GAS TURBINE - LITERATURE HISTORICAL PROSPECTIVE OF GAS TURBINE: In October 1791 idea of gas turbine was put by JOHN

BARBER of U.K.,British patent No. 1833. Dr. F. STULZE German scientist has developed GT with 0% efficiency. In between 1900-1906 1st GT of modern type was presented in paris,france,with continuous combustion ,subsequently G.E. has started program on GT with actual engineering and drawings. In between 1947-48 various capacity of GT have been put up in operation.1 st combined cycle plant of 3.5MW capacity was started in U.S.A. and in 1949 GT capacity enhanced to 50 MW. GAS TURBINE HISTORY OF INDIA 2*23 MW in 1965 April, at namrup ASSAM by ASSAM ELECTRICITY BOARD. First gas turbine in GUJARAT of 2*27 MW (FIAT DESIGN) was installed at Dhuvaran in 1970 by G.E.B. Subsequently WEST BENGAL,URAN (MAHARASHTRA), DESU,J&K and NTPC central sector enter into gas turbine power generation field. ENVIROMENTAL ASPECTS Natural gas without any sulphar contents used as a fuel for gas turbine, leaving no SO-2 emission, suspended and other polluting element particles to atmosphere after combustion. In comparison with fossil fuel power plant pollution, GT utility is more friendly to environment.

INTRODUCTION Energy of hot gases is converted in to work i.e. this conversion is taken place in nozzle section of turbine. Gases are expanded and energy converted in to kinetic energy in buckets. Turbine is also driving compressor, this compressor utilize 50% of energy for driving. Balance out put will be useful work available at turbine flange which is connected to load. Our is MS6001B series of GE make Model ,its firing temp is 2020F at base load .Heat rate is 11120 BTU/KWh. Exhaust temp is 1017F.

BRAYTON CYCLE: Invented by GEORGE BRAYTON.

1-2 = compression accured in compressor 2-3= Constant pressure heat addition in combustion chamber. 3-4= Expansion takes place in turbine. 4-1=Constant pressure cooling process in turbine. GAS TURBINE M.S. 6001B Gas turbine of GE make Ms6001B frame VI single shaft ,heavy duty latest state of art in gas turbine technology, whole package is supplied by BHEL.The MS6001B GT works thermodynamically on BRAYTON CYCLE. It has three stages of turbine and 17 stages of axial flow compressor connected directly with GT shaft, and 10 nos reverse flow combustion chamber control on MARK IV.Speedetronic series of controls.Its primover is diesel engine of capacity 650hp.Natural gas is utilized as fuel at pressure 20 kg/cm2 and temp 120 c received from GAIL at rate of 9900m3/hr for full load i.e. 30 mw .

SALIENT FEATURES: 1 Highly efficient

2. Heavy duty. 3. Best possible utilization and greater conservation of scare. 4. low capital cost. 5. Requirement of less space. 6. Quick start of loading facility. Generator unit is connected on same shaft through load gear, which reduced the turbine speed from 5100 rpm to 3000 rpm. Gas turbine unit comprising following systems. 1. 2. 3. 4. 5. 6. 7. Starting device system. Cooling water system. lubrication system Hydraulic system Air system Fuel gas system Water wash system.

1. STARTING DEVICE: 650 HP diesel engine is provided as prime mover which is directly connected with turbine shaft with speed clutch arrangement. Its cooling water system is tapped off from IDCT Unit. On execution of start command diesel engine will start and run on idle speed of about 700 rpm and gradually 20% speed achieved, thereafter gas control valve starts operating and ignition takes place. In combustion chamber which further raised the speed to about 65% i.e. 3300 rpm. The diesel engine cutoff and run for 5 minutes for uniform cooling of engine body. 2 COOLING WATER SYSTEM: Cooling water system will perform cooling of following. 1 Generator air cooler 2 Lubrication oil cooler 3 Turbine lag cooling 4 Cooling water to diesel engine D M Water system For this 450 m3/hr capacity two no IDCT PUMPS are installed. Its cooling water pressure is 2.5 Kg/cm2 over and above , tapping for this system is available from circulating water inlet as stand by arrangement. In event of IDCT out of service. IDCT system has two pumps, one in running and another as stand by with auto changed facility on dropping of cooling water discharge pressure is very low. Stand by pump will start within 12 seconds.

3 LUBRICATION OIL SYSTEM: This system is fulfilled lubrication oil requirement to all bearings. Oil for trip oil ckt, i.e. control oil, starting device etc. System consist 6500 ltrs capacity main oil reservoir in base of gas turbine with following auxiliary items. a. Electrical driven auxiliary oil pump discharge oil pressure 4.6 kg/cm2 and 946 litres/minute oil flow.

b. D.C. emergency oil pump D.C. supply driven pump on 125 V D.C. battery set is provided, discharging pressure 4.6 kg/cm2 and 1741 litres/minute oil flow which is connected directly on lubrication oil header by passing filter, cooler etc. This pump will come in service at time of total power failure as backing protection. c. Accessory driven MOP: This is very common system in high speed m/c. If force over it function at 95% of speed. All lubrication oil requirement in running m/c will be full fill by this arrangement. Lub oil at 1.8 kg/cm 2 pressure used for all BRGS; suction for auxiliary hydraulic pump & shaft driven hydraulic pump. Oil for starting device & rotated operation. Control oil, lub oil returns after performing its function back to MOT where lubrication is cooled upto 50 C. by means of lubrication oil cooler. 4. AIR SYSTEM: All requirement of air for GT m/c is fulfilled by 17 stage axial flow GT compressor. Suction of GT compressor is taken from 384 nos.air filters (8x24raws) system provided air requirement for following function. a. Seal air to turbine bearing nos 1 & 2. b. Cooling air to internal parts of buckets, nozzles. c. Cooling air in turbine outer shell & exhaust frame. d. Control air for air operated valves. e. Duloe air to self cleaning system of air filters. Air extraction from gas turbine compressor & its service 5th stage extraction:- for bearing sealing. This air is filtered and cleaned by air separator to provide dirt free air for BRGS. 11th stage extraction: Tapped from four points radially for bleed system. 16th stage extraction: This is used as cooling air for GT internal cooling air through centre of turbine bore, is forced for cooling of 1st and 2nd stage turbine buckets as well as after phase of second stage wheel. -forward stage of third stage wheel -forward side of 1st and 2nd stage nozzle -forward side of second stage wheel.

AIR PROCCESING UNIT Quality of air drawn form atmosphere by GT compressor is of prime importance air contaminants like, dust, dirt ,smoke vapor, fog, particles are normally found Such contaminants can cause erosion and corrosion and fouling of compressor blades. This further lead effect on compressor efficiency which can promote even erosion and corrosion of turbine blades too, as some quantity of air is being used in GT as cooling media. Air used in GT should have qualitative control. Air borne contaminanents is very harmful; so for removal of such particle matters air filters banks are provided in 8*24 raws; two tier viz.top/bottom. In this unit Automatic Reverse Jet self cleaning arrangement is made. For this

pressurized air is utilized from last stage of the GT compressor. For removal of the large particle pre filter arrangement is introduced, which proved to be extend the life of the main filter. In this system indicating filter element choking. Air DP measurement across filter box is provided which extend alarm at 150 mm of water column i.e. 6 WCL and shutdown machine if DP reaches 200mm WCL i.e. 8WCL (05)FUEL GAS SYSTEM: Natural gas is used as fuel at pressure 20 kg/cm2 and temperature 120degree Centigrade .Before entering gas in GT fuel system. All liquid condensate is removed at gas conditioning skid. Hydraulically operated valve and gas control valve are provided. (06) HYDRAULIC OIL SYSTEM: It required for operation of gas ratio and gas control valve and IGV actuator. This system provides 80 kg/cm2 oil pressure which is developed by means of electrical driven auxiliary. Hydraulic pump (88 HQ), shaft driven MHOP. At 95% of machine MHOP is taken over. Oil supply function of hydraulic system suction of both pump are tapped from lubrication oil header line. (07) COMPRESSOR WATER WASH SYSTEM: Even though micro filters are provided to filter air and removal of air borne particles matter, air will carry some particles which accumulate on compressor blade which leads to lower compressor efficiency ultimatelly, resulting in lower load operation. The compressor is required to be cleaned by water washing arrangement system consisting one w/w pump, and one detergent pump with sufficient quantity bearing their tanks. Washing is taken on hand during shut down. Operation sequence: (for water washing) a. shut down m/c and cooled up to 80 c when space temp reached. b. fill the tank fully by 80 c feed water c. fill detergents tank 100 lit of CASTROL GT CLEAN d. m/c is made ready to start. e. Isolation of valve ,opening of valve as mention in separated sheet. F. start IDCT and CW system for cooling. g. select OFF LINE WATER WASH ON in MARK IV. h. start on cranking mode. i. observed and ensure IGV is full open. J). start w/w pump and ensure water flow is established in system. k.) stop w/w pump. l.)start detergents pump ,keep running till 100 lit detergents used. m. stop m/c for soaking for 10 minutes . n)..restart m/c on opening of IGV.water wash is started keep running till clear water is observed from w/w drain line. o) stop m/c. p)all valve position make normal and isolation for water wash may be removed. After cleaning from TMD. Start m/c on cranking .20 min for drying it there after auto command may be given and synchronized, observed abnormal noise, vibration .

Both parameter before and after water washing may be recorded and compared. GAS TURBINE AUXILARY AND LOAD.

Sr. No 01

02

03 04 05 06 07 08

Auxiallry equipment Load gear compartment Vent fan VG1 VG2 VG3 Turbine acc. Gear compartment vent fan BT1 BT2 Exhaust frame blower fan TK1 TK2 Auxiliary oil pump (AOP) Auxiliary hydraulic pump IDCT A B CT FAN Emergency oil pump

Installed kw 2 2 0.37 5.5 5.5 37 37 37 2.25 55 55 30 7.5 kw

Running m/c KW 2 2 0.37 5.5 5.5

Function Hot air ,oil vapour, Exhaust in Atmospher Ventify of turbine acc gear compartment To cool turbine shell

37 37 55 30 -

Provide lub oil/hydraulic oil charging. Starting of m/c Cooling water for DE,LOC,GENAC,leg cooler Hot air and vapour vent out to atmosphere from IDCT sump top basine. At event of total power supply failure provides lub oil requirement to brg during cooling down and ratchet operation.

START-UP CHECK PERMISSIVES (as per mark 4 control) 1) Turbine is stopped. 2) Lub oil temp. normal. 3) Over speed bolt is not tripped. 4) Vibration sensor input is enable. 5) No Flame exists. 6) Control is not off. 7) Compressor bleed valve is open.(Both) 8) Inlet guide vanes are closed. 9) Brg. Seal air valve is open. 10) Fuel lockout valve is reset.

11) Master protective logic reset. Following Tripping test are to be carried out after long shut to check reliability of turbine protection. 1) Over-speed (mechanical\electrical) 2) Hydraulic trip 3) High vibration trip. 4) Low lub. Oil pressure trip 5) High lub. Oil temp. trip. 6) Exhaust pressure high trip. 7) Inlet Air DP. Shutdown 8) Turbine emergency PB trip 9) Generator emergency PB trip 10) All tripping from electrical records..... Operation of gas turbine ( functional Description) When the gas turbine starting system is actuated and the cluth is engaged, ambient air is drawn through air inlet plenum assembly, filtered and compressed in the 17 stage axial flow compressor. For pulsation protection during start-up, the 11th stage ezxtraction valves ate open and variable inlet guide vanes are in closed position. When the high speed relay actuates at 95% speed 11th stage extraction bleed valves closes automatically and variable inlet guide vane actuator energizes to open the inlet guide vanes to the normal turbine operating position. 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 liners and enters the combustion zone through metering holes in each of the combustion liners. Fuel from the fuel skid is provided to ten fuel nozzles prior to being distributed to the nozzles. The fuel is accurately controlled to provide equal flow to the ten nozzle feed lines at a rate consistent with the speed and load requirement of the gas turbine. Fuel mixes with air in the combustion chamber and is ignited by one or both the spark plugs. Flame from combustion chamber is propagated through connecting across fire tubes to all the combustion chambers. After the turbine reaches the operating speed (5100 rpm), combustion chamber pressure causes the spark plugs to retract from hit flame zone. The hot gases from combustion chamber pass through the transition pieces and flow from there to the 3 stage turbine. In each nozzle kinetic energy of the jet is increased for useful work on the turbine rotor. The gases form the last stage of the turbine is directed into the exhaust hood and diffuser which contains series of turning vane sto turn the gases from axial to radial direction to exhaust plenum from where it passes to atmosphere through exhaust stack. Starting procedure (normal) a. select NORMAL Display b. select AUTO on operation selector c. select START on the master control selector 1) Unit auxiliaries will be started including motor driven oil pump during SEQ IN PROCESS 2) If the starting clutch is not engaged, the ratchet will operate until the clutch is engaged.

3) Starting device will start and run at idle for 2 minutes to warm up. At the end of diesel warm up period, the ratchet will operate continuously and diesel engine will accelerate. 4) The turbine shaft will begin to rotate and \accelerate when unit speed reaches 10 rpm ,hydraulic ratchet will be turned off. 5) When unit reaches 20% speed ,minimum speed signal 14 HM will displayed on CRT. 6) FSR (fuel stroke reference) will be set to firing value. FSR is the electrical signal that determines amount of fuel delivered to the turbine combustion system.Ignition systems is initiated CRT display will change from start up,status cranking to firing. 7) When flame is established CRT display will indicate flame in combustion cans number 2,3,7 & 8. 8) FSR is set back to warm up value and CRT display will indicate START UPSTATUS WARMING UP. If flame gives out during the 60 sec. firing period, FSR will be reset to firing value. At the end of the ignition period, if flame has not been established, the unit will remain at firing speed. At this time unit can be shut or fired again selecting CRANK on the operation selector. This will neutralize the purge timer and firing, timer. Reselecting AUTO will cause the ignition sequence to repeat itself after the purge timer have been timed out. If the unit id being operated Remotely and no fire has been established at the end of the ignition period the unit will be purged of unburnt fuel. At the end of purge period of 1 to 2 minutes, ignition will be attempted again. If flame is not established this tome also, starting sequence will be terminated and the unit will be shutdown. At the end of warm up period with flame established FSR will begin increasing. The CRT will indicate STATUS ECCELERAING and the turbine will increase the speed. 9) At 60% speed, the starting device will disengage and shutdown after cool down at idle speed. At this stage CRT will display START UP CONTROL at 60% speed. 10) When the turbine reaches 95% speed, the operating speed signal 14HS will be displayed on CRT auxiliary pump will shut down & shaft driven MOP & MHOP will take over function of AOP & auxiliary hydraulic pump. Subsequently compressor bleed valve will closed. M/C loaded 100% speed i.e. FSNL Observed M/C locally for any abnormalities. If nothing is noticed, * * * * * * * Closed the isolator 89A/OR 89B Conformed locally Reset AVR Closed field breaker Gradually build up voltage up to 10.5 KV Motor bus voltage & generator voltage must be equal. Match bus frequency and the generator frequency may be adjusted or follows, a) generator frequency is less than bus frequency adjust by raising

speed. b) generator frequency is higher than bus frequency adjust it by lowering the speed. * Turn selector switch on manual. * ON synchronoscope switch. * Adjust synchronoscope pointer, movement as slow as possible match point & green bulb glowing. Closed generator breaker & take 5 MW load. * Execute preselect on mark IV to take over control on mark IV raised load gradually.

1. COMPRESSOR DATA 1.1 No. of stage 1.2 Type 1.3 Direction of rotation 1.4 Compression ratio 1.5 Air outlet temperature 1.6 Rated rpm 1.7 Blade tip speed 1.8 Extraction

: 17 : Axial flow : CCW viewing along air flow direction from compressor end (diesel engine side) : 1: 11.2 : 310 degree centigrade : 5100 rpm : 340 m/sec : 5th,11th.17th stages for cooling,sealing and sss