Chapter 4 01

Project Date Plant nr.
Turbine
: : : :
DLF Cyber City Building 10 01.09.08 877 4x T60
DESCRIPTION OF OPERATING SEQUENCES
Chapter: 4 Title: Electrical components
Page - 1 of 71 877-Chapter 4_01.doc
Project Date Plant nr. Turbine
: : : :
4
4.1 4.2
4.2.1 4.2.1.1 4.2.1.2 4.2.1.3 4.2.1.4 4.2.1.5 4.2.1.6 4.2.2 4.2.2.1 4.2.2.2 4.2.2.3 4.2.2.4 4.2.3 4.2.3.1 4.2.3.2 4.2.3.3 4.2.3.4 4.2.3.5 4.2.3.6 4.2.4 4.2.4.1 4.2.4.2 4.2.4.3 4.2.4.4 4.2.4.5 4.2.4.6 4.2.4.7
DESCRIPTION OF OPERATING SEQUENCES

Introduction Starting the gas turbine
1
5 6
Checks prior to start 6 Turbogenerator set..........................................................................................................6 Air filter system................................................................................................................7 Oil cooler .........................................................................................................................7 Electrical supply ..............................................................................................................7 Exhaust gas system ........................................................................................................8 Time intervals between repeated start-ups.....................................................................9 Switching on the control system 10 Presettings ....................................................................................................................10 Check and Reset of the pending alarms.......................................................................11 Command mode: LOCAL, REMOTE ............................................................................11 StandBy.........................................................................................................................11 Local start-up procedure in gas fuel. 12 Fuel selection ................................................................................................................12 Starting the turbine........................................................................................................12 Prelube ..........................................................................................................................12 Crank.............................................................................................................................13 Ignition Gas ...................................................................................................................15 Acceleration to nominal speed ......................................................................................15 Local start-up procedure in liquid fuel. 17 Fuel selection ................................................................................................................17 Starting the turbine........................................................................................................17 Prelube ..........................................................................................................................17 Crank.............................................................................................................................18 Low pressure liquid fuel pump check............................................................................18 Ignition liquid fuel ..........................................................................................................19 Acceleration to nominal speed ......................................................................................19
4.3
4.3.1 4.3.1.1 4.3.1.2 4.3.1.3 4.3.2 4.3.3 4.3.3.1 4.3.3.2 4.3.3.3 4.3.4 4.3.5
Synchronization
21
Synchronization with the busbar 22 Automatic synchronization ............................................................................................22 Manual synchronization ................................................................................................22 Busbar synchronization sequence ................................................................................23 Synchronization Test 24
Grid Back-synchronization (not applicable in this plant) 25 Automatic back-synchronization ...................................................................................25 Manual back-synchronization .......................................................................................25 Back-synchronization sequence ...................................................................................26 Back-synchronization Test (not applicable in this plant) Direct insertion of the generator circuit breaker 27 28
4.4
Operating modes and load charging
29
: : : :
4.4.1 4.4.1.1 4.4.1.2 4.4.2 4.4.2.1 4.4.2.2 4.4.2.3
Grid parallel operation (not applicable in this plant) 30 Grid voltage failure ........................................................................................................30 Manual opening of the generator circuit breaker in grid parallel operation...................30 Isle mode operation 31 Load charging Isle mode operation............................................................................31 Return to grid in isle mode operation (not applicable in this plant) ...............................31 Manual opening of the generator circuit breaker in isle mode operation......................32
4.5
4.5.1 4.5.2 4.5.2.1 4.5.2.2 4.5.2.3 4.5.2.4 4.5.3 4.5.3.1 4.5.3.2 4.5.4 4.5.4.1
Gas turbine operation

Functional test during operation
33
33
Generator settings and adjustment during operation 33 Adjustment of active power (not applicable in this plant)..............................................33 Adjustment of turbine speed (generator frequency) ....................................................34 Adjustment of the power factor (Cos) (not applicable in this plant) ............................35 Adjustment of the generator voltage .............................................................................36 Fuel transfer 37 Gas to liquid fuel transfer ..............................................................................................37 Liquid to gas fuel transfer..............................................................................................38 Water injection 39 Activating the water injection system. ...........................................................................39
4.6
4.6.1 4.6.1.1 4.6.2 4.6.2.1 4.6.3 4.6.3.1 4.6.4 4.6.4.1 4.6.5
Turbine stopping
40
Local stopping in grid parallel operation (not applicable in this plant) 40 Stopping sequence: ......................................................................................................40 Emergency shut-down (manual push button) 42 Emergency stop sequence: ..........................................................................................43 Local stopping in isle operation 43 Local shut-down in isle operation:.................................................................................44 Emergency shut-down (manual push button) in isle operation 45 Emergency stop sequence: ..........................................................................................45 Shut-down in liquid fuel 46
4.7
4.7.1 4.7.2 4.7.2.1 4.7.2.2 4.7.2.3 4.7.2.4 4.7.2.5 4.7.3 4.7.3.1 4.7.3.2 4.7.3.3 4.7.4
Safety procedure for fire alarm

Fire systems equipment
47
47
Fire system operation 48 Container door ..............................................................................................................49 Operational logic of the automatic detection.................................................................49 Fire monitoring and extinguishing system failure..........................................................50 Fire warning ..................................................................................................................51 Fire alarm ......................................................................................................................52 Operator container inspection and action 54 No fire within the container ...........................................................................................54 A small fire is detected in the container ........................................................................55 An important fire is detected in the container................................................................56 Precaution during maintenance works 57
: : : :
4.7.5
Re-establishment of the unit after the discharge of extinguishing agents
57
4.8
4.8.1 4.8.2 4.8.3 4.8.4
Safety procedure for gas alarm

Description of the gas monitor system Gas monitor system failure Gas leakage warning Gas leakage alarm
58
58 59 59 60
4.9
4.9.1 4.9.2 4.9.3 4.9.4
Turbogenerator alarms
General Description Alarm - Warning and no Turbine Stop (green) Cooldown - Alarm with Normal Turbine Stop (yellow) Shutdown - Alarm with Immediate Shutdown (red)
61
61 62 62 62
4.10 4.11 4.12

4.12.1 4.12.1.1 4.12.1.2 4.12.1.3 4.12.1.4
Taking the Plant out of Operation (weeks) Plant Shutdown (months) Crank
63 64 65
Start of the cranking process: 65 Pre-ventilation ...............................................................................................................65 Pre-lubrication ...............................................................................................................66 Cranking ........................................................................................................................66 End of cranking .............................................................................................................66
4.13
4.13.1 4.13.2
Compressor washing
Off-line compressor washing Washing release
67
67 67
4.14
4.14.1 4.14.2 4.14.3
Remote Control
Remote Controlled Start-up Procedure Remote Controlled Synchronization Procedure Remote Controlled Stopping Procedure
68
70 70 70
4.15
4.15.1 4.15.2
Operational Malfunctions
Compressor Surging Generator Overheating and Vibration
71
71 71
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4.1
Introduction
This chapter describes the various measures and steps, which are required for the operation of the gas turbine generator plant. The operator must strictly observe the instructions and information contained in this chapter in order to achieve the optimum operational reliability of the plant. The instructions include the checks to be carried out, the operating sequences and specify the most important messages displayed. Special situations are indicated in the individual operating steps by the terms NOTE, CAUTION and
WARNING. It is imperative that these instructions are observed. WARNING Indicates a measure, procedure, condition or safety measure that, if ignored, may lead to injury or loss of life. CAUTION Indicates a measure that, if ignored, may lead to damage or destruction of the plant. NOTE Indicates information, which is essential for understanding respectively observance of a measure, procedure, condition or description.
In addition, remarks on Chapter Safety must be observed. The descriptions of the operating sequences in this chapter include sequences and functions, which correspond to a fully equipped standard plant. Project-specific adaptations are therefore not considered.
: : : :
4.2
Starting the gas turbine
4.2.1
Checks prior to start

The checks specified below must be carried out before any start of the gas turbine plant. All these pre-start checks make it possible to detect any unusual conditions, which might impair the correct function and thus the operating performance of the plant. In general these checks should also be carried out - daily - in the normal operation of the gas turbine plant. The checks to be carried out cover several different systems.
WARNING The following subsections should be gone through point by point before each start, and the turbine should only be started once it has been established that the whole plant is in a fault-free condition.
4.2.1.1
Turbogenerator set
Check the interior of the container and the immediate environment. Examine all auxiliary equipments for the presence of any combustible objects or foreign bodies, which are not required for the operation of the gas turbine. Check that the entire plant is correctly mounted and installed. Check that all the connection valves to the measuring and protection equipments are correctly opened. Check that the hand valves of the lube oil pumps, if any, are widely opened. Check that both drain and vent hand valves, if any, are closed. Open the manual fuel-stop valves. Check the pressure of the plant fuel supply for the selected fuel. Check the pressure of the instrument air supply. Open the valves of the water cooling system, if applicable. Check the connection of both the DC-operated emergency lubrication pump and of the other lube oil pumps, if any, and ensure the correct operation. Check all lines and connections for leaks. All leaks must be corrected. Check the oil level; the oil tank must be filled to the permissible maximum level (see maintenance instructions). Check that the oil tank heater is functioning correctly; the temperature must be sufficient to start the gas turbine; the type of oil used determines the lowest permissible temperature. Check that the manual oil filter change-over valve is correctly positioned; check the drain and venting valves of the twin filter. All doors of the package must be closed during operation.
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4.2.1.2
Air filter system
Check that all the filters of the turbine combustion air system and the pocket filters of the container cooling air system are correctly installed. Check if there is any blocking or damage in the filter system.
4.2.1.3
Oil cooler

Check for leaks in the cooler or the supply pipes. All leaks must be corrected. Check that the cooler is clean and completely free of blocking, which can have an adverse effect on efficiency. In the event of extreme operating conditions or very low temperatures, it is necessary to check for frozen areas along the piping lines outside the container and in the oil cooler.
4.2.1.4
Electrical supply
Check that the battery charger is working properly, check all the connections of the distribution system; check the battery conditions and the wiring. Check that all circuit breakers and automatic miniature circuit breakers in the supply and control cabinet are connected. Check that all AC/DC main and auxiliary supplies in the control cabinet are connected. Check that the fire and gas monitoring systems are functioning correctly.
NOTE
The 400 V AC supply must be kept constant during the starting and the operation of the gas turbine, so that the correct function of the lubricating oil pump can be guaranteed. Any interruption in the power supply causes the start to be aborted or the shutdown of the turbine generator plant.
: : : :
4.2.1.5
Exhaust gas system

Dangerous explosive conditions can occur if: Fuel or other combustible materials reach the gas turbine exhaust gas system The ambient air and temperature conditions reach the flammability thresholds for these substances (flash point) Fuel can become trapped in the exhaust gas system before the turbine is started or after it is stopped, if for instance the burner flame goes out or ignition fails.

The following instructions are to be observed regularly and strictly:

Check that the turbine exhaust gas system is completely unobstructed. Check that the waste heat boiler control system as well as the bypass system for discharge into the atmosphere (if available) are correctly connected and are working properly. Check that all valves or dampers of the gas turbine exhaust gas system are correctly mounted. It is absolutely essential to check that these elements are functioning correctly. The exhaust gas ducts must in all cases be unobstructed during starting and continuous operation. Exhaust gas recovery systems are often equipped with bypass dampers to control the gas supply to the system. If a bypass damper is mounted, check that it is functioning correctly; make sure that it is able, when the gas turbine is started, to divert the entire exhaust gas flow into the atmosphere. Check that the fuel quality complies permanently with the specifications for the gas turbine. A deviation from the fuel specification may lead to a malfunction of the fuel regulation system.
CAUTION
Before starting the gas turbine make sure that the exhaust gas system has been completely freed of non-burned fuel or other combustible materials by means of purging.
The purging of the exhaust gas system with air is carried out automatically during the running up of the turbine. The operator must, however, regularly check that this purging process is taking place correctly (check duration and sequence). The purging process of the exhaust gas system takes place with the airflow delivered by the compressor of the gas turbine while turning with the starting motor system, without ignition. The total duration and the sequence of the purging process must be determined in accordance with local regulations and the purge volume. To start the purging process the gas turbine control system sends a signal to the boiler only if the turbine is turning without ignition. Upon completion of the purging process, the waste heat boiler control system triggers the ignition of the gas turbine with a corresponding signal.
CAUTION The activation and control of the exhaust gas system purging process is the responsibility of the waste heat boiler control system, which functions separately from the gas turbine control.
If the purging process exceeds the programmed maximum duration, i.e. usually 30 minutes, the gas turbine is stopped and an alarm is released.
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4.2.1.6
Time intervals between repeated start-ups

After a turbine shutdown it is possible to proceed with another start-up, two minutes after the turbine has decelerated below 5% speed. The start permission is given on the screen. In case of shutdown due to an alarm, do not proceed with the next attempt to start-up unless the problem is fixed.
ATTENTION After three repeated start-up failures, a deep troubleshooting is necessary. Further start-up attempts without having removed the fault may damage part of the plant.
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4.2.2
Switching on the control system

Check the self-initialization of the control system:
at first, switch on the PC at its main switch on the rack and wait until the PC has booted up and configured the I/O bus modules. as soon as a steady condition occurs, switch on the failsafe miniature controller at the main switch.
WARNING
When the control system is switched off, the gas and fire monitoring systems are not fully effective. With the safety system switched on, gas is detected and displayed visually, but the package ventilation is not active, which means that any escaped gas is not discharged. With the safety system switched on, fire is detected and the CO2 flooding initiated, but the container ventilation dampers remain closed, which means that a dangerous overpressure can build up in the container.
4.2.2.1
Presettings
In the Page Header, behind ENGINE STATUS is shown SYSTEM OFF and the CONTROL MODE INDICATES Start fuel control.
On page Maintenance under Operation Commands on the Navigation tree, you can find SYSTEM CONTROL MODE .The control system is being activated by pressing the button: System ON/OFF
The same command can be given on page Enclosure under Auxiliaries. Before the supply is switched on, a 30 second pre-ventilation sequence takes place, in order to discharge any concentration of gas present in the container. In the case that during the preventilation any of the in or outlet container louvres fails to open, an emergency shutdown will follow and a new command can only be given after an alarm reset. The ENGINE STATUS in the Page Header will indicate StandBy. and the control system waits for the start command.
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4.2.2.2
Check and Reset of the pending alarms

The pending alarms are listed In the Alarm Banner on the page bottom By giving the command Reset in the Page Header, all alarms will be reset. In the case that an alarm, which causes a shutdown, persists, the turbine cannot be started and the cause and the solution of the problem must be found first. When no alarms (shutdown/cooldown) are present, the ENGINE STATUS in the Page Header indicates StandBy and the CONTROL MODE indicates Start fuel control.
4.2.2.3
Command mode: LOCAL, REMOTE

On page OPERATION SUMMARY under COMMAND MODE, the command: LOCAL REMOTE
can be given, which activates local or remote mode of the control system. In local mode, only commands that are entered via the local screen will be accepted. If the machine is being operated by remote control, only commands will be accepted that are entered via the remote PC, client module and (if present) the supervision system connected via OPC/Modbus. Which mode is active, is indicated under COMMAND MODE behind Commands and Setpoints source.
4.2.2.4
StandBy
The turbine has carried out all internal resets and is ready to start. The ready to start signal (in the client module) is activated. Page header: ENGINE STATUS Standby CONTROL MODE Start fuel control
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4.2.3
Local start-up procedure in gas fuel.
4.2.3.1
Fuel selection
In the navigation tree under FUEL, on page Liquid or page Fuel Gas, the actual fuel mode is under FUEL SELECTION, behind GT Fuel Status. When running in liquid fuel, the GT Fuel Status is Liquid. For gas fuel, select button Fuel gas under FUEL SELECTION . If the machine is being operated with gas fuel, the gas fuel operation signal (in the client module) is activated.
4.2.3.2
Starting the turbine

Under OPERATION COMMANDS on page OPERATION SUMMARY or page OPERATION COMMANDS , the turbine can be started by giving the command under ENGINE CONTROL. Selecting the button START starts the machine. The start-up sequence runs fully automatically.
4.2.3.3
Prelube
4.2.3.3.1.
PreLube Ventilation
Time 45 s
To discharge any concentration of gas present in the container, the container inlet and exhaust fans are switched on and the container ventilated for 45 s. The container heaters are switched off. The start-up sequence signal (in the client module) is activated and the ready to start signal deactivated. Page header: ENGINE STATUS Prelube CONTROL MODE Start fuel control
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4.2.3.3.2.
Prelube Lubrication
Time 44 s
For the pre-lubrication the control system switches on the pre/post lub oil pump. The pre-lubrication oil pressure is checked during 44 seconds. If the oil pressure hasnt reached its minimum value, an alarm (shutdown) is generated and the start sequence will be interrupted. Page header: ENGINE STATUS Prelube CONTROL MODE Start fuel control
If the minimum oil pressure has been reached, the control system enters the crank sequence.
4.2.3.4
Crank
The electrical starting motor starts and and the control pressure in the hydraulic pump is checked. The oil must have reached its minimum temperature, otherwise a shutdown takes place. After 15 s waiting time, the hydraulic pump actuater is activated, the pressure in the main hydraulic system rises. The turbine receives torque and begins to turn.
The turbine has to reach the 16% speed within 60 s, otherwise a shutdown takes place. In order to enable the exhaust gas duct ventilation, the boiler purge signal is activated by the failsafe PLC. This signal is used by the boiler logic.
Page header: ENGINE STATUS Crank CONTROL MODE Start fuel control
4.2.3.4.1.
Gas valve check During cranking follows a gas valve sequence which checks for any leakage of the gas stop valves. This sequence is totally controlled by the failsafe PLC: The venting valve between the primary and secondary gas stop valve is closed for 20 seconds. If the pressure doesnt increase, the primary stop valve is considered to be closing tightly. Then, the primary stop valve is opened for 3 s and then closed again. The gas pipe between the two stop valves is now under pressure, which must be maintained for 20s. If the pressure is maintained, the secondary stop valve is considered to be closing tightly. The gas vent valve is opened for 5 s to discharge the enclosed volume of gas to atmosphere. The gas vent valve is closed again. Page header: ENGINE STATUS Crank CONTROL MODE Start fuel control
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4.2.3.4.2.
Crank exhaust purge
Max. time 50 s
To prevent the accumulation of unburned fuel or other combustible material in the turbine or the exhaust system, the engine and exhaust system is purged during each start sequence. The exhaust purge time is the minimum purge time during which no ignition can take place. As a backup, this time is monitored by the failsafe PC. Page header: ENGINE STATUS Crank CONTROL MODE Start fuel control
4.2.3.4.3.
Boiler purge
Max. time 300 s
In accordance with local regulations the exhaust gas duct and heat recovery system is purged with the air produced by the turbine. When crank speed (in the starting sequence) is reached, a signal is sent to boiler to start purge, and the control system now waits for an ignition release signal back from the boiler. This signal exchange is totally and only controlled by the failsafe PLC. The time monitoring of the exhaust gas duct purge is carried out by the boiler control system. If no ignition release has been given after 300 s from the boiler purge begin, an alarm is generated and the turbine shuts down. Page header: ENGINE STATUS Crank CONTROL MODE Start fuel control
Note The failsafe monitoring of the exhaust and heat recovery system must be integrated in the boiler control and is under responsibility of the boiler supplier.
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4.2.3.5
Ignition Gas
At ignition, the two gas stop valves and the ignition gas valve are opened, and the spark plug is activated. The main gas regulation valve is at an opening suitable for the ignition. The operating hours counter is started and the start counter increased by 1. The ignition time is also monitored by the failsafe PC. The spark plug is activated and within 20 s, the turbine temperature (T5) has to reach 204 C, if not the ignition is considered as failed. The turbine shuts down. After a successful ignition the spark plug is switched off and the ignition gas valve is closed. Page header: ENGINE STATUS Ignition Gas CONTROL MODE Start fuel control
4.2.3.6
Acceleration to nominal speed

After successful ignition, the control system enters the acceleration sequence. Page header: ENGINE STATUS Acceleration CONTROL MODE T5 control
4.2.3.6.1.
Acceleration To Starter Dropout
Max. time 360 s
The control system regulates the fuel supply in such a way that the 66% speed threshold is reached with an almost constant acceleration. If the T60 turbine does not reach this speed within 130 s, a shutdown takes place. At 66% speed the turbine is self-powering and able to accelerate without the help of the starting system. The starting motor is deactivated. Page header: ENGINE STATUS Acceleration CONTROL MODE T5 control
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4.2.3.6.2.
Acceleration To Gen Excite
Max. time 120 s
The turbine speeds up from de 66% to 90%. If the 90% speed hasnt been reached within 70 seconds, a shutdown takes place. At 90% speed, the generator excitation is switched on, the minimal voltage protection of the generator is activated. Page header: ENGINE STATUS Acceleration CONTROL MODE Speed control
4.2.3.6.3.
Adjusting rated speed
Max. time 90 s
The turbine now accelerates to 100% nominal speed. Page header: ENGINE STATUS Acceleration CONTROL MODE Speed control
4.2.3.6.4.
Ready to load The turbine has reached 100% nominal speed and is ready to synchronize. Page header: ENGINE STATUS Ready To Load CONTROL MODE Speed control The ready for load signal (in the client module) is now activated. Verify that the generator voltage is at nominal level.
4.2.3.6.5.
Ready To Synchronize The turbine has reached 100% nominal speed and is ready to synchronize. Page header: ENGINE STATUS Ready To Synchronize CONTROL MODE Ready To Synchronize
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4.2.4
Local start-up procedure in liquid fuel.
4.2.4.1
Fuel selection
In the navigation tree under FUEL, the actual fuel mode, is shown on page Liquid or page Fuel Gas, under FUEL SELECTION, behind GT Fuel Status. When running in gas fuel, the GT Fuel Status is fuel gas. For liquid fuel, select button Liquid under FUEL SELECTION . If the machine is being operated with liquid fuel, the liquid fuel operation signal (in the client module) is activated.
4.2.4.2
Starting the turbine

Under OPERATION COMMANDS on page OPERATION SUMMARY or page OPERATION COMMANDS , the turbine can be started by giving the command under ENGINE CONTROL. Pushing the button START starts the machine. The start-up sequence runs fully automatically.
4.2.4.3
Prelube
4.2.4.3.1.
PreLube Ventilation
Time 45 s
To discharge any concentration of gas present in the container, the container inlet and exhaust fans are switched on and the container ventilated for 45 s. The container heaters are switched off. The start-up sequence signal (in the client module) is activated and the ready to start signal deactivated. Page header: ENGINE STATUS Prelube CONTROL MODE Start fuel control
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4.2.4.3.2.
Prelube Lubrication
Time 44 s
For the pre-lubrication the control system switches on the pre/post lub oil pump. The pre-lubrication oil pressure is checked during 44 seconds. If the oil pressure hasnt reached its minimum value, an alarm (shutdown) is generated and the start sequence will be interrupted. Page header: ENGINE STATUS Prelube CONTROL MODE Start fuel control If the minimum oil pressure has been reached, the control system enters the crank sequence.
4.2.4.4
Crank
The electrical starting motor starts and and the control pressure in the hydraulic pump is checked. The oil must have reached its minimum temperature, otherwise a shutdown takes place. After 15 s waiting time, the hydraulic pump actuater is activated, the pressure in the main hydraulic system rises. The turbine receives torque and begins to turn.
The turbine has to reach the 16% speed within 60 s, otherwise a shutdown takes place. In order to enable the exhaust gas duct ventilation, the boiler purge signal is activated by the failsafe PLC. This signal is used by the boiler logic.
Page header: ENGINE STATUS Crank CONTROL MODE Start fuel control
4.2.4.5
Low pressure liquid fuel pump check

All the liquid fuel drain valves are closed, main shut-off valves opened and the digital output signal fuel oil pump M6300 on (in client module) is activated. The control system verifies that the low pressure liquid fuel transfer pump is working by checking the suction pressure at the inlet of the liquid fuel high pressure pump. Pressure should be reached within 9 seconds. Page header: ENGINE STATUS Crank CONTROL MODE Start fuel control
4.2.4.5.1.
Crank exhaust purge
time 50 s
To prevent the accumulation of unburned fuel or other combustible material in the turbine or the exhaust system, the engine and exhaust system is purged during each start sequence. The exhaust purge time is the minimum purge time during which no ignition can take place. As a backup, this time is monitored by the failsafe PC. Page header: ENGINE STATUS Crank CONTROL MODE Start fuel control
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4.2.4.5.2.
Boiler purge
Max. time 600 s
In accordance with local regulations the exhaust gas duct and heat recovery system is purged with the air produced by the turbine. When crank speed (in the starting sequence) is reached, a signal is sent to boiler to start purge, and the control system now waits for an ignition release signal back from the boiler. This signal exchange is totally and only controlled by the failsafe PLC. The time monitoring of the exhaust gas duct purge is carried out by the boiler control system. If no ignition release has been given after 300 s from the boiler purge begin, an alarm is generated and the turbine shuts down. Page header: ENGINE STATUS Crank CONTROL MODE Start fuel control
Note The failsafe monitoring of the exhaust and heat recovery system must be integrated in the boiler control and is under responsibility of the boiler supplier.
4.2.4.6
Ignition liquid fuel

As soon as the ignition release signal is received, the two liquid fuel shut-off valves, the atomization air valve and the liquid fuel ignition valve are opened, and the spark plug is excited. The main liquid fuel pump is at controlled speed suitable for the ignition. The operating hours counter is started. The ignition time is also monitored by the failsafe PC. The spark plug is excited and within 35 s, the turbine temperature (T5) has to reach 204 C, if not there is a start failure After a successful ignition the spark plug is switched off and the liquid fuel ignition gas valve is closed. Page header: ENGINE STATUS Ignition Gas CONTROL MODE Start fuel control
4.2.4.7
Acceleration to nominal speed

After successful ignition, the control system enters the acceleration sequence. Page header: ENGINE STATUS Acceleration CONTROL MODE T5 control
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4.2.4.7.1.
Acceleration To Starter Dropout
Max. time 360 s
The control system regulates the fuel supply in such a way that the 66% speed threshold is reached with an almost constant acceleration. If the T130 turbine does not reach this speed within 130 s, a shutdown takes place. At 66% speed the turbine is self-powering and able to accelerate without the help of the starting system. The starting motor is deactivated. Page header: ENGINE STATUS Acceleration CONTROL MODE T5 control
4.2.4.7.2.
Acceleration To Gen Excite
Max. time 120 s
The turbine speeds up from de 66% to 90%. If the 90% speed hasnt been reached within 70 seconds, a shutdown takes place. At 90% speed, the generator excitation is switched on, the minimal voltage protection of the generator is activated. Page header: ENGINE STATUS Acceleration CONTROL MODE Speed control
4.2.4.7.3.
Adjusting rated speed
Max. time 90 s
The turbine now accelerates to 100% nominal speed. Page header: ENGINE STATUS Acceleration CONTROL MODE Speed control
4.2.4.7.4.
Ready to load The turbine has reached 100% nominal speed and is ready to load. Page header: ENGINE STATUS Ready To Load CONTROL MODE Speed control The ready for load signal (in the client module) is now activated. Verify that the generator voltage is at nominal level.
4.2.4.7.5.
Ready To Synchronize The turbine has reached 100% nominal speed and is ready to synchronize. Page header: ENGINE STATUS Ready To Synchronize CONTROL MODE Ready To Synchronize
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4.3
Synchronization
This chapter deals with the sequence for synchronization and direct insertion of the generator circuit breaker.
CAUTION In the case of maintenance work, interventions or corrections to the gas turbine synchronization system , that means to the voltage measurement system or to the position signals of the circuit breakers , it must be ensured that the system is fully tested again before a synchronization is carried out.
When the turbine is running at its nominal speed, the three following possibilities exist:
The busbar voltage before the generator circuit breaker is present; in this case synchronization with the busbar can be carried out. The busbar voltage before the generator circuit breaker is not present after a cold start; in this case a direct insertion of the generator with the circuit breaker is possible. In praxis, the direct insertion operation is carried out very seldom. If the turbine has already been synchronized and is working in isle mode of operation, after a grid failure, there is the possibility of grid back synchronization, as soon as the grid voltage has returned to its nominal values.
CAUTION
The 3 mentioned possibilities can be started manually or automatically. It is important to be clear about the mode of synchronization before starting the turbine: with manual or automatic initialization. The Generator page, in the Navigation Tree under Generator, should therefore be called up before each start and the appropriate presettings implemented.
On the Generator page, the desired synchronization mode selection can be selected under SYNCHRONIZATION MODE.
NOTE: At DLF there will not be (at least for the time being) any connection with a (national) grid. The turbines will normally allways run in island mode and there will be no backsynchronization.The explanations regarding parallel running and back synchronization arent applicable for DLF. These chapters have been left in the manual in case of future change of configuration.
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4.3.1
Synchronization with the busbar

Go to page Generator , in the Navigation Tree under Generator. If the plant is ready to load and the busbar voltage is present; the gas turbine can be connected to the busbar with the generator circuit breaker by the synchro-sequence. In both modes, manual or automatic, the voltage, frequency and phase matching are performed automatically.
4.3.1.1
Automatic synchronization
The automatic synchronization begins immediately, without the action of the operator, at Ready To Load and Ready To Synchronize, if behind Synchro auto/manu, under SYNCHRONIZATION MODE is written AUTO. In case the indication MAN is active, the button SYNCHRONIZATION MODE AUTO / MAN has to be selected, in order to change synchronization mode.
4.3.1.2
Manual synchronization
The manual and automatic synchronization sequence are the same, the only difference lays in the start of the sequence. At manual, the control system waits for the start command of the operator. Behind SYNCHRONIZATION MODE must be written MAN. In case the indication AUTO is active, the botton SYNCHRONIZATION MODE AUTO / MAN has to be selected, in order to change synchronization mode. To command the manual synchronization, under SYNCHRONIZATION SEQUENCE, there are the following buttons: SYNCHRONIZATION SEQUENCE START STOP
On the operators decision, the synchronization can be started by selecting the start button. If for any reason the synchronization has to be interrupted, the STOP button can be selected. The SYNCHRONIZATION MODE feature to command the manual synchronization, can also be found on page Operation Commands, in the Navigation Tree under Operation Commands.
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4.3.1.3
Busbar synchronization sequence
4.3.1.3.1.
Synchronization conditions The busbar voltage must be present. The generator circuit breaker must be open. Page header: ENGINE STATUS Synchro CONTROL MODE Speed control
4.3.1.3.2.
Voltage connection All synchronization equipment is supplied with voltage. The synchronization instruments display the voltage and frequency differences between the AC generator and the busbar.
4.3.1.3.3.
Voltage and frequency regulation The synchronization system compares the frequency and the phase angle of the generator and busbar voltages and sends a correction signal to the control system, which adapts the turbine speed accordingly. The voltage regulator adapts automatically the generator voltage.
4.3.1.3.4.
Synchronization pulses
Max. Time each 120 s
If voltage, frequency and phase angle lie within the tolerance range and remain constant for a defined period, the synchronization system sends a synchronization pulse. The system remains active, in order to send several pulses. Before permitting the closure of the generator circuit breaker, the control system tests whether the entire synchronization channel is working properly. For this purpose a sequence of 3 pulses is carried out: Pulse 1 The first pulse is tested to make sure that the synchronization equipment is sending a correct pulse. The maximum permissible time interval between two pulses is 120 seconds. If this time is exceeded, the synchronization is aborted. The second pulse enables the connection of the undervoltage coil of the generator circuit breaker (if present). The third pulse is transmitted directly to the generator circuit breaker, allowing it to close.
Pulse 2 Pulse 3
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4.3.1.3.5.
Insertion of generator circuit breaker The generator circuit breaker must close within 2 seconds of the third pulse. The acknowledgement is sent directly from the generator circuit breaker position switch. If this time is exceeded, the synchronization is again aborted.
4.3.1.3.6.
End of synchronization The command to close the generator circuit breaker represents the end of the synchronization sequence. The machine is now in parallel operation with the grid network, delivering the power according to the power pre-set points. Page header: ENGINE STATUS Parallel mode CONTROL MODE KW control
4.3.1.3.7.
Synchronization alarms As indicated above, the synchronization is interrupted if:

The time interval between two pulses exceeds 120 seconds. The generator circuit breaker does not close within 2 seconds of the third pulse.
4.3.2
Synchronization Test
For maintenance and commissioning purposes, a test function of synchronization is available on page Generator or page Operation Commands, under SYNCHRONIZATION TEST. This test can only be used when the manual synchronization has been selected. When button SYNCHRONIZATION TEST ON/OFF has been selected ON, the synchronization sequence starts, with the only difference, that after the 3rd pulse the generator circuit breaker will not be commanded to close. When testing has finished, the synchronization test can be switched off by selecting again the button SYNCHRONIZATION TEST ON/OFF Synchro start on OFF.
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4.3.3
Grid Back-synchronization (not applicable in this plant)

Go to page Generator , in the Navigation Tree under Generator. If the gas turbine is in isle mode operation and the grid voltage has returned to its nominal values, e.g. after a grid failure, the turbine can be switched back to grid parallel operation. This will be stablished by a back synchronization sequence which sends a closing command to the grid circuit breaker. In both modes, manual or automatic, the voltage, frequency and phase matching are performed automatically.
4.3.3.1
Automatic back-synchronization
The automatic back-synchronization begins 180 s after the grid voltage has turned back to the nominal value, without the action of the operator, if behind Synchro auto/manu, under SYNCHRONIZATION MODE is written AUTO. In case the indication MAN is active, the botton SYNCHRONIZATION MODE AUTO / MAN has to be selected, in order to change synchronization mode.
4.3.3.2
Manual back-synchronization
The manual and automatic back-synchronization sequence are the same, the only difference lays in the start of the sequence. At manual, the control system waits for the start command of the operator. Behind SYNCHRONIZATION MODE must be written MAN. In case the indication AUTO is active, the botton SYNCHRONIZATION MODE AUTO / MAN has to be selected, in order to change synchronization mode. To command the manual synchronization, under SYNCHRONIZATION SEQUENCE, there are the following buttons: SYNCHRONIZATION SEQUENCE START STOP
On the operators decision, the synchronization can be started by selecting the start button. If for any reason the synchronization has to be interrupted, the STOP button can be selected. The SYNCHRONIZATION MODE feature to command the manual synchronization, can also be found on page Operation Commands, in the Navigation Tree under Operation Commands.
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4.3.3.3
Back-synchronization sequence
4.3.3.3.1.
Synchronization conditions The grid voltage has returned to its nominal values. The generator circuit breaker must be closed. The grid circuit breaker must be open. Page header: ENGINE STATUS Isle Mode CONTROL MODE Speed control
4.3.3.3.2.
Voltage connection All synchronization equipment is supplied with voltage. The synchronization instruments display the voltage and frequency differences between the AC generator and grid network.
4.3.3.3.3.
Voltage and frequency regulation The synchronization system compares the frequency and the phase angle of the generator and grid network voltages and sends a correction signal to the control system, which adapts the turbine speed accordingly. The voltage regulator adapts automatically the generator voltage.
4.3.3.3.4.
Synchronization pulses If voltage, frequency and phase angle lie within the tolerance range and remain constant for a defined period, the synchronization system sends a synchronization pulse. The system remains active, in order to send several pulses. Before permitting the closure of the grid circuit breaker, the control system tests whether the entire synchronization channel is working properly. For this purpose a sequence of 3 pulses is carried out:
Pulse 1
The first pulse is tested to make sure that the synchronization equipment is sending a correct pulse. The maximum permissible time interval between two pulses is 120 seconds. If this time is exceeded, the synchronization is aborted. The second pulse is yet a test (the min. voltage coil does not exist here). The third pulse is transmitted directly to the generator circuit breaker, allowing it to close.
Pulse 2 Pulse 3
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4.3.3.3.5.
Insertion of grid circuit breaker The grid circuit breaker must close within 2 seconds from the third pulse. The acknowledgement is sent back to the control system directly from the grid circuit breaker. If this time is exceeded, the synchronization is again aborted.
4.3.3.3.6.
End of back-synchronization The command to close the grid circuit breaker represents the end of the back-synchronization sequence. The generator set is now in parallel operation with the grid network. Page header: ENGINE STATUS Parallel mode CONTROL MODE KW control
4.3.3.3.7.
Synchronization alarms As indicated above, the synchronization is interrupted if:

The time interval between two pulses exceeds 120 seconds. The generator circuit breaker does not close within 2 seconds of the third pulse.
4.3.4
Back-synchronization Test (not applicable in this plant)

For maintenance and commissioning purposes, a test function of back-synchronization is available on page Generator or page Operation Commands, under SYNCHRONIZATION TEST. This test can only be used when the manual synchronization has been selected. When button SYNCHRONIZATION TEST ON/OFF has been selected ON, the synchronization sequence starts, with the only difference, that after the 3rd pulse the grid circuit breaker will not be commanded to close. When testing has finished, the synchronization test can be switched off by selecting again the button SYNCHRONIZATION TEST ON/OFF on OFF.
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4.3.5
Direct insertion of the generator circuit breaker

This is a very seldom situation, where the voltage after the generator circuit breaker is absent: there is no voltage or frequency to match and therefore no need to synchronize prior to close the generator circuit breaker. If the Gen CB insertion button has been preset, the circuit breaker closes automatically, as soon as the READY TO LOAD message is received. If the Gen CB insertion manu button has been preset, after the READY TO LOAD message the system waits the circuit breaker manual close command. The button Gen CB close can then be used to send the close command The Gen CB open button can be used to open the generator circuit breaker at any time independently from any regulation.
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4.4
Operating modes and load charging

When the synchronization sequence has been executed successfully, the generator circuit breaker is closed, the gas turbine generator set is connected with the busbar and it is possible to increase the electrical load. Depending on the position of the grid circuit breaker and the possible connection of more gas turbines (which determines the operating mode), the plant offers several operating possibilities:
Grid circuit breaker closed Page header: ENGINE STATUS Parallel Mode CONTROL MODE KW control
Activation of active power control. Activation of power factor (cos ) control.

Grid circuit breaker open (one unit only) Page header: ENGINE STATUS Isle Mode CONTROL MODE Speed control
Activation of speed control. Activation of voltage control. Grid circuit breaker open (operation with several units) Page header: ENGINE STATUS Isle Mode CONTROL MODE Speed control
Activation of speed control. Activation of voltage control. Activation of loadsharing
NOTE: At DLF, there is no connection with the grid, so the operating modes are reduced to the two situations with Grid circuit breaker open.
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4.4.1
Grid parallel operation (not applicable in this plant)

When operating in parallel to the grid network, the gas turbine generator set can supply active power (kW) and reactive power (kVAR) to a "considered infinite large" network. The ratio (cos phi) can be predefined. The control system adapts the power supplied by the gas turbine to the value preset by the operator, while the generator output is continuously measured and compared with the set point. The power adaptation is carried out in accordance with the increase or decrease in load at a constant rate until the desired value is achieved. When maximum power is required, the control system limits turbine temperature (T5) to its maximum permissible value and thus ensures maximum power output under the current ambient conditions. In case of a load change, the generator voltage regulator keeps the generator power factor constant at the preset value.
NOTE In order to ensure stable operating conditions in grid parallel operation, the gas turbine should be operated with at least 10% of its nominal power.
4.4.1.1
Grid voltage failure

In the event of a grid voltage failure when the gas turbine plant is working in grid parallel operation, the grid protection equipment immediately opens the grid circuit breaker. Page header: ENGINE STATUS Isle Mode CONTROL MODE Speed control
4.4.1.2
Manual opening of the generator circuit breaker in grid parallel operation

In grid parallel operation the operator has two possibilities for manually disconnecting the generator circuit breaker.
Press the red button on the generator cubicle. For safety reasons this button is located under a transparent protective cover. In the Generator Commands menu, activate the button. Gen CB open
NOTE The opening button for the generator circuit breaker is effective any time.
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4.4.2
Isle mode operation

In isle mode of operation, being separate from the grid network, the turbine generator plant must supply its own speed or generator frequency (Hz) and voltage (V) for a certain load and keep it constant. The gas turbine control system adjusts the speed to a predefined value (50Hz). The voltage regulator keeps the voltage constant.
4.4.2.1
Load charging Isle mode operation

The load on the busbar separated from the grid network is determined by the plant load connected to the busbar itself and cannot be changed or adjusted by the turbine generator plant. In isle mode of operation, the operator must connect the loads gradually, in order to avoid overloading the turbine generator plant and to prevent rejection of the loads which are already connected. The connection of a higher load produces severe frequency and voltage fluctuations and , under certain circumstances, the cut of the loads already connected. The type of load with which the gas turbine is charged also has an effect on these fluctuations: with a strongly ohmic load there are more pronounced fluctuations in speed than with a more inductive load. As a guideline one may consider that the load can be connected in increments of 1 MW. The maximum power for the gas turbine in isle mode of operation must be limited in relation to the anticipated load fluctuations. At the same time the decrease in load as a result of the rise in ambient temperature at the transition between night and day should also be considered. The generally recommended operational value is not more than 90% of maximum power. In the event of a changeover to isle mode of operation after a grid power failure, the gas turbine can deal with load changes from 100% to 0% of nominal power. When two or more units are running in Island mode on the same busbar, the total load is devided equally over the units by an automatic loadsharing control. This mode is a speed control as above, with the addition that the speed setpoint will be biased by the loadshare bias analog input. An analogue circuitry provides a signal to the loadshare bias input which is proportional to the units deviation to the average load.
4.4.2.2
Return to grid in isle mode operation (not applicable in this plant)

The grid voltage is checked by grid-specific protection equipment, which reports the state of the grid network to the control system with the aid of the Grid fault signal. This signal is used by the control system for activating the grid back synchronization function.
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4.4.2.3
Manual opening of the generator circuit breaker in isle mode operation

In isle mode of operation the operator has the option of manually disconnecting the generator circuit breaker. In isle operation the operator has two possibilities for manually disconnecting the generator circuit breaker. Press the red button on the front panel next to the touch-screen. For safety reasons this button is located under a transparent protective cover. In the Generator Commands menu, press the button. Gen CB open
NOTE The opening button for the Generator Circuit Breaker is effective any time. CAUTION Before opening the generator circuit breaker in isle mode of operation it should be ensured that the required power can be supplied by another plant. If this is not the case, the power supply is completely disconnected, which leads to the blackout of the entire plant.
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4.5
Gas turbine operation
4.5.1
Functional test during operation

Upon completion of the start-up sequence and after power stabilization, the turbine generator plant works in continuous operation and supplies the required energy. During this operating time the control system checks the operating conditions of the gas turbine, the generator and all associated equipments and ensures that these conditions lie within the tolerance range. If an operating condition changes, the control system reacts automatically in order to adapt the plant to the new situation. If a parameter exceeds the specified permissible range, the system informs the operator of this by means of an alarm signal. The operator must, however, in any case, regularly check that all the components of the plant are functioning correctly, in order to be able to introduce the necessary corrective measures as soon as possible. The checking procedures are in Maintenance section.
4.5.2
Generator settings and adjustment during operation

This section deals with the various settings and adjustment functions, which are to be carried out during the operation of the turbine generator plant.
4.5.2.1
Adjustment of active power (not applicable in this plant)

The active power produced by the generator can be set to the desired value by means of the appropriate function of the local control system or by the corresponding function of the remote control system. The new set point can be entered at any time; the adjustment of active power is, however, only effective if the plant is working in grid parallel operation. The actual value of generated power may be lower than the required power, as the power can be limited by other factors, for example by the maximal permissible temperature T5. For entering the desired setting, the Power setpoint window is available under ENGINE CONTROL on page Operation Commands or under GENERATOR POWER on page Generator.
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4.5.2.2
Adjustment of turbine speed (generator frequency)

The turbine speed (and thus the frequency supplied by the generator) can be set to the desired value by means of the appropriate function of the local control system or by the corresponding function of the remote control system.
4.5.2.2.1.
Isochronous mode of operation In this mode the governor will provide a fuel demand in order to maintain a constant turbine speed and hence electrical bus frequency (50 Hz), following an adjustable speed setpoint. This turbine control is automatically active, if the unit is at no load (gen CB open) or on load if selected by the operator. The load on the busbar is determined by the plant load connected to the busbar itself and cannot be changed or adjusted by the turbine generator plant. In this mode of operation, the operator must connect the loads gradually, in order to avoid overloading the turbine generator plant and to prevent rejection of the loads which are already connected. The connection of a higher load produces severe frequency and voltage fluctuations and , under certain circumstances, the cut of the loads already connected. The type of load with which the gas turbine is charged also has an effect on these fluctuations: with a strongly ohmic load there are more pronounced fluctuations in speed than with a more inductive load. As a guideline one may consider that the load can be connected in increments of 1 MW. The maximum power for the gas turbine in isle mode of operation must be limited in relation to the anticipated load fluctuations. At the same time the decrease in load as a result of the rise in ambient temperature at the transition between night and day should also be considered. The generally recommended operational value is not more than 90% of maximum power.
4.5.2.2.2.
Loadsharing This mode is the same speed control as above, with the addition that the speed setpoint will be biased by the loadshare bias analog input. An analogue circuitry provides a signal to the loadshare bias input which is proportional to the units deviation to the average load. This turbine control is active if there are 2 or more TGs on load in isoch control. In this way the total load on the busbar (or the remaining load after deducting the load taken by the unit(s) in droop control), will be divided equally over the units running in isoch.
4.5.2.2.3.
Droop mode of operation In this speed control, the speed setpoint is equivalent to an electrical power demand, whereby for a nominal 5% droop: 105% speed SP corresponds to full speed no load or 0% electrical power 100% speed SP corresponds to full speed full load or 100% electrical power This speed control is activated by a digital input signal which can be operated on either local or remote control. The droop offset can be changed by 2 digital inputs (droop + and droop -), which makes it possibile to increase or decrease the power produced by each unit running in droop control.
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4.5.2.3
Adjustment of the power factor (Cos) (not applicable in this plant)
4.5.2.3.1.
Adjustment of generator power factor The reactive power supplied by the generator is determined by the generator power factor (cos ). This setting is only effective in operation with the generator circuit breaker closed and in grid parallel operation. In this operating mode the generator voltage regulator keeps the power factor constant at the preset value. The set point is defined upon commissioning of the generator in accordance with the client's instructions. The power factor values usually are between 0.9 and 0.8. The control settings for cosphi adjustment can be found in the Navigation Tree under Generator on page Cos Phi. Under COS PHI CONTROL, the cosphi regulation can be (dis)activated by selecting the button: Cosphi reg. ON/OFF The Generator cosphi setpoint can be adjusted under GENERATOR COSPHI CONTROL. In this same window, the cosphi mode (inductive or capacitive) can be selected with button: Generator Cosphi Mode Normally however, the generator cosphi regulation must work in inductive. The generator cosphi is limited between 0.95cap and 0.8ind. If the value reaches either limit, the indication apparent power lim.mode will turn green.
4.5.2.3.2.
Adjustment of net power factor If requested, the amount of reactive power exchange between the cogeneration plant and the grid can be regulated. For this purpose, under COSPHI CONTROL the button: Gen/Net cosphi can be selected. By selecting NET, the control system maintains a certain imported or exported reactive power to the grid by following a Network cosphi setpoint. The network cosphi is a calculated value of the relation between the imported/exported active power and reactive power at the exchange point between the cogeneration plant and the grid, which is the grid circuit breaker. In order to calculate this value, the control system has 2 analog signals 4-20mA at disposal (the measurement equipment is not supplied by TBM). The operator has the possibility to choose 3 different bands of net cosphi, depending on the situation or law in different countries/areas. This selection can be done under NETWORK COSPHI CONTROL
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4.5.2.4
Adjustment of the generator voltage

The adjustment of generator voltage is controlled by the generator voltage regulator. This adjustment is only in operation with the generator circuit breaker open and in island mode. The set value is defined upon commissioning of the generator in accordance with the client's instructions and is normally identical to the nominal voltage of the plant. To correct the set value, clicc the software buttons cosphi ind / U+ or cosphi cap / U- on the local HMI or remote PC. These buttons can be found under generator commands. There are also 2 hardware buttons on the front panel in the control cubicle and 2 digital inputs which can be used by the external remote control. For plants in which several generators are connected to the same load busbar, it is important that the set voltage value remains unchanged. In isle mode of operation the adjustment of generator voltage takes place upon commissioning of the plant. A static value is defined which in isle mode of operation guarantees the most even possible distribution of reactive power to the individual plants.
CAUTION In isle mode of operation a modification of the generator voltage parameter may lead to uncontrolled fluctuations of reactive power and current, which may result in damage.
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4.5.3
Fuel transfer
During running, a fuel transfer can be carried out. The commands and information for this purpose, can be found in the Navigation Tree under Fuel system on the pages Gas, Liquid and Water Purge.
4.5.3.1
Gas to liquid fuel transfer

The actual fuel mode, is shown on page Liquid, under FUEL SELECTION, behind GT Fuel Status. When running in gas fuel, the GT Fuel Status is Gas. The transfer to liquid fuel starts by selecting the button Liquid under FUEL SELECTION .
4.5.3.1.1.
Liquid Fuel Status
Time 2 s
The control system checks the liquid fuel system status.
4.5.3.1.2.
Transfer-Preparation
Max. Time 2 + 7 + 2 + 2 + 3 s
The command for the external liquid fuel booster pump is activated. The failsafe PC (Simatic S7) opens both liquid fuel shutoff valves. The liquid fuel booster pressure is checked. The fuel transfer is communicated to the governor.
4.5.3.1.3.
Liquid Fuel Mode
Max. Time 45 s
The control system slowly closes the gas metering valve and increases the liquid fuel flow (frequency controlled pump). The end of the transfer is communicated to the governor. The fail safe PC closes both gas shutoff valves. The gas hours counter stops and the liquid counter starts. The counters can be found in the navigation tree under Operation Commands on the page Maintenance.
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4.5.3.2
Liquid to gas fuel transfer

The actual fuel mode, is shown on page Liquid, under FUEL SELECTION, behind GT Fuel Status. When running in liquid fuel, the GT Fuel Status is Liquid. The transfer to gas fuel starts by selecting the button Fuel gas under FUEL SELECTION .
4.5.3.2.1.
Gas pressure check
Time 2 s + Max. Time 50 + 3 s
The control system verifies the gas pressure. In case of gas pressure failure (high or low), no fuel transfer will take place.
4.5.3.2.2.
Gas valve check
Time 20 + 3 + 20 + 5 s
Next follows the same gas valve sequence which which is used during the starting sequence in gas fuel. The venting valve between the primary and secondary gas shut-off valve is closed for 20 seconds. If the pressure doesnt increases the primary shut-off valve is considered to be closing tightly. Then, the primary shut-off valve is opened for 3 s and then closed again. The gas pipe between the two shut-off valves is now under pressure, which must be maintained for 20s. If the pressure is maintained, the secondary shut-off valve is considered to be closing tightly. The gas vent valve is opened for 5 s to discharge the enclosed volume of gas to atmosphere. The gas vent valve is closed again.
4.5.3.2.3.
Transfer The failsafe PLC opens both gas shutoff valves. The fuel transfer is communicated to the governor.
4.5.3.2.4.
Gas Fuel Mode
Max. Time 45 s
The control system slowly decreases the liquid fuel flow (frequency controlled pump) and slowly closes the gas metering valves. The end of the transfer is communicated to the governor. The fail safe PC closes the liquid fuel shutoff valves. The liquid hours counter stops and the gas counter starts. The counters can be found in the navigation tree under Operation Commands on the page Maintenance.
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4.5.4
Water injection
The water injection system makes it possible to reduce the NOx emission values in the exhaust gas.
4.5.4.1
Activating the water injection system.

The water injection system can be activated above 3.5 MW of active power. The commands and information regarding the water injection can be found in the navigation tree under Fuel System on page Water Injection.
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4.6
Turbine stopping
4.6.1
Local stopping in grid parallel operation (not applicable in this plant)

The gas turbine can be stopped any time. The stopping sequence in grid parallel operation and under full load is described below.
CAUTION The local button for stopping the gas turbine is only effective if the local control mode has been selected. Likewise, the gas turbine can only be stopped by the remote control system if the remote control mode has been selected.
Under OPERATION COMMANDS on page OPERATION SUMMARY or page OPERATION COMMANDS , the turbine can be stopped by giving the command under ENGINE CONTROL. Selecting the button STOP Will start the automatic stopping sequence.
4.6.1.1
Stopping sequence:
This is a description of the sequences from the stopping command activation till the turbine stopping.
4.6.1.1.1.
Load reduction
Max. time 300 s
The plant begins to reduce the generated electrical power at a constant rate. During the power reduction phase the stopping sequence cannot be aborted.
Load reduction lasts no longer then 5 minutes Page header: ENGINE STATUS Stop CONTROL MODE KW control
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4.6.1.1.2.
Open circuit breaker When the gas turbine has reached its minimum power (approx. 500 kW) or when the time for the power reduction is elapsed, the generator circuit breaker disconnects the generator from the grid network. If the generator circuit breaker does not open, an alarm is generated.
4.6.1.1.3.
Cooldown
Time 600 s
A cool down sequence of 10 minutes duration begins. Page header: ENGINE STATUS Stop CONTROL MODE Speed control If no alarm is active the machine can be switched back to the READY TO LOAD mode ,at this step of the stop sequence ,by selecting the button: START and synchronized again with the appropriate sequences.
4.6.1.1.4.
Deceleration
Max. time 300 s
When the cooling time has elapsed, all fuel valves close and the gas turbine reduces its speed. Page header: ENGINE STATUS Deceleration CONTROL MODE Start fuel control When the gas turbine has reached 5% of nominal speed or 5 minutes have elapsed, the deceleration step is ended.
4.6.1.1.5.
PostLube + Turning
Time 10800 s
When reaching 5% speed or when the deceleration time has elapsed, the control system switches on the pre/post lub oil pump. At the same moment, the starting motor is switched on, in order to keep the turbine shaft in a slow turning speed during the entire postlub sequence of 3 hours. Page header: ENGINE STATUS PostLube CONTROL MODE Start fuel control
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4.6.1.1.6.
Post Lube Speed Rundown
Time 300 s
When the postlube time has elapsed, the pre/post lube oil pump is kept running for another 5 minutes, before being switched off. Page header: ENGINE STATUS PostLube CONTROL MODE Start fuel control
4.6.1.1.7.
Emergency Post Lube
Time 3600 s + 10800 s intermediate periods
In case of an, unlikely, problem in the program, the failsafe PC will automatically take over the postlub sequence. For the first hour, the lube oil pump will run continuously. After this, for a remaining total time of 3 hours, the pump will intermediately switch on for 2.30 min, subsequently switch off for 9.30 min. Page header: ENGINE STATUS PostLube CONTROL MODE Start fuel control
4.6.2
Emergency shut-down (manual push button)

A shutdown (emergency stop) of the gas turbine can be initiated at any time with the EMERGENCY SHUTDOWN buttons. These are located:

On the outside wall of the turbine container On the control panel In other plant specific places, if any.
CAUTION An immediate shutdown can be initiated with the EMERGENCY SHUTDOWN buttons. These buttons may only be used to shut down the gas turbine in the event of a clearly signalled danger or in an emergency.
An immediate shutdown of the systems is also required in the event of a danger to the gas turbine or other plant sections. This shutdown takes place automatically if a S xxx error (Shutdown) occurs. This type of error is displayed visually on the main interface of the control program and can be consulted in the Alarm Banner on the page bottom. Such an error may be generated both by the control system and by the safety system. The emergency stop sequence in grid parallel operation and at full load is described below. The essential differences from the normal stopping sequence are:

the circuit breaker is opened immediately the fuel stop valves are closed immediately there is no cooling sequence
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4.6.2.1
Emergency stop sequence:
4.6.2.1.1.
Closing fuel stop valves and opening circuit breaker The fuel stop valves are closed independently by the safety system and by the control system. The circuit breaker is opened under the currently driven load and disconnects the generator from the grid network. Page header: ENGINE STATUS Deceleration CONTROL MODE Start fuel control
4.6.2.1.2.
Deceleration As the fuel supply is off, the machine decelerates. Page header: ENGINE STATUS Deceleration CONTROL MODE Start fuel control When the gas turbine has reached 5% of nominal speed or 5 minutes have elapsed, the deceleration step is ended. The next steps in the program are identically to the steps of a normal stopping sequence, except for the slow turning of the shaft.
NOTE In order to restore the system, after an emergency shutdown caused by the push button, clear the pending alarms and reset the emergency switch in its normal position by turning the switch head in the arrow direction.
4.6.3
Local stopping in isle operation

In isle operation, the power control of the turbine can not change the produced power. Therefore it is impossible to de-load the turbine and the generator circuit breaker opens and rejects the whole load instantly.
NOTE The opening button for the Generator Circuit Breaker is effective any time. CAUTION Before opening the generator circuit breaker in isle mode of operation it should be ensured that the required power can be supplied by another plant. If this is not the case, the power supply is completely disconnected, which leads to the blackout of the entire plant.
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4.6.3.1
Local shut-down in isle operation:
4.6.3.1.1.
Open circuit breaker No de-loading is possible. Immediate opening of the generator circuit breaker. If the generator circuit breaker does not open, an alarm is generated.
4.6.3.1.2.
Cooling Provided that the turbine receives AC supply ,a cool down sequence of 10 minutes duration begins. Page header: ENGINE STATUS Stop CONTROL MODE Speed control If no alarm is active the machine can be switched back to the READY TO LOAD mode ,at this step of the stop sequence ,by selecting the button: START and synchronized again with the appropriate sequences. or select a direct insertion of the generator circuit breaker in case the grid circuit breaker is still open and no busbar voltage is present.
4.6.3.1.3.
Deceleration When the cooling time has elapsed, all fuel valves close and the gas turbine reduces its speed. Page header: ENGINE STATUS Deceleration CONTROL MODE Start fuel control When the gas turbine has reached 5% of nominal speed or 5 minutes have elapsed, the deceleration step is ended. The control system will continue with the same steps as a normal stop. If there is no 400 VAC available (blackout), the turning sequence cannot be started and the control system will continue with the normal postlube sequence.
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4.6.4
Emergency shut-down (manual push button) in isle operation

A shutdown (emergency stop) of the gas turbine can be initiated at any time with the EMERGENCY SHUTDOWN buttons. These are located:

On the outside wall of the turbine container On the control panel In other plant specific places, if any.
CAUTION An immediate shutdown can be initiated with the EMERGENCY SHUTDOWN buttons. These buttons may only be used to shut down the gas turbine in the event of a clearly signalled danger or in an emergency.
An immediate shutdown of the systems is also required in the event of a danger to the gas turbine or other plant sections. This shutdown takes place automatically if a S xxx error (Shutdown) occurs. This type of error is displayed visually on the main interface of the control program and can be consulted in the Alarm Banner on the page bottom. Such an error may be generated both by the control system and by the safety system. The emergency stop sequence in isle operation is described below. The essential differences from the normal stopping sequence are:

the circuit breaker is opened immediately the fuel stop valves are closed immediately there is no cooling sequence
4.6.4.1
Emergency stop sequence:
4.6.4.1.1.
Closing fuel stop valves and opening circuit breaker The fuel stop valves are closed independently by the safety system and by the control system. The circuit breaker is opened under the currently driven load and disconnects the generator from the grid network. Page header: ENGINE STATUS Deceleration CONTROL MODE Start fuel control
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4.6.4.1.2.
Deceleration As the fuel supply is off, the machine decelerates. Page header: ENGINE STATUS Deceleration CONTROL MODE Start fuel control When the gas turbine has reached 5% of nominal speed or 5 minutes have elapsed, the deceleration step is ended. The control system will continue with the same steps as a normal stop. If there is no 400 VAC available (blackout), the turning sequence cannot be started and the control system will continue with the normal postlube sequence.
NOTE In order to restore the system, after an emergency shutdown caused by the push button, clear the pending alarms and reset the emergency switch in its normal position by turning the switch head in the arrow direction.
4.6.5
Shut-down in liquid fuel

If the engine is shut down during liquid fuel operation, a drainage and water purge of the liquid fuel system takes place.
4.6.5.1.1.
Liquid fuel line drainage
Time 5 s
The liquid fuel main-and pilot lines are back-purged by the still present PCD (compressed air at the outlet of the compressor).
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4.7
Safety procedure for fire alarm

An automatic, electronically controlled fire detection system for the turbogenerator enclosure protection is provided. The system is monitored and operated from the fire monitor unit, and is equipped with CO2 extinguishing system. The installation is designed, executed and certified in accordance with local regulations. The fire monitoring and extinguishing system detects flames inside the package and, after a preset time delay, releases extinguishing agent (CO2), which will fill the enclosure.
WARNING Carbon dioxide CO2 is a colorless, odorless gas (unless, for safety reason, lemon odor is added). The discharge of carbon dioxide creates serious hazard to personnel, such as serious suffocation and reduced visibility during and after the discharging period. CAUTION The fire monitor system is an independent control device, however the system is directly connected with the turbine control system for the alarm transmission and safety sequence.
4.7.1
Fire systems equipment

The fire monitoring and extinguishing system consists of following main components:
a fire monitor unit consisting of : electronic control and monitoring unit with 220VAC supply, 24VDC internal battery and manual fire alarm button on the front panel in the container: infrared ray detectors outside the container: manual release push-button, alongside the enclosure warning horn and flashing light signals, above the inspection door a CO2 bottles set with sufficient filling for one extinguishing action weight switches for CO2 bottle leakage monitoring extinguishing agent release solenoid valve distribution piping, and spray nozzles.
CAUTION The CO2 cylinder set, is designed for one fire fighting action only. It must be refilled again to restore the fire fighting functionality.
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4.7.2
Fire system operation

The fire fighting system is designed to detect and extinguish a fire propagating in the enclosure. Fires, such as fuel fires or lube oil fires, are quickly extinguished by flooding the area with an inert gas. Discharging a high concentration of CO2 into the container creates the inert atmosphere. To accomplish this, the enclosure ventilation system is shutdown, the ventilation shutters are closed and the extinguishing agent is discharged into the enclosure. The fire detection system is equipped with its own emergency power supply and remains active even in the event of 220 VAC supply failure. Once armed, normal system activation is controlled by the fire detection system; the extinguishing agent can also be released any time by pressing the push button in case of an emergency. A manual fire alarm button is mounted outside the container. To operate, break the glass and press the button. In order to reset the button, replace the glass cover. The infrared flame detectors monitor the possible flame inside the enclosure. The infrared flame detector, with highly sensitive element reacts rapidly to all flaming fire in which carbonaceous materials are burnt, such as wood, plastic, alcohol, natural gas, petroleum products etc. A pyro-electric sensor evaluates a specific wavelength of the hot carbon dioxide emitted by the flame. The detector achieves high immunity to deceptive phenomena by means of a second pyro-electric sensor, which operates on another wavelength. Signal from both sensors are correlated which enables clear differentiation between flame radiation and deceptive phenomena. Thus the detector is widely insensitive to artificial light, sunlight, and all kinds of heat, ultraviolet, x-ray, and gamma radiation. As soon as a detector responds the control unit actuates a preventive warning signal. Acustic and optic warning panel is provided outside the enclosure above the maintenance door for operator's alerting. When both detectors respond simultaneously, or if a button is pressed, the control unit gives the extinguishing command. After a delay, a valve is actuated to release the extinguishing agent. The main discharge valve is installed on the pilot bottle, charged with nitrogen , which produces,when energised, the cascade opening of all the cylinder discharge valves of the set. For personnel safety reason, an odorant stored in a bottle, connected to the piping and actuated by the discharge pressure, may be mixed with the odourless CO2, while discharging into the enclosure. The discharged CO2 is flushed to the protected area through spray nozzles. The spray nozzles are designed to distribute the gas smoothly and evenly on the enclosure. The nozzles are sized for discharging the whole extinguishing agent in about 60 seconds. In the event of loss of extinguishing agent, the weight switch of the leaking cylinder in question transmits an alarm signal to the fire detection system.
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4.7.2.1
Container door
The door, located at the longitudinal side of the container, is provided with limit switch that locks the discharge of the extinguishing agent if the door is open. Personnel working inside the container have to keep the door open while working or to lock the extinguishing agent release with the special function button on the fire monitor control panel to avoid the possible release of the extinction during maintenance.
CAUTION Under normal operating conditions, if no personnel is working inside the container, the door must be kept closed in order to permit the action of the extinguishing system.
4.7.2.2
Operational logic of the automatic detection

The fire monitoring system provides the following main alarms:
System fault
Indicates a fault of the monitoring system or parts of it. The control system signals it as system error (ER). This alarm doesnt cause any automatic action.
Fire pre-alarm
Indicates that one automatic fire sensor detects a fire. The control system signals it as system warning (WR).
Fire alarm
Indicates that two sensors detect a fire, or The manual fire release buttons are actuated. The control system signals it as alarm (SD). The signals of the automatic detectors, equipped with infrared sensors, are processed by the following logic:
First detector OK not OK OK not OK not OK fire detected fire detected OK fire detected
second detector OK OK not OK not OK fire detected not OK OK fire detected fire detected
Alarm signal none fault fault fault fault, pre-alarm, fire alarm fault, pre-alarm, fire alarm pre-alarm pre-alarm pre-alarm, fire alarm
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4.7.2.3
Fire monitoring and extinguishing system failure

Monitoring or extinguishing system defects, such as sensor failure, line interruption, measurement unit failures or supply failure, activates this alarm.
WARNING In case of failure indication, part of or the whole system is out of service. Its the operators responsibility to re-establish as soon as possible nominal operating conditions and to take all the necessary precautions to assure a safe unit operation. CAUTION The fire system is primarily a safety device to protect personnel and equipment. It must be ALWAYS READY. The system will provide safe and continuos monitoring of hazardous areas only with proper installation, calibration and maintenance.
Functional system failure sequence

A defect in the monitoring system or parts of it is detected. The alarm in the fire monitor is activated. The control system signals it as system error (ER). This alarm doesnt cause any automatic action.
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4.7.2.4
Fire warning
This alarm is activated when one out of two automatic fire sensors detects a fire. The alarm is announced by a continuous sound emitted by the electric hooter present in the enclosure and by a warning signal in the main control system. Indication given by light diodes is also visible on the front panel of the fire detection monitoring system
WARNING IMMEDIATE operator intervention is mandatory in case of a fire detection warning, in order to verify the actual situation of the installation and take all necessary precautions to assure safety to avoid damage escalation. WARNING With the activation of the fire warning, the operator must proceed immediately to the turbine area and verify the situation in the enclosure. The operator must be equipped with appropriate portable extinguishing device. WARNING Extreme cautions must be taken when proceeding with enclosure inspection. CAUTION The main enclosure door (with handle) is equipped with a position switch; once opened automatic extinguishing is blocked in order to protect the personnel in the enclosure. For this reason, during normal condition main door must remain closed.
Functional fire warning sequence

A fire pre-alarm is detected. The alarm in the fire monitor is activated. The control system signals it as system warning (WR). This alarm doesnt cause any automatic action.
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4.7.2.5
Fire alarm
This alarm is activated when both automatic sensors detect a fire. Activation is also possible via manual push buttons installed on the enclosure and at the front panel of the fire detection monitoring system. The alarm is announced by an intermittent sound emitted by the electric hooter present outside the enclosure and by an alarm signal in the main control system. Indication given by light diodes is also visible on the front panel of the fire detection monitoring system The gas turbine unit is instantly shut down, in parallel the extinguishing sequence is activated.
CAUTION The extinguishing command may not be executed if a system failure was present before the fire alarm was issued. WARNING A fire detection alarm condition indicates a potential danger for fire development in all turbine area. It is in the operators responsibility to ensure safety to all personnel and equipment to avoid escalation of damages. CAUTION Do not push any of the reset push button before the fire has been completely extinguished. Nonobservance of this rule could cause interruption of the extinguishing sequence with inherent damages. WARNING With the activation of the fire alarm, the operator must proceed to the turbine area and verify immediately the situation in the enclosure. The operator must be equipped with appropriate portable extinguishing device. WARNING Extreme cautions must be taken when proceeding with enclosure inspection. CAUTION The main enclosure door (with handle) is equipped with a position switch; once opened automatic extinguishing is blocked in order to protect the personnel in the enclosure. For this reason, during normal condition main door must remain closed. WARNING When the extinguishing gas (CO2) has been discharged, the air concentration in the enclosure is extremely reduced; its highly dangerous to enter the enclosure without appropriate precautions, life danger persists. Do not enter the enclosure before ventilating sufficiently and after having checked oxygen concentration in the enclosure.
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4.7.2.5.1.
Fire alarm sequence
A fire alarm is detected. The intermittent alarm in the enclosure is activated. Inherent safety sequence is activated by the control system. Immediate shutdown of the turbine is commanded. All main fuel shutoff valves are closed and the vent valves opened. Enclosure fans are switched off. Enclosure air shutters remain open during 45 seconds. The safety system is warned. Timer for a delay of normally 30 seconds for the CO2 discharge in the enclosure starts. During this waiting period its possible to block the discharge with the corresponding switch installed on the fire monitor. The turbine decelerates. The operator has to intervene IMMEDIATELY in order to verify the real situation of the installation and to take the necessary precautions to guarantee safety. Actions such as the following are at the operators responsibility: Evacuate all personnel in the turbine area proximity Close all external manual fuel & pressure air supply shut-off valves. Follow the safety prescription as per safety specifications. Once the 30 seconds timer expires, CO2 discharge is activated. Approximately 60 seconds are required to empty the CO2 bottles. 15 seconds after the CO2 discharge start, air shutters are commanded to closed position. Such sequence is to enhance air evacuation, since CO2 has a greater specific gravity. Once the CO2 is completely discharged, electric hooter tone changes from intermittent to continuos. In the mean time, the turbine shaft will decelerate to standstill if it was running. The lubrication system remains in service.
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4.7.3
Operator container inspection and action

With the activation of fire alarms, the operator must go to the turbine area and verify immediately the situation in the enclosure. The operator must be equipped with appropriate portable extinguishing gear.
WARNING Extreme cautions must be taken when proceeding with enclosure inspection. CAUTION The main enclosure door (with handle) is equipped with a position switch; once opened automatic extinguishing is blocked in order to protect the personnel in the enclosure. For this reason, during normal condition main door must remain closed.
4.7.3.1
No fire within the container

In case the inspection did not reveal the presence of a developing fire, proceed as follows:
If possible, block the extinction with the corresponding switch on the fire control panel otherwise proceed on chapter re-establishment. If the situation is under control, cancel the present alarms on the fire control unit as well as on the main control system. After resetting the alarms, enclosure air gates are opened and the ventilation is automatically activated. Restart the engine. Observe long enough the enclosure to verify if there is a malfunction in the fire monitoring system or a real fire danger.
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4.7.3.2
A small fire is detected in the container

In case the enclosure inspection reveals the presence of a minor entity fire, proceed as follow:
Make sure that nobody is inside or in proximity of the enclosure, if necessary evacuate the person(s). Be sure that the fire can be controlled by means of a portable extinguisher. Extinguish the fire with the portable extinguisher. Once the fire is surely extinguished, block the automatic fire extinguishing from the fire monitor panel. Evaluate cause and damage entity. Once the cause has been identified assure the event cannot be repeated. If this is not possible stop immediately operation. Proceed with disconnection and repair of parts, if possible.
WARNING Avoid repair of functional parts when powered or under pressure, non-observance could cause personal injuries.
If necessary, stop the turbine and repair, otherwise cancel the alarms and continue with operation. Inspect periodically the development area for sufficient time.
WARNING
In case of doubt, close the inspection doors and push without hesitation the manual extinguishing switch in the enclosure area. Proceed as for important fires.
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4.7.3.3
An important fire is detected in the container

In case the enclosure inspection reveals the presence of a major entity fire, proceed as follow:
Make sure that nobody is inside or in proximity of the enclosure, if necessary evacuate the person(s). The fire cannot be manually controlled. Close the enclosure inspection doors. Actuate immediately the manual fire release button near the package or on the control panel in the control cubicle room. Call the internal or external fire-fighters department.
WARNING
In case of fire within the enclosure, fuels, lubrication and compressed air are an additional source that could increase the damage potential. Therefore it is mandatory to cut the medium supply from the external as soon as possible. The operator must immediately evaluate the situation and interrupt outer danger sources.

The turbo generator will shutdown. Close all the external manual liquid and gas fuel supply valves as well as the compressed air supply. If the oil spill is feeding the fire, for safety reasons, power-off lubrication oil pumps are required. The pumps must be switched off manually. The AC pre-post lube oil pumps can be disconnected by means of the corresponding automatic fuse. Once the AC pumps are off, the emergency oil pump will automatically run because of pressure drop. To switch off the emergency oil pump use the manual switch installed in the supply panel.
CAUTION Lubrication cut-off is an action fully under operators responsibility. Even if the turbine shaft is in standstill such action can lead to considerable damages, It is therefore mandatory to contact Turbomach SA before any further actions are taken.
Disconnect all enclosure equipment power supply. Because of the potential high risk of a back-draft, and the presence of CO2 within the enclosure, the enclosure doors MUST NOT be opened. Continue as explained under chapter re-establishment
WARNING Carbon dioxide (CO2) is a colorless, odorless (for safety reason, lemon odor is added), electrically non-conductive inert gas and is 1,5 times heavier than air. The discharge of carbon dioxide in fire extinguishing concentration creates serious hazard to persons, such as serious suffocation, which can be deadly, or reduce visibility in the protected area. Do not enter the enclosure before thorough ventilation and after having checked that the atmosphere in the enclosure contains enough oxygen.
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4.7.4
Precaution during maintenance works

During welding works inside the container, desactivate the fire detection and fire extinction system in order to avoid any useless discharge of extinguishing agents.
WARNING While the extinction system is out of service, it is necessary to install a portable extinguisher, with sufficient capacity, close to the zone where the welding works are carried out.
4.7.5
Re-establishment of the unit after the discharge of extinguishing agents

WARNING When the extinguishing gas (CO2) has been discharged, the air concentration in the enclosure is extremely reduced; its highly dangerous to enter the enclosure without appropriate precautions, life danger persists. Do not enter the enclosure before sufficient ventilation and after having checked oxygen concentration in the enclosure. WARNING Because of its physical composition CO2 is heavier then air, therefore CO2 has the tendency to stay on the ground.
When the fire is extinguished and qualified personnel have the situation under control, CO2 evacuation is mandatory. Open of all doors and inspection panels. By means of compressed air flush enclosure bottom and eventually cable trays, sections, rooms, etc. below the enclosure level that could have been potentially contaminated by enclosure leaks. Before undertaking any activity related to the enclosure be sure that all CO2 is now properly evacuated. Cancel the present alarms on the fire control unit as well as on the main control system. Disconnect the installation parts, which could be damaged. If necessary, proceed with repairs. Refill the bottles with new Extinguishing agent. In case condition at the above point cannot be respected, due e.g. logistic reasons, operators are responsible for supervision and operation. Inspect all the gas turbine generator set for fire damages. After a CO2-discharge the situation has to be carefully evaluated prior to restart.
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4.8
4.8.1
Safety procedure for gas alarm

Description of the gas monitor system
The unit is equipped with a gas leakage monitoring system that covers the enclosure internal area. The gas detection system is designed to continuously monitor the explosive level of the atmosphere within the enclosure The system consists of a gas sensors assembly installed in the container. The detection sensors are connected to the safety back-up PLC (Process Logic Controller) which provides the monitoring. The safety system triggers the system fault, warning and alarm signals. The processed value is in percent of the LEL (lower explosion limit) : typically 20% of LEL for warning and 40% of LEL for alarm The 100% LEL indication means the gas has reached a concentration where the gas/air mixture become sufficient to produce an explosion (= 5% vol. CH4 in air). If the gas concentration in the container increases the pre-selected levels, visual warnings, alarms, and safety sequence, including turbine shutdown, are initiated to protect personnel and equipment. In case the concentration of gas exceeds 40% LEL the turbine will be shut down.
WARNING In case of gas leakage detection alarm an explosion risk persists. Before resetting the system be sure that the gas is evacuated. To avoid personnel injuries, the system can only be restored once this condition is achieved.
The gas leakage monitoring system gives the following alarms ,which are displayed by the control system: Gas detection failure Indicates system or part of it out of service. A system fault message is issued (SD). The unit shut down, a dedicated safety sequence is activated. Gas detection warning Indicates a gas concentration in the package above 20% LEL and below 40 % LEL. The control system signals this as a warning (WR). Gas alarm Indicates a gas concentration in the package above 40 % LEL. The control system signals this as alarm (SD). The unit shut down, a dedicated safety sequence is activated.
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4.8.2
Gas monitor system failure

Monitoring system failure such as sensor failure, line interruption, measurement unit breakdown or supply failure, activates this alarm. Due to the high danger of the gas leakage within the enclosure, the monitoring is performed by the safety back-up PLC, working in the context of a redundancy control. For this reason in case of one channel failure a shutdown for discrepancy is activated.
WARNING In case of failure indication, part of or the whole system is out of service. Its operators responsibility to re-establish the correct system operation and take all necessary precautions to grant a safe operation of the plant. CAUTION The gas detection system is primarily a safety device for the protection of personnel and equipment It must always be operational The system will provide safe and continuous monitoring of hazardous areas only with proper installation, calibration and maintenance.
4.8.3
Gas leakage warning

This alarm is activated when the gas concentration in the enclosure exceeds the limit of the first threshold (> 20 % LEL). Warning (WR) will be commanded. Fans and air gates will be activated, if not already activated, to ensure gas evacuation.
WARNING If a gas leakage warning appears on the screen check the gas concentration in the container using a hand-held gas detector: if the gas detector confirms the presence of gas or the leakage location is detected shutdown immediately the gas turbine and close the main shutoff hand valve on the gas line to the turbine.
Find here below recommended procedure to follow in case of gas leakage leading to a warning:
When this alarm is activated, concentration inspection by means of a portable instrument must be executed. Inspection must cover all internal fuel supply lines, starting from inlet flange till fuel injectors connection ports. Once leak source has been identified, turbine must be stopped and external manual shut off valve closed. Once all valves are closed, all enclosure maintenance doors can be opened to improve evacuation of gas residues. If the concentration is high or the escaped gas cannot be contained, all electrical supplies in the enclosure must be powered off. If the situation is under control or the gas leakage repaired, cancel the present alarms and restart the installation, keep the unit under visual control for a sufficient period.
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4.8.4
Gas leakage alarm

This alarm is activated when the gas concentration in the enclosure exceeds the limit of the second threshold (> 40 % LEL). A shutdown signal (SD) is given. Enclosure fans and air gates are automatically activated to evacuate the detected gas.
WARNING In case of gas leakage an explosion risk persists, therefore all personnel in the area must be evacuated and the enclosure must be closed to allow proper ventilation. In a second time, but as soon as possible, authorized and skilled personnel must intervene to find the source of the leak and take the necessary actions. Inspection personnel must be equipped with appropriate protection.
Find here below recommended procedure to follow in case of gas leakage leading to an alarm: Gas leakage above alarm threshold is detected. The safety back-up circuit is activated (hardware-backup). Inherent safety sequence is activated by the control system. Immediate shut-down of the turbine is commanded. All main fuel shut-off fuel valves are closed and vent valves opened. Enclosure fans are switched on if not already on. Enclosure air gates are commanded to open if not already open Power supply to all non-explosion proof equipment in the enclosure is switched off, exceptions are made for all explosion proof equipment (fire sensors, gas sensors, lighting) and the components necessary for the safety back-up circuit. The turbine decelerates. The operator has to intervene IMMEDIATELY in order to verify the real situation of the installation and to take the necessary precautions to guarantee safety. Following actions are at operators responsibility: Evacuate all personnel in turbine area proximity.
Close all external manual fuel shut-off valves. Follow the safety prescription as per safety specifications.

The lubrication system remains in service since it is ex proof. Verify immediately the gas concentration in the enclosure. Inspection must be done by using a portable equipment and must cover all the gas fuel line, from inlet flange to injector connections. Once all valves are closed, all enclosure maintenance doors can be opened to improve evacuation of gas residues. If the concentration is high or the gas leakage cannot be contained, all the electrical supplies in the enclosure must be powered off and action that could lead to gas ignition must be avoided (welding, grinding, smoking,). If the situation is under control or gas leakage is repaired, reset alarms on the gas control unit and on the main control system. Once the unit is restarted, it is advisable to proceed with regular concentration measurements and visual inspections for a reasonable time.
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4.9
4.9.1
Turbogenerator alarms
General Description
The gas turbine generator plant is equipped with all the safety equipments required to ensure the correct functioning and reliable continuous operation of all its components. In the event of a complete or partial failure of a component, unusual events, malfunctions or in other cases, the messages displayed on the screen enable the operator to carry out troubleshooting and malfunction analysis. Although the automatic control system is very reliable, a constant monitoring of the various situations by the operator remains the best way of achieving safe and effective long-term operation. All displays which can provide detailed information on operating sequences should be checked as part of regular inspections at the plant. If the operator detects an unusual situation, the cause of the malfunction or deviation should be investigated and clearly determined before the operating sequences are continued, in order to avoid any greater damage to the plant or personal injury. It should not be waited until the automatic control system reacts; if the operator detects errors or deviations, he must take the necessary corrective measures to prevent or to limit any possible damage. The various alarm displays ,are generated by the control system, are shown below.
Group Name Alarm Cooldown Shutdown
Example description CP_Wr_Oil_Lev_Low Pck_Cd_TT0100Max CP_Sd_Diff_Curr
What does it do? Warning indicator or error condition (no shutdown yet) Alarm with normal turbine shutdown (shutdown with cooling phase) Alarm with immediate shutdown
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4.9.2
Alarm - Warning and no Turbine Stop (green)

An alarm signal indicates a sequence error or a warning condition in the various systems or a problem in connection with measuring, signal transmission or value recording. Value recording problems are caused by faults in the analogue transducers. The measurement channel in question is usually deactivated and the respective alarms or functions are no longer available. In the event of an alarm the operator must use his own judgement to decide what measures are required to ensure the reliable operation of the plant. The operator is also responsible for constantly checking the deactivated signals with the aid of other control parameters in order to prevent possible damage to the system. Also malfunctions in the course of the various functional sequences of the program, which are generally caused by defects in the systems involved, can produce an alarm. An alarm is also triggered by protective equipment which displays an unusual condition in a particular section of the plant. At this stage the situation is not (yet) critical for the safety of the plant; the operator must, however, immediately take suitable countermeasures to prevent the situation getting any worse, leading to more serious malfunctions or a shutdown of the plant.
4.9.3
Cooldown - Alarm with Normal Turbine Stop (yellow)

An alarm message with normal turbine shutdown indicates an error situation which may lead to damage to the gas turbine, but which does not demand an immediate shutdown. The shutdown caused by a cooldown is equivalent to manual stopping with the STOP button. The remaining sequence therefore corresponds to the stopping sequence described in corresponding section
4.9.4
Shutdown - Alarm with Immediate Shutdown (red)

An immediate shutdown signal indicates an instantanious danger to the gas turbine or other plant sections and demands an instantanious shutdown of the system. The shutdown is equivalent to the emergency stop. During the gas turbine post-lubrication phase the plant may be restarted at any time. It is, however, necessary to determine the causes of the stopping or shutdown of the turbine. This is to be mentioned in the plant operation report and all damages or errors are to be corrected immediately.
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4.10
Taking the Plant out of Operation (weeks)

If the plant is not going to be operated for a period of time, e.g. for a weekend or for one or more weeks, the plant may be taken out of operation.
CAUTION Before the plant is taken out of operation the gas turbine must be in the ready to start state, i.e. the post-lubrication phase must have been completed. CAUTION In principle the machine remains in ready to start conditions during this period and the machine state is monitored even at standstill.
The following points are to be observed in this connection: The turbine control system is active. On page Maintenance or Enclosure, behind System ON/OFF must indicate ON. If this is not the case, the button: System ON/OFF must be selected. Page header: ENGINE STATUS Standby CONTROL MODE Start fuel control
The safety system is active. The main current supply (AC main switch in the supply cabinet) is active, in order to ensure the power supply, e.g. to the container heater, or to keep the batteries at their optimum charge state via the battery charger. The gas detection system within the turbine enclosure is active. In the event of a gas leakage alarm the enclosure ventilation is immediately switched on and the heaters are switched off.
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4.11
Plant Shutdown (months)

CAUTION Before the plant is shut down the gas turbine must be in the ready to start state, i.e. the postlubrication phase must have been completed.
Even for long periods of standstill it is advisable to proceed like for short periods of standstill and to leave the turbine in READY TO START conditions, in order to:
have the lube oil tank heater switched on, to keep the oil at a sufficient temperature for the next start. have the generator heater on , to prevent condensation forming within the generator. have the container heaters (if installed) on , to prevent condensation or freezing. have the battery charger active , to keep the batteries full charged. monitor possible gas leakage inside the container. monitor possible fire. let the air conditioning work and regulate the humidity and temperature in the control room.
If a plant is taken out of operation for a long period, the turbine must be turned at regular intervals. The turbine should be briefly brought up to its starting speed using the start-up system, that means by activating the crank sequence. This process should be carried out every 14 days; the turbine can subsequently remain out of service for a further 14 days. If the turbine is installed in an especially aggressive environment, e.g. in proximity to the sea or in a location with severe industrial pollution, this process should be carried out several times a week (at least once a week).
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4.12
Crank
The gas turbine crank mode enables the turbine to be brought up to a sufficient speed for compressor washing. In this case only the turbine start-up system is activated, without any fuel supply or ignition taking place.
CAUTION It is not allowed to use the CRANK sequence for a quick cooling of the gas turbine. Instructions on gas turbine washing are in the Maintenance chapter.
The turbine can only be operated if the plant is in StandBy or PostLube. Page header: ENGINE STATUS Standby or PostLube CONTROL MODE Start fuel control
The machine must be in local control mode.
4.12.1
Start of the cranking process:

In the Navigation Tree under Operation commands the pages Maintenance or Crank can be found. The crank commands are in the window CRANK. The cranking process is initiated with the button. START Page header: ENGINE STATUS Prelube CONTROL MODE Start fuel control
4.12.1.1
Pre-ventilation
This sequence is identical to that one of the start procedure. Page header: ENGINE STATUS Prelube CONTROL MODE Start fuel control
If the turbine is in postlubrication sequence, the preventilation is not carried out.
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4.12.1.2
Pre-lubrication
This sequence is identical to that one of the start procedure. Page header: ENGINE STATUS Prelub CONTROL MODE Start fuel control
If the turbine is in postlubrication sequence, the prelube sequence is not carried out.
4.12.1.3
Cranking
This sequence is identical to that one of the start procedure. Page header: ENGINE STATUS Crank CONTROL MODE Start fuel control The turbine receives torque and begins to turn. The turbine has to reach the 16% speed within 60 s, otherwise a shutdown takes place.
4.12.1.4
End of cranking
The cranking process is terminated with the button. STOP In the window CRANK on the pages Maintenance or Crank. Page header: ENGINE STATUS Deceleration CONTROL MODE Start fuel control
The starter system is switched off, and the turbine reduces its speed. The turbine switches to the normal stopping sequence consisting of deceleration, turning and postlubrication
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4.13
Compressor washing
To restore the full efficiency of the gas turbine, which may be deteriorated by dirt in the compressor, compressor washing should be carried out at regular intervals. There are two washing processes:

Gas turbine cold washing by turning the gas turbine without combustion ("offline" washing). Gas turbine washing during operation and under load ("online" washing).
CAUTION When washing the gas turbine the instructions in the "Maintenance" chapter are to be followed exactly.
4.13.1
Off-line compressor washing

This section only describes the operating sequences for the activation of gas turbine washing. For the execution of the complete gas turbine washing the operator must follow the instructions contained in chapter "Maintenance" exactly.
CAUTION Before the start of gas turbine washing at least 8 (eight) hours must have elapsed since the plant was shut down; the average exhaust gas temperature (T5) must be less than 65 C.

Prepare the washing process, according to maintenance instructions. Start of the cranking process
Because of the standstill for the cool down and the preparation works to be done prior to wash the compressor , the turbine is usually is in stand-by and no postlube sequence is ongoing. The cranking process is initiated as described in the chapter Crank.
4.13.2
Washing release
At reaching crank speed, the water wash can be started/stopped, by selecting buttons: START or In the window WATER WASH CONTROL on page Maintenance. After termination of the compressor washing, the cranking process can be stopped as decribed in the chapter Crank. STOP
: : : :
4.14
Remote Control
In order to control the gas turbine unit from a distance, a Remote PC is connected to the local HMI-PC in the control cubicle via an ethernet/OPC connection, using a TCP/IP protocol. The HMI on the Remote PC has the same features as the local HMI. Furthermore, in the case that an upper-level supervision system is foreseen, this system can be connected to the HMI of the gas turbine unit via a serial or TCP/IP connection. The protocols used for this purpose are Modbus or OPC/ethernet. Beside Modbus or OPC, there is also a possibility to establish hardware wired connections between the customers supervision and the Turbine Control System. All the necessary hardware signals can be connected to the input and output modules in the client module, which is located in the auxiliary panel. In order to activate the remote control mode, either by the remote PC or customers supervision (either HW wired or via Modbus or OPC), select the button REMOTE, on page OPERATION SUMMARY under COMMAND MODE: COMMAND MODE LOCAL REMOTE
In this way, the turbine control system will only accept commands from the remote system. If only local control is required, the LOCAL button has to be selected. In this case, no commands will be accepted from the remote system. Using the Remote PC or upper-level supervision via Modbus or OPC, all signals in the turbine control system are available and active. Using the hardware signals, a limited amount of signals are available:
The following digital input signals (commands) are standard available for hardware connection: START STOP POWER UP POWER DOWN QUIET RESET GAS LIQUID Gas turbine Start Gas turbine Stop Power setpoint increment Power setpoint decrement Acknowledge and cancel acustic alarms Reset alarms Select operation with gas fuel Select operation with liquid fuel
: : : :
The following analog output signals are standard available for hardware connection: ACTIVE POWER Electrical power in kW
TURBINE SPEED Speed in % PCD T7 Turbine compressor outlet pressure in bar Exhaust gas temperature in C The following digital output signals are standard available for hardware connection: REMOTE READYTO START Remote mode chosen Turbine ready to start
READY TO LOAD Turbine running START SEQUENCE STOP SEQUENCE GAS MODE Turbine in start sequence Turbine in stop sequence Operation with gas fuel selected
BOOSTER PUMP Liquid fuel booster pump on POWER MAX POWER MIN WARNING SUMMARY ALARM SUMMARY SHUTDOWN SUMMARY SIREN Maximum electrical power reached Minimum electrical power reached Summary of all warnings Summary of all allarms (cooldowns) Summary of all shutdowns (immediate) Acustic alarm
The following digital output signals are standard available for hardware connection to the boiler system: POWER MAX POWER MIN ALARM SUMMARY SHUTDOWN SUMMARY STOP SEQUENCE Maximum electric power reached Minimum electric power reached Summary of all allarms (cooldowns) Summary of all shutdowns (immediate) Turbine in stop sequence
: : : :
4.14.1
Remote Controlled Start-up Procedure

Once activation has taken place the start-up sequence runs fully automatically, as described in the local start-up sequence.
4.14.2
Remote Controlled Synchronization Procedure

The synchronization procedure runs fully automatically, as described in the corresponding local synchronization. In remote control mode, as in local mode it is possible to initiate the synchronization sequences with the corresponding commands.

Automatic or manual synchro Start and stop synchro Close and open generator circuit breaker Synchro test on and off
4.14.3
Remote Controlled Stopping Procedure

Once activation has taken place the stopping sequence runs fully automatically, as described in the corresponding section on local stopping the plant.
: : : :
4.15
Operational Malfunctions
Certain conditions represent deviations from normal turbine operation. If the following malfunction symptoms are detected, corrective measures must be taken.
4.15.1
Compressor Surging
On all turbines a surging of the turbine compressor can occur under certain conditions. Transient conditions in the fuel or air systems can lead to turbine surging, which is identified by the noises and conditions described below: Surging in the lower speed range can be recognized by the fact that the turbine does not accelerate, that exhaust gas temperatures are higher than usual and that a rattling or fluttering noise can be heard. Surging in the upper speed range can be recognized by loud rumbling and/or bangs as well as the incapacity of the turbine to accelerate to its rated speed. If surging occurs, the turbine should be immediately shut down, in order to prevent a rapid and harmful rise in temperature. When the turbine has come to a standstill, a restart can be attempted in the usual manner. If surging reoccurs, specific troubleshooting should be carried out.
4.15.2
Generator Overheating and Vibration

Under certain conditions generator overloading may occur. The normal temperature rise in the generator windings is specified in the generator manual. Always check the winding temperatures. Overheating may be caused by conditions such as high ambient temperatures, insufficient circulation of air as a result of unsuitable or obstructed air cooling, overloading, excessive field current, contaminated or insufficient supply of lubricating oil and worn bearings. If the excessive temperature persists, the plant must be shut down and the cause determined. An increase in generator vibration during operation must always be investigated. Check the generator for misalignment, warping of the shafts, friction between fixed and rotating parts etc.

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Chapter 4 01

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Project Date Plant nr.

DLF Cyber City Building 10 01.09.08 877 4x T60

DESCRIPTION OF OPERATING SEQUENCES

Chapter: 4 Title: Electrical components

Page - 1 of 71 877-Chapter 4_01.doc

Project Date Plant nr. Turbine

DLF Cyber City Building 10 01.09.08 877 4x T60

DESCRIPTION OF OPERATING SEQUENCES

Operating modes and load charging

Chapter: 4 Title: Electrical components

Project Date Plant nr. Turbine

DLF Cyber City Building 10 01.09.08 877 4x T60

4.4.1 4.4.1.1 4.4.1.2 4.4.2 4.4.2.1 4.4.2.2 4.4.2.3

Gas turbine operation

Safety procedure for fire alarm

Chapter: 4 Title: Electrical components

Page - 3 of 71 877-Chapter 4_01.doc

Project Date Plant nr. Turbine

DLF Cyber City Building 10 01.09.08 877 4x T60

Re-establishment of the unit after the discharge of extinguishing agents

Safety procedure for gas alarm

4.10 4.11 4.12

Chapter: 4 Title: Electrical components

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DLF Cyber City Building 10 01.09.08 877 4x T60

Chapter: 4 Title: Electrical components

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DLF Cyber City Building 10 01.09.08 877 4x T60

Starting the gas turbine

Checks prior to start

Chapter: 4 Title: Electrical components

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DLF Cyber City Building 10 01.09.08 877 4x T60

Air filter system

Chapter: 4 Title: Electrical components

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Exhaust gas system

The following instructions are to be observed regularly and strictly:

Chapter: 4 Title: Electrical components

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DLF Cyber City Building 10 01.09.08 877 4x T60

Time intervals between repeated start-ups

Chapter: 4 Title: Electrical components

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DLF Cyber City Building 10 01.09.08 877 4x T60

Switching on the control system

Chapter: 4 Title: Electrical components

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DLF Cyber City Building 10 01.09.08 877 4x T60

Check and Reset of the pending alarms

Command mode: LOCAL, REMOTE

Chapter: 4 Title: Electrical components

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Project Date Plant nr. Turbine

DLF Cyber City Building 10 01.09.08 877 4x T60

Local start-up procedure in gas fuel.