SIEMENS SECTION 7 ECONOPAC / GAS TURBINE Gas Turbine and Generator General Description of Gas Turbine Detailed Description of Gas Turbine Gas Turbine Systems Gas Turbine Instrumentation and Control Not used Not used Gas Detection System Gas Turbine Noise Enclosure Siemens Power Generation Department: W621 / B-075603 Bid Ref. No. ALG296 (1202) W62! ~ Sb Sal Algerian Energy Company Projet Skikda CCPP — 2 x 18.V94.3A, KKS MB MB MB cya Section TA TAA TAZ 72 73 TA TAA 742 75 Table of ContentsSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A ECONOPAC Gas Turbine and Generator General Description Gas Turbine MB ‘The SIEMENS model V94.3A gas turbine is a single casing gas turbine of heavy duty design with common shaft for compressor and turbine and a nominal rating of approx. 260 MW (ISO condition, 100 % methane). The principal benefits and characteristic features of this gas turbine are: Annular combustion chamber with hybrid burners for firing gaseous and liquid fuels. Hybrid burners accomplish dry low-NOx control when firing gas or oil in the upper-load range. Depending on the specified emission requirements, water injection is possible, if required and provided ~— The design of the entire combustion system is uniquely simple and conservative with re- sultant high reliability. — Twenty-four burners ensure a uniform hot-gas temperature field ahead of turbine blading. — Film cooling ensures high cooling efficiency in the first two turbine stages. — The extremely stiff light-weight rotor is supported by only two bearings located outside the pressurized region at compressor intake and turbine exhaust — Smooth running performance under non-steady-state operating conditions due to rotor construction of bladed disks with self-centering facial serrations clamped together by a single central tie rod, — Rapid start-up and loading capability due to small thermal time constants of the built-up rotor. — The generator can be motored using the variable-frequency converter which ensures not only fast, but also smooth start-up of the gas turbine. It is not necessary to overfire the gas turbine, as in the case of start-ups using a relatively low-powered starting motor and a torque converter. — High design efficiency maintained during operation by thermally flexible support of rear compressor area and turbine inner-casing sections within common separate rigid outer- casing. — Simple axial diffuser allowing unobstructed in-line ducting of exhaust gas to any heat- recovery boiler since the generator is coupled to the compressor end of the machine. ~ Heavy-duty machine design and special construction features minimize maintenance costs. = All the compressor and turbine stationary and moving blades without exception can be individually replaced in situ, if necessary, and without lifting the rotor. A longitudinal section of the gas turbine is shown in Figure MB1 ‘Siemens Power Generation Section: 7.4.4 Department: G131 / B-075603 Page 10f2 Bid Ref, No. ALG296 (1202) WE21 ~ Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A Figure MB 1: Longitudinal Section of the V94.3A Gas Turbine (Not binding for execution) TAA i ‘Siemens Power Generation Section: Department: G131 / B-075603 Page: 20f2 Bid Ref. No, ALG296 (1202) WE2t ~ Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 18.V94.3A Detailed Description of Gas Turbine Compressor, Turbine, Casing, Rotor MBA COMPRESSOR ‘The compressor, consisting of 15 stages, has a pressure ratio of about 17. The pitch of the inlet guide vanes can be varied so as to maintain a constant exhaust gas temperature down to nearly half load without an appreciable loss of efficiency. For blow-off of sufficient air quantities to ensure stable operation of the compressor at low speeds, i.e. during start-up and shutdown, blow-off lines are provided downstream of com- pressor stationary blade 5, stationary blade 9 and stationary blade 13. This is realized by annular gaps between the stationary blade carriers which lead the compressed air into three annular chambers. The blow-off lines are equipped with pneumatic dampers and feed the discharged air to the exhaust diffuser. For cooling of the turbine section air is extracted at several stages of the compressor. Inlet guide vanes and stationary blades of the first 3 stages as well as the rotor blades of the first 4 compressor stages are coated with Sermetel to protect the blades against fouling. The rotor blade roots consist of a dovetail with a short parallel guide. Size is selected to match the airfoil length. The blades are inserted into corresponding grooves of the rotor disks at the required angle. To locate the blades in axial direction, the end faces of the blade roots are caulked in recesses provided in the disk groove. The inner rings of the disks, provided for sealing against the rotor, are supported by the stationary blades by means of a hook ar- rangement. The sealing is realized by labyrinth gland sealings. The variable inlet guide vanes have pins at both ends for insertion into an inner ring and an outer ring. Blade assembly and removal is possible without lifting of the rotor being required, To recover the loss of output due to blade fouling, the compressor has to be cleaned by washing. The cleaning intervals are determined in relation to the gas turbine performance loss. Compressor washing can be carried out on-load (up to 100 % load), but off-load wash- ing is recommended to achieve a better cleaning effectiveness. The washing procedure con- sists of a cool-down-period, a washing procedure with detergent, and rinsing only with water. ‘The compressor washing equipment is a skid-mounted system. TURBINE, ‘The hot gas from the combustion chamber is expanded in a four stage turbine. The rotor blades consist of an airfoil, an inner shroud and a blade root. The blades are twisted from base to tip according to the increasing peripheral speed. The blade root is a fir-tree-foot with two or three serrations. The biades are inserted into mating grooves of the rotor disks and locked in axial direction by means of keys. The blades are manufactured from high temperature alloys to withstand for the high me- chanical and thermal stresses. The blades of the first three stages are coated for protection against high temperature corrosion. The stationary blades consist of an outer shroud, the airfoil and an inner shroud. The outer shroud attaches the blades to the stationary blade carrier and forms the outer boundary of the hot gas path. The inner shroud forms the inner boundary and holds the inner sealing, Siemens Power Generation Section: 7.1.2 Department: G131 / B-075603 Page: 10f6 Bid Ref, No. ALG296 (1202) WE21 - Sb / SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2 x 18.V94.3A All four stationary blade rows and the first three rotor blade rows are air cooled. The cooling air for the turbine is extracted from appropriate compressor stages. Blade cooling is provided by means of film, impingement and convective cooling techniques, depending on the turbine stage. COMPRESSOR AND TURBINE CASING The pressure containing outer casing, consists of four parts — Compressor inlet casing with integral front bearing housing ~ Compressor casing — Centre casing with burner ring Turbine casing The front bearing housing as an integral part of the compressor inlet casing contains the combined journal / thrust bearing The turbine casing consists of an outer shell and an inner casing that contains the journal bearing and serves as turbine blade carrier. The entire casing is fitted with a combined thermal and acoustic insulation, Horizontal splits allow easy maintenance. COMPRESSOR AND TURBINE ROTOR The rotor combines the compressor and turbine sections on a single shaft that is supported in bearings at both ends. The rotor is built up of individual disks and a front, central and rear hollow shaft. The hollow shafts and disks are clamped together by a central tie rod. The indi- vidual parts are centred by Hirth facial serrations which allow free radial expansion and transmit the torque. The tie rod is braced against the disks by rings inserted in some of the disks. For balancing purposes 5 levels are available; 3 of them are used if necessary for re- adjustment of the balancing. All compressor and turbine rotor blades can be removed without the rotor having to be lifted out of its bearings TURBINE COOLING SYSTEM The turbine cooling air system cools the rotor and the turbine blading without the use of an extemal cooling system. The turbine blading must be cooled to prevent turbine material tem- peratures from exceeding maximum permissible limits. Cooling the hot-gas-path parts im- proves service reliability, protects the parts from overheating, and increases their resistance to high-temperature corrosion. Surrounding the rotor with cooling air prevents peak thermal stresses that could distort the rotor during load changes of fast start-ups. Surrounding the turbine rotor with air from the compressor also warms up the turbine disks after a cold start. This reduces stresses on the disks and shortens the time needed to reach steady-state clearances. The different turbine stages require cooling air at different pressures. For this purpose, the cooling air system extracts air from the compressor at different locations: ‘Siemens Power Generation Section: 7.1.2 Department: G131 / B-075603 Page: 20f6 Bid Ref, No. ALG296 (1202) WE21 - Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2 x 1S,V94.3A ~ Stage 1 The cooling air for the turbine stage 1 is extracted from the compressor outlet air. ~ Stage 2 The cooling air of the turbine stationary blades of stage 2 is taken from the 13th compres- sor stage. Pipes route air from the compressor to the turbine casing, from there the air flows via bores in the turbine blade carrier to the stationary blades. The moving blades are cooled with air extracted after the 12th-stage of the compressor. This air flows via the bores of the rotor disk and the cooling air partition pipe of the rotor to the blade roots and exits the blade tips. ~ Stage 3 The blades of stage 3 are cooled in a similar manner as for stage 2: For cooling of the turbine stationary blades two pipes route 9th-stage compressor air to the turbine casing. The cooling air for the turbine moving blades is extracted from the 10th-stage of the com- pressor. — Stage 4 A single pipe routes air from the 4th compressor stage to the turbine casing, from there the air is led to the turbine stationary blades analogously as for stage 2 and 3. On the 4th-stage only the root section of the turbine moving blades is cooled with 10th- ‘stage compressor air. ‘The cooling air also serves as seal air to prevent hot gases from entering hollow spaces in the turbine rotor casing DRAINAGE SYSTEM Cleaning solution from the compressor cleaning procedure and unburned fuel oil in case of failed start-up can accumulate at several points of the gas turbine. For this reason drain lines are integrated in the gas turbine to remove this drainage to a header. Bearings MBD The gas turbine has a common rotor for compressor and turbine, built up of several disks and three hollow shafts, all clamped together by a central tie rod. Thus only two bearings are necessary to support the rotor. These bearings are located at compressor intake and turbine exhaust, which means that the bearings are located in nonpressurized regions. ‘A combined journalithrust bearing is provided at the compressor inlet. It supports the rotor, compensates for axial thrust and locates the rotor in axial position. The thrust bearing con- sists of individual thrust pads. Their active surfaces are lined with white metal. The thrust pads are secured in the bearing sleeve with cylindrical pins and supported on resilient shims for obtaining a uniform load distribution. Tilting edges at the bearing faces provide for self- alignment of the pads and thus for the formation of the oil wedges. The oil is admitted from the laterally open cil pockets of the journal bearing. The temperature of the white metal is Siemens Power Generation Section, 7.1.2 Department: G131 / 8.075603 Page: 3 of Bi Re, No, ALG296 (1202) W521 ~ Sb Sal &SIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A monitored with thermocouples installed in the upper and lower half bearing sleeves at both ends. The journal bearing located at the turbine end consists of an inner cylinder supported by five radial ribs to the exhaust casing. The active surface is lined with white metal and shaped so that supporting oil wedges are produced between the bearing and the shaft journal during operation. Lube oil under pressure is fed to the oil pockets via ducts through a rib and an annular groove in the bearing cylinder for start-up and shutdown. High pressure shaft jacking cil is admitted in order to maintain fluid friction. The temperature of the white metal is moni- tored with a thermocouple that is located in the lower part at the point of maximum load. Gears MBK TURNING GEAR ‘The hydromotor is flanged to the front end of the generator. It has the function of turning the gas turbine rotor after shutdown, thereby preventing non-uniform cool down with a resulting shaft distortion. A minimum speed is required to form a load carrying oil wedge in the bearings to prevent semi-fuid friction. The hydromotor operates with lube oil supplied from the jacking oll pump. MANUAL TURNING On the shaft a provision for manual turning of the gas turbine rotor exists. For positioning during maintenance the rotor can be turned discontinuously with small increments. The rotor is turned with a pin spanner that engages in radial bores of the intermediate shaft flange. Prior to tuming, the hydraulic jacking system has to be started up. Combustion Chamber MBM The gas turbine is equipped with 24 hybrid burners distributed equally around the perimeter of the ring combustion chamber to achieve a homogeneous temperature field in the combus- tion chamber. This design ensures concentric gas and air paths from the compressor to the combustion chamber and from the combustion chamber to the turbine involving a minimum pressure drop. ‘The combustion chamber is accessible for inspection via manholes. Thereby inspection of burners and the first turbine stage is also possible. The hybrid burners are of HR3 Type for fuel gas or fuel oil operation. All hybrid bumer as- semblies are identical and consist of several individual nozzle systems as shown in Figure MBM 1 The HR3 burner was developed in 1995 to improve the reduction of NOx emission and to avoid flashback and autoignition. The design is based on the well proven features of the original hybrid burner (SIEMENS patent awarded in 1986) which are dry low-NOx control with minimal CO emission by means of premix combustion in the upper-load range and sta- ble and reliable combustion with fuel gas or fuel oil ‘Siemens Power Gene Section: 7.1.2 Department: G131 / B-075603 Page: 40f6 Bid Ret. No, ALG286 (1202) WE2t ~ Sb/SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2 x 1S.V94.3A At diffusion operation the fuel is burnt simultaneously while mixing with the air. At premix op- eration, however, the fuel is mixed with the air within the diagonal swirler channel before burning in the combustion chamber. Water injection for thermal NOx suppression purposes is possible, if required and if provided. The hybrid burners permit the following operating modes: GASEOUS FUEL OPERATION - Diffusion burning for start up operation up to 20 % of full load - The fuel gas supplied via the diffusion gas supply line enters the axial swirlers of the diffusion gas bumer nozzles. - Mixed burning for operation between 20% and 50% of full load - Additional to the diffusion gas premix gas through premix nozzles is added. Additionally, fuel gas is fed to the pilot burner nozzle generating a stabilizing diffusion flame. - Premix burning for operation between about half and full load - Fuel gas flows through nozzles located on the diagonal swirler and mixes with air on its way to the combustion chamber. Additionally, fuel gas is fed to the pilot burner nozzle generating a stabilizing diffusion flame. LIQUID FUEL OPERATION The fuel oil diffusion burners atomize the fuel oil so that it can ignite completely in the com- bustion chamber. - Diffusion burning for operation up to full load ~ The fuel oil supplied via the diffusion oil supply line enters the swirl chambers of the dif- fusion oil burner nozzles. The one portion of the fuel oil is injected directly into the com- bustion chamber via the central oil bumer lance, while the remaining portion flows into the fuel oil return line. = Premix burning for operation between about half and full load - Fuel oil is atomized by small nozzles located in the primary air channel of the burner assembly downstream of the diagonal swirler. In this way, fuel oil and air are mixed prior to entering the combustion chamber. Additionally, fuel oil is fed to the central oil burner lance generating a stabilizing diffusion flame. ‘Siemens Power Generation Section; 7.1.2 Department: G131 / B-075603 Page: 5 of6 Sic Ref. No, ALG296 (1202) WE21 ~ Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A Promix burner Ditusion oll burner (*) Diffusion gas burner Pilot gas burner Premisgas inet (*4) Premix gas distributor (*) emis gas outlet (**) 9 Inlet of main combustion sir 10 Diagonal swirler 11 Diagonal swirler ehunnet 12. Gas net into altfusion burner 13. Gas outet from diffusion gas burner 14 Airintet to axial swirler 15. Axial swirler 16 Igniter 17 Gasoutet from pilot burner 18 Fuel ofl inlet (*) 19 Diffusion oil burner outet(*) 20 Fuel oll return flow (*) 21 Promix fuel ol distributor (*) 22 Promix fuel oll nozzle (*) 23 Low NOx water inlet (f provided) 24 Low NOx water outlet if provided) “4 (*) closed down in case of fuel gas only closed down in case of fuel oll only Figure MBM I: HR3 Burner (Not binding for execution) ‘Siemens Power Generation Section: §— 7.4.2 C Department: 6131 / B-075603 Page: «6 of 6 Bid Ret No, ALG296 (1202) W821 ~ Sb / SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S,V94.3A Gas Turbine Systems Liquid Fuel System MBN This system supplies fuel to the multi-burner ring combustor and controls the fuel flow in ac- cordance with the requirements for start-up, operation and shutdown. Under certain condi- tions, the system also stops the fuel flow to the gas turbine. The system is divided into a dif- fusion and a premix subsystem and has to be fed by a forwarding pump system. The fuel oil requirements are detailed in Section 2.1.2 and have to be met to ensure safe operation and to prevent severe high-temperature corrosion. Diffusion System The fuel oil, provided by the injection pump that is common with the premix system, flows via two emergency stop valves - the second one being a combined control/stop valve - to each bumer where it enters a spill-return swirl atomizer. From there the fuel oil either is injected into the ring combustor, where it is atomized into minute droplets by centrifugal forces, or fiows into the return line passing through an emergency stop valve and the diffusion control valve. The return line is connected to the feed line upstream of the injection pump for recircu- lation operation. During operation of the gas turbine the return oil flows through this feed line while during start-up the oil returns to a tank. The fuel mass flow to the ring combustor is controlled by regulating the mass flow in the return line, i.e. the more the diffusion control valve is closed, the more fuel will be injected. Premix System The fuel mass flow, provided by the injection pump, passes through an emergency stop valve and a combined control/stop valve serving as the premix control valve, enters the pre- mix zone of the bumer via nozzles and is atomized into extremely fine droplets for thorough evaporation and mixing with air before burning. Purging Water System ‘When firing fuel oil the purging water system supplies demineralized water to the burners in the following cases — during loading before switchover from diffusion to premix mode to cool the premix burn- ers, after switchover from premix to diffusion mode for cleaning the premix burners and after shutdown for cleaning the diffusion burners to prevent them from coking of oil residues. ‘Siemens Power Generation Seetion: 72 Department: G131 / B-075603 Page: 10f7 Bi Ret. No. ALG295 (1202) W621 ~ Sb/SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A Sealing Air System The fuel oil supply lines of the hybrid bumers are connected to cooling air lines. When firing gaseous fuels or fuel oil in diffusion mode, air from the compressor outlet is cooled and flows through the fuel oil supply lines — in case of fuel oil diffusion operation only through the pre- mix burner line — into the combustion chamber thereby sealing the fuel oil lines and avoiding the formation of ignitable airlgas mixtures within them, = cooling the fuel oil lines and nozzles as well as — protecting them against coking. Gaseous Fuel System MBP Description Fuel Gas System The system supplies fuel gas to the multi-burner ring combustor and controls the fuel flow in accordance with the requirements for start-up, operation and shutdown. Under certain pro- tection conditions, the system also stops the fuel flow to the gas turbine. Dry, clean fuel gas must be supplied to the fuel gas system in order to prevent corrosion, erosion and the forma- tion of deposits on the components of the hot gas path. The pressure of the fuel gas at the fuel gas system inlet must be relatively constant regardless of the rate at which itis supplied Fuel: specifications are detailed in Section 2.1.2. As stated there it must be taken care that gaseous fuels shall not contain any liquid hydrocarbons (e.g. residual lube oil from gas sup- plier or gas compressing station). If this requirement is not met, severe damage to the burn- ers may result Ignition Gas System MBQ For ignition of the burners during the start-up procedure always a gaseous fuel is necessary, eg. natural gas with a calorific value > 35000 kJ/kg or propane gas. Gaseous Fuel Operation Proposed the calorific value meets the limit stated above, natural gas is fed to the burners via the gas diffusion supply line. Ignition flames are generated by the electric ignition device in- stalled in each hybrid burner. The ignition flame is then increased to the main diffusion flame. Liquid Fuel Operation If natural gas with a sufficient calorific value is available it is fed to the burners via the gas diffusion supply line. Ignition flames are generated by the electric ignition device installed in each hybrid burner. The ignition flame ignites the liquid fuel from the oil diffusion burner. If natural gas is not available e.g. propane gas from a tank is supplied to the gas diffusion line of the hybrid bumers and ignited by the electric ignition devices. The ignition flame ig- nites the liquid fuel from the oil diffusion burner. Siemens Power Generation Section: 72 Kh Department: G131 / B-075603, Page: -20f7 Bia Re No, ALG288 (1202) We2i ~Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A Lubrication Oil System MBV ‘The lube oil for the gas turbine, generator and steam turbine is supplied by one common lube oil system. For the description please refer to section 3, “Steam Turbine’. Mechanical Control and Protection Systems MB Blow-off System The axial compressor of the gas turbine is designed to run at the rated speed of the turbine generator unit. During start-up and shutdown procedure at speeds below rated speed all four blow-off valves of the compressor (downstream of stationary blade 5, stationary blade 9 and stationary blade 13) are fully or partially open, to minimize start-up energy and to avoid com- pressor surging. The blow-off pipes are connected with the exhaust gas duct downstream of the turbine. If the speed drops below 95 % of rated speed during load operation, the two blow-off valves located behind stage 5 are opened by the underfrequency protection system. If blow-off valves are fully or partially open during load operation, the output and efficiency of the gas turbine decrease. The blow-off system is activated automatically if necessary. Hydraulic System The purpose of the hydraulic system is to position the control and stop valves. The central hydraulic oil supply unit is preassembled serving as a carrier for all pumps, filters, accumula- tors, instrumentation, ete. There are 2 main hydraulic oil pumps, one serving the system and one kept as a standby pump in case of failure of the first pump. Department: G131 / B-075603 Page: 30f7 Bid Ref, No. ALG296 (1202) W621 - Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A Gas Turbine Instrumentation Speed Measurement MBA CS The gas turbine is designed for steady-state operation within a permissible range. The opera- tion of the gas turbine beyond this range is permissible only for a short period of time. Speed Rang of the Gas Turbine |) ‘The gas turbine operation in the range 95% to 103 % of rated speed is without restriction. ll) In the ranges 94% to 95 % and 103 % to 104 % operation is allowed for max. 20 seconds per event otherwise the generator will be disconnected from the grid, when the gas turbine is in normal operation. After a total of 30 minutes (i.e. several events), compressor and turbine have to be inspected. During start up or at full speed with no load, the gas turbine will trip. Ill) Operation below 94 % or above 104 % is not permissible. When the speed falls below 94 % or rises above 104 % during normal operation, the gas turbine generator will be disconnected from the grid, IV) Overspeed trip is set at 108 %. To prevent the gas turbine from operating at unpermissible speeds, the turbine is equipped with a speed sensing and an overspeed protection system. Speed sensors detect changes in the magnetic field created by slots on the intermediate shaft. The output signals undergo further processing in two three-channel redundant speed monitoring systems which forward their signals to the overspeed protection system. Each channel has its individual signal con- ditioning unit and limit value monitoring unit. If at least 2 out of 3 speed signals of either one of the two speed monitoring systems indicate that the speed exceeds, the gas turbine is tripped, Casing Vibration Measurement MBD CY The casing vibrations are measured at the turbine and compressor bearing housing by vibra- tion sensors. The casing vibrations are measured at the bearings because at these locations the vibration energy is transferred from the rotor to the machine components and supports. From the pickup signals a signal processing unit calculates the effective vibration velocity. The velocity value is forwarded as analogous output signal to the gas turbine control system If the effective value of the vibration velocity exceed the limit (e.g. 9.3 mm/s) at the compres- sor or at the turbine bearing a bearing warning is issued. The gas turbine is tripped if the higher limit (e.g. 14.7 mm/s) is exceeded. ‘Siemens Power Generation Section: 72 Department: G131 / B-075603 Page: 4of7 Bid Ret No, ALG298 (1202) WE2t ~ Sb/SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S,V94.3A Bearing Temperature Measurement MBD CT The gas turbine has two bearings: the compressor bearing, designed as a combined journal and thrust bearing and the turbine bearing, designed as a radial bearing. The bearings are cast with babbit metal. Four dual-element thermocouples and one triple-element thermocouple monitor the com- pressor bearing metal temperature. If the compressor bearing metal temperature exceeds a certain value (e.g. 100 *C) bearing alarm is issued. The turbine journal bearing temperature is monitored by a triple-element thermocouple. If a defined value (e.g. 110 °C) is reached bearing alarm is issued, A trip is initiated if either the compressor or the turbine bearing reaches a higher limit (e.g, 120 °C). Turbine Outlet Temperature MBA CT The turbine outlet temperature is measured by 24 triple-element thermocouples which are equally spaced on the circumference of the exhaust diffuser. The temperature signals serve two different tasks: temperature control in the combustion chamber area and temperature protection. If the temperature control system fails, the temperature protection system initiates a turbine trip, preventing that the turbine is operated at unpermissible high temperatures causing damage of the turbine. Flame Monitoring MBM CQ The combustion flames are monitored by means of two monitoring systems, each consisting of one flame scanner and an associated analog module. The radiation emitted by the flames (UV to IR range) is detected by the flame scanners, which are located somewhat offset from one another on the circumference of the combustion chamber. Each monitors a group of ap- proximately 7 burners. Both flame monitors cover an area encompassing approximately 11 bumers together. Non-monitored flames are ignited in the hybrid ring combustor by means of cross-ignition. Air Intake System for Gas Turbine MBL Description The air intake system provides filtered air to the combustion turbine compressor as required for operating the gas turbine in the locational environment. The intake system will be equipped with a self-cleaning filter system and a static filter. Furthermore silencers reduce the noise emissions of the gas turbine compressor inlet . The system is accessible for in- spection and maintenance. Department: G131 / B-075603 Page: 5of7 Bid Ref, No. ALG296 (1202) W621 - Sb/SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A, Filterhouse The filter system consists generally of a steel structure equipped with horizontally or vertically arranged filter cartridges Downstream of the pulse filters, a single stage of fine filters will be installed. ‘The filter cartridge elements will be self-cleaning, through a pulsejet system, in which short bursts of compressed air are administered from the inside of the cartridge, dislodging accu- mulated dust and dirt from the filter media and deposition it down and away from the car- tridges. The cleaning cycle is controlled by differential pressure switches. Pulse cleaning is to be ini- tiated when the system’s differential pressure exceeds a high vacuum set point and contin- ues sequentially through complete cycles for all cartridges until a low vacuum on the differen- tial pressure switch is reached. The high vacuum and low vacuum set points are adjustable. Additionally the control system will be equipped with a timer and a manual push button for the actuation of the self-cleaning system. Not more than 5 % of the filter elements will be cleaned simultaneously. During operation the differential pressure is monitored and an alarm is generated when the filter elements have become polluted To protect the air intake system against extreme subatmospheric pressure, a two out of three pressure signal can initiate a GT trip. Implosion doors will not be provided. Silencer The silencers contain sound absorbent baffles, The baffles are covered with perforated sheets and filled with high quality heat and moisture resistant mineral wool. The mineral wool is covered by a glass fiber material which gives an additional mechanical protection for the absorbent material. Ductwork The construction of the duct modules is of a double wall design. The space between inner and outer wall is filled with sound absorbent material. ‘The ductwork consists of welded steel profiles. The duct wall is welded to the steel profile construction. Anti-resonant material is applied to the steel plates, The ductwork is divided in two major parts connected by a flexible expansion joint to avoid sound transmission of structure-bome sound, - ft Siemens Power Generation Section: Department: G131 / B-075603 Page: 6of7 Bi Ret, No. ALG206 1202) W621 ~ Sb/SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 18.V94.3A Exhaust Gas System MBR Gas Turbine Diffuser Technical Description ‘The gas turbine exhaust system consists of the diffuser which connects the gas turbine with the heat recovery steam generator. Diffuser The diffuser is made of a welded construction and internally insulated. Thermal expansion between turbine and diffuser shall be accommodated by means of an expansion joint installed between the turbine outlet and the diffuser inlet. The diffuser shell is made of carbon steel and stiffening ribs are welded on the outside. The shell is intemally insulated by ceramic fibre material. The insulation is covered by a stainless steel liner consisting of sliding plates which are supported by pins and bars. The diffuser is ‘supported near the inlet and outlet end. ‘Siemens Power Generation Section: 72 ¢ Department: G131/ B-075603 Page: 7of7 Bid Ret. No, ALG296 (1202) W621 ~ Sb SalSIEMENS Algerian Energy Company Projet Skikda CCPP — 2 x 18.V94.3A Gas Turbine Instrumentation and Control Overall View of the Gas Turbine 1&C System ‘The gas turbine 1&C system is made up of components of the same electronic family as used for the I&C for the power plant. This enables the equipment to fully communicate through the bus link with the plant operating, monitoring and engineering system. A general description of the 1&C system and an overall I&C configuration overview will be given in section 11. Gas Turbine Automation Automatic Start-up Control - Programs for automatic start-up and shutdown of gas turbines. The programs ensure activation of the components involved in the correct sequence. The sequences include the following - Activation of auxiliaries such as lube and hydraulic oil supply and fuel supply systems - Activation of start-up converter — Initiation of ignition ~ Enabling of synchronization and loading = During standstil of the gas turbine generator the “ready to start" criteria is maintained by oil circulation and periodic turning of the rotor. ~ Digital display of the current program step at the control station - In case of program stop, indication at control station and printout of missing criteria in plain text on the event printer = It is not possible to switch each control in automatic and manual operation at any time. On restart of the start-up control (after a permitted manual operation), the program automatically proceeds to the actual step, which is required by the process. ‘Sub-loop Control Sub-loop control is employed for process-controlled automatic circuits (in particular, for turbine control cil and bearing oil circuits, rotor jacking, rotor turning, etc.) Drive Control = Control and monitoring for motors, actuators, and solenoid valves = Control of the drives by: ~ Commands for the automatic start-up control ~ Sub-loop control or protective logic Manual commands from the control station (where necessary) Department: G131 / B-075603 Page’ 10f8 Bid Ret, No. ALG206 (1202) WE21 ~ Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP — 2 x 1S.V94.3A Protective Logic - Passive protective logic for drive control enabling, signal logic for alarms, and checkback signals as well as all other logic gating are implemented by software. - Active protective logic commands act on the drive control and take priority over manual and automatic commands. - Aprotective logic cannot be switched OFF. GAS TURBINE PROTECTION ~The 2-or-3 channel process signals are connected redundantly = In normal operation availability is improved by the use of redundant trip logic. Upon failure of one protection path selected protection functions are maintained by converting the protection circuit from a multi-channel to at least single channel operation. ~ Warning signals for counteractions prior to gas turbine trip-out - Fault and trip alarms are transmitted via alarm log printer. ESSENTIAL PROTECTION CIRCUITS ~ Over-speed ~ Calculated turbine outlet temperature (OTC) Flame off = Lubrication oil pressure = Bearing pedestal absolute vibration - Bearing temperature ~ Surge protection FAILSAFE PROTECTION CIRCUITS ~ For control of fuel emergency stop valves - Break current trip circuits for over-speed protection and flame monitoring are approved by TUV (German Authority for testing technical equipment) ~ Redundant gas turbine manual remote trip using break current circuit Department: G31 / B-075603 Page: 2 of 8 Bid Ref, No. ALG296 (1202) WE21 ~ Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP — 2x 1S.V94.3A OVER-SPEED PROTECTION SYSTEM Because of the stringent requirements here, the over-speed protection system is of redundant and multi-channel design and based on the break current principle. It consists of: ~ Speed acquisition, limit signal formation - Turbine trip system SPEED ACQUISITION, LIMIT SIGNAL FORMATION - 6non-contacting magnetic field probes are used to acquire the speed. A toothed wheel machined into the turbine shaft generates a frequency proportional to the speed. - pickups are connected directly to Over-speed Protection System 1 (hardware), and 3 other pickups are connected to System 2 (software). = The turbine speed is monitored by special limit value monitors. The limit signals are input to the fault-tolerant automation system to derive the trip logic. Measurements for overspeed protection 1 Measurements for overspeed protection 2 -—— or ena Srarcoos | wh yo b+ orepees Le o— onnoens «| u " 71. caroa,, —_- a a Sora ance figure *- Overspeed measurements OVER-SPEED TURBINE TRIP SYSTEM - Special protection programs are provided within the automation subsystem. For over- speed two independent 2-out-of-3 functions are formed. In the case of a faulty input signal (break circuit working) the affected protection logic is changed over to 4-out-of-2 coincidence logic. Siemens Power Generation Section 7 Department: G131 / B-075603 Page: Sof Big Ref, No. ALG296 (1202) WE21 - Sb/ Sal 3 8SIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 18.V94.3A - Over-speed Protection System 1 has its own dedicated 2-out-of-3 coincidence hardware logic. This operates on the break current principle, acting on the signal paths to the solenoids. = The turbine trip signals are applied directly to the solenoids of the fuel emergency stop valves via redundant relay modules. - All safety-related inputs and outputs of the system are tested automatically and cyclically for safe functioning. Any malfunctions are shown on the operation terminal resp. printed on an alarmilog printer. - There is additional test logic for the over-speed protection. These test the 6 speed limit value monitors using a test generator. ‘Overspeed protection system 2 aw LS Pf i i cu : Boa ag ; aq Hy ; ; | ; pa i ! ee ee a Tit Seabee aan aT as | 1 eae ’ Law |_IE aH atl : Hr | i+} | = [In ala 2H # Te te ue figure 2: Overspeed protection systems: ‘Siemens Power Generation Section: 7.3 Sepurenen 1911 8.78803 Boos as Bid Ref, No. ALG206 (1202) WE2t - Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A Measurement and Monitoring Standard measurements, ¢.9. from thermocouples, resistance thermometers, 4-20 mA transducer output signals, are input directly into the coupling level of the automation subsystem with the aid of analogue input modules. Further signal processing is implemented by software logic. Important measured values are available on the operating and monitoring system in the central control room via the bus system for process monitoring For special measurement application equipment is mounted in a measuring cabinet: = Two sensors per combustion chamber in a two-channel configuration monitor the flame in the infrared to ultra-violet range. ~The electronics are housed in a sub-rack. ~ Hardware for signal conditioning for bearing vibration monitoring - Here, the signals from the piezoelectric vibration transmitters are amplified, transformed and output (2 channels; 4-20mA) for gas turbine protection and recording, ~The electronics are grouped together in one sub-rack Hardware for signal conditioning for shaft vibration monitoring - Redundant speed acquisition (2x3 channels) with the aid of non-contacting magnetic field probes = Creation of limit signals for protection, control and of 4-20 mA analogue signal = Transmitter power supply, limit value monitors and logic modules are housed in two sub- racks. MAJOR INSPECTION CLOCK The intervals between major inspections are measured by a major inspection clock. The following criteria are considered and counted: - Number of starts ~ Number of emergency loading sequencesiblack starts = Base load operating hours - Counting of dynamic operating hours Siemens Power Generation Section: 73 de Department: G131 / B-075603 Page: 5 of8 Bid Ref, No. ALG296 (1202) WE2t ~ Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP ~ 2x 1S.V94,3A Gas Turbine Contr FEATURES - Main closed-loop control functions are implemented within the controller, which is a redundant multi-micro-processor system. ~ The controller acts via electro-hydraulic actuators to transmit high positioning forces. - Testing and pre-setting will be at manufacturer's works. FUNCTIONS AND GENERAL STRUCTURE. - For the general control scheme please refer to figure 3. SPEED RUN-UP CONTROLLER = Ramped opening of the fuel control vaive starts when ignition speed is reached. - Run-up is monitored by a run-up protection function, which limits valve lift when activated, COMBINED SPEED / LOAD CONTROLLER - Speed controller takes over control of the turbine generator from the run-up controller after rated speed has been reached. - Load controller takes over control of the turbine generator from the speed controller after synchronization has been performed. - Loading of turbine generator up to target setpoint is performed by the load setpoint control in line with the load gradient. INLET GUIDE VANE (IGV) PITCH CONTROLLER - This controller enables high efficiency operation with high turbine inlet temperatures and low NOx-emission at reduced load output - especially for Combined Cycle Process - by control of the compressor air mass flow. - The IGV controller is operating in co-operation with the Temperature Limit Controller. So it is possible to meet the requirements of heat recovery steam generators (e.g. lower temperatures at high air mass flow). - After reaching the base load temperature, the guide vane pitch control starts to open the guide vanes to increase the air mass flow in the turbine. Increasing load is directly ‘coupled with the increase of the air mass flow. So the guide vane pitch controller enables to hold the outlet temperature constant over a certain load range. FUEL PROPORTIONING ~ This function will only be available, if 2 independent actuators, for diffusion and premix operation, are provided for the gas turbine (pls. refer to chapter 7.2) - In this case, the controller does the fuel proportioning changeover between both valves. ‘Siemens Power Generati Section 73 dt Department: G131 / B-075603 Page: 6 of8 Bid Ref, No, ALG296 (1202) WE21 ~ Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP — 2x 1S.V94.3A aE z Gas turbine controller | yd ~ Conpeser ——Conbton Charter figure 3: Gas turbine controller - schematic diagram without imit controller (general layout) OUTPUT MEASUREMENT Measurement of generated active power is provided with 2 separate transducers in MAX- selection. ll Siemens Power Generation Section: 73 Department: G131 / B-075603 Page: 70f8 Bid Ret. No, ALG296 (1202) W62! ~ Sb / SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 18.V94.3A OUTLET TEMPERATURE CONTROLLER (OTC-CONTROLLER) = This controller limits thermal loading on the gas turbine. = It takes over control of the turbine generator when base load temperature is reached and the guide vane pitch controller is fully opened. OUTLET TEMPERATURE CORRECTION (OTC) = 6 thermocouples for outlet temperature will be used for OTC calculation. = They are separately monitored and disabled in the event of a fault - The controller evaluates the average of these 6 temperatures and does a static correction with the average of all other outlet temperature measurements The average outlet temperature will be corrected with the compressor inlet temperature and the turbine speed. ‘Siemens Power Generation Section: 73 J Department: G131 / B-075603. Page: 8 of8 ‘Bed Ref. No. ALG236 (1202) W621 ~ Sb / SalSIEMENS Algerian Energy Company Projet Skikda CCPP — 2x 1S.V94.3A Electrical Package for Gas Turbine Introduction The electrical equipment is designed to assure high availability and reliability of the power plant in all modes of operation, using well proven standardized equipment complying with VDE, IEC and DIN regulations. The basic electrical circuit is shown on the electrical single line diagram for the power plant (please refer to section 6) GT-Package System Voltages please refer to section 10.1 Earthing Arrangements please refer to section 10.1 Generator Connection for the IPB please refer to section 10.3 Neutral Connection, Neutral Grounding Cabinet please refer to section 10.3 Current Transformers The generator current transformers are installed on the generator bushings on both the neutral and on the IPB side. Low Voltage Systems A low voltage switchgear and a DC-distribution board are provided for supply of Gas Turbine related consumers. For further information and technical data please refer to section 10.7 and the single line diagram of the plant (section 10.1) 741 9 ‘Siemens Power Generation Section: Department: W621 / B-075603 Page’ 10f4 Bid Rot. No. ALG298 (1202) W2t - Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP ~ 2x 18.V94.3A DC Systems The 220V-DC system provides power for Gas Turbine related consumers, e.g. switchgear control, protection, emergency lighting of PCC’s and emergency oil pumps, thus ensuring a secure run down of the turbosets without the need for manual intervention in case of total loss of the AC supply. The battery has an adequate capacity to supply the emergency loads for a discharge time of 1 hour. The 220V-DC system for each unit is fed from two battery chargers and one lead-acid battery. The battery chargers are supplied from the normal AC system. The 24V-DC loads are powered via DC/DC converters from the 220V-DC system. All important 24V-DC loads (@. g. cubicles for 1&C system) have a double infeed via decoupling diodes. These double infeeds are provided from different DC/DC converters. For further information and technical data please refer to section 10.8 and the single line diagram of the plant (section 10.1). Generator Protection, Synchronisation, Metering and Measuring For details please refer to section 10.11 Location of Electrical Equipment of the Gas Turbine Package A substantial portion of the electrical equipment of the gas turbine package is installed in ‘standardized, prefabricated Power Control Centers (PCC), located in front of the turbine package, very close to the corresponding gas turbine unit. The use of the PCC technique provides the following main advantages: — Basic pre-commissioning of the electrical and C&i equipment by well educated and specialized Siemens staff at the manufacturing plants = Minimizing of transportation risks due to special dispatch of the complete PCC modules = Shortened final commissioning and on time start-up at site PVC insulated cables and wiring according IEC 60332 Part 1 resp. VDE 0472 Part 804 will be used for the prefabricated cable connections inside of the Power Control Centers. The features of the PCC _modules as described below make them equivalent to a conventionally erected housing/building - The degree of protection of the switchgear rooms is IP54, - The switchgear room temperature in the PCC modules is controlled between 10°C and 35°C with air conditioning aggregates. At least one redundant air conditioning aggregate is provided. - The air is cleaned with a filter. Dehydration of the incoming air takes place at the heat exchangers, so that condensation inside the modules cannot occur. Any ingress of moisture or dust by leakage is prevented by the sealed construction. - The cable entries are from the bottom side of the PCC modules. EQUIPMENT IN THE TWO PCC’S - UBA 01/02 Siemens Power Generation Section: 7.4.1 fe Department: W621 / B-075603 Page: 20f4 Bid at. No, ALG206 (1202) W2i ~ Sb / SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A - Electrical generator and transformer protection = Gas turbine protection = All necessary control & instrumentation equipment = Low voltage Switchgear (AC) and 220V DC-Distribution = DCIDC-converters - Battery, Battery charger - Generator metering and measuring equipment - Synchronizing equipment = Starting frequency converter (SFC) - Static excitation equipment - Gas detection central unit EQUIPMENT INSTALLED OUTDOORS OR INSIDE GAS TURBINE BUILDING - Generator connection box ~ Generator neutral point cubicle - _ Dry-type transformers for excitation equipment and SFC with metal enclosure (IP23) Modes of Operation The GT-package electrical system is able to be controlled and monitored by the I&C system. The soreen based control system provides a graphical representation of the electrical system, as well as providing indication of the essential analogue and binary signals associated with the system. The I&C system automatic control program ensures that there is, little need for manual intervention in control of the electrical system. The following brief outline describes the electrical aspects of the different modes of operation: Siemens Power Generation Section: 7.41 7 Department: W621 / B-075603 Page: 3 0f 4 Bid Ref. No, ALG296 (1202) W621 ~ Sb / SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A START-UP The control system runs sequentially, so that the start-up of the turbine can only begin after all specific plant preparations have been made (e.g. fuel system). As a first step the static frequency converter will be switched to the generator leads. Then the frequency converter together with the static excitation is energized, The static excitation is controlled in such a way that with increasing generator speed the maximum operating voltage of the static frequency converter is not exceeded. If the turbine unit has reached approximately 70% of the rated speed the starting frequency converter (SFC) and the static excitation equipment (SEE) is switched off. The turbine accelerates itself up to the synchronous speed. Above 90% of rated speed, the no-load excitation will be released. Synchronization of the gas turbine unit is carried out by the use of a synchronizing equipment. After synchronization conditions have been reached, the ON-command will be initiate that the generator circuit breaker or the HV-breaker will be closed to connect the generator with the grid. After synchronization the power controller loads the turbine according to a pre-set gradient to the required power. Siemens Power Generation Section: 7.4.1 Department: W621 / B-075603 Page: 404 Bid Ref. No, ALG206 (1202) WE2t ~ Sb / Sal idSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A. Gas Detection System (CYQ) General The gas detection system is provided to monitor dangerous areas in order to warn the operation personnel immediately in the event of a leakage within the gas turbine area and the gas skid System Description The control and indication of the gas detection system is carried out by a main control unit. Detectors which are sensitive to the monitored gas will be installed at certain danger areas. In the event of gas is detected the operation personnel will automatically be warned against the hazardous situation by audible alarm. In areas with a high noise level a visual alarm is additionally provided. The main control unit is supplied by the 24V DC-system of the gas turbine unit. Block Diagram The following diagram shows the principal arrangement of the main components. Input Output Interface "Main Control | interface Unit : _—— LEZ\ i i i i Power ‘Supply Description of components The detectors are of the infra red (IR) type and suitable for natural gas (Methan CH,). The output signals to the GT I&C are system fault ( one contact) and the gas turbine trip signal (two contacts). The detectors are located in the combustion chamber area und the fuel gas valve package. Audible and visual alarm devices are located in the supervised areas and at the control station. = é Siemens Power Generation Section: 7.42 Department: G132 / 8-075603 Page: 1of1 Bid Ret. No. ALG296 (1202) W621 ~ Sb/ SalSIEMENS Algerian Energy Company Projet Skikda CCPP - 2x 1S.V94.3A Gas Turbine Noise Enclosure To reduce the noise level to 75 dB(A) for the Gas Turbine (measured in 1 m distance to the surface and 1.5m height) a noise enclosure including forced ventilation, lighting, CO,-fire fighting and fire detection system is supplied. Forced Ventilation for the Gas Turbine Noise Enclosure Ventilation is provided by a subatmospheric ventilation system. Basically the ventilation system maintains the following functions: ‘* Purging and removal of harmful vapors from the enclosure. ‘+ Maintaining of a defined temperature range inside the enclosure. The acoustic enclosure is ventilated by means of a mechanical exhaust system. Air from the surrounding space is sucked as ventilation air to the acoustic enclosure via air intakes at low level. The exhaust air is extracted via a system of ductwork and exhausted directly into the atmosphere by an exhaust air-handling unit. In operation, this system causes a slightly lower pressure within the acoustic enclosure than the ambient pressure. The exhaust air duct is connected to the enclosure on top of the enclosure roof. The air-handling unit is located according to standard arrangement next to the enclosure outside of the turbine hall The ventilation system is sufficient to exhaust the waste heat to the atmosphere and is designed as dilution ventilation for explosion protection. Design Criteria: Maximum intake air temperature into enclosure + 45°C Maximum temperature inside enclosure + 55°C (average) Enclosure for Fuel Gas Skid To reduce the noise level to 83 dB(A) for the Fuel Gas Skid (measured in 1 m distance to the surface and 1.5m height) a noise enclosure including forced ventilation, COz-fire fighting and fire detection system is supplied. The Fuel Gas Skid enclosure is attached to the GT enclosure. Ventilation and fire fighting systems are combined with the systems of the GT enclosure. Forced Ventilation for the Fuel Gas Skid Enclosure Ventilation system of the Fuel Gas Skid Enclosure is combined with the ventilation system of the GT enclosure. Department: G133 / B-075603 Page: 10f2SIEMENS Algerian Energy Company Projet Skikda CCPP — 2x 1S.V94.3A Enclosure for Gas Turbine Hydraulic Skid To reduce the noise level to 80 dB(A) for the Gas Turbine Hydraulic Skid (measured in 1m distance to the surface and 1.5 m height) a noise enclosure is supplied. The Gas Turbine Hydraulic Skid enclosure is tight fitting and ventilated by natural draft. ire Detection and CO2-Suppression System for Enclosures Amultizone CO,-Fire Fighting System will be provided for following extinguishing areas: — Gas Turbine enclosure and Fuel Gas Skid enclosure & ‘Siemens Power Generation Section: 15 Department: G133 / B-075603 Page: 20f2 Bid Rot, No, ALG296 (1202) W621 — Sb/ Sal