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If it has been provided already in portal, kindly provide the link. i could not
get the complete information of starting means all together on portal. We
use Diesel Engine as starter.
And, because the starting means will usually operate at a constant speed
when developing the maximum amount of torque to be applied to the
turbine/generator shaft and because the shaft will start from zero speed and
accelerate to purge speed and firing speed and then have to accelerate to
rated speed (Full Speed-No Load, FSNL) there needs to be some kind of
"variable" torque transmission device between the starting means and the
turbine/generator shaft. That device is most commonly a torque converter,
which is a hydraulic pump (driven by the starting means) and a hydraulic
motor (which is connected to the turbine/generator shaft). So, the output
torque/speed is different from the input torque/speed which is how the
starting means runs at constant speed(s) and the turbine/generator shaft can
rotate at speeds from zero to approximately 60% with the assist of the
starting means.
When a diesel engine is used as a starting means, it's usually for one of
two reasons. Either the grid can't provide sufficient electrical power to
operate an induction electric motor as the turbine starting means, or, there
is a perceived need for the turbine to start completely independently of the
grid--what's commonly referred to as "black start" (when the power plant
is "black" because there is NO power from the grid for lights or motors). It
could also be a combination of the two that necessitates the need for a
diesel engine starting means.
During starting, the diesel is usually started and allowed to "warm up" for
a couple of minutes at a low "idle" speed. And, then after the diesel engine
warm-up is complete the engine is accelerated to a much higher speed
which causes the torque output to increase significantly. The hydraulic
ratchet is also energized to help get the shaft turning (even if it's just a
fraction of a turn--it still helps overcome the inertia of the rotor at rest!)
and the torque being transmitted through the torque converter (from the
diesel engine) helps to accelerate the unit to purging speed (sometimes
called "cranking speed" which isn't always exactly correct depending on
the unit and the starting sequence).
Usually, at about 60% speed the torque output of the starting means of a
Frame 6B unit is no longer required to help accelerate the unit to rated
speed. This is called "self-sustaining speed", when the unit can produce
enough torque to accelerate itself without any assist from the starting
means. There is usually some kind of "clutch" which is used to couple the
output of the torque converter to the turbine/generator shaft during
starting/acceleration. When the unit reaches self-sustaining speed, the
clutch disengages, and that's usually the signal to shut down the starting
means. For a diesel engine starter, the fuel to the diesel engine is usually
reduced to the "idle" speed and the diesel goes into what's called it's
"cooldown" for a minute or a few minutes (depending on the vintage of the
machine).
Again, when the unit reaches zero speed during a normal shutdown or after
an emergency trip it's important to not let the axial compressor shaft sit for
very long in the same position--it will begin to sag or bow under its own
weight. So, the hydraulic ratchet mechanism periodically (usually about
every three minutes) rotates the turbine/generator shaft approximately 45
degrees (one-eighth of a turn) to prevent the shaft from bowing. This has
to go on for about 24 hours (sometimes less; sometimes more) before
cooldown can be turned off (usually by an operator) and the auxiliary L.O.
pump can be shut down. (The Auxiliary L.O. pump must continue to run
during cooldown operation to provide cooling oil flow to the bearings
AND to provide lubrication for the ratchet mechanism when it's turning
the shaft every three minutes.)
We can answer most questions about GE-design heavy duty gas turbines
and operation here on control.com--but we're not very good with assuaging
doubts. (Look up the definition of 'doubt' in your Oxford's English
Dictionary; it's not an appropriate word for questions or when clarity is
required or being requested.)
dear CSA,
i have gone through all the P and IDs and understood also with the help
of manual. but starting means part of manual is missing. description you
provided is basic operation.
can your please help me understand or get me some explanation of
"scheme for starting means" in frame 6B machines with diesel engine?
I am confused with the operation of electrical operated valves included in
this scheme, i.e. 20CS, 20DV, 20DA1, 2, etc.
khoriwal000,
I don't have access at this writing to provide exact details of what the
various solenoids do, but from the information provided it would seem
the unit is an older one because many of the newer units with diesel
starting means use digital electronic controls for the diesel, which get
very limited signals from the Mark* turbine control system.
If you have the P&ID for the Starting Means, it shouldn't be too hard to
sort out what each component does. There is a solenoid that controls a
hydraulically-operated fuel rack (the hydraulic system is self-contained
on the diesel and is NOT part of the turbine hydraulic system), and
some units have a second solenoid on the fuel rack that increases diesel
speed/torque when accelerating after flame has been established (I
believe these are usually designated as 20DA-1 and 20DA-2,
respectively). There is also usually a solenoid that shuts off the diesel by
forcing the fuel rack to the zero or very low flow position (20DS?).
Once the turbine/generator shaft speed is above the speed of the output
shaft of the torque converter the jaw clutch teeth disengage and a very
large spring on the clutch mechanism fully opens the jaw clutch. The
jaw clutch engagement limit switch contact should open as the jaw
clutch is disengaging and this tells the Mark* that the turbine/generator
shaft is now or should now be capable of sustaining its own speed by
virtue of the expansion of hot gases through the turbine section without
the need for any torque assist from the starting means.
Usually, the diesel starting motor runs for a minute or two or sometimes
longer at idle speed to cool the engine and then the Mark* energizes the
diesel stop solenoid to move the fuel rack to the position that shuts off
fuel and stops the engine.
Most of the problems with the starting means systems are the result of
1) problems with the diesel not providing sufficient torque during
starting to get the unit to self-sustaining speed; 2) misadjustment of the
jaw clutch limit switch, and, 3) torque converter problems. The diesel
engine problems can be and are usually related to poor or inadequate
maintenance of the diesel and its fuel system (injectors; fuel pump;
filters). Also, diesels do wear out--specifically the rings and valves, and
when they wear out the diesels don't make enough torque to get the unit
accelerated to self-sustaining speed. Dirty fuel filters can limit fuel flow,
also.
When the diesel isn't making enough torque during starting and
acceleration the jaw clutch will disengage early which can cause the
turbine-generator shaft speed to "stall" or even decrease. Sometimes the
newer Mark* control systems will try to increase fuel to maintain
acceleration--but because the air flow through the machine is very low
during low-speed operation and because the IGVs are also closed the
exhaust temperature is high and the exhaust temperature limit may be
reached which will limit fuel flow which can also cause speed to stall or
even decrease.
The speed control mechanism which relies on solenoid signals from the
Mark* can also be misadjusted after diesel maintenance, or because the
locking screws on the shafts loosen and slide. Unfortunately, there is no
guide or specification for the hydraulically-operated fuel rack
mechanism to dictate what speeds the diesel should operate at for each
of the solenoid settings. That's why it's very critical for maintenance
personnel to work with controls technicians to measure and record the
diesel speed at the various settings when the diesel is working correctly
so that the settings can be checked or adjusted properly in the future.
Some diesel engine service companies have never encountered a
mechanism like the one used on GE-design heavy duty gas turbine
diesel engine starters (before the advent of digital engine management
systems), and so adjusting them is not very precise--especially when the
owner can't provide proper specifications (because they usually weren't
supplied by the equipment packager). Again, this is where is critically
important to check and record as-running settings when the diesel is in a
new and clean condition.
The torque converters can also become worn and not transmit sufficient
torque even if the starting means is working fine. The results will be the
same: early disengagement of the jaw clutch and stalling or even
decreasing turbine/generator shaft speed.
The jaw clutch limit switch can vibrate out of adjustment, or can be
misadjusted during a maintenance outage during reassembly. Again, if
the Mark* was configured correctly during commissioning the contacts
of 33CS are to be actuated and closed when the jaw clutch is engaged,
and should deactuate and open as the jaw clutch is opening. The discrete
(contact) input L33CSE is normally NOT inverted, and is a logic "1"
when the jaw clutch is engaged, and a logic "0" as the jaw clutch is
disengaging and when it is disengaged. (That's how the limit switch and
input should normally be configured for proper operation.)
If you're having problems with the starting means, perhaps if you can
describe the problems we can try to help. If some other reader can scan
and email you a copy of their GE-design Frame 6B heavy duty gas
turbine Operation Manual 'Starting Means' section, that would be great
(I don't have a copy at this writing).
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