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ABCD 2 x KA13E2-2 DP SF
PV 2005-010 6.1 Gas Turbine and Auxiliaries
Figure 6.1-1 Gas turbine block during assembly (turbine casing not yet installed)
Figure 6.1-2 View of the gas turbine block with exhaust diffuser and foundation
Main Features
● Compact design: The turbine, the compressor, and the combustor together with the burners are
supplied as fully assembled units.
● Thermal and acoustic insulation of the thermal block
● A single shaft shared by the turbine and the compressor, made up of several forgings welded
together
● Simple suspension in two journal bearings and one thrust bearing, none of which is located in the
hot zone
● Cast outer casing of the turbine and the compressor is split at the level of the axis, providing full
access to both parts of the machine.
● The following can be done without requiring opening of the turbine:
○ inspection, repair, and replacement of the bearings
○ inspection and replacement of individual burners
○ endoscope inspection of compressor blading
○ inspection of the first stage in the compressor and the last stage in the turbine
○ inspection of the inner combustor and the first turbine stage through manhole in the turbine
casing
● An effective cooling system for all parts in the hot gas path (vanes, blades, vane carrier, shaft)
ensures that temperatures will remain within permissible limits and makes elevated process
temperatures possible
● Internal air-cooling of the first two rows of turbine vanes and the first three rows of turbine blades
● The turbine casing can be opened separately if required
● Simple and effective convection cooling of the rotor and the vane carrier using air from the
discharge end of the compressor
● Single annular combustor design, at present the largest of its type
● Uniform temperature distribution before the turbine resulting from the annular combustor
● 72 EV burners, arranged off-set in pairs
● The single annular combustor and the arrangement of the burners produce a very thorough
mixing in the hot gas. This means:
○ a uniform temperature distribution in the hot gas
○ full combustion
● Short flames, resulting from the EV burners
● Further developed 2nd generation of the "lean premix" technology with which the best emission
levels so far anywhere in the world have been attained
● Simple, compact burner design
● Good flame stability
● No flashback problems
● Combustor suitable for
○ liquid fuels
○ natural gas
● Electronic flame monitoring
Description
The gas turbine block consists of the turbine and the compressor. The annular combustor is installed
between these units. The main parts are (Figure 6.1-3):
● The rotor (1), with the turbine blades (5) and the compressor blades (6), supported and guided in
two journal bearings (2, 3) and one thrust bearing (4)
● The compressor casing and the turbine casing (7-9) which also surrounds the annular combustor
(10)
● The variable compressor inlet guide vanes (12)
● The compressor inlet (11)
● The compressor vanes (14), installed in the compressor casing and the compressor vane carrier
(13)
● The compressor diffuser (15)
● The turbine vane carrier (16) and turbine vanes (17)
● The exhaust casing (18)
● The blow-off system, with the blow-off valves of the first two stages (19) installed under the blow-
off hood (20) (the valve for the third stage is mounted at the side and blows off into the exhaust
duct)
● The supports on the turbine end (21) and the compressor end (22).
The rotor, welded together from several forgings, holds the blades of the turbine (5 stages) and the
compressor (21 stages). The turbine blades are fixed in position radially in "pine-tree" slots and are
also secured axially. In the front stages, some of them - depending on the materials used - are coated
(Refer also to the sub-section, "Vanes"). The compressor blades are mounted together with spacers
in circumferential T-slots. The blades in the first five stages of the compressor are coated to protect
them against corrosion and erosion.
In the turbine zone, the shaft is covered with heat shield segments to protect it against the severe
thermal stressing from the hot gas. Air taken from the discharge end of the compressor provides
additional cooling for these segments. This air is also used to cool the first three rows of turbine
blades (refer to the Chapter, Section "Cooling and Sealing Air Systems," for details). These actions
make it possible to attain a higher process temperature, thereby increasing the power output and
improving the efficiency of the unit.
Bearings
The rotor turns in two journal bearings (2, 3) mounted in their own casings, one at the compressor
inlet (11) and the other in the exhaust casing (18). The axial position of the entire rotor train (including
the generator) is defined by a friction thrust bearing (4) that is also located in the compressor inlet.
The support and slide surfaces are made of babbitt metal. All bearings are lubricated and cooled with
pressurised oil supplied from a special system (refer to the Chapter Lube and Power Oil System). The
temperatures of the bearing metals and the returning oil are monitored by built-in thermocouples.
Maintenance can be carried out on all friction bearings without requiring the opening of the turbine or
the compressor casings.
The turbine vane carrier is, like the shaft in this zone, covered with heat shield segments to protect it
against the effects of the very high temperatures resulting from the hot gas. In addition, the vane
carrier has intensive counter-flow cooling using air taken from the end of the compressor. Following
this use, the air then flows to the second row turbine vanes to cool them from the inside. The vanes of
the first stage are supplied directly with air taken from the end of the compressor.
Some of the vanes of the front stage in the turbine -depending on the materials used- are also coated
to protect them against oxidation and corrosion.
Main Features
● Increases overall efficiency of combined-cycle plants in the gas turboset's part-load range
● Automatic adjustment of the inlet guide vanes while the gas turbine is in operation via a control
circuit (control parameters = optimum part-load efficiency of the combined-cycle unit and limit
imposed by the maximum permissible temperature of the exhaust gas)
● Adjustment of the vanes in the guide vanes via an adjustment ring with a rotating suspension; the
ring itself is driven by a hydraulic linear drive
● Optimum adjustment of emission levels of noxious components in the part-load range
6.1.3 Combustor
Description
The main parts of the combustor are:
● Front segment and the support structure
● Heat shield segment and the support structure
● EV burners
● Transition piece to the turbine
● Flame monitors
● Igniter
● Annular casing
The combustor is placed in a ring within the turbine casing, between the compressor and the turbine
(refer to Figure 6.1-8). It consists of a primary zone, in which the actual combustion takes place, and a
secondary zone, which sends the hot gas on to the turbine with very slight losses (Figure 6.1-10).
The primary zone is formed by the front segments (1) with the EV burners (2) inserted into them and
the heat shield segments (3) attached above and below them. These parts are fixed in position by a
support structure (4), which, in turn, provides the connection to the turbine casing.
The secondary zone is formed of high-temperature resistant plates.
A casing (6,7) completely encloses the combustor in order to direct cooling air withdrawn from the end
of the compressor past the outside of the combustor in counter-flow cooling. In the primary zone, it
also accommodates the EV burners.
After the compressor air (A) flows through the compressor diffuser, it is deflected by turning vanes
into the surrounding chamber of the turbine casing. In so doing, it not only provides counter-flow
cooling for the combustor, but also cools the turbine vane carrier. The cover plate on the burner end
of the combustor (8) has holes through which the air from the end of the compressor can reach the
EV burners.
Figure 6.1-8 shows how these burners are arranged in the combustor. Neighbouring pairs are in each
case slightly offset in their radius, producing effectively four rows of burners. The burners are
mounted on the casing. They are supplied with fuel through ring-shaped lines attached on the outside.
Later Sections explain how the systems involved function.
The annular arrangement of the combustor makes possible a uniform and low-loss flow to the turbine
because the hot gas path can be kept quite short. In addition, the thorough mixing results in an even
temperature profile and a complete combustion.
During part-load operation, only every 4th burner is switched off so that the advantageous temperature
profile can be maintained even at low loads.
Two electrically activated ignition torches supplied from a gas system of their own are installed for
ignition of the burner flames. The flame then spreads from burner to burner without requiring further
intervention as soon as those burners are supplied with fuel.
The combustion process is monitored by three flame monitors, which are evaluated in 2 of 3-circuit.
The surrounding turbine casing is split horizontally in order to provide easy access to the combustor
for purposes of maintenance. For a fast access, a manhole is attached.
EV Burners
The EV Burner (Figure 6.1-9) is a premixing burner of a simple design based on our long years of
experience in developing and operating low NOx premixing burners and on investigations conducted
in our research centre of the scientific principles involved in the behaviour of strongly swirled flows.
The EV burner consists of a hollow cone (3) split axially, with its halves displaced cross-wise from one
another (refer to the cross-section in Figure 6.1-10). The combustion air flows into the combustion
zone through the slots that result.
The fuel gas flows through two gas channels (4), enters into the burner through a row of holes (1) at
the outlet of the burner, and mixes there with the air.
The burner geometry has been optimised so as to produce a strongly swirled flow with a back-flow
zone freely stabilised within the combustion zone. Only in this zone the flow velocities are slow
enough to allow the ignition of the fuel/air mixture, which has, in the meanwhile, become fully
homogeneous. The described flow and the lean mixture of the air and fuel produce low flame
temperatures, which result in the low emission levels attained.
If oil operation is offered during fuel oil operation, the liquid fuel is sprayed in through an atomiser
nozzle (2) integrated into the burner head. Additional water is mixed into the oil in order to meet
prescribed emission levels.
Figure 6.1-11 Fuel gas system (fuel gas flowmeter and fuel gas filter not shown)
Main Features
● Both the main gas shut-off valve and the gas relief valve are equipped with both motor and
manual drives.
● The trip valve and the gas-tight control valves are equipped with servomotors
● Control system as part of the control valve block is fully assembled, cabled, and tested in the
workshop
● Separate valves for controlling the gas flow and for trip
● Valves equipped with metal seals
● System de-pressurised when the gas turboset is at standstill
● EV Burners supplied with gas via a system of ring and stub-line pipes outside the combustor
● Monitoring of all critical parts of the system by the fire and explosion protection system.
Main Features
● Turbine flow meter with compensation for pressure and temperature
● Conversion of measured data into electrical signals
● Totalisation with the computer
● Electrical signals for use with process computer and recorder
● Transmittal of the signals computed locally to the control room
● Connections for possible annunciation, recording, and processing instruments
Description
The turbine gas flow meter is installed upstream of the main gas shut-off valve. Flow meters, pressure
and temperature transmitters are mounted directly on the metering tube. The pressure and
temperature values are converted into electrical signals and sent directly to a computer (flow
calculator) in a local cabinet. Together with the impulses (speed) from the gas metering wheel the
computer calculates the gas flow and displays it in the local cabinet.
Figure 6.1-12 Fuel oil system (Fuel Oil Block is part of the Combined Fuel Oil / NOx Water Block)
Main Features
● Trip valve, the three control valves and the drainage valve have hydraulic drives
● The three drainage valves are activated pneumatically
● The trip valve and the control, pilot, and blow-out valves have been incorporated into the control
valve block
● The pump, filter, and meter are mounted on the fuel oil block. This block is supplied completely
pre-assembled, including piping and cables, and tested
● The Combined Fuel Oil / NOx Water Block is located outdoors and suitable for any climate
● The EV burners are supplied with fuel oil group-by-group via three supply lines
● Monitoring of all critical parts of the system by the fire and explosion protection system.
● The pressure limiting valves protect the system from over-pressure due to thermal expansion
while at standstill.
● The measurement of differential pressure across the filter sets off an alarm in the control room is
the difference in pressure exceeds the permissible limit (excessive fouling).
● The measurement of pressure before the fuel oil pump prevents a start-up of the gas turboset if
there is not sufficient pressure present.
● The measurement of pressure after the fuel oil pump initiates an emergency trip if there is not
sufficient pressure present.
● If the temperature drops below the minimum level acceptable (the viscosity of the fuel becomes
too high), the measurement of temperature after the fuel oil pump sets off an alarm in the control
room. If the fuel in the tank rises above the maximum level permissible, an alarm is set off. Then,
if the fuel level continues to rise, the second measurement of level built in initiates an emergency
trip of the gas turboset
● The fire and explosion protection system monitors all endangered parts of the liquid fuel system.
Main Features
● Increases the availability of the gas turboset
● Automatic switch-over from fuel gas to fuel oil without interruption in operation if the gas supply
should fail
● Manual initiation of the switch-over from fuel oil to fuel gas
Description
Operation on Gas
The section, "Fuel Gas System," includes the procedures for operation, supply, and control on gas.
switch-over program proceeds. The oil trip valve and control valves open, enabling the fuel oil to flow
to the EV Burners and support the combustion. Simultaneously with the opening of the control valve
for fuel oil, the fuel gas supply is throttled down by the corresponding gas control valves. The process
has been completed when only fuel oil is flowing into the combustor, when the supply of gas has been
broken off completely, and when the fuel gas system has been de-pressurised.
Should the gas turbine load prior to switchover have been in the range of 35% to 70% load, the fuel
oil flow is increased until the load prior to initiation of switch-over is reached.
Note:
This design is based on the assumption that gas is normally burned as the main fuel and the oil
serves as a standby fuel. For that reason, a fully automatic switch-over from gas to oil is sufficient for
normal operation.
Main Features
● Standard system separate from the main fuel system
● Supplied from commercially available propane cylinders
● Automatic switch-over to the standby cylinder during normal operation
Main Features
● Control systems make it possible to operate the gas turboset properly and at the best possible
efficiency
● The hydraulic protection system protects the gas turboset, should the control systems fail
● The control system forms the link between the turbine controls and the machine.
Protection Systems
The protection systems protect the gas turboset from serious damage should the control systems fail.
The protection system is directed by a central set of valves (46) connected to the fittings involved via
power oil lines (45). (The NOx water injection system (C) has not been shown completely: it is
structured like the fuel oil system and has likewise been integrated into the protection system.)
The control and protection systems have been designed so that a collapse of pressure in the
hydraulic/pneumatic piping system causes an immediate return to a safe setting of important system
components supplied from that piping system (e.g., opening of the blow-off valves). This is in every
instance checked by means of limit switches. The electrical components of the control and protection
systems are de-energised while the gas turbine is in normal operation (open-circuit operation). The
only exceptions to this rule are the "fire protection valves" (which have not, however, been shown on
the schematic).
Fuel Control
Basically, there are two modes of gas turboset control:
● Frequency/power control
● Temperature control (based on the calculated temperature of the hot gas at the inlet to the
turbine).
The fuel control and protection system has been designed for fuel oil and fuel gas (dual fuel)
operation
Protection Systems
The protection systems have several functions to perform:
● Providing alarms
● Initiating protective load shedding
● Initiating trip.
● The protection systems include:
● Electrical and electronic monitoring and protection:
○ exhaust gas temperature after the turbine (5), including calculation of the turbine inlet
temperature (6)
○ electronic speed monitoring
○ an electro-hydraulic trip unit in 2-of-3 circuitry (46).
● Mechanical/hydraulic monitoring and protection:
○ the power oil system for initiating trips (45)
○ quick-action relief valves for the control pressure and the valve for the NOx water injection
system which has not been shown)
○ the manual trip (48).
Note: The description is made for a dual fuel machine. For a single fuel machine only the appropriate
part is applicable.
8 Generator non-drive end bearing 32 Lube oil drain sight glass 57 Emergency lube oil pump
section 33 Lube oil return 58 Return flow orifice
9 Generator auxiliary bearing 34 Power oil pump for rotor barring device 59 Non-return valve
10 Main lube oil pump 2 35 Manual pump for rotor barring device 60 Power oil pump
11 Main lube oil pump 1 36 Non-return valve 61 Shut-off valve
12 Shut-off valve 37 Pressure limiting valve 62 Non-return valve
13 Shut-off valve 38 Control valve for rotor barring device 63 Pressure limiting valve
14 Pressure accumulator 39 Power oil system for rotor barring device 64 Strainer
15 Orifice 40 Hydraulic rotor barring device 65 Power oil system
16 Temperature control valve 41 Rotor barring device lifting cylinder 66 Auxiliaries block lube oil heater
17 Lube oil cooler 42 Air intake filter 67 Tank
18 Twin lube oil filter 43 Ventilation orifice 68 Drain cock
20 Lube oil distribution system 44 Flame arrestor 69 Auxiliaries block
21 Lube oil supply orifice 45 Deaeration flap valve A Cooling water inlet
22 Lube oil supply orifice 46 Oil vapour fan B Cooling water outlet
23 Lube oil supply orifice 47 Temperature control valve C Power oil system
24 Lube oil supply orifice 48 Jacking oil pump
Main Features
● Same oil used for lube oil, power oil, jacking oil, the hydraulic-pneumatic control and protection
systems, and the hydraulic rotor barring device
● Two main AC lube oil pumps (10 and 11), each with a 100% capacity, with an automatic switch-
over if the oil pressure is too low
● DC power supply for the emergency lube oil pump (57), the power oil pump (32) for the hydraulic
rotor barring device, and the jacking oil pumps (48 and 49)
● Twin lube oil filter (18), with capability for switch-over during operation
● Temperature control valve (16) to ensure a uniform lube oil temperature at the inlet to the filter
● A separate power oil system for the hydraulic rotor barring device (40), with a DC pump (34) and a
manual pump (35) for emergencies
● A power oil system for the fuel control valves with built-in electro-hydraulic converters
● Solenoid safety valves for releasing pressure in case of emergency
● A very compact system with short piping paths, attained by central location of tanks, pumps,
coolers, filters, etc.
Power Oil Forwarding (39) for the Hydraulic Rotor Barring Device
This subsystem supplies the oil required for rotor barring to the lifting cylinder (41) of the hydraulic
rotor barring device (40).
The DC pump unit (34) pumps the oil to the control valve (38) of the power oil system for the hydraulic
rotor barring device. The valve (37) maintains a constant pressure in the system.
The manual power oil pump (35) can be used to carry out rotor barring in case of a DC power failure.
Main Features
● Cooling and sealing air is withdrawn from the compressor
● Short piping paths and the use of only a few fittings produce a compact, reliable system
● With this effective cooling system, material temperatures in hot gas path components remain
within permissible limits even at elevated gas turbine inlet temperatures
● The cooling air withdrawn from the compressor is returned to the process (except for sealing air
for the blow-off valves and for any water and steam injection valves provided).
Cooling and Sealing Air System for the Exhaust End of the Turbine (A)
The cooling air is withdrawn behind the fourth stage of the compressor (2) (first blow-off point), and is
directed to the turbine shaft bearing section (13) on the exhaust end. It cools the face of the shaft, at
the same time blocking out a back-flow of exhausts into the rotor cooling air system.
Cooling Air System for the Turbine Vane Carrier and the Turbine Vanes (B)
The air for cooling the vane carrier and the first two rows of turbine vanes is withdrawn downstream
from the compressor and directed to the turbine vane carrier. It cools the vane carrier in a flow
counter to that of the hot gas (15), starting from the low pressure section (back stages) and going as
far as the second stage in the vane carrier. The first row vanes in the turbine are supplied directly with
air from the discharge end of the compressor via a separate supply line (16).
During operation the vane carrier is continually surrounded by an air flow from the discharge end of
the compressor.
Cooling and Sealing Air System for the Turbine Rotor (B and D)
A large portion of the cooling air is branched off downstream from the compressor and directed into
the ring-shaped chamber in the shaft enclosure between the outlet from the compressor and the inlet
to the turbine. From that point, the air is supplied to several sections:
● On its path from the ring-shaped chamber to the face at the turbine end of the rotor, the rotor
cooling air flows through a swirl cascade that generates the tangential speed component required
to produce a relatively axial approach flow to the rotor.
● The cooling air flows into the holes in the face of the rotor at the turbine inlet. From this point,
some of it is directed into the blades in the first three stages (18), while the remainder cools the
heat shield segments on the surface of the rotor and enters into the hot gas flow as leakage (17)
between the segments.
● A small portion of the air from the discharge end of the compressor is withdrawn at the face of the
rotor and is directed across the shaft seal on the shaft drum, without being re-cooled, as sealing
air for the face on the turbine end (13).
The rotor is also cooled in the area of the fourth and fifth stages of the turbine. For this purpose, air
taken from the third compressor blow-off chamber is directed across a filter (10) and a condensate
trap (9) into the exhaust end bearing casing. From there, it passes through a hole bored in the shaft to
enter the pocket within the shaft (14). The cooling air flows through ducts to reach the blade roots and
the heat shields of the fourth and fifth stages. It cools these components and then comes out to mix
with the hot gas.
To Blow-off valve
exhaust
system
Main Features
● Three blow-off points with a total of four valves (two in stage 1, one in stages 2, and one in stage
3).
● The blow-off valves for stages 1 and 2 are mounted directly on the outer housing of the
compressor.
● The blow-off valve for stage 3 is located under the outer housing of the compressor and
connected to the exhaust duct via a blow-off air duct.
● Sound from the top-mounted valves is damped by the blow-off hood and silencer.
● Control air supplied by the gas turbine compressor and in shutdown mode by the wash cart
compressor.
Principle of Operation
There are five basic operating conditions:
● Standstill
● Start-up
● Operation
● Shut-down
● Trip
Standstill
Blow-off valves are in open position. For functional checks, or for compressor washing purposes they
can be operated by connecting a wash cart compressor.
Start-Up
Blow-off remain open when the gas turbine is started up. The valves close, as soon as the gas turbine
has reached 90 % of its nominal speed. Control valves are moved in that way that the safety relays
will open passage for control air which in turn will close the blow-off valves. Stage 3 closing will follow
at 95 % of its nominal speed.
The control air withdrawn from the compressor is cooled in a cooler and cleaned in filters, switch over
during operation can be accomplished. The pressure is reduced in valves.
Operation
Blow-off valves are closed.
Shut-Down
After de-loading to idling the control valves move. Oil pressure is dropping and the safety relays
change position due to their spring force. Control air will escape and as a result blow-off valves will
open by spring force.
Trip
A trip will force the power oil system to collapse immediately. The safety relays change position to
allow control air to escape. The blow-off valves will open by spring force.
Main Features
● Improved efficiency and power output resulting from periodic washing of the compressor.
● Piping permanently mounted from the stationary wash skid to the gas turboset
● Complete wash skid, equipped with tank for cleaning fluid, pump, hoses and cables.
The System
The gas turbine is shut down and cooled off at least to a pre-set limit.
The wash program is selected and the compressor cleaning progresses in several phases. The
cleaning fluid, mixed in the wash skid tank, is sprayed into the compressor through nozzles radially
installed around the rotor axis.
After the cleaning fluid has been allowed to soak into the deposits for a prescribed time, the
compressor is flushed in several stages with water and blown dry subsequently. The wash and rinse
water is removed through manually operated water drain cocks. The gas turboset can be put back
into operation immediately once the wash program has been completed.
B
1 3
2 5
4
Main Features
● Improved efficiency and power output resulting from periodic washing of the compressor.
● Spray nozzles installed in the intake section of the compressor
Main Features
● Carries off wash water from the air intake system, the compressor, annular combustor and the
equalising section.
● Carries off liquid fuel from the annular combustor after a starting failure occurred.
water is collected in a drain pit formed by the foundation. From here it may be pumped through an oil
separator either to the waste water system or to a waste oil barrel.
The water drain in the exhaust system downstream of the expansion joint and the NOx-water from the
control valve block are directly connected into the waste water system.
2 3
5 8
1
4
3
10 7 9 1
2
1
1
3 SM052
SM049
Main Features
● Filter specially developed for arid ambient conditions with severe dust loading, but also suitable
for low dust concentrations and arctic conditions
● Single-stage filter system with high dust-removal efficiency
● Modular filter with the filter elements in a horizontal or vertical arrangement (see figures above).
The modules are erected at an elevated level above the generator block.
● Large surface area and low passage velocity resulting from fold over of the filter medium
● Automatically controlled cleaning of filter elements during operation by means of a brief
compressed air jet in a reverse direction opposite the main flow
The System
The air drawn in flows from the outside to inside through the filter elements. Contaminants in the air
are entrapped by the folded high-efficiency filter media forming a dust cake.
Once cleaned, the air flows through the clean air ducts to the silencer, after which it passes through
intake elbow and intake manifold to the compressor.
The degree of fouling of the filter cartridges is monitored by measurement of the differential pressure.
The filter elements are cleaned automatically either after the differential pressure attains the pre-set
level or at fixed time intervals (at the choice of the customer).
2 3
3 SM052
The filter elements are cleaned in groups by jets of compressed air in counter-direction to the main
flow. These pulses free the dirt that accumulates on the filter cartridges.
The frequency and length of the pulses can be adjusted as required.
The oil free compressed air used for cleaning is either taken from a central compressed air system or
generated in an additional compressor (optional equipment).
The cleaning of the filter cartridges does not affect air intake because there is only a group of few
cartridges being blown out at any given time.
For effective cleaning of the filter elements, a pulse air pressure from 6 to 8 bars is required.
When the differential pressure over the filter elements exceeds the pre-set limit protective measures
are taken to protect the filter house.
SM268
Main Features
● Evaporative cooling media, cellulose or glassfibre
● Water sump tank with level control and centrifugal pump (flour level mounted)
● Water circulating system including stainless steel piping, valves and water tank
The System
The basic idea is the introduction of water into the air entering the gas turbine compressor and cooling
this air by enthalpy reduction through the requested evaporation energy of the water. This cooled air
results in a higher compressor intake mass flow due to a higher air density which finally results in a
higher power output and efficiency of the gas turbine.
The energy of the air is reduced proportionately to the amount of evaporation that takes place. The
type of evaporative cooler media used is a direct contact, irrigated media utilising crossfluted cellulose
or glassfibre blocs which are impregnated with insoluble anti-rot salts and rigidifying saturants.
Water enters the sump tank to a water supply located on the outer side of the tank and the water level
is controlled by a float switch.
Water is supplied to the distribution manifold by a pump located outside the cooler. The distribution
manifold is located directly above the evaporative cooler media.
The distribution manifold evenly wets the media by spraying water through small holes, spaced along
its length, onto a deflector shield. Only a small percentage of the water pumped to the media is
evaporated, the remainder is filtering through the media and back to the water tank. The pump
continually recirculates water to the media. Water amount to the evaporative cooler media is
regulated by a gate valve and can be monitored by a flow meter.
In order to prevent scale formation, a percentage of water must be discharged to the drain. This water
is referred to as “blowdown or bleed-off”. The exact amount will depend on conductivity of the water,
and the rate of evaporation.
The design system ensures a uniform airflow to prevent water carry-over with air velocity leaving the
media between 2.5 to 3.5 m/s. However, a water droplet eliminator is included downstream to ensure
no water re-entrainment into the airstream.
A failure of evaporative cooler during operation will also be indicated at the GT control room via a
common alarm signal.
Sensors: Temperature probe upstream and downstream of the cooler and conductivity measurement.
6 7 8 9 10 11 12 13
14
15
16
17
18
19 20
21
optional
22 23
24 25
27 28
26
29
31 32
30
33
34 35
36 37
40
38 39
Figure 6.1-25 Generator And Lube Oil Cooling System, Air Cooled
Legend
1 to 4 Generator cooler 21 Temperature control valve 31 Shut-off flap valve
5 Generator 22 Throttle and shut-off flap valve 32 Shut-off flap valve (optional)
6 to 13 Shut-off flap valves 23 Throttle and shut-off flap valve (optional) 33 Pressure limiting valve
14 Generator cooling water system 24 Non-return valve 34 Shut-off ball valves
15 Recooler (cooling capacity: 100%) 25 Non-return valve (optional) 35 Pressure accumulator
16 Throttle flap valve 26 Temperature control valve 36 to 39 : Shut-off ball valves
17 Shut-off ball valve 27 Circulating pump 40 Hand pump
Main Features
● Direct air re-cooling of the generator and lube oil cooling water
● Water/air recoolers installed outside the gas turbine building or enclosure
● A pressurised closed-circuit system with water or a mixture of water and glycol for cooling the
generator and the lube oil
● Regulation of the cooling water temperature by a temperature control valve (minimum
temperature limitation)
● Plate-type lube oil coolers integrated into the lube oil system
● Regulation of lube oil temperature in the lube oil circuit
● Modular design
The System
Circulating pump (27) forwards cooling water (or a mixture of water and glycol) through the closed
cooling circuit at a slight overpressure to the generator coolers (1) to (4), and the lube oil cooler (19).
The generator coolers (1 to 4) as well as the lube oil cooler (19) can be separated from the system by
closing the corresponding flap valves (6 to 13), (18), (20).
The cooling water flow to the generator and the lube oil cooler is adjusted by flap valves (16), (20),
(22) and (23). Additionally, the cooling water flow through each cooler can be adjusted by fixing the
flap valves (6 to 13) and (18) in a throttling position.
After passing the lube oil and generator coolers, the cooling water flows to the temperature control
valve (21). To maintain the cooling water temperature within a pre-defined range, the control valve
directs the flow, through water/air cooler (15) and/or its bypass. The AC fans cool the finned tubes of
the recooler with ambient air.
The filling unit with the hand pump (40) is used to fill or drain the intermediate circuit if there is no
central water supply system.
Legend
1 Diffuser 6 Not used 11 Transition
2 Not used 7 Duct supports 12 Platform (optional equipment)
3 Not used 8 Expansion joint 13 Silencer
4 Expansion joint 9 Support 14 Not used
5 Diverter casing 10 Stack 15 Blade
Main Features
● Stack height adjusted to fit overall layout of the gas turbine power plant
● Internally insulated stack and ducts
● Gas-tight connection between the exhaust diffuser and the exhaust duct
● Expansion joints to allow for free expansion
● Acoustic and thermal insulation of mineral wool over entire height of stack
● Diverter damper
● Multi-layer corrosion protection paint
The System
Gas turboset with a bypass stack and diverter damper.
Downstream from the gas turbine, the exhaust flows through the exhaust diffuser into the diverter
casing. Depending on the position of the diverter damper it is directed to the stack or through the heat
recovery steam generator (HRSG).