Operation Maintenance Course C40 PDF [PDF]

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Solar Gas Turbine Centaur 40 Pertamina Brandan Operation and Maintenance Course



Yushup Armansyah INDOTURBINE Technical Service



Operation and Maintenance Class



Course Timings Morning 08:00 – 11.45 Lunch 11.45 – 13.30 Afternoon 13:30 - 15.00



INDOTURBINE



General Package Description



Objectives



• Purpose of the package • Identify Package Major Element • Describe the function of the package major elements • Identity remote and ancilary equipment • identify package orientation



Compressor set Application A. Transmission • from gas field to user B. Storage/Re-injection • gas injected to a storage site for pressure maintenance or storage C. Gathering • gas collected upstream of the plant booster D. High Pressure • >1500 psi discharge



E. Gas Lift • gas injected to a well to aerate Crude



Purpose The Gas Turbine and Gas Boost Compressor Package provides a rise in Gas pressure for Pipeline Applications. It includes all the necessary equipment including the following major elements: • Base frame or skid • Turbine engine • Gas Boost Compressor • Interconnect shaft • Control system



• All support systems – Fuel – Oil – Start • Off-skid ancillary equipment – Air Inlet and Exhaust – Fire system – Enclosure ventilation – Battery charger – MCC, Switchgear, etc >



Package Orientation



SOLAR PACKAGE ORIENTATION IS TO VIEW THE PACKAGE FROM THE AFT OR EXHAUST END



Package Major Element Compressor Gage Panel



Turbine Air Inlet



Compressor Output Driver Shaft Exhaust



Skid Base Frame



Gas Turbine Engine



Package Major Element Turbine Air Inlet



Compressor Gage Panel Compressor



Output Driver Shaft



Exhaust



Gas Turbine Engine



Skid Base Frame



TCP



Base Frame (Driver Skid) RIGID WELDED ASSEMBLY MOUNTING FOR MAJOR COMPONENTS MOUNTING FOR ANCILLARIES INTEGRAL OIL TANK



Centaur 40 Gas Turbine Engine (2 Shaft) Exhaust Collector



Accessory Drive



Diffuser



Combuster Section



Compressor Section



Gas Producer Turbine



Power Turbine



Centaur 40 Gas Turbine Engine (2 Shaft) • Axial Compressor - 11 Stages • Gas Producer Turbine – 2 Stages • Axial Compressor – 15 stages • Power Turbine – 1 Stages • Fixed Stages – 9 • Combuster – Annular • Variable Stages – 6 • Fuel Injectors – 10 • Gas Producer Turbine – 2 stage • Power Turbine – 2 stages • T5 Thermocouple – 6 • Combustor – Annular • Max T5 – 1190F • Fuel Injectors – 14 (SoLoNox) • Pressure Ratio 11:1 • Output Power 4427 HP• Fuel Injectors – 21 (Conventiona • T5 Thermocouples – 17 (4500HP) • Max T5 – 13600F • Gas Producer Speed 15000 • Pressure Ratio – 17.4:1 RPM • Output Power – 15000 shp • Power Turbine Speed 15500 • GP Speed – 11,168 rpm RPM • PT Speed – 9500 rpm



Oil System Component



Oil Filters Accesory Gearbox Starter Oil Pumps



Oil Pump Component



Fillers



Filters DC BU Pump



AC Pump



Oil Pump Component AC Pump



DC Backup Pump



Oil Pump Component



Fillers



AC Starter



Starter Motor



AC Starter Motor Starter



Exhaust And Power Turbine



Ancillary Component • • • • • • • • • • •



Air Filters Exhaust System Oil Cooler Battery Charger Control Console MCC Fire System Enclosure Ventilation Yard Valve Anti Surge Valve Process Gas Cooling



Typical Remote And Ancillary Equipment



Vent Silencer



Turbine Exhaust Battery Charger Control Console



Lube Oil Cooler



Turbine Air Intake



Typical Remote And Ancillary Equipment



Component Removal Equipment



Engine Trolley Beam Extension



Typical Enclosure and Ancillary Equipment



Typical Offshore Package shown Self Cleaning air filter system



Typical Enclosure and Ancillary Equipment



Enclosure Set Ancillary Equipment and Enclosure • Typical off-shore package shown • Enclosed package • Enclosure ventilation system • Integrated fire system • Gas detection • Typical off-shore package shown • Enclosed package • Enclosure ventilation system • Integrated fire system • Gas detection



Air Inlet Filter



Clean air is essential in maintaining engine performance and longevity.



Typical Exhaust Silencer



CAN BE INSTALLED AT 45 OR 90 DEGREE ANGLES INCORPORATE EXPANSION BELLOWS



Control Console • Optional control console in nonhazardous area • Control switches and indicators • Display panel with data logging capability



• Main control system components located on-skid • Basic control switches and indicators • Operator Interface Panel



On-Skid Fire Control Panel



Typical Air-to-Oil Cooler Air Flow Fan



Motor



Typical Water to Oil Cooler



MORE COMMON FOR OFFSHORE PLATFORMS



Typical Exhaust Silincer



Typical Battery Charger, Controls And Indicator



Other Ancillary Equipment



• Other equipment that may be installed includes: • MCC – Electrical control of motors



• VFD’s – Control of starter



Engine Skid – Aft Right



Engine Skid – Forward Right



Engine Skid – Aft Left



Engine Skid – Forward Left



Engine - Left Hand



Engine - Right Hand Side



Question



CENTAUR 40 TURBINE ENGINE



Early Gas Turbine



Leonardo da Vinci ingeniously used the hot gases from the fire for driving the spit, thereby cooking the meat evenly. The conical shape of the chimney made the gases accelerate through the turbine.



Man studied birds and for years and attempted to copy their flight, it was discovered that the wings of birds had airfoil sections . This airfoil wing section gives birds lift when passing horizontally through the air. The air travels further over the upper surface of the airfoil thus causing a loss of some pressure, consequently permitting the normal pressure under the wing to give the wing a ‘lift’ upwards. All that was needed now was the forward motion - what man needed was a means of propulsion.



Thrust and Reaction



Garden water-sprinkler rotated by reaction to the water jets.



Artillery Gun Shell streaks away, gun leaps back



Hero Hero made a toy called AEOLOPILE to show that when steam-jet issues from a freely-mounted wheel, the wheel is caused to revolve in the opposite direction to that of the jet, once again demonstrating ACTION and the resultant REACTION. In 1687, Isaac Newton set this fact down in his ‘Third Law of Motion’, to the effect that ‘to every ACTION there is an equal and opposite REACTION’. Hero’s Aeolopile is reputed to be the first apparatus converting steam pressure into mechanical power. It was probably the earliest demonstration of the principle of jet reaction.



Objectives



•



• • • •



State The Purpose of the engine Describe the Brayton Cycle Identify the different section of the engine, and describe their purpose Describe how the air system is used for surge avoidance sealing and cooling Identify the four engine support system



Centaur Turbine Engine Purpose



HEAT ENGINE TAKE CHEMICAL ENERGY AIR AND FUEL



CONVERTS TO MECHANICAL ENERGY ROTATIONAL TORQUE TO DRIVE OTHER EQUIPMENT



Centaur Turbine Engine – Basic Data • Axial Compressor - 11 Stages • Gas Producer Turbine – 2 Stages • Power Turbine – 1 Stages • Combuster – Annular • Fuel Injectors – 10 • T5 Thermocouple – 6 • Max T5 – 1190F • Pressure Ratio 11:1 • Output Power 4427 HP (4500HP) • Gas Producer Speed 15000 RPM • Power Turbine Speed 15500 RPM



OPERATING PRINCIPLES BRAYTON CYCLE



Brayton Cycle



• COMPRESSION - Atmospheric Air Is compressed



• COMBUSTION - Fuel is added and ignited



• EXPANSION - The Hot Gases Expand Through a Turbine



• EXHAUST - The Gases are expelled to atmosphere



Brayton Cycle



How a Turbine Works



SHAFT



How a Turbine Works



SHAFT



Air Inlet



Compressor



How a Turbine Works



Shaft Fuel Injector Air Inlet



Combustor Compressor



How a Turbine Works



Shaft Fuel Injector Air Inlet Gas Generator Turbine Combustor Compressor



How a Turbine Works



EXHAUST GAS



Shaft



SHAFT



FUELInjector Fuel



OUTPUT SHAFT



INJECTOR



Output Shaft



Air Inlet



POWER



PowerTURBINE Turbine



AIR INLET



GasGAS Generator GENERATOR TURBINE Turbine Combustor COMBUSTOR COMPRESSOR Compressor



Simplified gas turbine arrangement Gas turbine



A V O N



Compressor



Combustion



Turbine



The compressor sucks air in and compresses it, the action of compressing the air heats it up and hot, high pressure air is passed into the combustion chamber, mixed with fuel and ignited. This increases the pressure and temperature further and the gases are passed to the turbine, which acts like a series of windmills with the nozzle guide vanes directing the hot gases from the combustion chamber into the rows of rotating turbine blades. These blades are attached to large discs which are directly connected to the compressor.



main menu



Brayton Cycle VS OTO Cycle Simplified gas turbin e arrangement Working Cycle Gas Turbine



A V O N



CONTINOUS AND SIMULTANEOUS CYCLE



Piston Engine



SUCK



SQUEEZE



BANG



BLOW



m ain me nu



Brayton Cycle – Constant Pressure Cycle PRESSURE / VOLUME 1. P - Up / V - Down 2. P - Constant / V - Up 3. P - Down / V - Up 4. P - Constant / V – Down PRESSURE / TEMP 1. P - Up / T - Up 2. P - Constant / T - Up 3. P - Down / T - Down 4. P - Constant / T - Down



Ducts Subsonic airflow through DIVERGENT DUCT - as in compressor PRINCIPLE Velocity - decreasing Pressure - increasing Temperature - increasing



EXAMPLE Typical axial flow compressor outlet casing



Divergent ducts are used in : 1. The passages between rotor blades and between the vanes of the axial compressor. 2. The passages between the impeller-vanes of centrifugal compressor, and their discharge diffusers. 3. Compressor delivery casings



Subsonic airflow through a Convergent Duct - as in a turbine PRINCIPLE



EXAMPLE



Velocity - increasing



Flow through turbine nozzle guide vanes



Pressure - decreasing Temperature - decreasing



Convergent ducts are used in the passages between rotor blades and nozzle guide-vanes in turbine sections



BASICS



An axial flow compressor consists of one or more rotor assemblies that carry blades of airfoil section. These assemblies are mounted between bearings in the casings which incorporate the stator vanes.The passageway between each blade on the rotor and between each stator vane is made to form a divergent duct. Moving rotor-blades draw in air at the front of the compressor and force it rearwards, thereby increasing its velocity and its pressure due to the mechanical force and the shape of the passageways.



Compressor In the stator vane passages the velocity is converted into pressure, again by the divergent form of the passageway, the air is lined up for the next row of moving blades.This process repeats itself throughout the compressor, increasing pressure by 10-20% at each stage.



BASICS



Pressure In An Axial Compressor



BASICS Pressure and velocity increase in a axial flow compressor



COMPRESSION



• Great amount of mass air • Compression ratio + 10-13 • Axial Compressor • Rotor • Stator • Number of stages • PCD



COMBUSTION



• • • • •



•



Annular Perfect Combustion. 15%-20% air enter the Combustion. Initial firing by ignition torch Flame pattern determined by FGCV, fuel nozzles, holes Mechanically centered held by fuel injectors



EXPANSION • • • • • •



Split or Single shaft power Turbine Newton III Law (ActionReaction) Impuls Force Nozzles and blade arrangement. The highest rotating parts temperature Temperature drops as it pass the blades.



Brayton Energy Transfer Cycle COMPRESSION COMBUSTION AIR IS DRAWN INTO THE 11 STAGE AXIAL COMPRESSOR AND COMPRESSED



FUEL IS ADDED AND IGNITED CAUSING RAPID EXPANSION



EXPANSION THE HOT GASES EXPAND THROUGH A TURBINE AND ENERGY EXTRACTED



Exhaust HOT GASES EXPELLED TO ATMOSHPHERE SOMITIMES THROUGH A HEAT EXCHANGER



IN A 2 SHAFT TURBINE THE TURBINE IS SPLIT INTO 2 – THE FWD STAGES DRIVE THE GP COMPRESSOR, THE REAR STAGES EXTRACT THE REMAINING ENERGY TO DRIVE THE OUTPUT SHAFT



ENGINE CONTROL • Two shaft engines are used for applications that require variable speed drive to the driven-equipment – Compressors and pumps • During startup the fuel system will be managed to accelerate the Gas Producer (GP) to idle speed (normally 72% NGP) • At some point, during acceleration to idle, depending on the compressor load placed on the Power Turbine (PT), the PT will breakaway • Gas Producer speed will then be controlled in order to maintain a desired PT speed, and therefore Boost Compressor speed – This can be managed according to Suction pressure, Discharge pressure or Flow requirements



ENGINE CONTROL • The actual PT speed will depend on two factors: 1. NGP speed and therefore available power 2. Load on the Boost Compressor • As Boost Compressor load increases, the PT speed would tend to drop • The control system will increase the fuel flow, and this will increase the NGP • More power is now “left over” to drive the PT, and the NPT will remain constant (until the setpoint is changed by the operator) • ALTHOUGH WE ARE DIRECTLY CONTROLLING NGP, THE NET EFFECT IS TO CONTROL NPT AND THEREFORE THE PROCESS GAS CONDITIONS • Maximum load is achieved when one of the following conditions applies: – Maximum NGP (100%) – Maximum NPT (100%) – Maximum engine temperature (T5 – 1190F) >



Temperature and Pressure • We monitor and sometimes control pressure and temperature at various points in the engine • The main terms you may hear are: • T1 – Ambient Temperature • TPZ – Temperature Primary Zone (Highest Temp) • T3 – 1st Stage Turbine Rotor Inlet Temperature (Critical) • T5 – 3rd Stage Rotor Inlet Temperature (Control) • T7 – Exhaust Temperature (Option) • P1 – Ambient Pressure • P2 – Compressor Discharge Pressure (PCD) (Highest Pressure) >



Temperature and Pressure Station T1/P1 Ambient Air Pressure and Temperature T2/PCD Measured at the diffuser, compressor discharge pressure and temperature TPZ Temperature of the Primary Zone (Fireball) T3/TRIT Turbine Rotor Inlet Temperature T5 Highest Measured Temperature on the Engine



Surge Control (Engine Compressor Stall) • During start up the compressor FWD stages produce more air than the AFT stages can accept • This would cause a back-pressure and may result in a damaging condition called ENGINE SURGE or ENGINE STALL • To avoid engine stall: – Excessive air is removed from the engine at low speeds by opening up a Bleed Valve – Variable guide vanes on the first 3 stages are partially closed to limit the airflow entering the engine >



Engine Surge / Stall Control • SURGE or STALL = REVERSAL OF AIRFLOW • SYMPTOMS – High T5 – Low PCD – Failure to accelerate – Axial vibration • RESULTS IN – Bearing and seal damage – Blade damage • IF YOU SUSPECT ENGINE SURGE / STALL – Shutdown the engine >



Effect of Engine Surge Extreme amounts of force exerted on compressor rotor



Surge Effect



DIRECT AC START SYSTEM



LESSON OBJECTIVES • State the function of the Direct AC Start System • Identify and state the function of the major components • Describe system operation during start and test crank • List annunciations and explain possible conditions for each



PURPOSE



• Centaur turbine engines are “self-sustaining” at 60% NGP • This point is known as “starter drop out” • They require rotational torque for initial cranking and up to this speed • This is provided by the start system • The start system can also be used to crank the engine at approximately 20% speed for maintenance such as engine cleaning



MAJOR COMPONENT



1. Variable Frequency Drive (VFD) 2. Electric Motor 3. Adapter and clutch assembly



VFD Controller • VFD430 works on the principle of Pulse Width Modulation • VFD430 communicates with the Controller via ControlNet • Start, Stop commands are sent from the Controller Via this network • Status information is sent to the Controller from the VFD VFD KEYPAD



CONTROLNET



Pulse Width Modulation



Starter Motor Low Maintenance Internal Heaters Thermal Detectors for motor protection



Sprag Clutch 1. Over-Running Clutch 2. Disengages as the turbine begins to rotate faster than the starter. 3. Prevents the AC Motor from rotating at engine speed 4. Allows for easy reengagement when the engine is restarted



Sprag Clutch Operation



DAC Start Schematic