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Gas Turbine-Generator Operation Training Manual Kuriemat Egypt Turbine Units

2010

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All rights reserved by the General Electric Company. No copies permitted without the prior written consent of the General Electric Company. The text and the classroom instruction offered with it are designed to acquaint students with generally accepted good practice for the operation or maintenance of equipment and/or systems. They do not purport to be complete nor are they intended to be specific for the products of any manufacturer, including those of the General Electric Company; and the Company will not accept any liability whatsoever for the work undertaken on the basis of the text or classroom instruction. The manufacturer’s operating and maintenance specifications are the only reliable guide in any specific instance; and where they are not complete, the manufacturer should be consulted. © 2010 General Electric Company

GE Energy

Gas Turbine-Generator Operation Training Manual Kuriemat Egypt Turbine Units 2010 Tab 1 Gas Turbine Overview Advanced F Technology for Mid Size Applications MS6001FA – An Advanced Technology 70MW Class 50 / 60 Hertz Gas Turbine MS6001FA Gas Turbine Assembly – Major Sections

GEA 12283 GER 3765 B00449

Tab 2 MS 6001FA Unit Description MS 6001FA Gas Turbine Description GT Compressor Rotor Assembly (MS6001FA) GT Turbine Rotor Assembly (MS6001FA) Turbine & Exhaust Frame Sect. Cooling & Sealing Air Flows Chamber Arrangement – Combustion (0701) Arrangement – Magnetic Pickup (0546)

GT_6FA 6FACOMP 6FATURB 6FA CSA 119E3058 121E1978

Tab 3 Turbine Control Device System System Description Schematic Diagram – Control Devices – Turbine (0415) Device Nomenclature and Location

OMMD_0415_6FA_E0765 206D7134 OMMDR_0415_6FA_01

Tab 4 Flow Inlet and Exhaust System System Description Schematic Diagram – Flow Inlet and Exhaust (0471) Device Nomenclature and Location

OMMD_0471_6FA_E0765 219D1448 OMMDR_0471_6FA_02

Tab 5 Inlet Air Heating System System Description Schematic Diagram – Inlet Air Heating (0432) Device Nomenclature and Location

OMMD_0432_6FA_E0765 219D1368 OMMDR_0432_6FA_01

Tab 6 Performance Monitoring System System Description Gas Turbine-Generator Operation Training Manual, Kuriemat, Egypt

g

OMMD_0492_6FA_E0765 1

GE Energy Schematic Diagram – Performance Monitor (0492) Device Nomenclature and Location

219D1449 OMMDR_0492_6FA_02

Tab 7 GT Lube Oil System System Description Schematic Diagram – Lube Oil (0416) Device Nomenclature and Location Lube Oil Recommendation

OMMD_0416_6FA_E0765 219D1445 OMMDR_0416_6FA_01 GEK 101941

Tab 8 Hydraulic Supply System System Description Schematic Diagram – Hydraulic Oil Supply (0434) Device Nomenclature and Device Location

OMMD_0434_6FA_E0765 219D1369 OMMDR_0434_6FA_01

Tab 9 Trip Oil System System Description Schematic Diagram – Trip Oil (0418) Device Nomenclature and Location

OMMD_0418_6FA_E0765 219D1364 OMMDR_0418_6FA_01

Tab 10 Inlet Guide Vane System System Description Schematic Diagram – IGV (0469) Device Nomenclature and Location

OMMD_0469_6FA_E0765 206D7147 OMMDR_0469_6FA_01

Tab 11 Fuel Gas System System Description Schematic Diagram – Fuel Gas (0422) Device Nomenclature and Location Device Nomenclature and Location Process Specification – Fuel Gas Gas Fuel Clean Up Standard

OMMD_0422_6FA_E0765 219D1366 OMMDR_0422_6FA_02 GT_0422_6FA GEI 41040J GER 3942

Tab 12 Cooling and Sealing Air System System Description OMMD_0417_6FA_E0765 Schematic Diagram – Cooling and Sealing Air (0417) 219D1446 Device Nomenclature and Location OMMDR_0417_6FA_01 Device Nomenclature and Location GT_0417_6FA Turbine and Exhaust Frame Sect. Cooling & Sealing Air Flows 6FA CSA Tab 13 Cooling Water System System Description Schematic Diagram – Cooling Water (0420) Device Nomenclature and Location Cooling Water Recommendations – Closed System

Gas Turbine-Generator Operation Training Manual, Kuriemat, Egypt

g

OMMD_0420_6FA_E0765 219D1365 OMMDR_0420_6FA_01 GEI 41004J

2

GE Energy Tab 14 Compressor Washing System System Description Schematic Diagram – Compressor Washing (0442) Device Nomenclature and Location

OMMD_0442_6FA_E0765 219D1370 OMMDR_0442_6FA_01

Tab 15 Load Gear System Description Schematic Diagram – Load Gear (0495) Device Nomenclature and Location

Assembly Drawing – Load Gear (Typ.)

OMMD_0495_6FA_E0765 206D7152 OMMDR_0495_6FA_01

RENK Dwg 3039242/0

Tab 16 Heat and Ventilation System System Description Schematic Diagram – Heat and Ventilation (0436) Device Nomenclature and Location

OMMD_0436_6FA_E0765 219D1589 OMMDR_0436_6FA_02

Tab 17 Fire Protection System System Description Schematic Diagram – Fire Protection (0426) Device Nomenclature and Location Device Nomenclature and Location

OMMD_0426_6FA_E0765 219D1447 OMMDR_0426_6FA_02 GT_0426_6FA

Tab 18 Gas Detection System System Description Schematic Diagram – Gas Detection (0474) Device Nomenclature and Location Device Nomenclature and Location

OMMD_0474_6FA_E0765 206D7149 OMMDR_0474_6FA_02 GT_0474_6FA

Tab 19 SPEEDTRONIC Mark VIe Control Control Hierarchy Schematic (4108) Alarm List

OMMO_5_6FA_E0765

Tab 20 Performance Characteristics GE Gas Turbine Performance Characteristics Performance Curves Base Load Compressor Air Inlet Temp. Vs. Output Effect of Inlet Guide Vane on Output Altitude Correction Humidity Correction

Gas Turbine-Generator Operation Training Manual, Kuriemat, Egypt

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GER 3567H 522HA395 522HA396 522HA397 416HA662 498HA697

3

GE Energy Tab 21 Gas Turbine Operation Operation Principle Operational Inspections Parameter Readouts and Analysis Normal Operation Sequences (Typ.) Special Operation Sequences

OMMO_1 OMMO_2 OMMO_3 OMMO_4 OMMO_6

Tab 22 Generator Description Descrip. – TEWAC 6FA Generator with Brushless Excitation Nameplate – 337X640 Schematic Diagram – Load Equipment (0440) Mechanical Outline Shaft Grounding Brushes Horizontal Duplex Air Cooler Oil Recommendations

GEK 103823b 137C2029 361B3419 132E3681 Sh 1-3 GEI 85803F GEK 106933 GEK 46135

Tab 23 N/A Tab 24 Generator Performance Operation – TEWAC Generator with Brushless Excitation Electrical Data Performance Curves Saturation and Impedance Reactive Capability Excitation Vee Curve Capability vs Cold Gas Temperature Capability vs Cold Liquid Temperature

GEK 95143b 237A7438 Sh 1-4 237A7438 Sh 5 237A7438 Sh 6 237A7438 Sh 7 237A7438 Sh 12 237A7438 Sh 13

Tab 25 Gas Turbine Fluid Specifications Lube Oil Recommendations Process Specification – Fuel Gas Cooling Water Requirement for Closed Systems

GEK 101941a GEI 41040k GEI 41004j

Tab 26 Reference Drawings Device Summary Piping Schematic Diagram Full Set Schematic Diagram – Control Devices – Turbine (0415) Schematic Diagram – Flow Inlet and Exhaust (0471) Schematic Diagram – Inlet Air Heating (0432) Schematic Diagram – Performance Monitor (0492) Schematic Diagram – Lube Oil (0416) Schematic Diagram – Hydraulic Oil Supply (0434) Gas Turbine-Generator Operation Training Manual, Kuriemat, Egypt

g

172A8969 206D7134 219D1448 219D1368 219D1449 219D1445 219D1369 4

GE Energy Schematic Diagram – Trip Oil (0418) Schematic Diagram – IGV (0469) Schematic Diagram – Fuel Gas (0422) Schematic Diagram – Cooling and Sealing Air (0417) Schematic Diagram – Cooling Water (0420) Schematic Diagram – Compressor Washing (0442) Schematic Diagram – Load Gear (0495) Schematic Diagram – Heat and Ventilation (0436) Schematic Diagram – Fire Protection (0426) Schematic Diagram – Gas Detection (0474) Schematic Diagram – Load Equipment (0440) Piping Symbols Glossary of Terms Basic Device Nomenclature International Conversion Tables

Gas Turbine-Generator Operation Training Manual, Kuriemat, Egypt

g

219D1364 206D7147 219D1366 219D1446 219D1365 219D1370 206D7152 219D1589 219D1447 206D7149 361B3419 C00023 A00029 GEK 95149b

5

Tab 1

GER-3765B

MS6001FA – AN ADVANCED-TECHNOLOGY 70-MW CLASS 50/60... Hz GAS TURBINE J. Ramachandran and M.C. Conway GE Power Systems Schenectady, NY the 7FA, just as the 9FA is derived from the 7FA. By scaling a proven advanced-technology design and combining it with advanced aircraft engine cooling and sealing technology, the 6FA gas turbine benefits from the experience gained in more than 500,000 fired hours of operation. The 6FA is also based on another proven GE gas turbine product — the MS6001B. The modular, packaged design characteristics of the 6B have 30 years of experience in addressing customer needs for high-speed geared gas turbines. By applying these same concepts to the 6FA, simpleand combined-cycle designs have been developed that allow power train components to be shipped assembled for both 50 Hz and 60 Hz applications (Figure 1). Table 1 compares the 6FA performance data with that of the 6B and the 7FA. The 6FA offers a 79% higher rating than the 6B (70.1 MW vs. 39.2 MW) and has an overall combined-cycle thermal efficiency (54%) typical of the more advanced Ftechnology gas turbines. As the world’s power generation needs continue to grow, interest in highly efficient mediumsized gas turbines for both simple- and combinedcycle applications is becoming more of a market need that the 6FA is positioned to address. This paper discusses the design, development and product introduction of the 70-MW class 6FA gas turbine, the latest addition to GE’s F-technology product line.

ABSTRACT The MS6001FA heavy-duty gas turbine is aerodynamically scaled from the MS7001FA and MS9001FA gas turbines to produce 70 MW of high-efficiency power. It uses advanced aircraft engine technology in its design with a rating based on a firing temperature class of 2350 F/1288 C and can be applied to both 50 Hz and 60 Hz markets since it drives a generator through a reduction gear at the compressor end. This produces 70 MW of simple-cycle power at more than 34% efficiency and nearly 110 MW of combinedcycle power at more than 53% efficiency. It is packaged with accessories to provide quick and cost-effective installations, making simple, costeffective solutions to repowering, combined-cycle installations and Integrated Gasification Combined-Cycle (IGCC) plants ideal.

INTRODUCTION The MS6001FA heavy-duty gas turbine has been successfully launched into the marketplace with five units to be produced during the first year of production. Commercial operation of the first two projects is scheduled for October 1996. Marketplace acceptance of the MS6001FA is high because it addresses the need for packaged, highefficiency power plants in the 100-MW combinedcycle range. The 6FA gas turbine is an aerodynamic scale of

GT25753

Figure 1. Typical gas turbine generator arrangement 1

GER-3765B

Table 1 COMPARISON OF GAS TURBINE RATINGS (ISO, BASE, 60 Hz)

Output (MW) Heat Rate (kJ/kWh) Efficiency LHV Air flow (kg/s) Pressure ratio Firing Temp. (F/C) Exhaust gas Temp. (F/C) Gas Turbine Speed (rpm)

6001B 39.2

Simple-Cycle 6001FA 70.1

7001FA 167.8

S106B 59.8

Combined-Cycle S106FA S107FA 107.1 258.8

S206FA* 218.7/217.0

11,320

10,530

9,940

7,390

6,795

6,425

6,605/6,705

31.8%

34.2%

36.2%

48.7%

53.0%

56.0%

54.1/53.7

138 11.8

196 14.9

432 14.8

138 11.8

196 14.9

432 14.8

196 14.8

2020/1104

2350/1288

2350/1288

2020/1104

2350/1288

2350/1288

2350/1288

1006/541

1107/597

1102/594

1000/538

1107/597

1117/603

1107/597

5,100

5,250

3,600

5,100

5,250

3,600

5,250

* 50 Hz/60 Hz GT24370

During all aspects of the 6FA’s design, careful attention was paid to experience gained during the 500,000 fired hours of operation with F technology gas turbines. The F-technology fleet represents the most proven advanced-technology available. The fleet experience leader, located at Virginia Power’s Chesterfield Station, has 35,000 hours of fired hours experience. Today, F-technology combined-cycle power plants are operating in excess of 55% efficiency with reliability in the mid to high 90s. Table 2

DESIGN APPROACH The 6FA gas turbine is a 0.69 scale of the 7FA, just as the 9FA is a 1.2 aerodynamic scale of the 7FA (Figure 2). GE has used aerodynamic scaling in gas turbine development for more than 30 years. This technique is exemplified in the derivative design of the 6B and 9E gas turbines, which were scaled from the 7E. The success of this gas turbine product family in worldwide power generation service illustrates the benefits of aerodynamic scaling.

GT24596A

Figure 2. GE F product line 2

GER-3765B

Table 2 6FA MATERIALS Component Casings Inlet case Compressor Compressor discharge case Turbine shell Exhaust frame Compressor Blading Wheels Compressor Turbine Combustion Transition piece Liner Buckets Stage 1 Stage 2 Stage 3 Nozzles Stage 1 Stage 2 Stage 3

Material

Experience

Ductile iron Ductile iron 2 1/4 Cr-Mo 2 1/4 Cr-Mo Carbon steel

All Fs All Fs All Fs All Fs All Fs

C450/403+ Cb

All Fs

NiCrMoV/CrMoV IN-706

All Fs All Fs; complete rotor since 3Q95

Nimonic 263 HASTX/HS-188

All Fs and DLN systems All Fs and DLN systems

GTD-111DS GTD-111 GTD-111

All Fs, 6B All Fs All Fs

FSX-414 GTD-222 GTD-222

All 6Bs, Fs, EAs All Fs, EAs All Fs, EAs

shows a listing of materials used in primary components of the 6FA, all of which have a proven history in GE heavy-duty gas turbines for power generation. Extensive component and full-unit testing is an integral part and cornerstone of the process of new product introduction. During the nine-year development cycle of the MS7001F, component testing confirmed design assumptions. In addition to these tests, loaded instrumented tests were also performed in Greenville, South Carolina, and at

Virginia Power’s Chesterfield station. In addition, an instrumented load test was completed on the 9F in France. Instrumented full-load tests of 7FAs at Sithe Energy, New York, and Florida Power and Light and of a 9FA at Medway, United Kingdom, formed the baseline from which the 6FA was designed. The 6FA gas turbine configuration includes an 18-stage compressor, six combustion chambers and a three-stage turbine (Figure 3). The shaft is supported on two bearings, as it is in the 7FA, 9FA,

RDC27030-1

Figure 3. 6FA gas turbine 3

GER-3765B

6 Combustors

18 Stage Compressor

2 Bearing Rotor

3 Stage Turbine

Hand Holes and Man Holes for Maintenance GT25694

Figure 4. Gas turbine configuration 5P and 6B gas turbines. This design was made to enhance the maintainability of these gas turbines. Five casings form the structural shell: the inlet casing, compressor casing, compressor discharge casing, turbine shell and exhaust frame. Figure 4 shows the gas turbine section in more detail. The aft diffuser is attached to the exhaust frame and is shipped assembled on the turbine base with the thermal insulation factory-installed. The inlet plenum and the unit piping and wiring are shipped assembled with the unit on the base. The basic gas turbine compressor has an evolutionary 30-year history and originates from the MS5001 (Figure 5). The compressor rotor uses NiCrMoV and CrMoV in its rotor construction, alloys similar to those used on the 7FA. The compressor rotor has grit-blasted flange surfaces, enhancing torque transmissibility by a minimum of 70% over untreated flange sur faces. Compressor extraction air, which does not require external coolers, provides the cooling for the first

two stages of buckets and all three stages of nozzles. The cooling circuit for the buckets is internal to the rotor and there is no loss of air in its transfer at stationary to rotating seals. The compressor air extraction locations are similar to the 7FA. Airfoil materials used in the compressor are the same as those used on the 7FA and do not require coatings. The combustion system comes in two variations, both of which are capable of multi-fuel applications (natural gas, distillate oil, propane and fossil fuels): • Dry Low NOx (DLN) — standard offering • Integrated Gasification Combined Cycle (IGCC) — option for using a wide spectrum of low heating value fuels, including gasified coal or heavy oil and steel mill gases The combustion system is comprised of six chambers that are similar to the 9FA in design and operating conditions, and also uses common head end components (nozzles, swirlers, cap and

GT25755

Figure 5. Growth in compressor design evolution 4

GER-3765B

Stage 2 & 3 Bucket Tip Seals

High Pressure Packing Seals

Interstage Diaphragm

GT2577

GT25770

Figure 7. Honeycomb seal locations faces for enhanced torque transmissibility. The airfoil and coating materials used in the turbine are the same as those used in the 7FA. The 6FA also incorporates a number of other features to its design to enhance performance and endurance: • Static honeycomb seals and coated rotating cutter teeth are used in locations (Figure 7) that significantly affect performance. These include the high pressure packing seal, turbine interstage diaphragm seals and bucket tip seals. Performance is improved through tighter clearances at these seal locations. • Extensive experience has been accumulated with honeycomb seals. They have been used in similar applications on GE Aircraft Engines since the early 1960s. They have also been successfully used on GE Power Generation heavy duty design units since 1994 on 7EA, 9E and 6B units. • Tighter compressor blade and bucket tip clearances are also maintained by equivalent thermal masses distributed around the periphery of the casings (Figure 8), which provide compensation for the cold flanges at the split lines. This provides for rounder casings and tighter tip clearances during operation. • External casing flanges use an optimized bolting arrangement for reduced leakage, which has been validated by factory tests. This results in less power required for compartment cooling and an overall improvement in performance. • Reduced use of cooling air in the hot section of the turbine. Judicious use of cooling air for airfoil and shroud cooling in the stage 1 nozzle, bucket, shroud and stage 2 nozzle have allowed for more uniform temperature gradients that improve life and performance. The

RDC27664-11

Figure 6. Thermal paint verification test for transition piece end cover) with the 9FA. Commonality is afforded by the fact that the flow per can in the 6FA is within 2% of the 9FA. A further improvement of the 6FA combustion system is the integral multiple of stage 1 nozzle vanes with the number of combustors. This provides for a repeatable, chamber-tochamber, thermal distribution going into the stage 1 nozzles. The large exit span of the transition pieces, which resulted from a six-chamber configuration, has been engineered using state-ofthe-art analytical techniques. Cold flow visualization tests coupled with computational fluid dynamic and finite element stress analyses have been used in optimizing the transition piece geometry. Analytical predictions have been verified with full temperature and pressure combustion tests on a fully instrumented transition piece. Figure 6 shows another transition piece used in a temperature verification test using thermal paint. Emissions levels are at 25/15 ppm NOx/CO with a DLN system, in the range of 40% to 100% load operating on natural gas. For operation in distillate oil with water or steam injection, the levels are 42/15 ppm NOx/CO. Up to 5% steam may be used for power augmentation. The turbine rotor is a scale of the current 7FA. The turbine wheels, spacers and aft shaft are made from INCO 706 with INCO 718 bolting, similar to the current 7FA. As in the compressor, the turbine rotor also has grit-blasted flange sur5

GER-3765B

RDC27664-09

Figure 9a. Load gear in assembly at Renk AG RDC227644-8

Figure 8. Typical equivalent “thermal mass” to cold flanges at split line stage 1 bucket serpentine circuit has enhanced leading edge cooling and cast-in cooling slots at the trailing edge, to improve life in these areas. The 6FA load gear (Figure 9) was developed in association with a world-class gear manufacturer, Renk AG, of Augsburg, Germany. In design, the 6FA load gear is a horizontally offset gearbox designed to transmit 90 MW with a 1.1 service factor, as defined per American Petroleum Institute (API) specifications. The shaft power output from the 6FA gas turbine is driven through a flexible coupling to the high-speed pinion. The low-speed bull gear drives the generator though a rigidly coupled quill shaft that operates at either 3,600 rpm or 3,000 rpm. The 6FA gear is furnished with case carburized and precision ground double-helical gearing. The high-speed and low-speed shafts are mounted on babbitt-lined, offset, half-type sleeve bearings. The bearing housings are integral to the steel-fabricated casing, and provisions are provided for bearing metal thermocouples and eddy current vibration probes. The load gear also incorporates provisions for mounting a turning gear to the high-speed shaft for establishing unit breakaway during startup. A new level of understanding in the design of load gears has been achieved in the design and development of the 6FA load gear. Resources from GE Power Systems, GE Aircraft Engines and specialists at GE Corporate Research and Development were used in the design, development and reliability assurance studies of the 6FA load gear. Included in the process were review and approval of: • Design parameters • Stress and life analyses • System lateral and torsional analyses • Material specifications • Forging supplier processes

RDC27664-10

Figure 9b. Load gear in assembly at Renk Ag • Non-destructive testing (NDT) procedures • First-part qualification and testing The generator applied with the 6FA gas turbine is GE’s model 7A6C. The 7A6C has a proven history; it is a fully packaged, base-mounted unit that has been installed with GE’s higher-rated frame 7EA gas turbines since the early 1990s. As of August 1996, approximately 100 7A6C generators have been shipped; 90 are in operation. It is available in both open-ventilated and water-to-air cooled (TEWAC) configurations and with either brushless or static exciters. It can accommodate motor start or static start options and is applicable to both 50 Hz and 60 Hz systems. An excellent reliability record has been recorded during the past five years. When applied at the lower 6FA rating, the increased capability yields lower operating temperatures and enhanced reliability. The increased thermal capability can accommodate demanding off-voltage, off-frequency conditions and can meet a wide range of requirements.

6

GER-3765B

size as the 6B, and with fewer combustion chambers (six vs. eight), installation and maintenance times are conservatively estimated to be the same as the 6B. Easy access to the Dry Low NOx combustion system was a primary focus in the design of the piping systems. Finally, an approximate 25% parts count reduction in compressor, combustor and turbine components, in comparison to the 7FA and 9FA, should manifest in faster and easier field maintenance operations.

RELIABILITY AND MAINTAINABILITY The design of the 6FA and 7FA gas turbines has focused on operating reliability and maintainability. Reference 2 reports the development of reliability features in the controls and accessories. Redundancy has been designed into the controls and accessories areas of the gas turbine power plant to meet these goals. The Mark V control applied to the 6FA, similar to the 7FA has a triple-redundant, microprocessorbased computer control. During normal operation, three computers share control of the gas turbine. Should one of the computers or one of the triple-redundant sensors fail, internal voting logic switches control of the gas turbine to the two remaining control computers and associated sensors. Alarms that indicate a fault in the other computer or its system of sensors are displayed. Upon repair, the two remaining computers interrogate the repaired system to ensure that it is functioning properly. Upon determining its proper function, the three computers again share the responsibility for controlling the gas turbine. This type of control system has raised reliability from a mean-timebetween-forced-outages of 3,800 hours to 30,000 hours, as demonstrated in an EPRI-sponsored test on an operating MS7001 on the Salt River Project system at their Santan site. Redundancy has been designed into the 6FA accessory systems in all areas, including filters, pumps and compressors, similar to the 7FA. Redundancy of apparatus and power supply duplication, including crossover of sources, transformers, switchgear for medium and low voltage and DC chargers and batteries for emergency supply, ensure starting, on-line reliability and equipment safety. Maintainability has been considered with a step-by-step analysis of: • Handling means for routine or daily inspections in each module. Borescope inspection ports have been provided for inspecting 5 stages of the compressor and all 3 stages of the turbine. Four man-holes and six hand-holes are also provided (Figure 4) for routine inspections of the transition pieces and attaching seals. • Major inspections of the gas turbine and the main auxiliaries • Special maintenance needs, such as rotor removal, using specially-designed tools such as trolleys for generator rotors or hoists fitted to cranes for the turbine rotor With the 6FA being approximately the same

PLANT ARRANGEMENT The most frequent applications for the 6FA are expected to be in mid-range and base load service as part of combined-cycle or co-generation plants. Taking these requirements into account, the 6FA gas turbine, like the 7FA, is designed specifically for combined-cycle applications with the following features: • A cold-end drive gas turbine, which allows the exhaust to be directed axially into the heat recovery steam generator • Factory-assembled accessory packages on separate skids for easy installation and maintainability • An off-base turbine enclosure that provides more space for maintenance and better control of noise emissions • High compressor discharge extraction capability for Integrated Gasification Combined Cycle (IGCC) applications • Slab-mounted single- (Figure 10) or multishaft (Figure 1) configurations Air enters the unit through a standard singlestage, multiple-element filter located above the generator and provides fouling protection for the gas turbine. Exhaust gases from the gas turbine go through an axial exhaust diffuser, pass through silencers, and either enter the heat recovery boiler or exit to the stack. As discussed, the shaft power output from the gas turbine is driven through a flexible coupling attached to its cold end, to the high-speed pinion of the load gear. The low-speed bull gear drives the generator though a rigidly coupled quill shaft. A turning gear for breakaway during startup is attached to the blind end of the pinion gear. A motor torque converter that drives through the generator is the standard starting means. However, the generator can be a starting motor when supplied with a static frequency converter (SFC). The generator shaft end is kept free when this technique is used. The torque level can be readily adjusted to permit fast starts and slow cool7

GER-3765B

GT25758

Figure 10. Slab-mounted single-shaft arrangement down rotation of the gas turbine. A disconnecting coupling or clutch can also be installed to allow synchronous condenser operation. The mechanical accessories are motor driven and arranged in two modules. One of these modules is used only for liquid fuel operation. Electrical devices, such as auxiliary transformers, switchgears, static frequency converters, are contained in the electrical/control module close to the generator. The modules are fully assembled and factory-tested prior to shipment. The two mechanical accessory modules are located at fixed locations relative to the gas turbine, which allows for quick field installations using prefabricated piping. An array of site-specific designs for these modules provides: • Aesthetic appearance

• Thermal and acoustic insulation • Heating and ventilation • Fire protection • Redundancy of power supply • Space and means available for maintenance These features are established for each plant according to customer requirements and service considered (in/out door, new/existing plant, etc.). Additionally, the skid layouts for the various systems have generous space to permit easy maintenance without speciality tools. The typical general plant arrangement (Figure 11) can be adapted to many indoor or outdoor configurations. However, the location of the two main accessory modules must be retained, and the off-base gas turbine enclosure must be used to achieve 85dBA maximum sound from the unit. To minimize field installation work, the gas turbine is

GT25759

Figure 11. Typical general plant arrangement 8

GER-3765B

RDC27664-06

RDC27664-02

Figure 12a. Assembled stage 1 nozzle segments

Figure 12d. Stage 3 nozzle segments with diaphragm seal

RDC27664-07

Figure 12b. Stage 1 shroud (background); stage 2 shroud (foreground)

RDC27664-04

Figure 12e. Stage 1 nozzle assembly fan coolers. Site civil work can be kept to a minimum with grade-level foundations for installation of all modules and pipeways.

STATUS Five units are scheduled to be shipped by the end of 1996, two of which are to be in commercial operation by October 1996. Figures 12a through 12h show hardware for these units in various stages of assembly. Orders as of August 1996 have shown the wide range of both application and customer acceptance of the 6FA design, in both the 50 Hz and 60 Hz markets. The variety of applications covered by these projects, which include combined-cycle, cogeneration and IGCC, fully demonstrate the

RDC27664-01

Figure 12c. Honeycomb seals on stage 2 and 3 diaphragm seals mounted on a steel base structure with factoryinstalled piping and electrical components, similar to the 6B. Side-by-side arrangements are particularly suitable for multiple unit plants. Cooling water needs are secured by external supply (river, sea water with intercooling, etc.) or through fin9

GER-3765B

RDC27664-03

Figure 12f. Turbine shell RDC27664-12

capabilities of this gas turbine. Combined-cycle applications include both single-shaft and multishaft combined-cycle plant configurations. Figure 13 shows the expected fired hours accumulation of these machines over the next three years. The two launch projects are Destec Cogeneration, a natural-gas-only site (Figure 14) in Kingston, Ontario, Canada, and the Sierra Pacific Power Company’s Piñon Pine Power Project, a dual-fuel IGCC site located in Reno, Nevada (Figure 15). Both projects’ equipment was shipped in the first quarter of 1996, with mechanical and electrical erection essentially completed in the second quarter and first firing of the units in August. The Destec Cogeneration and the Sierra Pacific Power Projects are both scheduled to be commercial on natural gas in October 1996, with the IGCC portion of the Sierra Pacific Project going on-line in December 1996. Subsequent projects scheduled to go commercial in late 1996 or 1997 include a cogeneration facility in Finland, a single-shaft base load com-

Figure 12g. Rotor being installed into unit at Greenville, South Carolina, plant

RDC27644-05

Figure 12h. Unit being assembled at Greenville, South Carolina, plant

140 - 6FA Fleet (Total)

Hours (Thousands)

120 100 80

50 Hz Applications

60 40 20 0

60 Hz Applications

3Q96

1Q97

3Q97

1Q98

3Q98

1Q99

End of Year GT25766

Figure 13. 6FA operational experience 10

GER-3765B

GT27640-2

GT25781

Figure 15b. Sierra Pacific Power Company’s Piñon Pine Power Project

Figure 14. Destec Cogeneration Kingston, Ontario, Canada

design. All bolted flanges and shell/casing joints exhibited no leakage.

CONCLUSION GE’s design philosophy, based on a firm analytical foundation and years of experience of gas turbine operation, has resulted in reliable, heavy-duty gas turbines. On this basis, successful designs are carefully scaled to larger or smaller sizes. Scaling has been used to produce similar designs that range from 25 MW to 200 MW. Improved materials and components that have been prudently and carefully applied to increase power and thermal efficiency have resulted in the evolution of proven designs. Finally, designs are carefully tested and demonstrated in extensive development facilities and by fully instrumented unit tests in order to provide full confirmation of the design under actual operating conditions. Using this methodology, the 6FA has been scaled from the proven 7FA and successfully launched into production. Five units are scheduled to be shipped by the end of 1996, two of which are scheduled to be operational in the same period. The full-speed no-load tests and initial site startup operations of these first units were successful.

RDC27640-6

Figure 15a. Sierra Pacific Power Company’s Piñon Pine Power Project bined-cycle facility in Italy and a multi-shaft combined-cycle facility in the United States. The no-load tests on these first three units have successfully demonstrated that the design tools used accurately predicted the operating characteristics of the unit (Table 3). The units exhibited flawless starting and acceleration to full-speed conditions. Rotor vibration levels for these units were well below design criteria and indicated satisfactor y stiffness characteristics of the scaled

Table 3 6FA TEST RESULTS AT FULL SPEED — NO LOAD

Airflow (lb/s / kg/s) Compressor pressure ratio Compressor efficiency Turbine efficiency Turbine inlet temperature (F/C) Turbine exhaust temperature (F/C)

ISO Performance Expected (nominal) 437 10.68 86.4% 84.6% 1074/579 490/254

11

ISO Performance as Tested 438 10.74 86.2% 84.9% 1083/584 495/257

GER-3765B

REFERENCES 1. Rowen, W.I., “Operating Characteristics of Heavy-Duty Gas Turbines in Utility Service,” ASME paper No. 88-GT-150, presented at the Gas Turbine and Aeroengine Congress, Amsterdam, Netherlands, June 6-9, 1988. 2. “Design of High-Reliability Gas Turbine Controls and Accessories,” EPRI Final Report, AP-5823, June 1988.

© 1996 GE Company 12

GER-3765B

LIST OF FIGURES Figure 1. Typical gas turbine generator arrangement Figure 2. GE F product line Figure 3. 6FA gas turbine Figure 4. Gas turbine configuration Figure 5. Growth in compressor design evolution Figure 6. Thermal paint verification test for transition piece Figure 7. Honeycomb seal locations Figure 8. Typical equivalent “thermal mass” to cold flanges at split line Figure 9a. Load gear in assembly at Renk AG Figure 9b. Load gear in assembly at Renk AG Figure 10. Slab-mounted single-shaft arrangement Figure 11. Typical general plant arrangement Figure 12a. Assembled stage 1 nozzle segments Figure 12b. Stage 1 shroud (background) and stage 2 shroud (foreground) Figure 12c. Honeycomb seals on stage 2 and 3 diaphragm seals Figure 12d. Stage 3 nozzle segments with diaphragm seal Figure 12e. Stage 1 nozzle assembly Figure 12f. Turbine shell Figure 12g. Rotor being installed into unit at Greenville, South Carolina, plant Figure 12h. Unit being assembled at Greenville, South Carolina, plant Figure 13. 6FA operational experience Figure 14. Destec Cogeneration, Kingston, Ontario, Canada Figure 15a. Sierra Pacific Power Company’s Piñon Pine Power Project Figure 15b. Sierra Pacific Power Company’s Piñon Pine Power Project LIST OF TABLES Table 1. Table 2. Table 3.

Comparison of gas turbine ratings (ISO, Base, 60 Hz) 6FA materials 6FA test results at full speed — no load

Jay Ramachandran Jay Ramachandran is currently Manager, 6FA Engineering Programs. He has 18 years of design and project management experience at GE’s Power Generation and Aircraft Engine divisions. His engineering experience is primarily in the design of turbine high-temperature components. He also has significant experience gas turbine system design from his contribution to GE’s advanced H-generation machines. Jay graduated from the University of Cincinnati with an MS in engineering. He is also a graduate of GE’s ABC gas turbine engineering program. He holds two patents on his work in gas turbine engineering at GE.

Michael C. Conway Michael Conway has 16 years of power generation experience and is currently Product Line Manager, F Technology. He graduated from Clarkson University with a BS in engineering.

A list of figures and tables appears at the end of this paper

B00449 1/97

LOAD

Ó

STARTING DEVICE

AIR INLET

VIGV’s

MS6001FA Gas Turbine Assembly Major Sections

COMPRESSOR

DLN2 NOZZ ARRGMT

IGNITER

LINER

TRANSITION PIECE

COMBUSTION

TURBINE

EXHAUST FRAME

DIFFUSER

EXHAUST

ÖÖÖÖÖÖÖÖÖÖÖ ÖÖÖÖÖÖÖÖÖÖÖ Ö Ö Ö Ö Ö Ö Ö Ö Ö Ö Ö ÖÖÖÖÖÖÖÖÖÖÖ

Tab 2

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GAS TURBINE 1. 1.1. 1.1.1. 1.1.2. 1.2. 1.2.1. 1.2.2. 1.3. 1.3.1. 1.3.2. 1.3.3. 1.3.3.1. 1.3.3.2. 1.3.3.3. 1.3.3.4. 1.3.3.5. 1.4. 1.4.1. 1.4.2. 1.4.3. 1.4.4. 1.4.5. 1.4.6. 1.4.7. 1.5. 1.5.1. 1.5.2. 1.5.2.1. 1.5.2.2. 1.5.2.3. 1.5.2.4. 1.5.2.5. 1.5.2.6. 1.5.2.7. 1.5.2.8. 1.5.3. 1.5.3.1. 1.5.3.2. 1.5.3.3. 1.5.3.4. 1.5.3.5. 1.5.3.6. 1.5.3.7. 1.5.3.8. 1.5.3.9.

GAS TURBINE ......................................................................................................................3 INTRODUCTION ......................................................................................................................3 GENERAL ................................................................................................................................3 DETAIL ORIENTATION ...........................................................................................................6 TURBINE BASE AND SUPPORTS..........................................................................................7 TURBINE BASE .......................................................................................................................7 TURBINE SUPPORTS .............................................................................................................8 COMPRESSOR SECTION.......................................................................................................9 GENERAL ................................................................................................................................9 COMPRESSOR ROTOR........................................................................................................10 COMPRESSOR STATOR ......................................................................................................11 GENERAL ..............................................................................................................................11 INLET CASING ......................................................................................................................12 COMPRESSOR CASING.......................................................................................................13 COMPRESSOR DISCHARGE CASING ................................................................................13 BLADING................................................................................................................................14 COMBUSTION SYSTEM .......................................................................................................15 GENERAL ..............................................................................................................................15 OUTER COMBUSTION CHAMBERS AND FLOW SLEEVES ...............................................16 CROSSFIRE TUBES..............................................................................................................18 FUEL NOZZLES END COVER ..............................................................................................19 CAP AND LINER ASSEMBLIES ............................................................................................20 SPARK PLUGS ......................................................................................................................21 ULTRAVIOLET FLAME DETECTORS...................................................................................22 TURBINE SECTION...............................................................................................................24 GENERAL ..............................................................................................................................24 TURBINE ROTOR..................................................................................................................25 STRUCTURE .........................................................................................................................25 WHEEL SHAFTS ...................................................................................................................25 WHEEL ASSEMBLIES ...........................................................................................................25 COOLING...............................................................................................................................26 FIRST-STAGE WHEELSPACES ...........................................................................................27 SECOND-STAGE WHEELSPACES ......................................................................................27 THIRD-STAGE WHEELSPACES...........................................................................................27 BUCKETS ..............................................................................................................................28 TURBINE STATOR ................................................................................................................31 STRUCTURE .........................................................................................................................31 TURBINE CASING .................................................................................................................31 NOZZLES...............................................................................................................................31 FIRST-STAGE NOZZLE.........................................................................................................31 SECOND-STAGE NOZZLE....................................................................................................32 THIRD-STAGE NOZZLE ........................................................................................................32 DIAPHRAGM..........................................................................................................................32 SHROUDS .............................................................................................................................32 EXHAUST FRAME .................................................................................................................33

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1.6. 1.6.1. 1.6.2. 1.6.2.1. 1.7. 1.7.1. 1.8. 1.8.1.

BEARINGS.............................................................................................................................34 GENERAL ..............................................................................................................................34 LUBRICATION .......................................................................................................................34 LUBRICANT SEALING...........................................................................................................34 ENCLOSURES.......................................................................................................................35 GENERAL ..............................................................................................................................35 COUPLING.............................................................................................................................36 GENERAL ..............................................................................................................................36

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1.

GAS TURBINE

1.1.

INTRODUCTION

1.1.1.

GENERAL A heavy duty gas turbine unit is a mechanical power engine installed in a plant to drive a generator to supply an electrical network. The gas turbine power engine includes an axial airflow compressor, a multi chamber combustion system and a three stages turbine. 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 • Six combustion chambers where the fuel burns permanently from firing speed to full load • Six cross fire tubes connecting the combustion chamber • Six 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 generator at the front end.

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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 six 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 introduce the fuel into each of the six combustion chambers where it mixes with the combustion air and burns. The hot gases from the combustion chambers expand into the six separate transition pieces 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 nozzle 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. Then, the gases pass into the exhaust plenum and are introduced to atmosphere through the exhaust stack or used in a heat recovery steam generator. Resultant shaft rotation turns the generator rotor to generate electrical power. Starting sequence : The gas turbine cannot run itself from zero speed. A starting means bring the shaft line up to the self-sustaining speed. The starting means is usually the generator itself piloted through a Static Frequency Converter (SFC) 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 and 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 means sequence. The gas turbine reaches nominal speed, the IGV move to full speed no load (FSNL) operating position and the bleed valve closes. Main electrically driven lube oil pump provides lubricating oil for the shaft line bearings from zero speed to full load.

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Cool 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. The various assemblies, systems and components that comprise the compressor, combustion and turbine sections of the gas turbine are described in the text, which follows. Refer to the illustrations in this section and elsewhere in this volume, the inspection and maintenance instructions volume and the parts lists and drawings volume for gas turbine component detailed information.

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1.1.2.

DETAIL ORIENTATION Throughout this manual, reference is made to the forward / front and aft / rear ends, and to the right and left sides of the gas turbine and its components. By definition, the air inlet of the gas turbine is the forward / front end, while the exhaust is the aft / rear end. The forward / front and aft / rear ends of each component are determined in like manner with respect to its orientation within the complete unit. Standing forward and looking aft determine the right and left sides of the turbine or of a particular component. On a drawing or picture, the forward end is usually on the left side and the aft end is on the right side.

GAS TURBINE ARRANGEMENT (TYPICAL)

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1.2.

TURBINE BASE AND SUPPORTS

1.2.1.

TURBINE BASE The base that supports the gas turbine is a structural steel fabrication of welded steel beams and plate. Its prime function is to provide a support upon which to mount the gas turbine. Lifting trunnions and supports are provided, two on each side of the base in line with the two structural cross members of the base frame. Machined pads on each side on the bottom of the base facilitate its mounting to the site foundation. Two machined pads, atop the base frame are provided for mounting the aft turbine supports.

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1.2.2.

TURBINE SUPPORTS The MS 6001 FA has rigid leg-type supports at the compressor end and supports with top and bottom pivots at the turbine end. The support legs maintain the axial and vertical positions of the turbine, while two gib keys coupled with the turbine support legs maintain its lateral position. One gib key is machined on the lower half of the exhaust frame. The other gib key is machined on the lower half of the forward compressor casing. The keys fit into guide blocks which are welded to the cross beams of the turbine base. The keys are held securely in place in the guide blocks with bolts that bear against the keys on each side. This key-and-block arrangement prevents lateral or rotational movement of the turbine while permitting axial and radial movement resulting from thermal expansion. To maintain of the exhaust diffuser, there are also two supports fixed on the turbine base. They are equipped with top and bottom pivots.

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1.3.

COMPRESSOR SECTION

1.3.1.

GENERAL The axial-flow compressor section consists of the compressor rotor and the compressor casing. Within the compressor casing are the variable inlet guide vanes, the various stages of rotor and stator blades, and the exit guide vanes. In the compressor, air is confined to the space between the rotor and stator where it is compressed in stages by a series of alternate rotating (rotor) and stationary (stator) airfoilshaped blades. The rotor blades supply the force needed to compress the air in each stage and the stator blades guide the air so that it enters the following rotor stage at the proper angle. The compressed air exits through the compressor discharge casing to the combustion chambers. Air is extracted from the compressor for turbine cooling and for pulsation control during startup.

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1.3.2.

COMPRESSOR ROTOR The compressor portion of the gas turbine rotor is an assembly of wheels, a speed ring, tie bolts, the compressor rotor blades, and a forward stub shaft. Each wheel has slots broached around its periphery. The rotor blades and spacers are inserted into these slots and held in axial position by staking at each end of the slot. The wheels are assembled to each other with mating rabbets for concentricity control and are held together with tie bolts. Selective positioning of the wheels is made during assembly to reduce balance correction. After assembly, the rotor is dynamically balanced. The forward stubshaft is machined to provide the thrust collar, which carries the forward and aft thrust loads. The stubshaft also provides the journal for the N° 1 bearing, the sealing surface for the N° 1 bearing oil seals and the compressor low-pressure air seal. The stage 17 wheel carries the rotor blades and also provides the sealing surface for the high-pressure air seal and the compressor-to-turbine marriage flange.

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1.3.3.

COMPRESSOR STATOR

1.3.3.1. GENERAL The casing area of the compressor section is composed of three major sections. These are the : 1. inlet casing 2. Compressor casing 3. Compressor discharge casing Those casings, in conjunction with the turbine casing, form the primary structure of the gas turbine. They support the rotor at the bearing points and constitute the outer wall of the gaspath annulus. All of these casings are split horizontally to facilitate servicing. COMPRESSOR DISCHARGE CASING COMPRESSOR CASING INLET CASING

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1.3.3.2. INLET CASING The inlet casing is located at the forward end of the gas turbine. Its prime function is to uniformly direct air into the compressor. The inlet casing also supports the #1 bearing assembly. The #1 bearing lower half housing is integrally cast with the inner bellmouth. The upper half bearing housing is a separate casting, flanged and bolted to the lower half. The inner bellmouth is positioned to the outer bellmouth by nine airfoil-shaped radial struts. The struts are cast into the bellmouth walls. They also transfer the structural loads from the adjoining casing to the forward support, which is bolted and doweled to this inlet casing. Variable inlet guide vanes are located at the aft end of the inlet casing and are mechanically positioned, by a control ring and pinion gear arrangement connected to a hydraulic actuator drive and linkage arm assembly. The position of these vanes has an effect on the quantity of compressor inlet airflow.

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1.3.3.3. COMPRESSOR CASING The forward compressor casing contains the stage 0 through stage 4 compressor stator stages. The compressor casing lower half is equipped with two large integrally cast trunnions, which are used to lift the gas turbine when it is separated from its base.

The aft compressor casing contains stage 5 through stage 12 compressor stator stages. Extraction ports in aft casing permit removal of 13th-stage compressor air. This air is used for cooling functions and is also used for pulsation control during startup and shutdown. 1.3.3.4. COMPRESSOR DISCHARGE CASING The compressor discharge casing is the final portion of the compressor section. It is the longest single casting, is situated at midpoint - between the forward and aft supports - and is, in effect, the keystone of the gas turbine structure. The compressor discharge casing contains the final compressor stages, forms both the inner and outer walls of the compressor diffuser, and joins the compressor and turbine casings. The discharge casing also provides support for the combustion outer casings and the inner support of the first-stage turbine nozzle.

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The compressor discharge casing consists of two cylinders, one being a continuation of the compressor casing and the other being an inner cylinder that surrounds the compressor rotor. The two cylinders are concentrically positioned by fourteen radial struts. A diffuser is formed by the tapered annulus between the outer cylinder and inner cylinder of the discharge casing. The diffuser converts some of the compressor exit velocity into added static pressure for the combustion air supply. 1.3.3.5. BLADING The compressor rotor and stator blades are airfoil shaped and designed to compress air efficiently at high blade tip velocities. The blades are attached to the compressor wheels by dovetail arrangements. The dovetail is very precise in size and position to maintain each blade in the desired position and location on the wheel. The compressor stator blades are airfoil shaped and are mounted by similar dovetails into ring segments in the first five stages. The ring segments are inserted into circumferential grooves in the casing and are held in place with locking keys. The stator blades of the remaining stages have a square base dovetail and are inserted directly into circumferential grooves in the casing. Locking keys hold them in place.

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1.4.

COMBUSTION SYSTEM

1.4.1.

GENERAL The dry low NOx 2.6 (DLN 2.6) control system regulates the distribution of fuel delivered to a multi-nozzle, total premix combustor arrangement. The fuel flow distribution to each combustion chamber fuel nozzle assembly is calculated to maintain unit load and fuel split for optimal turbine emissions. The combustion system is of the reverse-flow type with the 6 combustion chambers arranged around the periphery of the compressor discharge casing. Combustion chambers are numbered counterclockwise when viewed looking downstream and starting from the top of the machine. This system also includes the fuel nozzles, a spark plug ignition system, flame detectors, and crossfire tubes. Hot gases, generated from burning fuel in the combustion chambers, flow through the impingement cooled transition pieces to the turbine. High pressure air from the compressor discharge is directed around the transition pieces. Some of the air enters the holes in the impingement sleeve to cool the transition pieces and flows into the flow sleeve. The rest enters the annulus between the flow sleeve and the combustion liner through holes in the downstream end of the flow sleeve. This air enters the combustion zone through metering holes for proper fuel combustion and through slots to cool the combustion liner. Fuel is supplied to each combustion chamber through six nozzles designed to disperse and mix the fuel with the proper amount of combustion air.

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1.4.2.

OUTER COMBUSTION CHAMBERS AND FLOW SLEEVES The outer combustion chambers act as the pressure shells for the combustors. They also provide flanges for the fuel nozzle-end cover assemblies, crossfire tube flanges, and, where called for, spark plugs, flame detectors and false start drains. The flow sleeves form an annular space around the cap and liner assemblies that directs the combustion and cooling air flows into the reaction region. To maintain the impingement sleeve pressure drop, the openings for crossfire tubes, spark plugs, and flame detectors are sealed with sliding grommets.

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COMBUSTION CHAMBER ARRANGEMENT (TYPICAL)

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1.4.3.

CROSSFIRE TUBES All combustion chambers are interconnected by means of crossfire tubes. The outer chambers are connected with an outer crossfire tube and the combustion liner primary zones are connected by the inner crossfire tubes.

CROSSFIRE TUBE ASSEMBLY (TYPICAL)

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1.4.4.

FUEL NOZZLES END COVER The MS 6001 FA nozzle combustor utilizes six fuel nozzles in each combustion end cover. On the nozzle combustor, the fuel nozzle is functionally integrated with the combustor end cover. Internal manifolds within the cover supply gas to the six fuel nozzles. The steam injector is mounted through the center of the cover. Heavy-walled tubing supplies steam to each gas swirl tip. The steam is directed into the swirl vanes through small holes in the tubing where it then enters the combustor for NOx reduction. The tubing is attached to the body of the distributor with special tubing fittings and supported in a groove cut around the gas tip. The assembly is locked in place using a special lockplate.

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1.4.5.

CAP AND LINER ASSEMBLIES The combustion liners use conventional cooling slots but are fabricated from a heavier material. All but the seal (in contact with the transition pieces) of the liner is made from Hastelloy-X. Inconel is used for the seal of the liner. Interior surfaces of the liner and the cap are thermal barrier coated to reduce metal temperatures and thermal gradients. The cap has five floating collars to engage each of the five fuel nozzle tips. It is cooled by a combination of film cooling and impingement cooling and has thermal barrier coating on the inner surfaces.

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1.4.6.

SPARK PLUGS Combustion is initiated by means of the discharge from two spark plugs, which are bolted to flanges on the combustion cans and centered within the liner and flowsleeve in adjacent combustion chambers. A typical spark plug arrangement is shown in the following. These plugs receive their energy from high energy-capacitor discharge power supplies. 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 interconnect the reaction zone of the remaining chambers.

SPARK PLUG ASSEMBLY (TYPICAL)

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1.4.7.

ULTRAVIOLET FLAME DETECTORS During the starting sequence, it is essential that an indication of the presence or absence of flame be transmitted to the control system. For this reason, a flame monitoring system is used consisting of multiple flame detectors located as shown of the following figure. The flame detectors have water cooled jackets to maintain acceptable temperatures. The ultraviolet flame sensor contains a gas filled detector. The gas within this detector is sensitive to the presence of ultraviolet radiation, which is emitted by a hydrocarbon flame. A DC 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 indicating flame. Conversely, the absence of flame will generate an output indicating no flame.

The signals from the four flame detectors are sent to the control system, which uses an internal logic system to determine whether a flame or loss of flame condition exists. For detailed operating and maintenance information covering this equipment, refer to the vendor publications.

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FLAME DETECTOR ASSEMBLY (TYPICAL)

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1.5.

TURBINE SECTION

1.5.1.

GENERAL The three-stage turbine section is the area in which energy in the form of high temperature pressurized gas, produced by the compressor and combustion sections, is converted to mechanical energy. MS 6001 FA gas turbine hardware includes the turbine rotor, turbine casing, exhaust frame, exhaust diffuser, nozzles, and shrouds.

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1.5.2.

TURBINE ROTOR

1.5.2.1. STRUCTURE The turbine rotor assembly consists of the forward and aft turbine wheel shafts and the first-, second- and third-stage turbine wheel assemblies with spacers and turbine buckets. Concentricity control is achieved with mating rabbets on the turbine wheels, wheel shafts, and spacers. The wheels are held together with through bolts mating up with bolting flanges on the wheel shafts and spacers. Selective positioning of rotor members is performed to minimize balance corrections. 1.5.2.2. WHEEL SHAFTS The turbine rotor distance piece extends from the first-stage turbine wheel to the aft flange of the compressor rotor assembly. The turbine rotor aft shaft includes the #2 bearing journal. 1.5.2.3. WHEEL ASSEMBLIES Spacers between the first and second, and between the second and third-stage turbine wheels determine the axial position of the individual wheels. These spacers carry the diaphragm sealing lands. The 1-2 spacer forward and aft faces include radial slots for cooling air passages. Turbine buckets are assembled in the wheels with fir-tree-shaped dovetails that fit into matching cutouts in the turbine wheel rims. All three turbine stages have precision investment-cast, long-shank buckets. The long-shank bucket design effectively shields the wheel rims and bucket root fastenings from the high temperatures in the hot gas path while All right reserved copyright - Droits de reproduction réservés

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OPERATION AND MAINTENANCE MANUAL

DESCRIPTION providing mechanical damping of bucket vibrations. As a further aid in vibration damping, the stage-two and stage-three buckets have interlocking shrouds at the butcket tips. These shrouds also increase the turbine efficiency by minimizing tip leakage. Radial teeth on the bucket shrouds combine with stepped surfaces on the stator to provide a labyrinth seal against gas leakage past the bucket tips. The increase in the size of the buckets from the first to the third stage is necessitated by the pressure reduction resulting from energy conversion in each stage, requiring an increased annulus area to accommodate the gas flow. 1.5.2.4. COOLING The turbine rotor is cooled to maintain reasonable operating temperatures and, therefore, assure a longer turbine service life. Cooling is accomplished by means of a positive flow of cool air extracted from the compressor and discharged radially outward through a space between the turbine wheel and the stator, into the main gas stream. This area is called the wheelspace.

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OMMD_TG_6FA_EN

Revision: A

Date: 02/2008

GE Energy Products – Europe Rev. : A Page : 27/36

OPERATION AND MAINTENANCE MANUAL

DESCRIPTION

1.5.2.5. FIRST-STAGE WHEELSPACES The first-stage forward wheelspace is cooled by compressor discharge air. A honeycomb labyrinth seal is installed at the aft end of the compressor rotor between the rotor and inner barrel of the compressor discharge casing. The leakage through this labyrinth furnishes the air flow through the first-stage forward wheelspace. This cooling air flow discharges into the main gas stream aft of the first-stage nozzle. The first-stage aft wheelspace is cooled by 9th stage extraction air ported through the 2nd stage nozzle. This air returns to the gas path forward of the 2nd stage nozzle. 1.5.2.6. SECOND-STAGE WHEELSPACES The second-stage forward wheelspace is cooled by leakage from the first-stage aft wheelspace through the interstage labyrinth. This air returns to the gas path at the entrance of the second-stage buckets. The second-stage aft wheelspace is cooled by 13th stage extraction air ported through the 3rd stage nozzle. Air from this wheelspace returns to the gas path at the third-stage nozzle entrance. 1.5.2.7. THIRD-STAGE WHEELSPACES The third-stage forward wheelspace is cooled by leakage from the second-stage aft wheelspace through the interstage labyrinth. This air reenters the gas path at the third-stage bucket entrance. The third-stage aft wheelspace obtains its cooling air from the discharge of the exhaust frame cooling air annulus. This air flows through the third-stage aft wheelspace, and into the gas path at the entrance to the exhaust diffuser.

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OMMD_TG_6FA_EN

Revision: A

Date: 02/2008

GE Energy Products – Europe Rev. : A Page : 28/36

OPERATION AND MAINTENANCE MANUAL

DESCRIPTION

1.5.2.8. BUCKETS

Air is introduced into each first-stage bucket through a plenum at the base of the bucket dovetail. It flows through serpentine cooling holes extending the length of the bucket and exits at the trailing edge and the bucket tip. The holes are spaced and sized to obtain optimum cooling of the airfoil with minimum compressor extraction air.

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OMMD_TG_6FA_EN

Revision: A

Date: 02/2008

GE Energy Products – Europe Rev. : A Page : 29/36

OPERATION AND MAINTENANCE MANUAL

DESCRIPTION

Unlike the first-stage buckets, the second-stage buckets are cooled by spanwise air passages the length of the airfoil. Air is introduced like the first-stage, with a plenum at the base of the bucket dovetail. Again airfoil cooling is accomplished with minimum penalty to the thermodynamic cycle.

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OMMD_TG_6FA_EN

Revision: A

Date: 02/2008

GE Energy Products – Europe Rev. : A Page : 30/36

OPERATION AND MAINTENANCE MANUAL

DESCRIPTION

The third-stage buckets are not internally air cooled ; the tips of these buckets, like the second-stage buckets, are enclosed by a shroud, which is a part of the tip seal. These shrouds interlock from bucket to bucket to provide vibration damping. All right reserved copyright - Droits de reproduction réservés

OMMD_TG_6FA_EN

Revision: A

Date: 02/2008

GE Energy Products – Europe Rev. : A Page : 31/36

OPERATION AND MAINTENANCE MANUAL

DESCRIPTION

1.5.3.

TURBINE STATOR

1.5.3.1. STRUCTURE The turbine casing and the exhaust frame constitute the major portion of the MS 6001 FA gas turbine stator structure. The turbine nozzles, shrouds, and turbine exhaust diffuser are internally supported from these components. 1.5.3.2. TURBINE CASING The turbine casing controls the axial and radial positions of the shrouds and nozzles. It determines turbine clearances and the relative positions of the nozzles to the turbine buckets. This positioning is critical to gas turbine performance. Hot gases contained by the turbine casing are a source of heat flow into the casing. Heat flow limitations incorporate insulation, cooling, and multi-layered structures. 13th and 9th stage extraction air is piped into the turbine casing annular spaces around the 2nd and 3rd stage nozzles. From there the air is ported through the nozzle partitions and into the wheel spaces. Structurally, the turbine casing forward flange is bolted to the bulkhead flange at the aft end of the compressor discharge casing. The turbine casing aft flange is bolted to the forward flange of the exhaust frame. 1.5.3.3. NOZZLES In the turbine section there are three stages of stationary nozzles, which direct the highvelocity flow of the expanded hot combustion gas against the turbine buckets causing the turbine rotor to rotate. Because of the high pressure drop across these nozzles, there are seals at both the inside and the outside diameters to prevent loss of system energy by leakage. Since these nozzles operate in the hot combustion gas flow, they are subjected to thermal stresses in addition to gas pressure loadings. 1.5.3.4. FIRST-STAGE NOZZLE The first-stage nozzle receives the hot combustion gases from the combustion system via the transition pieces. The transition pieces are sealed to both the outer and inner sidewalls on the entrance side of the nozzle ; this minimize leakage of compressor discharge air into the nozzles. The Model 6001 FA gas turbine first-stage nozzle contains a forward and aft cavity in the vane and is cooled by a combination of film, impingement and convection techniques in both the vane and sidewall regions. The nozzle segments, each with two partitions or airfoils, are contained by a horizontally split retaining ring which is centerline supported to the turbine casing on lugs at the sides and guided by keys at the top and bottom vertical centerlines. This permits radial growth of the retaining ring, resulting from changes in temperature, while the ring remains centered in the casing.

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Revision: A

Date: 02/2008

GE Energy Products – Europe Rev. : A Page : 32/36

OPERATION AND MAINTENANCE MANUAL

DESCRIPTION The aft outer sidewall of the nozzle is loaded against the forward face of the first-stage turbine shroud and acts as the air seal to prevent leakage of compressor discharge air between the nozzle and turbine casing. On the inner sidewall, the nozzle is sealed by a flange cast on the inner diameter of the sidewall that rests against a mating face on the first-stage nozzle support ring, a locating dowel that engages a lug on the inner sidewall. The nozzle is prevented from moving forward by the lugs on the aft outside diameter of the retaining ring at 60 degrees from vertical and horizontal centerlines. By moving the horizontal joint support block and the bottom centerline key and the 60°blocks, the lower half of the nozzle can be rolled out with the turbine rotor in place. 1.5.3.5. SECOND-STAGE NOZZLE Combustion air exiting from the first stage buckets is again expanded and redirected against the second-stage turbine buckets by the second-stage nozzle. This nozzle is made of cast segments, each with two partitions or airfoils. The male hooks on the entrance and exit sides of the outer 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. This 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 sidewall. The second-stage nozzle is cooled with 13th stage extraction air. 1.5.3.6. THIRD-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 cast segments, each with three partitions or airfoils. It is held at the outer sidewall forward and aft sides in grooves in the turbine shrouds in a manner similar to that used on the second-stage nozzle. The third-stage nozzle is circumferentially positioned by radial pins from the shell. 9th stage extraction air flows through the nozzle partitions for nozzle convection cooling and for augmenting wheelspace cooling air flow. 1.5.3.7. DIAPHRAGM Bolted to the inside diameters of both the second and third-stage nozzle segments are the nozzle diaphragms. These diaphragms prevent air leakage past the inner sidewall of the nozzles and the turbine rotor. A honeycomb labyrinth seal is brazed into the inside diameter of the diaphragm. They mate with opposing sealing teeth on the turbine rotor. Minimal radial clearance between stationary parts (diaphragm and nozzles) and the moving rotor are essential for maintaining low interstage leakage; this results in higher turbine efficiency. 1.5.3.8. SHROUDS Unlike the compressor blades, the turbine buckets tips do not run directly against an integral machined surface of the casing but against annular curved segments called turbine shrouds. The shrouds'primary function is to provide a cylindrical surface for minimizing bucket tip clearance leakage. All right reserved copyright - Droits de reproduction réservés

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Date: 02/2008

GE Energy Products – Europe Rev. : A Page : 33/36

OPERATION AND MAINTENANCE MANUAL

DESCRIPTION The turbine shrouds' secondary function is to provide a high thermal resistance between the hot gases and the comparatively cool turbine casing. By accomplishing this function, the turbine casing cooling load is drastically reduced, the turbine casing diameter is controlled, the turbine casing roundness is maintained, and important turbine clearances are assured. The first stage stationary shroud segments are in two pieces; the gas-side inner shroud is separated from the supporting outer shroud to allow for expansion and contraction, and thereby improve low-cycle fatigue life. The first-stage shroud is cooled by impingement, film, and convection. The second and third stage stationary shroud segments are a single piece configuration with a honeycomb seal brazed into the inside diameter to form the seal surface to the bucket seal tooth. The shroud segments are maintained in the circumferential position by radial pins from the turbine casing. Joints between shroud segments are sealed by spline seals. 1.5.3.9. EXHAUST FRAME The exhaust frame is bolted to the aft flange of the turbine casing. Structurally, the frame consists of an outer cylinder and an inner cylinder interconnected by the radial struts. The #2 bearing is supported from the inner cylinder. The exhaust diffuser located at the aft end of the turbine is bolted to the exhaust frame. Gases exhausted from the third turbine stage enter the diffuser where velocity is reduced by diffusion and pressure is recovered. At the exit of the diffuser, the gases are directed into the exhaust plenum. Exhaust frame radial struts cross the exhaust gas stream. These struts position the inner cylinder and #2 bearing in relation to the outer casing of the gas turbine. The struts must be maintained at a constant temperature in order to control the center position of the rotor in relation to the stator. This temperature stabilization is accomplished by protecting the struts from exhaust gases with a metal fairing that forms an air space around each strut and provides a rotated, combined airfoil shape. Off-base blowers provide cooling air flow through the space between the struts and the wrapper to maintain uniform temperature of the struts. This air is then directed to the thirdstage aft wheelspace. Trunnions on the sides of the exhaust frame are used with similar trunnions on the forward compressor casing to lift the gas turbine when it is separated from its base.

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OMMD_TG_6FA_EN

Revision: A

Date: 02/2008

GE Energy Products – Europe Rev. : A Page : 34/36

OPERATION AND MAINTENANCE MANUAL

DESCRIPTION

1.6.

BEARINGS

1.6.1.

GENERAL The MS 6001 FA gas turbine unit has two four-element, tilting pad journal bearings, which support the gas turbine rotor. The unit also includes a thrust bearing to maintain the rotor-tostator axial position. Thrust is absorbed by a tilting pad thrust bearing with eight shoes on both sides of the thrust bearing runner. These bearings and seals are incorporated in two housings, one at the inlet casing, one in the exhaust frame. These main bearings are pressure-lubricated by oil supplied from the main lubricating oil system. The oil flows through branch lines to an inlet in each bearing housing.

1.6.2.

LUBRICATION The main turbine bearings are pressure-lubricated with oil supplied, from the oil reservoir. Oil feed piping, where practical, is run within the lube oil drain lines, or drain channels, as a protective measure. In the event of a supply line leak, oil will not be sprayed on nearby equipment, thus eliminating a potential safety hazard. When the oil enters the housing inlet, it flows into an annulus around the bearing. From the annulus, the oil flows through machined holes or slots to the bearing rotor interface.

1.6.2.1. LUBRICANT SEALING Oil on the surface of the turbine shaft is prevented from being spun along the shaft by oil seals in each of the bearing housings. These labyrinth seals are assembled at the extremities of the bearing assemblies where oil control is required. A smooth surface is machined on the shaft and the seals are assembled so that only a small clearance exists between the oil seal and the shaft. The oil seals are designed with tandem rows of teeth and an annular space between them. Pressurized sealing air is admitted into this space to prevent lubricating oil vapor from exiting the bearing housing. The air that returns with the oil to the main lubricating oil reservoir is vented to atmosphere after passing through an oil vapor extractor.

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OMMD_TG_6FA_EN

Revision: A

Date: 02/2008

GE Energy Products – Europe Rev. : A Page : 35/36

OPERATION AND MAINTENANCE MANUAL

DESCRIPTION

1.7.

ENCLOSURES

1.7.1.

GENERAL Gas turbine enclosures, referred to in this manual as compartments, are those partitioned areas in which specific components of the overall power plant are contained. These compartments are built for all-weather conditions and designed for accessibility when performing maintenance. They are provided with thermal and acoustical insulation and lighted for convenience. The aim of those enclosures is : •

To provide weather protection for the equipment.

•

To detect and extinguish the fire and to contain fire fighting medium

•

To provide proper cooling and ventilation for the equipment including during gas turbine cooling down sequence.

•

To dilute gas leak to avoid hazardous area

•

To provide attenuation of the noise generated by the equipment

•

To protect personnel from high temperature and fire risks.

•

To heat the enclosure during cold period

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OMMD_TG_6FA_EN

Revision: A

Date: 02/2008

GE Energy Products – Europe Rev. : A Page : 36/36

OPERATION AND MAINTENANCE MANUAL

DESCRIPTION

1.8.

COUPLING

1.8.1.

GENERAL The load coupling links the gas turbine shaft to the load gear high speed shaft. It is flexible type coupling which is capable of accommodating shortening and lengthening of its normal flange to flange dimension by ± 25 mm and 0,25 degrees of misalignment while operating at normal torque maximum continuous speed and maximum axial excursion. The coupling length is approximately of 1250 mm and the flange diameter is approximately of 573 mm. For more details refer to subcontractor literature.

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OMMD_TG_6FA_EN

Revision: A

Date: 02/2008

6FACOMP 1/98

Forward Coupling

Thrust Bearing Runner

#1 Bearing Journal

Forward Stub Shaft (Stage Zero)

Speed Indicating Ring Assembly

Ring Retaining Pin

Speed Indicating Ring

Locknut

FWD Balance Weight Groove

12 Point Nut

1st Stage Compressor Wheel Note: Blades Not Shown In All Wheels For Dwg Simplicity

Compressor Rotor Stud Assembly Qty 15

Rotor Stud

Compressor Wheels Stage 2 thru 15

16th Stage Comp Wheel AFT Side Bore Fan Configuration. A Machined Gap Between The 16th Stage & AFT Stub Shaft (At The Outer Rim) Permits The Fan To Draw Air From The Compressed Air Flow and Direct It Through The AFT Stub Shaft Cooling Air Passages To Cool Down Stream Turbine Components.

Rotor Nut

16th Stage Compressor Wheel & AFT Stub Shaft

Compressor Rotor AFT Stub Shaft

Cooling Air Passages AFT Side

AFT Balance Weight Groove

AFT Bearing Surface (Manufacturing Use)

16th Stage Compressor Wheel

Cooling Air Passages 15 Thru Holes

Compressor AFT Coupling (To Turb Rotor)

6FATURB 1/98

Turbine Cooling Air Passages 15 Thru Holes

1st Stage 12PT Nut FWD Side Qty 24

1st Stage Bkt Qty 92

1st Stage Turbine Wheel AFT Side

Cooling Air Slots

Distance Piece Compressor to Turbine

Turb Rotor FWD Bearing Surface (Manufacturing Use)

1st Stage Rotor Stud Qty 24

1st Stage Turbine Wheel

2nd Stage 12PT Nut FWD Side 1st Stage 12PT Nut AFT Side Qty 24 Ea.

Bucket Lockwire Assembly Typical All Buckets All Stages

Lockwire Retaining Pin Qty 9/Whl

Bucket Lockwire

Distance Piece

1 to 2 Spacer

2nd Stage Bkt Qty 92

2nd Stage Rotor Stud Qty 24

2nd Stage Turbine Wheel

2nd Stage 12PT Nut AFT Side Qty 24

3rd Stage Bkt Qty 92

Integral Turbine Cooling Air Fan

AFT End of Cooling Air Passages

Bucket Lockwire

2 to 3 Spacer

Shank Seal Pins

3rd Stage Rotor Stud Qty 18

3rd Stage 12PT Nut AFT Side Qty 18

Platform Seal Pin

3rd Stage Turbine Wheel

Bucket Seal Pin Assembly Typical All Buckets All Stages

Bucket Lockwire

Turbine AFT Shaft

AFT Bearing Journal

AFT Plug

Retaining Plate

Plate Bolts & Lockplates

6FA CSA 4/98

16th STAGE EXTRACTION COOLING & SEALING AIR

COMPRESSOR DISCHARGE AIR

COMPRESSOR DISCHARGE AIR

13th STAGE EXTRACTION COOLING AIR

Turbine Case

MS6001FA Gas Turbine Turbine and Exhaust Frame Sections Cooling and Sealing Air Flows

9th STAGE EXTRACTION COOLING AIR

CL

#2 Bearing

CL Unit

COOLING & SEALING AIR SUPPLIED BY OFF BASE EXHAUST FRAME COOLING BLOWERS

COOLING & SEALING AIR SUPPLIED BY OFF BASE EXHAUST FRAME COOLING BLOWERS

Exhaust Frame

Tab 3

GE Energy Rev. : A Page : 1/3

OPERATION AND MAINTENANCE MANUAL

DESCRIPTION

TURBINE CONTROL DEVICE SYSTEM

1 - Definition Turbine and compressor control and protection sensors are grouped as a single system including: x x x x x x

Turbine speed sensors Ignition transformers, spark plugs and flame detectors Vibrations sensors Compressor temperature measurement Turbine cooling temperature measurement Gas turbine exhaust temperature measurement x Turbine bearings oil and metal temperature measurement

2 - Component function 28FD-1

Detects flame in the secondary zone of chamber combustion n°1

28FD-2

Detects flame in combustion chamber n°2

28FD-6A

Detects flame in the secondary zone of chamber combustion n°6

28FD-6B

Detects flame in the secondary zone of chamber combustion n°6

30SG-1

Detects an ignition transformer trouble

39V-1A

Measures vibrations on the hat of bearing n°1

39V-1B

Measures vibrations on the hat of bearing n°1

39V-2A

Measures vibrations on the flange of oil return piping of bearing n°2

39V-2B

Measures vibrations on the hat of bearing 2

39VS-11

Measures the movement of the rotor in the plan X,Y of bearing n°1

39VS-12

Measures the movement of the rotor in the plan X,Y of bearing n°1

39VS-21

Measures the movement of the rotor in the plan X,Y of bearing n°2

39VS-22

Measures the movement of the rotor in the plan X,Y of bearing n°2 All right reserved copyright - Droits de reproduction réservés

OMMD_0415_6FA_E0765_A_EN

Revision: A

Date: 01/2009

GE Energy Rev. : A Page : 2/3

OPERATION AND MAINTENANCE MANUAL

DESCRIPTION 77HT-1

Measures shaft line speed specific circuit of overspeed

77HT-2

Measures shaft line speed specific circuit of overspeed

77HT-3

Measures shaft line speed specific circuit of overspeed

77NH-1

Measures the shaft line speed

77NH-2

Measures the shaft line speed

77NH-3

Measures the shaft line speed

77RP-11

Detects the shaft position

95SG-4

Provides high voltage for ignition to the spark plug

95SG-5

Provides high voltage for ignition to the spark plug

95SP-4

Realizes ignition of combustion

95SP-5

Realizes ignition of combustion

96VC-11

Measures the axial movement of the turbine rotor

96VC-12

Measures the axial movement of the turbine rotor

BT-J1-1A, 1B

Measures temperature of bearing bushing n°1

BT-J1-2A, 2B

Measures temperature of bearing bushing n°1

BT-J2-1A, 1B

Measures temperature of bearing bushing n°2

BT-J2-2A, 2B

Measures temperature of bearing bushing n°2

BT-TA-6A, 6B

1Measures temperature of pad n°6 of thrust bearing n°1

BT-TA-12A, 12B

Measures temperature of pad n°12 of counter thrust bearing n°

BT-TI-4A, 4B

Measures temperature of pad n°4 of counter thrust bearing n°1

BT-TI-8A, 8B

Measures temperature of pad n°8 of thrust bearing n°1

CT-DA-1

Measures air temperature of the outlet of compressor

CT-DA-2

Measures air temperature of the outlet of compressor

CT-DA-3

Measures air temperature of the outlet of compressor

CT-IF-1A, 1B

Measures air temperature of the inlet of compressor

CT-IF-2A, 2B

Measures air temperature of the inlet of compressor

TT-IB-1

Measures air temperature in exhaust tunnel

TT-IB-2

Measures air temperature in exhaust tunnel

TT-IB-3

Measures air temperature in exhaust tunnel

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OMMD_0415_6FA_E0765_A_EN

Revision: A

Date: 01/2009

GE Energy Rev. : A Page : 3/3

OPERATION AND MAINTENANCE MANUAL

DESCRIPTION

TT-WS1AO-1

Measures wheel space temperature, external position after first wheel

TT-WS1AO-2

Measures wheel space temperature, external position after first wheel

TT-WS1FI-1

Measures wheel space temperature, internal position before first wheel

TT-WS1FI-2

Measures wheel space temperature, internal position before first wheel

TT-WS2AO-1

Measures wheel space temperature, external position after second wheel

TT-WS2AO-2

Measures wheel space temperature, external position after second wheel

TT-WS3AO-1

Measures wheel space temperature, external position after third wheel

TT-WS3AO-2

Measures wheel space temperature, external position after third wheel

TT-XD-1 to 21

Measures temperature of GT exhaust

3 - Additional information Gas turbine speed: Magnetic pick up sensors measure the pulse given by the toothed wheel fitted at compressor shaft front end. The frequency in Hz is equal to the speed in RPM due to the 60 tooth of the wheel. Vibration measurements: Seismic sensors and proximity probes measure the shaft vibrations. The vibration map after commissioning load tests represents the original vibration signature. Gas turbine cooling: Gas turbine cooling is monitored by wheel space thermocouples. Two thermocouples situated at the same wheel space level should measure similar temperature. A temperature difference between two thermocouples in the same wheel space, detected by the Speedtronic® , represents a cooling fault or a measurement fault which must be analyzed and rectified quickly. Gas turbine exhaust temperature: TT-XD thermocouples measure gas turbine exhaust temperature. An exhaust spread, detected by the Speedtronic® , represents a combustion fault or a measurement fault and must be analyzed and rectified quickly. All right reserved copyright - Droits de reproduction réservés

OMMD_0415_6FA_E0765_A_EN

Revision: A

Date: 01/2009

G

E

O

DT-1C

l a i ff ic

G

E

O

l a i ff ic

G

E

O

l a i ff ic

GE Energy Rev : A

OPERATION AND MAINTENANCE MANUAL

Page : 1/7

DRAWINGS - CONTROL DEVICES TURBINE PART

NOMENCLATURE

1

28FD-1, 2, 6A, 6B

Flame detector combustion chambers 1, 2, 6

2

30SG-1

Diagnostic ignition exciter switch

3

39V-1A, 1B

Vibration sensor turbine (N°1 bearing cap)

4

39V-2A, 2B

Vibration sensor turbine (N°2 bearing cap)

5

39VS-11, 12

Vibration sensor, non contracting probes (N°1 bearing)

6

39VS-21, 22

Vibration sensor, non contracting probes (N°2 bearing)

7

77HT-1 to 3

Turbine shaft overspeed high pressure set magnetic pick-up speed

8

77NH-1 to 3

Turbine shaft high pressure set magnetic pick-up speed

9

77RP-11

Shaft angular position indicator (keyphasor)

10

95SG-4, 5

Ignition exciter for 95 SP-4, 5

11

95SP-4, 5

Combustion chamber spark plug n°4, 5

12

96VC-11, 12

Vibration sensor

13

BT-J1-1A, 1B, 2A, 2B

Thermocouple, N°1 turbine bearing

14

BT-J2-1A, 1B, 2A, 2B

Thermocouple, N°2 turbine bearing

15

BT-TA-6A, 6B, 12A, 12B

Thermocouple, turbine thrust bearing

16

BT-TI-4A, 4B,

Thermocouple, turbine counter thrust bearing

8A, 8B 17

CT-DA-1, 2, 3

Thermocouple compressor discharge temperature

18

CT-IF-1A, 1B,

Thermocouple compressor inlet temperature

2A, 2B 19

TT-IB-1,2,3

Turbine temperature inner barrel

20

TT-WS1A0-1, 2

Thermocouple turbine temperature wheelspace 1st stage after

21

TT-WS1F1-1, 2

Thermocouple turbine temperature wheelspace 1st stage forward

22

TT-WS2A0-1, 2

Thermocouple turbine temperature wheelspace 2nd stage after

23

TT-WS3A0-1, 2

Thermocouple turbine temperature wheelspace 3rd stage after

24

TT-XD-1 to 21

Exhaust temperature thermocouple

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N°

OMMDR_0415_6FA_01_A_EN

Revision : A

Date : 11/07

1

95SG-4, 5

30SG-1

10

2

VIEW A-AISOMETRIC VIEW

3

95SP-4

95SP-5

3 39V-1A

DETAIL D-A BEARING 1 - ISOMETRIC VIEW

39V-1B

11

11

(Sh.6)

Date : 11/07

12 96VC-11

5 39VS-11

5

(Sh. 3)

E-2

39VS-12

Revision : A

12

96VC-12

Page : 2/7

Rev : A

N° OMMDR_0415_6FA_01_A_EN

All rights reserved Copyright – Droits de reproduction réservés

ISOMETRIC VIEW BEARING 1

(Sh. 3)

E-1

- CONTROL DEVICES TURBINE -

DRAWINGS

OPERATION AND MAINTENANCE MANUAL

GE Energy

B-1

B-2

C

B-3

C SECTION B-1

C

C

SECTION C-C

16 BT-TI-8A, 8B

16 BT-TI-4A, 4B

15

VIEW E-1

BT-TA-12A, 12B

13

BT-J1-1A, 1B

15 BT-TA-6A, 6B

SECTION B-2

C

C

C

C

DETAIL D

SECTION B-3

B-3

13

Date : 11/07

SEE DETAIL - D

B-1

B-2

BT-J1-2A, 2B

VIEW E-3

VIEW E-2

Revision : A

9 77RP-11

Page : 3/7

Rev : A

N° OMMDR_0415_6FA_01_A_EN

All rights reserved Copyright – Droits de reproduction réservés

77NH-1 to 3

8

77HT-1 to 3

7

E-3

- CONTROL DEVICES TURBINE -

DRAWINGS

OPERATION AND MAINTENANCE MANUAL

GE Energy

TT-WS2A0-1 22

(Sh.5)

C-4

(Sh.5)

C-4

C-1

VIEW LEFT SIDE GAS TURBINE MODULE

20 TT-WS1A0-1

22 TT-WS2A0-2

C-2

C-2

VIEW RIGHT SIDE GAS TURBINE MODULE

TT-WS1A0-2

20

C-1

(Sh.5)

C-3

(Sh.5)

C-3

Date : 11/07

(Sh.5)

E-4

20

TT-WS1A0-1

SECTION C-2

TT-WS1A0-2

Revision : A

22 TT-WS2A0-2

Page : 4/7

Rev : A

N° OMMDR_0415_6FA_01_A_EN

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TT-WS2A0-1

22

SECTION C-1

20

- CONTROL DEVICES TURBINE -

DRAWINGS

OPERATION AND MAINTENANCE MANUAL

GE Energy

23

19

TT-WS3A0-1

CT-IF-1A, 1B

18

TT-IB-3

19

VIEW E-4

SECTION C-3

TT-IB-1

19 TT-IB-2

24

TT-XD-1 to 21

CT-IF-2A, 2B

18

23 TT-WS3A0-2

Date : 11/07

CT-DA-1 17

21

TT-WS1F1-1

Revision : A

17 CT-DA-2

21 TT-WS1F1-2

17 CT-DA-3

Page : 5/7

Rev : A

N° OMMDR_0415_6FA_01_A_EN

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SECTION C-4

- CONTROL DEVICES TURBINE -

DRAWINGS

OPERATION AND MAINTENANCE MANUAL

GE Energy

4

4

39V-2A

DETAIL N-B BEARING 2 - ISOMETRIC VIEW

39V-2B

ISOMETRIC VIEW BEARING 2

(Sh.7)

E-5

Date : 11/07

28FD-2

1

28FD-1

1

6

28FD-6A

1

28FD-6B

Revision : A

11 95SP-4

11 95SP-5

Page : 6/7

Rev : A

N° OMMDR_0415_6FA_01_A_EN

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39VS-22

6 39VS-21

VIEW E-A (sh.2) AT COMBUSTION CHAMBERS ASSY.

1

- CONTROL DEVICES TURBINE -

DRAWINGS

OPERATION AND MAINTENANCE MANUAL

GE Energy

F-2

VIEW E-5

F-2

BT-J2-2A, 2B

14

Date : 11/07

SECTION F-2

Revision : A

Page : 7/7

Rev : A

N° OMMDR_0415_6FA_01_A_EN

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BT-J2-1A, 1B

14

- CONTROL DEVICES TURBINE -

DRAWINGS

OPERATION AND MAINTENANCE MANUAL

GE Energy

Tab 4

GE Energy Rev. : A Page : 1/1

OPERATION AND MAINTENANCE MANUAL

DESCRIPTION

FLOW INLET AND EXHAUST SYSTEM

1 - Definition The flow inlet & exhaust is designed for insuring the following functions : x x x x x

To supply the gas turbine with filtered air flow To provide anti-icing To distribute the bleed heating air flow in homogeneous spray To reduce the compressor air inlet acoustical level To protect the air inlet duct against high pressure drop

2 - Component function 27TF-1

Gathers the air filter alarms

63CA-1

Detects the compressed air low pressure

63TF-2A

Detects high pressure drop in the air inlet duct

63TF-2B

Detects high pressure drop in the air inlet duct

96RH

Measures the ambient air temperature and humidity

96TF-1

Measures the air filter pressure drop

3 - Additional information Refer to gas turbine air filter documentation for complementary information.

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OMMD_0471_6FA_E0765_A_EN

Revision: A

Date: 01/2009

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