OPERATING MANUAL

COGENERATION PLANT

MODULE-1 Gas Turbine LM-6000/ PD sprint

Prepared By: Reviewed By:

Zahid Shah Syed Masood ul Hassan

T11 PTA PLANT PORT QASIM PAKISTAN

DESIGNED ACTUAL CAPACITY 400,000 TONNES OF PURE TEREPHTHALIC ACID

OPERATING MANUAL

Cogeneration Plant

MODULE

Gas Turbine LM-6000 PD sprint (50-Hz)

FIRST EDITION FIRST PRINTING Jun e 2011.

TABLE OF CONTENTS
Chapter 1 Chapter 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 INTRODUCTION. THEORY OF GAS TURBINES.

Gas Turbines as prime movers. Gas turbi ne operating principles T ypes of Gas turbines & applications . T ypes of Gas turbines. Gas turbi ne thermodynamic cycle. Gas turbi ne thermal efficiency. Factors affecti ng performance of Gas turbines. ISO Rating Of Gas Turbin e.

Chapter 3 GAS TURBINE AT LOTTE PPTA (GE-LM6000 PD sprint). 3.1 Specifications of GE -LM 6000 PD sprint gas turbi ne. 3.2 3.3 Air Flow & Mai n parts Layout of GE - LM 6000 PD spri nt gas turbi ne. Main Parts of GE -LM 6000 Gas turbine.

3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.3.7 3.3.8

Variable inlet guide vane (VIGV) assembly. Five-stage low pressure com pressor (LPC). Front frame assembly and By pass air collector. 14-stage variable -geometry (VG) high pres sure compressor (HPC). Compressor rear frame (CRF) assembly. Triple annular combustor as sembly. High pressure turbi ne (HPT). Low pressure turbi ne (LPT ).

3.3.9 Turbine rear frame (TRF) assembly. 3.3.10 Acces sory gearbox (AGB) as sembly and accessories. 3.3.11 Beari ngs.

Chapter 4

MAIN SY STEMS OF GE-LM 6000 PD SPRINT GAS TURBINE.

4.1 .1 Variable -Geom etry Control S ystem. 4.1.1. 1 VIGV System 4.1.1.2 VBV System. 4.1.1.3 VSV System 4.1.2 Gas Fuel Systems 4.1.2.1Gas Manifold and Fuel Hoses 4.1.2.2 Air/Gas Premi xers. 4.1.2.3 Fuel Stagi ng V alves. 4.1.3 Gearbox Assemblies 4.1.4 Hydraulic Starter 4.1.4 Hydraulic Starter.

4.1.5 Lube Oil S ystem 4.1.5.1 Lube Supply Circuit 4.1.5.2 Sc avenge Oil Circuit 4.1.5.3 Engine Drains 4.1.5.4 Sump Vent Circuit 4.1.5.5 Lube and Scavenge Li ne Cooli ng. 4.1.5.6 Sump Pressurization 4.1.6 Ignition Sys tem. 4.1.7 Bleed S ystem. 4.1.8 Hi gh Pressure and Low Pressure Rec oup System. 4.1.9 Water-Wash Sys tem. 4.1.10 Low Pressure Rotor Balance Piston System. 4.1.11 Air System Tubing and Frame Strut Functions . 4.1.11.1 A-, B-, C-, D-, and E-Sump Vents. 4.1.11.2 B- and C-Sump Pressurization. 4.1.11.3 Balance Piston. 4.1.11.4 HPC Stage 8 Bleed. 4.1.11.5 Compressor Discharge Pressure Bleed. 4.1.11.6 High Pressure and Low Pressure Recoup. 4.1.11.7 HPT Cooling. 4.1.11.8 LPT Cooling. 4.1.11.9 Pas sive Clearance Control. Chapter 5 INSTRUMENTATION & CONTROLL OF GE-LM 6000 PD 5.1 Electrical Panels 5.2 Engine Control U nit 5.3 Sensors and Indicating Sys tems

5.3.1 Speed Indication 5.3.2 Acoustic Sensors 5.3.3 Vibration Sensors 5.3.4 Temperature Sensors 5.3 .5 Lube Supply and Scavenge Temperature 5.3.6 Pressure S ensors 5.3.7 Chip Detectors 5.3.8Variable-Geometry Position 5.3.9 Flame S ensors 5.3.10 Bleed Air Control System .

Chapter 6 STARTUP & SHUTDOWN OF GAS TURBINE. 6.1 Turbi ne Start Up. 6.1.1 Prestart up Checks 6.1.2 Dry Motoring 6.1.3 Normal S tarti ng Sequence (Cold Startup). 6.1.4 Hot Startup of GTG 6.2 Shutdown of Gas Turbine: 6.2 .1 Normal Shutdown. 6.2.2 Emergenc y Shutdown of GT G 6.2 .3 Post-Shutdown Fire 6.3 . Restart of GTG 6.3.1.1Hot Restarts 6.3 .2 Restart within 10 Minutes after S hutdown . 6.3 .3Restart more than 10 m inutes after Shutdown . 6.4 Wind milling

Chapter 7 TROUBLE SHO OTING 7.1 Troubleshooting Reference Table . 7.2 Numbered Troubleshooting Procedures .

LIST OF FIGURES: Fi gure 1- 1 Gas turbi ne thermodynamic cycle .

Figure 3-1 LM6000 PD Gas turbi ne Layout and Air. Figure 3-1 LM6000 PD Gas turbi ne Layout and Air. Figure 3-2 LM6000 PD Gas turbi ne major c omponent. Figure 3-3 Sump Areas and beari ng Locations. Figure 4-1 VIGV S ystem Figure 4-2 VBV S ystem Figure 4-3 VSV System Figure 4-4 LM6000 PD Model Operati ng Modes.

Figure 4-5 Natural Gas Fuel Syst em Figure 4-6 Transfer Gearbox Assembly Figure 4-7 Hydraulic Starter Performance Figure 4-8 Typical Hydraulic Starter Schem atic. Figure 4-9 LM 6000 PD Model Lube Sys tem Schematic. Figure 4-10 Sump Function Diagram Figure 4-11 LM6000 PD Engine Sumps and Mai n Beari ng Locati ons. Figure 5-12 Low Pres sure Rotor Balance Pi ston Sys tem Figure 4-13 LM6000 PD Model Gas Turbine - Strut Functions Figure 4-14 LM6000 PD Model Gas Turbine - Left Side View Figure 4-15 LM6000 PD Gas Turbine - Ri ght Side View. Fi gure 5- 1 LM6000 PD Model Electrical Panel Locations Fi gure 7- 1 Roadmap to Troubleshoot Nozzles Based on Abnormal T48 Fi gure 7- 2 Troubleshooti ng LM6000 Hi gh Oil Cons umption Due to Gas Turbine Leaks

LIST OF TABLES:

Table 4-1 Gas Turbine Lube/Scavenge System. Table 5-1 LM6000 PD Electrical Cable Panel Nomenclature Table 6-1 Typical Operating Levels Table 6-2 Fuel System Parameters Table 6-3 Limits and Operati ng Requirements. Table 6-4 Protective Function Causes Requiring Resolution Prior to Restart or Motori ng. Table7-1 Troubleshooting Reference Tables Table7-2 Trouble shooting procedures ( TS -1 to TS-35)

Chapter1

INTRODUCTION

This Operating manual has been prepared by Lotte PTA Cogeneration Process and Commissioning team, keepi ng in view the training needs of cogeneration operations team. The concept behi nd these manuals is to gather theoretical and specific technical data pertaining to packaged equipment at one place so that sufficient information could be obtained at good pace without extra efforts.

These manuals first describe basic working principle and theory of general class of equipment and then progress to details of specific equipment installed at cogeneration facility at Lotte -PPTA.

This manual is not a substitute of detailed Operation and maintenance manual. Set of GE P&IDs of individual s ystem are necessary to understand the information given in this manual.

Chapter 2
2.1

THEORY OF GAS TURBINES

Gas Turbines as prime movers.

Various prime movers are available i n present industries, some of which are given below. 1) Combustion gas turbi ne. 2) Steam Turbine. 3) I.C. Engine. 4) Electric Motor 5) Expansion Turbine. If comparison is drawn b/w these pri me movers following points are nota ble. Thermal efficiency of G.T. ~25 - 32% whereas in I.C. Engine ~35 -45%. For the same power output, larger size I.C. Engine is required as compared to G.T.

 Maintenance cost of I.C. Engine is much higher than G.T. Thermal efficiency of Steam Turbi ne ~70 - 80 %. Steam turbine requires installation of Boiler, condenser, and pumps etc. so initial capital investment becomes higher. Motors becomes un -economical at hi gher power output because of inefficient Conversion of energy into electri c power. Expansion Turbines used to recover waste energy from process. These supplement the main prime mover.

2.2 Gas turbine operating principles.

Conversion of Chemical Energy of fuel to Mechanical Energy. Air Compressor/Turbine mounted on single shaft are brought to speed by Diesel engine.

Air Compressor draws atmospheric air & i ncreases its pressure. High pressure air flows to combustion chamber where fuel adm itted under pressure. Spark i gni tes fu el/ai r mixture initially. Hot gases at high pressure expand thru Turbine wheels.

Rotor spi ns and produces shaft output. Part of the shaft output is used i nternally by air compressor, the remaining output available for dri ven unit. 2.3 Gas turbines applications.

1) Stationary applications As a Prime mover for; Compressors. Large Pumps. Electric Generators. 2) Mobile Applications Aircraft field Marine propulsion

2.4 Types of gas Turbines: 2.4.1 Jet Engines Air breathi ng jet engines are gas turbines optimized to produce thrust from the exhaust gases, or from ducted fans connec ted to the gas turbines. Jet engines that produce thrust primarily from the direct impulse of exhaust gases are often called turbojets , whereas those that generate most of their thrust from the a ction of a ducted fan are often called turbofans . 2.4.2 Aero derivative gas turbines Aero derivatives gas turbines are used in electrical power generation due to their ability to be shut d own, and handle load c hanges more quickly than i ndustrial machines. They are also used in the mari ne industry to reduce weight. The General Electric LM2500 , General Electric LM6000 , Rolls-Royce RB211 and RollsRoyce Avon are common models of this type of machine. 2.4.3 Indust rial gas turbines for power generation Industrial gas turbines differ from aero derivative in that the frames, beari ngs, and baldi ng are of heavier cons truction. Industrial gas turbines range in size from truck-mounted mobile plants to enormous, complex systems. They can be particularly efficient up to 60% when waste heat from the gas turbi ne is recovered by a heat recovery steam generator to power a conventional steam turbine in a combi ned cycle configuration. They can also be run in a cogeneration configuration: the exhaust is used for spac e or water heati ng, or drives an absorption chiller for cooling or refri geration. Su ch engines require a dedicated enclosure, both to protect the engine from the elements and the operators from the noise. 2.4.4 Auxiliary power units Auxiliary power units are small gas turbines designed for auxiliary power of larger machines, such as those i nside an ai rcraft. They supply compressed air for aircraft ventilation (with an appropriate c ompress or design), start -up power for larger jet engines , and electrical and hydraulic power.

2.5

Gas t urbine thermodynamic cycle.

Figure 1-1 Gas turbine thermodynamic cycle .

1 2 : Reversible Adiabatic Compression

(Ideal)

1 2 : Ir -reversible Adiabatic Compression (Actual) 2 3 : Constant Pres sure Heat Supply i n c ombustion chamber 3 4 : Reversible Adiabatic Expansion 3 4 : Ir -reversible Adiabatic Expansion (Ideal) ( Actual)

2.6

Gas t urbine thermal efficiency.

At Compressor, W ork Input = CP (T2 T1 ) In Combustion Chamber, Heat Supplied = CP ( T3 T2) At Turbine, Work Output = CP (T3 T4) Net Work Output = CP (T3 T4 ) CP (T2 T1) Thermal Efficiency = Net Work Output / Heat Supplied

= CP (T3 T4) CP (T 2 T1)/CP (T3 T2)

CP for Compression Process CP for Combustion & Expansion Proces s Normal Range of Effi ciency

= 1.005 KJ / Kg -KO = 1.11 KJ / Kg -KO = 24 32 %.

Efficiency of Gas Turbine depends upon m ax. Cycle Temp. (T3) Max. Cycle Temp. Lim ited by metallurgical considerations. The Higher max. Cycle Temp. The shorter Turbine Life. In aircraft field, max. Cycle Temp. Usually higher than i ndustrial & marine propulsion Turbines. Different methods of Blades cooling allow max. Cycle Temp. to i ncrease to some extent & thus increas ing Turbine Efficienc y.

2.7 Factors affecting performance of Gas turbines.

Atmospheric Pressure. With pressure reduction, Specific wei ght of air reduces which reduces power output. For the same power output fuel consumption increases. For every 100 mm wc pressure reduction efficiency reduces by ~ 1 %. Ambient Temperature. Increase in ambient temperature also reduces specific weight of air which reduces power output. For every 10 o C increase in ambient temperature efficiency reduces by ~ 1 %. P Across F ilter House. Increase in P acros s filter house reduces Turbine efficiency. Humidity in Air. Humid air tends to clog filters & increases P across filters. Load. At hi gher load Turbine efficiency improves & vice versa.

2.8

ISO Rating Of Gas Turbine: Performance of Gas T urbines varies from location to location depending upon the ambient conditi ons and altitude of si te from sea level.ISO has developed specific standard that specify input conditions while specifying Gas turbines. (ISO 3977-2).

ISO rati ngs are given below.

Ambient temperature, relative humidity, and Elevation:

Three standard conditions specified in the ratings are 15 o C Ambient Temperature, 60% Relative Humidity and Ambient Pressure at Sea Level.

Inlet and Exhaust Losses. Standard Conditions specify that Inlet and exhaust loss es are zero. Intake system and exhaust system causes resistance to air flow which results In net decrease in Turbine Output.

Operation at 100% rated Power. The s tandard considers that gas turbine operates at 100% rated Load. The efficiency of Gas turbine at Part Load Operation is different from that at 100% load.

Chapter 3
GAS TURBINE AT LOTTE PPTA (GE-LM6000 PD sprint)

3.1

Specifications of GE -LM 6000 PD sprint gas turbine.

The LM6000 PD is a dual -rotor gas turbi ne that consists of a variable i nlet guide vane assembly (VIGV), a 5 - stage low pressure c ompressor (LPC), a 14 -stage variable -geometry hi gh pressure compressor (HPC), a triple annular combustor, a 2 -stage hi gh pressure turbine (HPT), a 5 -stage low pressure turbine (LPT), an accessory gearbox assembly (AGB), and accessories. The low pressure (LP) rotor consists of the LPC and the LPT that dri ve it. Attachment flanges are available on both the front and/or rear of the LP rotor for connection to the pack-ager-suppli ed power shaft and load. The high pressure (HP) rotor consists of the 14-stage HPC and the 2 -stage HPT that drive i t. The HP c ore consists of the HPC, the combustor, and the HPT. The HPT and LPT drive the HPC and LPC through concentric drive shafts. 3.2 Air F low & Main parts Layout of GE -LM 6000 PD sprint gas turbine.

Air enters the gas turbine at the VIGV and passes into the LPC. The LPC compress es the air by a ratio of approximately 2.4:1. Air leav ing the LPC is directed into the HPC. Variable bypass valves (VBV) are arranged in the flow pass age between the two compressors to regu late the airflow entering the HPC at idle and at low power. To further control the airflow, the HPC is equipped with variable stator vanes (VSVs). The HPC compresses the air to a ratio of approximately12:1, resulting in a total compression ratio of 30:1, relative to ambient. From the HPC, the air is directed into the tri ple annular combustor section, where it mixes with the fuel from the 75 air/gas premixers that are packaged i n 30 externally removable modules. The fuel/air mixture is initial ly ignited by an i gniter and, once combustion is self -sustaining, the igniter is turned off. The hot gas that results from combustion is directed into the HPT which drives the HPC. This gas further expands through the LPT, which dri ves the LPC and the outp ut load.

Figure 3-1 LM6000 PD Gas turbine Layout and Air.

Figure 3-1 LM6000 PD Gas t urbine Layout and Air.

3.3

Main Parts of GE -LM 6000 Gas turbine.

The LM6000 PD gas turbine is a dual -rotor, concentric drive shaft gas turbine, capable of driving a load from the front and/or rear of the low pressure (LP) rotor. Figure 3-1 is a cross section of the engine, showing the significant design features of the LM6000 PD gas turbine. Fi gure 3 -2 identifies the princi pal LM6000 PD gas turbine components, as listed below:

Variable i nlet guide vane (VIGV) assembly. Five-stage low pressure compressor (LPC). Front frame assembly and By pass air collector. 14-stage variable-geometry (VG) high pres sure compressor (HPC). Compressor rear frame (CRF) assembly. Triple annular combustor assembly. High pressure turbine (HPT). Low pressure turbi ne (LPT). Turbine rear frame (TRF) assembly. Accessory gearbox (AGB) assembly and accessories. Bearings.

Figure 3-2 LM6000 PD Gas turbine major component .

Figure 3-2 LM6000 PD Gas turbine major component .

Figure 3-2 LM6000 PD Gas turbine major component .

3.3.1

Variable inlet guide vane (VIGV) assembly.

The air intake section of the engine consi sts of an axial flow s ection containing a VIGV sys- tem. The VIGV assembly is loc ated at the front of the LPC and allows flow modulation at partial power, resulting i n in creased engine efficiency. The VIGV system consists of 43 stationary leading edge vanes and variable trai ling flaps. The variable flaps can be rotated from -10 degrees open to +60 degrees closed by means of an actuator ring (unison ring) dri ven by t win hydraulic actuators at the 3:00 and 9:00 o'clock positions. Both actuators are equipped with linear variable differential transformers (LVDTs).

Normal engine operation range is approxi mately -5 degrees open (full power) to +35 degrees closed (i dle). The flaps will also close during large power reductions to reduce the LPC flow rate quickly i n order to maintain the LPC stall margin. The VIGV system improves performance for both simple cycle and heat recovery cycles. It also helps minimize VBV b ypass flow and pressure levels, thereby reducing associated flow noise. A pressurized rotating seal between the VIGV hu b and the LPC rotor prevents ingestion of unfiltered air into the flow path.

The air intake section is designed to i nterface with a radi al inlet duc t (which allows inlet air to be drawn from the side or top, rather than from the front) or an axial i nlet system. The radial inlet duct is compatible with either for - ward or rear drive i nstallations; the axial inlet can be used only i n rear dr ive installations.

3.3.2

Five-st age low pressure compressor (LPC) .

The LM6000 LPC is a five stage, axial flow compressor. The LPC features a five stage fi xed stator. Provision is made for LPC discharge flow to be bypassed through modulating bypass doors to ass ure adequate LPC stall margin at lower power settings and during large power reduction transients.

3.3.2.1 LPC Rot or

Individual disks are used in stages 0 and 1. Stages 2 through 4 of the LPC rotor are an integral s pool. Stages 0 through 3 b lades have squealer tips.

Stage 0 blades are i ndividually retained i n the axial dovetail s lots of the disk by a one piece blade retainer. Stages 1 through 4 LPC blades are retained i n circumferential slots in the stage 1 disk and stages 2 through 4 spool. The blade retention features permit indi vidual blade replacement. Blades in stages 1 through 3 can be rem oved without removi ng the rotor.