TRAINING MANUAL

ON
GAS TURBINE OPERATION

BY
Engr. Nwachukwu Azubuike N.

MODULE ONE
 POWER PLANT
The Power Plant is to cater for the power demand of the complex. A
general overview of the specifications are as follows.
IPL GAS TURBINE FEATURES
No of turbine…………………………… six
Max load …………………………….33MW
Main fuel…………………………………. Natural Gas
Alternative fuel ………………………Automotive gas oil (AGO)
Fuel supply logistic. Natural gas through pipeline from AGIP/FCU/FERT
Back up fuel (AGO) ………Through tankers.
Purpose: To produce power as per requirement of the complex.

WHAT IS A TURBINE
Turbine is a rotary engine in which the kinetic energy of a moving fluid
is converted into mechanical energy by causing a blade rotor to rotate.
The moving fluid can be gas, steam, wind etc.
1.0 GAS TURBINE
1.1 GENERAL, FUNCTIONAL DESCRIPTION
1.1.1 INTRODUCTION
A GAS TURBINE is a rotary engine in which the kinetic energy of a hot
gas is converted into mechanical energy by causing a blade rotor to
rotate.
A heavy duty gas turbine unit is a mechanical power engine installed in a plant.
 In most application to drive a generator to supply an electrical network.
 Or sometimes to drive a compressor or pump for gas treatment plant.
The gas turbine power engine includes an axial airflow compressor, a multi
chamber combustion system and a three stages turbines. Main components of
the gas turbine are listed here below.
The axial airflow compressor is a 17 stages compressor with:
 Adjustable inlet guide vanes (IGV) to control the airflow during starting and
loading sequences.
 Bleed valves to bypass part of the air flow for starting and shut down to
escape from surging.
The combustion system comprises:
 Fuel nozzles fitted on the combustion
chamber’s cover.
 Ten combustion chambers where the fuel
burns permanently from firing speed to full
load.
 Ten cross fire tubes connecting the
combustion chamber.
 Ten transition pieces downstream the
combustion chamber connected to the first
turbine stage nozzle.
 Two spark plugs for the fuel ignition.
 A set of flame detectors.
The three stages turbine include first, second and third stage nozzle and first,
second and third wheel.
The turbine and the axial flow compressor belong to the same shaft connected
to:
 The auxiliary gear box and the starting means at the front end.
 The generator at the rear end.
The gas turbine components and function are detailed in the text here after.
2.0 OPERATING PRINCIPLE
A gas turbine works in the following way:
 It aspirates air from the surrounding environments;
 It compresses it to a higher pressure;
 It increases the energy level of compressed air by the
addition of fuel gas which undergoes combustion in a
combustion chamber;
 It directs high pressure and high temperature air to a
turbine section, which converts thermal energy into
mechanical energy that makes the shaft revolve; this
serves, on the one hand, to supply useful energy to the
driven machine, coupled to the machine by means of a
coupling and, on the other hand, to supply energy
necessary for air compressions, which takes place in a
compressor connected directly with the turbine
section itself;
 It expels low pressure temperature gases resulting
from the above mentioned converting process into the
atmosphere.
2.1 GAS TURBINE FUNCTIONAL DESCRIPTION
(Refer to gas turbine simplified flow diagram here below)
Functional description at nominal speed:
While the gas turbine is running, filtered ambient air is drawn through the inlet
plenum assembly, then compressed in the 17th stage axial flow compressor.
Compressed air from the compressor flows into the annular space surrounding
the ten combustion chambers, from which it flows into the spaces between the
outer combustion casings and the combustion liners, and enters the combustion
zone through metering holes in each of the combustion liners.
The fuel nozzles introduced the fuel into each of the ten combustion chambers
where it mixes with the combustion air and burns.
The hot gases from the combustion chambers expand into the ten separate
transition piece attached to the downstream end of the combustion chamber
liners and flows from there to the three- stage turbine section of the machine.
Each stage consists of a row of fixed nozzles followed by a row of turbine buckets.
In each nozzles row, the kinetic energy of the jet is increased, with an associated
pressure drop, and in each following row of moving buckets, a portion of the
kinetic energy of the jet is absorbed as useful work on the turbine rotor.
After passing through the 3rd stage buckets, the exhaust gases are directed into
the exhaust casing and diffuser which contains a series of turning vanes to turn
the gases from an axial direction to a radial direction, thereby minimizing exhaust
hood losses. Then, the gases pass into the exhaust plenum and are introduced to
atmosphere through the exhaust stack.
Resultant shaft rotation turns the generator rotor to generate electrical power or
to drive a centrifugal compressor in industrial power applications and drives the
auxiliaries through the accessory gearbox.
2.1.1 Starting sequence:
The gas turbine cannot run itself from zero speed. A starting means bring the
shaft line up to the self sustaining speed.
When the starting means is actuated, the IGV are in the closed shut down
position and the compressor bleed valves are open. The cranking torque from the
starting means system breaks away the turbine shaft, the cranking motor brings
the gas turbine to firing speed. Fuel is injected in the combustion chamber, spark
plug provide ignition in two combustion chambers and the flame spreads to the
other combustion chambers through the crossfire tubes. Flame detectors confirm
full ignition to the control panel.
Starting means remain actuated to accelerate the unit to self sustaining speed. A
gas turbine speed threshold stops the starting motor. The gas turbine reaches
nominal speed, the IGV move to full speed no load (FSNL) operate position and
the bleed valve closes.
Main shaft driven lube oil pump provides lubricating oil for the shaft line bearings.
During starting sequence the auxiliary lube oil pump feeds the header.
2.1.2 Cooling down sequence
Due to the high temperature of the gas path, the gas turbine must follow a 24
hours turning gear sequence at low speed, after shut down, to provide a
homogeneous cool down to the shaft line.
Therefore, the turning gear motor starts automatically during the run down.

MAJOR SECTIONS THAT CAN

BE IDENTIFIED FROM THE GAS
TURBINE
Auxiliary section
 Compressor section
 Combustion section
 Turbine system
 Exhaust section
 Load gear section
 Generator section
 Exciter section

Figure 1 Gas Turbine simplified Flow Diagram

3.0 MAJOR COMPONENTS OF
A GAS TURBINE
 Axial Compressor
Air flow is in direction of compressor
Axis
 Combustion Section
Burns fuel/ Air mix
 Turbine Section
Produces power
Figure 2 Components of A Gas Turbine
Components of a gas turbine
As discussed a gas turbine is basically a simple machine consisting of three main
components: Compressor, Combustor, Turbine
The compressor takes air in from atmosphere and increases the pressure and
decreases the volume. The higher the pressure ratio across a gas turbine
compressor the more fuel can be burnt and the higher the output.
GE use a can Annular combustor. The fuel is burnt in separate combustion cans
and the hot gas discharges at a common discharge annulus.
A Gas turbine combustion system is very robust and can burn many types of fuels
including gas, distillate, heavy crudes oil and residual fuels. By far the best fuel for
a gas turbine is gas as it burns cleaner and has less associate maintenance
requirements.
The turbine section is an expansion turbine and the hot gas expands through
stages of blades, decreasing the gas pressure and increasing the volume. This is
the section of the machine that produces the power. Approximately 2/3 of the
power produced by the turbine is used to power the compressor. Therefore, it is
very important we keep the compressor as efficient as possible hence the
introduction of water washing to keep the compressor clean and reduce losses.
For a stand alone gas turbine the air leaving the turbine is expelled to atmosphere
at a temperature of approximately 500 Deg C and this heat energy is wasted
energy.

3.1 Axial Compressor

 Compresses Air for use in combustion
 Compressor Air also used for cooling,
Bearing Sealing and for Pulsation control
 Compressor construction consists of
many stages
Each stage has one row of rotor blades and one row of
stator blades
 Air intake controlled by Inlet Guide
Vanes

Axial Compressor
An axial compressor is used on most industrial Gas Turbines. An axial compressor
has the advantage of being able to deliver a higher pressure ratio across the
compressor and can move larger quantities of air.
The pressure rise across each stage may only be as small as 1.2:1, however, add
this up across say 12 stages, and you get an overall ratio of over 10:1.
Figure 3 Compressor Intake and IGV
3.11 Air Intake and IGVs
Above is the upper half of the inlet casing. Air passes through the air intake and
then into the IGVs. There are 64 IGV`s in total. The IGV`s are activated by
hydraulic oil via a cylinder. The rack and pinion system then rotates, as it rotates
each one of the pinion gears is moved exactly the same amount by the rack
mechanism as it moves around the air intakes.
Figure 4.0 Air Intake and IGVs
This picture shows the complete Inlet Plenum and IGV`S. Here we can see each
individual pinion gear. The upper half casing is fixed to the lower half casing by
bolts on each side of the half casing.
Bearing one is located in the middle of the inlet plenum.
3.1.2 Gas Turbine Rotor
Above is a picture of a frame 6 Rotor. The rotor is one complete assembled
component. It is supported by turbine bearings. The rotor consists of two main
parts. The turbine rotor and compressor rotor.
The compressor rotor consists of seventeen stages or wheels. The wheels are held
together by compressor tie bolts that go right through the middle of each wheel.
The air into the rotor is controlled by Inlet Guide Vane (IGV). The IGV system is
actuated by hydraulic oil via a solenoid or a servo system depending on the
machine. The 4th stage and 10th stage extractions can be seen on the left hand
side of the casing. These are used for cooling, bearing sealing and pulsation
control through the compressor bleed valves.
The air flow into the compressor comes through a filtration system to remove any
contaminants in the air and then is directed into the compressor via the IGV`s
3.1.3 Compressor Rotor Blades
The Compressor rotor is built of separate wheels. Each wheel has more blades per
wheel as the stage number increases. Also the blades get smaller at each
successive stage. This is necessary due to higher pressure at each stage as longer
blades would flex and not operate properly at higher pressures as the air pressure
increases.
EGV`s are shown as the air leaves the compressor. The Exit Guide Vanes are used
to reduce turbulence as the air exits the compressor.
3.1.4 Compressor Stator Blades
Here we have the stator blades for a frame 6 machine. The stator blades come in
blade segments for the 1st 4 stages and then as individual blades as we move
down the stages.
On a Frame 6 air extraction is from the 5th and 11th stage as can be seen from the
photograph above. Each half of the casing has 5 combustion can holes. The cans
are numbered anticlockwise (looking downstream) starting from the top left of
the machine. Therefore, the can 3 holes is on the left hand side of this photograph
and can 7 on the right.
All cans discharge into discharge annulus that forms a circle around the 1st stage
nozzle.

4.0 Combustion Section

 Burns Air/Fuel mix to produce energy
 Fuel can be Gas, Distillate or Heavy fuel
oil
 Fuel nozzle can be single fuel or dual
fuel
 Liquid fuel requires atomizing air
Combustion Section
Combustion section burns air/fuel mix. Fuel can be Gas/Distillate. Liquid Fuel can
be mechanically atomized or atomized using Atomizing Air. Atomizing is required
to disassociate the liquid fuel such that the liquid fuels burns more completely
and with a shorter flame. Atomizing air is the most common method of
disassociating the liquid fuel and uses an atomizing air compressor which takes air
from the compressor discharge and pressurizes it to a higher pressure which is
then fed in to the fuel nozzles.

4.1 Combustion Components

 Combustion Can
 Crossfire Tube
 Spark Plug
 Flame Detector
 Combustion Liner
 Fuel Nozzle
 Transition Piece
Combustion Components
We will now discuss the main combustion components as used in a can annular
combustion system.
Combustion Section
The above image shows the combustion section of a Gas Turbine during an
outage. Usually only two of the combustion cans on a GE Gas Turbine will have
spark plugs (igniters). Therefore, a crossfire tube is used to allow ignition to take
place in those cans without spark plugs. The crossfire tube forms a ring linking all
10 combustion cans together and can clearly be seen in the above photograph.
4.1.1 Spark Plugs
Combustion is normally initiated by means of the discharge from two high-
voltage, retractable-electrode spark plugs installed in adjacent combustion
chambers. These spring injected and pressure retractable plugs receive their
energy from ignition transformers. At the time of firing, a spark at one or both of
these plugs ignites the gases in a chamber; the remaining chambers are ignited by
crossfire through the tubes that interconnected the reaction zones of the
remaining chambers. As rotor speed increases, increasing chamber pressure
causes the spark plugs to retract and the electrode are removed from the
combustion zone.
4.1.2 Flame Detector
Most turbines will use a flame Detector device to detect that the combustion
process is properly established. However, some turbines will use an increase in
the exhaust temperature as method of verifying that the fuel has successfully
ignited.
The ultraviolet flame sensor consists of a flame sensor containing a gas filled
detector. The gas within this flame sensor detector is sensitive to the presence of
ultraviolet radiation which is emitted by a hydrocarbon flame. A.D.C. voltage,
supplied by the amplifier, is impressed across the detector terminals. If flame is
present, the ionization of the gas in the detector allows conduction in the circuit
which activates the electronics to give an output defining flame. This output is a
frequency which is proportional to flame intensity. Conversely, the absence of
flame will generate an opposite output defining ` no flame~.
Figure 5.0 Combustion Liner
4.1.3 Combustion Liner
The combustion liner is a critical component of any Gas Turbine as this
component operates at high temperature and is used to ensure proper
combustion of the fuel by allowing mixing of the air and fuel. The combustion
liner is made of a high temperature alloy known as Hastealloy X. This alloy has a
mixture of properties that means it can withstand the high temperatures
produced by the combustion process whilst also being easy to machine to allow
combustion and cooling air holes/passages to be created.
The above liner is used in a frame 6 Gas Turbine. The design uses cooling louver
holes to allow compressor air to flow into the combustion liner and form an
insulating layer around the inside of the liner and prevent the hot combustion
gases from contacting the liner itself.

Figure 6.0 Fuel Nozzle

4.1.4 Fuel Nozzle

The above picture shows a swirler tip dual fuel nozzles. The liquid fuel is sprayed
from the hole in the middle of the nozzle.
The Gas exits from the outside of the fuel nozzles through the swirler tip. The
swirler tip is designed to make the gas rotate to aid more complete combustion.
Atomizing air exits around the outside of the liquid fuel nozzles.
Figure 7.0 Transition Piece
4.1.5 Transition Piece
This type of component is used in Multi Can or Can Annular Systems. The function
of the transition piece is take the Hot Combustion gases leaving each can and
form one discharge annulus at the exit which is connected to the Turbine section.
The above component has had a thermal barrier coating applied to provide
resistance to high temperature.
 5.0 Turbine Section
 Generates the power
 Hot gases enter first stage nozzle from
Transition Piece
 Consists of Turbine Stages
Each stage has one row of Rotor Blades and one row of
Stator Nozzles
 Blades cooled by Compressor Air

Turbine Section
We will now discuss the Turbine Section of a Gas Turbine and the components
contained therein.
Figure 8.0 Turbine Rotor
5.1 Turbine Rotor Section
Most Turbine Rotor sections will consist of either a 2 or 3 stages of turbine blades.
However, some small machines may only contain a single stage turbine wheel
while some of the newer larger machines may contain up to 4 to 5 stages.
A GE Frame 5 Gas Turbine has a 2 stage turbine and a frame 6 Gas Turbine has a 3
stage turbine.
For Frame 6 to Frame 9 Gas Turbines stage 1 and 2 of the turbine blades are air
cooled using air that passes through the centre of the rotor shaft. The 3rd
Stage blade is not air cooled as this operates at a lower temperature and
pressure. The cooling air enters the rotor through a slot between the 16th
And 17th compressor stages. This slot can be clearly seen in the photograph
above.
Figure 9.0 3 Stage Turbine
3 Stage Turbine
Most turbine used shrouded blades (buckets) for the longer blades as used in
stages 2 and 3 of a Frame 6 Gas Turbine. Shrouded blades are used to lock the
blades tips together to prevent vibration as a 360O Degree ring. The above image
shows stage the complete turbine assembly for a Frame 9 Gas Turbine.
Figure 10.0 Turbine Stationary Nozzles

5.1.1 Gas Turbine Nozzle

Any turbine larger than a frame 5 will have 3 Nozzle stages. The above
photograph shows the 2nd and 3rd stage nozzles for a Frame 6 Gas Turbine.
2nd Stage Nozzle
Combustion gas exiting from the first stage buckets is again expanded and
redirected against the second stage turbine buckets by the second stage nozzles.
The second stage nozzle is made of 16 cast segments, each with three partitions
(or airfoils). The male hooks on the entrance and exit sides of the sidewall fit into
female grooves on the aft side of the first stage shrouds and on the forward side
of the second stage shrouds to maintain the nozzle concentric with the turbine
shell and rotor. The close fitting tongue-and-groove fit between nozzle and
shrouds acts as an outside diameter air seal. The nozzle segments are held in a
circumferential position by radial pins from the shell into axial slots in the nozzle
outer side wall. The second stage nozzle partition are cooled with compressor
discharge air.
3rd stage Nozzle
The third stage nozzle receives the hot gas as it leaves the second stage buckets,
increases its velocity by pressure drop and directs this flow against the third stage
buckets. The nozzle consists of 16 cast segments, each with four partition (of
airfoils). It is held at the outer sidewall forward and aft sides in grooves in the
turbine shrouds in a manner identical to that used on the second stage nozzles.
The third stage nozzles are circumferentially positioned by radial pins from the
shell.

6.0 Major Additional GT

Components
 Starting Device
 Torque Converter
 Bearing
 Accessory Gearbox
 Generator
 6.1 Starting Device
 Used to bring the Gas Turbine to Self
Sustaining Speed
 Many Different Types of Starting Device
 Diesel Engine
 Electric Motor
 Smaller Gas Turbine
 Steam Turbine
 Static Starter
Starting Device
The starting device is used to bring the Gas Turbine to self sustaining speed.
This is defined as the point at which the Gas Turbine no longer requires the input
from the starter in order to maintain the increase in turbine speed (i.e. the
machine is taking generating enough energy from the combustion of the fuel).
This is usually define by a speed relay set point within the speedtronic control
system normally set to 50% speed
This means that if the starter trips after at a higher speed than this set point then
the starter will shutdown but the turbine will continue to operate. If the starter
trips before this set point then both the turbine and starter will shut down/trip.
 6.2 Torque Converter
 Torque Converter transmits the power
from the starter device to the engine drive
shaft, via a clutch.
 They are oil operated.
 3 main components in the casing are:
- Input Shaft – connected to starting device
- Output Shaft – connected to Gas Turbine
- Stator – re-direct oil from Output back to
Input
Torque Converter
The torque converter allows the starting device to reach starting speed before oil
is supplied to rotate the output shaft, connected to the Gas Turbine. It is
sometimes referred to as a hydraulic coupling as there is no physical connection
between the output shaft and input shaft. The coupling, and therefore torque,
comes for the fact that high pressure oil is being forced from the input shaft onto
the output shaft through vanes on both shafts.

6.3 Bearings
 Different Gas Turbines use different
bearing types and assemblies
 Commonly Bearing 1 Housing contains
Journal Bearing and Thrust Bearing
- Journal Bearing is a support bearing
- Thrust Bearing prevents axial movement
- Thrust Bearing consists of loaded and
unloaded Thrust (or Active and Inactive)
- Additional Bearings are usually Journal
Bearings
Figure 11.0 Turbine Bearing
6.4 Accessory Gearbox
 Used to drive Turbine Accessories
 Accessory devices include
- Main Lube Oil Pump
- Main Hydraulic Oil Pump
- Liquid Fuel Pump
- Atomizing Air Compressor
The accessory Gearbox is used to drive the main turbine accessory
devices that are required to support the operation of the machine. This
would include the list of devices as give on the slide above.
Accessory Gearbox Shafts
When describing devices fitted to the Accessory Gearbox it is usual to
reference these to the Inboard/Outboard side of the Gearbox. The
inboard side being the side towards the turbine and the outboard side
being the side toward the starting device.
Figure 12.0 Accessory Gearbox Shafts
6.5 Load Gear Box
 Used on Generator Applications
 Used to convert Turbine speed to
required Generator speed
 Located between Turbine Section and
Generator.

Figure 13.0 Load Gearbox

Most Gas Turbine Generators are two pole rotor devices and therefor
need to spin at 3000rpm in order to produce the AC voltage at the
required frequency (i.e. 50Hz on most systems but for the United State,
Saudi Arabia etc then 60Hz).
The above image shows the gearbox with cover opened. The two pinion
gears have gear teeth that act in opposite directions to reduce any axial
thrust that may be transferred from the Gas Turbine rotor to the
Generator rotor.

6.6 Generator
 Used to Generate Electrical
Power
 Separate air cooled Rotor
 Stator used to conduct
electricity
The Generator is used to create Electrical Power. This is done by having
DC Field current that is connected to the rotor and produces the
Magnetic Field. As the Magnetic field rotates within the Stator it
produces a 3 phase AC voltage.
The DC current that is connected to the rotor is sometimes known as
the “Field Current” or “Excitation Current”.
Generator Rotor
The Generator Rotor contains the copper windings that are used to
carry the DC current. The DC current is connected to the rotor using
either a Brushless Excitation System or a Static (with brushes) Excitation
System.

Figure 14.0 Generator Rotor

Generator Stator
The stator windings produce the AC Voltage that is transmitted to the
grid. Generators produce voltage at different ratings depending on the
Generator manufacturer and design. Most Generators would produce
11KV or greater at the output terminals.

Figure 15.0 Generator Stator

7.0 Auxiliaries System with
Their Function
 Lube Oil System
 Hydraulic Oil system
 Trip Oil System
 Fuel Gas System
 Fuel Oil System
 Atomizing Air System
 Cooling and Sealing Air System
 Cooling Water System
 Starting System
 Purge Air System
7.1 Lube oil system
Lubrication of the gas turbine power plant is accomplished with a forced feed
lube oil system complete with tank, pumps, coolers, filters, valves and
miscellaneous control and protective devices. The lube oil is circulated to the two
main bearings of the gas turbine, various turbine accessories, flexible couplings
and load equipment. A portion of the oil is diverted and filtered for use by the
various hydraulic control devices and functions as hydraulic control oil.
The lube oil pump takes their suction from the oil tank and the control oil pumps
takes their suction from a bearing header. It is worthy to note that correct oil
pressure is necessary for the bearings and hydraulic control trip oil circuits. The
main lube oil tank is usually fabricated as an integral part of the turbine base
under the accessory compartment.
Lube oil from the main, auxiliary and emergency pumps is supplied from the
reservoir. The lube oil used for control purposes is supplied from the bearing
header. The lubricant must be regulated to the proper predetermined pressure to
meet the requirements of the main bearings and the accessory lube system, as
well as the hydraulic control and trip circuits. All lube oil is filtered and cooled
before being piped to the bearing header.

The major system components include:

 Lube Oil Reservoir in the turbine base
 Main Lube Oil Pump – shaft-driven by the accessory gear
 Auxiliary Lube Oil Pump – a.c. motor – driven 88QA
 Emergency Lube Oil Pump – d.c. motor – driven 88QE
 Pressure Relief Valve VR1 in the main pump discharge
 Bearing Header Pressure Regulator VPR-2
 Lube Oil Heater Exchangers LOH-1 and LOH-2
 Lube Oil Filters LOF-1 and LOF-2
7.2 Purpose of lube oil system
a. To supply proper lube oil pressure and temperature to the equipment (e.g
acceleration/load couplings and bearings etc)
b. To control the cooling down and emergency lube oil pump, which provides
lube oil pressure during startup, rated condition and shutdown of the gas
turbine.
7.2.1 Filter: are used in the lube oil pipe system to ensure a clean supply of oil to
the bearings, couplings, accessories and load equipment. The main lube oil
is mounted on the lube oil tank cover provides a nominal 5micron filtration
for bearing and accessories feed header with hydraulic trip circuit oil while
oil used for fuel gas control is filtered to a nominal ½ micron.
7.2.2 Oil Cooler (Heat exchanger): The oil is cooled with water from the cooling
water system. Cooling water flow is adjusted by a regulator, which
automatically controls the flow of water through its valve by responding to
temperature changes, which affects the sensing bulb.
7.2.3 Oil Level Gauge and Alarm: The oil level gauge and alarm device are
mounted in the side of the lube oil. The float mechanism operates two
electric switches, which are a part of the device. The switches are
connected into the enunciator circuit of the turbine control panel and
operate an enunciator level should rise above, fall below the normal level.

8.0. Hydraulic Supply System

The primary function of the hydraulic oil system is to provide hydraulic
fluid at the required pressure for:
1. A Hydraulic supply system, which supplies the fluid power required
for:
a. Fuel Control Valve Positioning
b. Inlet Guide Vane Actuating System
2. The Hydraulic Ratchet/Start Clutch Sub-Assembly
3. Control and Trip Oil requirements
Pressure-regulated, filtered lube oil from the bearing header of the Gas
Turbine is used as the high pressure fluid necessary for the hydraulic
supply system requirements. The system provides the fluid power for
operating the fuel control valves and inlet guide vane actuator.

The major system components include:

1. Main Hydraulic Pump – shaft-driven by accessory gear
2. Auxiliary Hydraulic Pump – motor-driven
3. Hydraulic Supply Manifold
4. Hydraulic supply filters FH2-1 and 2
5. Pressure Sensor 96HQ-1
Purpose
a. To supply hydraulic pressure to actuate the hydraulic cylinders of
the ratchet assembly, starting clutch and inlet guide vane control
ring.
b. To control the ratchet pump which is used to rotate the gas
turbine rotor.

9.0 Trip Oil or Control oil system:

The hydraulic trip oil system is the primary interface between the
turbine control and protection system (SPEEDTRONIC control
system), and the component on the turbine which admit or shut
off fuel to the turbine. The system includes devices which are
electrically operated through the turbine control panel by
SPEEDTRONIC signals as well as other mechanical devices which
operate directly on the turbine components, independently of the
turbine control panel.
Purpose
a. To control the fuel gas stop/speed ratio valve and control valve.
 b. To supply proper oil pressure to trip the gas turbine under
emergency condition.
Note: The control oil is supplied from the lube oil system and is
connected to the low-pressure trip oil circuit through an orifice and
supplies oil to the gas turbine over speed trip valve, the manual
emergency valve, and fuel oil stop valve loss of oil pressure, through
operation of any one of these components, reduces the trip oil circuit
pressure to almost zero, causing the piston of fuel shut off valve to
drop shutting off fuel flow to the gas turbine. On the other, this oil
supplied from hydraulic supply system is connected to the
stop/speed ratio and control valve.

10.0 Cooling and sealing air system

The cooling and sealing air system provides the necessary air flow from
the Gas Turbine compressor to other parts of the Gas Turbine rotor and
stator to cool these parts during normal operation and to seal the
turbine bearings.
Atmospheric air from centrifugal type blowers mounted on the
compartment roof, is used to cool the turbine exhaust frame. The
cooling and sealing functions are provided by the system to:

1. Seal the turbine bearings

2. Seal the load gear bearings
3. Cooling the internal parts
4. Cooling the turbine outer shell and
exhaust frame
5. Provide an operating air supply for the
pneumatically operated valves
 Purpose
a. To cool the vane, the after surface of the first stage wheel rim, the
forward surface of the second stage rim, and turbine shell.
b. To seal the gas turbine No 1 and No 2 bearing assembly.

11.0 Cooling water system

The cooling water system is designed to accommodate the heat-
dissipation requirements of:

1. Lube Oil system

2. Atomizing Air system
3. Turbine Support Legs
4. Flame Detectors

Purpose
(a) To control the lube oil temperature of the lube oil system. It is a
close system designed to accommodate heat dissipation
requirement of lube oil system and generator cooling. After
performing the cooling function, the water is circulated back to
the main cooling water unit where it is cooled by air.

12.0 Starting System

Before the Gas Turbine can be fired and start it must be rotated
(cranked) by accessory equipment. This is accomplished by an electric
motor, operating with a torque motor to provide the breakaway torque
and speed required by the Gas Turbine for startup.

The starting system components include:

1. Cranking Motor 88CR
2. Torque Converter
3. Ratchetting Motor 88HR
4. Torque Adjustment Solenoid 20TU
In addition, there are several supplementary components required for
sequencing and operation of the turbine starting system. During the
starting sequence, the Gas Turbine is driven through the accessory gear
by the starting motor, torque converter, output gear and the starting
clutch. The output from the Torque converter is permanently coupled
to the turbine compressor shaft by a flexible coupling. The accessory
gear drives the main lube oil pump, the main hydraulic supply pump
etc.
Purpose
To start the gas turbine, power from cranking motor is transmitted
through the torque converter, starting clutch, and accessory gear to
the main shaft of the gas turbine. When the gas turbine fires and
accelerates beyond the governed cranking speed, the starting clutch
overruns and disengages.

13.0 FUEL GAS SYSTEM

Fuel gas is delivered to the combustion chambers by the on-base fuel gas system.
The system is designed to deliver fuel gas at the correct pressure and flow rates to
meet all starting, acceleration and loading requirements of Gas Turbine
operation.

MAJOR COMPONENTS OF FUEL GAS SYSTEM.

1. Stop/Speed Ratio Valve
2. Gas control Valve
3. Gas strainer
4. Gas Vent Solenoid Valve
5. Gas Pressure Sensor
6. Pressure Transducers
7. Pressure Gauges
8. Linear Variable Differential Transducers
(LVDTs)
Fuel gas from the off-base supply system passes through the strainer. The fuel gas
flow is controlled by the stop/speed ratio and control valve assembly, before
passing to the distribution manifold and combustion system.
The gas control valve (GCV) meters fuel gas for use by the combustion chambers.
It is activated by a SPEEDTRONIC control signal to admit the proper amount of
fuel gas as required by the turbine for a given load or speed. The fuel gas stop
ration valve (SRV) is used to shut off fuel flow to the turbine whenever necessary.

14.0 FUEL OIL SYSTEM

Fuel oil at the low pressure from the off-base forwarding system, enters at the
fuel oil stop valve (VSI) prior to entering the main fuel oil pump (PFI). The pump
delivers the fuel oil at high pressure to the flow divider (FDI). The flow divider
distributes the fuel oil evenly to the ten fuel nozzles in the combustion system.
The bypass valve (VC3) modulates the fuel oil flow, as required, for the operating
conditions of the Gas Turbine.
In the event of an unsuccessful Gas Turbine start, fuel oil accumulations in the
combustion chambers and compressor discharge casing are drained through the
false start drain valve (VA17).

MAJOR COMPONENTS OF FUEL OIL SYSTEM.

1. Fuel Oil Stop Valve (VSI)
2. Main Fuel Oil Pump (PF-1)
3. Bypass Valve Assembly (VC3)
4. Flow Divider (FDI)
5. Magnetic Pickups (77FD-1,2 and 3)
6. Check Valves (VCK1-1 to 10)
7. Fuel Nozzles
8. False Start Drain Valve Assembly (VA17)
9. Pressure Sensor (96FL-2)
15.0 EPCL POWER SYSTEM
The EPCL Power System is composed of six Gas Turbine Generators,
four Emergency Diesel Engine Generators and Power Distribution
Equipment.
The Gas Turbine Generator (GTG) units are package Generator
Electric modal MS6001 type and are rated at 33MW, 11500Volts, 3
Phase and 50Hertz.
The GTG is connected through a step-up transformer to a 33KV
double bus bar which can be separated by bus section and bus
coupler switches.
One normal feeder and one 100% standby feeder supplies power
from the 33KV switchboard to the 11KV, 3.3KV and 415V
switchboards.
The Switchboard is provided with two incoming feeders each rated to
supply the total load of the switchboard. The 11KV, 33KV and 415V
switchboards normally have open bus section circuit breakers with
auto transfer scheme.
The power distribution system is composed of the following
transformers.
1. 11.5KV/34.9KV Transformer
2. 33KV/12KV Transformer
3. 11KV/3.45KV Transformer
4. 11KV/433V Transformer
5. 3.3KV/433V Transformer
The power distribution system is composed of the following
substations;
1. Main substation 1 & 2
2. Substation 3 (PPCB: Power Plant Control Building)
3. Substation 4
4. Substation 7
5. Substation 8
6. Substation 9
7. Substation 10
8. Substation 11
9. Substation 30
10. Substation 31
11. Substation 32
12. Substation 33
13. Substation 34
14. Substation 3 (EGCB: Emergency Generator Control Building)
15. Substation 61
16. Substation 62