Siemens Typhoon V1 CH01 PDF

Turbine Package Operators Manual
1-1
Revision 6/30/2004
Chapter 1
Turbine Package System Overview
Turbine and Gearcase Assembly.................................................................................................. 7
General Description.................................................................................................................................. 7
Air Inlet Casing.......................................................................................................................................... 7
Inlet Bearing Housing............................................................................................................................... 7
Compressor Stator Casings .................................................................................................................... 7
Compressor Turbine Bearing Housing................................................................................................... 8
Turbine Rotor Assembly .......................................................................................................................... 8
Combustion System................................................................................................................................. 8
Turbine Pressure Casing ......................................................................................................................... 8
Exhaust Diffuser ....................................................................................................................................... 8
Gearbox ..................................................................................................................................................... 8
Cooling and Sealing Air System.............................................................................................................. 9
Instrumentation......................................................................................................................................... 9
Turbine Instrumentation........................................................................................................................................... 9
Gearbox Instrumentation........................................................................................................................................ 10
Lubricating Oil System.................................................................................................................11
General Description.................................................................................................................................11
Oil Tank.....................................................................................................................................................11
Oil Pumps .................................................................................................................................................11
Oil Temperature Control Valve ...............................................................................................................12
Oil Pressure Control Valve......................................................................................................................12
Oil Filters ..................................................................................................................................................12
Oil Cooler..................................................................................................................................................13
Hydraulic Pressure Control and Relief Valves......................................................................................13
Oil Mist Eliminator ...................................................................................................................................13
Instrumentation........................................................................................................................................13
Temperature Monitoring......................................................................................................................................... 13
Pressure Monitoring............................................................................................................................................... 13
VGS Blade Position Monitoring.............................................................................................................................. 13
Driven Unit Oil Flow Monitoring.............................................................................................................................. 14
Chapter 1
1-2
Oil Tank Level Monitoring...................................................................................................................................... 14
Lubricating Oil Requirements.................................................................................................................14
Fuel System...................................................................................................................................15
Main Fuel Filter.........................................................................................................................................16
Fuel Pump.................................................................................................................................................16
Throttle Control Valves ...........................................................................................................................16
Fuel Block Valve Position Monitoring..................................................................................................................... 16
Solenoid Operated Shut-Off Valve Assemblies..................................................................................................... 16
Liquid Fuel - Primary and Secondary Manifold Drain Vavles................................................................................. 17
Fuel Filter Pressure Monitoring.............................................................................................................................. 17
Fuel Pump Pressure Monitoring............................................................................................................................. 17
Liquid Fuel Manifold Pressure Monitoring.............................................................................................................. 17
Forward Purge Air.................................................................................................................................................. 17
Instrument Air Purge.............................................................................................................................................. 17
Burner Instrumentation........................................................................................................................................... 17
Fuel and Air Supply Requirements ........................................................................................................18
Instrument Air Supply............................................................................................................................................. 18
Ignition System.............................................................................................................................19
High-Energy Spark Generators...............................................................................................................19
Retractable Igniter Assembly .................................................................................................................19
Starting System.............................................................................................................................21
Underbase and Acoustic Enclosure............................................................................................23
Inlet and Outlet Silencers........................................................................................................................23
Package Air System......................................................................................................................25
Combustion Air Intake System...............................................................................................................25
General Description................................................................................................................................................ 25
Air Intake Filter....................................................................................................................................................... 25
Air Intake Silencer.................................................................................................................................................. 25
Instrumentation...................................................................................................................................................... 25
Combustion Exhaust System.................................................................................................................25
Exhaust Silencer .................................................................................................................................................... 26
Gas Turbine Ventilation...........................................................................................................................26
Chapter 1
1-3
Dampers................................................................................................................................................................. 26
Generator Ventilation ..............................................................................................................................26
Compressor Cleaning System.....................................................................................................29
Compressor Cleaning System Requirements.......................................................................................29
Wash Trolley Air Supply......................................................................................................................................... 29
Water Wash Trolley Tank....................................................................................................................................... 30
Compressor Washing Water and Cleaning Fluids................................................................................................. 30
Fire System....................................................................................................................................31
System Control and Operation...............................................................................................................31
Heat Detectors..........................................................................................................................................32
Flame Detectors.......................................................................................................................................32
Extinguisher Bottles................................................................................................................................32
Generator.......................................................................................................................................33
Ventilation and Cooling System.............................................................................................................33
Generator Bearing Lubrication...............................................................................................................33
Electrical Operation.................................................................................................................................33
Vibration Monitoring............................................................................................................................................... 34
Generator Winding Temperature Monitoring.......................................................................................................... 34
Generator Control System............................................................................................................35
Operation..................................................................................................................................................35
Electrical Equipment.....................................................................................................................37
Electrical Cables.................................................................................................................................................... 37
Junction Boxes....................................................................................................................................................... 37
Battery Charger...................................................................................................................................................... 38
Unit Control Panel .................................................................................................................................................. 38
Generator Control Panel ........................................................................................................................................ 38
Motor Control Center.............................................................................................................................................. 38
AC Distribution Panel ............................................................................................................................................. 38
DC Controller / Emergency Lubricating Oil Pump Motor Contactor....................................................................... 38
Chapter 1
1-4
Engine Control Unit ................................................................................................................................................ 38
Igniter Controller..................................................................................................................................................... 38
Turbine Control Module................................................................................................................39
Control Console.......................................................................................................................................39
System Access and Data Entry.............................................................................................................................. 39
Control Data and Status Display............................................................................................................................ 40
Operator Panel .........................................................................................................................................40
Control Cabinet Hardware Interface Chassis........................................................................................40
24V DC Power Supply........................................................................................................................................... 41
3.5MB Controller Module....................................................................................................................................... 41
Special Applications Module.................................................................................................................................. 41
ModBus Communication Module........................................................................................................................... 42
Digital Input Module............................................................................................................................................... 42
Analog Input Modules............................................................................................................................................ 42
Isolated Digital Input-Output Module...................................................................................................................... 42
Ethernet Module..................................................................................................................................................... 42
DeviceNet Module.................................................................................................................................................. 42
ControlNet Bridge Module...................................................................................................................................... 43
ControlNet System...................................................................................................................................43
Gateway Module.................................................................................................................................................... 43
I/O Modules............................................................................................................................................................ 43
ControlNet Nodes................................................................................................................................................... 43
Vibration Monitoring Control Panel........................................................................................................43
Fire Protection System............................................................................................................................44
Overspeed Module...................................................................................................................................44
Controls Software Interface....................................................................................................................44
Fire Module............................................................................................................................................................ 44
System Monitoring and Control Module................................................................................................................. 44
Panel Support Module............................................................................................................................................ 44
Command Link Module.......................................................................................................................................... 44
Enclosure Ventilation Module................................................................................................................................. 45
Turbine Combustion Inlet Module.......................................................................................................................... 45
Air Supply Module.................................................................................................................................................. 45
Vents and Drains Module....................................................................................................................................... 45
Turbine Start Module.............................................................................................................................................. 45
Turbine Starter Module.......................................................................................................................................... 45
Turbine Bearing Temperature Modules.................................................................................................................. 45
Turbine Vibration Module....................................................................................................................................... 45
Lubricating Oil Module........................................................................................................................................... 45
Turbine Wash Module............................................................................................................................................ 46
Interstage Bleed Module........................................................................................................................................ 46
Core Messaging Modules...................................................................................................................................... 46
ECU Monitoring Module......................................................................................................................................... 46
Core Interface Module............................................................................................................................................ 46
Framework Module................................................................................................................................................. 46
Instrument Scaler Module...................................................................................................................................... 46
Contract Configuration Module.............................................................................................................................. 46
Turbine Governor Module...................................................................................................................................... 46
Chapter 1
1-5
Turbine Temperature Monitor................................................................................................................................. 46
Turbine Guide Vane Control .................................................................................................................................. 47
SAM Messaging Modules...................................................................................................................................... 47
Contract Control Module........................................................................................................................................ 47
Generator Monitoring and Control Module............................................................................................................. 47
Emergency Stop Loop.............................................................................................................................47

Chapter 1
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Chapter 1
1-7
Turbine and Gearcase Assembly
The SGT-100 Typhoon is a single shaft, simple open cycle, non-regenerative industrial gas
turbine designed for constant speed operation to drive an AC generator through a reduction
gearbox.
General Description
The turbine consists of a radial inlet casing through which air enters the ten-stage axial
compressor for compression before entry to the combustion system.
Reverse flow combustion chambers mix, burn, and expand the air-fuel mixture to drive the
two-stage turbine assembly. Exhaust gases exit through the exhaust diffuser.
Journal and thrust bearings in the inlet and compressor turbine bearing housings support and
locate the integrated compressor and turbine rotor assembly.
A cold end driven epicyclical gearbox reduces the turbine speed to the speed required by the
generator. Refer drawing RM12 Sectional Arrangement SGT100 (Typhoon) Single Shaft
located in Appendix A of this Manual Volume.
Air Inlet Casing
The air inlet casing is secured to the gearbox casing and inlet bearing housing and shaped to
provide a smooth path for the incoming airflow to the compressor. An inlet screen and a flexible
joint that accommodates relative movements due to thermal expansion are fitted to the
rectangular casing entry point to which external ducting is connected.
Inlet Bearing Housing
The inlet bearing housing mounted on the main gearbox and turbine support casing provides
support for the air inlet casing and low-pressure compressor stator casing. A tilting pad journal
and a thrust bearing assembly within the housing supports and locates the inlet end of the
turbine rotor.
Compressor Stator Casings
The compressor stator casings consist of a low-pressure casing and a high-pressure insert in
which the compressor stator blades are located.
The low-pressure stator casing is split along the centerline and flanged to the inlet bearing
housing at the inlet end. The turbine center casing is split at the exit end. Borescope access holes
are provided in the top half of the casing to enable examination of the compressor stator and
rotor blades.
Variable geometry inlet guide vanes form the first four rows of compressor stator blading to
facilitate starting and prevent compressor surge. An externally mounted operating mechanism
controls vane movement. The remaining low-pressure stator blades are retained by dovetail
grooves in the casing.
Chapter 1
1-8
Compressor Turbine Bearing Housing
The compressor turbine bearing housing provides support for the hot end of the turbine
assembly, including the combustion, power turbine stator, and exhaust systems. A tilting pad
journal bearing provides support for the exit end of the turbine rotor.
Turbine Rotor Assembly
The gas turbine rotor assembly is comprised of compressor and turbine rotor sections.
The compressor rotor is a single-spool ten-stage axial design made up of a series of discs
carrying dovetail-rooted compressor blades, with Hirth couplings at the outside diameter. These
blades are held together with a central tension bolt.
The turbine rotor is a two-stage axial design consisting of one high-pressure and one
low-pressure rotor disc carrying fir-tree rooted turbine blades. The turbine rotor discs are
overhung from the compressor rotor, located with Hirth couplings, and secured to the
compressor rotor with a central tension stud bolt.
Combustion System
The combustion system is comprised of six symmetrically-positioned combustion chambers that
are inclined at 30 degrees to the engine axis.
The system has a reverse flow design. Air leaving the compressor exit nozzle is reversed and
enters the heads of the combustion chambers through swirler plates. These plates impart a rapid
swirling motion to the flow to ensure complete mixing of fuel and air.
Turbine Pressure Casing
The turbine pressure casing is flanged to the turbine bearing housing and provides a location for
the turbine stator assembly and support for the exhaust diffuser.
Exhaust Diffuser
The insulated exhaust diffuser, which is mounted on the turbine pressure casing, provides
diffusion of the exhaust gases for the exhaust ducting system.
Gearbox
The Gearbox is a self contained star type epicyclical speed reducing gear mounted from the main
turbine support casing to form an integral part of the turbine assembly. The Gearbox contains
the starter clutch and gearing. Flanges for mounting the electric turbine starter motor and the
main lubricating oil pump are provided.
A quill shaft type gear coupling transmits torque from the cold end of the compressor rotor to the
reduction gear sun-wheel and the gearbox output shaft is provided with an integral flange to suit
interfacing to the output shaft flexible disk coupling.
Chapter 1
1-9
Cooling and Sealing Air System
Compressor air is used for sealing at labyrinth seals and for cooling of high-temperature
components.
Refer to the Cooling and Sealing Air diagram RM-8D-1 in Appendix A of the Manual Volume.
Medium-pressure air, taken from the bleed band at the sixth stage of the compressor, is used to:
Pressurize the inlet labyrinth seal.
Pressurize the labyrinth seals located on either side of the compressor turbine journal
bearing to prevent stage ten high-pressure air from entering the bearing housing.
Stage ten high-pressure bleed air taken from before the compressor exit guide vane is used to:
Balance the medium-pressure air used to pressurize the labyrinth seals at the
compressor journal bearing.
Cool the turbine rotor discs and the interstage diaphragm.
Compressor exit air is used to:
Cool the high-pressure nozzle assembly through holes in the inner and outer carrier
rings of the nozzle. The exit air then moves through the cooling tube of each nozzle
and is discharged into the gas stream through trailing edge slots.
Cool the high-pressure rotor blades by using their triple pass convection system prior
to being ejected into the gas stream.
Used medium-pressure air is vented to atmosphere through the secondary breather system. Used
stage ten high-pressure air is vented into the exhaust system through the primary breather
system.
Instrumentation
Instrumentation is provided to monitor the turbine parameters and provide warning and trip
control functions. Refer schematic diagram 1405039-C01-070 Typhoon Single Shaft
Instrumentation located in Appendix A, Volume I Turbine Package Operators Manual for
instrumentation location.
Turbine Instrumentation
Thermocouples TC19 and TC20 mounted in the air inlet casing and thermocouples TC1 to TC13
inclusive mounted in the exhaust outlet monitor engine operating temperature deviation.
Additionally the output thermocouples monitor combustion condition and will shut the turbine
down in the event of flame out in one of the combustion chambers.
Single plus redundant thermocouples TC21 to TC24 inclusive, positioned in the appropriate
bearings, measure journal and thrust bearing temperatures.
Speed probes SD3 and SD6 are used for speed detection and over-speed protection. Speed
probes SD1 and SD5 are used for speed control indication and over-speed protection. Probes
monitor from the cold end of the compressor rotor.
X-Y non-contacting vibration probes (UD10X1, UD10Y1, UD11X1 and UD11Y1) adjacent to each
rotor journal bearing monitor radial vibration. Four spare probes (UD10X2, UD10Y2, UD11X2 and
UD11Y2) are also fitted as non-active spares.
Chapter 1
1-10
Axial non-contacting vibration probes (ZD10T1 and ZD10T2) monitor axial rotor movements at
the inlet end of the compressor.
A key phaser probe (ND10K1) provides a phase angle reference. A second key phaser probe
(ND10K2) is fitted as a non-active spare.
Pressure transmitter PT7 is provided to monitor the combustion air inlet static pressure and is
used in engine control.
Pressure transmitter PT8 is provided to monitor the compressor exit pressure. The signal is used
in engine control.
Pressure transmitter PT9 is provided to monitor the turbine exhaust pressure. The signal is used
in engine control.
Pressure transmitter PT258 is provided to monitor the interdict static pressure. The signal is
used in engine control.
Gearbox Instrumentation
An accelerometer (UD39) mounted on the gearcase monitors gearcase vibration and provides
warning and trip control functions.
Chapter 1
1-11
Lubricating Oil System
The mineral oil-based lubricating oil system supplies oil to lubricate and cool the following:
Turbine journal and thrust bearings
Gearbox gear teeth and bearings
Driven unit bearings
In addition, lubricating oil supplied by a hydraulic pump provides the hydraulic pressure needed
to operate the variable geometry stator (VGS) blades on the gas turbine.
General Description
The gas turbine lubrication system consists of three lubricating oil pumps and a hydraulic pump
for the gas turbine VGS system. This system also includes a temperature control valve, pressure
control valves, filters, instrumentation, and associated piping to provide the correct delivery
conditions.
Gravity drainage returns used oil to the tank to create a continuously circulating system. Oil
fumes generated while the turbine is running are vented to the atmosphere by the lubricating oil
tank breather system.
The schematic diagram of the lubricating oil system 1405039-C01-050 is located in Appendix A of
this Manual Volume.
Oil Tank
The lubricating oil tank is an integral part of the underbase fabrication and is provided with
internal baffles to aid circulation and maximize removal of entrapped air. Covers are provided to
facilitate cleaning of the tank interior if contamination occurs.
The tank is fitted with an immersion heater to maintain the correct prestart oil temperature.
Integral thermal protection is also provided.
A flip-lid filler with an integral strainer is provided for filling and replenishment of the oil supply. A
level gauge provides visual indication of the oil level within the oil tank.
Oil Pumps
An AC motor driven auxiliary pump (XP2) mounted on the lubricating oil tank provides lubrication
during prestart and initial run-up, and after turbine shutdown. This positive displacement gear
type pump is capable of providing the full package lubricating oil flow requirement. The pump is
equipped with an integral relief valve (PSV8).
The auxiliary pump purges the lubrication system and establishes and maintains lubricating oil
flow and pressure to the lubrication system before the gas turbine is started. During the prestart
period and while starting the turbine, the auxiliary pump primes the main oil pump and the
emergency oil pump piping, as well as supplying lubricating oil to the turbine bearings.
After the gas turbine is started and running, the control system shuts down the auxiliary pump
and the main oil pump supplies lubricating oil to the system. During gas turbine shutdown, the
control system restarts the auxiliary pump when the turbine slows to a preset speed and supplies
lubricating and cooling oil to the bearings during the shutdown process.
Chapter 1
1-12
A gearbox-driven main oil pump (XP1) supplies lubricating oil to the package during normal
operation. The positive displacement gear-type pump is equipped with an integral relief valve
(PSV7). A hydraulic pump (XP4) mounted in tandem with the main pump supplies lubricating oil
for control of the VGS blades on the gas turbine.
The main pump discharge goes to a temperature control valve (TCV1) to regulate the oil
temperature. Until the oil reaches a predetermined temperature, it is diverted around the cooler.
The oil is filtered by a duplex filter (XF2, XF3) before it is fed to the turbine bearings. A remote
sensing pressure control valve (PCV1) is installed in the system to maintain a nominal 30 PSIG (2
barg) operating pressure.
A hydraulic pump (XP4) controls the VGS system on the gas turbine. A pressure relief valve
(PSV12) and pressure control valve (PCV109) form part of the pump assembly.
A DC motor-driven pump (XP3), mounted on the lubricating oil tank, provides emergency
lubrication during a fire emergency shutdown. All AC power is isolated from the package, and the
DC-driven pump supplies oil only to the turbine hot bearing during and after shutdown. This
positive displacement gear-type pump is equipped with an integral relief valve (PSV9).
Non-return valves (XV46, XV273, XV271, XV5), located in each pump delivery system, control
circulation between the three pumps.
Oil Temperature Control Valve
A temperature control valve (TCV1) operates at a set value to divert lubricating oil through the oil
cooler as necessary to maintain oil temperature at the optimum level. The valve is also supplied
with a manual bypass.
A lockable manual drain shut-off valve (HV193) is positioned in a branch pipeline between the
temperature control valve and the cooler. The valve is opened only during commissioning or
following a maintenance activity to assist in the flushing or priming of the oil cooler. At all other
times, the valve must be locked in the closed position.
Oil Pressure Control Valve
A remote sensing pressure control valve (PCV1) maintains constant oil pressure to the bearings.
Excess oil is returned through the valve to the lubricating oil tank.
Oil Filters
Three high-pressure oil filters are provided:
The main duplex filter (XF2, XF3) is installed on the main line flow of lubricating oil
from the main and auxiliary pumps. Differential pressure gauges (PDI1 and PDI23)
indicate the pressure drop across the filter. A change over valve (HV184) enables
either filter to be isolated for maintenance without shutting down the gas turbine.
Either filter is capable of handling the full flow of oil.
The emergency oil filter (XF4), which is installed downstream of the DC motor-driven
emergency pump, filters the lubricating oil supplied to the engine in an emergency.
The VGS filter (XF11), which is installed in the hydraulic circuit, cleans the oil before
it reaches the VGS actuator.
Chapter 1
1-13
Oil Cooler
An oil cooler circuit incorporating an air blast oil cooler dissipates heat from the lubricating oil
before its entry into the main supply line. A temperature control valve (TCV1) controls oil flow to
the cooler circuit.
Hydraulic Pressure Control and Relief Valves
A pressure control valve (PCV109) maintains the hydraulic system pressure. A pressure relief
valve (PSV12) protects the pump in the event of control valve failure. Excessive oil pressure is
relieved by returning the oil to the lubricating oil tank.
A solenoid valve (SOL294) allows hydraulic pressure to operate the VGS actuator on demand.
The VGS actuator controls the position of the inlet guide vanes and first, second, and third stages
of compressor stator blades.
Oil Mist Eliminator
A static element type oil mist eliminator in the lubricating oil tank breather system reduces the
amount of oil mist exhausted to atmosphere.
Instrumentation
Instrumentation monitors the lubricating oil system parameters and provides warning and trip
control functions.
Temperature Monitoring
A thermocouple (TC75) mounted in the lubricating oil supply tank monitors the tank oil
temperature and provides a permissive signal for the tank immersion heater control. This
information also inhibits a start until the tank oil temperature is above a set value.
A thermocouple (TC61) and a temperature switch (TS2) mounted in the manifold block measure
the temperature of the lubricating oil. The information is used to display the oil temperature and
provide warning and gas turbine shutdown signals.
Pressure Monitoring
A pressure transmitter (PT6) mounted in the hot bearing supply line provides lubricating oil
pressure, low and high warning signals, and auxiliary and emergency lubricating oil pump control
signals. A pressure switch (PS4) mounted in the same line provides a low oil pressure shutdown
signal.
A differential pressure transmitter (PDT8) monitors the pressure drop across the main lubricating
oil filter assembly to provide a warning of deteriorating element conditions.
Each lubricating oil filter housing is fitted with a pop-up indicator button to provide a visual
indication of when a filter element needs replacement.
VGS Blade Position Monitoring
A potentiometer (ZT9) monitors the position of the VGS blades and inlet guide vanes.
Chapter 1
1-14
Driven Unit Oil Flow Monitoring
Local flow indicators positioned in the driven unit oil supply lines monitor oil flow to the driven
unit.
Oil Tank Level Monitoring
A level switch (LS2) is used to monitor the level of the oil in the lubricating oil tank. The
information provided is used to inhibit starts if the oil level is below a set value during the gas
turbine starting process and to initiate a warning or shutdown if the oil level falls below a set
value during normal gas turbine operation.
The level switch is also used to inhibit the operation of the immersion heater if the level of the oil
in the tank is below a predetermined level.
Lubricating Oil Requirements
In normal conditions, the turbine is designed to run on mineral oil to ISO/VG46 in accordance
with Fluids Specification 65/0027, located in Appendix A of this Manual Volume. Where it is
necessary to use a heavier or lighter viscosity grade of oil due to prevailing ambient conditions or
driven machinery requirements, ISO/VG68 or ISO/VG32 may be used respectively. However,
SIEMENS must be consulted before these alternative oils are used.

Caution: It is important to use the correct type of lubricating oil. The use of oil
with insufficient or incorrect additives will cause oil performance to deteriorate.
Chapter 1
1-15
Fuel System
The liquid fuel system is designed to deliver fuel to the combustion system at the correct
pressure and flow required for the applicable power demand.
General Description
A liquid fuel system is comprised of off-skid and on-skid components. The off-skid components
include:
A block valve
A low-pressure duplex fuel filter
Differential pressure indicators for each filter
A thermal relief valve
The following components are located in the turbine underbase:
An AC motor-driven fuel pump
A high pressure filter
Primary and secondary throttle valves
Solenoid operated shut-off valve assemblies
A piping system connects the components and delivers fuel to each burner. The piping
arrangement provides for forward and reverse purging of the liquid fuel during and after turbine
shutdown.
At the start of the turbine start cycle, the turbine control system purges the fuel system of air.
This purge cycle ensures that there is no air trapped in the system that might inhibit proper
combustion when the control system attempts to ignite the fuel during the turbine start cycle.
Only the primary fuel supply provides fuel to start the gas turbine and to operate the turbine
under light to medium loads. The secondary fuel supply provides the additional fuel required to
meet peak power demands after the turbine is running under load. When the turbine is running,
compressed air is introduced into the fuel stream at the fuel distribution manifold to the burner
assembly to atomize the fuel, thus assisting combustion.
The shutdown purge sequence prevents fuel from being trapped in the burners, decomposing,
and carbonizing or blocking the burner nozzle. When turbine shutdown is initiated, the controller
terminates fuel delivery to the turbine, and a reverse purge is initiated to force the unused fuel in
the primary and secondary fuel supply lines back to the fuel tank using the instrument air supply.
After a short delay, the turbine control module sequences the valves as necessary to force any
remaining fuel out of the burner injection nozzles and to cool them. The forward purge also
provides cooling for the burner walls to further assist in the prevention of blockages. The
schematic diagrams of the fuel system 1405039-C01-040 can be found in Appendix A of this
Manual Volume.
Chapter 1
1-16
Main Fuel Filter
The duplex fuel filter (XF19, XF98) is located off-skid and filters the incoming fuel before it
reaches the pump. Differential pressure gauges (PDI2, PDI49) indicate excessive pressure drop
across the filter element and possible filter blockage. A changeover valve (HV225) enables either
filter to be isolated for maintenance without shutting down the turbine. A thermal relief valve
(PSV13) prevents excessive pressure buildup on the low-pressure side of the fuel system.
Fuel Pump
An AC-driven main fuel pump (XP7) supplies high-pressure fuel to the primary and secondary fuel
supply lines through the high-pressure fuel filter (XF20). A control valve (XV217) regulates the
fuel pressure.
Throttle Control Valves
The pressure and stream control valves are controlled by the turbine control module. The primary
pressure control valve (XV215) and primary stream control valve (XV213) regulate the fuel flow
through the primary liquid fuel supply piping to the gas turbine burners. The secondary pressure
control valve (XV216) and secondary stream control valve (XV214) regulate the fuel flow through
the secondary liquid fuel supply piping to the gas turbine burners when the load demand is
sufficiently high to require the additional fuel.
Instrumentation
Instrumentation is provided to monitor the fuel system parameters and provide warning and
protective control functions if unsafe or damaging conditions are detected.
Fuel Block Valve Position Monitoring
A position switch (ZS10) monitors the closed position of the off-skid block valve (XV75). If the
position switch indicates that the block valve is closed prior to turbine start, a start inhibit signal
is initiated.
Solenoid Operated Shut-off Valve Assemblies
A liquid fuel valve (XV156) primes the liquid fuel system by purging air out of the system. In the
startup mode before the engine is ready for ignition, the liquid fuel valve returns the full flow of
the pump to the tank. The liquid fuel pump position transmitter (ZT92) monitors the valve
position.
The fuel block valves (XV154 and XV155) are the fuel shutoff valves to the gas turbine in the
primary and secondary fuel lines. The liquid fuel position transmitters (ZT3 and ZT106) monitor
the valve position.
The primary (XV157) and secondary (XV158) fuel spill line block valves control the return fuel
line. The liquid fuel position transmitters (ZT91 and ZT107) monitor the valve position.
The (XV238) valve is the reverse purge drain shutoff valve assembly. The fuel position switches
(ZS440 and ZS441) provide valve position monitoring.
The instrument air block valve assembly (XV148) purges the burner assembly using instrument
air. The air position transmitter (ZT111) monitors the valve position.
Chapter 1
1-17
A secondary air purge gas generator (XV152) purges the burner assembly using gas generator
air. The air purge position switches (ZS382 and ZS383) monitor valve positions.
The valve assembly (XV195) is a three-way valve that air assists the burner assemblies. The
position transmitter (ZT128) monitors the valve position.
The instrument valve assembly (XV147) is a three-way valve used for instrument air purge
control. The instrument air position transmitter (ZT110) monitors the valve position.
An air pressure control valve (PCV86) maintains the air purge to the burner.
The bypass valve (SOL471) supplies instrument air for air assist.
The solenoid valve (SOL111) controls instrument air purge to the liquid fuel burner.
Liquid FuelPrimary and Secondary Manifold Drain Valves
Position transmitters monitor the closed and open position of the primary (ZT79) and secondary
(ZT78) manifold purge drain valves.
Information on the position of the drain valves switches is also used to determine if the valves
are in the correct position during turbine start and operation.
Fuel Filter Pressure Monitoring
A differential pressure transmitter (PDT6) provides a warning of deteriorating element conditions
by monitoring the pressure drop across the low-pressure fuel filter assembly. Pressure differential
indicators (PDI2, PDI49) provide a visual indication of excessive filter element blockage.
Fuel Pump Pressure Monitoring
A pressure transmitter (PT10) monitors fuel pump suction for low or high pressure. The
information is used to initiate start inhibit, warning, and turbine shutdown signals.
Liquid Fuel Manifold Pressure Monitoring
A pressure transmitter (PT163) monitors the pressure in the reverse purge drain line. The
pressure transmitter initiates a permission to purge, low/high pressure warning, and high-
pressure shutdown signals.
Forward Purge Air
A pressure transmitter (PT238) monitors the instrument air forward purge supply to the burners.
The pressure transmitter initiates low- and high-pressure warning and shutdown signals.
Instrument Air Purge
A pressure switch (PS92) monitors the instrument air purge control to the liquid fuel burner.
Burner Instrumentation
Six thermocouples (TC255TC260) mounted in each of the burner assemblies continuously
monitor burner operation and provide operational data to the turbine control system. Six reserve
thermocouples (TC255RTC260R) are available if one of the primary devices fail.
Chapter 1
1-18
Fuel and Air System Requirements
For more specific information on fuel requirements, refer to SIEMENS Fluids Specification
65/0027 located in Appendix A of this Manual Volume.

Note: Skid edge connection by customer.

Instrument Air Supply
The following section discusses the instrument air supply functions and requirements.
Instrumentation
The pressure transmitter (PT185) monitors the instrument supply pressure. The pressure
transmitter initiates high- and low-pressure warning and shutdown signals.
Table 1-1 Instrument Air Supply Requirements
Air System Parameter Minimum Maximum
Supply Pressure 5.5 barg (80 psig) 6.9 barg (100 psig)

Chapter 1
1-19
Ignition System
During the start-up cycle, a high-energy pulse spark from the ignition system is used to ignite the
combustion chamber fuel/air mixture.
General Description
The ignition system is comprised of a multiplexer spark generator unit mounted in the underbase
and two retractable igniters (IG1 - IG2), one in each of two combuster flame tube. High-tension
leads enclosed in an armored conduit connect the units.
High-Energy Spark Generators
The high-energy spark generator is a capacitor discharge system encapsulated within a steel
enclosure with appropriate supply and high-tension terminations.
Retractable Igniter Assembly
The retractable igniter assembly is comprised of an igniter rod mounted on a piston-operated
retractor.
The retractor piston is spring loaded in the out position with the igniter rod inserted into the
flame tube.
During the starting cycle, the increasing combustion system pressure acts on the piston to
overcome the spring pressure and retract the igniter rod.
Chapter 1
1-20

Chapter 1
1-21
Starting System
The starting system consists of an AC electric motor driven by a variable speed drive. The motor
is coupled to the gearbox through a clutch. The gearbox rotates the gas generator compressor
shaft during the start cycle. The clutch limits the torque applied to the gearbox to prevent
damage to the motor or gears.
General Description
The AC electric starter motor is mounted on a pedestal on the gearbox. A variable-speed drive
controls the AC motor speed. The motor is capable of three consecutive attempted starts with a
five-minute rest period between starts. The cycle can be repeated after 10 minutes of cooling
time. For compressor cleaning purposes, the motor can also drive the turbine for a 10-minute
period.
If the engine fails to reach a predetermined speed within a specified time, the current
limiter/fault protection circuit will operate to stop the starter motor. Thermistor temperature
detectors, integral to the motor, are installed to protect against thermal overloads. These devices
will prevent the motor from being operated until its windings have cooled to a safe temperature
before attempting another start. If a thermal overload on the motor is detected during the start
cycle, the motor will automatically shut down, and the start cycle will be aborted.
Instrumentation
Temperature detectors (TD6, TD8, TD10) are integral to the AC starter motor and provide for
overload protection.
Chapter 1
1-22

Chapter 1
1-23
Underbase and Acoustic Enclosure
The underbase forms a structure for mounting the turbine, gearbox, generator, and associated
systems.
An acoustic enclosure is provided over the turbine and gearbox and also may be provided over
the generator driven unit to reduce machinery noise levels to an acceptable level. A ventilation
system is used to purge the turbine enclosure prior to a start, to cool the turbine while it is
running and for a period following shutdown, and to ventilate the enclosure. Separate ventilation
is included to cool the generator while it is running.
General Description
A single-piece underbase of fabricated steel construction, which incorporates an integral
lubricating oil tank, provides mounting points for the main turbine and gearbox support, the
turbine combustion casing support, and the generator mounting feet. Torque reactions between
the turbine and gearbox assembly and the generator are transmitted from the fabrication to the
foundation upon which the underbase is mounted through multiple mounting pads and
foundation bolting.
The underbase incorporates mounting points for all the turbine support systems. Customer
supply, vent, and drain connections are integrated into the main side members of the fabrication.
The underbase also incorporates integral plating on the underside of the fabrication that forms a
spillage collection feature for any system leakage.
The turbine acoustic enclosure is comprised of a load-bearing framework with removable
paneling and hinged doors mounted on the turbine underbase. Sound attenuation is achieved by
a combination of material thickness, acoustic filler material, and an acoustic skirt, if required.
The ventilation system draws air from the atmosphere and directs it through ducting and system
components before discharging it back to the atmosphere in a safe area.
Fire extinguisher-activated dampers are located at the gas turbine enclosure ventilation inlet and
outlet openings. These dampers close positively when subjected to extinguisher pressure. The
outlet damper is supplied with a spring-loaded flap to prevent over-pressurization of the
enclosure.
The dampers require manual resetting to the open position after fire extinguisher release.
A schematic diagram of the ventilation system 1405039-C01-080 is located in Appendix A of this
Manual Volume.
Inlet and Outlet Silencers
Silencers are provided to reduce noise emissions through the ventilation ducting from the gas
turbine and the package ventilation fans.
Chapter 1
1-24

Chapter 1
1-25
Package Air System
The package ventilation system consists of:
The combustion air intake system
The exhaust system
The gas turbine ventilation system
The generator ventilation system
Combustion Air Intake System
The combustion air intake system filters and delivers the air necessary to support combustion to
the turbine inlet casing. This system incorporates a silencer to reduce noise emissions from the
turbine intake.
General Description
The combustion air intake system consists of an air intake filter, air intake silencer, and
associated ducting.
A flexible joint is included in the system to compensate for thermally-induced movement between
the inlet ducting and the turbine inlet casing.
A schematic diagram of the air intake system 1405039-C01-080 is included in Appendix A of this
Manual Volume. Refer to the manufacturers documentation entitled Cullum Installation,
Operation, and Maintenance Instruction Manual located in the Cullum section of Volume V Vendor
Information Manual for additional information regarding the combustion air intake system.
Air Intake Filter
The main filter section is a pulse cleaning type filter. Refer to the manufacturers documentation
Cullum Installation, Operation, and Maintenance Instruction Manual located in the Cullum section of
Volume V Vendor Information Manual more information regarding the air intake filter.
Air Intake Silencer
A silencer reduces noise emissions from the turbine air intake.
Instrumentation
Pressure switch (PDS17) provides pulse cleaning sequence for the air filter. The system is also
fitted with a differential pressure transmitter (PDT1) and gauge (PDI9) to provide visual reading
of the pressure drop across the filter elements. High differential pressure indicates that filter
maintenance is required.
Combustion Exhaust System
The exhaust system ducts the turbine exhaust gases to atmosphere and incorporates a silencer
to reduce noise emissions.
Chapter 1
1-26
General Description
The exhaust system consists of an exhaust silencer, diffuser and thermocouples. Acoustic flexible
joints must be installed in the system to compensate for thermal movement within the turbine exhaust
ducting. Insulation must also be installed to provide heat and noise protection from the exhaust
system.
Exhaust Silencer
The exhaust silencer reduces noise emissions from the turbine exhaust.
Instrumentation
Thirteen thermocouples (TC1-TC13) monitor the exhaust component temperature to ensure
proper gas turbine operating conditions.
Gas Turbine Ventilation
Cooling air is filtered, ducted to the turbine to maintain operating temperatures within prescribed
limits, and exhausted to the atmosphere.
General Description
Ambient air is filtered and ducted to an inlet silencer to reduce noise pollution. An AC
motor-driven fan located in the outlet duct draws air through the turbine enclosure and exhausts
it to the atmosphere.
Dampers
Air inlet and outlet dampers located in the turbine cooling air ducts close in the event of a fire.
Once closed, these dampers must be manually reset before the gas turbine can be restarted.
Instrumentation
Airflow is monitored by a switch (FS1) to provide a warning if turbine air flow drops below
prescribes limits.
Two switches (ZS16, ZS17) monitor damper position to provide a permissive signal for engine
start.
Generator Ventilation
Cooling air is filtered, ducted to the generator to maintain operating temperatures within
prescribed limits, and exhausted to the atmosphere.
General Description
Cooling air is filtered and then ducted to the generator to maintain operating
temperatures within prescribed limits. Separate inlet and outlet ducting is provided for the
generator.
Chapter 1
1-27
Instrumentation
Generator winding RTD's (RTD 25-30) provides a warning signal to the turbine control module if the
generator overheats.
Chapter 1
1-28

This page is intentionally left blank.
Chapter 1
1-29
Compressor Cleaning System
The compressor cleaning system is designed to remove fouling from the compressor blades and
achieve performance recovery by an online wash of the compressor while the turbine is running
under load or by an offline wash while the turbine is rotated by the starter motor.
General Description
The system consists of a mobile water wash trolley containing a cleaning fluid and rinse water
tank and an electric motor driven pump. The trolley is supplied with a flexible hose for connection
to the turbine skid water wash inlet connection.
The fluid is routed through turbine skid pipework and a final wash filter to the turbine-mounted
water wash injection nozzles.
To prevent combustion chamber flame out during an online wash cycle, cleaning fluid is injected
into the compressor while the engine is running at medium to high load.
Depending on site conditions, online washes should be carried out every two to three days to
prevent fouling of the compressor. Offline washes are performed at less frequent intervals to
remove severe fouling that cannot be rectified by the online wash cycle.
During an offline wash, the turbine rotor is slowly rotated while the cleaning system cycles
through an injection, soak, drain, rinse, drain sequence. During the offline wash sequence, air is
injected into the compressor labyrinth seals to prevent cleaning fluid contamination of the
lubricating oil and seal air systems. The air is also used to overcome blow-off valve spring
pressure to drive the normally open valves to the closed position for the duration of the offline
wash sequence.
A drain system, incorporating automatic drain valves drains the turbine and exhaust of excess
fluids.
A schematic diagram of the Compressor Cleaning System 1405039-C01-060 is located in
Appendix A of this Manual Volume.
Instrumentation
A pressure switch (PS60) monitors the air pressure to the labyrinth seals during the offline wash
cycle and provides permission-to-start-wash and low-air-pressure-alarm signals.
Compressor Cleaning System Requirements
Wash Trolley Air Supply
Table 1-2 provides the wash trolley air supply pressure requirements.
Table 1-2 Wash Trolley Air Supply
Requirement Pressure
Maximum supply pressure 100 psig (6.89 barg)
Minimum supply pressure 80 psig (5.5 barg)
Chapter 1
1-30
Water Wash Trolley Tank
The water wash trolley tank capacity is twenty (20) U.S. gallons (75 liters).
Compressor Washing Water and Cleaning Fluids
Compressor washing water and cleaning fluids must meet the criteria of SIEMENS Fluids
Specification 65/0027 located in Appendix A of this Manual Volume. This specification, along with
a list of approved manufacturers cleaning fluids, can be obtained from SIEMENS Customer
Service Department.
If the cleaning fluid is supplied as concentrate, dilute it with demineralized water according to
manufacturer instructions before injection into the engine.
Add antifreeze to the cleaning fluid for a wash in low ambient temperature in order to prevent
the formation of ice on the compressor.
This antifreeze should be mono propylene glycol-based.

Caution: Online washing should never be carried out when the ambient air
temperature is below 14F (-10C).
Table 1-3 Online Wash Cleaning Fluid Antifreeze Requirement
Ambiant Air
Temperature
Compressor Air
Inlet Temperature
Mono propylene
glycol
Volume
+50
o
F (10
o
C) 32
o
F (0
o
C) 20%
14
o
F (-10
o
C) -4
o
F (-20
o
C) 30%

Table 1-4 Offline Wash Cleaning Fluid Antifreeze Requirement
Ambiant Air Temp Mono propylene glycol Volume
41 to 23
o
F (+ 5 to - 5
o
C) 20%
23 to -4
o
F (- 5 to -20
o
C) 30%
-4 to -22
o
F (-20 to -30
o
C) 40%
-22 to -40
o
F (-30 to -40
o
C) 50%

Caution: Due to the combustibility of mono propylene glycol, the percentage
quantities listed in the above table MUST NOT be exceeded. Mono propylene
glycol may be treated on some sites as a hazardous substance.
For an offline wash in a low ambient temperature, the 30% limit on mono propylene glycol does
not apply, because the engine remains unfired. However, because cleaning efficiency is reduced
as the volume of mono propylene glycol increases, the use of more than a 50% volume of mono
propylene glycol is not recommended. Due to the low air velocity in an offline wash, temperature
drop is negligible and cleaning in ambient air temperatures down to 40 degrees Fahrenheit (-40
degrees Celsius) can be carried out. Refer to Table 1-3 and Table 1-4 for the volume of mono
propylene glycol required at various ambient temperatures.
Chapter 1
1-31
Fire System
A fire monitoring system and a fire extinguishing system are provided to protect the installation if
a fuel leak or fire is detected. A schematic diagram of the fire and gas extinguishant system
1405039-C01-090 is located in Appendix A of this Manual Volume.
General Description
The system consists of ultra-violet flame detectors and heat detectors mounted in the turbine
enclosure. Fire extinguisher cylinders are mounted externally to the enclosure with an associated
release mechanism that delivers the CO
2
through pipework to nozzles located inside the
enclosure. The fire- and gas-monitoring module located within the turbine control module
automatically controls the system. Two manual discharge buttons located on the outside of the
enclosure and one on the turbine control module enable manual operation of the system. Audible
and visual alarm units are fitted to the turbine enclosure roof to signal that the fire system has
detected a fire and that personnel should leave the immediate area.
Ventilation dampers, which are located in the enclosure ventilation inlet and outlet ducts, are
used to prevent the loss of extinguisher to atmosphere if a fire occurs. When the fire and gas
extinguishing system is activated, the dampers are automatically closed by extinguisher that is
directed from the extinguisher cylinders to actuators connected to the dampers.
System Control and Operation
A twin shot system provides initial 100% plus 100% reserve extinguisher charges. If a fire is
detected by the heat detectors or ultra-violet flame detectors, the control system:
Isolates all AC power supplies.
Shuts down all fuel systems.
Isolates all fuel systems.
Starts the DC motor-driven lubrication oil pump.
Activates lights and horns to warn personnel to clear the area.
Releases the initial charge of CO
2
after a 30-second delay .
The initial CO
2
release causes the ventilation dampers to close. These dampers must be manually
reset before the gas turbine can be restarted.
Following a 90-second delay, the control system resets the fire detection system and continues to
monitor the heat and flame detectors. If a fire is detected within the next three hours, then the
reserve shot of CO
2
is released and the DC motor-driven lubrication oil pump is isolated. Isolating
the emergency lubrication oil pump will probably cause damage to the turbine bearings and
instrumentation. If no indication of fire is detected within this period, the reserve shot of
extinguisher is NOT released and the DC motor-driven lubrication oil pump continues to run.
The CO
2
extinguisher cylinders must be isolated from the engine package during maintenance. A
signal from the isolation valve inhibits a gas turbine start attempt when the valve is in the
isolated position.
Chapter 1
1-32
Heat Detectors
Two heat detectors (TD1, TD2) are mounted in the turbine enclosure. If either heat detector
detects a fire, the fire shutdown sequence is initiated immediately, and the CO
2
is released after
a predetermined time delay.
Flame Detectors
Four flame detectors (YD7YD8) are mounted in the turbine enclosure. If two flame detectors
detect a fire, the fire shutdown sequence is initiated immediately, and the CO
2
is released after a
predetermined time delay.
Extinguisher Bottles
Two initial and two reserve bottles are positioned on a skid outside the turbine acoustic
enclosure, with connecting pipework to nozzles within the enclosure.
The fire extinguisher is released by either a signal from the turbine control module or manual
activation from the manual button located on the corners of the turbine enclosure package and
one on the turbine control module. Both sets of bottles can be manually fired by operating the
manual lever actuators located on the tops of the bottles.
A valve (HV142) is located adjacent to the extinguisher bottle skid for manual isolation. The valve
is fitted with limit switches (ZS235, ZS384) to indicate when the valve is fully open or closed.
When the valve is closed, the enclosure vent system trip and gas turbine start are inhibited.
Instrumentation
Pressure switches (PS8, PS73) provide the turbine control module with a CO
2
Gas Gone warning
for both initial and reserve cylinders respectively.
Position switches (ZS384, ZS235) monitor the open and closed positions of the CO
2
isolation
valve.
Chapter 1
1-33
Generator
The driven unit generator is of salient-pole construction with brushless excitation; it has a
permanent magnet generator for the automatic voltage regulator power supply. The design of
the generator facilitates commissioning, operation, inspection, and maintenance of the generator.
General Description
All the items that comprise the generator are fixed to the base frame, which is the main
structural member. It carries the bearings, main stator core-pack, and overall cover. The exciter
stator and permanent-magnet generator stator are fixed to an extension of the main baseframe
at the non-drive end.
For more information, refer to General Arrangement Drawing 1405039-B01-001, located in
Appendix A of this Manual Volume, as well as the manufacturers documentation entitled
9300-0018 WEG Generator Operations and Maintenance Manual located in Volume III Driven Unit
Manual.
Ventilation and Cooling System
Ventilation air provides generator cooling. The air enters the generator from an external
source that provides the same ambient temperature as that for the turbine intake. Refer to the
Generator Ventilation section in this Manual Volume for additional information.
Generator Bearing Lubrication
The generator bearings are supplied with lubricating oil from the turbine lubricating oil system.
Refer to the Lubricating Oil System section of this Manual Volume for additional information.
Electrical Operation
The AC generator converts mechanical energy into electrical energy by electro-magnetic
induction. To produce a voltage, there must be a relative motion between the armature windings
of the stator and the field windings of the rotor. The motion is produced by the action of the gas
turbine engine turning the rotor through the gearbox.
An automatic voltage regulator (AVR) controls the DC power from a permanent magnet
generator for driven unit excitation. A manual method for excitation control is provided as a
backup to the automatic voltage regulator. Refer to the manufacturers documentation entitled
9-3601-00-990 Instruction Manual for Digital Excitation Control System DECS-200 located in
Balser Section, Volume V Vendor Information Manual. Engineering Data Sheet S2M-7 DECS-200
Digital Excitation Control System is also available for reference in the previous mentioned section.
A power factor/VAR control circuit enables the generator to operate at constant power factor or
constant VARs when in parallel with the public supply. In island mode, MVAR sharing between
generators is using voltage drop or cross-current compensation.
The over current limit circuit protects the AVR and generator excitation system against overloads
by limiting the maximum excitation output from the AVR.
An excitation fault detector detects the improper operation of the generator caused by faulty
excitation. The diode failure detector provides additional protection by warning of shorted or
open diodes in the exciter diode ring.
Chapter 1
1-34
Instrumentation
One resistance temperature detectors are fitted to all bearing housings to monitor bearing
temperature and provide warning and turbine shutdown functions if the temperature reaches
predetermined levels. A second RTD is fitted on each bearing as a spare.
Vibration Monitoring
The generator is monitored for vibration by velometers located at the drive end and non-drive
end bearings. The velometers provide warning and turbine shutdown functions if vibration
reaches predetermined levels.
Generator Winding Temperature Monitoring
Resistance Temperature Detectors (RTDs) are fitted on the stator windings to monitor
temperature and to provide warning and turbine shutdown functions if the temperature reaches
predetermined levels.
Chapter 1
1-35
Generator Control System
The generator control system protects and monitors the operation of the generator.
General Description
The generator control system consists of a cubicle housing various metering, indication, control,
protection, and synchronizing devices and instrumentation as well as the panel switches that
enable generator functions.
Operation
Control of the generator is achieved through a Generator Control Panel (GCP). Links exist
between the GCP and the Turbine Control Panel to enable emergency stop, raise, and lower
command signals.
For specific details of the GCP, refer to the manufacturers documentation entitled M & I MCC
Generator Control Documentation located in section M & I, Volume V Vendor Information Manual.
Chapter 1
1-36

Chapter 1
1-37
Electrical Equipment
This section describes details of the electrical equipment associated with the turbine package.
General Description
For turbines with off-skid electrical controls, the major components of the electrical system
include:
Electrical cables
Junction Boxes
Battery Charger
Unit Control Panel
Generator Control Panel
Motor Control Center
AC Distribution Panel
DC Controller / Emergency DC Lube Contactor
Engine Control Unit
Igniter Control
Electrical Cables
The cabling on the package is either MEPR or PTFE cable, depending on the duty to be
performed. Cables are routed between items of equipment and junction boxes located on the
outside of the underbase to connect to site cabling.
Junction Boxes
Each of the following junction boxes provides connections for a specific range of electrical
functions:
AC junction boxConnection of on-skid AC equipment
Non-IS junction boxConnection of DC circuits
IS junction boxConnection of intrinsically safe circuits
SD probe and thermocouple junction boxConnection of speed probes and
thermocouples
Option/CSR junction boxConnection for customer-specific options
Vibration junction boxFitted for connection to eddy current probes
Fire and gas junction boxFitted for connection to fire and gas equipment
Liquid fuel junction boxContains the remote I/O for the liquid fuel and associated
controls
Fire detection junction box (JB5)Provides an interface between the fire detectors
and the fire detection/suppressor control in the generator control panel
Chapter 1
1-38
Battery charger
A battery charger and batteries provide the DC supply. The supply is directed through a DC
distribution plate to the package systems.
AC supply to the battery charger is provided from the AC distribution panel.
Unit Control Panel
The Unit Control Panel (UCP) contains the main turbine control PLC and the central processing
unit (CPU). The UCP also houses the vibration detector controls, the fire detection/suppression
controller, and the overspeed protection module.
Generator Control Panel
The generator control panel (GCP) panel contains the automatic voltage regulator (AVR) and
associated contactors and control relays. The AVR consists of a digital primary controller, manual
voltage controller as a backup, diode ring failure detection module, and a module to detect
exciter failure. The GCP provides both manual and automatic synchronization controls for the
turbine generator. The GCP also functions as a power meter of the generator output.
A generator digital protection relay provides additional generator protection.

Note: Off-skid MCC is provided for all on-skid and off-skid loads associated with
the Turbine Generator Package. Refer to the manufacturers documentation M & I
MCC Generator Control Documentation located in section M & I for more details.
Motor Control Center
The Motor Control Center (MCC) provides AC motor control for on and off skid AC motors
associated with the turbine, for starting, fans, lubricating oil pumps, heaters and so forth.
AC Distribtuion Panel
The AC Distribution Panel is the source of the 120/240 volt power for the battery charger,
lighting, and for various space heaters located in the panels and motors.
DC Controller / Emergency Lubricating Oil Pump Motor Contactor
The DC controller distributes the DC input from the battery charger to the different DC loads.
The DC controller also houses the relays that control the power to the motor that drives the
emergency lubricating oil pump and provides isolation from a potentially explosive environment.
Engine Control Unit
The engine control unit (ECU) reads the speed reference signal from the PLC and controls the
gas or liquid fuel actuators.
Igniter Controller
The AC igniter controller provides the signals necessary to generate the high voltage necessary to
ignite the fuel-air mixture inside the turbine during the start procedure.
Chapter 1
1-39
Turbine Control Module
The turbine control module provides control signals and monitoring for all the turbine systems
and associated instrumentation to allow safe starting, normal running, and safe shutdown of the
gas turbine.
The system, which is microprocessor-based, provides control and monitoring functions including:
Turbine sequencing and protection
Fault monitoring
Fault or status change annunciation
Gas turbine speed control and temperature monitoring
Vibration monitoring
Generator bearing and winding temperature monitoring
Fire and gas monitoring
Maximum consideration has been given to all safety aspects of the control system. Extensive
watchdog and self-testing features are built-in, and a hardwired emergency stop loop is provided
to ensure that all fuel systems are shut off in the event of a complete system failure.
General Description
The control module is housed within a cabinet that consists of a rack assembly mounted in a
hinged frame and terminal rails mounted on the inside faces of the cabinet side panels.
The operator/controls interface is through a remote panel PC and VDU with a touch screen.

Control Console
The features of the industrial-type panel PC that provide the control and monitoring user
interface include:
Minimum processor capability of an Intel Celeron 566MHz processor
Installed memory of 128MB
Minimum hard disk capacity of 10.2GB
Video RAM of 4MB
Horizontally mounted 3.5-inch floppy disk drive
Horizontally mounted, 2X write speed rewriteable CD-ROM
System Access and Data Entry
A keyboard and mouse are used to access and input data to the system, including software
maintenance information as well as configuration of the display system and the process controller
software.

Chapter 1
1-40

Figure 1-1 Turbine control cabinet
Control Data and Status Display
A touch screen display provides control data and status information on the control processes.
The displays are selected by using touching the approriate sections to make selections
using a menu system.
Operator Panel
This panel contains dedicated pushbuttons and status lamps to enable the operator to monitor
and control operation of the turbine and generator. Control mode and emergency lubrication oil
pump control selector switches are also mounted on the panel.
A fire break glass unit is placed on the left of the control panel and an emergency stop button is
placed on the right on the control panel.
Control Cabinet Hardware Interface Chassis
The Allen Bradley ControlLogix logic controller chassis is located inside the cabinet. The chassis
provides slots to accept electronic interface modules. The modules plug into electrical
connections at the back of the chassis.
The interface modules are provided to control and monitor the turbine frame and systems
components and to support the internal management/control and monitoring of the control
system.
Chapter 1
1-41
The modules are positioned in numbered slots, as shown in Table 1-5 and described in the
following paragraphs.
Table 1-5 Control module slot assignments
Slot Number Module
PSU 24V DC power supply unit
00 3.5MB controller module
01 Special Applications Module (Core Engine Control)
02 Vibration monitoring module
03 Spare slot
04 DeviceNet module
05 ControlNet module
06 Ethernet module
07 16-channel DC I nput module
08 16-channel DC Output module
09 Spar e sl ot
10 Spare slot
11 Spar e

24V DC Power Supply
A 24V DC power supply unit (PSU) is located on the left side of the ControlLogix rack. This PSU is
supplied from the cabinet 24V DC regulated power supply through a rail-mounted miniature
circuit breaker (MCB).
3.5MB Controller Module
The controller is a ControlLogix 5555 Processor module with a factory-installed 3.5MB battery-
backed static RAM. The multitasking operating system of the ControlLogix platform supports 32
configurable continuous or periodic tasks that can be prioritized for executing the program code
according to the application. Up to 32 programs, each with its own local data or ladder logic, may
be assigned to a task, allowing virtual machines to operate independently within the same
processor.
The controller implements a power-up handler that clears initialization flags, powers the vibration
and overspeed monitoring equipment, and activates the controller watchdog.
When a major fault is detected, the controller uses the controller watchdog contacts to
implement a major fault handler to break the emergency stop loop.
Special Applications Module
The Special Applications Module (SAM) provides a PC-based platform that runs the Core Engine
Controller (CEC). The primary objectives of this controller are:
Chapter 1
1-42
Turbine governing
Turbine temperature control
Turbine guide vane control
The controller interfaces with the on-skid fuel valve/guide vane control system through a
DeviceNet link. The interface to the ControlLogix Processor Module is provided over the chassis
backplane, with a DeviceNet scanner module interfacing with the on-skid Electronic Control Unit
(ECU) over DeviceNet.
ModBus Communication Module
This module is a variant of the Allen Bradley Multi-Vendor Interface module.
Port PRT1 is reserved for programming the module using an RS-232 cable and text-based
communication terminal. Port PRT2 interfaces with the Bently-Nevada 3500 Vibration Monitoring
System, which monitors the turbine and compressor vibration as well as acoustic pressure
sensors.
This module has its ports configured as Modbus Master, thus allowing it to interrogate the
Modbus interface on external slave devices in order to retrieve runtime process data from the
device.
Digital Input Module
The digital input module provides 16 switch inputs that are used for higher priority inputs, such
as fire or gas and emergency shutdown signals.
Analog Input Modules
These modules provide either 16 single-ended analog inputs or 8 differential inputs. They are
used to incorporate external analog signals into the control system for providing control
information to be displayed on the turbine controls display or relayed to other systems.
Isolated Digital Input-Output Module
The Isolated DC Input-Output module provides 16 outputs that are used for high-priority outputs,
such as fire and gas and emergency shutdown signals.
Ethernet Module
The Ethernet module provides the gateway to the controller for the following components:
Ethernet hub
Remote station control system telemetry
Programming and configuration software
DeviceNet Module
The DeviceNet module facilitates the connection of DeviceNet devices to the ControlLogix system.
The DeviceNet module is used primarily for connection to the on-skid ECU, which provides the
core controller functions. Any connection failure by a DeviceNet module with the controller in run
mode initiates a major fault on the controller.
Chapter 1
1-43
ControlNet Bridge Module
The ControlNet module facilitates the connection of an additional chassis and other ControlNet
devices to the ControlLogix system.
ControlNet System
The ControlNet system network provides fast and efficient gathering and control of I/O data from
the ControlNet nodes at predetermined intervals.
Gateway Module
Each ControlNet node has a Gateway module. This module forms the interface between the
ControlNet trunk cable and the I/O modules. Up to eight I/O modules can be stacked on to the
gateway module. The gateway module and the Flex I/O modules communicate with each other
through a FlexBus interface. The gateway module features a pair of thumbwheel switches that
are used to set the ControlNet address of the gateway. A network access port (NAP) allows a
handheld terminal to be connected to the network for diagnostic purposes. The gateway module
is dual-redundant and has two coaxial sockets, one for each bus.
I/O Modules
I/O modules include:
Digital Output module with 24V DC 16 channel capacity
Digital Input module with 24V DC 16 channel capacity
Electronically Fused module at 24V DC
Eight Relay Sink/Source modules
Frequency module with two channels
Thermocouple/RTD Analog Input module with 8 channels
Isolated Analog module with 4 channels
Refer to the package maintenance manual for module use.
ControlNet Nodes
The ControlNet system I/O interfaces with the package systems through system nodes that are
configured for system control and monitoring.
Vibration Monitoring Control Panel
The Bently-Nevada vibration monitoring rack provides slots to accept electronic interface
modules. The modules plug into electrical connections at the back of the chassis.
The interface modules measure and monitor the mechanical condition of the rotating elements of
the turbine and driven unit. Warnings are displayed on the VDU (IDS) or a turbine shutdown is
initiated if preset vibration levels are exceeded.
Chapter 1
1-44
Fire Protection System
The fire and gas panel located within the cabinet provides complete protection for the package.
The panel is powered from a separate DC supply in the control system DC supply. Audible and
visual alarms are initiated on any fire or gas devices connected to the panel. Full integration into
the control system, displaying fire and gas system status and health, is achieved with a ControlNet
link to the programmable logic controller and hard-wire connections to the emergency stop system.
Overspeed Module
A dedicated, stand-alone overspeed module is located within the control cabinet. The input to
this module is directly fed from the package speed probes. The output is a relay contact that
breaks the emergency stop loop when turbine overspeed is detected. The module implements a
three channel voting system that prevents nuisance trips and requires two channels to detect
overspeed in order to trip the emergency stop loop. The module is also able to detect speed
probe open circuit and signal failure.
Controls Software Interface
The turbine control system software is divided into two areas:
Frame and system/control system
Core engine
The frame and system/control system software resides on the ControlLogix controller, while the
core engine software is incorporated into the SAM. The turbine system software architecture is
modular.
Fire Module
This software interface is provided so that the controller can determine the condition and status
of the fire and gas system and any alarms or trips annunciated. The fault status of the system is
also monitored by the controller.
System Monitoring and Control Module
This module monitors the condition of the 24V DC supply, the internal circuit breakers, and the
cabinet battery charger. This module is also responsible for monitoring and switching the SAM
watchdog.
Panel Support Module
This module drives the operator panel lamps and counters to reflect the current state and
operation of the turbine.
Command Link Module
This module processes all turbine operation requests, such as start, stop, increase speed, and
reduce speed. These commands typically originate from the operator panel, although an
additional interface is provided for either hardwired remote pushbuttons or control through a
network.
Chapter 1
1-45
Enclosure Ventilation Module
This module controls and monitors the purging and ventilation of the package acoustic enclosure.
Turbine Combustion Inlet Module
This module monitors the combustion inlet filter for high differential pressure, which indicates
when the filter is blocked.
Air Supply Module
This module monitors the instrument air supplies for low/high pressure alarm and trip levels.
Vents and Drains Module
This module monitors the turbine engine drain tanks and lines.
Turbine Start Module
The Turbine Start module is responsible for starting the turbine and plays a key role in stopping
the turbine and resetting the system for further turbine operation. It is responsible for the
coordination and synchronization of various stages during a start, from fuel valve proving and
instrument state testing through shaft acceleration to spin speed, ignition, and acceleration to a
minimum governing speed.
Turbine Starter Module
Rotation of the gas turbine during starting is achieved using a variable speed drive (VSD) motor.
The input to this starter control module is a demand speed, which is determined by the start
sequence control. When a demand to the starter is received, the VSD demand is ramped up until
the gas generator speed approaches the demand speed. Control of the VSD is then achieved by
PID loops.
Turbine Bearing Temperature Modules
These modules monitor bearing temperature levels against predefined alarm and shutdown set
points to provide protection from high temperatures.
Turbine Vibration Module
This module monitors bearing vibration levels against predefined alarm and shutdown set points
to provide protection from high vibration.
Lubricating Oil Module
Lubrication oil is used to reduce friction in the moving parts of the engine and to assist in heat
removal from areas such as the turbine shaft bearings. Lubrication oil supply pressure monitoring
ensures that the engine is tripped when the pressure is low and protects the engine if pump
failure occurs. This module ensures that a sufficient supply of oil is provided to those areas of the
system that require cooling/lubrication by operating auxiliary or emergency oil pumps, depending
on the operating condition of the turbine and its auxiliaries. Oil heaters and coolers are also
controlled by this system to maintain the lubricating oil temperature within optimum operating
parameters.
Chapter 1
1-46
Turbine Wash Module
A wash system is implemented with the turbine package. When it is activated, this module is
responsible for operating and managing the turbine wash system.
Interstage Bleed Module
This module controls and monitors the air supply pressure to the turbine labyrinth seals and
blow-off valves.
Core Messaging Modules
These modules allow the controller to manage the message data received from the CEC, which
runs on the special applications module. The CEC sends data on alarms to a local or remote
interface, and initiates shutdown of the turbine when the trip level is reached.
ECU Monitoring Module
This module allows the controller to confirm communication with the ECU, manage message data
received from the ECU, and shuts down the turbine when the trip level is reached.
Core Interface Module
This module allows the controller to manage information passing to or from the CEC and
information passing to the ECU from the CEC.
Framework Module
This module allows the controller to define and manage the hardware interface to the I/O
system, perform housekeeping functions, and allocate programs to their respective tasks.
Instrument Scaler Module
This module allows the controller to produce real tag values by scaling from/to hardware inputs
and outputs, and to monitor analog inputs for out-of-range errors.
Contract Configuration Module
This module allows the controller to set any configuration flags required by other aspects of the
system, to interface to the remote speed and control signals, and to provide the functionality for
any miscellaneous features that do not warrant a module of their own.
Turbine Governor Module
The turbine governor incorporated within the SAM manages the operation of fuel valves to
maintain the required speed of the turbine. During a turbine start, the governor facilitates speed
control governing in droop or isosynchronous modes and in fuel valve tests.
Turbine Temperature Monitor
The turbine temperature monitor incorporated within the SAM monitors the power turbine exit
and inlet thermocouples. The temperature of the turbine can be controlled and limited using this
information.
Chapter 1
1-47
Turbine Guide Vane Control
The turbine guide vane controller incorporated within the SAM is responsible for monitoring and
positioning the inlet guide vanes and first three rows of stator blades of the turbine gas
generator.
SAM Messaging Modules
To allow messaging from the special applications module to the man-machine interface a SAM
messaging module manages the message data received from the SAM and enables these
messages to be passed to the display interface.
Contract Control Module
This module provides an interface to the unit control panel for the remote speed control signal
and remote trip signals and provides a controlled ramp-down to minimum demand speed during
a normal stop.
Generator Monitoring and Control Module
This module monitors the temperature of the generator windings and bearings by using RTDs. A
pair of velometers monitors the generator bearings for vibration. An interface is provided to the
GCP to enable and disable the permissive signals associated with the generator.
Emergency Stop Loop
A dedicated hardwired emergency stop circuit, independent of any software function, is provided
to halt the operation of the turbine when potentially dangerous or unsafe conditions exist. The
loop is powered by the battery-backed power supply and consists of a series of contacts derived
from the following components:
Fire/gas monitoring system
Controller watchdog timer
Emergency stop button (on-skid)
Overspeed trip module
Emergency stop button (control system)
Customer-located stop button
An additional contact is employed to allow the controller to make or break the emergency stop
loop during testing.
All emergency stops disable the DC supplies to the on-skid fuel valve solenoids, with the result
that these valves failsafe and shut off the supply of fuel to the turbine, thus shutting it down.
Chapter 1
1-48


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