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Document No.
Revision
Date of issuance
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GTG (MS-5001-PA)
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AND GENERAL GUIDE LINES
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When the services before mentioned are available and the commissioning activities referred to all
systems involved in GTG operation are completed, the Operators may proceed with the initial start
activities.
17.2 PREPARATION FOR START-UP
17.2.1 General
The gas turbine MS5001PA is provided with automatic sequence for start-up and shutdown by
means of SPEEDTRONICTM Mark VI.
The aim of this paragraph is to briefly remind some of the activities involved in the initial start-up,
especially referring to all the preparation work to be carried out prior to initial operation.
Technical terms for distinguishing the different phases included inPreparation for start-up are:
Pre-commissioning:
Commissioning:
Systematic conformity checks, carried out on each item of equipment or component, visual
verification of the condition of equipment, the quality of the installation, compliance with project
drawings and specifications, manufacturers instruction, safety rules, codes, standards and good
construction practice.
Calibration of instruments
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Machinery alignments
Testing of cables and electric equipments (insulation resistance, continuity, etc), functional
Cleaning and flushing of the unit (air blowing, oil flushing), dry all equipment.
All initial fill of lubrication oil, grease, chemicals, etc. Commissioning of the units includes:
Dynamic tests: (electrical motors uncoupled runs, instrument loops tests, electrical breakers
Mechanical preparation: (running-in and on line tests for a significant period of the utilities or
17.2.2 Introduction
The scope of the preparatory works to get the GTG plant started is:
1)
Commissioning and put in service GTG Fire & Gas detection and protection System.
2)
Commissioning and put in service Fire & Gas Detection System for Control Cabin (at least), if
any.
3)
Commissioning and energize the MCC and all utilities needed for a normal operation of GTG,
such as:
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When the right pressure is restored permission to continue with starting sequence is given.
When the gas turbine reaches the OPERATING SPEED, at 95% of the rated speed, the AC
auxiliary lube oil pump will be manually stopped and the accessory gear driven main lube oil pump
guarantees the oil flow amount.
As long as the gas turbine is above the OPERATING SPEED, if the conditions LUBE OIL
HEADER PRESSURE LOW (MK VI command name 4QA) will be detected, the AC auxiliary oil
pump will be automatically started. If normal conditions are restored, the stand by pump can be
stopped manually from the HMI or from the MCC according to the duty/standby philosophy.
The lube oil header pressure low-level threshold [63QT-2A 63QT-2C]/[PT-12618-A/B/C], installed
on the Generator lube oil header, causes the DC emergency lube oil pump to start if lube oil header
pressure is lower than the shutdown level.
With such threshold, when the emergency pump comes in operation, the unit is in shutdown
condition.
Once the pump is started, it runs continuously for 15 minutes and then 30 seconds on, 3 minutes off
cycle is started for power supply batteries safeguarding until the end of cool down. The DC
emergency lube oil pump will be stopped as soon as the conditionLUBE OIL HEADER
PRESSURE NORMAL is detected [96QA-1 3]/ [PT-12618-A/B/C].
During normal GT operation, the operator is normally allowed to manually start and stop the standby
pump, unless it is prevented to run or required on by the control logic.
17.4 Hydraulic oil system
Valves position (opened/closed) for initial start-up and normal operation of the hydraulic system is
indicated in Schematic Piping Diagram.
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The Gas Turbine is equipped with one mechanical shaft-driven pump installed on the Accessory gear
box. Its purpose is to operate the axial compressor IGV nozzles and the GT gas valves. [SR V-1 and
GCV-1]/[FCV-12601 & FCV-12602].
The H.P oil pump is designed for continuous operation but is not operated after the gas turbine
package is shut down.
To operate the Hydraulic oil pump, the oil pressure shall be inside the operation limit; if the pressure
value is not OK (6500 kPaG min.) an alarm will occur. The maximal pressure admitted for the
hydraulic mechanical driven pump delivery is 9000 kPaG regulated by a overpressure valve [VR21]/ [PSV-12601]; and is also protected from overpressure by a pressure regulating valve [VPR3-1]/
[PCV-12610] inside the pump body that will be regulated at 8000 kPaG.
If the pressures decrease under the minimal pressure (6500 kPaG) during the Unit operation an
alarm is generated by a pressure switch [96HQ-1]/[PT-12614]
When the hydraulic oil pump driven by accessory gear box reaches the 1500 RPM it guarantees the
oil pressure and flow amount during gas turbine operation.
17.5 Lube oil mist separator
Valves position (opened/closed) for initial start-up and normal operation of oil vapor separator is
indicated in Schematic Piping Diagram.
Prior to starting the GT operator selectsAuto control in MCC for [9-CM-12605X] lube oil vapor
separator.
One of the two lube oil vapor separator fans [9-CM-12605X] (the selected one as main) will be
started at turbine start-up and will continue to operate up to the end of cool down sequence. The
stand-by one will be started, by intervention of differential pressure transmitters, in case of oil tank
pressure increasing over the rated limit. Set: Alarm 20 mm.H2O; Trip 50 mm.H2O.
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The fan will be started also in case of pressure detected in the lube oil tank after cool down end.
17.6 Fuel gas system (on base)
Prior to first gas-in, fuel gas system will be leak tested at normal operating pressure afterwards
followed by fuel gas system inerting using nitrogen (filling and purging until oxygen content at point
of supply to stop / ratio valve drops below 2%).
Required fuel gas supply pressure at point of supply to GTG must be between 1600 kPaG min. and
2400 kPaG max.
AFuel gas pressure low alarm is given in the Mark VI software by the [96FG-1]/ [PT-12602A/B/C] pressure transmitter, when gas pressure drops to 1400 kPaG.
Required fuel gas temperature for normal running at point of supply to GTG will be 28C above dew
point and in any case between 45C and 60C.
17.7 Cooling & sealing air system
The antisurge valves will be checked and will be open to be enable to start the Unit, the control of
opening of the valves will be verified by the signal transmitted by the positioning micro-switches
[33CB-1 and 33CB-2] sending a signal to the Control Panel.
Check the correct operation of the antisurge valves, before starting the turbine, using an external
source of air, to be able to open them by acting the relevant servovalve [20CB-1].
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The operator is normally allowed to manually start and stop the standby fan, unless it is prevented to
run or required on by the control logic.
The operator is allowed to initiate any time a duty/standby changeover: the selection is performed by
means of the MK VI <HMI> operator interface software pushbutton.
17.9 Starting system
A visual inspection of the turbine should be performed before attempting to operate the GTG.
Prior to starting the gas turbine, the operator will close the switch of [9-PD-12606X] starting motor
in MCC.
Before starting will be selected the mode of GTG operation putting the Main Selector in required
condition (CRANK, FIRE, MANUAL, AUTO, and RE-MOTE).
Will be checked the correct operation of the [33CS-1] (starting clutch limit switch).
17.10 GT Fire detection & fighting system
Valves position (opened/closed) and instruments condition for initial start-up and normal operation
of fire fighting system is indicated in Schematic Piping Diagram.
The two banks of CO2 bottles (main and spare) are operated by the Turbine Control System.
The condition ready to start will be given by the limit switches [33CP-1A/B] positioned on the
quick and slow discharge valves installed on the CO2 line to the turbine enclosure.
In case of fire the sensors installed on the accessory compartment [45FA-1/2] [45FT -14] fire
detectors; on the turbine compartment fire detectors and/or [45FT-5/6] heat detectors send fire
signals to UCP and this one generate a CO2 discharge command.
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There are in the system two discharge solenoid valves operating the different groups of CO2 bottles
(for quick discharge and for slow discharge). When the fire is detected the valves [45CR-1/2] in
bank A (main bank) e energized opening the quick discharge group and consequently also the slow
discharge flow.
When is detected the fire signal are activated two alarms signal on the acoustic enclosure, through
the horns [XA-12] as acoustic signal and through the flashing lights [XL-12] as a visual signal.
The UCP fire fighting system is provided with two Fire fighting auto-inhibit switch [33CP-1A and
33CP-2Ato inhibit the discharge phase of CO2 for permission to start-up. Every inhibit signals from
the fire fighting system send an alarm to the UCP inhibiting the turbine start-up.
The start-up of the turbine will be also inhibited when the signal System fault (66XX-A/B) send
an alarm to the UCP.
The Discharge inhibition on the fire fighting system is signaled by a green lamp, lighted with the
system in AUTO mode and with an amber light when the discharge is inhibited. But the inhibition is
actuated for CO2 discharge only, while the detection modules with the relevant indications are
operating.
17.11 Generator
Valves position (opened/closed) for initial start-up and normal operation of lube oil system of
Generator is indicated in Schematic Piping Diagram.
Prior to starting the gas turbine, the operator shall check the correct oil supply pressure to the
generator bearings by the pressure indicators on the oil header, on the bearings inlet piping DE and
NDE side respectively. Will be checked also the oil flowing through the discharge oil piping flow
gauges (FG12632X; FG12633X).
The operator will check on the vibration monitor, Generator section, and the correct readings of
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vibration sensors, the key-phasor values and the bearings temperature elements, to verify the correct
operation.
Will be checked also the stator winding cooling thermo elements readings for correct operation.
17.12 Load Gear Box
Valves position (opened/closed) for initial start-up and normal operation of lube oil system of Gear
Box is indicated in Schematic Piping Diagram.
Prior to starting the GTG, the operator shall check the correct oil supply pressure to the Gear Box
bearings by the pressure indicator on the oil header and the oil flowing through the bearings
discharge oil piping flow gauge (FG12631X).
Furthermore will be checked on the vibration monitor, gear box section, the correct axial positioning
of the shaft and the readings of vibration sensors and the bearings temperature elements, to verify the
correct operation.
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that it
has been refilled with recommended quality and quantity of lube oil. If lube oil flushing has been
conducted verify that all filters have been replaced and any blinds if used, removed.
5) Check operation of auxiliary and emergency equipment, such as lube oil pumps, etc. Check for
obvious leakage, abnormal vibration, noise, or over-heating.
6) Check lube oil piping for obvious leakage. Also using provided oil flow sights; check visually
that oil is flowing from the bearing drains. The turbine should not be started unless flow is visible at
each flow sight.
7) Check condition of all thermocouples and/or resistance temperature detectors. Reading should be
approximately ambient temperature.
8) Device requiring manual lubrication is to be properly serviced.
9) Check the Cooling and Sealing Air Piping against the assembly drawing and piping schematic,
that all orifice plates between flanges or in orifice unions are of designated size and in designated
positions.
10) At this time all enunciated ground faults should be cleared. It is recommended that units not be
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operated when a ground fault is indicated. Immediate action should be taken to locate all grounds
and correct the problems.
With turbine oil pumps running check the oil flushing through the generator bearings and the
3)
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Crank
1.
Listen for rubbing noises in the turbine compartment, load gear and generator.
2. A sound scope or some other listening type device is suggested. Shutdown and investigate if
unusual noise occurs.
3. Check for unusual vibration
4. Inspect for oil leakage.
Fire
1.
Check entire fuel system and the area immediately around the fuel nozzle for leaks. In
Monitor the turbine control panel readings for unusual exhaust thermocouple temperature,
wheel-space temperature, lube oil drain temperature, highest to lowest exhaust temperature spreads
and hot spots, combustion chamber burning hotter than all others.
3.
4.
if a noise persists.
2. Monitor lube oil tank, header, white metal bearing and bearing drain temperatures continually
during the starting period.
3. At this time a thorough vibration check is recommended, using portable vibration test equipment
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OFF
CRANK
FIRE
MANUAL
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General
The GT Unit Control Panel is equipped with two HMI: one (local) in the Main Sub Station Building,
for controlling purposes, and the other (remote) in the Central Control Room(CCR-I) for monitoring
purposes, as normal options.
Once the main HMI fails, the controlling functionality of the second HMI is enabled and the
operator can continue to control the unit.
Modes of operation and sequences
There are six operating modes varying from no start acceptance to full automatic start. Only one
mode can be active selecting one mode (position) of MASTER SELECTOR means disabling all the
other modes.
The mode selection can be performed at the local MKVI HMI (PC operator inter-face) and at the
operator back-up panel mounted in the front of the Mark VI panel. The back-up feature is required to
give the operator the ability to control the unit (basic function as START, STOP) in case of a failure
of the MKVI HMI or loss of customer UPS power supply.
Mode selection can be used to bring in some hold points in the start sequence and to monitor the
process at these stages.
a)
O f f Mode
When the OFF Mode is selected, the UCP does not accept the START command, and is thus not
possible to start-up the machine. All other functions remain active.
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Crank Mode
CRANK sequence may only be selected after the gas turbine has stopped rotating.
Starting the turbine with this selection is possible if the unit start permissive is satisfied.
Starting the turbine with this selection will bring the shaft up to crank/purge speed value of 20%
(14HM).
Sequence will precede changing Master Selector position to FIRE, MANUAL, AUTO, or REMOTE
position. The shaft will continue to rotate at 20% of speed value until the operator initiates a normal
STOP, changes the Master Selector position or a shutdown occurs. Gas turbine shaft can remain at
this speed indefinitely if the operator will not select another command.
For OFF-LINE WATER WASH the selection of CRANK mode is mandatory, and as long as the
wash cycle is enabled the CRANK mode will be locked.
c)
Fire Mode
This mode of operation shall primarily be used to verify that the GT start sequence functions
properly.
Once the start permissive are valid/healthy, the operator may initiate start.
The turbine will continue to run at warm-up speed, unless the operator selects another operation
mode or initiates a normal stop or shutdown.
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In the MANUAL Mode a start signal will result in an automatic start-up and loading to the minimum
operating speed, then the shaft speed is controlled by raise and lower commands on HMI.
e)
Auto Mode
In the AUTO Mode a start signal will result in an automatic start-up and loading to the selected
value, an external signal from DCS is taken as shaft speed set point.
f)
Remote Mode
In REMOTE Mode position, the set point of load may be varied from outside through the commands
from DCS. The increase and decrease variation speed of the turbine shaft depends on the value
imposed by the automatic ramp and can be modified through the Operator Interface.
Start-up sequence AUTO / REMOTE mode
AUTO or REMOTE Mode enables initiation of the complete start sequence, up to the pre-selected
speed of turbine shaft.
a)
No other modes selected and/or other sequences initiated and/or in progress (except lube oil
GT speed = 0 RPM
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Fuel gas vent valve 20VG-1 in correct position (check status of output relay)
All parameters that are monitored for alarm and trip purposes are in the healthy state for start-
up (lube oil tank has the correct oil level and temperature, etc.)
b)
When the Shut Down reset and Ready to start check condition as per (Control system
functional description) are satisfied, the message UNIT READY TO START will be shown on the
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The START command can be initiated by the software pushbutton on MK VI<HMI> and the
Start automatically the Gas Turbine Lube Oil auxiliary pump [9-PM-1 2604X]. When the lube
oil header pressure is restored, the lube oil system is considered ready for operation.
e)
f)
Start automatically the Gas Turbine main ventilation fan [9-CM-12608XA]. The compartment
is equipped with 2100% ventilation fans. Automatic start of standby fan for the GTG is initiated by
high temperature and/or high gas concentration and/or main fan failure.
g)
(theMASTER PROTECTIVE RELAY (4x) is still activated), the MK VI logic will give the
command to start the starting motor.
h)
i)
The turbine will accelerate up to crank speed (20% of shaft speed value 14HM).
j)
Start the turbine purge phase (approximately 2 minutes, to be configured in field) to purge the
turbine, combustion air inlet and exhaust systems, and wait for purge completion.
k)
Open the fuel gas vent valve [20VG-1] and when the fuel gas temperature reaches the set
m)
MKVI will check for excessive fuel flow, if that condition is detected a trip is initiated.
n)
Allow a maximum of 1 minute for light off; activate fail to ignite alarm if flame is not
p)
At the end of warm-up period (1 minute), the torque converter raises output torque unless Fire
mode is selected; in this case the turbine shaft will continue to rotate at warm-up, more than 20%
speed.
q)
The torque converter is accelerated and fuel is increased to reach the mini-mum operating
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speed; during the acceleration sequence, when the turbine shaft reaches the 60% speed (14HC), the
clutch will automatically disconnected. The starting system decelerating up to minimum speed, the
starting system is stopped five minutes later (cooling time).
r)
At 90% speed of the shaft (14HSX), minimum operative speed, the lube oil auxiliary pump [9-
PM-12604X] (4QA) will receive a command to stop. The generator excitation is enabled.
s)
When the turbine shaft reaches 95% of speed (14HS-1) will be closed the axial compressor
After completing the Start up sequence, are enabled the speed set-point variation and the
Activities on Generator
The following operating activities are only suggested.
Reached the complete sequence of the turbine shaft, and before synchronizing the Generator with the
network, it will be possible to perform the Generator checks, as follows:
a)
b)
c)
Check the unbalance protection increasing the stator current and noting the trip value.
e)
Check the rotor earth protection increasing the current excitation at the required value.
f)
g)
After the no load test check the Min. and Max. Voltage protections.
h)
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i)
j)
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- The synchronoscope 0,
- The differential voltage 0,
- The frequency at the coupling switches closing on an out of voltage network.
Synchronization sequences
At minimum operating speed excitation control will be enabled. The Mark VI checks the
synchronization permissive conditions and the speed reference is set at 100.3%. When 100.3% is
reached Unit ready to synchronize is displayed.
The operator has the opportunity to select in the Mark VI<HMI> Synchronization Mode Selector
the following mode: off, manual, automatic or dead bus.
a)
Off mode
Manual mode
The synchronization will be made in manual mode. The panel will send the raise/lower commands
signals to excitation panel for the voltage regulation. When the unit is synchronized, the operator
will close the breaker from the HMI.
c)
Auto mode
The Mark VI will adjust the speed and voltage, and will issue the command for breaker closure when
unit is synchronized.
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For this mode, the breaker is closed before to close contactor on ECP. This will avoid high inrush
current due to energization of transformer.
As soon as the breaker is closed, the closing command to excitation contactor on ECP is given and
the generator rise on voltage and energize transformers. Once the rated voltage is reached the UCP
can start to load the machine.
Load control
Droop or isochronous control is selected on HMI.
Droop mode
When the GTG unit is connected in parallel to the main grid, the system frequency is determinate by
the grid itself and is maintained constant. The excess of fuel flow does not result in speed variation,
but in augmentation of power ex-ported to the grid.
The operator can enter a certain MW value as a load control constant. When pre-selected load is
selected the unit will automatically load or unload till the required value.
The selected mode of control (spinning reserve, preselected) will be reset to manual control when the
operator uses the raise/lower commands on HMI or when the governor control is transferred from
droop to isochronous.
The VAR control is based upon the use of voltage raise and lower signals to ECP.
Isochronous
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The unit is controlled to maintain a constant speed, regardless of the grid load re-quest and
regardless of the supplier power. When the unit is in this mode, it is not possible to set a supplied
power set point.
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