Gas Turbine Operating Manule

8/10/2019 Gas Turbine Operating Manule

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Version 02.2008 General service and maintenance information MAN TURBO AG 1 | 1 - 5

Table of contents

1 General service and maintenance information.. .................................. 1

1.1 Safety information...................................................................... 1

1.2 Abbreviations............................................................................. 2

1.3 Performance of service and maintenance measures.. ............... 3

1.4 Cleanliness.. .............................................................................. 3

1.5 Impact of adhesive tape.. ........................................................... 3

1.6 Consumables.. ........................................................................... 3

1.7 Examination of component parts ............................................... 4

1.8 Identification of component parts............................................... 4

1.9 Storage of spare parts .. ............................................................. 4 1.10 Performance of welding work .................................................... 4

1.11 Installation of O-rings................................................................. 5

1.12 Use of graphite pastes.. ............................................................. 5

1.13 General notes on the exchange of component parts.. ............... 5

1.13.1 Safety information....................................................... 5 1.13.2 Exchange of pressure switches .. ................................ 5 1.13.3 Exchange of electric motors........................................ 5

1.13.4 Exchange of limit switches.......................................... 6 1.13.5 Exchange of thermometers and pressure gauges .. ....6 1.13.6 Exchange of swing check valves and shut-off

valves.......................................................................... 6 1.13.7 Exchange of transmitters (resistance

thermometers, pressure sensors, etc.) .. ..................... 6

1.14 Use of SWAGELOK adapters.................................................... 7

1.15 Use of thread sealing tape and thread sealant .. ........................ 8

1.15.1 Thread sealing tape .. .................................................. 8

1.15.2

Thread sealants .. ........................................................ 8

1.16 Storage and installation of hoses.. ............................................. 9

1.17 Installation of locking plates..................................................... 10

1.18 Snap rings ... ............................................................................ 11

1.19 Use of lockwire ........................................................................ 11

1.20 Tightening torques................................................................... 15

1.20.1 Tightening torques for pipe flanged connections ......15 1.20.2 Tightening torques for base engine connections ... ...15 1.20.3 Tightening torques for other connections.................. 16


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Service and Maintenance Instructions for Gas Turbine

General service and maintenance information Version 02.2008

1 | 2 - 5 MAN TURBO AG

1.21 Service and maintenance Definition of terms andobjectives................................................................................ 18

1.21.1 Inspection................................................................. 19 1.21.2 Maintenance... .......................................................... 19 1.21.3 Repair... .................................................................... 19

2 Base engine.. ...................................................................................... 1

2.1 System-related information ....................................................... 1

2.1.1 Design and function of base engine .. ......................... 1 2.1.2 Functional principle .................................................... 1 2.1.3 Calculation of equivalent operating hours .................. 2 2.1.4 Safety information ...................................................... 3 2.1.5 Inspection measures V1, V2, V3, and V4................... 3 2.1.6 Maintenance.. ............................................................. 4 2.1.7 General repair information.......................................... 4 2.1.8 Spare parts catalogue .. .............................................. 4

2.2 Gas generator .. ......................................................................... 5

2.2.1 Design and function of gas generator.. ....................... 5 2.2.2 Modular design of gas generator.. .............................. 5 2.2.3 Modules of gas generator.. ......................................... 6 2.2.4 Inspection measures V1, V2, V3, and V4................. 15

2.3 Power turbine.......................................................................... 16

2.3.1 Design and function of power turbine....................... 16

2.3.2

Modular design......................................................... 17

2.3.3 LP1 stator blade carrier casing... .............................. 17 2.3.4 LP turbine rotor / LP2 stator blade carrier ................ 18 2.3.5 Support of LP turbine rotor....................................... 19 2.3.6 Inspection measures V1, V2, V3, and V4................. 21

3 Instrumentation base engine.. ............................................................. 1


3.1.1 Design and function.................................................... 1 3.1.2 Safety information ...................................................... 3

3.1.3

Inspection................................................................... 3

3.2 Speed measurement (nGG, nPT) .. ........................................... 3

3.2.1 Design and function.................................................... 3

3.3 Inlet temperature measurement on power turbine (T4).. ........... 4

3.3.1 Design and function.................................................... 4 3.3.2 Exchange of T4 thermocouple ................................... 6

3.4 Vibration measurement.. ........................................................... 6


3.5 Phase angle measurement .. ..................................................... 7


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3.5.1 Design and function .................................................... 7

3.6 Bearing temperature measurement .. ......................................... 7


3.7 Wear measurement on thrust bearing .. ..................................... 7


4 Fuel gas system .. ............................................................................... 1

4.1 System-related information........................................................ 1

4.1.1 Design and function .................................................... 1 4.1.2 Fuel gas specification ................................................. 1 4.1.3 Safety information....................................................... 5 4.1.4 Service and maintenance .. ......................................... 5 4.1.5 Inspection ................................................................... 8

4.1.6 Repair ......................................................................... 8 4.2 Job-specific and system-related documents.. ............................ 8

4.2.1 Drawings..................................................................... 8

4.3 Fuel gas metering valve.. ........................................................... 8


4.4 Fuel gas filter........................................................................... 11

4.4.1 Subcontractor documentation... ................................ 11 4.4.2 Drawings................................................................... 11

4.5 Trip valve................................................................................. 11 4.5.1 Design and function .................................................. 11

4.6 Vent valve................................................................................ 11

4.6.1 Design and function .................................................. 11

4.7 Pressure transducer ... ............................................................. 11

4.7.1 Subcontractor documentation... ................................ 11

5 Ignition system .. ................................................................................. 1

5.1 System-related information........................................................ 1 5.1.1 Design and function .................................................... 1 5.1.2 Safety information....................................................... 1 5.1.3 Inspection ................................................................... 1 5.1.4 Ignition test ................................................................. 1 5.1.5 Repair ......................................................................... 2

5.2 Ignition transformer.................................................................... 3

5.2.1 Design and function .................................................... 3 5.2.2 Replacement.. ............................................................. 3

5.3 Igniters....................................................................................... 4


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6 Guide vane actuator.. .......................................................................... 1

6.1 System information ................................................................... 1

6.1.1

Design and function.................................................... 1

6.1.2 Diagram guide vane angle vs. GG speed.. ................. 2 6.1.3 Safety information ...................................................... 3 6.1.4 Maintenance.. ............................................................. 3 6.1.5 Inspection................................................................... 3

6.2 Position sensor .. ....................................................................... 3


6.3 Switch - Calibration of guide vane positioning system .............. 4


7 Blow-off and instrument air system .. ................................................... 1


7.1.1 Design and function.................................................... 1 7.1.2 Safety information ...................................................... 3 7.1.3 Inspection................................................................... 3 7.1.4 Repair.. ....................................................................... 3

7.2 Blow-off valves.......................................................................... 3


7.2.2 Replacement .. ............................................................ 4 7.3 Solenoid valves (for activation of blow-off valves)..................... 5


7.4 Pressure sensors compressor discharge pressure / PTinlet pressure .. .......................................................................... 6


8 Drainage system.. ............................................................................... 1


8.1.1 Design and function.................................................... 1 8.1.2 Safety information ...................................................... 1 8.1.3 Inspection................................................................... 1 8.1.4 Repair.. ....................................................................... 2

9 Cleaning system .. ............................................................................... 1


9.1.1 Design and function.................................................... 1 9.1.2 Time of cleaning......................................................... 1

9.1.3

Use of cleaning additives ........................................... 2


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9.1.4 Use of antifreeze......................................................... 2 9.1.5 Cleaning sequence .. ................................................... 3 9.1.6 Wash water specification / approved cleaning

additives...................................................................... 3 9.1.7 Safety information....................................................... 5

9.1.8 Measures to be taken before initiating thecleaning sequence.. .................................................... 5 9.1.9 Performance of cleaning............................................. 6 9.1.10 Measures after cleaning.. ............................................ 6 9.1.11 Examination of cleaning result.................................... 7 9.1.12 Repair ......................................................................... 7

9.2 Cleaning nozzles .. ..................................................................... 7


9.3 Mobile cleaning unit................................................................... 8


10 Annex.. ............................................................................................... 1

10.1 Spare Parts Catalog .. ................................................................ 1

10.2 Curves ....................................................................................... 1


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1 General service and maintenance information

1.1 Safety information

DANGER

Danger to life and limb as well as risk of severe damage topropertyPrior to performance of a service and maintenance measurethe Operating Instructions of Machine unit and the safetyinformation included in the system and component partdescriptions shall be observed.

ATTENTION

Damage to components of the gas turbine unitThe general service and maintenance notes listed belowhave to be observed to avoid damage to the gas turbineunit.


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1.2 Abbreviations

AC Alternating Current

AD Outer diameter (Aussendurchmesser)

ANPT American National Pipe Thread

BG Subassembly (Baugruppe)

DC Direct Current

DF Remote data transmission (Datenfernbertragung)

DLN Dry-Low-NOx, DLN combustion chamber combustor which is capable ofreducing the nitrogen oxides (NOx) generated during combustion, withoutthe injection of water.

GG Gas generator

GT Gas Turbine

HP High Pressure

ID Inner Diameter

MAX / Max. Maximum

MCC Motor Control Centre (low-voltage switchgear unit)

MIN / Min. Minimum

LP Low Pressure

NPT see ANPT

PT Power Turbine (PT) = Low Pressure Turbine (LPT)

psia pound per square inch absolute (absolute pressure)

psig pound per square inch gauge (gauge pressure)

WAF Width Across Flats

UNC Unified National Course Thread

ZB Assembly (Zusammenbau)

AC Alternating Current


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1.3 Performance of service and maintenance measures

Gas generator, power turbine and coupling may only be replaced oraligned under instruction by a representative of MAN TURBO AG, sincespecial knowledge is required for the performance of these measures.This also applies to the performance of repair work on internal baseengine parts.Service and maintenance work which is not described in thedocumentation supplied may only be carried out by persons with specialqualification and skills to whom adequate information is available. Lackinginformation may be requested from the competent contact for the plantunit with the After Sales Service of MAN TURBO AG.

1.4 Cleanliness

Care has to be taken to ensure that dust, dirt, locking elements or otherforeign objects do not get into the gas turbine. Should this ever happen,the service and maintenance activity must be interrupted until therespective objects have been found, even if this requires a considerableinput of cost and time.Suitable plugs, caps or other covers are to be used for the protection of allnon-covered openings. Protective caps for open pipes shall not be placedinside but on top of the pipe ends in order to prevent their being installedunintentionally. Use of adhesive tape is not permitted (see Section 1.5 Impact of adhesive tape [ 1 | 3] ).Anti-corrosion agents, applied for the storage of component parts, as well

as dirt and packaging material shall be carefully removed prior toinstallation of a part. Suitable solvents shall be used for the removal ofanti-corrosion agents.After completion of service and maintenance work, especially the intakearea is to be thoroughly checked for foreign objects which might, forexample, get into the gas path of the base engine.

1.5 Impact of adhesive tape

Investigations have shown that remainders of adhesive tape oncomponent parts with increasing temperature attack the surface and

reduce the expansion capability. Remainders of adhesive tape are to beremoved carefully, before a component part is installed and exposed tohigh temperatures.

1.6 Consumables

During each assembly operation all seals and rubber parts are to bereplaced. Prior to installation, non-metallic new parts have to be checkedfor indications of damage resulting from extended periods of storage.Consumables, such as for example locking wire, locking washers, lockingplates, split pins, etc., must not be reused.


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1.7 Examination of component parts

Prior to installation of a component part it has to be checked whether thepart to be installed is correct and undamaged. Use of incorrect ordamaged component parts or of other than original parts not procuredfrom MAN TURBO AG may result in failure or major damage to the plantunit.During disassembly of component parts watch out for indications of wear,burns or other undesirable changes.

1.8 Identification of component parts

During disassembly note the installation location of each individual part forease of reinstallation. Mark the parts, if necessary, taking the followingnotes into account.Damaged component parts or subassemblies which cannot be reused areto be marked with a tag in order to avoid unintentional installation.The internal parts of gas generator and/or power turbine shall only bemarked using special pens. We recommend using the glass chromium penby Messrs Stade or a silver pen by Messrs Faber for the marking ofcomponent parts.

1.9 Storage of spare parts

As a rule, spare parts procured from MAN TURBO AG are packaged andpreserved for storage according to requirements.Spare parts shall be stored in a room at constant temperature between 15

and 25C. The relative humidity must not exceed 70%. Temperaturevariations are to be limited to max. 1C per hour.Anti-friction bearings are delivered in the manufacturer's originalpackaging. As a rule, the maximum storage period is 2 years. After this,exchange the parts if preservation proves too expensive.Component parts from rubber-like materials, e.g. shaft sealing rings, O-rings, flexible nozzles, vibration dampers, V-belts, etc. have to beprotected from light and seal-welded into black film. Check these partsannually for elasticity and brittleness. The maximum storage period is 5years or less, depending on the instructions by the respectivemanufacturer. For this reason, these parts are to be marked with the dateof storage to permit checking.Stored component parts with metallic surfaces are to be checked annually.The preservation of machined surfaces has to be touched up, ifnecessary. Bright, metallic surfaces are to be greased.Stored component parts shall be identified with the material number ofMAN TURBO AG and recorded in an inventory list.

1.10 Performance of welding work

If welding work is carried out in the area of the GT base frame, properearthing must be ensured in order to avoid damage to the electrical


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components installed on the base frame. Additionally, appropriate fireprevention measures are to be taken.

1.11 Installation of O-rings

For ease of installation, O-rings which come into contact with oil are to becoated with the oil of the system in which the O-ring is used.O-rings which come into contact with water may be coated with Vaselinefor ease of installation.

1.12 Use of graphite pastes

To facilitate future removal of screwed joints in hot areas, graphite pasteNever-Seez (Material No. S0913821) shall be applied to the thread faces.

1.13 General notes on the exchange of component parts

1.13.1 Safety information

CAUTION

Hazard of personal injury and damage to propertyPrior to the dismounting of component parts the Operatinginstructions for Machine unit shall be observed.

1.13.2 Exchange of pressure switches Observe Section 1.13.1 Safety information [ 1 | 5] .

1. Shut down the plant unit and lock it to prevent restarting.2. Isolate the measuring line, and depressurize.3. De-energize the measuring circuit to exclude any risk of a short circuit

which may result in damage to digital/analog cards.4. Exchange the pressure switch.5. Use a calibration device to check the measuring range and the switch

point. Adjust the switch point, if necessary (for values see).

1.13.3 Exchange of electric motorsIn the case of motors which are new, which have been cleaned or repairedand in the case of motors which have been in store or shut down for 6months, determine the minimum insulation resistance of the motorwinding. After an extended period of operation also check the criticalinsulation resistance.During and immediately after the measurement the terminals sometimeshave dangerous voltages and must not be touched.If the minimum insulation resistance or critical insulation resistance hasdecreased below the specified value, the motor must not be started up orhas to be shut down at once.


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Possible causes for this could be, for example, humidity, damagedwindings or winding parts.

Observe Section 1.13.1 Safety information [ 1 | 5] .1. Shut down the plant unit and lock it to prevent restarting.

2. Safely isolate the motor.3. Lock the motor to prevent restarting.4. Verify safe isolation from supply.5. Ground and short-circuit the motor.6. Cover or barrier off adjacent, live parts.7. Reverse the above measures only after the motor has been completely

reinstalled and connected again.

1.13.4 Exchange of limit switches Observe Section 1.13.1 Safety information [ 1 | 5] .

1. Shut down the plant unit and lock it to prevent restarting.2. De-energize the measuring circuit to exclude any risk of a short circuit

which may result in damage to digital/analog cards.3. Exchange the limit switch.

Note: If the limit switch is designed as initiator, make sure that thepolarity is correct.

1.13.5 Exchange of thermometers and pressure gauges Observe Section 1.13.1 Safety information [ 1 | 5] .

1. Shut down the plant unit and lock it to prevent restarting.2. Isolate the piping, and depressurize.3. Exchange the thermometer or pressure gauge.

1.13.6 Exchange of swing check valves and shut-off valves Observe Section 1.13.1 Safety information [ 1 | 5] .

1. Shut down the plant unit and lock it to prevent restarting.2. Isolate the piping, and depressurize.3. Exchange the swing check valve or shut-off valves. Use new gaskets

and observe the direction of flow.

1.13.7 Exchange of transmitters (resistance thermometers, pressure sensors,etc.)

Observe Section 1.13.1 Safety information [ 1 | 5] .1. Shut down the plant unit and lock it to prevent restarting.


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2. De-energize the measuring circuit to exclude any risk of a short circuitwhich may result in damage to digital/analog cards.

3. Exchange the transmitter.Note: If the transmitter is designed as initiator, make sure that thepolarity is correct.

4. For exchanging a resistance thermometer in case an immersion sleeveis not installed: Isolate the piping, and depressurize.

5. Use a calibration device to check the setting or programming andfunction, and pass through the entire measuring range for checking thelinearity (values see).

1.14 Use of SWAGELOK adapters

In the gas turbine area SWAGELOK adapters are used with a maximumdiameter of 25 mm since pre-assembly tools are not necessary up to this

size. SWAGELOK adapters can be loosened and re-tightened severaltimes without any of the parts shown in the illustration below having to beexchanged.

SWAGELOK adapter

1 Cap nut 3 Front clamping ring

2 Rear clamping ring 4 Body

If an adapter has to be exchanged or installed all the same, take care toensure that the pipe end is rectangular and free from burs. Remnantsfrom burs and other contaminations must not get into the piping. Thefollowing procedure has to be observed:

1. Insert the pipe into the assembled SWAGELOK adapter. Make surethat the pipe has been introduced into the adapter up to the stop andthe cap nut tightened "finger-tight".

2. Prior to tightening the cap nut mark it in 6 o'clock position.3. While holding the body with a wrench tighten the cap nut by 1-1/4 turns.

Note that the marking has to be turned further up to 9 o'clock positionafter one complete turn.


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NOTE

Use of sealants.Sealants must not be applied to SWAGELOK adapters.

On SWAGELOK adapters the measurement of tightening torques is not asuitable means for checking the tightening. Merely the 1-1/4 turn of thecap nut is the correct measure for adequate tightening. If the referencegauge fits between the cap nut and the body hexagon, the adapter has notbeen tightened sufficiently. If it does not fit, the adapter has been tightenedsufficiently.

1.15 Use of thread sealing tape and thread sealant

1.15.1 Thread sealing tape

NOTEUse of thread sealing tape.Thread sealing tape may only be used for tapered male threads. Usefor connections with flanges, cones or pipe unions is not allowed.

For tapered male threads with a diameter of 1/8", 1/4" and 3/8" a threadsealing tape with a width of 1/4" is to be used. For a larger thread a tapeof " width is to be used. The following procedure has to be observed:

1. Clean the male and female threads in order to remove any anti-seizecompound or sealing residues.

2. Starting on the first flight, wind the sealing tape with slight overlaparound the thread in threading direction. For tapered threads fromspecial steel, winding the tape twice around the thread isrecommended.

3. Make sure that the tape does not protrude beyond the first turn of thethread, since otherwise it might break and get into the structuralcomponent.

4. Protruding sealing tape has to be cut off. The tape, especially theoverlapping ends, shall be pressed against the thread.

1.15.2 Thread sealants

NOTE

Use of thread sealants.Thread sealants may only be used for tapered male threads. Use forcable glands is not permitted.

Prior to the application of thread sealant the whole thread has to becleaned from oil, grease and other impurities. The thread sealant is to beapplied to the second and third flights.


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1.16 Storage and installation of hoses

NOTE

Open hose ends.Open ends of stored hoses have to be capped or plugged in order toprevent any accumulation of dirt in the hose interior. The service life of a hose largely depends on the correct installation.The following has to be observed for the installation of hoses:

1. Hoses shall be reeled and unreeled as shown in the followingillustration "Reeling and unreeling of hoses".

2. Check prior to installation that the hose interior is free from dirt. As aprecautionary measure blow the hose through with compressed air priorto installation.

3. As a rule, the hoses are equipped with one loose and one fixed hoseconnection fitting. The fixed hose connection fitting always has to betightened first to prevent torsional stress.

4. Always use a wrench as dolly to avoid co-rotation of the connectionmating piece or damage to the piping to be connected.

5. External straining of the hose by chafing on edges, surfaces or on theground has to be avoided, as the service life may be reducedconsiderably by bending or by reduction of the wall thickness.

6. During installation care must be taken that the minimum bending radiusspecified in the table below is maintained.

7. Attachment of a hose in the way such as illustrated in "Inadmissibleattachment of hose" is not permissible.

Reeling and unreeling of hoses

Hose minimum bending radius


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Inadmissible attachment of hose

Minimum bending radius for corrugated hoses of special steel

Nominal diameter (inch) Bend minimum radius (mm)

3/8 200

1/2 220

5/8 300

3/4 330

1 390

1-1/4 410

1-1/2 490

2 570

2-1/2 680

3 770

4 960

1.17 Installation of locking plates

NOTE

Reuse of locking platesLocking plates must be used only once.

When using locking plates care has to be taken to ensure that the gap

between the bent-over tabs and the contact face is max. 0.50 mm. At least75% of the securing tab must be in contact with the face of the structuralcomponent.


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Installation of locking plates

1.18 Snap rings

Suitable pliers are to be used for the installation of snap rings. Internalsnap rings must not be pressed together beyond the point where the endsof the rings meet. External snap rings must only be expanded to such anextent that installation is possible without bending the rings. Afterinstallation it has to be ensured that the snap ring rests firmly in the grooveand is neither loose nor deformed. Deformed snap rings have to bereplaced.Chamfered snap rings additionally serve for absorbing the toleranceclearance of the structural component to be retained. Such snap ringshave a chamfer of 15 on one side. Chamfered snap rings may only beinserted in correspondingly chamfered grooves. The non-chamfered sideis to be directed towards the structural component to be retained.

1.19 Use of lockwire

NOTE

Use of lockwire.The use of lockwire which has been in use before, which is bent ordamaged is not admissible.

No other than the lockwire supplied by MAN TURBO AG shall be used.

The bores for the lockwire are to be aligned as shown in the followingillustrations. During alignment the specified tightening torques must not beexceeded. Subsequently, the lockwire is to be fitted as shown. The end ofthe lockwire has to be bent over to avoid any hazard of injuries.In THM gas turbine units lockwires with a diameter of 0.8 (material no.S0293782) and 1.25 mm (material no. S0293781) are used.In FT8 gas turbine units lockwire of material no. TAS3214-02 is mainlyused.


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Examples for the securing of component parts with lockwire


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1.20 Tightening torques

CAUTION

Hazard of personal injury and damage to machinery.If tightening torques are not observed, structuralcomponents may work loose and - especially where rotatingstructural components are concerned - may hit people in thevicinity of the plant unit. Above that, hot and pressurizedliquids or gases may escape from pipes and casings andlikewise hit people in the vicinity of the plant unit.

NOTE

Prerequisites for the tightening of threaded unions.Structural components shall only be tightened to the final torque afterroom temperature has been reached.

Flanged connections are to be tightened crosswise alternately withapprox. 75% of the tightening torque, before the final tightening torque isreached. Torque wrenches are to be calibrated regularly.For information about the tightening torques for the driven machine andother plant unit components please refer to the relevant documentation.

1.20.1 Tightening torques for pipe flanged connections

In most cases, threaded bolts with UNC thread are used for theconnection of pipe flanges. Flanged connections are to be tightenedalternately and crosswise by applying the following tightening torques. Thedata apply for non-greased threaded bolts which are stamped with "B7" onthe front face. Where the stamping is different, other tightening torquesapply.

Tightening torques for stud bolts with UNC thread

Dimension (inch) Tightening torque (Nm)

1/2 95

5/8 199

3/4 347

7/8 554

1.20.2 Tightening torques for base engine connections

The following table lists the standard tightening torques for the baseengine. Do not apply these tightening torques unless in the description ofservice and maintenance measures express reference is made to thetightening torques in this table. In all other cases special tightening torquesapply which must be observed by all means.


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Tightening torques for base engine connections

Bolt / nut diameter Minimum (Nm) Maximum (Nm)

M 5 2.6 3

M 6 4.8 6

M 8 11 15

M 10 23 28

M 12 39 45

M 14 63 80

M 16 96 130

M 18 130 180

M 20 187 250

M 22 250 320

M 24 320 450

M 27 469 580

M 30 588 750

If not indicated otherwise, thread faces are to be greased.

1.20.3 Tightening torques for other connections

NOTETightening torques for other connections.The tightening torques listed in the table below are not valid for thebase engine and for flanged pipe connections.

The standard tightening torques for other connections are indicated in thefollowing table. Do not apply these tightening torques unless in thedescription of service and maintenance measures express reference ismade to the tightening torques in the table below. In all other casesspecial tightening torques apply which must be observed by all means.

Tightening torques for other connections (part 1 of 2)

Bolt / nut diameter Bolt strengthcategory/Material

Tightening torqueMa (Nm)

MoS2 - lubr.


lightly oiled

5.6 10 11

8.8 21 19

10.9 30 34

A2-70 12 13

M 8

A4-80 17 19


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Bolt / nut diameter Bolt strengthcategory/Material


MoS2 - lubr.


lightly oiled

1.7258 15 17

5.6 20 238.8 43 48

10.9 so 68

A2-70 23 26

A4-80 33 38

M10

1.7258 29 33

5.6 33 40

8.8 71 85

10.9 100 120

A2-70 39 47

A4-80 56 67

M12

1.7258 49 59

5.6 83 117

8.8 178 248

10.9 250 350

A2-70 97 136

A4-80 139 194

M16

1.7258 122 171

5.6 150 200

8.8 320 426

10.9 450 600

A2-70 175 233

A4-80 250 333

M20

1.7258 220 293

Tightening torques for other connections (part 2 of 2)

Bolt / nut diameter Boltstrength category/

Material


MoS2 - lubr.


lightly oiled

5.6 267 367

8.8 569 782

10.9 800 1.100

A2-70 311 428

M24

A4-80 444 611


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Bolt / nut diameter Boltstrength category/

Material


MoS2 - lubr.


lightly oiled

1.7258 391 537

5.6 417 5508.8 889 1.173

10.9 1250 1.650

A2-70 486 641

A4-80 694 917

M27

1.7258 611 807

5.6 550 733

8.8 1.173 1.564

10.9 1.650 2.200

A2-70 642 856

A4-80 917 1.222

M30

1.7258 807 1.076

5.6 933 1.267

8.8 1.991 2.702

10.9 2.800 3.800

A2-70 1.089 1.478

A4-80 1.556 2.111

M36

1.7258 1.368 1.858

1.21 Service and maintenance Definition of terms and objectives

Service and maintenance is aimed at maintaining or restoring the desiredcondition of the plant unit. Service and maintenance which is carried outregularly and carefully has a positive effect on the reliability of the plantunit and contributes to reduction of the operating costs.

The following measures are covered by the term service andmaintenance: Maintenance measures (cleaning, readjustment) for maintaining the

desired condition; Inspection measures (measurement, check, diagnosis) for assessment

of the actual condition; Repair measures (replacement, rework) for restoring the desired

condition.


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1.21.1 Inspection

1.21.1.1 Routine inspections / walk-around checksThe overall process plant has to be inspected daily for external damage,leakages and safe attachment. If continuous operation of the plant unitdoes not allow inspection of the components installed inside the acousticenclosure they are to be inspected after every run-down.

1.21.1.2 Oil analysesThe oil analyses which are to be carried out regularly are aimed atpermitting statements about the degree of fouling, ageing or the additivevalues, and at protecting the unit against inadequate cooling of thebearings due to excessive viscosity, detrimental deposits and corrosion inthe areas of the lube-oil system of gas generator and power turbine. Forinformation about the applicable requirements please refer to the lube oil

specification.1.21.1.3 Checking of major functional component parts and protective equipment

Service and maintenance is aimed at maintaining or restoring the desiredcondition of the plant unit. Service and maintenance which is carried outregularly and carefully has a positive effect on the reliability of the plantunit and contributes to reduction of the operating costs.The following measures are covered by the term service andmaintenance: Maintenance measures (cleaning, readjustment) for maintaining the

desired condition; Inspection measures (measurement, check, diagnosis) for assessmentof the actual condition;

Repair measures (replacement, rework) for restoring the desiredcondition.

1.21.2 Maintenance

Major maintenance measures include regular filling of the lube oil tank,cleaning of the gas generator compressor and relubrication of motors. Theinformation in the respective system or component part description has to

be observed before maintenance work is started.1.21.3 Repair

Repair of component parts or subassemblies is mainly carried outdepending on the respective actual condition, which means that fixeddates and/or regular intervals for repair measures are not specified.Relevant information provided by MAN TURBO AG shall only be regardedas reference values for planning purposes. Point in time and scope ofnecessary repairs depend on the operating conditions and on the stateand/or operating behaviour of the plant unit.


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Version 02.2008 Base engine MAN TURBO AG 2 | 1 - 22

2 Base engine

2.1 System-related information

2.1.1 Design and function of base engineGas generator and LP turbine are the core components of the gas turbineunit. They are collectively referred to as base engine which is mounted ona base frame.

2.1.2 Functional principle

The THM is a twin-shaft gas turbine operating according to theconventional simple principle of combustion at constant pressure.This principle (see the figure below) comprises the following steps: Adiabatic compression of air (i.e. without exchange of heat) in an axial-

centrifugal compressor. Combustion of a mixture at constant pressure in two combustion

chambers. The mixture consists of the air discharged from thecompressor and the fuel (liquid fuel or fuel gas) which is routed to thecombustion chambers via nozzles.

Initial expansion of the pressurized hot gases from the combustionchambers takes place in a two-stage backpressure turbine which isreferred to as high-pressure turbine (HP turbine) and which is used fordrive of the axial-centrifugal compressor.

Secondary expansion of the hot gases leaving the HP turbine takes

place in a second backpressure turbine which is referred to as low-pressure turbine or power turbine (LP turbine or PT). This turbinesupplies the energy required for driving a processing machine (e.g.pipeline compressor or electric generator) via a shaft that is notconnected to the HP turbine of the gas generator.


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Base engine Version 02.2008


Functional principle of gas turbine

1 Gas generator compressor 5 Driven machine

2 Combustion chamber 6 Temperature curve

3 Gas generator turbine 7 Pressure curve

4 Power turbine

2.1.3 Calculation of equivalent operating hours

Calculation of the equivalent operating hours (EOH) in the course ofdetermination of service and maintenance intervals or service lives isnecessary for the consideration of factors which have a major influence onthe condition of the base engine parts. Calculation is based on thefollowing formula:

EOH = operating hours A 1 A 2 A 3 + 10 number of starts

Factors for calculation of the equivalent operating hours

Factor Operating conditions Value

A1 Weighting factor for load stage Base load (operation at nGG or T4 limitation)Operation predominantly below 80% base loadBase load operation with recurring, short-term overload

above the T4 limitation for base load

1.00.92.0


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Factor Operating conditions Value

A2 Weighting factor for fuel Low-sulphur fuel gasHigh-sulphur fuel gas

Fuel oil EL, DieselOther fuels

1.01.3

1.3on request

A3 Weighting factor for suction air Low-pollutant suction airCorrosive suction air, e.g. off-shore operation

1.01.3


WARNINGHazard of personal injury and damage to property.Work on base engine components may only be carried outduring standstill and after a cool-down period of severalhours. Prior to performance of service and maintenancemeasures the following Sections shall be observed.

2.1.5 Inspection measures V1, V2, V3, and V4

Inspection measures V1, V2, V3, and V4 are aimed at assessing thecondition of the internal base engine components.The following tables provide an overview of the times for performance ofthese measures and of the scope of components to be inspected.At the time of inspection of the base engine, the component parts andprotective equipment which are relevant for proper functioning may bechecked.

Inspection times for base engine

Equival. OH* 10 20 30 40 50 60 70 80 90 ...

Measure V1 V2 V2 V3 V1 V2 V2 V4 V1 ...* OH = Operating Hours. The values are to be multiplied by 1,000.

Scope of base engine parts to be inspected

Inspection measure

V1 V2 V3 V4

Flame tubes Compressor

Gas collector Combustion chambers

HP1/HP2 stator blades Gas collector


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Inspection measure

V1 V2 V3 V4

HP1/HP2 rotor blades HP turbine

LP1 stator blades LP turbine

Flame tubes Compressor

Checking of major functional component parts and protectiveequipment [ 1 | 19]

2.1.6 Maintenance

Maintenance work (cleaning, readjustment) on the base engine is limited

to keeping the outer area and/or the surroundings of the base engineclean and to condition-dependent cleaning of the compressor.

2.1.7 General repair information

Repair of the components of the base engine depends on the respectivecondition, which means that fixed dates and/or regular intervals for repairmeasures are not specified. Relevant information provided by MANTURBO AG shall only be regarded as reference values for planningpurposes. Point in time and scope of necessary repairs depend on theoperating conditions and on the state and/or operating behaviour of theplant unit. Assessment of the actual condition is made by the time-dependent repair measures V1, V2, V3 and V4 as well as based on theevaluation of operating data.

2.1.8 Spare parts catalogue

Data of spare parts for the base engine are listed in an electronic spareparts catalogue which will be found on the electronic documentation datacarrier included in the supply. This catalogue which is structured accordingto subassemblies covers all component parts of the base engine which areindicated in parts lists and explosion drawings. A search function isavailable for finding parts e.g. by means of the part no. or part designation.Above that, a facility is provided for generating spare parts enquiries orpurchase orders. If requested, the EPOS E lectronic P arts OrderingS ystem can be set up; this system makes it possible - via the internet - tolook e.g. for spare parts prices, delivery times, and parts available fromstock. Furthermore, enquiries or purchase orders for spare parts can besubmitted to MAN TURBO AG via the internet.


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2.2 Gas generator

2.2.1 Design and function of gas generator

The compressor, the combustion chamber section, and the HP turbine arethe main components of the gas generator and are shown along with othercomponents in the following figure.The gas generator generates the energy required for drive of the powerturbine.Having passed through the compressor, the air drawn in enters the V-shaped combustion chambers where it is mixed and burnt with the fuel.Via a gas collector the hot exhaust gases reach the two-stage HP turbinewhich drives the compressor of the gas generator. The surplus exhaustgas energy is transferred further to the power turbine (LP turbine). Part ofthe air from the compressor is also used for cooling the combustionchambers and turbines.Ignition is made by two igniters operating independently from each other.Subsequently, combustion is self-sustaining.Fuel supply to the gas generator is adjusted by means of a control valvewith reference to the power requirement.

2.2.2 Modular design of gas generator

The following figure illustrates the modular design of the gas generator ofa THM 1304 gas turbine unit with standard combustion chambers. Themodular design of a THM permits the exchange of all modules inside theacoustic enclosure with only few equipment needed.

Modular design of gas generator


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1 Gas generator 9 Upper half compressor stator bladecarrier

2 Combustion chamber 10 Planetary gear unit*

3 Flame tube 11 Planetary gear unit connecting

shaft*4 HP1 stator blade carrier 12 GG front bearing

5 HP turbine rotor 13 Compressor inlet casing

6 HP2 turbine ring 14 Compressor rotor

7 Upper half GG main casing 15 Upper half GG rear bearing

8 Gas collector 16 Lower half GG main casing

* These parts are only installed in units with a starter system equipped with anauxiliary gearbox.

Compressor inlet casing [ 2 | 6]

Combustion chambers [ 2 | 11]

Gas collector [ 2 | 10]

HP turbine [ 2 | 11]

Support of the GG rotor [ 2 | 13]

Compressor [ 2 | 8]

2.2.3 Modules of gas generator

2.2.3.1 Compressor inlet casingThe compressor inlet casing is a single-part casing with four hollow strutswhich interconnect the inner and outer casings. The inlet casingaccommodates the GG front bearing for supporting the rotor. Furthercomponents of the inlet casing are 18 inlet guide vanes (IGV's) with anassociated adjusting mechanism / actuator (see figure below).The first stator blade / guide vane row of the GG compressor on the THM1304 is of adjustable design in order to allow control of the air flow rate(especially during start-up and rundown as well as during turndown). Thiscontrol feature makes it possible to achieve an optimum GG compressorefficiency throughout the total speed range.Actuation of the adjusting mechanism by means of an electrically operatedstepping motor is initiated by the GT control system as a function of theGG speed.


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The description of the guide vane positioning system includes a diagramwhich illustrates the speed-dependent guide vane position as well as theother components of the guide vane positioning system.

Compressor inlet casing

1 Strut 4 Variable inlet guide vane

2 Guide vane positioning mechanism 5 Front GG bearing3 Bore for instrument cable


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part of the air present there is routed through two elbows into thecombustion chambers. The residual air is passed on via ducts and boresfor cooling of the HP turbine which serves as driver for the compressorrotor.

Compressor design and numbering of stages

1 Annular duct stage 3 4 Stator blades

2 Annular duct stage 6 5 Smoothing chamber

3 Rotor blades

GG rotor

1 Radial stage 3 Axial compressor

2 HP turbine


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BladingIdentification of the compressor stages had to be adapted in the course offurther development of the THM 1304 as the compressor capacity wascontinuously increased by adding stages 000, 00 and 0. All compressorblades are provided with an anti-corrosion coating. Teflon segments arescrewed to the tips of the stator blades of stages 000, 00, 0, 1 and 2. Thelabyrinth strips at the rotor discs of the compressor rotor work into theTeflon in the course of the first operating hours.This kind of sealing makes it possible to minimize clearances and thus tokeep the performance and/or efficiency losses low. The discs (into whichthe blades are inserted in dovetail grooves), the radial flow impeller andthe shaft ends of the rotorare held together by 13 tie bolts.

Blow-off and cooling systemUnder certain operating conditions compressor air has to be removed viablow-off valves in order to prevent surging of the compressor. For thispurpose, the compressor stator blade carrier is fitted with radially runninggrooves between the 2nd and 3rd as well as between the 5th and 6thstages, via which the compressor air is routed into two annular ducts.Depending on the type of machine, the drawn-off air is discharged via twoor three blow-off valves installed on top of the GG main casing. The blow-off valves installed on the bottom GG main casing half (one or two,depending on the machine type) serve to remove the compressor air fromthe last stage. For further information about the arrangement and purposeof the blow-off valves please refer to the description of the blow-off andinstrument air system.

2.2.3.3 Gas collectorThe gas collector guides the hot exhaust gases from the combustionchamber into the HP turbine. The gas collector is cooled from outside withthe air that has been routed before via the smoothing chamber into thecombustion chambers for cooling of the flame tubes. The lower section ofthe gas collector accommodates a drain connection.


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Gas collector

1 Gas collector 2 Drain connection

2.2.3.4

Combustion chambers2.2.3.5 HP turbine

The HP turbine of the gas generator (an axial-flow two-stage backpressureturbine) consists of the following components: HP1 stator blade carrier, HP turbine rotor, HP2 stator blade carrier (2-part, vertical split joint).


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HP turbine

1 HP turbine rotor 3 HP2 stator blade carrier casing

2 HP1 stator blade carrier 4 HP2 stator blade

The single-part HP1 stator blade carrier which is centred by eight pins onthe GG main casing consists of one inner and one outer support ring aswell as the HP1 stator blades. The inner ring is bolted to the gas collectorand the outer ring to the GG main casing.The HP turbine rotor consists of two discs and the HP1 and HP2 rotorblades, inserted in fir-tree-shaped grooves. The pair of discs is connected

to the rear shaft end of the compressor rotor by four centring pins and four


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bolts.Sealing of the HP turbine rotor is by honeycomb seals. In the courseof the first operating hours, the labyrinth strips mounted on the rotorblades and on the turbine disc work into the honeycomb seals. This kind ofsealing keeps the clearances and as such the performance and efficiencylosses very low.

For inspection of the hot gas parts, one carrier half can be removed (afterhaving shifted apart the gas generator and the power turbine).

2.2.3.6 Support of the GG rotorThe GG rotor is supported by two hydrodynamic tilting pad sleevebearings. With this bearing type, the lube oil pressure required forsupporting the shaft is generated by the rotary movement of the GG rotor.With increasing speed, more and more oil is transferred from the contactsurface of the shaft into the lubricating gap. As a result, the oil pressure inthe lubricating gap increases until the shaft floats on the lube oil film.

The GG front bearing comprises one axial thrust, axial backpressure andsleeve-type radial bearing each. During start-up the backpressure bearingabsorbs the axial force acting opposite to the direction of flow. At higherspeeds, the conditions of the axially acting forces change and the rotor ispressed against the thrust bearing in the direction of flow.Sealing towards the compressor space at the rear end of the GG frontbearing is made via a floating ring sliding on the shaft end of the GG rotorand via a labyrinth seal. The required seal air is routed from the inner areaof the compressor rotor to the labyrinth seal through bores.Thrust and backpressure bearings are formed by 12 ball-supported tilting

pads each. The sleeve bearing which serves for absorption of the radiallyacting forces consists of five tilting pads.The GG rear bearing like the GG front bearing is of two-part design, butconsists of one sleeve bearing only, the design of which is similar to that ofthe GG front bearing. Contrary to the GG front bearing, sealing at bothends of the bearing is made via floating rings and labyrinth seals. The sealair is routed through the inner area of the compressor rotor and throughbores to the labyrinth seals.Supply of lube oil to the GG front bearing is made through a lineconnected to the GG inlet casing. Through internal ducts and lines, the oil

is fed into the annulus of the bearing and injected there through five boreslocated between the tilting pads of the sleeve-type radial bearing. The oilthen gravitates from the bearing over the lower strut of the GG inlet casinginto the lube oil tank.The line for lube oil supply to the GG rear bearing is connected to thelower GG main casing half in the rear area. The oil is injected in the sameway as on the GG front bearing through a hose and internal ducts insidethe gas generator. By gravitational force the oil flows into a collectingchamber and from there through a hose that is also inside the gasgenerator back into the lube oil tank. Details about the instruments on theGG bearings and on the rear GG bearing housing will be found in thedescription of the base engine instrumentation.


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Lube oil connections on the gas generator

1 Oil feed 2 Oil return

Front bearing gas generator


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2 Carrier for labyrinth / floating ringseal

7 GG shaft

3 Backpressure bearing 8 Thrust collar

4 Sleeve bearing 9 Thrust bearing5 Bearing support


The gas generator components to be inspected during the scheduledinspection measures V1, V2, V3, and V4 are listed in the following table.For determination of the times of implementation, the equivalent operatinghours shall be calculated according to Section 2.1.3 Calculation of

equivalent operating hours [ 2 | 2] .Inspection measures for gas generator (part 1 of 2)

Point in timeomponents to be checked

V1 V2 V3 V4

Disconnection of the gas generator from the power turbine x x

Air inlet elbow

External inspection x x x x

Disassembly, inspection, and assembly x x

Air inlet casing of compressor


Internal inspection x x

Disassembly, inspection, and assembly of

- front gearbox or inner shaft x x

- front bearing x x

- oil sealing ring and labyrinth seal x x

- inlet guide vanes x x

Compressor

Borescopic examination of stages 000 and 00 x

Axial displacement measurement of stages 000 and 00 x x


- upper main casing half x x

- upper stator blade carrier half x x

- clearances between rotor/stator blade carrier x x

- compressor rotor x x


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Point in time

- rear bearing x x

Inspection measures for gas generator (part 2 of 2)

Point in timeomponents to be checked

V1 V2 V3 V4

Combustion chambers

External inspection

Borescopic and visual inspection x x


- flame tubes x x x

- slide rings x x x

- fuel nozzles x x x

- igniters x x x

Gas collector

Borescopic and visual inspection x x


- slide rings x x

- air manifold x x

- main casing, top part x x

- gas collector x x

HP turbine

Borescopic examination of HP1 stator blades x x

Borescopic examination of HP rotor x

Checking of clearances between rotor and stator blade carrier x x


- HP1 stator blades x x

- HP rotor x x

- HP2 stator blades x x- replacement of HP1/HP2 honeycomb seals x x

2.3 Power turbine

2.3.1 Design and function of power turbine

The LP turbine consists of one each LP1 stator blade carrier, LP2 stator blade carrier,


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LP turbine rotor, Main casing, Exhaust elbow.The LP turbine is an axial-flow two-stage backpressure turbine whichconverts the energy contained in the exhaust gas from the gas generatorinto rotary movement and transfers it to the processing machine via theoutput coupling.

2.3.2 Modular design

The following figure illustrates the modular structure of the LP turbine of aTHM 1304 gas turbine unit with standard combustion chambers. Themodular design of a THM permits the exchange of all modules inside theacoustic enclosure with only few equipment needed.

Modular design of the power turbine

1 LP1 stator blade carrier 4 LP turbine shaft

2 LP2 stator blade carrier 5 LP main casing3 LP turbine rotor

2.3.3 LP1 stator blade carrier casing

The gas generator is connected to the power turbine via the inlet flange ofthe single-part LP1 stator blade carrier. Eight thermocouples (T4) formonitoring the PT inlet temperature and the LP1 stator blades arearranged in the LP1 carrier.


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LP1 stator blade carrier casing

1 T4 thermocouple 3 LP1 stator blade

2 LP1 stator blade carrier

2.3.4 LP turbine rotor / LP2 stator blade carrier

The LP2 stator blades are inserted in the two-part LP2 stator blade carrier.For inspection of the hot gas parts, one carrier half can be removed (afterhaving shifted apart the gas generator and the LP turbine).The LP turbine rotor consists of two discs with the LP1 and LP2 rotorblades, inserted in fir-tree-shaped grooves. The pair of discs is connectedto the LP shaft via four body-bound studs and four bolts. The shaft isconnected to the output coupling which transmits the torque to the drivenmachine. Sealing of the LP turbine rotor is made by honeycomb seals. Inthe course of the first operating hours, the labyrinth strips mounted on therotor blades and on the turbine disc work into the honeycomb seals. This


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kind of sealing keeps the clearances and as such the performance andefficiency losses very low.

LP turbine rotor / LP2 stator blade carrier

1 LP2 stator blade carrier 3 LP turbine rotor with shaft

2 LP2 stator blade 4 Borescope port

2.3.5 Support of LP turbine rotor

The LP turbine rotor is supported by two hydrodynamic tilting pad sleevebearings the design and function of which is similar to that of the GGbearings. Contrary to the GG rotor, the axial thrust, axial backpressureand sleeve-type radial bearings are arranged at the rear shaft end.


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Sealing towards the LP turbine at the front end of the LP front bearing iseffected via a floating ring which slides on the shaft end of the LP rotorand via a labyrinth seal. There is no sealing at the rear end of the LP frontbearing. The cooling air from the space between the two LP turbine discsis used as seal air for the labyrinth seal. On the LP rear bearing a floating

ring and/or labyrinth seal is not installed.Supply of lube oil to the two LP bearings is made through a line connectedto the LP rear bearing housing. Part of the oil flows directly into the LP rearbearing while the remaining oil flows to the LP front bearing through aninternal line connecting the two bearings. Oil injection in the bearing ismade in the same way as on the GG bearings. The oil from the LP frontbearing then gravitates into the internal casing of the LP main casing.Approximately half of the oil from the LP rear bearing also flows into theinternal casing while the remaining oil flows into the coupling guard. Theoil then returns through the line connected to the internal casing and/or to

the coupling guard into the lube oil tank.The description of the base engine instrumentation includes information onthe instruments that are installed on the bearings and/or the rear bearinghousing.

Lube oil connections on the LP turbine



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Rear bearing power turbine

1 Bearing support 5 Sleeve-type radial bearing

2 Oil feed 6 LP shaft3 Thrust bearing 7 Oil supply connection

4 Backpressure bearing 8 Oil supply line to the LP frontbearing


The LP turbine components to be inspected during the scheduledinspection measures V1, V2, V3, and V4 are listed in the following table.For determination of the times of implementation, the equivalent operating


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hours shall be calculated according to Section 2.1.3 Calculation ofequivalent operating hours [ 2 | 2] .

Inspection measures for power turbine

Point in timeomponents to be checkedV1 V2 V3 V4

LP1 stator blades


LP2 stator blades


LP turbine rotor

Measurement of axial displacement x x

Checking of clearances between rotor and stator blade carrier x x


LP turbine shaft and bearings

Disassembly, inspection, and assembly of x x

- oil sealing ring and labyrinth seal x x

- LP turbine shaft x x

- front and rear bearing x x

Plate lining of LP casing

Visual inspection x x

Exhaust elbow




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Version 02.2008 Instrumentation base engine MAN TURBO AG 3 | 1 - 8

3 Instrumentation base engine


3.1.1 Design and functionThe instrumentation of the base engine mainly comprises the speed,pressure, vibration, bearing wear, and temperature measuring deviceswhich are installed on gas generator and power turbine and which arerequired on the one hand for control purposes and on the other hand formonitoring of the gas turbine.

Location of base engine measuring devices*

1 Drive coupling with gear wheel for speed measurement of GG rotor

(in the case of units with mechanically driven main lube oil pump the GG speedsensors are located on the auxiliary gearbox.)

2 Front GG bearing with vibration measurement, keyphasor, bearing monitoring(temperature, wear)

3 Rear GG bearing with bearing temperature monitoring

4 PT inlet temperature measurement

5 Front PT bearing with bearing temperature monitoring

6 Rear PT bearing with vibration measurement, keyphasor, bearing monitoring(temperature, wear), speed measurement

* The Figure shows a gas generator with standard combustion chambers. In thecase of gas generators with DLN combustion chambers the measuring locationsare the same as shown in the illustration.


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Instrumentation base engine Version 02.2008


Instrumentation front GG bearing

1 Bearing wear sensors 2 Keyphasor

Instrumentation rear PT bearing


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1 Cables of vibration sensors arranged directlybehind the speed sensors.

2 Speed sensors

3 Keyphasor 4 Bearing wear sensors


WARNING

Hazard of personal injury and damage to property.Work on base engine components may only be carried outduring standstill and after a cool-down period of severalhours. Prior to performance of service and maintenancemeasures the following Sections shall be observed.

3.1.3 Inspection

Routine inspections and walk-around checks have to be carried outregularly. Additionally, an annual major inspection of the described systemis recommended.

Routine inspections / walk-around checks [ 1 | 19]

Checking of major functional component parts and protective

equipment [ 1 | 19]3.2 Speed measurement (nGG, nPT)

3.2.1 Design and function

The main components for speed measurement are 4 inductive speedsensors, and 2 overspeed protection relays installed in the GT controlcabinet.The two speed sensors envisaged for monitoring the GG rotor areinstalled on the auxiliary gearbox. The two speed sensors envisaged formonitoring the PT rotor are installed in the rear PT bearing location.The speed sensors generate a frequency proportional to the number ofimpulses. In the case of the gas generator the impulses are generated bymeans of a gear wheel (number of teeth = 50) which is fixed to theauxiliary gearbox. In the case of the power turbine the impulses aregenerated by means of a shaft toothing (number of teeth = 60).Two speed signals are picked up for each rotor (GG, PT); one of thesesignals is processed by the GT control system and the other one by theoverspeed protection relay. The sensor cabling is routed through a rib ofthe GG inlet casing or the PT main casing via a terminal box installed onthe GT base frame to the GT control panel.


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Arrangement of GG speed sensors

1 Auxiliary gearbox 4 Cardan shaft

2 Fitting plates for GG speed sensors 5 Gas generator connecting flange

3.3 Inlet temperature measurement on power turbine (T4)


The main component parts of PT inlet temperature measurement are 8double thermocouples, 10 temperature measuring transducers and oneevaluation unit (component part of the GT controller).

Measurement serves amongst others for monitoring the ignition process,for protecting the gas turbine unit against overfiring and for measuringindividual and averaged values which are necessary for control of the gasturbine unit.Two thermal e.m.f's are generated for each thermocouple, one serves fordetermining the individual values and the other for average valuegeneration. Average value generation is made by means of thetemperature measuring transducers.Arrangement of the thermocouples in the LP1 stator blade carrier casingof the power turbine is shown in the figure below. There is a total of 12ports in the LP1 casing; 4 of these are closed by blind flanges and are notidentified by a number in the figure below.


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Arrangement of the T4 thermocouples (shown in the direction of flow)

Assembly location of a T4 thermocouple

1 T4 cable 4 LP1 casing

2 Thermocouple element 5 HP2 casing

3 Protection sleeve


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3.3.2 Exchange of T4 thermocouple

NOTE

Note concerning installation.When installing the T4 thermocouple take special notice of the groovein the thermocouple cartridge and the tongue of the T4 thermocouplewhich is visible when looking into the cap nut. The tongue and grooveensure that the openings in the area of the thermocouple tip point inthe direction of flow and the T4 temperature can thus be measuredcorrectly.

Observe Section 3.1.2 Safety information [ 2 | 3] .1. Loosen the cable ends of the T4 thermocouples to be exchanged in the

terminal box.2. Loosen the cap nut of the T4 thermocouple on the LP1 stator blade

carrier casing.Note: The screws of the T4 protection sleeve need not be loosened.

3. Install the T4 thermocouple.4. Tighten the cap nut.

Note: Observe the tightening torque in Chapter General service andmaintenance information.

5. Connect the cable ends of the T4 thermocouple in the terminal box.

Tightening torques for base engine connections [ 1 | 15]

3.4 Vibration measurement


4 inductive proximity sensors (vibration pick-ups), 4 signal transducers andelectronic cards are installed to monitor the vibrations of the GG and PTrotors.The two sensors for monitoring the GG rotor vibration are installed in thefront GG bearing section and the PT vibration sensors in the rear PTbearing section (see figures in Section 3.1.1 Design and function [ 3 | 1]). The sensor cabling is routed through a rib of the GG inlet casing and thePT main casing to the signal transducers.Due to the radial movement of the rotor the oscillating circuit created bythe sensor coil is dampened considerably, i.e. the cyclic stress is greatlyreduced. The generated negative voltage signal is proportional to thedistance between sensor and shaft.The measured signals are transmitted by the signal transducers to thevibration monitor in the GT control cabinet where they are evaluated andindicated. If a limit value is exceeded, either an alarm is issued or trippinginitiated.


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3.5 Phase angle measurement


Phase angle measurement comprises 2 keyphasor sensors, 2 signaltransducers and, depending on the design, either 1 or 2 electronic card(s).One keyphasor each is located in the front GG bearing section and one inthe rear PT bearing section (see figures in Section 3.1.1 Design andfunction [ 3 | 1] ). The sensor cabling is routed through a rib of the GGinlet casing and the PT main casing to the signal transducers. Theelectronic cards for evaluation are a component part of the vibrationmonitor which is installed in the GT control cabinet.The keyphasor is a position transducer or a capacitive proximity sensorwhich once every revolution generates a voltage signal via a square bar orpin fastened on the GG or PT shaft; this signal is transmitted to thevibration monitor via a signal transducer. The keyphasor signal serves forillustrating the relation between speed and vibration frequency.

3.6 Bearing temperature measurement


Bearing temperature measurement comprises 12 thermocouples and 6temperature transducers.Each bearing is provided with 2 thermocouples; one of these is connectedto a temperature transducer and the other - which is routed to themeasuring transducer - serves as standby and is connected only in the

event of failure of a thermocouple.The thermocouple is passed through a bore in the tilting pad of thebearing. Cabling of the thermocouples is routed through a rib of the GGinlet casing or the PT main casing to the GT control panel via terminalboxes.

3.7 Wear measurement on thrust bearing


Wear measurement on the thrust bearing comprises 4 capacitive proximity

sensors and 4 signal amplifiers (proximitors).Two sensors each for monitoring axial wear on the thrust bearing arearranged in the front GG bearing section and in the rear PT bearingsection (see figures in Section 3.1.1 Design and function [ 3 | 1] ).The sensor cabling is routed through a rib of the GG inlet casing and thePT main casing to the signal transducers.The electronic cards for evaluation are a component part of the vibrationmonitor which is installed in the GT control cabinet.Due to the axial movement of the rotor the oscillating circuit created by thesensor coil is dampened considerably, i.e. the cyclic stress is greatly


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reduced. The generated negative voltage signal is proportional to thedistance between sensor and shaft.


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Version 02.2008 Fuel gas system MAN TURBO AG 4 | 1 - 11

4 Fuel gas system


4.1.1 Design and functionThe fuel gas system mainly comprises: trip and vent valves; fuel gas filter;monitoring instruments (e.g. for pressure, temperature, etc.) as well as onefuel gas metering valve.The fuel gas system operating in conjunction with the GT control systemsupplies the gas turbine with fuel gas during start-up and subsequentoperation. Further, it warrants immediate isolation of fuel gas feedespecially in the case of a trip (e.g. due to overtemperature and overspeedconditions or component malfunctions).The fuel gas flows through a fuel gas filter and trip valve(s) to the fuel gasmetering valve. The fuel gas flow rate is regulated in line with theoperating condition and the gas turbine power setting and routed to thetwo combustion chambers.In the event of a gas turbine unit trip, the fuel gas trip valve is closed, thevent valve is opened and the fuel gas present in the pipes is dischargedthrough vent pipes.

4.1.2 Fuel gas specification

4.1.2.1 General

This fuel gas specification defines the requirements for gaseous fuels tobe used in THM gas turbines. Natural gases with a methane content ofmore than 80% by volume are used by preference. Generally, the limitvalues for physical and chemical properties listed in the table below haveto be adhered to.Gaseous fuels which do not correspond to the limit values given in thetable may possibly be approved for THM gas turbines nonetheless. Forthis, however, the technical department of MAN TURBO AG has to make adetailed assessment of these values. By special protective measurescarried out on gas turbine components it may become permissible to

exceed individual limits. In the case of gas turbines which are equippedwith Dry-Low-NOx (DLN) combustion chambers further limit values have tobe observed to ensure trouble-free operation.When assessing the gas analysis especially those substances have to beconsidered which can lead to corrosion, e.g. alkaline metals (sodium,potassium, etc.) or sulphur compounds so that adequate steps can betaken for minimising corrosion in the gas turbine or the fuel system.In addition to assessment of the gas analysis and of impurities containedin the fuel gas envisaged for operation customer is urgently recommendedto set up a suitable system for fuel supply and conditioning as well as formonitoring the fuel gas quality.


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Fuel gas system Version 02.2008


The table specifies limit values for the concentration of various impurities.Further possible sources of impurities are the inlet air, and, if applicable,the water which is injected into the combustion chamber. The limit valuesin the table are valid on the assumption that additional impurities will notbe added through air or water. If, however, this should be the case, the

limit values for fuel gas have to be reduced for each component as shownin the following formula:

C max,corrected = C max, table - AFR x C air - WFR x C water

Cmax,corrected = Corrected max. permissible concentration

Cmax, table = Maximum permissible concentration from the table

Cair = Expected concentration in the airCwater = Expected concentration in the injection water

AFR = Mass flow ratio air to fuel (typically approx. 60 : 1)

WFR = Mass flow ratio injection water to fuel (typically 0.5 - 1.0 : 1)

4.1.2.2 Minimum physical and chemical properties profile of gaseous fuels

Fuel gas properties

Property Limit value Test method

Lower heating value (LHV) 31 - 48 MJ/mN3 *)

Wobbe Index (Note 1) 40 - 53 MJ/mN3 *)

Admissible fluctuation of heatingvalue and Wobbe Index with setcontrol

10%

Methane content (CH4) min. 80% by vol. (only DLN)

Content of hydrocarbons C3 or

heavier

max. 4.0 vol.-% (only DLN)

Hydrogen content (H2) max. 1.0 vol.-% (only DLN)max. 60 vol.-%

(standard combustion chamber)

Ratio between upper and lowerquenching limit(at 101.3 kPa, 25C)

min. 2.2 (only DLN)

Water content (H2O) (Note 2)


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Property Limit value Test method

Dust particle impurities:Particle diameter > 10mmParticle diameter 2 - 10mm

max. 20 ppm wt0 vol.-%

10 vol.-%

ISO 3735

Impurities with corrosive effect :Total sulphur content

Sodium + potassium

max. 100 ppm vol. (withoutspecial coating)max. 1.5 vol.-%

(with special coating in theturbine section)

(Note 3)max. 0.5 ppm wt

ISO 8754

DIN 51797

*) mN referred to standard conditions (0C, 101.3 kPa)

Note 1Wobbe Index (corrected to 15C) =

T = Fuel gas temperature [C]

d = ratio of standard density of fuel gas to standard density of airHu = lower heating value [MJ/Nm]

Note 2The water content must not exceed a max. concentration during which gashydrates might develop immediately upstream the fuel gas control valve,taking into consideration the fuel gas temperatures, pressures, andcompositions which are possible during operation. Gas hydrates are notallowed. Heating up of the fuel is permissible.

Note 3Sulphur dioxide (SO2) develops through combustion of sulphurcompounds in the fuel gas. The total sulphur content must therefore belimited to such an extent that compliance with the emission limit valuesspecified by the local approval authorities is ensured.Among other elements, the total sulphur contains hydrogen sulphide(H2S), mercaptan, carbon disulphide (CS 2), carbonyl sulphide (COS),thiopenes and sulphur oxides.


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Property Limit value

Maximum dew point temperature 50C

Maximum fuel gas temperature 70C *)

Admissible transient temperature change max. 4 K/min

*) With minor modifications to the fuel gas system 90C are also acceptable.


WARNING

Hazard of personal injury and damage to propertyThe service and maintenance work described for the fuelgas system can only be carried out with the gas turbine unit

at standstill and cooled down. Where work can be carriedout during ongoing operation (e.g. work on a change-overtype filter) a note is added under the relevant componentdescription.For safety reasons the components of the fuel gas systemmust not be dismantled and repaired at site but only in anauthorized workshop.Prior to performance of service and maintenance measuresthe

Documents

Gas Turbine Operating Manule