Download - Maintenance Manual for GPB30
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KAWASAKI GPB30
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This document is the property of KawasakiGas Turbine Asia (KGA) . It has beenprepared exclusively for PPGJ GTG internaluse only. It contains confidential andproprietary information of KGA and is not tobe disclosed to any person outside of PPGJ.The reproduction of this document in anymanner or medium is strictly prohibitedwithout written authorization from KGA. Anyuse made of this document, in whole or inpart, other than for evaluation purposes ispart, other than for evaluation purposes isstrictly prohibited without the express priorw r i t t e n c o n s e n t o f K G A .
Warning: Warning: The purpose of this training is to provide basic information and principles of Gas Turbine Generator (GTG) and its components. Under no circumstances, this note is to be used as a reference during GTG maintenance or operation.
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CONTENTSYSTEM:
a. GTG in General
b. Enclosure and Inlet/Exhaust System
c. Fuel System
d. Lube Oil System
e. Instrument Air System
f. Electrical System
g. Control System
OPERATING INSTRUCTION
a. Pre-operation Check
b. Starting Procedure
c. Load Transfer Procedure
d. Stopping Procedure
e. Cranking
f. Log and Operating Condition
TROUBLESHOOTING
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GTG IN GENERAL AND SPECIFICATION
GPB30 Engine Arrangement and Specification
Engine Assembly: consists of 2 power sections, main reduction Engine Assembly: consists of 2 power sections, main reduction Engine Assembly: consists of 2 power sections, main reduction Engine Assembly: consists of 2 power sections, main reduction gearbox and 2 accessory gearboxes.gearbox and 2 accessory gearboxes.
Package Assembly: consists of engine assembly and generator.Package Assembly: consists of engine assembly and generator.
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POWER SECTION
Called Gas Turbine or GT
Consists of:-
- Two stages of CENTRIFUGAL Compressors
- Three stages of AXIAL Turbine
- Single CAN type combustor
- Double end supported BEARINGS
Speed: 21870 rpmSpeed: 21870 rpm
Weight: 1.19 ton
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MAIN REDUCTION GEARBOX AND
ACCESSORY GEARBOXMain Reduction Gearbox:- Accessory Gearbox
- Type: Parallel - Mounted to main reduction gearbox
- Output Speed: 1,500 rpm (50Hz)
- Reduction Gear Ratio: 14.58
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GENERATORType: Synchronous AC generator type
Capacity: 2812.5 kVA
Voltage: 6.6 kV
Frequency: 50 Hz
Number of poles: 4 poles
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Enclosure and Inlet/Exhaust System
Enclosure Cooling Air
Turbine Inlet Air
Exhaust Air
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FUEL SYSTEM
Engine Gas Fuel System
EOV PGV
To Gas Exhaust
Gas Filter
SSV1 SSV2MGV
SGV
Gas Control
Valve
ACEEL FITCHRectangleACEEL FITCHRectangleACEEL FITCHTypewritten TextGas fuel filterdifferensial presure highACEEL FITCHTypewritten TextFTACEEL FITCHTypewritten TextACEEL FITCHTypewritten TextPTACEEL FITCHTypewritten TextTEACEEL FITCHTypewritten TextACEEL FITCHRectangleACEEL FITCHPolygonACEEL FITCHSticky NoteACEEL FITCHRectangleACEEL FITCHPolygonACEEL FITCHLineACEEL FITCHLineACEEL FITCHLineACEEL FITCHLineACEEL FITCHLineACEEL FITCHLineACEEL FITCHLineACEEL FITCHLineACEEL FITCHTypewritten TextKHI/PLCACEEL FITCHTypewritten TextKHI/PLCACEEL FITCHTypewritten TextACEEL FITCHOvalACEEL FITCHLineACEEL FITCHLineACEEL FITCHTypewritten TextPT, FT, TEACEEL FITCHOvalACEEL FITCHLineACEEL FITCHTypewritten TextTemperatur/Presure compensationACEEL FITCHLineACEEL FITCHLineACEEL FITCHTypewritten TextPA -
FUEL SYSTEM
Engine Diesel Fuel System
Pressurizing
Valve
Supply Fuel
Start Fuel
Pump
Main Fuel
Pump
Start Fuel
Valve
Fuel Control
Valve
Bypass Fuel
ValveMain Fuel
Valve
Return to
service tank
Supply Fuel
Shutoff
Valve
ACEEL FITCHRectangleACEEL FITCHCalloutPASSINGACEEL FITCHRectangleACEEL FITCHCalloutDIESEL FUEL LEAK -
LUBE OIL SYSTEMEngine Lube Oil System
Oil mist separator Vent
Manifold
LO Cooler
Main LO Pump
Pre Post
Pump
Gearbox
Generator
LO Tank
160L
M
Gas Turbine
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INSTRUMENT AIR SYSTEMEngine Instrument Air SystemPressure for air starting: 0.9 1.0 MPa
Pressure for instrument: 0.6 MPa
P
G
P
G
P
G
Air
Dryer
Instrumen
t Air TankM
Instrumen
t Air Tank
Regulating
Valve
Pressure
Control
Valve
Pressure
Control
Valve
Fuel Line Purge
SSV-1 & SSV-2
EOV
Intake Filter
JB Pressurizing
Gas Pressure Regulating
Valve
Air for Starting
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ELECTRICAL SYSTEM
Engine Electrical System
1. Ignition System
2. EGT Hardness
3. Speed Pick Up (Pulse)3. Speed Pick Up (Pulse)
4. Turning Motor
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1. Ignition System
Ignition Plug:
Manufacturer: NGK Spark Plug Co.Ltd.
Ignition system is required to ignite the mixture of fuel and air inside the combustor during start up.
Ignition Exciter:
Manufacturer: Yamamoto Electric Works Co. Ltd.
Input voltage: DC24V
Discharge cycle: 3.5 sparks per seconds
Discharge specification: 1 Joule per spark
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2. Exhaust Gas Temperature (EGT) Hardness
EGT Hardness is required to measure result of the combustion of fuel before discharge into the atmosphere.
It is also used to compare and monitor the performance of the gas turbine.
Thermocouple type : K type, T1 biasThermocouple type : K type, T1 bias
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3. Speed Pickup Pulse
Speed Pickup Pulse for power section:
Manufacturer: Yamamoto Electric Works Co. Ltd.
Type: Magnetic detection
Voltage: 4.5 V p-p (output)
Speed Pickup Pulse is required to detect the rotation speed of the power section and gearbox by magnetic pulse.
Speed Pickup Pulse for gearbox:
Manufacturer: Yamamoto Electric Works Co. Ltd.
Type: Magnetic detection
Voltage: 85-120 V p-p (output)
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4. Turning Motor
Turning motor is required to rotate the turbine shaft slowly after shutdown to allow uniform cooling to the turbine shaft.
The turning duration is controlled automatically by the gas turbine control panel.
Manufacturer: Sawamura Denki Kogyo Co.Manufacturer: Sawamura Denki Kogyo Co.
Type : DC Electrical motor
Rating : 24 VDC, 0.5A
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CONTROL SYSTEM
Engine Control System
1. Timing Schedule (Gas)
2. Timing Schedule (Diesel)
3. Alarm and Interlock3. Alarm and Interlock
4. Operation Display Panel
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TIMING CHARTStart com
Pre Purge On Pre Purge
Off
4%
22%
55%
95%
Voltage establish
CB close
Stop com Stop
95%
55%
4%
Starter Motor
Ignition Exciter
CB open
22%
Aux Machine cooling 30 min
GTG cooling 5 min
Fuel C
hangin
g
Unlo
adin
g
Loadin
g
3 min
Loading completed
Fuel C
hangin
g
Synchro
niz
ing
3 min2 sec
Pre
-exc
ite
Gas Pressure Established
Safety Shutoff Valve 2 (SSV2)
Safety Shutoff Valve 1 (SSV1)
Main Gas Valve (MGV)
Start Gas Valve (SGV)
E. Open Valve Close (EOV)
Oil Cooler Fan
Encl Vent Fan
Turning Motor
Pre Post LO Pump
Main Fuel Valve (MFV)
Start Fuel Valve (SFV)
Bypass Fuel Valve (BFV)
Purge Gas Valve (PGV)
Assist Air Valve (AAV)
Liquid Fuel Cooler Fan
1 sec
1 sec
10 sec
1 sec
30 sec
Turning 10 hours
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TIMING CHARTStart com
Pre Purge On
4%
22%
55%
95%
Voltage establish
CB close
Stop com Stop
95%
55%
4%
Starter Motor
Ignition Exciter
CB open
22%
Aux Machine cooling 30 min
GTG cooling 5 min
Fuel C
hangin
g
Unlo
adin
g
Loadin
g
Loading completed
Fuel C
hangin
g
Synchro
niz
ing
3 min2 sec
Pre
-exc
ite
Gas Pressure Established
Pre Purge Off
Safety Shutoff Valve 2 (SSV2)
Safety Shutoff Valve 1 (SSV1)
Main Gas Valve (MGV)
Start Gas Valve (SGV)
E. Open Valve Close (EOV)
Oil Cooler Fan
Encl Vent Fan
Turning Motor
Pre Post LO Pump
Main Fuel Valve (MFV)
Start Fuel Valve (SFV)
Bypass Fuel Valve (BFV)
Purge Gas Valve (PGV)
Assist Air Valve (AAV)
Liquid Fuel Cooler Fan
1 sec
1 sec
10 sec
1 sec
30 sec
Turning 10 hours
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TIMING CHART (DIESEL)Start com
5%
22%
55%
95%
Voltage establish
CB close
Stop com Stop
95%
55%
4%
Starter Motor
Ignition Exciter
CB open
22%
Aux Machine cooling 30 min
GTG cooling 5 min
Unlo
adin
g
Loadin
g
Loading completed
Synchro
niz
ing
2 sec
Pre
-exc
ite
Safety Shutoff Valve 2 (SSV2)
Safety Shutoff Valve 1 (SSV1)
Main Gas Valve (MGV)
Start Gas Valve (SGV)
E. Open Valve Close (EOV)
Oil Cooler Fan
Encl Vent Fan
Turning Motor
Pre Post LO Pump
Main Fuel Valve (MFV)
Start Fuel Valve (SFV)
Bypass Fuel Valve (BFV)
Purge Gas Valve (PGV)
Assist Air Valve (AAV)
Liquid Fuel Cooler Fan
30 sec
Turning 10 hours
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TIMING CHART (DIESEL)Start com
5%
22%
55%
95%
Voltage establish
CB close
Stop com
95%
55%
4%
Starter Motor
Ignition Exciter
CB open
22%
Aux Machine cooling 30 min
GTG cooling 5 min
Unlo
adin
g
Loadin
g
Loading completed
Synchro
niz
ing
2 sec
Pre
-exc
ite
Stop
Safety Shutoff Valve 2 (SSV2)
Safety Shutoff Valve 1 (SSV1)
Main Gas Valve (MGV)
Start Gas Valve (SGV)
E. Open Valve Close (EOV)
Oil Cooler Fan
Encl Vent Fan
Turning Motor
Pre Post LO Pump
Main Fuel Valve (MFV)
Start Fuel Valve (SFV)
Bypass Fuel Valve (BFV)
Purge Gas Valve (PGV)
Assist Air Valve (AAV)
Liquid Fuel Cooler Fan
30 sec
Turning 10 hours
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ALARM AND INTERLOCKFailure Description Set Point
1 Major Fault
1.1 Start Failure 0-55% 352 seconds
1.2 Start Failure 55-95% 202 seconds
1.3 Over Speed 110+0, -2%
1.4 Under Speed 55-95% 54+0, -4%
1.5 Under Speed 95%~ 94+0, -4%
1.6 LO Supply Temperature HH 905C
1.7 LO Supply Pressure LL (starting) 0.1+0.05, -0 MPa
1.8 LO Supply Pressure LL (running) 0.2+0.05, -0 MPa1.8 LO Supply Pressure LL (running) 0.2+0.05, -0 MPa
1.9 Exhaust Gas Temperature HH (starting) 700+0, -40C
1.10 Exhaust Gas Temperature HH (running) 58010C
1.11 Emergency Shutdown Push Button
1.12 Main Shaft Vibration HH 2D3m
1.13 Gearbox Vibration HH 2D0.5 mm/s
1.14 Flame Out 20010C
1.15 Miss Fire
1.16 GTG Package Gas Leak HH 10000 ppm
1.17 Generator Stator Winding Temperature HH 1502C
1.18 Generator Bearing Temperature HH 952C
1.19 Under Voltage (27G) 85V, 2 seconds
1.20 Over Voltage (59G) 130V, 2 seconds
1.21 Loss of Excitation (40G) 2 seconds
1.22 Generator Differential Protection (87G) 0.4A, 10%, instant
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ALARM AND INTERLOCKFailure Description Set Point
1.23 Revolving Rectifier Failure (71G)
1.24 GTG Package Fire
1.25 Emergency Opening Valve Open
1.26 Pre-Post LO Supply Pressure L 0.0150.0013 MPa
1.27 Fuel Gas Valve Leak
1.28 PLC Major Fault
1.29 Control Power Fault
1.30 Supply Fuel Shutoff Valve Abnormal
1.31 Strainer Differential Pressure HH 0.35 MPa1.31 Strainer Differential Pressure HH 0.35 MPa
1.32 Package Inlet Air Damper Close
1.33 Package Ventilation Air Damper Close
2 Middle Fault
2.1 Over Current (51G) 111%, M:1
2.2 Reverse Power (67PG) 10%, 10 seconds
2.3 Negative Sequence Current (46G) M:10, 30%
2.4 Over Frequency (95HG) 54 Hz, 0.1 second
2.5 Under Frequency (95LG) 47.5 Hz, 0.1 second
2.6 Ground Over Current (51N)
2.7 AVR Failure
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ALARM AND INTERLOCKFailure Description Set Point
3 Light Fault
3.1 Main Shaft Vibration H 1.5D3 m
3.2 Gearbox Vibration H 1.5D0.5 mm/s
3.3 GTG Package Gas Leak H 2500 ppm
3.4 Exhaust Gas Temperature H 56010C
3.5 LO Supply Temperature H 805C
3.6 LO Tank Level L 12010 L
3.7 LO Filter Differential Pressure H 0.240.04 MPa
3.8 LO Supply Pressure L 0.260.02 MPa3.8 LO Supply Pressure L 0.260.02 MPa
3.9 Sensor Failure
3.10 Turning Motor Power Failure
3.11 Pulse Filter Differential Pressure H
3.12 Intake Air Filter Differential Pressure H 0.7 kPa
3.13 Gas Fuel Control Valve Failure
3.14 GTG Oil Leak
3.15 Fuel Gas Pressure L (for fuel change)
3.16 Generator Stator Winding Temperature H 1352C
3.17 Generator Bearing temperature H 852C
3.18 Auxiliary Machine Failure
3.19 Fail to Syncoro 2 minutes
3.20 PLC Minor Fault
3.21 Display Failure
3.22 Starting Air Pressure L
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ALARM AND INTERLOCKFailure Description Set Point
3.23 Strainer Differential Pressure L 0.3 MPa
3.24 Gas Fuel Filter Differential Pressure L
3.25 Liquid Fuel Filter Differential Pressure H 0.24 MPa
3.26 UPS Panel Failure
3.27 DC Battery Failure
3.28 Fire Extinguish Panel Failure
3.29 Ground Over Current (51N)
3.30 Fuel Gas Pressure LL 0.880.025 MPa
3.31 Supply Fuel Shutoff Valve Abnormal3.31 Supply Fuel Shutoff Valve Abnormal
3.32 Junction Box Air Pressure L 500 Pa
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OPERATION INSTRUCTION
a. Pre-operation Check
b. Starting Procedure
c. Load Transfer Procedure
d. Stopping Procedured. Stopping Procedure
e. Cranking
f. Log and Operating Condition
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a. PRE OPERATION CHECKSFollowing checks to be carried out prior to start GTG by Diesel Fuel Mode
NO DESCRIPTION CRITERIA JUDGEMENT
1 Intake Air Filter Ensure security & no obstruction
2 GTG
a Area Ensure clear and no abnormality
b GTG Ventilation Inlet Filter Ensure security & no obstruction
3 Diesel Fuel System
a Service Tank Outlet Supply Valve Open
b GTG Inlet Supply Valve Open
c GTG Outlet Return Valve Open
d FO Cooler Inlet Return Valve Open
e Service Tank Inlet Return Valve Open
f Service Tank Level Confirm Full
4 Instrument Air
a Supply Confirm Supply Available
b GTG Inlet Supply Valve Open
5 Lubrication Oil (GTG)
a Oil Tank Level Confirm >120
b Visual Inspection No Leak
c Oil Mist Vent Confirm no obstruction
6 Power Supply
a AC120V supply to TCP confirm energize
b DC24V supply to TCP confirm all energize
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a. PRE OPERATION CHECKSFollowing checks to be carried out prior to start GTG by Gas Fuel Mode
NO DESCRIPTION CRITERIA JUDGEMENT
1 Intake Air Filter Ensure security & no obstruction
2 GTG
a Area Ensure clear and no abnormality
b GTG Ventilation Inlet Filter Ensure security & no obstruction
3 Lean Gas Fuel System
a Lean Gas Fuel Valve Open
b Lean Gas Supply Pressure > 1.323 MPa
c Confirm Gas Filter Select Valve Open
4 Diesel Fuel System
a Service Tank Outlet Supply Valve Open
b GTG Inlet Supply Valve Open
c GTG Outlet Return Valve Open
d FO Cooler Inlet Return Valve Open
e Service Tank Inlet Return Valve Open
5 Instrument Air
A Supply Confirm Supply Available
B GTG Inlet Supply Valve Open
6 Lubrication Oil (GTG)
A Oil Tank Level Confirm >120
B Visual Inspection No Leak
C Oil Mist Vent Confirm no obstruction
7 Power Supply
a AC120V supply to TCP confirm energize
b DC24V supply to TCP confirm all energize
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b. STARTING PROCEDURE
Starting and Loading in Manual Mode
1. On Operation page, select MANUAL mode and execute
2. If GTG starting in Diesel Mode, confirm following
On Operation page, select DIESEL and execute
3. If GTG starting in Gas Mode, confirm following
On Operation page, select GAS and execute
4. On Menu Bar, select READY
5. Confirm followings:
GTG Speed
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b. STARTING PROCEDURE
Starting and Loading in Semi Auto Mode
1. On Operation page, select SEMI AUTO mode and execute
2. If GTG starting in Diesel Mode, confirm following
On Operation page, select DIESEL and execute
3. If GTG starting in Gas Mode, confirm following
On Operation page, select GAS and execute
4. On Menu Bar, select READY
5. Confirm followings:
GTG Speed
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b. STARTING PROCEDURE
Starting and Loading in Auto Mode
1. On Operation page, select AUTO mode and execute
2. If GTG starting in Diesel Mode, confirm following
On Operation page, select DIESEL and execute
3. If GTG starting in Gas Mode, confirm following
On Operation page, select GAS and execute
4. On Menu Bar, select READY
5. Confirm followings:
GTG Speed
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c. LOAD TRANSFER PROCEDURELoad Transfer in Manual Mode
1. On Operation page, select MANUAL mode and execute
2. Start another GTG according to starting procedure
3. Synchronize another GTG to existing on load GTG for PARALLEL OPERATION
4. Manually raise another GTG speed and lower existing GTG speed
5. Observe the load (kW) is transferring to another GTG
6. Manually OPEN/TRIP the generator CB when load reduced to
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c. LOAD TRANSFER PROCEDURELoad Transfer in Semi Auto or Auto Mode
1. On Operation page, select SEMI AUTO or AUTO mode and execute
2. Start another GTG according to starting procedure
3. Synchronize another GTG to existing on load GTG for PARALLEL OPERATION
4. On Operation page of existing GTG, select AUTO UNLOAD and execute
5. Observe the load (kW) is transferring to another GTG
6. The generator CB will automatically OPEN/TRIP when load reduced to
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d. GTG STOPPING PROCEDURE
Stopping in Manual Mode:
On Operation page, select MANUAL mode and execute.
Unload GTG according to manual unload manual.
Wait for 5 minutes for GTG cooling.
Carry out fuel change to DIESEL mode
After GTG cooling sequence completed, select the STOP on the Operation page and execute.
After GTG completely stopped, carry out inspection and verify for pre-post pump and turning motor operation.
Stopping in Semi Auto Mode:
On Operation page, select SEMI AUTO mode and execute.
Unload GTG according to semi auto unload manual.
GTG will auto fuel change to DIESEL mode after 3 minutes of cooling and resume another 2 minutes cooling on DIESEL mode.
After GTG cooling sequence completed, select the STOP on the Operation page and execute.
After GTG completely stopped, carry out inspection and verify for pre-post pump and turning motor operation.
Stopping in Auto Mode:
On Operation page, select AUTO mode and execute.
Then select STOP on the Operation page and execute.
GTG will unload, cooling, fuel change and stop automatically.
After GTG completely stopped, carry out inspection and verify for pre-post pump and turning motor operation.
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e. GTG MANUAL PURGING (CRANKING)
On the Operation page, select PURGE, push and hold the execute button.
Verify that GTG speed will rise up.
Cranking will stop if: Cranking will stop if:
GTG speed > 25%
Release the execute button.
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f. LOG AND OPERATION CONDITIONDescription Unit Criteria Time Time Time Time Time
#1 Engine Speed % 95~108
#2 Engine Speed % 95~108
Gearbox Speed % 95~108
#1 Intake Air Temp C
#2 Intake Air Temp C
#1 Exhaust Gas Temp (1) C
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f. LOG AND OPERATION CONDITIONDescription Unit Criteria Time Time Time Time Time
#1 LO Supply Press (PP) MPa >0.015
#2 LO Supply Press (PP) MPa >0.015
Starting Air Pressure MPa
Intake Air Filter Diff Press kPa 0.26
#2 LO Supply Pressure MPa >0.26
#1 Strainer Inlet Pressure MPa
#1 Strainer Outlet Pressure MPa
#1 Strainer Diff Pressure MPa
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f. LOG AND OPERATION CONDITIONDescription Unit Criteria Time Time Time Time Time
Generator Voltage (U-V) V 400
Generator Voltage (V-W) V 400
Generator Voltage (W-U) V 400
Generator Current (U) A
Generator Current (V) A
Generator Current (W) A
Generator Power Factor
Generator Frequency Hz 50
Generator kWh kWhGenerator kWh kWh
Generator kW kW
Generator kVar kVar
Excitation Voltage V
Excitation Current A
Gen Winding Temp (U) C
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f. LOG AND OPERATION CONDITIONDescription Unit Criteria Time Time Time Time Time
Gas Governor Actuator %
Bus Voltage C 400
Bus Frequency Hz 50
Gas Fuel Flow Nm3/h
Gas Fuel Pressure MPa
Gas Fuel Temperature C
Gas Fuel Flow (Pulse) Nm3
Combustor Inlet Gas Fuel Pressure
MPaPressure
Accumulator Gas Fuel Pressure
MPa
Gas Fuel Flow MMSCFD
Remarks
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TROUBLESHOOTING
1. Large Vibration
2. High Exhaust Gas Temperature
3. Overspeed
4. Startup Failure4. Startup Failure
5. Low Lubrication Oil Pressure
6. High Lubrication Oil Temperature
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1. Large Vibration
Vibration of gas turbine shaft is monitored to detect Large Vibration. Specific alarm value and trip value has been set in the PLC.PLC.
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1. Large Vibration
Possible causes of this problem are as follows:
1. Defect of gas turbine itself: Abnormal bearing or rotary part, etc.bearing or rotary part, etc.
2. External factor: Rubbing with foreign matters entering through intake port.
3. Defect of control system: Abnormal vibration system, etc.
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1. Large Vibration1.1 Simplified Inspection of Equipment
Gas Turbine
Inspection item 1
Visually check that engine (output shaft) is rotating smoothly as driven by turning motor
Objective
To confirm that rotor system is not on contact with stationary part and that foreign matter has not been caught. If there is such abnormality, engine rotation is not smooth and generating friction sound.
Inspection item 2
Manually rotate engine by hand to check for abnormal rotation or abnormal rotating soundManually rotate engine by hand to check for abnormal rotation or abnormal rotating sound
Objective
This method is to be conducted if above inspection item 1 cannot be done by turning motor.
Inspection item 3
Study of data before occurrence of problem
- Change in gas turbine shaft vibration value or reduction gear vibration value
- Generator output
- Lubrication oil temperature and pressure
- Change in temperature for No.1, No.2 lube oil drain.
Objective
To obtain data useful to determine whether vibration increase is sudden or gradual as the result of aged deterioration or false meter indication
To confirm that load is normal
To confirm that bearings are lubricated properly.
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1. Large Vibration1.2 Inspection of Individual Control Devices
Vibration System
Inspection item 1
Check monitor cable connection for looseness. If connection is loose or disconnect then connect cable properly.
Objective
To confirm that signal is input properly to monitor
Inspection item 2Inspection item 2
Check sensor wiring connection for looseness
Objective
To confirm that signal is output properly from sensor
Inspection item 3
Disconnect wire from sensor and measure DC resistance. Normal value is between 2.5-3.0 ohm
Objective
To confirm that wire is not broken
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2. High Exhaust Gas Temperature
Exhaust gas temperature of gas turbine is monitored to detect High Exhaust Gas Temperature. Specific alarm value and trip value have been set in the PLC.trip value have been set in the PLC.
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2. High Exhaust Gas Temperature
Possible causes of this problem are as follows:
1. Defect of gas turbine itself: Deteriorated
performance of turbine, deteriorated
performance of compressor due to soil, etc.performance of compressor due to soil, etc.
2. External factor: Clogged intake/exhaust line,
overload, etc.
3. Defect of control system: Abnormal load
control, abnormal exhaust gas temperature
thermocouple, etc.
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2. High Exhaust Gas Temperature2.1 Simplified Inspection of Equipment
Gas Turbine
Inspection item 1
Visually check that engine (output shaft) is rotating smoothly as driven by turning motor.
Objective
To confirm that gas turbine itself and reduction gear are normal.
Inspection item 2
Manually rotate engine by hand to check for abnormal rotation or abnormal rotating sound
Objective
This method is to be conducted if above inspection item 1 cannot be done by turning motor.
Inspection item 3
Study of data before occurrence of problem
- Gas turbine shaft vibration
- Gas turbine intake air temperature and ambient temperature
- Generator output
- Compressor discharge pressure
- Lubricating oil temperature
- Operation mode: island or parallel with another GTG or Diesel Gen Set.
Objective
To confirm that gas turbine itself is normal
To confirm that air intake line is normal
To confirm that gas turbine is not operated under overload
To confirm that compressor is not soiled (check pressure data for the last one week or more)
To confirm that bearing is lubricated
To see if gas turbine is operated in island or parallel with other machines.
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2. High Exhaust Gas Temperature2.2 Inspection of Individual Control Devices
Instrumentation Devices
Inspection item 1
Inspection of exhaust gas temperature thermocouple for broken wire
Measure insulation resistance. Normal value is 1.5 ohm or higher as measured with a 500-V megohmmeter at ordinary temperature
Objective
To confirm that thermocouple is not damaged
Inspection item 2Inspection item 2Heat up temperature sensing elements sequentially while checking if output voltage increasesObjective
To confirm that exhaust gas temperature is detected.
Inspection item 3Inspection of rotation pickup for loosenessObjectiveTo confirm that connector or pickup is not loose
Inspection item 4Disconnect cable from pickup and measure resistance. Normal value is 30050 ohm at 25 degCObjectiveTo confirm that wire is not brokenMiscount during operation as interconnected with commercial power system can cause high exhaust
gas temperature.
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3. Overspeed
Rotation of gas turbine power section is monitored to detect Overspeed. Specific trip value has been set in the sensor.
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3. Overspeed
Possible causes of this problem are as follows:
1. Defect of gas turbine itself: Broken coupling of output shaft of power section coupling of output shaft of power section rotor system, etc.
2. External factor: Sticking fuel control valve, etc.
3. Defect of control system: Abnormal rotation pickup, etc.
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3. Overspeed3.1 Simplified Inspection of Equipment
Gas TurbineInspection item 1Visually check that engine (output shaft) is rotating smoothly as driven by turning motor.ObjectiveTo confirm that gas turbine itself and reduction gear are normal
Inspection item 2Manually rotate engine by hand to check for abnormal rotation or abnormal rotating soundObjectiveThis method is to be conducted if above inspection item 1 cannot be done by turning motor.
Inspection item 3Study of data before occurrence of problem- Gas turbine shaft vibration- Gas turbine speed- Whether any problem occurred at startup or during operation- If problem occurred during operation, check generator output for change- Operation mode: island or parallel with other GTG or Diesel Gen set.ObjectiveTo confirm that gas turbine itself is normalTo clarify the time of problem occurrence
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3. Overspeed3.2 Inspection of Individual Control Devices
Instrumentation Devices
Inspection item 1
Inspection of rotation pickup connector for looseness
Objective
To confirm the connector or pickup is not loose
Inspection item 2
Measure resistance for rotation pickup. Normal value is 30050 ohm at 25 degC
Objective
To confirm that sensor is normal
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4. Startup Failure
Rotation and exhaust gas temperature of gas turbine are monitored to detect Startup Failure. Alarm signal is output when specified conditions are not met.when specified conditions are not met.
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4. Startup Failure
Possible causes of this problem are as follows:
1. Defect of gas turbine itself: Defective fuel nozzle, etc.nozzle, etc.
2. External factor: Abnormal starter equipment, abnormal ignition system, etc.
3. Defect of control system: Defective rotation pickup, defective controller, etc.
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4. Startup Failure
4.1 Simplified Inspection of Equipment
Gas TurbineInspection item 1Visual check that engine (output shaft) is rotating smoothly as driven by turning motor.ObjectiveTo confirm that gas turbine itself and reduction gear are normal.
Inspection item 2
Manually rotate engine by hand to check for abnormal rotation or abnormal rotating soundManually rotate engine by hand to check for abnormal rotation or abnormal rotating soundObjectiveThis method is to be conducted if above inspection item 1 cannot be done by turning motor.
Inspection item 3Study of data before occurrence of problem-- Increase in turbine speed- Increase in exhaust gas- Instrument air pressure 0.45MPa or higher- Fuel filter differential pressure indicationObjectiveTo confirm that gas turbine itself and reduction gear are normalTo confirm that fuel system is normalTo confirm that shutoff valve opening air pressure is normal
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4. Startup Failure
4.1 Inspection of Individual Control Devices
Instrumentation DevicesInspection item 1Inspection of solenoid valve operation of starter valve unitObjectionTo confirm the integrity of starter air supply equipment
Inspection item 2
Inspection of exciter and ignition plug. Visual check for damageInspection of exciter and ignition plug. Visual check for damageObjectiveTo confirm that ignition system is normal
Inspection item 3Inspection of exhaust gas temperature thermocouple for broken wire. Measure insulation resistance. Normal value is
1.5Mohm or higher as measured with a 500V megohmmeter at ordinary temperatureObjectiveTo confirm that thermocouple is not damaged
Inspection item 4Inspection of rotation pickup for looseness. Disconnect cable from pickup and measure resistance. Normal value is
30050 ohm at 25 degC.ObjectiveTo confirm that pickup is not loose and wire is not broken.
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5. Low Lubrication Oil Pressure
Lubrication oil pressure is monitored to detect Low Lubrication Oil Pressure. Specific alarm value and trip value have been set in the sensor.been set in the sensor.
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5. Low Lubrication Oil Pressure
Possible causes of this problem are as follows:
1. Defect of gas turbine itself: Abnormal lubrication oil pump, clogged filter lubrication oil pump, clogged filter caused by abnormal bearing, etc.
2. External factor: Drop of lubrication oil level, etc.
3. Defect of control system: Defective oil pressure switch, etc.
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5. Low Lubrication Oil Pressure5.1 Simplified Inspection of Equipment
Gas TurbineInspection item 1Visually check that engine (output shaft) is rotating smoothly as driven by turning motor.ObjectiveTo confirm that gas turbine itself and reduction gear are normal
Inspection item 2Manually rotate engine by hand to check for abnormal rotation or abnormal rotating soundObjectiveThis method is to be conducted if above inspection item 1 cannot be done by turning motor.
Inspection item 3Inspection item 3Check piping for any lubrication oil leakage.ObjectiveTo confirm that there is no oil leakage which can cause low oil pressure
Inspection item 4Check oil level of lubrication oil tank.ObjectiveTo confirm that there is no oil level drop which can cause low oil pressure
Inspection item 5Study of data before occurrence of problem- Lubrication oil temperature at bearing outlet.- Interval between alarm and trip.- Indication of clogged lubrication oil filterObjective
To confirm that bearing are normalTo confirm that filter is free of foreign matters
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5. Low Lubrication Oil Pressure5.2 Inspection of Individual Control Devices
Instrumentation Devices
Inspection item 1
Inspection of lubrication oil pressure transmitter for looseness. Visual check for damage.
Objective
To confirm that the lubrication oil pressure transmitter is normal.
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6. High Lubricating Oil Temperature
Temperature of lubricating oil supplied to gas turbine bearings is monitored to detect High Lubricating Oil Temperature. Specific alarm value has been set in the Specific alarm value has been set in the PLC.
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6. High Lubricating Oil Temperature
Possible causes of this problem are as follows:
1. Defect of gas turbine itself: Abnormal bearing, etc.bearing, etc.
2. External factor: Deteriorated oil cooler performance, etc.
3. Defect of control system: Defective oil temperature sensor, etc.
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6. High Lubricating Oil Temperature
6.1 Simplified Inspection of Equipment
Gas Turbine
Inspection item 1
Visually check that engine (output shaft) is rotating smoothly as driven by turning motor.
Objective
To confirm that gas turbine itself and reduction gear are normal
Inspection item 2
Manually rotate engine by hand to check for abnormal rotation or abnormal rotating sound
Objective
This method is to be conducted if above inspection item 1 cannot be done by turning motor.
Inspection item 3
Study of data before occurrence of problem
- Lubricating oil temperature
- Lubricating oil at bearing outlet
Objective
To confirm that bearing are normal
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6. High Lubricating Oil Temperature
6.2 Inspection of Individual Control Devices
Instrumentation Devices
Inspection item1
Inspection of lubrication oil temperature sensor (Pt 100-ohm resistance bulb). Measure resistance value.
Objective
To confirm that sensor is normal.To confirm that sensor is normal.