and scavenge pump, variable geometry
hydraulic pump, and other accessories will be mounted and driven from the
accessory gearbox. The accessory
gearbox, located below the front HPC casing at the six o'clock position on the
air collector, will be driven from the transfer gearbox through a short
horizontal shaft. The transfer
gearbox will be driven by the high-pressure rotor system.
4.11
Variable Geometry (VG) Control System
The variable geometry system consists of a positive displacement
hydraulic pump, with torque motor positioned hydraulic servos for porting fluid
at regulated pressure, two HPC variable stator vane actuators and six LPC bleed
valve actuators. Electrical inputs
from the SSEP controls operate three separate servo valves mounted on the gas
turbine. The variable output
pressures from these servos position the low-pressure compressor variables bleed
valves (VBV) and the high-pressure compressor variable stator vanes (VSV).
Position feedback of the moving elements will be provided by linear
variable differential transformers (LVDT) integral with the actuators.
4.12
Gas Generator Overall Features
Included are modular LPC assembly, fabricated compressor front frame and
air collector, modular HPC and HPT, fabricated compressor rear frame and turbine
mid-frame and modular LPT. Each
rotating mass will be supported by roller bearings, and rotor axial thrust loads
are carried by ball bearings. Labyrinth
type, long-life seals will be used in the bearing sumps.
Each sump will be individually scavenged. A common line to an air/oil separator vents the “A”,
“B-C” and “D-E” sumps.
4.13
Starting Motor
A hydraulic motor will be installed on the accessory gearbox to provide
starting torque to the gas turbine. A
200 HP (150 kW) electric motor and hydraulic pump mounted on the auxiliary
equipment module provide pressured hydraulic oil to power the hydraulic starter
motor. (See Section 9).
4.14
Fuel Systems
The Purchaser will supply fuel in accordance with GE M&IAD Spec
MID-TD-0000-1 at the baseplate connection.
The components downstream of the baseplate connection are supplied by the
Seller.
4.15
Lubrication System
A complete lubrication system for the gas turbine will be furnished as
described in Section 10. The lube
oil system includes mechanical pump, duplex filters, pressure and temperature
instrumentation, 304 stainless steel reservoir and a 304 stainless steel piping
system. The gas turbine uses
rolling element dry sump bearings. There
will be no need for auxiliary lube oil pumps.
Bearing sumps will be sealed with knife-edge seals and pressurized with
compressor bleed air. Oil will be
removed from the seal air by an air-oil coalescer mounted on the roof skid.
4.16
Ignition System
The ignition system includes one ignition unit, which converts the 115 V, 60 Hz power to high voltage, and includes a high tension lead and igniter. The ignition system will be used only during starting and will be turned off once the engine reaches idle speed.
4.17
Borescope Inspection Provisions
Ports and removable covers in the casing permit borescope inspection of
the blades and vanes of the low pressure compressor, the high pressure
compressor, the high pressure turbine, the low pressure turbine, combustor,
frames, and accessory gearbox.
4.18
Turbine Mounted Instruments
These devices will be incorporated into an electronic control system
furnished. Details of the control
system are described in Section 13.
The gas turbine will be equipped with the following sensors:
2
Speed sensors (XN25) high-pressure rotor - magnetic pickup type - located
on accessory gearbox.
Speed sensors (XNSD) LP turbine rotor - magnetic pickup type - located in
the LP turbine rear frame.
1
Low-pressure turbine inlet temperature (T48) sensor system - chromel
alumel thermocouples - located on LPT case.
2
Accelerometers - located on the gas turbine, compressor rear frame, and
LPT rear frame.
7
Resistance Temperature Detectors (RTD) will be provided to measure and
monitor the temperature of lube oil in the Transfer Gearbox, the B-C sump, D-E
sump scavenge lines, the accessory gearbox and the lube supply line to the gas
turbine.
1
Low-pressure turbine inlet pressure probe (P48) - total pressure -
located on the low-pressure turbine case.
1
Low-pressure compressor inlet temperature and total pressure probe (T2,
P2) - located on the IGV case. The
probe is a dual element RTD (two separate RTDs in one probe).
The probe also includes a P2 (total pressure) sensing port.
1
High-pressure compressor inlet temperature and total pressure probe (T25,
P25) - located on front frame. The
probe will be a dual element RTD (two separate RTDs in one probe).
The probe also includes a P25 (total pressure) sensing port.
2
Variable stator vane (VSV) position sensors - linearly variable
differential transformer (LVDT) - located on the actuators.
2
Variable bleed valve (VBV) position sensors - linearly variable
differential transformer (LVDT) - located on the actuators.
1
High-pressure compressor discharge temperature (T3) sensor - A dual
element chromel - alumel thermocouple mounted on the compressor rear frame.
3
Remote indicating chip detectors, located in scavenge oil return lines.
2
Liquid manifold temperature sensors will be provided.
Type K thermocouples (furnished on dual-fuel or
gas-fuel-with-water-injection units only).
4.20 Water
Injection System
The
water injection system consists of inlet strainer, valves, piping controls and a
duplex or two simplex boost pump skid(s) to boost water pressure to the required
pressure. Purchaser must supply
demineralized water to the customer connection located on the water injection
boost skid. A minimum supply
pressure of 5 psig will be available during gas fuel operation at a maximum rate
of 55 gpm. NOx water cleanliness
will satisfy GE M&IAD Spec MID-TD-0000-3.
5.0
GENERATOR AND AUXILIARIES
5.1
Generator Design
The generator will be an air cooled, self-ventilated, cylindrical rotor
machine. It will be a two pole
synchronous generator with a brushless excitation system and a permanent magnet
pilot exciter. The generator
utilizes an open, drip-proof design and will be packaged in a housing which
reduces average noise levels to 85 dB(A) at 3 feet from unit and 5 feet above
grade. The rotor will be supported
by two split sleeve bearings, which will be lubricated with a pressurized
mineral oil system. The generator
has a design life of 25-30 years, utilizes Class F insulation and will be sized
to operate with Class B temperature rise. The
generator will be capable of absorbing the site rated power output of the gas
turbine for baseload operation throughout the entire ambient temperature range
of the application.
The generator will be capable of a 110% power overload for 2 hours out of
every 24 hours of operation with no loss of operating life. The generator will also be capable of withstanding a 30%
overload current for 1 minute.
The generator and turbine shall be capable of operating at full output at
plus/minus 3-percent frequency deviation continuously.
5.2
Brushless Excitation System
A brushless exciter will be furnished with each generator.
The brushless exciter will be the direct connected, rotating type,
electrically and mechanically coordinated with the generator to insure a
reliable generating unit. The exciter will be powered by a Permanent-Magnet-Generator
(PMG) mounted on the shaft of the main generator.
A rotating, full-wave bridge rectifier converts the AC output of the
exciter to DC, which will be fed directly into the generator field. The
voltage regulator controls the output of the exciter.
5.3
Voltage Regulator System
The generator will be furnished with an auto-manual electronic voltage
regulator system. The voltage
regulator system will be rack-mounted in the unit control panel and maintains
generator output voltage within +0.5% under steady state operating
conditions. The voltage regulator
utilizes single phase sensing circuitry and includes:
- diode
failure alarm
- under
excitation limiter
- flux
limiter
- auto follower & null balance
- over-excitation
limiter
- auto
transfer to manual control
-
volts per Hz control
5.4
Neutral Cubicle and Line Side Cubicle
Separate terminal boxes are provided on opposite sides of the generator
to house the neutral and line terminals.
5.4.1
Line Side Cubicle
The line side cubicle will be the Purchaser's connection point to the
high voltage output of the generator. The
cubicle bolts to the right hand side of the generator enclosure, as viewed from
the exciter end. It contains
3-phase power lugs, lightning arrestors and surge protectors and bus work.
The cubicle will be adequately sized to accommodate stress cones supplied
by others. The line compartment,
provided by the Seller as an option, shall contain 6 CTs for generator
protective relaying in Public Utility applications.
5.4.2
Neutral Cubicle
The neutral cubicle will be the Purchaser's connection point for
grounding the generator. The
cubicle bolts to the left-hand side of the generator enclosure, as viewed from
the exciter end. Within the cubicle
the three phases will be brought together to a "Y" point with bus bar.
The "Y" point will be connected to a high impedance grounding
system* furnished by the Seller. The
grounding system includes a transformer and a secondary grounding resistor in an
enclosure mounted on the neutral cubicle.
The neutral cubicle contains 7 CTs supplied by the Seller; 3 for
metering, 3 for protective relaying, and 1 for cross current compensation.
5.5
Generator Accessories
5.5.1
Stator Temperature Detectors
A minimum of six platinum resistance temperature detectors (two per
phase) will be embedded in the stator windings.
The RTD's will be the 100-ohm at 32oF type.
5.5.2
Bearing Temperature Detectors
An embedded RTD will be provided for each radial bearing.
In addition, an RTD and local thermometer will be furnished in the drain
line of each bearing. Monitoring and temperature indications will be provided at
the unit control panel.
5.5.3
Space Heaters
The generator will be equipped with space heaters located inside of the
generator enclosure. The space
heaters will have adequate capacity to prevent condensation of moisture within
the generator enclosure when the unit is not operating.
The space heaters will be designed for operation on a three phase, 480
VAC, 60 Hz system. The space heater
will be automatically switched ON/OFF by the unit control panel and a contactor
in the Unit motor control center.
5.5.4
Vibration Detectors
Two Bently Nevada vibration detectors will be mounted 90 degrees apart at
each radial bearing (Total 4). The
proximeters and cables will be wired to the main termination box in the
generator compartment. Monitoring
equipment will be provided in the unit control panel.
5.5.5
Ground Fault Monitoring
Continuous electronic monitoring of the generator rotor winding and its
connections will be provided. Indication
of a ground fault will be provided at the unit control panel.
6.0
AIR INLET SYSTEM - MULTI STAGE DESIGN
The air inlet system:
1.
Maintains
clean airflow required by the gas turbine, generator cooling, and enclosure
ventilation.
2.
Minimizes
frequency of high efficiency filter replacement.
3.
Permits the
inclusion of optional equipment including inlet conditioning and anti-ice
protection.
6.1
Filtration Specifications
The Unit air inlet system has a three-stage filter which removes 99.9
percent of all particles 5.0 micron and above under the specified environmental
conditions. The filter is not designed to protect the gas turbine against
salt laden air.
Total AirFlow:
335,000 SCFM
Engine Combustion Air
230,000 SCFM
Ventilation Air for Turbine &
105,000 SCFM
Generator Compartments
6.2
Filter House Construction
6.2.1
General Arrangement
The filter house will be a three-section unit, assembled at the job-site.
The left side and right side filter house sections contain the filtering
elements. The center section will
be a fabricated plenum with a bottom outlet for the filtered air flow.
Weather hoods shield the filter sections from driving rain or hail.
A pre-designed transition duct with expansion joint mates the filter to
the engine enclosure. Ladders and
platforms will be furnished to provide access to the service doors at each
filter section. Internal walkways
and lighting will be provided within each filter section to simplify operator
changeout of filter elements. The
filtered airflow will be divided into two air streams by ducting within the
filter assembly, providing:
-
Combustion
air for the gas turbine
-
Generator
Cooling Air
-
Ventilation
air flow for the generator and turbine compartment
6.2.2
Material
The filter housing will be constructed of steel plate.
Two (2) coats of protective paint will be applied to the exterior and
interior carbon steel surfaces.
6.3
Filtration System Details
6.3.1
Inlet Screen
The inlet air passes first through a wire mesh screen that removes trash,
paper, and other loose objects.
6.3.2
Prefilter
Next, the air stream passes through a replaceable pre-filter.
The pre-filter removes coarse particles and extends the life of the high
efficiency barrier filter.
6.3.3
Barrier Filter
The final filtration stage consists of a high efficiency barrier filter
with an extended surface area. The
replaceable cylindrical canister filter elements will be rugged, provide high
dirt-holding capacity and have low pressure drop.
6.3.4
Restriction Indication
A pressure switch will be provided for alarm and shutdown based on the
filter system pressure drop:
- New and Clean (Typical)
4" H2O (9.9 mbar)
- Alarm
5" H2O (12.4 mbar)
- Shutdown
8" H2O (19.8 mbar)
6.4
Air Inlet Anti-Ice
Sixteen row heating/chilling coils will be installed in the combustion
air stream located in the air filter house in which the customer can circulate a
hot water/glycol solution to heat the inlet air of the gas turbine.
This protects against ice formation on the inlet bellmouth when
temperatures drop below 45°F
with relatively high humidity. Ice
entering the inlet of the gas turbine has potential to cause catastrophic
damage. The heating coils will be
built with copper tubes and aluminum fins. The piping and equipment external to
the coils, including valves, drains and controls will be provided by others.
6.5
High Performance Chilling Coils
This coil will be sized to lower the temperature of the inlet combustion
air to 50oF, from a 95oF dry bulb and 74oF wet
bulb.
Cold water supply, and piping, fittings, valves and controls exterior to
the exchanger will be furnished by others unless the packaged chiller option is
required as outlined in section 6.6 or heater package in section 6.7.
6.6
Turbine Inlet Air Chiller Package (Optional Feature)
WPS
offers a 2200 Ton single lift inlet chiller module measuring 14’W x 45’L x
12’H with an estimated operating weight at 114,000 lbs. Redundant pumps for
the condenser and evaporator will be included as well as controls, switchgear,
valves, piping, and insulation. For further benefit, the WPS can supply as an
option, a Marley Cooling Tower designed around the chiller module.
A
complete indoor motor control panel containing all the electrical switchgear,
breakers, and power distribution system is located inside the acoustically
treated module. The Purchaser will provide one 480 volt and one 4160 volt feed
to the chiller package.
6.7
Anti-Ice Heater (Optional Feature)
Depending on site conditions, this module will
house between five and nine, one million BTUH input Natural Gas Fired Boilers.
This option allows for the advantage of utilizing the chilled water pumps
already located on the chiller module. A
small stream of water/glycol will be taken out of the chiller water loop,
heated, and then mixed downstream to give a minimum five degree temperature rise
in the heater coil, with a corresponding combustion air inlet temperature
increase of 10 degrees. Materials for integration with the Chilling module
include, pumping, control, and auto changeover from inlet cooling to heating.
Similar to the chiller module, the anti-ice heater
includes the required electrical, lighting, starters, controls, and disconnects
for a single point 480V, 3 phase, 60 hertz power connection.
7.0
ENCLOSURE, VENTILATION AND NOISE CONTROL
7.1
Enclosure
The unit enclosure will be designed for outdoor installation and wind
loads of 100 mph. It will be
divided into turbine and generator compartments by a bulkhead.
The inlet volute will be an enclosed structure located in the turbine
compartment. The turbine
exhaust flows axially, out a flanged connection at one end of the enclosure.
Access doors and air conditioning (ac) will be located in each
compartment. The engine compartment contains an integral overhead bridge crane
to facilitate engine removal.
The enclosure walls utilize a sandwich construction filled with
high-density fiberglass insulation blankets.
The inner wall panel will be fabricated from perforated 18-gauge
stainless steel. The outer wall
panel will be 14-gauge cold rolled carbon steel.
The turbine and generator compartment walls will be supported by a
structural steel framework and will withstand the internal pressure developed by
the fire extinguishing system. The
enclosure hinges, latches and mounting hardware are stainless steel or chrome
plated.
7.2
Ventilation
The ventilation system removes heat from the turbine and generator
compartments and reduces the hazards in the event of a fuel system failure.
Both the engine compartment and generator compartment will be fully
ventilated by redundant fans. Ventilation
air will be filtered to the same quality as the combustion air for the gas
turbine.
7.2.1
Gas Turbine Compartment Ventilation
Ventilation air enters the compartment at the bottom front center of the
room. The ventilation system
maintains airflow of 60,000 SCFM through the gas turbine compartment. During normal operation, 1 vent fan provides sufficient
airflow for ventilation purposes. If
engine compartment temperatures reach 140 °F, the standby fan will assist until temperatures
are below the high temperature alarm conditions.
The ventilation system maintains a negative pressure in the turbine
compartment.
7.2.2
Generator Compartment Ventilation
Duplex fans provide ventilation to generator compartment and cooling air
to the generator. During normal
operation conditions, a single ventilation fan provides the 45,000 SCFM flow
required for ventilation and cooling with the second fan on standby.
The generator compartment will be classified as a non-hazardous enclosure
because a positive pressure is maintained.
7.2.3
Noise Control
The equipment enclosure and air inlet silencer reduce near field noise to
85 dB(A) at 3 ft. from the enclosure and 5 ft. above grade.
8.0
TURBINE EXHAUST SYSTEM (Optional Feature)
The UNIT exhausts through an axial exhaust outlet at the end of the
turbine enclosure to facilitate in-line mounting of an optional simple cycle
exhaust stack. The stack assembly
will consist of expansion joint, 85 dBA silencer, 90° elbow and 45-ft. stack. An optional 15’ extension may be available separately.
For requirements greater than 60’, a separate reinforced assembly will
be required.
The stack shall include EPA emissions ports with access ladders and
platforms per recognized “Good Engineering Practice” design.
9.0
STARTING & WATER WASH SYSTEMS AND AUXILIARY EQUIPMENT MODULE
The gas turbine will be started by an electro-hydraulic system that
includes:
-
An
electric motor-driven hydraulic pump mounted on the auxiliary equipment module.
-
A
hydraulic motor mounted on the turbine auxiliary gearbox, which rotates the HPC.
-
Controls,
valves, filters, interconnect hoses and heat exchanger.
The same system cranks the turbine for purging, water washing, and cool
down.
9.1
Starting System Operation
To start the gas turbine, the hydraulic motor must
-
rotate
the HPC to purge the engine
-
accelerate
the HPC to ignition speed
-
continue
acceleration to self-sustaining speed
The starter accelerates the
HPC to 2,200 RPM, and cranks at this speed for two minutes to purge the exhaust
stream for simple cycle applications. The
purge cycle is a safety measure performed at the onset of each start routine.
After completing the purge cycle, the HPC slows to a light-off speed of 1,700 RPM. Once ignition is verified, the starter and the turbine then work together to accelerate the HPC to 4,500 RPM, where the starter disengages automatically. The gas generator continues to accelerate until it reaches idle speed and is stabilized by the governor. The turbine will then be self-sustaining and support a start time of ten minutes or less as defined in section 3.1.
9.2 Hydraulic System Description
The hydraulic starting system consists of:
Hydraulic cranking motor (mounted on turbine auxiliary gearbox)
And the following equipment mounted on the auxiliary equipment module:
-
200
HP (150 kW) electric motor
-
6000
psi hydraulic pump
-
40-gallon
hydraulic reservoir
-
Air/Oil
cooler with hydraulic fan motor
-
Duplex
Filter
-
Control
system
The hydraulic circuit will be a closed loop design with a 40-gallon
reservoir. The system requires an initial fill of approximately 35
gallons of ISO VG 46 premium, anti-wear petroleum based hydraulic fluid.
A small charge pump on the cover of the main pump draws fluid from the
reservoir to prime the system during each start cycle.
The control system modulates pump flow from zero to approximately 55 GPM
during the starting cycle. This
flow regulation permits accurate control of gas generator speed for purging,
ignition and acceleration. The
Air/Oil cooler prevents overheating of the hydraulic oil and permits extended
cranking for cool down or water wash.
9.3 Water
Washing Equipment
The following equipment will be mounted on the auxiliary equipment
module:
- 304
Stainless steel water wash reservoir
- Manual
fill connection for washing chemicals
- Manual
water fill valve
- Solenoid
valves for water wash sequencing
- Interconnect
hoses between auxiliary skid and main unit
The following equipment will be mounted in the turbine enclosure:
- "On-line"
spray nozzles
- "Crank-soak"
spray nozzles
- Stainless
steel piping
Purchaser will supply compressed air,
between 80-120 psig filtered to 20 microns, cleaning solution, and
demineralized water for the water wash system.
9.3.1
Cleaning Solution Specifications
The LPC and HPC sections of the engine will be cleaned with a
water/detergent mixture followed by a thorough rinsing.
Rochem solvent and B&B Chemical Company compound 3100 are recommended
cleaning agents. Other cleaning
agents must conform to GE standard MID-TD-0000-5.
Water will be used to dilute the solvent and also for rinsing after
completion of the cleaning process. A
water/anti-freeze mixture must be used for dilution and rinsing in ambient
temperatures of 50oF, or below.
See above specifications for suitable anti-freeze recommendations.
9.3.2
Water Quality Standards
Please refer to GE Spec MID-TD-0000-4 for compressor cleaning water requirements.
10.0
LUBE OIL SYSTEMS
The gas turbine will be
lubricated with synthetic lube oil. A
separate lube oil system using mineral oil will be provided for the electric
generator.
Fin fan coolers or water to
oil coolers will be used for lube oil cooling.
Coolers will be built to the same specifications as the other auxiliary
equipment supplied with the Unit including paint specification, weld
specification, seismic design, and wind loading. Coolers will be designed to operate in ambient conditions up
to 95°F.
Coolers will be carbon steel with 304 stainless tubes and aluminum fins.
Fans will be aluminum with 7-½ hp Marathon motors.
10.1
Gas Turbine Lube Oil System
1.
Supply System - Provides clean, cool oil to the turbine bearings at
the proper pressure.
2.
Scavenge System - Recovers (scavenges) the lube oil from the bearing
drain sumps, then filters and cools the oil and returns it to the reservoir.
These sub-systems combine to provide dependable and efficient lubrication
for the gas turbine.
10.1.1
Gas Turbine Lube Supply System
Approximately 130 U.S. gallons of lube oil are stored in the 150 U.S.
gallon capacity stainless steel reservoir mounted on the auxiliary equipment
module. The reservoir will be
fitted with a low level alarm switch, a level gauge, a filler connection, and a
vent demister. An electric heater
with thermostatic control will be included.
A positive displacement lube oil pump, mounted on the gas turbine
accessory drive gearbox, takes suction from the lube oil reservoir. The pump provides approximately 17 GPM of cooled, filtered
lube oil to the turbine bearings.
Oil from the pump discharge will be filtered by a duplex, full-flow
filter (6 microns absolute) located on the auxiliary equipment module for ease
of replacement. Filter elements can
be serviced during turbine operation. A local differential pressure indicator
will be provided to monitor the lube oil filter condition. A high differential pressure alarm will be provided to
indicate that filter service is required.
Lube oil supply temperature will be measured by an RTD. The temperature will be shown on the control panel CRT, and
controls provide high temperature alarm and shutdown. The lube oil supply passes through an anti-siphon check valve
and will then be distributed to the bearing chambers where oil is sprayed onto
each engine bearing. Pressure
switches provide low-pressure alarm and shutdown signals to protect the turbine.
10.1.2
Gas Turbine Lube Scavenge System
Lube oil is removed from the bearing sumps by a 5 element scavenge pump.
RTDs measure scavenged oil temperature at sumps B, C, D, and E.
Scavenge oil temperature will also be measured via RTD at the accessory
gearbox and transfer gearbox discharge. ,
with readout, alarm and shutdown at the unit control panel.
A check valve on the pump discharge prevents siphoning of oil back into
the engine during shutdown.
The scavenged oil will be filtered through a duplex full-flow filter (6
microns absolute) located on the auxiliary equipment module. A local pressure indicator and pressure instrumentation will
be provided to indicate when filter service is required.
10.1.3
Air/Oil Separator Operation
To prevent excessive oil consumption, the bearing sumps will be vented to
an air/oil separator rated to minimize oil carryover to the environment per
accepted “Good Engineering Practice”. The
air/oil separator is mounted on the ventilation module on top of the generator
set enclosure. The recovered oil
will be returned to the reservoir by gravity flow.
The air removed from the mixture will be de-misted and vented to the
atmosphere.
10.2
Generator Lube Oil System
The generator lubrication system provides approximately 30 GPM of cooled
and filtered oil to the generator bearings.
The generator lube oil reservoir, pumps and filters will be located in
the generator compartment. Two
doors provide easy access to these components, and the operator can check the
lube oil gauges without entering the generator compartment.
The lube oil filters may be changed while the unit is operating.
10.2.1
Generator Lube Oil Supply
The stainless steel reservoir includes a sight level gauge, fill
connection and drain valve. A
switch provides a low-level alarm at the unit control panel.
A thermostatically controlled immersion heater will be provided to
maintain adequate lube oil temperature in the reservoir.
The main oil pump will be a gear type and mechanically coupled to the
generator shaft outboard of the exciter. An
AC motor-driven auxiliary lube oil pump will be used during the start/stop
sequencing and as a backup to the main pump.
Rundown tanks provide lubrication during coast down, if the AC lube oil
pump should fail or if AC power is lost.
Oil flow will be regulated at each bearing housing by an orifice plate.
The oil flows through the orifice and into the bearings and forms a film
that cools and lubricates the journal. Pressure
switches at the bearing supply header provide low pressure alarm and shutdown
signals to the unit control panel.
If the supply pressure drops, a low lube oil pressure switch
automatically starts the auxiliary lube oil pump. If the lube oil pressure falls
to a lower level, the turbine generator set shuts down and special
“run-down” oil tanks slowly feed the generator bearings during coast down.
The primary and auxiliary lube oil pumps can each supply 100% of the
generator lube oil requirements. Each
pump will be equipped with a pressure relief valve piped to the reservoir.
Lube oil pressure at the supply header will be controlled by a
pressure-regulating valve, which bypasses excessive oil flow to the reservoir.
A local pressure indicator and pressure instrumentation will be provided
to indicate when filter service should be required.
Filters may be serviced during operation.
10.2.2
Generator Lube Oil Return
Each bearing will have a gravity drain and sight glass, which permits the
operator to visually verify oil flow. A
dual element RTD will be embedded in each bearing to measure the actual metal
temperature. These RTDs will be
continuously monitored at the unit control panel and provide alarm and trip
signals. In addition, an RTD and a
temperature gauge will be provided in each drainpipe to monitor bearing
discharge oil temperatures.
11.0
FUEL SYSTEM AND WATER INJECTION SYSTEM
The base gas turbine will be configured for gaseous fuel operation.
11.1
Gaseous Fuel System
The gaseous fuel system contains the following major components that are
to be mounted in the turbine compartment, adjacent to the engine:
-
Duplex
gas strainer, pressure switches and local gauges
-
Primary
shut-off valve
-
Fuel
metering valve
-
Secondary
shut-off valve
-
Fuel
flow meter
-
Fuel
gas manifold
-
30
Fuel gas nozzles
Gaseous fuel will be supplied to the baseplate connection at 675-psig ± 20 psi for full power operation.
A Purchaser supplied filter, pressure regulator, pressure relief valve
and manually operated shut-off valve will be installed in the purchaser fuel
supply system adjacent to the Unit baseplate.
To protect the turbine against both high and low pressure conditions, the
gaseous fuel system will be provided with pressure switches located upstream of
the fuel control valve. The fuel
control valve will be an electrically actuated Woodward design.
The fuel control valve provides an accurate, non-pulsating flow of fuel
to the engine for initial light off, acceleration and on-line operation.
11.2
Gaseous Fuel Specification
The minimum temperature of gas fuel supplied to the gas turbine shall be
either 50°F greater than the saturated vapor temperature of the gas
at the supply pressure or the hydrate temperature, whichever is greater.
The temperature of the gas fuel should not exceed 300°F at the gas fuel manifold
inlet. Gas fuel temperatures above
300°F will result in a shutdown procedure.
The gas fuel will be defined for each application by the Purchaser and
should comply with the attached GE Spec MID-TD-000-1 .
11.3
Water Injection
The water injection metering system is added to reduce NOx emissions.
Demineralized water will be injected into the combustor through ports in
the fuel nozzles to produce NOx suppression.
Water will be supplied to the nozzles by a special water manifold.
The Seller will supply the complete metering system, controls, and boost
pump skid.
11.3.1
Water Quality Specifications
Purchaser will supply demineralized water to the Seller defined
connection on the water injection boost skid.
A minimum 5-psig, supply pressure will be available to the Seller at a
flowrate of 55 GPM per GE Spec MID-TD-0000-3 for NOx water requirements.
12.0
FIRE AND GAS DETECTION AND EXTINGUISHING SYSTEM
12.1
General
The gas turbine generator set includes an extensive safety system to
detect fire, unsafe temperatures or explosive atmospheres in the equipment
enclosure. The system releases CO2
should a fire be detected.
The enclosures will be designed to reduce the hazard of fire and
explosion. A wall separates the
turbine and generator/gearbox compartments to provide isolation. Individual ventilation systems, with redundant fans, create a
positive pressure in the generator/gearbox compartment and a negative pressure
in the turbine compartment to maintain separation. In addition to this fundamental safeguard, gas detectors,
thermal detectors, optical flame detectors and an extinguishing system that
conforms to NFPA will protect the enclosures.
12.2
Unit Mounted Equipment
12.2.1
Gas Detectors
Two (2) hydrocarbon gas detectors will be provided in the turbine
compartment near the ceiling. A
third detector will be located in the front of the generator compartment. If any gas detector senses a gas concentration of 15% LEL, a
warning will be initiated. If a
sensor detects a gas concentration of 60% LEL, an emergency shutdown will be
initiated.
12.2.2
Optical Flame Detectors
Four (4) optical flame detectors will be provided. Three (3) are mounted
in the front of the engine compartment and operate with 2-out-of-3 voting logic.
One (1) optical flame detector will be mounted in the generator
compartment. A flame indication by
the generator room sensor or any two (2) engine room sensors initiates an
emergency shutdown and extinguishing agent release.
12.2.3
Thermal Detectors
Thermal detectors monitor the enclosure temperatures as follows:
GAS TURBINE ENCLOSURE:
-
Two
(2) RTDs. Alarm at 140o F
and shutdown at 150o F.
-
Two
(2) spot temperature detectors. Shutdown
at 450o F.
GENERATOR ENCLOSURE:
-
One
(1) RTD. Alarm at 115o F
and Shutdown at 150o F.
-
Two
(2) spot temperature detectors. Shutdown
at 225o F.
In addition to alarm and shutdown functions, the RTDs provide enclosure
temperature signals for the unit control panel CRT. The spot temperature detectors will be a bimetallic design
and respond to both rate-of-rise and compartment temperature.
They cause a unit shutdown and release of the extinguishing agent when
tripped.
12.2.4
Manual System Trip
Three (3) manual trip stations will be located on the rotating equipment
module; one (1) on each side, near the center of the package, and the third at
the exciter end of the generator.
12.2.5
Extinguishing System
A CO2 extinguishing system will be provided with the Unit package.
The system components include:
-
Main
extinguishing agent storage cylinder(s)
-
Reserve
extinguishing agent storage cylinder(s)
-
Necessary
valves, piping and wiring
The extinguishing agent will be stored in pressurized cylinders in a
mounting, complete with rack and clamps to hold the cylinders and piping to
connect the cylinders to the distribution header and nozzles. The reserve cylinders will be an "automatic
backup", and will be released if detectors still indicate a hazard ninety
(90) seconds after release of the main cylinders.
The piping within the equipment package, from the pressure connection to
the nozzles in the turbine and generator compartment, will be installed.
The fire system control panel controls release of the extinguishing
agent.
12.3
Fire System Controls
12.3.1 General
The fire and gas detection system will be controlled by solid-state
modules, which are to be rack-mounted in an enclosure on the front of the unit
control panel. These modules
monitor signals from the detectors mounted on the equipment.
Other panel-mounted modules provide logic, memory and output functions to
complete the system.
12.3.2
Power Supply
In accordance with NFPA, the fire and gas detection controls will be
powered by a dedicated 24V DC battery system.
12.3.3 Sensor Monitoring
Each equipment mounted sensor will be monitored by the fire and gas
detection system control panel. Solid
state modules compare each signal to alarm and shutdown set points. Readout of gas detector signals will be provided
in the HMI. An alarm from any gas
detector provides a contact closure in the alarm summary channel and sounds the
panel alarm horn. A shutdown signal
from a gas detector, optical detector, thermal detector, or manual station
provides a contact closure in the shutdown summary bus.
This closure initiates an emergency shutdown.
12.3.4 Defective Sensor Protection
Each sensor will be connected with closed loop circuitry to verify its
readiness. Should the sensor or its
wiring become defective, a "fault" condition will be indicated on the
fire and gas detection control panel. A
faulty sensor will not trip the unit nor initiate an extinguishing agent
release.
12.3.5
Extinguishing Agent Release Logic
When a CO2 release situation may be imminent, ventilation fans will be
turned off and a horn will sound. After
a time delay, the extinguishing agent will be released into both generator and
turbine compartments. Fire dampers
will be closed the instant CO2 should be released.
A concentration level sufficient to extinguish flames will be established
in approximately thirty (30) seconds. If
the primary cylinders fail to discharge within four (4) seconds, the reserve
cylinders will be discharged. If
flames are still detected ninety (90) seconds after the primary extinguishing
agent cylinders have been discharged, the reserve cylinders will be discharged.
13.0
CONTROL AND MONITORING SYSTEM
The control and monitoring system for the gas turbine generator set will
provide a highly reliable, operator friendly package.
System components will include:
-
Turbine
Generator Unit Control Panel
-
Control
Batteries and Charger Assembly
-
Gas
turbine wet gauge panel and water wash panel (local)
-
Generator
wet gauge panel (local)
The unit control panel will be the primary control point for the system.
The gas turbine wet gauge panel will be mounted on the turbine enclosure
and provides process readouts and safety devices necessary for maintenance.
Switchgear cubicles containing circuit breakers, protective relays,
transformers and motor control center equipment may be available as optional
equipment, as described in Section 16.
13.1
Unit Control Panel
13.1.1 General
The unit control panel will be the focal point for operating the gas turbine generator system. The panel uses state of the art electronics and is suitable for installation in a non-hazardous local control room near the gas turbine generator. The control panel includes digital meters for key parameters control switches and HMI for operator commands, a programmable, microprocessor based sequencer, a CRT display, and Ethernet port to export data to a customer DCS, remote terminal or printer.
13.1.2 Remote Panel Interface
The Unit Control Panel will have a built-in interface for easy connection
of a Purchaser's Remote Control Panel or Distributed Control System.
The Unit Control Panel will accept Start/Stop and other operating
commands from "dry" relay contacts in the Purchaser's system.
This allows the Gas Turbine/Generator to be integrated into the
Purchaser's overall plant control system.
To provide information at a remote location, the Unit Control Panel
transmits status information (Stopped, Starting, Running, etc.), Alarms and
Shutdowns, and operating parameters (Pressure, Temperature, Flow, etc.) via an
Ethernet port in the sequencer. The
Purchaser may use this information on a remote CRT to monitor the operation of
the unit.
13.1.3 Cabinet Construction
The unit control panel will be housed in a freestanding cabinet. The
cabinet will be constructed of welded cold rolled steel.
Approximate dimensions are 90"H x 114"L x 30"D.
Special care will be given to panel appearance and finish. A high quality corrosion protection, primary painting and
finish painting process will be employed. The
standard finish will be textured semi-gloss ANSI gray color paint.
13.2
GE Mark VI Fuel Control/9070 Sequencer
A GE Mark VI Fuel Control/9070 Sequencer in the unit control panel
provides sequencing, monitoring and fuel management control for the system.
The Mark VI uses a 32-bit processor and high-speed digital circuitry to
control the turbine and generator. A
front-mounted HMI will permit tuning of selected system variables while in
operation. Plug-in modules provide
flexibility of operation and permit future system expansion.
The Mark VI controls turbine speed with an electrically actuated fuel
valve mounted in the engine room adjacent to the turbine.
13.2.1 Fuel Management System
The Fuel Management System provides the following:
13.2.1.1 Light Off Fuel Control
This function accurately controls minimum fuel flow for reliable engine
light off.
13.2.1.2 Acceleration Control
This function controls the rate of increase of fuel flow to the engine.
While increasing the gas generator speed, the acceleration control
continuously checks the rate of speed increase to prevent over fueling
conditions which could damage the engine.
13.2.1.3 Deceleration Control
This function prevents flameout by controlling the rate of reduction of
fuel flow to the engine. The
deceleration schedule will be a function of HPC minimum speed, corrected by
compressor inlet temperature, which will be set to prevent flameout.
13.2.1.4 Temperature Control
The gas generator LP turbine inlet temperature (T48) will be monitored at
all times. During start-up and
acceleration the temperature limits will be lower than the steady state,
full-power limit. After the engine
has accelerated to operating speed, the engine will be allowed to operate at its
base load T48 temperature to produce full power.
13.2.1.5 Speed Governing
The Fuel Management Systems varies the speed of the high-pressure
compressor by controlling the rate of fuel flow.
For maximum safety and stability, the fuel management system incorporates
"low select" circuitry. This
circuit uses the lowest of the following signals to control the high-pressure
compressor speed:
.
High-pressure compressor speed control
.
Low-pressure compressor/output shaft speed control
.
Maximum temperature control
.
Acceleration control
.
Deceleration control
13.2.2 Programmable Sequencer
The programmable sequencer controls automatic starting, running and
stopping of the turbine generator set. Programmed
time delays will be used to ensure that the sequence will be orderly and that
permissive conditions exist before starting the next event.
This careful sequencing provides dependable control and permits the unit
to be started and stopped, either locally or remotely, with a single pushbutton.
13.2.2.1 Starting Sequence
A "ready to start" indication shows that the required trips
have been reset, the start permissive sequence has been accomplished, the oil
and bearing temperatures meet minimum start temps, and the unit stands ready to
be restarted.
From a "ready to start" condition, the following automatic start and load sequence will occur when the operator turns the "start" switch:
-
The
GE 9070 PLC turns on the primary ventilation fans;
-
The
generator AC lube oil pump system activates and output pressure will be
verified;
-
The
starter motor switches on, and the engine begins cranking at 2,200 RPM to
purge the system for a minimum of two minutes, depending on exhaust
configuration;
-
Engine
slows to 1,700 RPM;
-
The
fuel system shutoff valves open;
-
The
ignition system starts;
-
The
turbine fires and accelerates to 4,500 RPM;
-
The
starter disengages, and the turbine accelerates under its own power to idle
speed;
-
The
ignition system de-energizes.
-
The
turbine warms-up at idle speed for a pre-set time before automatically ramping
to synchronous speed;
-
Generator
voltage builds;
-
The
automatic synchronizer matches generator speed, phase and voltage to the
electrical bus;
-
The
synchronizer issues a "breaker-close" command (verified by two
"synch-check" relays) and the breaker closes;
-
The
"ready to load" indicator turns on and the operator can begin loading
the generator manually. (Optional
automatic loading can also be supplied).
Sequence events must be completed within preset times, or the start will
be aborted. The sequencer provides
similar automatic shutdown sequence when the Stop button is pushed.
13.3
Additional Control System Functions
The control system also includes the following equipment and control
functions:
13.3.1 Engine Temperature
Eight chromel-alumel dual element thermocouple probes measure the LP
turbine inlet temperature. A
connecting harness permits individual readout of the eight input signals, which
will be transmitted to the unit control panel and used by the fuel management
system.
13.3.2
Low Pressure Compressor (LPC) Speed
Two eddy-current type speed sensors will measure the low-pressure shaft
speed . These sensors detect the
blade-passing frequency and provide an electrical signal to the fuel management
system. This signal will be used to
control acceleration and output shaft speed, and to actuate overspeed and
underspeed switches. The LPC speed
will be indicated on the unit control panel.
13.3.3 High Pressure Compressor (HPC)
Speed
Two magnetic pickups in the accessory gearbox sense HPC speed.
The speed signals will be used by the fuel management system to control
acceleration/ deceleration and to activate switches in the control sequence,
including overspeed alarm and shutdown. The
HPC speed will be indicated on the HMI.
13.3.4 Alarm and Shutdown System
A comprehensive alarm and shutdown system will be provided for the
turbine generator set and its auxiliaries.
Field-mounted sensing devices (level, pressure, temperature, etc.)
provide signals to input modules of the programmable sequencer and fuel
management system. If an abnormal
condition should be detected on any sensor, then an alarm and/or shutdown will
be initiated. A HMI display
indicates system malfunctions sequentially.
An optional hard copy printer provides a sequential history of alarm and
shutdown conditions.
An “acknowledge” push button on the unit control panel HMI silences
the audible alarm. Pressing the
Reset button clears the HMI display if the system faults have been corrected.
For additional safety following a shutdown, the operator must acknowledge
and reset the alarms before restarting the turbine.
13.3.5 Vibration Monitor
Vibration monitoring will be provided for the gas turbine and electric
generator. Two accelerometers on
the Gas Turbine casing will be monitored in accordance with the General Electric
Aircraft standards. Two (2) Bently
Nevada proximity probes will be located at each generator bearing (total four
(4) probes).
A Bently Nevada vibration module mounted in the unit control panel
continuously monitors each vibration channel.
Vibration levels will be indicated on the HMI. Excessive vibration causes alarm or shutdown.
13.3.7 Automatic Synchronizer
Synchronization may be accomplished manually with the synchroscope in the
unit panel, or by selecting an automatic synchronizer included in panel.
The auto synchronizer matches the generator's frequency, phase and
voltage with the bus and then issues a "breaker close" command signal.
The "breaker close" signal (auto or manual) will be monitored
by two (2) independent "synch check relays" to prove synchronization
before breaker closure will be permitted.
13.3.8 Control Batteries and Charger
Assembly
A 24-volt DC lead calcium battery system, complete with dual chargers and
integral protection equipment will be furnished. The battery system will be capable of supplying the control
loads for at least three (3) hours without recharging. The battery rack will be made of steel, properly insulated
and painted with two (2) coats of acid resistant paint.
The two (2), 100% battery chargers have 208 volt, 60 Hz, 1 phase power
supply. The chargers will be the
static rectifier type. Either
charger, operating alone, can maintain the battery fully charged.
13.3.9 Fire and Gas Detection System
The Seller will provide an independent control rack dedicated to the
monitoring of optical flame detectors, thermal detectors and gas detectors as
part of the unit control panel. The
rack will be as described in detail in Section 13.
The fire and gas detection system will have it own independent 24V DC
battery system with charger.
13.3.10 Gas Turbine Wet Gauge and Water Wash Panel
(Local)
Gauges showing system temperatures and pressures will be mounted in a
panel on the side of the main enclosure. Controls
to "water wash" the turbine will be conveniently located in a small
panel, near the water wash equipment. The
water wash controls will be interlocked with the turbine control panel for safe
operation.
13.3.11 Generator Wet Gauge Panel (Local)
Gauges for the generator lube oil system will be located on a small panel
adjacent to the generator lube oil reservoir.
The gauges may be monitored without entering the generator compartment.
14.0 TESTING
14.1
Gas Turbine Test
The gas turbine will be full-load tested at the factory to verify power
capability, fuel efficiency and mechanical integrity.
A copy of the factory test report is included in the documentation
package.
14.2
Generator Test
The generator will be built in accordance with ANSI C50.14 or IEC 34-3
and tested to IEEE 115 standards. The
factory tests include high voltage, cold resistances, bearing insulation and
vibration levels, open and short circuit losses, voltage and current balance and
phase rotation. These tests will be performed at the generators manufacturers
works.
14.3
Generator Set Package Testing
A full load string test will be performed on six of the twenty-four gas
turbine generator sets at the Seller’s factory.
The proper operation of the selected entire units will be tested and
confirmed, including the gas turbine, generator, fuel management system, alarm
and shutdown devices, auxiliary systems and unit vibration.
Electrical loads will be
picked up and rejected. Water
injection valves and piping will be checked for completeness and operation.
The water injection system will not be tested during the full-load string
test.
The remaining generator sets will undergo an Unfired Test Procedure that
includes functional check-out of the generator set without firing the turbine
and generator together. This
procedure includes oil-flushing, verification of piping connections, and
calibration of instruments- the same steps taken for a fired test.
Electrically, each individual control panel will be
powered up, loaded with software, and fully simulated in our test lab to test
the safeties and alarms. Furthermore,
the Bently Nevada system will be calibrated and the Integrated Generator
Protection System programmed. As a
final check, the Seller connects the control panel up to available diesel
generators on the test facility to certify the synchronizer circuits. The Unfired Test results will be measured, recorded and
included in the Test Report for submittal to the Purchaser.
14.4
Field Performance Testing
Performance and Sound Level Tests shall be performed in accordance with
the Commercial Contract, (Exhibit F).
15.0
ELECTRICAL EQUIPMENT
15.1
Purchaser’s Electrical Interface
The package is arranged to simplify the Purchaser’s field connections.
Electrical devices on the rotating equipment module will be wired to
junction boxes in the turbine and generator compartments.
Neutral and line-side cubicles will be bolted onto the outside of the
generator enclosure for the Purchaser's power connections.
15.2
Area Classification
Electrical components located inside the turbine compartment will be
suitable for Class I, Group D, Division 2 areas.
This applies primarily to switches, sensors and electrically actuated
valves. Engine mounted instruments
and the 115-volt AC ignition system used during start-up will be constructed to
aircraft standards, and, in general, meet the requirements of Class I, Group D,
Div. 2, but need not be so qualified or stamped.
The filter house, roof-mounted fans, generator compartment, auxiliary
equipment module and optional control house will be classified as non-hazardous
areas.
15.3
Electric Motors
The AC electric motors 5 HP (3.7 kW) and larger are 460V AC TEFC or
explosion proof motors with a 1.15 service factor. Continuously running motors
will be the "high efficiency" type.
Nameplate ratings and normal operating loads for each motor will be
selected based on system requirements, which have been proven through the
Seller’s experience on numerous successful installations.
.
15.4
CTs, Lightning Arrestors, Surge Capacitors
Seller shall furnish seven CTs, mounted in the neutral cubicle; three (3)
for metering, three (3) for generator protection and one (1) for cross current
compensation. Three (3) lightning
arrestors and three (3) surge capacitors will also be mounted in the line-side
cubicle. Optional line-side CTs for
redundant protective relaying may also be provided.
15.5
Generator Metering
The unit control panel supplied includes a synchroscope and a front
mounted digital meter for frequency, voltage, amperage, power factor and vars.
A rack mounted microprocessor based electronic voltage regulator, with
both VAR and PF control, will also be included in the unit control panel, along
with the rotor ground-fault detection equipment.
15.6
Lighting
The scope-of-supply includes AC lighting for the interior of the gas
turbine compartment, filter house and generator compartment. Turbine and generator compartments will be fitted with
high-pressure sodium fixtures.
15.7
Modular Control Room (Optional
Feature)
The Seller may supply an optional control room as required by the Purchaser. When required, the control rooms will be designed to accommodate GT control panels, motor control centers, and unit battery/charger systems. The control room will be a single lift module using a steel I beam base.
15.7.1 Structural Design
The modular control room base will be fabricated with 8" wide flange
beams welded into a rigid baseplate. The
control room walls will be a "sandwich construction,” consisting of an
18-gauge carbon steel outer panel, 3” of fiberglass insulation and an inner
panel of 18-gauge galvanized steel. The
floor-plate will be 1/4" carbon steel.
15.7.2 Air Conditioning/Heating
The modular control module will be equipped with redundant air
conditioning units. For colder
climates, heat pumps may be substituted, or the control module may be arranged
with supply/return flanges for Purchaser-supplied heating and cooling fluids.
15.7.3 Lighting
The modular control room will be complete with ceiling-mounted
fluorescent lighting fixtures and switches at each entrance door.
15.7.4 Equipment in Modular Control Room
Seller will mount the unit control panel, batteries and chargers and
Purchaser-selected optional equipment in the modular control room. Optional items often include:
-
Switchgear
(See 15.8 )
-
Unit
Motor Control Center (See 15.10 )
15.7.6
Battery Room
The modular control room contains a separate area for battery racks and
charger assemblies. The basic
scope-of-supply includes a 24V DC battery pack with a capacity of 300 AMP hours,
redundant 208VAC chargers for the unit control system, a 24V DC battery pack
with a capacity of 55 AMP hours and a single 120V AC charger for the unit fire
protection system.
A separate 125V DC
battery/charger assembly to power the switchgear may be provided as an option. The chargers will be wall-mounted near the battery room and
wired to the rack-mounted batteries.
15.8
Switchgear (Optional Feature)
The metal clad switchgear, includes a generator circuit breaker, draw out
potential transformers and high-voltage current transformers for generator
protective relaying. The switchgear
may be supplied as ship-loose cubicles, for installation by others at the job
site, or as part of an integrated modular control room as described in Section
15.7.
The main generator breaker and auxiliaries will be mounted in a cubicle
approximately 36"W x 94 "D x 95 "H, containing the following
components:
-
1
- 3000 AMP, 3 phase, 3 wire, main bus system, copper, fully insulated for 15 kV
-
1
- 1/4" x 2" copper ground bus
-
1
- Set (3) 3000 AMP insulated copper bus bars.
-
1
- 3000 AMP, 3 pole, 15 kV, 1000 MVA - electrically operated drawout type, vacuum
circuit breaker, 125V DC close and trip (GE type VBB-1-15-1000-30 or
equal)
-
4
- Drawout type PTs (for synchronization, protection and metering)
-
3
- CT's (for generator differential protection)
15.9
Generator Protection
The generation protection module will be rack mounted in the gas turbine
control panel and contains the following protective functions:
-
#59N
– Neutral Overvoltage
-
#51V
AC Time Overcurrent – Voltage Restrained
-
#87
Phase differential current
-
#46
Reverse phase current
-
#27
Undervoltage
-
#59
Overvoltage
-
#40
Field failure
-
#81
Over/under frequency
-
#24
Overexitation
-
#60
Balanced voltage supervision
-
#21
Directional impedance
-
#xx
Inadvertent energization
15.10
Unit Motor Control Center (MCC) (Optional
Feature)
The MCC will be built in accordance with NEMA 1, Class 1, with Type B
wiring. The MCC will be a
freestanding unit, and may be incorporated into the modular control room as
described in Section 15.7.
The standard MCC includes:
-
Modular,
plug-in starters or contactors for each motor or 480-volt load in the Unit
package.
-
Lighting
transformer, 15 to 45 kVA, 3 Phase, dry type, 480/208 /120 volt.
- Lighting distribution panel with circuit breakers for individual /120 volt loads in the Unit package, Integrated into the MCC with the transformer.
16.0
MAINTENANCE, SPECIAL TOOLS
AND SPARE PARTS
16.1
Special Tools and Fixtures
Special tools and fixtures are required to provide Level 1, maintenance
activities. These are as listed
below and offered at a separate price. The
Seller will provide the bridge crane required for removing and installing the
turbine from the engine compartment in the basic scope of supply.
The items listed in the fixtures group designated with (*) are required
at initial start-up and shall be furnished by the Seller without charge if
returned undamaged within 60 days (freight prepaid).
-
*Main
Baseplate lifting pins
1
-
*Main
Baseplate rigging cables
1
-
*Alignment
tool
1
-
*Alignment
axial gauge
1
-
*Alignment
spreader tool
1
Nomenclature
Tool Number
-
Engine
Handling Support
Tool # Not Assigned
-
Dolly,
Engine Transfer
TC9025
-
Gage,
Immersion Depth Igniter
1C9096/2C6613
-
Borescope
Set
2C6388/GE-CTF-120-5
-
Wrench
Set
2C6352/1C6344
-
Kit,
Mechanics Hand Tool
9448M18G01/GE-CTF-106-80C
-
Tool
Set, Engine Rigging
1C5714G05
-
Actuator
Unit
2C6395/1C3569
-
Tool
Set, Radial Drive Shaft
1C6361
-
Wrench,
Speed Sensor - S.V.
1C8062
-
VSV
Transmitter
2C6451
-
VSV
Indicator
2C14232
-
Installation/Removal
Tools
Tool # Not Assigned
-
Adapters
Tool # Not Assigned
-
Gages
Tool # Not Assigned
**This list is preliminary. Please
consult S&S Energy Products for current details.
16.2
Spare Parts
Two spare parts lists will be presented as follows:
- Start-up Spares and Consumables
- Operating Spares and Consumables
The gas turbine spares considered as a minimum start-up spares are listed
below and shall be included in the Seller’s basic equipment price.
Operating spares for the gas turbine, generator and major systems will be
offered separately.
An operating spare parts list will be prepared on a project-specific
basis after the unit details have been designed.
The list will reflect the fuel type, water injection provisions, air
inlet filter type, and Purchaser specified requirements.
Additions and deletions will be made as appropriate for multiple unit
sites or remote sites.
16.3.1
Start-Up
Spares
Start-up spares will be
provided in accordance with the recommended quantities below:
Nomenclature
Recommended Quantity
1. Filter Elements - Fuel
1 Set
2. Filter Elements - Lube Oil
1 Set
3. Filter Elements - Hydraulic Oil
1 Set
4. Flexitalic Gaskets for Raised-Face
1 Set
Connection
Flanges
5. "O" Rings and Mating Flanges for
1 Set
High Pressure
Hydraulic Connections
6. Fasteners?
17.0 DRAWINGS, DOCUMENTATION AND TRAINING
17.1
General
A comprehensive drawing package will be provided for the gas turbine
generator set on a Facility basis, which includes simplified flow diagrams of
the fuel system, starting system and lube oil systems. Mutually agreeable
corrections will be made and the final drawing reissued by Seller.
Certified drawings will be provided only for anchor bolt locations,
foundation design and Purchaser’s piping connection locations.
In addition to the approval drawing package, general arrangement drawings
of skid mounted auxiliary equipment and the unit control panel will be presented
for the Purchaser’s information to complete the site layout plans and
establish interface locations. To
assist the operator in checkout and trouble shooting, complete internal system
wiring diagrams will be provided in the operation and maintenance manuals.
A typical list of drawings will be is provided in Section 17.5.
17.1.1
Drawing Quantities and Format
Four sets of drawings to support each Facility shall be provided within
the Contract Purchase Price. Each
set contains six copies of the package drawings. The drawings shall be 11"
x 17" and shall be reproducible on most photocopy machines. Electronic format submittals of final drawings will be
provided in AutoCad, version 14.
17.2
Drawings Available
The Seller will furnish the following documents and drawings.
17.2.1 General Arrangement Drawings
These drawings define the orientation of the major Seller’s modules to
be installed by the Purchaser. A
main unit, general arrangement drawing, showing plan and elevation views, will
be issued for the Purchaser’s approval.
The general arrangement
drawings include the following information:
- Overall
dimensions of the equipment
- Direction
of rotation of equipment
- Access
space required for removal or maintenance of major components
- Foundation
bolt hole locations and sizes, plus any special requirements (Main unit
foundation information will be shown on a separate drawing)
- Static and
dynamic foundation loads
- Lifting
lug locations
- Center of
gravity information
- Layout of
Purchaser piping and electrical connections, complete with dimensions and
locations.
17.2.2 One-Line and Three-Line
Electrical Drawings
These drawings provide electrical description of the power system from
the generator terminals to the purchaser's high voltage bus and ground.
Included will be protective relaying, the excitation system and the
synchronizing system. Also shown on these drawings will be auxiliary power systems,
with a simplified display of distribution panels.
If the Seller’s equipment will be interfaced with an existing facility
or with customer supplied protective devices, Purchaser will supply facility
one-line drawing to Seller for preparation of the Seller’s one-line electrical
diagram.
17.3
Drawings for Information
The following drawings provide the Purchaser a reference for field
construction purposes. The drawings
will be submitted for "information only" and will not be subject to
approval.
17.3.1
Electrical System Interconnection Plan
This drawing contains information for recommended interconnecting cables
and conduit between Seller supplied modules, and, if applicable, the
Purchaser’s control room. The
drawing includes information to assist the Purchaser in purchasing wire and
cable for interconnection and in planning the site layout.
Point-to-point interconnection wiring diagrams will also be provided.
These drawings will be completed when other system approval drawings have
been finalized.
17.3.2 Auxiliary General Arrangement
Drawings
The following drawings show physical layout and interconnection details
required for proper installation of auxiliary equipment.
-
Auxiliary
equipment module
-
Water
Injection Module
-
Enhanced
Sprintä Skid
17.3.3 Flow and Instrument Diagrams (F
& ID)
F & IDs will be issued for each of the fluid systems in the
Seller’s scope of work. This
includes:
-
Natural
gas fuel system
-
Fuel
Oil System, if required
-
Water
injection system (Enhanced Sprintä
and NOx Injection)
-
Water
wash system
-
Hydraulic
starting system
-
Gas
turbine lube oil system
-
Generator
lube oil system
-
Fire
protection system
-
Air
inlet and ventilation system
-
Inlet
Air Refrigeration System, if required
-
Turbine
auxiliary instrumentation
Each F & ID drawing shows the equipment components, piping, valves
and instruments in the system, complete with piping line sizes.
The manufacturer and model number of items on the F & ID will be
shown on a Bill of Material, which will be a part of each F & ID drawing.
The F & IDs also show the pressure, temperature and volume
limitations of the system, including set points for alarms & shutdowns. Each working fluid in the system will be identified, and
initial fill quantities for fluid reservoirs will be shown. For clarity, the F & ID drawings will be considered
schematic in nature. Therefore,
pipe elbows, fittings and similar details will be omitted.
17.3.4 Unit Control Panel Plan &
Elevation
This drawing provides installation details for operator information. The drawing shows the front of the unit control panel as viewed by the operator, including meters, HMI and switches which initiate start/stop and other events. Cable entry locations and overall dimensions will be shown on this drawing.
17.3.6 Documentation List
Seller provides a list of procedures and specifications used in our plant
during manufacturing. The following
specifications will be included:
. Factory
welding and inspection procedures
. Application
of paint & protective coatings
. Drafting
symbols for contract drawings
. Factory
testing procedures
. Quality
control inspection point program
17.4
Drawings With Manuals
In addition to the above drawings, a complete set of system wiring diagrams will be included in the operation and maintenance manuals to serve as a reference for field check-out and troubleshooting.
17.5 Typical Drawing List
Submittal
Title
Code
Time (Weeks)
General Arrangement, Main Unit
CA
8
Foundation Loading Diagram, Main Unit
CI
8
Installation Foot Print, Main Unit
CI
8
Anchor Bolt & Jack Screw Detail, Main Unit
CI
8
Lift Plan
CI
12
Shipping Data
CI
12
Flow & Equipment Symbols
CI
10
Flow & Instrument Diagram, Turbine Fuel System
CI
10
Flow & Instrument Diagram, Turbine Lube Oil System
CI
10
Flow & Instrument Diagram, Generator Lube Oil
system
CI
10
Flow & Instrument Diagram, Water Wash System
CI
10
Flow & Instrument Diagram, Ventilation System
CI
10
Flow & Instrument Diagram, Fire Protection System
CI
10
Flow & Instrument Diagram, Turbine Hydraulic System
CI
10
Instrumentation Diagram, Auxiliary System
CI
10
General Arrangement, Hydraulic Start Module
CI
8
General Arrangement, Air Filter, Ladder and Platforms
CI
8
Electrical Abbreviations Symbols & Reference Data
CI
8
One Line Diagram, Generator 13.8 kV
CA
8
Three Line Diagram, Generator Metering
CA
12
System Schematic, Generator Excitation
CI
12