Maintenance Manual for GPB30

KAWASAKI GPB30

This document is the property of KawasakiGas Turbine Asia (KGA) . It has beenprepared exclusively for PPGJ GTG internaluse only. It contains confidential andproprietary information of KGA and is not tobe disclosed to any person outside of PPGJ.The reproduction of this document in anymanner or medium is strictly prohibitedwithout written authorization from KGA. Anyuse made of this document, in whole or inpart, other than for evaluation purposes ispart, other than for evaluation purposes isstrictly prohibited without the express priorw r i t t e n c o n s e n t o f K G A .

Warning: Warning: The purpose of this training is to provide basic information and principles of Gas Turbine Generator (GTG) and its components. Under no circumstances, this note is to be used as a reference during GTG maintenance or operation.

CONTENTSYSTEM:

a. GTG in General

b. Enclosure and Inlet/Exhaust System

c. Fuel System

d. Lube Oil System

e. Instrument Air System

f. Electrical System

g. Control System

OPERATING INSTRUCTION

a. Pre-operation Check

b. Starting Procedure

c. Load Transfer Procedure

d. Stopping Procedure

e. Cranking

f. Log and Operating Condition

TROUBLESHOOTING

GTG IN GENERAL AND SPECIFICATION

GPB30 Engine Arrangement and Specification

Engine Assembly: consists of 2 power sections, main reduction Engine Assembly: consists of 2 power sections, main reduction Engine Assembly: consists of 2 power sections, main reduction Engine Assembly: consists of 2 power sections, main reduction gearbox and 2 accessory gearboxes.gearbox and 2 accessory gearboxes.

Package Assembly: consists of engine assembly and generator.Package Assembly: consists of engine assembly and generator.

POWER SECTION

Called Gas Turbine or GT

Consists of:-

- Two stages of CENTRIFUGAL Compressors

- Three stages of AXIAL Turbine

- Single CAN type combustor

- Double end supported BEARINGS

Speed: 21870 rpmSpeed: 21870 rpm

Weight: 1.19 ton

MAIN REDUCTION GEARBOX AND

ACCESSORY GEARBOXMain Reduction Gearbox:- Accessory Gearbox

- Type: Parallel - Mounted to main reduction gearbox

- Output Speed: 1,500 rpm (50Hz)

- Reduction Gear Ratio: 14.58

GENERATORType: Synchronous AC generator type

Capacity: 2812.5 kVA

Voltage: 6.6 kV

Frequency: 50 Hz

Number of poles: 4 poles

Enclosure and Inlet/Exhaust System

Enclosure Cooling Air

Turbine Inlet Air

Exhaust Air

FUEL SYSTEM

Engine Gas Fuel System

EOV PGV

To Gas Exhaust

Gas Filter

SSV1 SSV2MGV

SGV

Gas Control

Valve
ACEEL FITCHRectangleACEEL FITCHRectangleACEEL FITCHTypewritten TextGas fuel filterdifferensial presure highACEEL FITCHTypewritten TextFTACEEL FITCHTypewritten TextACEEL FITCHTypewritten TextPTACEEL FITCHTypewritten TextTEACEEL FITCHTypewritten TextACEEL FITCHRectangleACEEL FITCHPolygonACEEL FITCHSticky NoteACEEL FITCHRectangleACEEL FITCHPolygonACEEL FITCHLineACEEL FITCHLineACEEL FITCHLineACEEL FITCHLineACEEL FITCHLineACEEL FITCHLineACEEL FITCHLineACEEL FITCHLineACEEL FITCHTypewritten TextKHI/PLCACEEL FITCHTypewritten TextKHI/PLCACEEL FITCHTypewritten TextACEEL FITCHOvalACEEL FITCHLineACEEL FITCHLineACEEL FITCHTypewritten TextPT, FT, TEACEEL FITCHOvalACEEL FITCHLineACEEL FITCHTypewritten TextTemperatur/Presure compensationACEEL FITCHLineACEEL FITCHLineACEEL FITCHTypewritten TextPA

FUEL SYSTEM

Engine Diesel Fuel System

Pressurizing

Valve

Supply Fuel

Start Fuel

Pump

Main Fuel

Pump

Start Fuel

Valve

Fuel Control

Valve

Bypass Fuel

ValveMain Fuel

Valve

Return to

service tank

Supply Fuel

Shutoff

Valve
ACEEL FITCHRectangleACEEL FITCHCalloutPASSINGACEEL FITCHRectangleACEEL FITCHCalloutDIESEL FUEL LEAK

LUBE OIL SYSTEMEngine Lube Oil System

Oil mist separator Vent

Manifold

LO Cooler

Main LO Pump

Pre Post

Pump

Gearbox

Generator

LO Tank

160L

M

Gas Turbine

INSTRUMENT AIR SYSTEMEngine Instrument Air SystemPressure for air starting: 0.9 1.0 MPa

Pressure for instrument: 0.6 MPa

P

G

P

G

P

G

Air

Dryer

Instrumen

t Air TankM

Instrumen

t Air Tank

Regulating

Valve

Pressure

Control

Valve

Pressure

Control

Valve

Fuel Line Purge

SSV-1 & SSV-2

EOV

Intake Filter

JB Pressurizing

Gas Pressure Regulating

Valve

Air for Starting

ELECTRICAL SYSTEM

Engine Electrical System

1. Ignition System

2. EGT Hardness

3. Speed Pick Up (Pulse)3. Speed Pick Up (Pulse)

4. Turning Motor

1. Ignition System

Ignition Plug:

Manufacturer: NGK Spark Plug Co.Ltd.

Ignition system is required to ignite the mixture of fuel and air inside the combustor during start up.

Ignition Exciter:

Manufacturer: Yamamoto Electric Works Co. Ltd.

Input voltage: DC24V

Discharge cycle: 3.5 sparks per seconds

Discharge specification: 1 Joule per spark

2. Exhaust Gas Temperature (EGT) Hardness

EGT Hardness is required to measure result of the combustion of fuel before discharge into the atmosphere.

It is also used to compare and monitor the performance of the gas turbine.

Thermocouple type : K type, T1 biasThermocouple type : K type, T1 bias

3. Speed Pickup Pulse

Speed Pickup Pulse for power section:


Type: Magnetic detection

Voltage: 4.5 V p-p (output)

Speed Pickup Pulse is required to detect the rotation speed of the power section and gearbox by magnetic pulse.

Speed Pickup Pulse for gearbox:


Type: Magnetic detection

Voltage: 85-120 V p-p (output)

4. Turning Motor

Turning motor is required to rotate the turbine shaft slowly after shutdown to allow uniform cooling to the turbine shaft.

The turning duration is controlled automatically by the gas turbine control panel.

Manufacturer: Sawamura Denki Kogyo Co.Manufacturer: Sawamura Denki Kogyo Co.

Type : DC Electrical motor

Rating : 24 VDC, 0.5A

CONTROL SYSTEM

Engine Control System

1. Timing Schedule (Gas)

2. Timing Schedule (Diesel)

3. Alarm and Interlock3. Alarm and Interlock

4. Operation Display Panel

TIMING CHARTStart com

Pre Purge On Pre Purge

Off

4%

22%

55%

95%

Voltage establish

CB close

Stop com Stop

95%

55%

4%

Starter Motor

Ignition Exciter

CB open

22%

Aux Machine cooling 30 min

GTG cooling 5 min

Fuel C

hangin

g

Unlo

adin

g

Loadin

g

3 min

Loading completed

Fuel C

hangin

g

Synchro

niz

ing

3 min2 sec

Pre

-exc

ite

Gas Pressure Established

Safety Shutoff Valve 2 (SSV2)


Main Gas Valve (MGV)

Start Gas Valve (SGV)

E. Open Valve Close (EOV)

Oil Cooler Fan

Encl Vent Fan

Turning Motor

Pre Post LO Pump

Main Fuel Valve (MFV)

Start Fuel Valve (SFV)

Bypass Fuel Valve (BFV)

Purge Gas Valve (PGV)

Assist Air Valve (AAV)

Liquid Fuel Cooler Fan

1 sec

1 sec

10 sec

1 sec

30 sec

Turning 10 hours

TIMING CHARTStart com

Pre Purge On

4%

22%

55%

95%

Voltage establish

CB close

Stop com Stop

95%

55%

4%

Starter Motor

Ignition Exciter

CB open

22%


GTG cooling 5 min

Fuel C

hangin

g

Unlo

adin

g

Loadin

g

Loading completed

Fuel C

hangin

g

Synchro

niz

ing

3 min2 sec

Pre

-exc

ite

Gas Pressure Established

Pre Purge Off






Oil Cooler Fan

Encl Vent Fan

Turning Motor

Pre Post LO Pump







1 sec

1 sec

10 sec

1 sec

30 sec

Turning 10 hours

TIMING CHART (DIESEL)Start com

5%

22%

55%

95%

Voltage establish

CB close

Stop com Stop

95%

55%

4%

Starter Motor

Ignition Exciter

CB open

22%


GTG cooling 5 min

Unlo

adin

g

Loadin

g

Loading completed

Synchro

niz

ing

2 sec

Pre

-exc

ite






Oil Cooler Fan

Encl Vent Fan

Turning Motor

Pre Post LO Pump







30 sec

Turning 10 hours

TIMING CHART (DIESEL)Start com

5%

22%

55%

95%

Voltage establish

CB close

Stop com

95%

55%

4%

Starter Motor

Ignition Exciter

CB open

22%


GTG cooling 5 min

Unlo

adin

g

Loadin

g

Loading completed

Synchro

niz

ing

2 sec

Pre

-exc

ite

Stop






Oil Cooler Fan

Encl Vent Fan

Turning Motor

Pre Post LO Pump







30 sec

Turning 10 hours

ALARM AND INTERLOCKFailure Description Set Point

1 Major Fault

1.1 Start Failure 0-55% 352 seconds

1.2 Start Failure 55-95% 202 seconds

1.3 Over Speed 110+0, -2%

1.4 Under Speed 55-95% 54+0, -4%

1.5 Under Speed 95%~ 94+0, -4%

1.6 LO Supply Temperature HH 905C

1.7 LO Supply Pressure LL (starting) 0.1+0.05, -0 MPa

1.8 LO Supply Pressure LL (running) 0.2+0.05, -0 MPa1.8 LO Supply Pressure LL (running) 0.2+0.05, -0 MPa

1.9 Exhaust Gas Temperature HH (starting) 700+0, -40C

1.10 Exhaust Gas Temperature HH (running) 58010C

1.11 Emergency Shutdown Push Button

1.12 Main Shaft Vibration HH 2D3m

1.13 Gearbox Vibration HH 2D0.5 mm/s

1.14 Flame Out 20010C

1.15 Miss Fire

1.16 GTG Package Gas Leak HH 10000 ppm

1.17 Generator Stator Winding Temperature HH 1502C

1.18 Generator Bearing Temperature HH 952C

1.19 Under Voltage (27G) 85V, 2 seconds

1.20 Over Voltage (59G) 130V, 2 seconds

1.21 Loss of Excitation (40G) 2 seconds

1.22 Generator Differential Protection (87G) 0.4A, 10%, instant


1.23 Revolving Rectifier Failure (71G)

1.24 GTG Package Fire

1.25 Emergency Opening Valve Open

1.26 Pre-Post LO Supply Pressure L 0.0150.0013 MPa

1.27 Fuel Gas Valve Leak

1.28 PLC Major Fault

1.29 Control Power Fault

1.30 Supply Fuel Shutoff Valve Abnormal

1.31 Strainer Differential Pressure HH 0.35 MPa1.31 Strainer Differential Pressure HH 0.35 MPa

1.32 Package Inlet Air Damper Close

1.33 Package Ventilation Air Damper Close

2 Middle Fault

2.1 Over Current (51G) 111%, M:1

2.2 Reverse Power (67PG) 10%, 10 seconds

2.3 Negative Sequence Current (46G) M:10, 30%

2.4 Over Frequency (95HG) 54 Hz, 0.1 second

2.5 Under Frequency (95LG) 47.5 Hz, 0.1 second

2.6 Ground Over Current (51N)

2.7 AVR Failure


3 Light Fault

3.1 Main Shaft Vibration H 1.5D3 m

3.2 Gearbox Vibration H 1.5D0.5 mm/s

3.3 GTG Package Gas Leak H 2500 ppm

3.4 Exhaust Gas Temperature H 56010C

3.5 LO Supply Temperature H 805C

3.6 LO Tank Level L 12010 L

3.7 LO Filter Differential Pressure H 0.240.04 MPa

3.8 LO Supply Pressure L 0.260.02 MPa3.8 LO Supply Pressure L 0.260.02 MPa

3.9 Sensor Failure

3.10 Turning Motor Power Failure

3.11 Pulse Filter Differential Pressure H

3.12 Intake Air Filter Differential Pressure H 0.7 kPa

3.13 Gas Fuel Control Valve Failure

3.14 GTG Oil Leak

3.15 Fuel Gas Pressure L (for fuel change)

3.16 Generator Stator Winding Temperature H 1352C

3.17 Generator Bearing temperature H 852C

3.18 Auxiliary Machine Failure

3.19 Fail to Syncoro 2 minutes

3.20 PLC Minor Fault

3.21 Display Failure

3.22 Starting Air Pressure L


3.23 Strainer Differential Pressure L 0.3 MPa

3.24 Gas Fuel Filter Differential Pressure L

3.25 Liquid Fuel Filter Differential Pressure H 0.24 MPa

3.26 UPS Panel Failure

3.27 DC Battery Failure

3.28 Fire Extinguish Panel Failure

3.29 Ground Over Current (51N)

3.30 Fuel Gas Pressure LL 0.880.025 MPa

3.31 Supply Fuel Shutoff Valve Abnormal3.31 Supply Fuel Shutoff Valve Abnormal

3.32 Junction Box Air Pressure L 500 Pa

OPERATION INSTRUCTION

a. Pre-operation Check

b. Starting Procedure

c. Load Transfer Procedure

d. Stopping Procedured. Stopping Procedure

e. Cranking

f. Log and Operating Condition

a. PRE OPERATION CHECKSFollowing checks to be carried out prior to start GTG by Diesel Fuel Mode

NO DESCRIPTION CRITERIA JUDGEMENT

1 Intake Air Filter Ensure security & no obstruction

2 GTG

a Area Ensure clear and no abnormality

b GTG Ventilation Inlet Filter Ensure security & no obstruction

3 Diesel Fuel System

a Service Tank Outlet Supply Valve Open

b GTG Inlet Supply Valve Open

c GTG Outlet Return Valve Open

d FO Cooler Inlet Return Valve Open

e Service Tank Inlet Return Valve Open

f Service Tank Level Confirm Full

4 Instrument Air

a Supply Confirm Supply Available


5 Lubrication Oil (GTG)

a Oil Tank Level Confirm >120

b Visual Inspection No Leak

c Oil Mist Vent Confirm no obstruction

6 Power Supply

a AC120V supply to TCP confirm energize

b DC24V supply to TCP confirm all energize

a. PRE OPERATION CHECKSFollowing checks to be carried out prior to start GTG by Gas Fuel Mode

NO DESCRIPTION CRITERIA JUDGEMENT

1 Intake Air Filter Ensure security & no obstruction

2 GTG

a Area Ensure clear and no abnormality

b GTG Ventilation Inlet Filter Ensure security & no obstruction

3 Lean Gas Fuel System

a Lean Gas Fuel Valve Open

b Lean Gas Supply Pressure > 1.323 MPa

c Confirm Gas Filter Select Valve Open

4 Diesel Fuel System

a Service Tank Outlet Supply Valve Open


c GTG Outlet Return Valve Open

d FO Cooler Inlet Return Valve Open

e Service Tank Inlet Return Valve Open

5 Instrument Air

A Supply Confirm Supply Available

B GTG Inlet Supply Valve Open

6 Lubrication Oil (GTG)

A Oil Tank Level Confirm >120

B Visual Inspection No Leak

C Oil Mist Vent Confirm no obstruction

7 Power Supply

a AC120V supply to TCP confirm energize

b DC24V supply to TCP confirm all energize

b. STARTING PROCEDURE

Starting and Loading in Manual Mode

1. On Operation page, select MANUAL mode and execute

2. If GTG starting in Diesel Mode, confirm following

On Operation page, select DIESEL and execute

3. If GTG starting in Gas Mode, confirm following

On Operation page, select GAS and execute

4. On Menu Bar, select READY

5. Confirm followings:

GTG Speed


Starting and Loading in Semi Auto Mode

1. On Operation page, select SEMI AUTO mode and execute







GTG Speed


Starting and Loading in Auto Mode

1. On Operation page, select AUTO mode and execute







GTG Speed

c. LOAD TRANSFER PROCEDURELoad Transfer in Manual Mode

1. On Operation page, select MANUAL mode and execute

2. Start another GTG according to starting procedure

3. Synchronize another GTG to existing on load GTG for PARALLEL OPERATION

4. Manually raise another GTG speed and lower existing GTG speed

5. Observe the load (kW) is transferring to another GTG

6. Manually OPEN/TRIP the generator CB when load reduced to

c. LOAD TRANSFER PROCEDURELoad Transfer in Semi Auto or Auto Mode

1. On Operation page, select SEMI AUTO or AUTO mode and execute

2. Start another GTG according to starting procedure

3. Synchronize another GTG to existing on load GTG for PARALLEL OPERATION

4. On Operation page of existing GTG, select AUTO UNLOAD and execute

5. Observe the load (kW) is transferring to another GTG

6. The generator CB will automatically OPEN/TRIP when load reduced to

d. GTG STOPPING PROCEDURE

Stopping in Manual Mode:

On Operation page, select MANUAL mode and execute.

Unload GTG according to manual unload manual.

Wait for 5 minutes for GTG cooling.

Carry out fuel change to DIESEL mode

After GTG cooling sequence completed, select the STOP on the Operation page and execute.

After GTG completely stopped, carry out inspection and verify for pre-post pump and turning motor operation.

Stopping in Semi Auto Mode:

On Operation page, select SEMI AUTO mode and execute.

Unload GTG according to semi auto unload manual.

GTG will auto fuel change to DIESEL mode after 3 minutes of cooling and resume another 2 minutes cooling on DIESEL mode.

After GTG cooling sequence completed, select the STOP on the Operation page and execute.


Stopping in Auto Mode:

On Operation page, select AUTO mode and execute.

Then select STOP on the Operation page and execute.

GTG will unload, cooling, fuel change and stop automatically.


e. GTG MANUAL PURGING (CRANKING)

On the Operation page, select PURGE, push and hold the execute button.

Verify that GTG speed will rise up.

Cranking will stop if: Cranking will stop if:

GTG speed > 25%

Release the execute button.

f. LOG AND OPERATION CONDITIONDescription Unit Criteria Time Time Time Time Time

#1 Engine Speed % 95~108

#2 Engine Speed % 95~108

Gearbox Speed % 95~108

#1 Intake Air Temp C

#2 Intake Air Temp C

#1 Exhaust Gas Temp (1) C


#1 LO Supply Press (PP) MPa >0.015

#2 LO Supply Press (PP) MPa >0.015

Starting Air Pressure MPa

Intake Air Filter Diff Press kPa 0.26

#2 LO Supply Pressure MPa >0.26

#1 Strainer Inlet Pressure MPa

#1 Strainer Outlet Pressure MPa

#1 Strainer Diff Pressure MPa


Generator Voltage (U-V) V 400

Generator Voltage (V-W) V 400

Generator Voltage (W-U) V 400

Generator Current (U) A

Generator Current (V) A

Generator Current (W) A

Generator Power Factor

Generator Frequency Hz 50

Generator kWh kWhGenerator kWh kWh

Generator kW kW

Generator kVar kVar

Excitation Voltage V

Excitation Current A

Gen Winding Temp (U) C


Gas Governor Actuator %

Bus Voltage C 400

Bus Frequency Hz 50

Gas Fuel Flow Nm3/h

Gas Fuel Pressure MPa

Gas Fuel Temperature C

Gas Fuel Flow (Pulse) Nm3

Combustor Inlet Gas Fuel Pressure

MPaPressure

Accumulator Gas Fuel Pressure

MPa

Gas Fuel Flow MMSCFD

Remarks

TROUBLESHOOTING

1. Large Vibration

2. High Exhaust Gas Temperature

3. Overspeed

4. Startup Failure4. Startup Failure

5. Low Lubrication Oil Pressure

6. High Lubrication Oil Temperature

1. Large Vibration

Vibration of gas turbine shaft is monitored to detect Large Vibration. Specific alarm value and trip value has been set in the PLC.PLC.

1. Large Vibration

Possible causes of this problem are as follows:

1. Defect of gas turbine itself: Abnormal bearing or rotary part, etc.bearing or rotary part, etc.

2. External factor: Rubbing with foreign matters entering through intake port.

3. Defect of control system: Abnormal vibration system, etc.

1. Large Vibration1.1 Simplified Inspection of Equipment

Gas Turbine

Inspection item 1

Visually check that engine (output shaft) is rotating smoothly as driven by turning motor

Objective

To confirm that rotor system is not on contact with stationary part and that foreign matter has not been caught. If there is such abnormality, engine rotation is not smooth and generating friction sound.

Inspection item 2

Manually rotate engine by hand to check for abnormal rotation or abnormal rotating soundManually rotate engine by hand to check for abnormal rotation or abnormal rotating sound

Objective

This method is to be conducted if above inspection item 1 cannot be done by turning motor.

Inspection item 3

Study of data before occurrence of problem

- Change in gas turbine shaft vibration value or reduction gear vibration value

- Generator output

- Lubrication oil temperature and pressure

- Change in temperature for No.1, No.2 lube oil drain.

Objective

To obtain data useful to determine whether vibration increase is sudden or gradual as the result of aged deterioration or false meter indication

To confirm that load is normal

To confirm that bearings are lubricated properly.

1. Large Vibration1.2 Inspection of Individual Control Devices

Vibration System

Inspection item 1

Check monitor cable connection for looseness. If connection is loose or disconnect then connect cable properly.

Objective

To confirm that signal is input properly to monitor

Inspection item 2Inspection item 2

Check sensor wiring connection for looseness

Objective

To confirm that signal is output properly from sensor

Inspection item 3

Disconnect wire from sensor and measure DC resistance. Normal value is between 2.5-3.0 ohm

Objective

To confirm that wire is not broken


Exhaust gas temperature of gas turbine is monitored to detect High Exhaust Gas Temperature. Specific alarm value and trip value have been set in the PLC.trip value have been set in the PLC.



1. Defect of gas turbine itself: Deteriorated

performance of turbine, deteriorated

performance of compressor due to soil, etc.performance of compressor due to soil, etc.

2. External factor: Clogged intake/exhaust line,

overload, etc.

3. Defect of control system: Abnormal load

control, abnormal exhaust gas temperature

thermocouple, etc.

2. High Exhaust Gas Temperature2.1 Simplified Inspection of Equipment

Gas Turbine

Inspection item 1

Visually check that engine (output shaft) is rotating smoothly as driven by turning motor.

Objective

To confirm that gas turbine itself and reduction gear are normal.

Inspection item 2

Manually rotate engine by hand to check for abnormal rotation or abnormal rotating sound

Objective


Inspection item 3


- Gas turbine shaft vibration

- Gas turbine intake air temperature and ambient temperature

- Generator output

- Compressor discharge pressure

- Lubricating oil temperature

- Operation mode: island or parallel with another GTG or Diesel Gen Set.

Objective

To confirm that gas turbine itself is normal

To confirm that air intake line is normal

To confirm that gas turbine is not operated under overload

To confirm that compressor is not soiled (check pressure data for the last one week or more)

To confirm that bearing is lubricated

To see if gas turbine is operated in island or parallel with other machines.

2. High Exhaust Gas Temperature2.2 Inspection of Individual Control Devices

Instrumentation Devices

Inspection item 1

Inspection of exhaust gas temperature thermocouple for broken wire

Measure insulation resistance. Normal value is 1.5 ohm or higher as measured with a 500-V megohmmeter at ordinary temperature

Objective

To confirm that thermocouple is not damaged

Inspection item 2Inspection item 2Heat up temperature sensing elements sequentially while checking if output voltage increasesObjective

To confirm that exhaust gas temperature is detected.

Inspection item 3Inspection of rotation pickup for loosenessObjectiveTo confirm that connector or pickup is not loose

Inspection item 4Disconnect cable from pickup and measure resistance. Normal value is 30050 ohm at 25 degCObjectiveTo confirm that wire is not brokenMiscount during operation as interconnected with commercial power system can cause high exhaust

gas temperature.

3. Overspeed

Rotation of gas turbine power section is monitored to detect Overspeed. Specific trip value has been set in the sensor.

3. Overspeed


1. Defect of gas turbine itself: Broken coupling of output shaft of power section coupling of output shaft of power section rotor system, etc.

2. External factor: Sticking fuel control valve, etc.

3. Defect of control system: Abnormal rotation pickup, etc.

3. Overspeed3.1 Simplified Inspection of Equipment

Gas TurbineInspection item 1Visually check that engine (output shaft) is rotating smoothly as driven by turning motor.ObjectiveTo confirm that gas turbine itself and reduction gear are normal

Inspection item 2Manually rotate engine by hand to check for abnormal rotation or abnormal rotating soundObjectiveThis method is to be conducted if above inspection item 1 cannot be done by turning motor.

Inspection item 3Study of data before occurrence of problem- Gas turbine shaft vibration- Gas turbine speed- Whether any problem occurred at startup or during operation- If problem occurred during operation, check generator output for change- Operation mode: island or parallel with other GTG or Diesel Gen set.ObjectiveTo confirm that gas turbine itself is normalTo clarify the time of problem occurrence

3. Overspeed3.2 Inspection of Individual Control Devices


Inspection item 1

Inspection of rotation pickup connector for looseness

Objective

To confirm the connector or pickup is not loose

Inspection item 2

Measure resistance for rotation pickup. Normal value is 30050 ohm at 25 degC

Objective

To confirm that sensor is normal

4. Startup Failure

Rotation and exhaust gas temperature of gas turbine are monitored to detect Startup Failure. Alarm signal is output when specified conditions are not met.when specified conditions are not met.

4. Startup Failure


1. Defect of gas turbine itself: Defective fuel nozzle, etc.nozzle, etc.

2. External factor: Abnormal starter equipment, abnormal ignition system, etc.

3. Defect of control system: Defective rotation pickup, defective controller, etc.

4. Startup Failure

4.1 Simplified Inspection of Equipment

Gas TurbineInspection item 1Visual check that engine (output shaft) is rotating smoothly as driven by turning motor.ObjectiveTo confirm that gas turbine itself and reduction gear are normal.

Inspection item 2

Manually rotate engine by hand to check for abnormal rotation or abnormal rotating soundManually rotate engine by hand to check for abnormal rotation or abnormal rotating soundObjectiveThis method is to be conducted if above inspection item 1 cannot be done by turning motor.

Inspection item 3Study of data before occurrence of problem-- Increase in turbine speed- Increase in exhaust gas- Instrument air pressure 0.45MPa or higher- Fuel filter differential pressure indicationObjectiveTo confirm that gas turbine itself and reduction gear are normalTo confirm that fuel system is normalTo confirm that shutoff valve opening air pressure is normal

4. Startup Failure

4.1 Inspection of Individual Control Devices

Instrumentation DevicesInspection item 1Inspection of solenoid valve operation of starter valve unitObjectionTo confirm the integrity of starter air supply equipment

Inspection item 2

Inspection of exciter and ignition plug. Visual check for damageInspection of exciter and ignition plug. Visual check for damageObjectiveTo confirm that ignition system is normal

Inspection item 3Inspection of exhaust gas temperature thermocouple for broken wire. Measure insulation resistance. Normal value is

1.5Mohm or higher as measured with a 500V megohmmeter at ordinary temperatureObjectiveTo confirm that thermocouple is not damaged

Inspection item 4Inspection of rotation pickup for looseness. Disconnect cable from pickup and measure resistance. Normal value is

30050 ohm at 25 degC.ObjectiveTo confirm that pickup is not loose and wire is not broken.


Lubrication oil pressure is monitored to detect Low Lubrication Oil Pressure. Specific alarm value and trip value have been set in the sensor.been set in the sensor.



1. Defect of gas turbine itself: Abnormal lubrication oil pump, clogged filter lubrication oil pump, clogged filter caused by abnormal bearing, etc.

2. External factor: Drop of lubrication oil level, etc.

3. Defect of control system: Defective oil pressure switch, etc.

5. Low Lubrication Oil Pressure5.1 Simplified Inspection of Equipment

Gas TurbineInspection item 1Visually check that engine (output shaft) is rotating smoothly as driven by turning motor.ObjectiveTo confirm that gas turbine itself and reduction gear are normal

Inspection item 2Manually rotate engine by hand to check for abnormal rotation or abnormal rotating soundObjectiveThis method is to be conducted if above inspection item 1 cannot be done by turning motor.

Inspection item 3Inspection item 3Check piping for any lubrication oil leakage.ObjectiveTo confirm that there is no oil leakage which can cause low oil pressure

Inspection item 4Check oil level of lubrication oil tank.ObjectiveTo confirm that there is no oil level drop which can cause low oil pressure

Inspection item 5Study of data before occurrence of problem- Lubrication oil temperature at bearing outlet.- Interval between alarm and trip.- Indication of clogged lubrication oil filterObjective

To confirm that bearing are normalTo confirm that filter is free of foreign matters

5. Low Lubrication Oil Pressure5.2 Inspection of Individual Control Devices


Inspection item 1

Inspection of lubrication oil pressure transmitter for looseness. Visual check for damage.

Objective

To confirm that the lubrication oil pressure transmitter is normal.

6. High Lubricating Oil Temperature

Temperature of lubricating oil supplied to gas turbine bearings is monitored to detect High Lubricating Oil Temperature. Specific alarm value has been set in the Specific alarm value has been set in the PLC.



1. Defect of gas turbine itself: Abnormal bearing, etc.bearing, etc.

2. External factor: Deteriorated oil cooler performance, etc.

3. Defect of control system: Defective oil temperature sensor, etc.


6.1 Simplified Inspection of Equipment

Gas Turbine

Inspection item 1

Visually check that engine (output shaft) is rotating smoothly as driven by turning motor.

Objective

To confirm that gas turbine itself and reduction gear are normal

Inspection item 2

Manually rotate engine by hand to check for abnormal rotation or abnormal rotating sound

Objective


Inspection item 3


- Lubricating oil temperature

- Lubricating oil at bearing outlet

Objective

To confirm that bearing are normal


6.2 Inspection of Individual Control Devices


Inspection item1

Inspection of lubrication oil temperature sensor (Pt 100-ohm resistance bulb). Measure resistance value.

Objective

To confirm that sensor is normal.To confirm that sensor is normal.

Date post:	06-Sep-2015
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Maintenance Manual for GPB30

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