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Gas Turbine
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As per the provision of the CONTRACT, SEGAS are permitted to the use of this Product for reproduction and future reference only for SEGAS internal use. No part of this Presentation may be reproduced in any form or resold for other purposes without written permission from The Consortium.
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Lesson 12 : Lube Oil Instrumentation Lesson 13 : Hydraulic Oil System Lesson 14 : Trip Oil System Lesson 15 : Fuel Systems Lesson 16 : Fuel Gas Supply System Lesson 17 : Fuel Gas Control System Lesson 18 : Liquid Fuel System Lesson 19 : Liquid Fuel System Lesson 20 : Pneumatic Starting
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Lesson 21 : Hydraulic Starting Lesson 22 : Diesel Starting Lesson 23 : Enclosures Lesson 24 : Fire Detection Lesson 25 : Gas Detection l Lesson 26 : Extinguisher System Lesson 27 : Principles of Power Gen Lesson 28 : Generator Components
Lesson 29 : Lube Oil System Lesson 30 : Generator Components Lesson 31 : Generator Control Lesson 32 : Principle of Components Lesson 33 : Compressor Lesson 34 : Compressor Lube Oil Lesson 35 : Compressor Cooling l Lesson 36 : Compressor Control
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A gas turbine engine is divided into five sections: air inlet section
compressor section combustion section turbine section exhaust section
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The sections of a gas turbine are contained in the engine case. The engine case is a horizontal tube-like container that is open at both ends. Each section of the gas turbine has a specific function. Engine Design: Air Inlet & Compressors Huge quantities of air enter the case through an opening at the front end called the engine air inlet. After passing through the engine air inlet, the air flows to the compressor section. The compressor section contains the first moving part, the compressor. Compressor wheels increase the pressure of the incoming air.
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Combustion
In the narrow section of the case, the air is compressed. Fuel gas is injected into the compressed air through fuel nozzles. The fuel and air are mixed together and ignited. Burning the fuel and air mixture creates hot combustion gases. The heat increases the temperature and available energy of the gases. A turbine captures this energy and changes it into mechanical energy.
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Turbine Rotation
The turbine in the rear of the engine case extracts mechanical energy from the flow of the gases acting on the blades. The turbine rotates because of the pressure and velocity of the hot expanding gases acting on the blades of the turbine. As the hot gases pass through the turbine, the energy in the gas is reduced. The gases exit the rear of the case and into the atmosphere.
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Combustion
In the narrow section of the case, the air is compressed. Fuel gas is injected into the compressed air through fuel nozzles. The fuel and air are mixed together and ignited. Burning the fuel and air mixture creates hot combustion gases. The heat increases the temperature and available energy of the gases. A turbine captures this energy and changes it into mechanical energy.
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Turbine Rotation
The turbine in the rear of the engine case extracts mechanical energy from the flow of the gases acting on the blades. The turbine rotates because of the pressure and velocity of the hot expanding gases acting on the blades of the turbine. As the hot gases pass through the turbine, the energy in the gas is reduced. The gases exit the rear of the case and into the atmosphere.
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Turbine Rotor
The turbine uses energy from the thrust force created by the expanding gases. This energy is changed into shaft horsepower to drive the turbine compressor, the engine accessories, and the load. Most of this energy is expended to drive the turbine compressor. (Contd.)
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The rotor blades (sometimes called buckets) are attached to the rotor disc. The rotor disc is mounted on the rotor shaft. The entire assembly of blades and disc is often called a rotor.
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Basic Operation
The figure shows how all the components of the gas turbine engine work together. The fan has been replaced by a single set of compressor blades. The compressor creates the compressed air that is needed for combustion. Fuel gas is mixed with the compressed air and is ignited. The burning mixture creates a force in the rear of the engine case. The force is changed into rotating mechanical energy that turns the turbine.
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The turbine turns the rotor shaft that is shared by the compressor and the turbine. The compressor and turbine are connected to the same rotor shaft. The rotating force of the turbine is used to drive the compressor.
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If the shaft is lengthened on the compressor end of the engine, it is a front end drive or a cold end drive. If the shaft is lengthened on the turbine end of the engine, it is a rear end drive or a hot end drive.
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Laws of Thermodynamics
The laws of thermodynamics explain the effects of heat in an engine. The first law states that energy can be changed but it cannot be destroyed. In a gas turbine engine, heat energy is changed to mechanical energy. The second law of thermodynamics states that heat cannot be transferred from a cooler body to a hotter body. In a gas turbine engine, heat is transferred from the hotter engine to the cooler lube oil.
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Boyle's Law
Compressibility is an important factor in gas turbine performance. Gas turbines use compressed air for combustion. Boyle's Law can be explained by placing a quantity of gas in a cylinder that has a tightly fitted piston. When a force is applied to the piston, the gas is compressed to a smaller volume. When the force is doubled, the gas is compressed to half its original volume. The force exerted on the turbine blades increases as the pressure of the combustion air increases.
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Charles' Law
Charles' Law explains the expansion of gases when heat is added by burning fuel in an engine. Charles' Law is explained using the figure. The first container holds a certain volume of air. If the air in the container is heated, it expands and its pressure increases. The expanding air pushes against the container. The higher the temperature, the greater the force applied by the expanding volume of air. In the gas turbine, the forces created by the hot, expanding gases push against the blades of the turbine and turn the rotor.
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On a very cold day, a gas turbine can exceed its peak load. On a very hot day, a gas turbine will produce much less power. The atmosphere also contains foreign matter that is harmful to gas turbines, such as pollen and dust. The contaminants reduce the efficiency of the turbine and damage internal parts.
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Brayton Cycle
. Expansion
. Combustion . Compression The Brayton Cycle defines what takes place in the gas turbine engine. These events are controlled by the physical laws described on the previous pages. The events in the Brayton Cycle take place in specific sections of the gas turbine. These events are: Compression Combustion Expansion Exhaust
The Brayton Cycle is unique among engine cycles because all the events in the cycle take place at the same time without interruption. The exhaust event is the only part of the cycle that does not take place in the engine.
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Filter Assembly
The first component of the air inlet system is the filter assembly. The filter assembly consists of the following parts: weather louvers inlet screens filters ( Contd. )
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The filter assembly separates moisture and particles such as dirt, dust, and insects from the inlet air. This prevents contamination and foreign object damage to the compressor. Weather Louvers, Screens, & Filters The purpose of the weather louvers is to prevent direct rainfall from entering the air inlet system. Inlet screens, usually constructed of wire mesh, are designed to prevent large items and other contaminants from entering the compressor inlet. The inlet screens are located behind the weather louvers. Filters trap small particles of dust, dirt, and other contaminants to prevent them from entering the compressor section. Filters are constructed of materials which meet the specific operating and climatic conditions of the gas turbine location.
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Bypass Doors
Some air inlet systems have bypass doors located just downstream of the air filters. The purpose of the bypass doors is to protect the air inlet from excessive differential pressure. High differential pressure is usually caused by excessively dirty air inlet filters or some other abnormal blockage of the air inlet system restricting airflow through the filter. ( Contd. )
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Anytime the bypass doors are open during gas turbine operation, the engine is unprotected and is operating with unfiltered air. Operating under these conditions reduces engine reliability and operating life. Operators should take immediate action to determine why the bypass doors are open and take corrective action.
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Trash Screens
The inlet silencer is a baffle arrangement intended to quiet the noise vibration of the compressor blading. The trash screens are the next component in the inlet ducting assembly. Trash screens prevent foreign objects from entering the compressor inlet. Trash screens are installed downstream in the ducting before the compressor inlet. ( Contd. )
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Access doors are provided to allow cleaning and servicing of the trash screens. Trash screens are constructed of stainless steel and should not require maintenance other than periodic cleaning and inspection.
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Air Plenum
The final component in the duct assembly is the air plenum. The purpose of the air plenum is to provide equal distribution of ducted air to the compressor inlet. The air plenum is located just forward of the compressor inlet. One of the most common types of compressor inlets is the bellmouth inlet. Air Plenum
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Silencers
Silencers are usually installed in both the air inlet system and the exhaust section of the gas turbine to reduce operating noise. Silencing is accomplished by baffles covered with sound-absorbing material. In some air inlet ducts, the interior walls of the ducting and air plenum chambers are also lined with this sound-absorbing material. ( Contd. )
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Gas turbine operating noise is harmful to the human ear. Silencers help but do not totally eliminate gas turbine noise. If you work near a gas turbine that is operating, you should wear ear protection to avoid hearing loss.
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Introduction
The preceding lesson discussed the general construction of an axial flow gas turbine engine. It also described the engine case and the components of the air inlet. In this lesson you will learn about the compressor section of an axial flow gas turbine.
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UNION FENOSA gas SEGAS Services Gas Turbine Compressor Components: Rotor
The rotor is the rotating element of the compressor. The rotor contains blades fixed on a spindle, drum, or wheel. These blades push air to the rear in the same way a propeller does. The movement of air is caused by the angle and the shape of the blades. When turning at high speed, the rotor takes in air at the compressor inlet, increases the air pressure, and accelerates the air toward the rear of the engine through a series of stages. Energy is transferred from the compressor to the air as velocity energy
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Stator vanes also act as diffusers, changing velocity to pressure. Stator vanes on the discharge end of the compressor are aligned to straighten the airflow and reduce turbulence. These vanes are called straightening vanes, outlet vane assemblies, or exit guide vanes.
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The vanes may be welded into the shrouds. The shroud is secured to the inner wall of the compressor case. In some cases, individual blades are inserted into slots cut in the case. Each component plays an important role in compressor operation, which is our next topic.
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UNION FENOSA gas SEGAS Services Gas Turbine Axial Flow Compressor: Operation
When air enters the compressor through the air inlet, incoming air passes through the first row of vanes, called inlet guide vanes. As the air enters the first set of rotating blades, it is deflected in the direction of blade rotation. The air is then caught and turned as it passes through a set of stator vanes. From there, the air is picked up by another set of rotating blades. This process continues through the compressor. The pressure of the air increases each time it passes through a rotor/stator blade set (called a stage).
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Compressor Surge
Compressor surge is a characteristic common to all types of gas turbines. In general, surge is the result of unstable airflow in the compressor. This unstable condition is often caused by air building up in the rear stages of the compressor. When a compressor is not operating at its optimum speed, the forward compressor blades may provide more air than the downstream stages can compress. The air then tends to reverse flow. The compressor surges.
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Compressor Surge
Surging causes the machine to vibrate excessively. Several methods are used to control surging. For example, the two-shaft gas turbine design reduces the possibility of surging. Compressors with higher compression ratios have a greater tendency to surge. Compression ratios are discussed next.
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Compression Ratio
Large, high-powered gas turbines require greater efficiency and higher compression than can be obtained with a single axial flow compressor. Single axial compressors usually have a compression ratio of approximately 8:1. Compression ratio is determined by the discharge pressure (psia) divided by the suction pressure (psia). For example, a gas turbine with a compression ratio of 8:1 discharges 117.6 psia of discharge pressure for every 14.7 psia of suction pressure. In two-shaft gas turbines, one or more turbine stages drive the compressor.
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Two-Shaft Compressor
Two-shaft compressors can operate with lower compression ratios. The lower compression ratio helps reduce the possibility of surging. For example, if a gas turbine had a compression requirement of 20:1, a twoshaft (dual compressor) would share the load. Each compressor, operating in series, may have only a 4:1 or 5:1 compression ratio. The net compression ratio of the dual compressors is higher than that of a single compressor.
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Diffuser: Purpose
The diffuser is located between the compressor section and the main components of the combustion section. The purpose of the diffuser is to prepare the air for entry into the combustion section. The front end of the diffuser is bolted to the compressor case, and the back end is attached to the combustion section. ( Contd.)
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The diffuser has an expanding internal diameter that looks like an upside down funnel. This provides additional space, like the air plenum, for the compressed air to expand. In an operating gas turbine, the point of highest pressure is in the diffuser exit.
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Diffuser: Airflow
The diffuser straightens the flow of air into the combustion section and provides equal distribution to each chamber. When the air leaves the diffuser, it enters the next main section of the gas turbine, the combustion section.
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UNION FENOSA gas SEGAS Services Gas Turbine Combustion Section: Purpose
The combustion section is located between the compressor and turbine sections. The purpose of the combustion section is to add heat energy to the flowing gases. This addition of heat causes the gases to expand and accelerate into the turbine section. The hot gases that are generated by burning fuel in the combustion chambers are used to power the turbine and the load.
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The outer case forms the shell or chamber in which the combustion process takes place. The perforated inner liner, also called a combustion liner, is designed to provide paths for compressed air and gases to flow through the chamber for efficient combustion and expansion. The fuel injectors are located at the inlet of the combustion chamber.
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UNION FENOSA gas SEGAS Services Gas Turbine Components: Combustion Chamber
The fuel system supplies clean, pressureregulated fuel to the combustion chamber where it is mixed with the incoming compressed air from the diffuser. During start-up, the fuel and air mixture is ignited by a spark plug (source of ignition). After combustion occurs, the spark plug stops firing. The burning gases supply the heat energy required to operate the turbine and load.
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To supply the needed source of ignition, the flame from the combustion chamber is carried through a crossfire tube to the next chamber. It is then used as the source of ignition for the next chamber. This process continues until all chambers are ignited.
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UNION FENOSA gas SEGAS Services Gas Turbine Combustion Section: Operation
We turn now to the overall operation of the combustion section. Compressed air enters the combustion chamber, fuel is injected, and the fuel/air mixture is ignited and burned. The burning or combustion gases expand and travel toward a point of lower pressure at the rear of the chambers. Because high pressure compressed air surrounds the burner on all sides except the rear, the hot, expanding gases are directed toward the turbine section.
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Operation: Airflow
To operate efficiently, a combustion chamber must provide: a means for proper mixing of air and fuel a way to cool the hot combustion products to a temperature the turbine section components can tolerate.
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Operation: Airflow
To accomplish these actions, airflow through the combustor is divided into two air paths: primary secondary The primary air is approximately 25% of the total air that enters the chamber. Primary air is sent to the fuel nozzle area for combustion.
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The remaining air that enters the chamber, approximately 75%, is secondary air. Half of this air provides a cooling air blanket over the inside and the outside surfaces of the combustion liner.
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The combustion process is accomplished in the first third of the combustion liner. In the remaining two thirds of the combustion liner, combusted gas and air mix to provide even heat distribution to the turbine nozzle.
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Note the similarity of the elements of the turbine nozzle to the compressor stator vanes discussed in an earlier lesson. We will now look at the purpose and operation of the turbine nozzle vanes.
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These passages:
change the direction of gas flow increase gas velocity reduce pressure and temperature of the gas
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The remaining energy available for work is used to drive the load. The purpose and operation of the exhaust section are described next.
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These components act as a diffuser, to reduce the turbulence and velocity of exhaust gases.
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Introduction
Subsystems and accessories are separate from the main gas turbine engine assembly. This lesson presents information on three gas turbine engine subsystems and accessories: ignition system accessory drives (gearbox) vibration monitoring system Subsystems and accessories are essential for gas turbine engine operation. The first subsystem discussed is the ignition system.
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UNION FENOSA gas SEGAS Services Gas Turbine Typical maintenance procedures include the following:
Ensure that system power is locked out before performing any maintenance on the system. To remove the igniter plug, disconnect the transformer input lead, wait the time specified by the manufacturer (usually 1 to 5 minutes), then disconnect the igniter lead and ground the center electrode to the engine to discharge the capacitor.
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Vibration Monitoring
Several protective systems are used to alert operators to abnormal operating conditions that could result in damage to the turbine or other equipment. Vibration is one of the critical operating parameters that is monitored by a protection system. A vibration monitoring system is usually a part of the gas turbine's programmable logic control and operator terminal. The figure shows typical vibration detector locations in relation to the rotor.
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Shaft Movement
Vibration monitoring systems are installed on gas turbines and driven equipment to monitor and sometimes record axial and radial shaft movement. Shaft movement is monitored in either displacement (mils), velocity (length/unit-time), or acceleration (g's).
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One mil equals 0.001 of an inch. A shaft movement of 5 mils could generate an electrical impulse of one volt. Either of these measurements may be used as setpoints to initiate an alarm or shutdown.
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UNION FENOSA gas SEGAS Services Gas Turbine Vibration Monitoring Probes: Function
Axial movement is usually monitored by two probes, as shown in the figure. One probe is mounted at the end of the shaft, and the other is mounted at the thrust collar. During operation, any of the vibration monitors can usually be read on the PLC display. (Contd.)
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Introduction
This lesson presents information about bearings and oil seals commonly used in gas turbine engines. The main bearings of a gas turbine engine are mounted in a bearing housing. Most bearing housings contain seals to prevent oil leakage into the gas path. In this lesson, bearings are discussed first, followed by oil seals. The lesson begins with the purpose of bearings.
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Bearings: Purpose
Bearings have several purposes. They: support engine parts minimize friction minimize wear allow freedom of movement carry loads ( Contd. )
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Types: Plain
There are several types of bearings used in gas turbines: plain or sleeve ball and roller Plain bearings are the simplest type of bearing. Plain bearings are used in minor load locations, such as engine accessories.
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Labyrinth seals are installed in both ends of the bearing housing with bleed air pressure against the outer surfaces of the seals. The air flows between the teeth and grooves of the seals into the bearing housing. This prevents lube oil from leaking through the seals.
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UNION FENOSA gas SEGAS Services Gas Turbine Types: Labyrinth Air-Oil Seal
The controlled leakage of air into the bearing housing prevents oil leakage. Pressurized air that leaks outward along the shaft prevents gases from leaking into the bearing housing. This type of air-oil seal prevents the introduction of oil into the gas path. Oil leaking into high velocity combustion gases will damage turbine parts.
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Lube oil:
seals
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As the oil flows through the engine, it collects foreign matter and carries it away with the oil returning to the lube oil reservoir. Foreign matter is removed in the lube oil filter.
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Requirements: Viscosity
To function properly, lube oil must have a certain thickness, or viscosity. Viscosity is a measurement of the resistance of a fluid to flow. For example, water has low viscosity because it flows easily. Honey has high viscosity because it flows slowly. If lube oil is too viscous (thick), it may not pass through the small spaces at the required flow rate.
If the oil is not viscous enough (too thin), the oil film could be broken, causing the moving parts to wear rapidly.
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The sample is tested by spectrometric oil analysis. A spectrometer measures silicon (dirt) and wear metal levels in parts per million (ppm). It analyzes the color and measures the intensity of brightness that result when oil is burned in a specific light spectrum. The result of the analysis is used to monitor gas turbine internal wear. This allows the operator to take corrective actions to avoid costly repair or loss of equipment.
The gas turbine may require maintenance as indicated by oil analysis results.
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.If a hand pump is used to service lube oil, use that pump for one specific lube oil only. Do not mix incompatible lubricants. This can result in improper lubrication of the engine. Record the amount of oil serviced.
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After lubricating the bearings and gears, the lube oil is returned to the lube oil reservoir. Lube oil system operation will vary from manufacturer to manufacturer, but the components are basically the same.
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Reservoir: Purpose
The purpose of the lube oil reservoir is to contain an ample supply of lubricant for the gas turbine, accessory drive systems, gearbox, and driven equipment. The lube oil reservoir also provides the oil for starting, control, positioning inlet guide vanes, and trip oil circuits.
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Lube oil temperature is usually measured in the reservoir. Proper lube oil temperature is necessary for most gas turbines. Low oil pressure, low oil level, and high oil temperature will initiate shutdowns of most gas turbine engines. Reservoirs may have both a level sight glass and a level indicator to indicate oil level. A sealed float device operates level transmitters (LT), indicators (LI), and switches. The switches activate high (LSH) and low (LSL) level alarms and shutdowns.
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The lube oil reservoir is vented to the atmosphere to maintain an even pressure in the tank. A flame arrestor is often installed in the vent to prevent a source of ignition from entering the reservoir. The purpose of the pressure regulator (PCV) is to control the lube oil system pressure by returning excess lube oil to the reservoir.
System protection is provided by a pressure relief valve (PSV) located at the discharge of each pump.
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The most commonly used lube oil pump is the gear pump shown in the figure on the following page.
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The gears rotate in a direction that forces the oil to move between the gear teeth and the pump inner case until the oil is delivered to the pump outlet port. The idler gear seals the pump inlet from the outlet and prevents the oil from reversing flow.
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The next topic discusses how these pumps function within the operation of a typical lube oil system.
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UNION FENOSA gas SEGAS Services Gas Turbine Lube Oil Filters: Purpose
The purpose of lube oil filters is to remove particles that collect in the oil. These particles can lodge in the close spaces between bearings and seals. Contaminants in lube oil will increase the friction between moving parts, resulting in excessive wear and bearing failure.
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The purpose of these pleats is to provide a maximum surface area for filtration. The figure shows a typical disposable filter assembly. Cleanable screen filters can be removed, cleaned, and reinstalled.
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The filter case is shaped like a cylinder and contains replaceable filter elements.
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This position ensures maximum oil flow through the selected filter. It also traps lube oil under pressure in the filter element removed from service. All pressure must be bled from the unused filter case before it is opened.
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Oil coolers are heat exchangers. The two most common types of oil coolers are: oil-to-water oil-to-air
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High bearing header lube oil temperature may indicate that the oil cooler tubes are fouled and in need of cleaning. Lube oil coolers can be damaged by thermal shock, overpressure, and hydraulic hammer. Thermal shock is prevented by starting the flow of cooling water through the oil cooler before the hot lube oil flow is started.
If the lube oil system has been down for maintenance, the system must be gradually filled with fluids as air is vented from the system. Pulsations of fluids through oil coolers can cause vibrations that may damage the cooler and shorten its operating life.
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UNION FENOSA gas SEGAS Services Gas Turbine Lube Oil Coolers: Operation
The transfer valve directs oil flow into the coolers. As shown in the figure, the transfer valve is controlled by a flow control valve and control system. Under high oil temperature conditions, the transfer valve can direct oil flow into both oil coolers. The control system automatically starts the fan motor on the oil cooler. The vent valve and the drain valve must both be opened to drain oil from the oil cooler.
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Introduction
The preceding lessons in this series discussed the lube oil system, its operation, and individual components of the system. This lesson provides information about lube oil system pressure and temperature controls, instruments, and alarms. Proper lubrication of gas turbine engines is critical to engine performance and operating life. Proper lubrication depends on oil pressure and oil temperature. High oil pressure can damage lube oil system components. Low oil pressure can prevent oil from reaching internal engine parts.
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Introduction
Proper lubrication also depends on oil viscosity, which is affected by oil temperature. Cold oil is more viscous than hot oil. Cold oil also produces higher oil pressure at the pump discharge. Hot oil loses film strength because of reduced viscosity. Information about the devices used to control lube oil pressure and temperature begins the lesson.
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Relief Valves
Lube oil pumps are protected by a relief valve. If the oil pressure at the pump discharge outlet is high, the valve is lifted off its seat and some of the excess oil is returned to the pump inlet. Some systems return the oil to the reservoir. A lube oil system pressure relief valve relieves excessive oil pressure. Like the pump relief valve, this valve opens when oil pressure overcomes spring pressure, and excess oil is returned to the reservoir.
The pressure relief valve can be adjusted by increasing or decreasing spring tension.
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Diaphragm Valve
A diaphragm valve regulates lube oil pressure within a very narrow range. A diaphragm valve senses lube oil pressure in the bearing header and opens or closes to maintain the pressure in the correct operating range. As mentioned at the beginning of this lesson, oil pressure and oil temperature are closely related. Information about temperature control devices is presented next.
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UNION FENOSA gas SEGAS Services Gas Turbine Lube Oil Regulator Assembly
A typical lube oil regulator assembly contains: two thermal bypass valves a pressure regulating unloading valve The figure shows these components and the flow of the oil through the lube oil regulator assembly.
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In the figure, lube oil flows from the pumps to the oil coolers, oil filters, and the bearing header. Lube oil for the generator is discharged from the main lube oil header. The differential pressure indicator (PDI) is connected across the lube oil filter inlet and outlet lines. The purpose of the differential pressure indicator is to monitor the pressure drop across the lube oil filter that is in operation. The device identified as 63QQ-1 is the main lube oil filter differential pressure alarm switch. This switch initiates an alarm when the differential pressure reaches the setpoint.
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G. E.: Thermocouples
The device labeled LT-TH-1A,B represents thermocouples located in the bearing header. These thermocouples provide high temperature alarms and trip signals to the control system. To trip the unit, the trip temperature must be sensed by at least two thermocouples. This concludes the information about oil instruments and alarms in the G.E lube oil system. The Solar lube oil system will be discussed next.
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UNION FENOSA gas SEGAS Services Gas Turbine Solar Instruments & Alarms
The figure shows a typical Solar lube oil schematic. Information about Solar lube oil system instruments and alarms begins on the next page with the level indicator.
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The prelube oil pressure switch also shuts down the prelube oil pump. During the start cycle, as main lube oil pump pressure exceeds the prelube oil pump pressure, the prelube oil pressure switch actuates at the increasing oil pressure setpoint. This shuts down the prelube oil pump.
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UNION FENOSA gas SEGAS Services Gas Turbine Hydraulic Oil System: Purpose
The purpose of a hydraulic system is to distribute fluid forces to various moving parts. This fluid is required for the operation of gas turbine electrohydraulic control system components, the fuel system, variable inlet guide vane mechanisms, and the hydraulic components of some starting systems. The lesson begins with information about Solar hydraulic oil systems.
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The oil filter removes particles from the servo oil that are 25 microns or larger. The purpose of the relief valve is to protect the pump and other components in the servo oil system against excessive oil pressure. Information about a G.E. hydraulic oil system is presented next.
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Hydraulic oil at 1500 psig leaves the manifold through a manual filter transfer valve to enter one of two filter manifolds. Each filter is equipped with a differential pressure switch. An alarm is initiated if the differential pressure increases to 60 psig. Hydraulic oil leaving the filter system discharges to the inlet guide vanes and the fuel control system. Hydraulic accumulators are located upstream of these systems.
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Cavities are located above and below the piston. The top cavity is precharged with 750 lbs. of dry nitrogen. The hydraulic system pressure forces the piston up against the nitrogen pressure until equilibrium is attained at 1500 lbs.
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In case of a turbine trip, the bleed valves open and the inlet guide vanes move to their "closed" position. Inlet guide vanes are automatically positioned during start-up and shutdown sequences to avoid gas turbine compressor surge.
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The pressure reducing valve decreases the 100 psig lube oil supply to 25 psig for the following systems: bearing lubrication accessory gear lubrication hydraulic pump supply pressure starting means control fluid and lubrication
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The loss of trip oil pressure allows spring B to extend, closing the valve plug in the trip valve. Hydraulic oil pressure is released, the fuel flow is shut off, and the turbine stops. After a turbine trip, the trip valve must be manually reset and the cause of the trip corrected before normal operation resumes.
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NOTE: Always check the turbine manufacturer's fuel specifications to ensure that the fuel meets the specifications for the gas turbine you are operating. The main components of a fuel gas system and liquid fuel system are given next. We will begin with the fuel gas system.
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NOTE: Nozzles are not shown in the figure. The components for both of these fuel systems are discussed in detail along with their operation in later lessons. The main difference between the two systems is that the liquid fuel system has a storage tank and fuel pumps, whereas a fuel gas system does not.
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Lesson : 16 Fuel Gas Supply System Fuel Gas Supply System: Purpose
The purpose of the gas turbine fuel gas supply system is to provide the correct amount of clean, dry fuel gas to the engine under all operating conditions. Each component of the fuel gas supply system is important to its overall operating efficiency. The information on the following page highlights the seven main components in a typical fuel gas supply system.
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In the figure, a hand switch controls a four-way air valve to send instrument air pressure to either side of the shutoff valve actuator piston. In some cases actuator piston movement is controlled by hydraulic control oil ported through a servo valve. The actuator is operated by the hand switch or by the fire detection system by means of an interlock. This operation is discussed next.
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The interlock receives signals from the hand switch and the fire detection system to change the positions of the fuel shutoff valve and the vent valve. When the fuel shutoff valve is closed, the vent valve must be open. The interlock is usually a part of the control system logic that closes the vent valve before the fuel shutoff valve opens.
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The pressure transmitter signals gas pressure information to the DCS pressure indicator (PI), low pressure alarm (PAL), and high pressure alarm (PAH). The fuel gas pressure can be read from the turbine control system CRT and from the DCS.
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Filter Separators
The purpose of the filter separators in the fuel gas supply system is to provide filtration and separation of the fuel gas before it enters the fuel control system. The fuel gas should be relatively clean and dry by the time it reaches this part of the system. Operators should monitor the filter separator sight glass (LG) during routine operating checks. Any liquid accumulation must be drained off. If liquid levels in the filter separator become excessively high, the high level switch (LSH) signals the DCS high liquid level alarm (LAH) and an alarm is initiated.
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Filter Separators
Like the lube oil and some hydraulic oil filters, the filter separators are equipped with differential pressure indicators and alarms. The system shown in the figure contains a high differential pressure indicator switch (PDISH) and a DCS differential pressure alarm (PDAH). The differential pressure initiates the high differential pressure alarm when the high differential pressure setpoint is reached. Operators should place the standby filter in operation and service the operating filter before the high differential pressure alarm is initiated.
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Control System
Fuel gas flows from the filter to the gas turbine fuel system which is controlled by the turbine control system. Several measuring devices are located between the filter separator and the gas turbine: pressure transmitter (PT) flow transmitter (FT) - optional temperature measuring elements (TE)
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These devices provide fuel gas supply information to the control system instruments. This information may be used for pressure indicators, pressure recorders, pressure alarms, flow indicators, totalizers, recorders, temperature indicators, and temperature recorders.
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Control System
The information is also analyzed and computed by the control system to schedule fuel flow to the engine as needed for speed and load requirements. The control system is discussed in more detail in the next lesson.
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The focus of the preceding lesson was the operation of a fuel gas system before the fuel supply enters the gas turbine package. This lesson focuses on the control of a fuel gas system in relation to gas turbine operation. The figure shows a simplified gas turbine package fuel gas system. It represents the system on the gas turbine being controlled.
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Strainer
The purpose of the strainer is to remove foreign particles from the fuel gas before it enters the stop/speed ratio valve assembly. A blowdown connection on the bottom of the strainer body is used for periodic cleaning of the strainer screen. The next fuel gas control system component discussed is the supply pressure switch.
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When control oil pressure is low, a spring moves an internal spool to the "dump" position. When hydraulic pressure is removed, a closing spring on the stop/speed ratio valve plug closes the valve. Fuel gas flow to the gas control valve and gas turbine is stopped.
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Pressure Transducer
The pressure control loop senses the fuel gas pressure exiting the stop/speed ratio valve. The pressure transducer changes the gas pressure input signal to a DC voltage output signal. The output signal is relayed to the stop/speed ratio valve Speedtronic control. The Speedtronic control compares the signals received from the intervalve pressure, position control loop, and turbine speed. The control system then adjusts the stop/speed ratio valve to maintain fuel gas pressure requirements.
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LVDTs sense the position of the SRV and the GCV and transmit signals to the appropriate Speedtronic control system segment. Here the signals are changed into DC signals, which are compared to the FSR. This signal is then transmitted to the servo valves, which regulate the flow of oil to the actuator cylinder, repositioning the SRV and the GCV.
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Servo Valves
The electrohydraulic servo valves are two-stage, four-way flow control devices. They provide directional and proportional hydraulic flow control in response to a low power DC input signal from the Speedtronic control system. The servo valves control the direction and rate of movement of the pistons in the stop/speed ratio valve and gas control valve actuating cylinders. The first-stage valve changes the small electric signal into a hydraulic force that precisely positions the piston of the second-stage valve.
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Servo Valves
The second-stage valve meters hydraulic pressure to and from the actuating cylinder. Movement of the single-acting piston actuator is opposed by a spring in the gas control valve. The last two components in the fuel gas control system are the pressure gauges and Speedtronic control system. The pressure gauges are discussed next.
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Pressure Gauges
Three gas pressure gauges are installed in the fuel gas supply line. The upstream gauge measures fuel gas pressure entering the stop/speed ratio valve. The middle gauge measures fuel gas pressure between the stop/speed ratio valve and the gas control valve. The downstream gauge measures the pressure of the gas that has been metered to the fuel gas manifold and fuel nozzles. Next we will discuss the Speedtronic control system as a component of the overall fuel gas control system.
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We will now take a more in-depth look at the components of the Speedtronic control system.
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Turbine operations are sensed and used as feedback signals to the Speedtronic control system. The Speedtronic control system is also equipped with protective devices as a backup to the main system.
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Control Loops
The Speedtronic control system consists of three major control loops: start-up and shutdown speed temperature The output of these control loops is connected to a minimum value select logic circuit.
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The minimum value select logic circuit interfaces the speed, temperature, and start-up control output signals to FSR for fuel control. Only the control segment (e.g., start-up, speed, or temperature) calling for the lowest voltage output is allowed to pass the gate to the fuel control system as controlling FSR voltage. FSR control is the command signal for fuel.
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The following is a basic description of how these sensors function. If speed is zero, permissive logic allows clutch engagement and the cranking sequence for turbine start-up is initiated. The zero-speed detector provides a signal when the turbine shaft starts rotating.
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Exhaust temperature is measurable and is proportional to the firing temperature. Thermocouples mounted in the exhaust provide temperature feedback proportional to the firing temperature. Air is more dense on cool days, causing the firing temperature to increase for a given speed.
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Protective System
The increased firing temperature improves turbine efficiency, but the control system must prevent overfiring the machine. This is accomplished by the control system lowering the temperature control point. Protection systems are also provided to prevent abnormal conditions that can damage the turbine. Contd.
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These control and protective systems are independent systems that back up the primary control systems. The protective systems will trip the machine when overspeed or overtemperature trip conditions occur. The over-temperature system protects the gas turbine against possible damage caused by overfiring. It is a backup system that operates only after failure of the temperature control loops.
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If the system malfunctions, exhaust temperature can exceed control limits. If a malfunction occurs, the over-temperature protection system provides an over-temperature alarm before it trips the gas turbine. Speed control software changes the FSR based on the difference between the actual turbine generator speed/load and the speed/load reference set point.
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The relief valve (PSV) is a safety device designed to prevent excessive pressure in the tank.
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When both pump switches are placed in the A position, the running pump becomes the lead pump and the other pump is in auto standby. If the lead pump fails when operating with both pumps in auto, the standby pump will start automatically with no interruption in fuel supply.
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The boost pump is installed upstream from the low pressure duplex fuel filters. An electric boost pump is a rotary, positive-displacement, gear, motor-driven pump. The pump takes fuel from the low pressure liquid fuel supply and delivers it to the fuel system inlet at the required pressure.
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Fuel Filters
Fuel oil flows from the fuel oil pump to the gas turbine via the pump discharge header. In the figure, a filter removes solid particles from the fuel oil. In a liquid fuel system, filters are of two types: low pressure duplex filters high pressure fuel filter The duplex filter assembly incorporates two parallel-mounted filters equipped with a selector valve, filter check valves, and a differential pressure switch.
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Fuel Filters
Each filter contains two replaceable filter elements with a 10-micron nominal rating, connected to the fuel system through the control valve so that fuel flow may be directed through either filter. This arrangement serves two purposes: servicing of the inactive filter during engine operation manual transfer to the clean filter without engine shutdown (Contd.)
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The high pressure fuel filter is installed in the fuel line between the high pressure fuel pump and the fuel control valve. It contains a replaceable filter element rated at 40 microns nominal. The fuel manifold is discussed next.
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Fuel Manifold
The purpose of a fuel manifold is to divide a single fuel supply into several outlet streams. A liquid fuel manifold usually has an inlet and outlet orifice called a boss. There is an inlet boss and an outlet boss for each fuel nozzle. Injector tube assemblies are connected to the fuel outlet bosses and carry the fuel to the fuel nozzle. A liquid fuel manifold is sometimes called a fuel flow divider manifold. It incorporates inlet and outlet fuel connections for manifold-to-injector tube assemblies that carry the liquid fuel to the fuel nozzles.
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Fuel Manifold
Solar gas turbines may also have an air assist manifold. Air assist manifold-toinjector tube assemblies carry fuelatomizing air to the fuel nozzles. The fuel and air mixture ratio is the weight of combustor primary air in relation to the weight of the fuel. A specific proportion of air is needed for efficient operation. Liquid fuel flows from the fuel manifold to the fuel nozzles, which are discussed next.
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Fuel Nozzles
Fuel nozzles are located in the inlet of the combustor. The purpose of fuel nozzles is to deliver highly atomized fuel in a controlled spray pattern in the combustors. Fuel nozzles are of three types: simplex duplex air blast
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The higher volume and higher pressure fuel flow from the outer orifice narrows the spray pattern so that fuel does not touch the combustion liner. Single line nozzles also use a spin chamber for each orifice. This chamber provides efficient fuel mixing and fuel-air residence time over different fuel pressures. The head of the fuel nozzle usually has air holes that provide some primary air for combustion. This air also cools and cleans the nozzle head and spray orifices.
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A cone-shaped, atomized spray pattern provides a large fuel surface of very fine fuel droplets. This pattern optimizes mixing of fuel and air and ensures the highest heat release from the fuel for more complete combustion. The most desirable flame pattern occurs at higher compressor discharge pressures. During start-up and other off-rated speeds, flame length increases because of low compression.
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Compression Ratio
Recall from a previous lesson that a gas turbine engine must maintain its rated compression ratio for efficient operation. Compression ratio is the amount of discharge pressure in pounds per square inch absolute (psia) over suction pressure in psia. As compressor discharge pressure increases, fuel pressure to the engine also increases. As the engine nears rated speed, fuel flow is regulated according to load requirements.
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On engine shutdown, the purge valve again opens to permit drainage (purging) of the liquid fuel lines. The valve closes as engine speed drops below 15% speed. The linkage assembly is the interconnecting device between the fuel control valve and the electrohydraulic servo actuator. The assembly consists of a linkage rod and rod ends. One end of the rod is attached to the servo actuator output shaft, and the opposite end is connected to the fuel control valve fuel metering lever. Movement of the servo actuator results in repositioning the fuel metering valve.
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Flyweight Governor
A flyweight governor consists of a pair of weights, called flyweights, a tension spring, and a governor rod. The governor rod rotates, and centrifugal force moves the flyweights apart. Movement in the flyweight position also repositions the governor rod. The rod connects the action of the flyweights to the throttle valve, which controls fuel flow.
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Modern gas turbines use an electric or electronically controlled main fuel actuator to control turbine speed. The main fuel actuator controller can be programmed to maintain a constant gas producer turbine speed, a constant power turbine speed, or a constant compressor discharge pressure, depending on the requirements of the system.
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Shaft rpm is compared with speed setpoints by the main fuel actuator controller. The controller then increases or decreases fuel flow until the desired speed is reached.
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Temperature Sensors
Exhaust gas temperature is the most critical of all gas turbine engine operating parameters. Exhaust gas temperature sensors send signals to the main fuel actuator controller. The exhaust gas temperature is monitored by several thermocouples, which signal temperature information to the engine temperature controller. (Contd.)
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The rest of this lesson describes the operation of a typical liquid fuel system during start-up, run, and shutdown sequences. Operation of the liquid fuel system during the start-up sequence is described first. NOTE: The start-up operation is for a local, manual initiation after all pre-start conditions have been satisfied.
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1) The Pcd bleed valve opens and begins to act on the acceleration limiter. 2) The purge valve closes. 3) The torch valve and the fuel valve open. 4) The electric motor-driven main fuel pump starts, if used. 5) The ignition relay and ignition exciter are energized. Spark plug starts firing. 6) Fuel flows through the torch valve to the torch. (Contd.)
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After light-off occurs, turbine temperature increases rapidly. If temperature exceeds setpoint while accelerating to 90% engine speed, engine temperature control warning IMPENDING HIGH ENGINE TEMPERATURE is initiated.
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The electronic load/speed controller (governor) takes control of the electrohydraulic servo actuator and positions the fuel control linkage to accelerate to operating speed. 2) Offset setpoints are transferred to normal operating values for engine temperature control. (Contd.)
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6) Engine speed increases to operating speed. 7) The following events take place if a turbine over-temperature condition occurs when the engine is operating above 90% speed: 8) At approximately 1,155F, the engine shutdown timer is de-energized. 9) After a 5-second delay, allowing for transient over-temperatures, HIGH ENG TEMP alarm is indicated. 10) At approximately 1200F, engine shutdown is immediate and HIGH ENG TEMP is indicated and engine shutdown is initiated.
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UNION FENOSA gas SEGAS Services Gas Turbine Starting System: Components
Natural gas must meet the manufacturer's specifications. A typical pneumatic starting system requires approximately 2600 scfm.
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The main components of a Solar Centaur starting system are as follows: gas inlet strainer
pilot gas filter solenoid-operated pilot valve starter motor shutoff valve lubricator starter motors
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UNION FENOSA gas SEGAS Services Gas Turbine Starting System: Lubricator
A lubricator, located downstream of the starter motor shutoff valve, injects lubricating oil into the gas flow. The purpose of the lubricator is to provide atomized lubricating oil to the starter motor vanes. A sight dome is used to check oil flow. In addition, the lubricator bowl has an oil level sight glass. (Contd.)
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On Solar Centaur gas turbines, two vane-type, pneumatically operated starter motors are mounted on the starter adapter housing, located on the reduction gear. The motors transmit starting power to the engine through a common overrunning clutch and shaft.
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UNION FENOSA gas SEGAS Services Gas Turbine System Operation: Turbine At 15% Speed
When gas turbine speed reaches 15%:
Purge timer relay inhibits fuel while purging the machine. Ignition begins when fuel is admitted 10 seconds after 15% speed. (Purge timer times out.) Lightoff occurs and combustion begins. The engine continues to accelerate with assistance from the starter motors.
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UNION FENOSA gas SEGAS Services Gas Turbine System Operation: Temperature @ 350F
When engine turbine temperature reaches 350F: Ignition system is shut off. Pre/postlube pumps stop when engine-driven lube oil pump pressure reaches 35 psig.
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UNION FENOSA gas SEGAS Services Gas Turbine System Operation: Engine Speed @ 66%
When engine speed reaches approximately 66% or self-sustaining speed:
The starter clutch overruns. The start-relay and start circuits are deenergized. The solenoid-operated pilot valve is deenergized. The starter motor shutoff valve is closed by pilot pressure. Acceleration continues. The start cycle is complete at approximately 66% engine speed.
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UNION FENOSA gas SEGAS Services Gas Turbine Hydraulic Starting System: Components
The main components of a hydraulic starting system are as follows: electric motor hydraulic pump hydraulic fluid reservoir hydraulic starter motor (engine mounted) filter elements
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UNION FENOSA gas SEGAS Services Gas Turbine Hydraulic Pump: Pumping Action
During the last half of the revolution, the piston moves outward toward the head. The hydraulic fluid that filled the cylinder during the first half of the revolution is now forced out through the outlet port as the piston returns to point 1 to start another cycle.
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The angle of the swash plate is controlled by two different means: A solenoid selects high or low flow operation. An internal compensator limits output pressure to 5000 psig by reducing the swash plate angle to reduce cylinder displacement.
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UNION FENOSA gas SEGAS Services Gas Turbine Hydraulic Starting System: Operation
The typical hydraulic start system is a closed loop system with all return lines to the hydraulic fluid reservoir. The reservoir usually stores 40 to 50 gallons of hydraulic fluid. Automatic temperature controls maintain hydraulic oil temperature between 50F and 60F.
( Contd. )
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Alarms and shutdown switches are provided for high and low hydraulic oil temperatures and low liquid levels. During starting system operation, the charge pump takes suction from the hydraulic fluid reservoir through a suction strainer.
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UNION FENOSA gas SEGAS Services Gas Turbine Hydraulic Starting System: Operation
The hydraulic starter motor is similar to the hydraulic pump. The motor is variable displacement with a swash plate. The power cylinders are arranged axially around a shaft. The angle of the swash plate on the shaft is controlled by a speed-sensing mechanism. ( Contd. )
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At speeds up to 2500 rpm, the swash plate is held at its maximum angle, and the pistons are working through their full stroke. At speeds over 2500 rpm, the swash plate angle decreases. At about 4500 rpm, the swash plate is almost square to the shaft.
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The fluid discharges from the starter to the low pressure side of the system (about 150 psig) and returns through a filter to the supply pump inlet. Solenoid control valves are sequenced and controlled by the main unit control panel.
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UNION FENOSA gas SEGAS Services Gas Turbine Hydraulic Starting System: Operation
When a start is initiated, the system accelerates the gas generator from static conditions to self-sustaining idle speed. The hydraulic starter motor has an overrunning clutch, which disconnects the starter shaft from the gas turbine during engine operation.
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UNION FENOSA gas SEGAS Services Gas Turbine Diesel Starting System: Purpose
The purpose of a diesel starting system is to provide power to start the turbine axial flow compressor. A diesel starting system performs three primary functions during the start cycle: start the turbine roll (breakaway from standstill) accelerate the gas turbine to firing speed assist the gas turbine to self-sustaining speed A diesel starting system has three main components. Each is described in the information that follows.
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Diesel Engine
A diesel engine is the primary component of a gas turbine diesel starting system. It is used to rotate (crank) the gas turbine for start-up. A diesel engine is an internal combustion engine that converts the heat of fuel into work in the cylinders of the engine. Diesel engine operation is based on the reciprocating (upward and downward) movement (stroke) of a piston in a cylinder. ( Contd.)
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In a two-cycle engine, the combustion cycle is completed in each cylinder during one revolution of the crankshaft, which is one piston stroke. The diesel starting engine for G.E. Frame 5 gas turbines is a 12 cylinder, two-cycle engine rated at 2300 rpm.
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The action taking place during each of these events is shown in the figure. The next component discussed is the torque converter.
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Torque Converter
The torque converter is a hydraulic device that transmits the torque (turning force) of the diesel engine to the gas turbine through the ratchet jaw clutch. The hydraulic ratchet's jaw clutch couples and uncouples the torque converter and diesel engine from the gas turbine. Rotation of the hydraulic turbine causes the output shaft of the torque converter to rotate. This turning force (torque) is transmitted to the gas turbine through a starting clutch. The third component of the diesel starting system is the hydraulic ratchet assembly. The purpose of this component is discussed next.
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UNION FENOSA gas SEGAS Services Gas Turbine Hydraulic Ratchet Assembly Consortium
The purpose of the hydraulic ratchet assembly is to assist the starting device to begin the rotation of a gas turbine rotor at breakaway.
The ratchet system also rotates the gas turbine rotor during the cooldown cycle, after gas turbine shutdown. The ratchet is controlled partially by the starting control system. The diesel starting system has several auxiliary systems that are essential to its operation. These auxiliary systems are discussed next.
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UNION FENOSA gas SEGAS Services Gas Turbine Diesel Starting System: Auxiliary Systems
A diesel engine has the following auxiliary systems: cooling lube oil air fuel starter control
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Cooling Systems
A diesel engine uses one of two types of cooling systems:
radiator and fan heat exchanger
Both systems use a centrifugal water pump to circulate coolant and a thermostat to maintain operating temperature. The radiator and fan cooling system is discussed first.
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Air System
The purpose of a diesel engine air system is to provide air for scavenging (removing) exhaust gases from the engine cylinders and for combustion. In a two-cycle diesel, a charge of air is forced into the cylinders by the blower(s). Each cylinder is filled with fresh, clean air. ( Contd.)
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The air charge thoroughly sweeps all of the burned gases out through the exhaust valve ports. The air helps to cool internal engine parts, particularly the exhaust valves. The diesel starting fuel system is discussed next.
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Fuel System
The main components of the diesel engine fuel system are: diesel fuel tank fuel charge pump canister tank main fuel pump filters fuel header fuel injectors (Contd. )
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A diesel fuel tank is built into the base of the gas turbine. The fuel charge pump is driven by the diesel engine camshaft. This pump supplies fuel from the base tank to a small canister tank mounted on the side of the engine.
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Fuel System
The main fuel pump takes suction from the canister tank. It pumps the fuel under pressure through the fuel filter to the fuel header. The main fuel pump is a positive displacement gear pump that is attached to the blower. The fuel header delivers fuel to the fuel injectors. The fuel is filtered through filter elements in the injectors and then atomized through small spray tip orifices into the combustion chamber of each cylinder.
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Control System
This section discusses the starter control system. The primary diesel controls are: starter speed control system stop mechanism electronic logic
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Control System
The starter is a DC electric starter motor. The starter motor is attached to the diesel engine block. Lead-acid storage batteries provide electric power for starting. Diesel engine speed is controlled by the variable speed governor. A hydraulic actuator positions the governor speed control lever. A small, engine-driven pump supplies engine oil for actuator operation. When the accelerating solenoid is energized, the governor lever is driven to the high operating speed position.
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Control System
When the solenoid is de-energized, the lever is returned to the idle position. The diesel engine stop mechanism is a solenoid connected to the governor. When the stop solenoid is energized, it activates the shutdown mechanism, shutting off fuel and stopping the engine. Electronic logic in the gas turbine control panel provides automatic sequencing of the starter and control solenoids for normal diesel engine start-up, for normal and emergency engine shutdown, and for exercising and testing the engine.
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Control System
To protect the diesel engine, electronic logic also monitors the starting clutch position, the engine lube oil pressure and the engine speed. Alarms and emergency shutdowns are initiated for out-of-limit operating conditions.
If the diesel engine is tripped when the throttle is in the full open position, the throttle does not reset.
The next diesel engine restart will be made with the throttle set at full power. The throttle lever should be manually reset before the next start attempt. The next section discusses the operation of a diesel starting system.
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UNION FENOSA gas SEGAS Services Gas Turbine Diesel Starting System: Operation
The following describes the operation of a diesel starting system. The procedure assumes the gas turbine is off cooldown, in a ready to start condition with all prestart-up checks complete. When START is selected: starting clutch is engaged starting motor is energized to start the diesel engine
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Operation
Following gas turbine breakaway:
acceleration solenoid is de-energized and the diesel engine slows to approximately 1900 rpm acceleration stop solenoid controls diesel engine speed until the gas turbine is sequenced through the warm-up cycle acceleration stop solenoid is de-energized acceleration solenoid is energized to accelerate the diesel engine to maximum rpm for acceleration of the gas turbine
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Operation
At diesel engine speed of 3000 to 3400 rpm: clutch automatically disengages acceleration solenoid is deenergized At this time, the diesel engine: returns to idle speed idles through a cooldown period stops when the stop solenoid is energized
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Previous lessons discussed gas turbine components and operation. This lesson provides information on the enclosures that house the gas turbine and its driven and auxiliary equipment. A gas turbine/generator set is used as an example through out the lesson. A basic gas turbine/generator set consists of the gas turbine, gearbox, and generator with complete selfcontained operating systems.
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Enclosure: Purpose
The purpose of an enclosure is to protect the gas turbine/generator set from environmental elements, to improve appearances, and to reduce noise, to meet local area classifications, and to provide an easier means for fire protection and containment.
The enclosure discussed in this lesson is designed for outdoor installation and high wind loads. The enclosure is divided into compartments by bulkheads (walls). Each compartment contains lighting, access doors, and, when needed, removable panels for inspection and maintenance.
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UNION FENOSA gas SEGAS Services Gas Turbine Ventilation System: Purpose
A ventilation system is provided when a gas turbine/generator set is enclosed. The purpose of an enclosure ventilation system is to minimize temperatures in the turbine and generator compartments.
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Ventilation System: Air Inlet The purpose of an enclosure air inlet system is to: take in air for ventilation of the enclosure treat the quality of inlet air to make it suitable for turbine use The main components of an enclosure air inlet system are: inlet screens weather louvers filters ducting
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Incoming air passes through weather louvers where moisture is removed. These louvers provide a moisture "trap" using the inertia of the water droplets as the means of separating the droplets from the incoming air. The filters remove foreign particles from incoming air. Filters should be checked regularly. Dirty filters can result in overheating of the equipment in the enclosure.
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Some enclosures have an air inlet. Others take ventilation air from the gas turbine air inlet system. The duct exterior walls and inlet support structure are either stainless steel or carbon steel with multiple coats of protective paint. Information about an enclosure's airflow system is next.
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The purpose of dampers is to control the airflow in the enclosure. Air inlet and outlet dampers are normally open. They are closed by gravity to provide an airtight enclosure when the fire protection system is activated.
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Fans provide ventilation by drawing air through the air intake and exhausting it to the atmosphere. The purpose of fans is to increase circulation in the enclosure. Fans may be installed in either the inlet or the exhaust duct. An enclosure exhaust system is discussed next.
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be durable and able to resist environmental damage incorporate an accurate and effective testing system to ensure system integrity operate without special electrical equipment and require a minimum of power
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Thermal Switches
Thermal switches are either: single wire two wire The single-wire thermal switch fire/rate-of-rise detection system has heat-sensitive thermal switches located at points in the enclosure where temperatures are likely to be highest.
The switches contain a pair of contact points that are normally open. The contact points close at a preset temperature. When the switch heats up, the heat-sensitive arms with the contact points expand. The expansion is in the direction opposite the electrical terminal.
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Thermal Switches
The sliding piston moves to the end of the switch, the points close, and the thermal switch completes an electric circuit for the alarm switch. When the circuit is complete, the alarm switch initiates an alarm signal. The switch automatically resets when it has cooled.
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Thermocouples
Thermocouples are temperature sensing devices, primarily used in temperature indicating systems, such as exhaust gas temperature or turbine outlet temperature.
(Contd.)
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A thermocouple is the junction of two dissimilar metals that generate a small electrical current that varies with the difference between the temperature of the hot junction and the cold junction. The dissimilar metals can be any combination of metals or alloys that will produce the required results such as iron-constantan (Type J) or ChromelAlumel (Type K). The complete thermocouple circuit consists of a "cold" junction, a "hot" junction, electrical leads made from the same material as the thermocouple, and a galvanometer-type indicating instrument
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Thermocouples
The point where the two dissimilar metals are joined that will be most exposed to the heat of a fire is called the hot junction. The cold junction, sometimes called the reference junction, is enclosed in dead air space between insulation blocks. ( Contd. )
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A metal cage or sheath protects the thermocouple without hindering free movement of air to the hot junction. Some thermocouple element wires are surrounded with magnesium oxide to prevent vibration damage to the wires. Magnesium oxide also enhances heat transfer between the medium being measured and the measuring junction
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Thermocouples
A typical thermocouple is installed in a protective well or cage. Other thermocouple cages have several passages that allow air (or gas) to enter the protective cage and surround the elements. A thermocouple fire detection system has a different response to the thermal switch system. (Contd.)
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Thermistor
A thermistor (thermal resistor) is a resistive circuit component. When cool, a thermistor has high resistance to current flow. As the temperature of a thermistor increases, its resistance decreases. A thermistor fire/rate-of-rise detection system is a continuous loop system that usually surrounds the surveillance area. (Contd.)
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Single-wire and two-wire systems are commonly used on large gas turbines. In the single-wire system, the outer case provides the ground potential. In the two-wire system, the second wire provides the ground.
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Thermistor
In both systems, the power lead is insulated from ground. The single-wire system uses an insulator of ceramic beads that are coated with a substance called eutectic salt. The two-wire system uses a thermistor material to insulate the wires. Each of these materials loses electrical resistance when heated. In the fire/rate-of-rise circuit diagram shown in the figure, 24V DC is supplied to the hot lead through an alarm relay coil. When cool, the insulation does not allow current flow between the hot lead and ground.
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Thermistor
When a fire condition heats the insulator material, it loses electrical resistance and a path is complete from the hot lead to ground. The thermistor system, like the thermal switch systems, automatically resets when cooled. A pneumatic fire detection system is discussed next.
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The gas returns to a low pressure after the heat source is removed. The check valve arrangement and diaphragm force the gas back into the tube, ready for another operation.
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When a fire or hot object is detected in a compartment, the detector signals the controller, which powers the fire alarm. A fire signal is generated only when a fire is detected by both sensors. Three optical fire detectors are shown in the figure, two in the turbine compartment and one in the generator compartment.
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The gas detection system should prevent the possibility of a gasfueled fire, which is considered potentially the most likely and the most dangerous. However, should a fire occur it will be detected by one or more of the sensors. Enclosure fire detection system operation is discussed next.
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Sensors
Two or more sensors are installed in the gas turbine compartment and one or more in the generator compartment near the divider wall where the drive shaft or coupling penetrates the wall. Two sensing elements are used in a sensor. One element is calibrated to detect a low combustible gas concentration of 15% or 20% L.E.L. L.E.L. is the lower explosive limit. The other element is calibrated to detect a high combustible gas concentration of 60% L.E.L.
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Sensors
The sensors detect the combustible gas concentration with air at the lower explosive limits (L.E.L.). A 5% methane concentration with air is the lowest concentration that can be ignited. A 15% methane concentration is the highest concentration that can be ignited. Lower or higher concentrations cannot be ignited.
The 5% methane concentration with air is 100% of the L.E.L. An alarm that occurs at 20% L.E.L. actually indicates a combustible gas concentration of 1%. The detection circuit is discussed next.
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Detection Circuit
Most gas detection systems are calibrated to initiate an alarm when the gas concentration in the enclosure reaches 15% to 20% L.E.L. This is the low L.E.L. alarm. For a low L.E.L. alarm, the combustible gas detection system usually initiates both an audible and a visual alarm. Enclosure ventilation fans that are not already running are started. The fans continue to operate until the gas detection/protection system is reset and the alarm indication is cleared by the operator.
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Detection Circuit
The gas detection system is normally provided with readout indicators. These indicators allow the operator to observe the presence and concentration level of any combustible gas that may be inside the enclosure. The protection system is discussed next.
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Protection System
A high L.E.L. alarm is initiated at 60% L.E.L. A 60% L.E.L. is a 3% combustible gas concentration. On some gas turbine/generator sets, a 60% L.E.L. alarm initiates the following actions: immediate gas turbine/generator shutdown, if operating immediate shutdown of all operating enclosure ventilation fans
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Cylinders
Halon is stored in cylinders, on or near the gas turbine/generator package. The number of Halon cylinders in a system depends on the volume of the protected area. A minimum of two cylinders is required. One cylinder supplies the initial discharge, and the other provides the extended discharge. Any signal which initiates Halon discharge also trips the turbine. (Contd. )
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When Halon is discharged into a compartment, the initial discharge is at a rapid rate The reason for a rapid rate during initial discharge is to build an extinguishing concentration as quickly as possible. This is followed by an extended discharge at a slower rate to maintain the extinguishing concentration and minimize the possibility of re-ignition of combustibles exposed to hot metal surfaces.
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Cylinders
Halon cylinders are manufactured in different sizes from 18 to 600 pounds. The cylinders are purged with nitrogen and then filled with Halon. Halon cylinders are held in the upright position by mounting brackets. The cylinders should be located in an area that does not receive direct sunlight because Halon is extremely temperature sensitive. Halon cylinders should not be exposed to temperatures above 130F.
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When the vent valve is actuated, there is a large pressure difference between the top (B) and bottom (A) areas of the valve. When the ball check valve closes the bleed port, Halon cannot flow to the top of the piston and the pressure in areas A and B are no longer equal
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The figure shows various types of valve actuators. Each is described in the information that follows.
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When mounted on the Halon valve vent fitting, the pneumatic valve actuator provides direct actuation of the vent valve. When mounted on an electrical actuator, the pneumatic actuator closes a switch that causes the electrical actuator to operate.
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UNION FENOSA gas SEGAS Services Gas Turbine Manual-Local Override Actuator
The manual-local override actuator is installed when the system requires manual Halon release at the cylinder. This actuator is mounted either directly on the valve assembly vent fitting or indirectly on an electrical actuator. A pneumatic actuator is incorporated so that the manual-local override also functions as a pneumatic actuator. The manual-local override actuator is operated by pulling the ring pin and depressing the palm button or by providing a minimum of 30 psi pneumatic pressure to the inlet port.
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Pressure Switches
Pressure switches are installed in Halon fire extinguisher systems to monitor the pressure in the storage cylinders and in the discharge piping. In the figure, low pressure switches (PSL) monitor the pressure in the two Halon cylinders. If the pressure in a cylinder decreases to 185 psig, the switch iniates an alarm. The high pressure switch is identified as PSH in the figure. When the Halon pressure in the discharge manifold reaches 150 psig, the high pressure switch signals the control system that a cylinder has discharged.
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Pressure Switches
Most fire extinguisher control systems are programmed to discharge another cylinder if the high pressure signal has not been transmitted within a certain period, usually 5 seconds. The components used to discharge the extinguishing agent are discussed next.
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An audible alarm (horn) is installed at each enclosure fire-protected zone, or one horn for each major piece of equipment. This alarm, along with a flashing red light or beacon, is activated by the control system when a fire is detected in the enclosure. When an alarm is activated, it will continue until it is manually switched off by the operator.
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Monitor Controller
The last component discussed in the Halon fire extinguishing system is the fire monitor controller. This controller works in conjunction with other gas turbine control systems. The controller uses a microprocessor system to monitor signals from sensors installed in the enclosure. An example of a monitor controller is shown in the figure. The controller illustrated is typical of a monitor controller for an optical fire detection system with two independent types of detectors. A signal is sent to the controller only when both detectors sense a fire simultaneously.
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Monitor Controller
The controller monitors up to eight zones. One LED (light emitting diode) is provided for each zone. An LED blinks when a fire is present in the corresponding zone. One LED is also provided for each voting zone. A lit LED signals that the voting zone is actuated. The Test/Accept push-button disables an energized alarm or initiates a manual test of a selected detector. The inhibit LED is illuminated in the Test or Reset mode to indicate that the controller outputs are inhibited.
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Monitor Controller
When the lamp test switch is depressed, all LEDs and digital displays illuminate. In the reset mode, the lamp test switch indicates a complete system reset. The mode switch is used to select Normal, Reset, or Test mode. The power LED illuminates when power is applied to the fire detection system. The fault LED illuminates on fire detection system malfunction or when the controller is in the Reset or Test mode. The system status display provides a numerical code to report the system status.
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Monitor Controller
The zone digital display identifies the zone and the fire detection system conditions in that zone. The select push-button selects the desired detector for testing. Halon and CO2 fire extinguisher systems are very similar. A brief discussion of the CO2 system follows.
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The oxygen content is reduced from an atmospheric normal of 21% to less than 15%, an amount that will not support combustion. To reduce the oxygen content, a quantity of CO2 equal to or greater than 34% of the compartment volume is discharged into the compartment in 1 minute.
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Actuator Arrangement
A CO2 system may be actuated by several different methods. Pilot-operated selector valves in the CO2 discharge valve are opened when solenoid valves are energized, when the pull lever is actuated, or when another cylinder is discharged. The solenoid valves are actuated by an electric signal from the fire detectors. The system may also be manually actuated by switches located on the electrical control cabinet or by manual valves located in the control cabinet.
Actuation of the system, either automatically or manually, will trip the turbine.
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This concentration is maintained by the gradual addition of more CO2 from the extended discharge system, compensating for compartment leakage. CO2 flow rate is controlled by the orifices in the discharge nozzles.
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In addition to their use of similar components, both the Halon and CO2 extinguisher systems operate the same. The discussion about extinguisher systems continues with a description of the operation of a typical fire extinguisher system.
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When more than one optical flame detector is installed in an enclosure, a voting system is usually programmed into the fire monitor controller. With a voting system, an alarm signal from one optical detector will initiate an alarm but no other action. An alarm signal from one optical detector and a thermal detector or from two optical detectors is needed to initiate turbine shutdown and extinguisher release.
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UNION FENOSA gas SEGAS Services Gas Turbine Theory of Electrical Power Generation
The solution reacts with the anode and cathode causing current to flow through the conductor. The electric current that flows from a battery is known as direct current (DC). Direct current flows through the conductor in only one direction. DC current is used to supply electricity to electrical circuits in battery-operated equipment, such as radios and flashlights, DC motors, lights, etc.
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The power supply provides emf. Examples of power supplies are batteries and generators. The term emf is also called potential or voltage. The load is the resistance to current flow in the circuit. Examples of loads include motors, light bulbs, and heaters. The conductor is used to carry the electrical current to the load.
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The resistance can be calculated after the voltage and current are measured. For example, if the voltage is 24 volts and the current is 6 amps, the resistance of the load is 4 ohms. Information about the theory of magnetism is presented next.
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Magnetic Fields
Electricity flowing in a circuit creates a magnetic field. The figure shows the effect of a magnetic field on a compass needle. The needle aligns itself parallel with the magnetic field lines created by the current.
This alignment is caused by the force of the magnetic field. (Contd.)
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The strength of the magnetic field is proportional to the amount of current flowing through the conductor. If the current is increased, the strength of the magnetic field increases. If the current is decreased, the strength of the magnetic field decreases.
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Magnetic Fields
The strength of a magnetic field can be increased by winding a conductor around a core, forming a coil. The magnetic field strength increases as the number of windings increases. The direction and amount of current flowing through the coil determines the magnetic pole and strength of the magnetic field.
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Electromagnetic Induction
Just as current flowing through a conductor creates a magnetic field, a magnetic field can cause current to flow through a conductor. This principle is the basis for a simple generator. The conductor is moved through a magnetic field, and current flow is induced. This is known as electromagnetic induction. The current is produced only when the conductor is moving in a direction that is perpendicular (90) to the magnetic field.
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UNION FENOSA gas SEGAS Services Gas Turbine Magnetic Field Flux Lines
The magnetic field consists of flux lines that always point from the north pole of a magnet to the south pole. The conductor moving through the flux lines causes current to flow. A simple generator consists of a single-loop conductor called a coil. To create current flow, the coil must move through the field in a perpendicular direction. (Contd.)
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When the coil is in a vertical position, no current flows through the conductor. The current flow is maximum when the coil is in the horizontal position.
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Generation of AC Current
Electricity is generated as the coil rotates through the magnetic field. At position 1, no current is generated. As the coil rotates to position 2, the current increases to a maximum output. The current output returns to zero as the coil is rotated to position 3. As the coil is rotated to position 4, the current reverses direction to a maximum negative value. ( Contd.)
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As the coil continues rotating and returns to position 1, the current output returns to zero. This is how alternating current (AC) is generated. The current and voltage alternates between a positive and negative value.
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AC Frequency
The AC frequency is the number of complete cycles generated per second. The unit of measurement for frequency is hertz, abbreviated Hz. A complete cycle occurs when the current moves from zero to a maximum positive to zero to a maximum negative and back to zero. A complete cycle in one second equals one (1) Hz. Common frequencies generated are 50 Hz and 60 Hz.
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Calculating Frequency
The generators discussed so far are two-pole generators. A two-pole generator has one magnetic field with one north pole and one south pole. Remember that each cycle completed in one second is 1 Hz. A generator with four poles completes two electrical cycles for each mechanical revolution. The output frequency of any generator can be determined using the following equation: f=p(rpm)/120 Where f is the output frequency, P is the number of poles, rpm is rotational speed of the generator shaft.
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Three-Phase Generator
Three-phase current is generated by three coils on the same shaft. A three-phase generator has three coils, also known as windings. Each coil carries the current produced as it passes through the magnetic field. The coils are located at 120 increments around the shaft. ( Contd.)
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This arrangement produces three waveforms 120 out of phase. The generator has one terminal for each phase, A, B, and C, and a neutral terminal, N. If the neutral terminal is brought outside of the generator, the voltage across any terminal (A, B, or C) to the neutral terminal is the phase voltage. The voltage between any two of the three line terminals (A, B, or C) is called the line voltage.
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In the DELTA connection, one side of A is connected to B, the other side of A is connected to C, and the other side of B is connected to C. The power generated by either a wye or delta connected generator is the same, but the voltage and current relationship varies.
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Generator-Control: Transformer
The voltage produced by either a wye or delta connected generator is often different from that needed by the load. A transformer is used to regulate the voltages. For example, a motor that requires a 480 volt source cannot be driven by a 24,000 volt supply. In this situation, a transformer steps down the voltage. A transformer uses electromagnetic induction to regulate the voltages.
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This creates a magnetic field that induces current to flow in the secondary coil. Transformers only work with AC because of the current flowing into, then out of, the primary coil determines the voltage output in the secondary coil. The fluctuating magnetic field produces the same result as moving a conductor in a magnetic field. The ratio of the number of windings in the primary coil to the number of windings in the secondary coil is the electromagnetically induced voltage.
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Step-Up Transformer
Based on the ratio of windings, transformers are one of two types: step-up step-down A step-up transformer has fewer windings in the primary coil than in the secondary coil. It increases the voltage. (Contd.)
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Step-Down Transformer
A step-down transformer has a greater number of windings in the primary coil than in the secondary coil. It decreases the voltage. For example, if the primary coil has 100 turns at 110 volts AC and the secondary coil has 10 turns, the secondary coil has 11 volts AC across it. The transformer is a step down transformer because it steps down the voltage produced by the generator.
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Rectification is the process of turning AC voltage into DC voltage. Diodes are electronic parts that allow current flow in only one direction. This allows only positive voltage to flow. The voltage regulator (transformer) and diodes are very important to basic generator operation, which is described next.
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The permanent magnet generator produces AC current. The current is rectified to DC using diodes. The DC current is then used to supply power to the exciter generator. However, the current first flows through a voltage regulator that adjusts the amount of voltage applied to the exciter.
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Exciter Generator
The exciter generator is connected to the main generator field. Current from the exciter generator flows through the main generator field. Remember the current flowing from the exciter generator to the main generator field is controlled by the voltage regulator. Diodes are also used in the exciter generator to supply the main generator field with DC current.
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Main Generator
The main generator field induces current to flow in the main generator windings, supplying power to the loads in the area, such as motors. The output of the main generator windings is sensed by the voltage regulator. If the voltage sensed is low, additional voltage is supplied to the exciter generator. (Contd.)
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If the voltage sensed is high, less voltage is supplied to the exciter generator. In this way, the main generator output is controlled.
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Frame
The generator frame has two purposes: house the internal parts of the generator support the weight of the rotor and stator plus any rotational or vibrational forces The frame is finished with a coating, usually paint, that provides protection against corrosion and the environment. (Contd.)
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A frame is usually of one piece construction and includes the generator case. The case is designed with air passages to allow cooling air to circulate into and out of the generator.
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Case
As shown in the figure, the case contains: rotor bearings and seals generator field windings stator The generator rotor is discussed next.
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Rotor
The generator rotor is housed within the generator case and is supported at each end by bearings. One end of the rotor is the drive end and the other is the exciter end. Mounted on the rotor are: cooling fans main generator field windings PMG magnets exciter windings. (Contd.)
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The purpose of the rotor is to rotate the field windings to move magnetic lines of force through the windings of the stator core. The moving field induces emf in the stator windings. The rotor assembly is dynamically balanced to minimize vibration.
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Bearings
The purpose of the bearings that support the rotor ends is to minimize friction associated with the rotating shaft. Damage to bearings usually occurs as a result of high temperatures. Temperature sensors are installed in the bearings to provide an alarm or automatic shutdown if overheating occurs. (Contd.)
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The generator lube oil system, discussed in detail in the next lesson, provides lubrication of the bearings and removes heat created by friction. The rotor windings are the main generator field. This field causes electromagnetic induction to occur in the stator windings.
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Stator
The stator contains the stator windings, or armature. The stator is made out of segmented plates called laminates. The purpose of the stator is to generate the AC voltage that is conducted to the electrical circuit. (Contd.)
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Recall from the preceding lesson that a three-phase generator has three separate stator windings. One end of each phase is connected to a terminal for circuit connection. The other end of each phase is connected to a common neutral terminal.
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A reliable lube oil system is critical for generator operation. If the lube oil supply to the bearings is stopped during operation, the bearings and rotor shaft journal will be severely damaged. Lube oil must be supplied to the generator bearings before and during start-up, during operation, while the generator is coasting to a stop, and during the cool-down cycle.
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lube oil reservoir lube oil pumps - engine-driven main - auxiliary or pre/postlube - emergency oil cooler (Contd.)
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. oil filters instruments and controls piping If needed, return to the lessons covering these components and review the information before continuing on in this lesson. This lesson continues with information on the generator lube oil system's instruments and alarms.
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The PT signals lube oil pressure to the control system for operator readout. Lube oil system pressure may be observed at the local pressure indicator (PI).
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Temperature Instruments
A temperature element (TE) monitors lube oil temperature in the oil header to the generator. This device initiates an alarm if lube oil temperature reaches or exceeds 160F. If lube oil temperature reaches 190F, a shutdown signal is transmitted to the control system. Lube oil from the generator oil header is separated into two equal flows to the bearings. Oil flow into each bearing is controlled by an orifice in the supply line. ( Contd. )
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In the figure, each bearing has two temperature detector elements. These detectors are imbedded in the bearings to measure the temperature of the bearing metal. The TEs initiate an alarm at 197F and shut down at 203F. These TEs may also signal the fire monitor/controller to discharge the fire extinguisher agent.
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inlet filter inlet duct heavy duty axial flow fan(s) internal air passages exhaust ducts heat exchangers (generators with closed air circuits) temperature measuring devices
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High temperature accompanied by vibration indicates the possibility of plugged rotor cooling air holes or broken shaft cooling fan. If vibration is not indicated, dirty air inlet filters is probable.
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Heat Exchanger
Some site conditions such as severe desert conditions, salty atmosphere, contaminated environment or hazardous area classification require a closed cooling air circuit. In a closed cooling air circuit, the hot exhaust air from the generator is cooled in an exchanger loop and then returned to the generator. (Contd.)
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Make-up cooling air for the generator's closed air circuit is provided by the pressurized generator enclosure. Air cooling is accomplished by a water-to-air or air-to-air heat exchanger.
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Heat Exchanger
The heat exchanger is usually mounted in a steel housing on top of the generator, but it can be designed and positioned as needed. A common arrangement places the heat exchanger on the roof of the generator enclosure with ducting to and from the heat exchanger.
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RTDs in smaller generators only measure winding temperatures. An RTD is similar to a thermocouple. Both devices measure temperature and are similar in appearance. The main difference between an RTD and a thermocouple is that dissimilar metals in a thermocouple generate an electrical signal and an RTD requires an external source of DC power.
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The control system initiates an alarm when the level of the signal from the RTD reaches the calibrated setpoint.
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Large generators usually have nine RTDs to monitor the stator core temperature. Three RTDs are installed at strategic locations in each of the three stator windings. Two of these RTDs are active, and one is a spare. The small to medium size generators usually have three active RTDs and three spare RTDs. Temperature readout and protection are provided by the control system in the turbine control room.
(Contd. )
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In the system shown, the circuit provides an alarm when one of the stator RTDs senses stator temperature in excess of 270F. The system initiates a shutdown when the stator RTD level of temperature increases to 290F.
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(Contd.)
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Ventilating air circulates through both sides of the enclosure and exits to the atmosphere via exhaust ducts. During normal gas turbine/generator operation only one of the ventilation fans is operating. The other one serves as a standby unit.
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Consortium
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The purpose of the voltage regulator is to match the output voltage of the main generator with the voltage of the distribution system. The voltage regulator senses the output voltage of the generator and adjusts the voltage applied to the field of windings.
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After matching the frequency and the phase, the operator ensures that the generator voltage is the same as the distribution system voltage. The main circuit breaker is then engaged.
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. over/under frequency overvoltage undervoltage overvoltage ground relay Protective relays follow a standard numbering system that is used for all generators. The synch check relay, number 25, confirms that the generator is synchronized with the distribution system. It prevents circuit breaker operation when the generator is not synchronized with the distribution system.
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Without this relay, a faulty motor could shut down the distribution system. This relay allows time for the motor's circuit breaker to trip first, allowing the generator to continue operation. If the overcurrent condition continues after the time delay, the 51V relay will trip the generator breaker.
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The vibration monitoring system consists of vibration sensors and a vibration monitor. The vibration sensors detect the vibration and relay this information to the vibration monitor. The monitor initiates an alarm and a shutdown if the vibration exceeds preset levels.
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Store Energy
Air tools such as jackhammers and impact ratchets are operated by compressed air. These tools work by changing potential energy into kinetic energy. When a gas is compressed and put in a "receiver tank", the potential energy is stored. The figure shows potential energy and kinetic energy. The balloon is full of air under pressure and is not moving. This is an example of potential energy or energy at rest and stored energy.
Once the balloon is released, potential energy is changed to kinetic energy or energy in motion. The pressure and volume start decreasing, as the mass of the balloon and remaining air moves away.
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Reservoir Maintenance
Compressed gas is used in reservoir maintenance to keep sufficient gas pressure in the reservoir to maintain production levels. A reduction in gas pressure occurs naturally in reservoirs. As oil is produced, gas in the reservoir has a larger space to occupy. This decreases the reservoir pressure and reduces oil flow to the surface. (Contd. )
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Another way reservoir pressure is reduced is, as oil is extracted from the reservoir, gas molecules become entrained in the oil. When the oil and gas mixture is produced from the wellhead, the amount of gas in the reservoir is reduced and reservoir gas pressure begins to decline.
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Gas Transmission
Compressing a gas allows its transmission through a pipeline. The gas will always move from a higher pressure to the lower pressure. The balloon mentioned previously contains air that is at a higher pressure than the outside air. When the stem of the balloon is released, the higher pressure air inside moves to the lower pressure air outside. If the stem of the balloon were attached to a tube with the opposite end opened to atmosphere, the air would move down the tube.
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Production of Liquids
Compressing gases can also produce liquids. Normally, oxygen is a gas. The molecules are relatively far apart. Compressing the oxygen forces the molecules closer together. The oxygen will become a liquid if compressed to a high enough pressure. Many gases will liquify if they are compressed to a high enough pressure.
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Gas Lift
Compressed gas is also used in gas lift. Compressed gas is sent down into the earth to force oil to the surface. The gas carries the crude to the surface where it is then separated. Gas injection increases the gas specific density which allows it to move to the surface at the same downhole pressure. The next section of this lesson explains the operating principle of centrifugal gas compressors.
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Operating Principle
Centrifugal compressors operate on the principle of centrifugal force. This principle is illustrated in the figure. When a ball on a string is swung around in a circle, a centrifugal force requires that the string be held or the ball will fly off. If a long string is used and is slowly let out, the circle gets bigger and bigger. When gas in a compressor is forced to move in a circle, centrifugal force causes it to move away from the center of the circle at high speed.
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The figure shows the gas flow in a basic single-stage centrifugal compressor. The components of a gas compressor include: eye impeller volute
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Compression Ratio
The figure shows the pressure rise across the compressor. The discharge pressure is equal to the suction pressure plus the pressure rise across the compressor stage. If the suction pressure is increased, the discharge pressure also increases. The ratio of the discharge pressure to the suction pressure is the compression ratio. (The discharge pressure divided by the suction pressure).
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Compressor Drivers
The compressor requires a driver to spin the impeller. The driver can be a gas turbine, steam turbine, gas or diesel engine, or an electric motor. The figure shows a typical gas turbine-driven compressor set. The next section of this lesson explains multistage centrifugal compressor operation.
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Compressor Operation
As mentioned previously, the discharge pressure is equal to the suction pressure plus the pressure increase across the compressor stage. The pressure can be increased significantly if the discharge from one compressor is fed to the inlet of another compressor. The discharge pressure of the second stage equals the suction pressure of the first stage plus the pressure rise across both stages. This is an example of tandem compressors.
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Compressor Operation
Multistage compressors use multiple impellers to achieve a greater pressure increase than is possible using a single impeller. A four-stage centrifugal compressor is shown in the figure. This compressor has four impellers. Each impeller in the compressor is known as a compression stage. The impellers are separated by diaphragms. Diaphragms direct the flow from the outlet of the impeller to the eye of the next impeller.
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Compressor Casing
The purpose of a compressor casing is to house the internal parts, hold the pressure created by the impeller, and direct the flow toward the discharge. The figure shows a single-stage compressor. The rotating impeller accelerates the gas, which is then directed to the gas outlet nozzle.
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One advantage of a vertically split casing is that the seal formed by the end cover and casing is not subject to high pressure. Therefore, vertically split casings are used for high pressure applications. Another advantage of a vertically split casing is that it can withstand higher temperatures. The casing expands uniformly when it is exposed to the heat of compression, which reduces the stress on the case.
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Impellers
The purpose of impellers is to increase the velocity of the incoming gas, which is then converted into an increase in pressure and temperature. This increase in velocity occurs as the impeller rotates. The gas enters the center of the impeller, known as the eye. It is accelerated outward and collected in the volute. The pressure increase results from decreasing the volume of the gas.
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Impeller Designs
Impellers are classified by their design and manufacturing method. Impellers are open, semi-closed, or closed. Some types of impellers are shown in the figure. Impellers are dynamically spin balanced to reduce vibration. Balancing RPM varies with the size of the impeller.
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Sleeves are fitted onto the shaft. Impellers are attached to the sleeves to prevent wear to the shaft. This arrangement also allows removal of the impeller without damaging the shaft.
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Mounting Methods
Various methods are used to attach impellers to the sleeves. One method uses a key that prevents the impeller from turning independently of the shaft. Another method is called shrink fitting. With this method, the impeller is gradually heated and allowed to expand. The impeller is then slipped over the sleeve on the shaft and allowed to cool. Once cool, it contracts and forms a tight friction fit onto the sleeve. This same procedure is used for fitting the sleeves to the shaft.
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Rotor Thrust
Compressors increase the pressure of the gas. As a result, the outlet pressure of each stage is higher than the inlet pressure. These forces produce a thrust on the rotor. The resulting force tends to move the rotor toward the lower suction.
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Balancing Drum
A balancing drum is used to compensate for the thrust. A balancing drum is a solid metal cylinder with a labyrinth seal that is attached to the rotor shaft behind the last impeller. High pressure discharge gas exists on a very small area on one side of the drum. Suction pressure is piped to the full face area on the other side. This arrangement produces a counteracting force that reduces the total thrust.
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Load Bearings
Two types of bearings are used in compressors: load and thrust bearings. Load bearings, also called main or journal bearings, support the weight of the rotor and prevent radial movement. The load bearings have no rotating elements. The lubrication system provides a film of oil between the bearing and the shaft. This oil film prevents metal-to-metal contact and reduces wear.
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Thrust Bearings
Thrust bearings prevent axial movement of the shaft caused by thrust forces. A thrust collar is fitted to the shaft and rotates with the shaft. The thrust bearing is stationary with the casing. Pads tilt on the leveling plates. The leveling plates tilt-a result of lube oil hydraulic forces caused by aligning the pads with the thrust collar pad. The plates ensure that every shoe carries an equal load.
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Seals
Seals prevent most of the gas from leaking into the atmosphere and leaking between stages. The types of seals discussed in this module include the following: labyrinth segmented ring mechanical liquid film (Contd.)
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The simplest type of seal is the labyrinth seal. The basic labyrinth seal has teeth machined into a metal ring attached to the casing. The labyrinth seal can also be an interlocking seal with teeth machined into the shaft and into the ring as shown in the figure.
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Mechanical Seals
Mechanical seals rely on contact to provide sealing. One element of the seal is stationary, (stationary face) and the other moves with the rotor (rotating face). To reduce wear, a carbon ring is placed between the two metal surfaces. Lubrication is provided to reduce the friction.
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Guide Vanes
The purpose of guide vanes is to re-direct the flow of gas entering the compressor and through the compressor. An example of an adjustable inlet guide vane is shown in the figure. Inlet guide vanes direct the incoming gas in the desired direction of flow. The guide vanes for interstage impellers are not adjustable and are built into the diaphragm. Interstage guide vanes direct the flow of gas into the next impeller eye.
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Multi-Stage Compressor
A multi-stage compressor has two or more impellers on a single shaft. The shaft includes sleeves, impellers, balance drum, etc., and is called a rotor. These are the parts that rotate inside the casing. The figure shows a four-stage and a two-stage compressor. The stage components permit easy changing of parts. Stages can be removed or changed to meet changing operating requirements. Impeller rotation and centrifugal forces maintain the gas flow through the compressor.
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Compressor Surge
A condition called surge occurs when the flow of gas being discharged is less than the gas flowing into the suction. This condition causes areas of high pressure in the compressor where the gas flow stops. Severe damage can occur if this condition is allowed to continue.
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Diaphragms
The impellers on the rotor shaft are separated by diaphragms. Diaphragms divide the individual stages in a multistage compressor. Diaphragms convert velocity to pressure and are sometimes referred to as diffusers. Additionally, diaphragms redirect the gas flow evenly into the following impeller suction eye. Couplings are the last of the compressor components to be discussed.
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Couplings: Purpose
The purpose of couplings is to connect the driver to the compressor. Couplings are also used to connect gearboxes to the driver and to the compressor. Couplings provide a flexible connection to reduce compressor and driver vibration and wear.
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Couplings: Types
Three types of couplings are discussed in this section: spring grid coupling gear coupling flexible disc coupling
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Primary Purpose
The primary purpose of the compressor lube oil system is to reduce friction between moving parts. It does this by providing a film of oil between the moving parts. As long as the oil film is unbroken, any friction in the compressor is fluid friction instead of metal-to-metal friction. For example, oil pressure lifts the journal of a shaft off the bearing on which it is resting. As the shaft rotates, a layer of oil prevents the journal from touching the bearing.
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Reservoir
The purpose of the lube oil reservoir is to store lube oil and provide a reliable supply of lube oil to the lube oil pumps.
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Oil Coolers
The purpose of oil coolers is to remove heat passed to the lube oil from the compressor. The oil carries heat away from the compressor. The heat is removed from the oil when the oil is routed to the oil cooler. Because heat can cause decomposition of the oil, oil temperatures must be carefully controlled by automatic temperature regulators. Two coolers are generally provided so that maintenance can be done on one while the other is in service.
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Oil Filters
The purpose of oil filters is to remove particles that are suspended in the oil. As the oil circulates through the compressor, it collects foreign matter and carries it away with the oil that is returned to the lube oil reservoir. Any foreign matter in the oil is removed by the filtration systems so only clean oil is circulated to the compressor.
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Control System
The last area of the lube oil system is the control system. This system is discussed in greater detail in the next lesson. The lube oil control system has various sensors that provide shutdown or alarms if the system is operating outside predetermined parameters. The figure shows some of these sensors, including a low pressure switch, differential pressure across the filters, lube oil temperature, pressure switches, and lube oil reservoir level. The seal oil system is discussed next.
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A method used to ensure a higher seal oil pressure during an emergency shutdown is the head tank. The head tank is pressurized by reference pressure during normal operation. The head tank also contains seal oil at a certain level. This provides a liquid head and reference gas pressure.
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Manual Control
Manual control is the simplest level of control. Manual control depends on the actions of the operator. In this level of control the operator: sets valve positions starts and stops pumps makes all adjustments to the process The next level of control is sequence control.
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Sequence Control
Sequence control uses an automated system and operating instructions. The instructions are listed in the order required to perform a certain task to reach a desired result. The sequence may begin with the operator pushing a button in a remotely located control room. ( Contd.)
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Decision-Making Control
Decision-making control (PLC) adjusts the process and makes decisions based on compressor performance feedback. Examples of this level of control are automatic start-up and shutdown of compressors based on header pressure. ( Contd. )
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Optimizing Control
Optimizing control is the most complex control. This control system measures the process performance and makes adjustments to reach an optimal level. Optimizing control measures changes in process variables, predicts the resulting changes to the process, and adjusts the process to reach a predetermined level of performance. (Contd.)
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Optimizing devices are the most complex devices in a control system. Optimizing systems can look at one variable or can be connected to a computer-based system that controls the entire process. The programmable logic computer (PLC) is an optimizing device. Compressor capacity control is discussed next.
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The left side of the graph shows the surge line. Compressor surge occurs when there is an insufficient flow of gas through the compressor for a given differential pressure or compression ratio. The compressor will be damaged if it continuously operates in the surge region.
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The operating curves show compressor capacity and compression ratio at different compressor speeds. Capacity varies with compressor discharge pressure at a constant suction pressure. Compression ratio is used to control compressor capacity because it is related to both suction pressure and discharge pressure.
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Compressor surge occurs when there is an insufficient flow of gas through the compressor for a given compression ratio.
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The diagram on the following page shows a complete fuel gas control system with the main components highlighted. Each of the highlighted components and its operation are discussed in the following pages.
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Strainer
The purpose of the strainer is to remove foreign particles from the fuel gas before it enters the stop/speed ratio valve assembly. A blowdown connection on the bottom of the strainer body is used for periodic cleaning of the strainer screen. The next fuel gas control system component discussed is the supply pressure switch.
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UCUF
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UCUF
The stop/speed ratio valve has two functions: a stop valve gas pressure regulation
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UCUF
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UCUF
When control oil pressure is low, a spring moves an internal spool to the "dump" position. When hydraulic pressure is removed, a closing spring on the stop/speed ratio valve plug closes the valve. Fuel gas flow to the gas control valve and gas turbine is stopped.
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