CENTAUR 40, CENTAUR 50 AND TAURUS 60 GAS TURBINE

COMPRESSOR SETS

Introduction
Solar Turbines Incorporated is a worldwide leader in the design, manufacture and installation of industrial gas turbines. Solars 40 years of successful integration of high technology into fluid compression, liquid pumping, and industrial power generation applications has resulted in more than 10,000 gas turbine installations in 86 countries around the world. More than 850 million hours of operation has been logged in a wide range of applications, which gives testimony to the mature design and wide user acceptance of Solar's products. The gas turbine packages, with their selection of driven equipment and control system arrangements, are completely packaged systems that require a minimum of site preparation prior to installation. Solars gas turbine packages represent years of intensive development by the engineering and manufacturing groups of Solar Turbines Incorporated. The gas turbine packages are designed and applied by engineers specifically trained and experienced in the operation of gas turbines, gas compression and liquid pumping systems, power generation, and equipment installation. The gas turbines are manufactured to rigid industrial standards and are thoroughly tested in modern facilities. Solars operations are currently certified by Det Norske Veritas (DNV) to conform to the ISO 9000 series of Quality Systems Standards. The heart of the mechanical-drive and power generation package systems, the gas turbine, offers many reliable features. Its continuous-burning combustion cycle, combined with continuous rotation of the turbine rotor, allows virtually vibration-free operation. The gas turbine package delivers efficient and dependable performance. Both predesigned packages and custom-engineered systems are reviewed by specialists in equipment installation to help assure the optimum configuration. Qualified technical representatives from Solars Customer Services organization are available around the world to provide start-up supervision, maintenance planning and services, and operator training. We invite you to read further into this booklet to gain a greater appreciation of the features and benefits of Solars gas turbine packages and Solars commitment to single-source responsibility for high quality turbomachinery systems. This product description presents the basic package configuration, available options, ancillary equipment, installation requirements, and support services as of the date of publication. Please note that changes in the equipment and service descriptions and specifications may occur without prior notice.

Contents
Centaur 40, Centaur 50 and Taurus 60 Gas Turbine Compressor Sets
BASIC PACKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Centaur 40, Centaur 50 and Taurus 60 Gas Turbines

BASIC GAS TURBINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Driven Equipment
GAS COMPRESSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Control System
TURBOTRONIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL SYSTEM OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GAS COMPRESSOR CONTROLS AND MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL SYSTEM ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 10 10 14 18 19

Start Systems
PNEUMATIC START SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 DIRECT-DRIVE AC START SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Fuel System
NATURAL GAS FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 SOLONOx COMBUSTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Lubrication System
BASIC LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Seal Systems
SEAL OIL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 DRY GAS SEAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Ancillary Equipment
ENCLOSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INLET SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GAS TURBINE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXHAUST HEAT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 35 35 35 36 36 38 38 38 40 40 41 41 41

Installation Requirements
SITE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MECHANICAL INSTALLATION REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL INSTALLATION REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION AND MAINTENANCE MANUALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing and Quality Assurance

TEST FACILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERFORMANCE REVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . QUALITY ASSURANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT IMPROVEMENT PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Support Services
CONSTRUCTION SERVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 CUSTOMER SERVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 CONTRACT POWER AND LEASING SERVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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Illustrations
Typical Gas Turbine Compressor Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Typical Gas Turbine Gauge Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Typical Two-Shaft Gas Turbine and Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Typical Gas Turbine Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Typical Centrifugal Compressor Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Typical Centrifugal Compressor Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Typical Turbotronic Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Typical Operation Summary Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Typical Battery and Charger Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Typical Pneumatic Start System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Typical Direct-Drive AC Start System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Typical Variable Frequency Drive Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Typical Natural Gas Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Typical Lube Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Typical Compressor Seal Oil and Buffer Gas System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Typical Dry Gas Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Typical Dry Gas Seal System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Typical Dry and Wet Seal Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Typical Enclosure Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Typical Water-Wash Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Typical Service Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Typical Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Solars Customer Services Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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Conversion Chart
ABBREVIATIONS
abs ata Btu Btu/h C cfm cm cm2 cm3 cu ft F ft/s ft-lb ft-lbf /lb m fps gal hp in. in. Hg in. H2O kcal kg kg m kJ kPa ksi kW L m mm MMSCFD MPa m2 m3 m3/min mph N N/m2 nm3/h sm 3/h psi psia psig scf scfd scfm sq absolute atmosphere absolute British thermal unit British thermal unit/hour Degrees Celsius cubic foot/minute centimeter square centimeter cubic centimeter cubic foot Degrees Fahrenheit foot/second foot-pound foot-pound force/pound mass foot per second gallon horsepower inch inch mercury inch water kilocalorie kilogram kilogram mass kilojoule kilopascal 1000 pounds/square inch kilowatt liter meter millimeter millions of standard* cubic foot/day Megapascal square meter cubic meter cubic meter/minute miles per hour Newton Pascal normal** cubic meter/hour standard*** cubic meter/hour pounds/square inch pounds/square inch absolute pounds/square inch gauge standard* cubic foot standard* cubic foot/day standard* cubic foot/minute square To Convert From English sq in. sq ft lb/cu ft ft-lbf /lb m Btu Btu/h Btu/scf in. ft yd lb hp psi psia psig in. Hg in. H2O F F (Interval) mph ft/s cu ft gal (U.S.) cfm cfm scfm MMSCFD cm 2 kcal

CONVERSION FACTORS
To S.I. Metric mm2 m2 kg/m 3 kJ/kg kJ W kJ/nm 3 mm m m kg kW kPa kPa (a) kPa (g) kPa kPa C C (Interval) km/h m/s m3 L m3/min m3/s nm3/min nm3/min mm2 kJ Multiply By 645.16 0.0929 16.0185 0.0029891 1.0551 0.2931 39.3694 25.400 0.3048 0.914 0.4536 0.7457 6.8948 6.8948 6.8948 3.3769 0.2488 (F-32) 5/9 5/9 1.6093 0.3048 0.028317 3.7854 0.028317 0.00047195 0.0268 18.62 100 4.1868 To Old Metric cm 2 m2 kg/m 3 kJ/kg kcal kcal/h kcal/nm3 cm m m kg kW kg/cm 2 bars abs ata cm Hg cm H 2O C C (Interval) km/h m/s m3 L m3/min nm 3/h nm3/h Multiply By 6.4516 0.0929 16.0185 0.002989 0.252 0.252 9.382 2.540 0.3048 0.914 0.4536 0.7457 0.070 0.068948 0.070 2.540 2.540 (F-32) 5/9 5/9 1.6093 0.3048 0.028317 3.7854 0.028317 1.61 1117

To Convert From Old Metric kcal/h cm kg/cm 2 bars atm cm Hg cm H2O nm 3/h

To S.I. Metric W mm kPa kPa kPa kPa kPa nm 3/min

Multiply By 1.16279 10 98.0665 100.0 101.325 1.3332 0.09807 0.0167

PA98045M

* standard = 60F and 14.7 psia ** normal = 0C and 1.01325 x 105 Pascals *** standard = 15C and 760 mm Hg

Caterpillar is a registered trademark of Caterpillar Inc. Solar , Centaur, Taurus , Mars , SoLoNOx and Turbotronic are trademarks of Solar Turbines Incorporated. Specifications subject to change without notice. Printed in U.S.A. 1998 Solar Turbines Incorporated. All rights reserved.

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Centaur 40, Centaur 50 and Taurus 60 Gas Turbine Compressor Sets

BASIC PACKAGE
The gas turbine package is a completely integrated, fully operational package consisting of a power module for mating with the compressor skid and equipped with all accessories and auxiliary systems necessary for normal operation when connected to suitable facilities. In addition to the wide range of driven equipment available, various optional features can be supplied to meet varying installation and operating requirements. Designed specifically for industrial service, the gas turbine package is a compact, lightweight unit requiring minimum floor space for installation. Proven packaging features greatly reduce installation costs, time, materials, and labor. The gas turbine compressor set includes: Two-shaft industrial gas turbine Centrifugal gas compressor Gas turbine air inlet and exhaust collectors Gas turbine/compressor control console Start system Fuel system Lubricating oil system Seal system Base skid with drip pans Onskid electric system and wiring The base frame is a structural steel assembly with beam sections and cross members welded together to form a rigid foundation suitable for three-point mounting. Mechanical interface connection points for fuel, air, and water (for gas turbine cleaning) are conveniently located on the outer skid edge. Electrical connection points are made in onskid junction boxes and terminal strips. Package piping and manifolds are 316L stainless steel material. This applies to all package piping systems including the start, fuel and lube oil systems, supply, drain and vent lines up to and including 102 mm (4 in.) in diameter. In addition, the associated flange assembly hardware is 316 stainless steel. Piping sizes 152 mm (6 in.) in diameter and larger are carbon steel. The following items are not stainless steel, but may be considered for a material change: Valve bodies or blocks and system functional components Pipe supporting hardware such as cushion clamps and brackets Oil tank cover assemblies with connection piping and fittings welded in place Sliding lube oil drain couplings and plates Pipe flexible couplings Filter housings Lube oil tank

Onskid Tube Fittings

All tubing is 316 stainless steel using Swagelok brand dual ferrule 316 stainless steel compression fittings.

Onskid Gauge Panel

The onskid gauge panel includes various gauges depending on type of fuel system used and other fluid system options. Available as digital display or fluid gauges.

Onskid Electric System

Solar offers National Electrical Code (NEC) and International Electrotechnical Commission (IEC) onskid electric system options and several threephase motor voltage options to meet varying electrical supply and code requirements.

NEC, Class I, Group D, Division 1 or 2

All electric equipment on the basic package can be provided in accordance with the National Fire Protection Agency (NFPA) 70 (NEC) requirements for equipment installed in a Class I, Group D, Division 1 or 2 hazardous area. All wire runs are made in conduit for physical protection and isolation from combustible atmospheres. The gas turbine console and optional batteries and battery charger are nonexplosionproof and must be installed in a nonhazardous area.

LUBE OIL FILTERS Top View

OUTPUT DRIVE SHAFT

2438 mm (8')

TURBINE GAUGE PANEL

AIR INLET

EXHAUST

CENTRIFUGAL GAS COMPRESSOR

GAS TURBINE 2718 mm (8' 11") 2388 mm (7' 10")

2286 mm (7' 6")

EXHAUST COLLECTOR

LUBE OIL TANK VENT

COMPRESSOR GAUGE PANEL

1448 mm (4' 9") CONTROL CONSOLE Depth: 800 mm (2' 7-1/2") Side View

BASE FRAME

FORWARD MOUNT

AFT MOUNT 8915 mm (29' 3")

APPROXIMATE WEIGHTS

Centaur 40 kg lb 5700 7700

Centaur 50 kg 2631 3538 lb 5800 7800

Taurus 60 kg 3084 4173 lb 7200 9200

Gas Turbine Gas Turbine - SoLoNOx Gas Turbine Base and Accessories Gas Compressor - C401 Gas Compressor Base & Accessories Enclosure (not shown) Total Installed Dry Package Weight Standard SoLoNOx Control Console

2586 3493

7938 17,500 9772 21,500 4536 10,000 5443 12,000

7938 17,500 9772 21,500 4536 10,000 5443 12,000

7938 17,500 9772 21,500 4536 10,000 5443 12,000

26 853 59,200 26 898 59,300 27 533 60,700 27 760 61,200 27 805 61,300 28 440 62,700 635 1400 635 1400 635 1400
SPCUCS-002M

Typical Gas Turbine Compressor Set

1. 2. 3. 4. 5. 6. 7. 8.

Lube Oil Filter P Compressor Discharge Pressure Lube Oil Pressure Fuel Gas Pressure Lube Oil Temperature Enclosure Pressure (Optional) Intrinsically Safe Junction Box Junction Box

PA98016M

Typical Gas Turbine Gauge Panel

IEC, Zone 1
All electric equipment is in accordance with IEC standards for electric equipment in Zone 1, Group IIA hazardous locations per Solars specifications ES 1762 and ES 2007. The package is wired with armored multi-conductor cables and cable glands where the cable enters a component or terminal box. Stainless steel cable trays are used to support, protect and route the armored cables. Separate cable trays are used to segregate intrinsically safe cables from instrumentation and control cables. The gas turbine console and optional batteries and battery charger are

nonexplosionproof and must be installed in a nonhazardous area.

Three-Phase Motor Voltage

All three-phase motors on the package have the same voltage rating. The required motor starters are not included. The standard available motor ratings are: 460 Vac, 60 Hz 575 Vac, 60 Hz 380 Vac, 50 Hz 400 Vac, 50 Hz 415 Vac, 50 Hz

Centaur 40, Centaur 50 and Taurus 60 Gas Turbines

BASIC GAS TURBINE
The gas turbine is a self-contained, completely integrated prime mover of a two-shaft, axial-flow design. The exceptionally compact gas turbine has four basic sections: compressor, combustor, gas generator turbine, and power turbine. The gas generator and power turbine have separate shafts and are mechanically independent. The gas turbine assembly consists of: Accessory drive assembly Air inlet collector Axial-flow compressor Annular combustor Gas generator turbine assembly Power turbine assembly Gas turbine exhaust collector The components of the gas turbine are maintained in accurate alignment by mating flanges with pilot surfaces and are bolted together to form a rigid assembly. The accessory drive assembly is driven by the compressor rotor shaft. The accessory drive supports and drives the main lube oil pump and start motor, as well as other accessories depending on the application. The gas turbine design includes the fundamental principles of long life and low maintenance. Reflecting a design philosophy that combines the outstanding performance traits of the gas turbine with the rugged construction best suited for industrial use, the gas turbine has been designed for a high degree of compliance with American Petroleum Institute (API) requirements. One of the key design parameters of the gas turbine is to operate at gas temperatures and stress levels that provide maximum assurance of long life for the major rotating and stationary components. Another prime design objective is dependability. While many factors contribute to the dependability of the basic gas turbine, the selection of proper controls and gas turbine accessories is a major element. The gas turbine incorporates Solars advanced aerodynamic and mechanical technology and design. The structural concept of Solars gas turbines is unique in the engineering of gas turbines. With a few exceptions, contemporary machines have been designed to two extremes: either they are designed specifically to aircraft practices of highly sophisticated construction for lightweight but short life or they are designed with the massiveness of industrial steam turbines to ensure long life. In keeping with an optimum philosophy, the construction of Solars gas turbines lies between the two extremes.

Principles of Operation
The continuous power cycle and rotary motion of a gas turbine provides several advantages over other types of engines, including relatively vibrationless operation, as well as fewer moving parts and wear points.

SoLoNOx Gas Turbine

The SoLoNOx gas turbine is a self-contained, completely integrated prime mover of a two-shaft, axialflow, dry emissions control design. The combustion system is an annular type with lean-premixed fuel injectors. This system reduces pollution by limiting the formation of nitrogen oxides (NOx) and carbon monoxide (CO). Lean-premixed combustion results in lower maximum flame temperature which reduces pollutant formation.

FUEL AIR

COMBUSTOR EXHAUST

GEARBOX (if required)

SHAFT DRIVEN EQUIPMENT

PA98017M

COMPRESSOR

TURBINE

Typical Two-Shaft Gas Turbine and Load

EXHAUST COLLECTOR TURBINE EXHAUST DIFFUSER NOZZLE CASE ASSEMBLY BLEED AIR VALVE FUEL INJECTOR COMPRESSOR DIFFUSER ASSEMBLY COMPRESSOR CASE ASSEMBLY COMPRESSOR ROTOR ASSEMBLY ACCESSORY DRIVE ASSEMBLY OUTPUT DRIVE SHAFT ASSEMBLY

POWER TURBINE ROTOR ASSEMBLY GAS GENERATOR TURBINE ROTOR ASSEMBLY COMBUSTOR HOUSING ASSEMBLY COMPRESSOR VARIABLE VANE ASSEMBLIES AIR INLET ASSEMBLY GAS FUEL MANIFOLD

PA98018M/S

Typical Gas Turbine Cutaway

Driven Equipment
GAS COMPRESSORS
Solar has developed a line of centrifugal gas compressors designed specifically to match the operating speeds of Solars gas turbines. All of Solars gas turbine packages can be provided with matching integrated centrifugal compressor modules, available in single-body, two-body, or three-body tandem units for direct-drive or gear-driven applications. Solars approach to compressor design is to maximize simplicity and flexibility. Solar gas compressors are designed to achieve a minimum of three years of continuous full-load duty between inspections, and major components are designed for 20 years of continuous operation. Many of the features commonly used in Solar compressor designs conform to American Petroleum Institute (API) 617. Standard features include: Vertically split barrel-type construction Tilt-pad journal bearings Self-aligning tilt-pad thrust bearings Rigid modular rotor construction Rotor trim balancing Overcompensating balance piston Radial vibration measurement Thrust bearing temperature sensors Solars compressor packages are complete with all unique system requirements built into the basic package. This inherent single-source responsibility eliminates any risk of drive train incompatibility or performance questions that may arise when the driver and driven compressors are built by different manufacturers. For more details about Solars centrifugal compressors and compressor sets, please refer to Solars publications B-O&G, SPCC, DS40CS, DS50CS and DS60CS. Impellers. Compressor impellers are designed to conservative stress levels. All impellers are suitable for sour gas applications. Each impeller, after machining, is proof tested to 115% of its maximum mechanical speed. Rotor Assembly. The rotor assembly consists of stub shafts, impellers, and, if required, rotor spacers (to maintain a constant bearing span) and a centerbolt. These components are individually balanced and are rabbet-fit to each other for concentric alignment. Torque is transmitted through dowel pins. The entire assembly is clamped together with the centerbolt. 6 The rotor assembly is easy to disassemble. The benefits from this type of construction are two-fold. Impellers that can be used in a restaged rotor are easily salvaged and downtime is minimized. Reusing old impellers, instead of purchasing new ones to match new operating conditions, enhances the economic feasibility of restaging to maintain optimum compressor performance and the lowest possible operating costs. Casings. The pressure-containing outer casing of a compressor is an assembly of three components: the suction and discharge end caps, which contain the bearing and seal assemblies, and the centerbody, which holds the rotor and stator assemblies. This is considered a vertically split barrel design. The end caps contain all the service ports for oil and gas. Compressor Module. The compressor module includes the centrifugal compressor(s) mounted on a structural steel matching base which, when bolted to the driver skid, forms a continuous base plate on which all the required subsystems are installed. Lube Oil System. The gas turbine, gearbox (if required), and compressor modules have a common lube oil system. Seal Oil System. On certain compressor models, a seal oil system and a seal buffer gas system are provided to contain the gas within the gas compressor. The high pressure main seal oil pump is turbine driven and an auxiliary seal oil pump is provided for start-up and shutdown. Dry Seals. On some compressor models, it is possible to provide a complete dry seal system. Solars gas compressor tandem dry seal consists of a primary seal, a secondary backup seal, and a shaft buffer air (or nitrogen) circumferential seal which prevents lubricating oil leakage into the secondary seal. Hydrostatic Testing. Hydrostatic pressure testing of all compressor casings and end caps is done per API 617 for 30 minutes at 1.5 times the maximum casing design pressure, regardless of application. Test water is treated with a wetting agent to allow better penetration of possible casing defects. After the hydro and final magnetic particle test, the casing is steam cleaned and bead blasted for surface preparation. Afterwards, it is painted per Solars specification ES 9-58.

Shaft Coupling. Solars standard shaft interconnect is a Kop-Flex dry coupling. In some cases, a continuously lubricated gear-type coupling is provided.

Preliminary Alignment. The drive train is aligned preliminarily at the factory to simplify final field alignment.

INLET GUIDE VANE

INLET HOUSING

STATOR ASSEMBLY

IMPELLER

CASING

DISCHARGE CAVITY SUCTION FLANGE (Port) DISCHARGE BEARING AND SEAL ASSEMBLY

BALANCE PISTON

DISCHARGE FLANGE (Port) COUPLING HUB OR BALANCE SLEEVE SUCTION BEARING AND SEAL ASSEMBLY STATOR DIFFUSER PASSAGE

PA98020MS

Typical Centrifugal Compressor Cutaway

END CAP

CASING

INLET CAVITY

VANELESS DIFFUSER

DIAPHRAGM

DISCHARGE CAVITY

LABYRINTH SEAL

STATIC

ROTATING

TRIM BALANCE

THRUST BEARINGS

STUB SHAFT

IMPELLER

ROTOR SPACER

TIE BOLT

SHAFT SEALS

JOURNAL BEARING

COUPLING HUB
PA98021M

Typical Centrifugal Compressor Cross Section

Compressor Characteristics
Compressor Frame No. of Size Stages Casing Pressure Rating (a,b), kPa (psig) Maximum Flow (a), 3 m /min (cfm) Minimum Flow (a), 3 m /min (cfm) Maximum Head per Stage (a), kJ/kgm (ft-lb f/lbm ) Maximum Total Head (a), kJ/kg m (ft-lb f/lb m) Maximum Impeller Dia., mm (in.) Maximum Speed, rpm

C160A C160B C160C C160RA C160RB C166S C167S C167P C284 C304 C306 C334I C336I C337IS C337IP C338I C401 C402 C404A C404B C406A C406B C451 C452 C505J C505U C651 C652

1-10 1-10 1-10 1-10 1-10 1-6 2-6 1-3 1-4 1-4 1-6 1-6 1-9 2-8 1-4 1-12 1 1-2 1-5 1-5 2-6 2-6 1 1-2 1-5 1-5 1 1-2

10 350 10 350 10 350 15 513 20 700 31 050 10 350 10 350 5 175 10 350 10 350 13 800 13 800 8 280 8 280 13 800 11 040 11 040 13 800 17 240 13 800 17 240 15 500 15 500 2 760 10 350 11 040 11 040

(1500) (1500) (1500) (2250) (3000) (4500) (1500) (1500) (750) (1500) (1500) (2000) (2000) (1200) (1200) (2000) (1600) (1600) (2000) (2500) (2000) (2500) (2250) (2250) (400) (1500) (1600) (1600)

50.95 50.95 50.95 50.95 50.95 50.95 45.30 90.60 274.60 212.35 212.35 268.95 243.53 232.20 461.57 237.85 269.00 269.00 254.85 254.85 254.85 254.85 453.07 254.85 566.34 509.71 566.34 566.34

(1800) (1800) (1800) (1800) (1800) (1800) (1600) (3200) (9700) (7500) (7500) (9500) (8600) (8200) (16,300) (8400) (9500) (9500) (9000) (9000) (9000) (9000) (16,000) (9000) (20,000) (18,000) (20,000) (20,000)

4.25 4.25 4.25 4.25 4.25 4.25 4.25 4.25 22.65 22.65 22.65 22.65 22.65 22.65 22.65 22.65 33.98 42.48 22.65 22.65 22.65 22.65 79.29 99.10 70.80 62.30 113.27 141.59

(150) (150) (150) (150) (150) (150) (150) (150) (800) (800) (800) (800) (800) (800) (800) (800) (1200) (1500) (800) (800) (800) (800) (2800) (3500) (2500) (2200) (4000) (5000)

22.1 22.1 22.1 22.1 22.1 22.1 21.5 21.5 59.8 37.4 31.4 59.8 38.8 38.8 38.8 35.9 52.0 53.8 44.8 44.8 44.8 44.8 66.0 44.8 56.8 44.8 57.0 53.8

(7400) (7400) (7400) (7400) (7400) (7400) (7200) (7200) (20,000) (12,500) (10,500) (20,000) (13,000) (13,000) (13,000) (12,000) (19,000) (18,000) (15,000) (15,000) (15,000) (15,000) (22,000) (15,000) (19,000) (15,000) (19,000) (18,000)

215 215 215 215 215 132 129 64 239 149 191 299 281 281 140 323 57 96 170 170 254 254 66 90 284 224 57 96

(72,000) (72,0000 (72,000) (72,000) (72,000) (44,000) (43,000) (21,500) (80,000) (50,000) (64,000) (100,000) (94,000) (94,000) (47,000) (108,000) (19,000) (32,000) (57,000) (57,000) (85,000) (85,000) (22,000) (30,000) (95,000) (75,000) (19,000) (32,000)

191 191 191 191 191 191 178 178

(7.50) (7.50) (7.50) (7.50) (7.50) (7.50) (7.00) (7.00)

22, 300 22, 300 22, 300 22, 300 22, 300 22, 300 22, 300 22, 300 22, 300 16, 500 15, 500 20, 800 16, 500 16, 500 16, 500 16, 500 14, 300 14, 300 14, 300 14, 300 14, 300 14, 300 12, 000 12, 000 12,000 12, 500 9730 9730

305 (12.00) 305 (12 00) 305 (12.00) 327 (12.86) 327 (12.86) 327 (12.86) 327 (12.86) 327 (12.86) 452 (17.80) 419 (16.50) 381 (15.00) 381 (15.00) 381 (15.00) 381 (15.00) 560 (22.06) 560 (22.06) 457 (22.06) 457 (18.00) 665 (26.17) 616 (24.25)

(a) Capability of the compressor may vary depending upon maximum package speed, suction conditions, gas composition, impeller material and discharge condition. (b) Mating flange limit could be lower than the case rating pressure.

Compressor Casing Data

Maximum Compressor Weight, kg (lb)

Frame Size

Suction Port, mm-kPa (in.-psig)

Discharge Port, mm-kPa (in.-psig)

C160A C160B C160C C160RA C160RB C166S C167 C284 C304 C306 C334I C336I C337I C338I C401 C402 C404A C404B C406A C406B C451 C452 C505J C505U C651 C652

1066 1066 1066 1996 1996 2631 515 3084 4264 5443 5443 7031 9526 7983 752 12 200 10 569 10 569 12 088 12 088 19 051 22 680 9072 19 278 28 350 34 474

(2350) (2350) (2350) (4400) (4400) (5800) (7750) (6800) (9400) (12,000) (12,000) (15,500) (21,000) (17,600) (21,500) (26,900) (23,300) (23,300) (26,650) (26,650) (42,000) (50,000) (20,000) (42,500) (62,500) (76,000)

203-4137 152-6205 203-4137 203-6205 203-10 342 203-17 237 356-4137 305-2758 406-6205 406-6205 406-6205 406-6205 610-4137 406-6205 508-6205 508-6205 406-6205 406-10 324 406-6205 406-10 324 610-6205 610-6205 610-2068 610-6205 762-6205 762-6205

(8-600) (6-900) (8-600) (8-900) (8-1500) (8-2500) (14-600) (12-400) (16-900) (16-900) (16-900) (16-900) (24-600) (16-900) (20-900) (20-900) (16-900) (16-1500) (16-900) (16-1500) (24-900) (24-900) (24-300) (24-900) (30-900) (30-900)

203-4137 152-6205 152-6205 203-6205 203-10 342 203-17 237 356-4137 305-2758 406-6205 406-6205 406-6205 406-6205 610-4137 406-6205 508-6205 508-6205 406-6205 406-10 324 406-6205 406-10 324 610-6205 610-6205 610-2068 610-6205 762-6205 762-6205

(8-600) (6-900) (6-900) (8-900) (8-1500) (8-2500) (14-600) (12-400) (16-900) (16-900) (16-900) (16-900) (24-600) (16-900) (20-900) (20-900) (16-900) (16-1500) (16-900) (16-1500) (24-900) (24-900) (24-300) (24-900) (30-900) (30-900)

Control System
TURBOTRONIC CONTROLS
The Turbotronic control system is a highly integrated programmable logic controller (PLC) based control system with a video display terminal (VDT) and operator interface panel. The main elements of the system are the PLC, input/output modules, VDT, relay backup system, control and monitoring software, freestanding console, and the package sensing and control elements. ous area. The gas turbine control panel, with all necessary switches and indicators for gas turbine operational status, is installed on the front of the control console. All components within the console are factory interconnected and wired to terminal strips to facilitate user connection to the turbomachinery package and other equipment as necessary. Labels and labeled user connections are in English, but can be provided in other languages. The package parameters displayed on the VDT can be in SI, Metric or English units. Please refer to Solars publication BTT(1), Turbotronic Systems, for additional information.

CONTROL OPERATION
The control system, operating on 24-Vdc power, provides for automatic starting, acceleration to operating speed, sequencing control, gas turbine and driven compressor monitoring during operation, and normal and malfunction shutdown. During operation, the control system, by means of automatic warning and shutdown devices, protects the gas turbine and driven compressor from possible damage resulting from hazards such as turbine overspeed, high turbine temperature, low lubricating oil pressure, and excessive oil temperature. The PLC performs control, sequencing and protection functions, as well as detection and annunciation of abnormal operating conditions. The PLC also controls start-up, operation, and shutdown sequences. Control for these functions comes from signals the microprocessor receives from solid-state devices, control switches, speed probes, pressure and temperature transmitters, relays, and solid-state vibration monitors. These components provide the PLC with the data necessary to control and maintain gas turbine speed and temperature at safe levels. In the event of an abnormal condition or malfunction, the control system indicates the nature of the malfunction. When an alarm or shutdown is displayed on the VDT, a sequence of appropriate operations begins in response to the detected condition. In the event of a control system failure, the backup relay system provides for a safe and orderly shutdown. The backup relays operate the lubricating oil system and other subsystems, as required, to avoid gas turbine and driven compressor damage during shutdown.

Controls and Instrumentation

Typical gas turbine controls located on the face of the console include the following:

Operation Switches. Off/Local/Remote (control selector with lockable positions) Start Normal Stop (shutdown with normal no-load cooldown) Emergency Stop (shutdown without cooldown) Horn Silence, audible alarm Acknowledge (alarms and shutdowns) Reset (alarms and shutdowns) Lamp Test Backup Reset Speed Control (increase and decrease) Manual Antisurge Valve (open/close) (with optional surge control system) Series/Parallel Select (with series/parallel compressor) Load Set Point Auto/Manual (with process control option) Test Crank Gas Turbine Wash (with selected option) Operation Indication Lights. Local/Remote Ready Starting Ready to Load On Load Backup Active

CONTROL SYSTEM COMPONENTS

The control system is normally provided in a freestanding, nonexplosionproof, front-access console. The console is designed for mounting in a nonhazard-

10

View A 6 7 8 9 10 11 1 18 19 20 21 22 28 29 30 31 2 (see View A) 3 4 5 32

2286 mm 90"

12 13 14 15 16 17 24 25 26 27 23 34 35 36 37 33

1448 mm (57")

1. CO2 Release Button (a) 2. Turbine Control Panel 3. Video Display Terminal 4. Numeric Key Pad 5. Function Keys 6. Unit Ready Indicator 7. Starting Indicator 8. Ready to Load Indicator 9. On Load Indicator 10. Spare Indicator 11. Local/Remote Operation Indicator 12. Spare Indicator 13. Cooldown Indicator 14. Stopping Indicator 15. Alarm Summary Indicator 16. Shutdown Summary Indicator 17. Backup Active Indicator 18. Gas Select Indicator 19. Liquid Select Indicator

20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37.

Open LP Surge Control Valve (b) Close LP Surge Control Valve (b) Off/Local/Remote Switch Emergency Stop Button Open IP Surge Control Valve (b) Close IP Surge Control Valve (b) Open HP Surge Control Valve (b) Close HP Surge Control Valve (b) Horn Silence Switch Acknowledge Switch Reset Switch Lamp Test Switch Backup Reset Switch Normal Stop Switch Start Switch Auto/Manual Switch Speed Decrease Switch Speed Increase Switch

NOTE: (a) Optional with fire detection system (b) Optional with gas compressor surge control system
PA98022M

Typical Turbotronic Control Console

Cooldown Stopping Alarm Summary Shutdown Summary (lockout)

Local Video Display Terminal

The operator interface is a color video display terminal, which allows the operator to address and monitor most vital parameters in the system. The following displays and features are typical: Operation Summary operating mode, status and analog information Temperature Summary Vibration Summary (with vibration monitoring option) Meters display of all analog parameters First-Out Alarms status display of first four alarms/shutdowns Alarms listing of alarms/shutdowns with time and date stamp Trigger Log when selected event occurs, stores data in RAM for later viewing Discrete Event Log history of all discrete changes

Data Download saves selected range of data for use in playback mode Program Constants display and modification of constant values (K-values) System Manager display of system maintenance screens Unit Valve Summary (when appropriate for application)

PA98024M/S

Typical Operation Summary Display

11

Typical Gas Turbine Package Alarm and Shutdown Indications

Indication Turbine Systems
Turbine Temperature (T5) High Turbine Temperature (T5) High Delayed Shutdown Gas Generator and Power Turbine Thrust Bearing Temperature High Ignition Failure Power Turbine Overspeed Power Turbine Backup Overspeed Power Turbine Underspeed Gas Turbine Flameout Vibration High (Turbine Summary) Vibration High, Individual Channels Gas Generator Overspeed T 5 T High Lube Oil Drain Temperature High, No. 1 Bearing Lube Oil Drain Temperature High, No. 2 & 3 Bearings Lube Oil Drain Temperature High, No. 4 & 5 Bearings NOx Concentration High X X FSL CSN FSL Basic Set Basic Set Thrust Bearing Temperature Monitoring (Provided on Centaur 50 and Taurus 60. Not available on Centaur 40.) Basic Set Basic Set Basic Set Basic Set Exhaust Heat Recovery Interface Vibration Monitoring Vibration Monitoring Basic Set Basic Set Lube Oil Drain Temperature Monitoring Lube Oil Drain Temperature Monitoring Lube Oil Drain Temperature Monitoring Predictive Emissions Monitoring Gearbox Applications X X FSN CSN Gearbox Vibration Monitoring Gearbox Lube Oil Drain Temperature Monitoring

Alarm

Shutdown

Supplied with

X X X X X X X

FSN FSN FSL FSN FSN FSN FSN FSN

Gearbox Systems
Vibration High, Individual Channels Lube Oil Drain Temperature High

Compressor Systems
Discharge Pressure High Discharge Temperature High Suction Pressure Low Compressor Surge Yard Valve Sequence Failure Thrust Bearing Temperature High Suction Journal Bearing Temperature High Discharge Journal Bearing Temperature High Suction Lube Oil Drain Temperature High Discharge Lube Oil Drain Temperature High Suction Bearing Vibration High, per Channel Discharge Bearing Vibration High, per Channel X X X CSN FSN CSN FSL FSL FSL FSL FSL Basic Set Basic Set Basic Set Surge Detection System Basic Set Thrust Bearing Temperature Monitoring Journal Bearing Temperature Monitoring Journal Bearing Temperature Monitoring Lube Oil Drain Temperature Monitoring Lube Oil Drain Temperature Monitoring Vibration Monitoring Vibration Monitoring

X X X X X X X

FSN FSN

Control Systems
T1 RTD Failure Multiple T 5 TC Failure T 5 Reference Junction RTD Failure Vibration Monitor Failure Power Turbine Breakaway Failure Backup Overspeed Probe Open Emergency Stop Manual Low Battery Voltage High Battery Voltage Battery Charger Failure PLC Monitoring Atmospheric Pressure Transmitter Failure Atmospheric Humidity Transmitter Failure Surge Control Transmitter Failure Gas/PCD P Transmitter Failure Lube Oil Header Temp RTD Failure Fuel Primary Valve Output Module Failure Fuel Secondary Valve Output Module Failure CSL CSL CSL X FSN FSL FSL FSL Basic Set Basic Set Basic Set Basic Set Basic Set Basic Set Basic Set Basic Set Basic Set Control Battery System Basic Set Predictive Emissions Monitoring Predictive Emissions Monitoring Solars Surge Control Basic Set Basic Set Basic Set Basic Set

X X X X X

FSL

CSN FSL CSL FSL FSL

12

Typical Gas Turbine Package Alarm and Shutdown Indications, Contd

Indication Start System
Fail to Crank Fall to Start FSN FSN Basic Set Basic Set

Alarm

Shutdown

Supplied with

Fuel System
Gas Fuel Start Flow High Gas Fuel Supply Pressure High Gas Fuel Supply Pressure Low Gas Fuel Valve Fail X X X FSN FSL FSN Basic Basic Basic Basic Set Set Set Set

Lubrication System
Lube Oil Tank Temperature Low Lube Oil Header Temperature High Oil Pressure Low Prelube Oil Pressure Low Oil Level Low Oil Level High Oil Filter P High Lube Oil Tank Pressure High Backup Postlube Pressure Low X X X X X X FSN CSN FSL FSN CSL Basic Set Basic Set Basic Set Basic Set Basic Set Lube Oil Auto-Fill System Basic Set Lube Tank Ventilation Backup Postlube Pump

CSN FSL

Seal System
Seal Gas Filter P High Seal Gas P Low Seal Leakage Discharge High Seal Leakage Suction High Buffer Air P Low Seal Oil P Low Seal Oil Filter P High Seal Buffer Gas P High Seal Buffer Gas P Low X X X X X X X X X FSL FSL FSL CSN FSL Dry Seal Dry Seal Dry Seal Dry Seal Dry Seal Oil Seal Oil Seal Oil Seal Oil Seal

Ancillary Systems
Inlet Air Filter P High Inlet Air Filter Blower Motor Failure Enclosure Ventilation Failure Enclosure Temperature High Enclosure Pressure Low Gas LEL High, Enclosure Gas Level Transducer Failure Fire System Fault Fire System Locked Out Fire System Fire Detected Fire System Discharged Enclosure Vent Filter P High Fuel Gas Filter P High Evaporative Cooler System Failure Exhaust Heat Recovery System Gas Turbine Start Inhibit Exhaust Heat Recovery System Malfunction X X X X X X X X CSN FSL Inlet Air Filter Air Inlet Air Filters with Scavenge Fan Enclosure Enclosure Alarms Pressurized Enclosure Gas Detection System Gas Detection System Basic Set Fire Protection System Fire Protection System Fire Protection System Enclosure Vent Filter Requires External Input Signal Inlet Evaporative Cooler Requires External Input Signal Requires External Input Signal

FSL

FSL FSL X X X X X

CSN FSL

13

Typical Gas Turbine Package Alarm and Shutdown Indications, Contd

Indication External Process Systems
Gas Scrubber 1 Level High Gas Scrubber 2 Level High Gas Scrubber 3 Level High Gas Scrubber 1 Level Low Gas Scrubber 2 Level Low Gas Scrubber 3 Level Low Station Gas Cooler Discharge Temperature High Gas Cooler 1 Discharge Temperature High Gas Cooler 2 Discharge Temperature High Gas Cooler 3 Discharge Temperature High Station Gas Cooler Vibration High Gas Cooler 1 Vibration High Gas Cooler 2 Vibration High Gas Cooler 3 Vibration High FSN FSN FSN FSN FSN FSN FSN FSN FSN FSN FSN FSN FSN FSN Requires External Input Signal Requires External Input Signal Requires External Input Signal Requires External Input Signal Requires External Input Signal Requires External Input Signal Requires External Input Signal Requires External Input Signal Requires External Input Signal Requires External Input Signal Requires External Input Signal Requires External Input Signal Requires External Input Signal Requires External Input Signal

Alarm

Shutdown

Supplied with

CSL CSN FSL FSN

= = = =

Cooldown Stop Lockout, initiated by automatic shutdown Cooldown Stop Nonlockout, initiated by automatic shutdown and Stop button Fast Stop Lockout, initiated by automatic shutdown and Emergency Stop button Fast Stop Nonlockout, initiated by automatic shutdown Driven equipment load is shed and unit is run at no-load for five minutes at idle speed before shutdown. Driven equipment load is shed and unit is shutdown immediately. System is reset from local gas turbine control panel only. System is reset from local gas turbine control panel or optional remote video display, optional serial link interface or customer provided switch.

Cooldown: Fast Stop: Lockout: Nonlockout:

Data stored in memory (such as trigger log, data download and optional historical displays) can also be viewed using the Playback (Online and Off-line) Modes.

Gas Turbine Compressor Cleaning Systems, On-Crank and On-line (Optional)

Two separate compressor cleaning systems are available. These systems are designed for washing the contaminating deposits of dust, salt, oil or other impurities which may collect on the gas turbine compressor blades and degrade gas turbine performance. Both systems include a distribution manifold with spray nozzles and associated onskid piping and solenoid-operated shutoff valves. With the on-crank system, the gas turbine is operated at the maximum speed attainable from the start system, with fuel and ignition systems deactivated. The on-line cleaning system is operable between 90% and 100% gas generator speed, with or without load on the driven equipment. The on-line system is available as a supplement to the on-crank system and does not replace the requirement for periodic on-crank detergent or fluid cleaning (depending on site-specific contamination). Gas turbine cranking is initiated from the onskid gauge panel or the control console operator

CONTROL SYSTEM OPTIONS Local and Remote Video Display Terminal (Optional)
In addition to the local display terminal described above, a remote VDT is supplied for display and control of specific functions. The display provides all of the information available on the control console VDT, but at a separate location. Screen displays can be selected independent of the control consolemounted VDT and include the ability to start, normal stop, acknowledge, reset and control package speed/ load set point. The remote VDT and control operate over a usersupplied RS232C serial link connected to the local gas turbine control console and can be connected up to 15 m (50 ft). For longer distances, boosters, converters, modems, telemetry, or common carrier approaches may be used.

14

interface panel and water/cleaning solution flow is activated from the operator interface panel.

The following table provides a summary of the available configurations:

Available Vibration Monitoring Configurations
Quantity Gas Turbine
2 5 10 Velocity Proximity Proximity Gas Turbine Diffuser/ Power Turbine Case 1Y each Bearing (Not available on Centaur 40.) 1X and 1Y each Bearing (Not available on Centaur 40.)

Vibration Monitoring Systems (Optional)

This system consists of a Bently Nevada Model 2201 vibration monitoring system designed specifically to operate within and interface directly with the Turbotronic PLC. As an integral part of the monitoring system, the PLC is used to configure the 2201 system which communicates monitoring status back to the PLC. The reading of current values, processing of alarm signals, and system configuration are some of the functions performed by the PLC. The 2201 system monitor and associated channel monitors plug into the Turbotronic chassis and receive input power from the PLC. User interface with the monitor is provided via the PLC video display terminal (VDT). The system monitor communicates with the PLC as an intelligent I/O module employing block transfer for configuration and transferring data to the PLC. Some alarm status information is accomplished via discrete data transfer. All data available to the PLC are also available via serial link for user remote monitoring, diagnostics and trending. Several different package vibration monitoring configurations are available to provide vibration indication and protection through preset warning indication and shutdown initiation in the event of unacceptable vibration levels in the gas turbine, gearbox and compressor. Vibration level, alarm and shutdown indications are displayed on the control system video display terminal. The available configurations provide a varying degree of protection and transducer types. Gas turbine vibration monitoring is available with velocity transducers mounted on the gas turbine diffuser case and the power turbine case, or single proximity probes at each of the five gas turbine bearings, or two proximity probes placed 90 degrees apart at each gas turbine bearing. In addition, both types of transducers may be employed using the velocity transducers for package alarm and protection and the proximity probes for gas turbine diagnostics. Gearbox vibration monitoring is also available using either accelerometers, single proximity probes or dual proximity probes at the input and output shaft bearings. The vibration monitoring system will also accommodate as many channels as are required from velocity, accelerometer or proximity probe inputs to support the compressor vibration monitoring and protection requirements. A power turbine keyphasor is also available for use with the dual proximity probe configuration to provide additional vibration diagnostic capability with the use of externally applied diagnostic equipment.

Type

Location

Gearbox
2 2 4 Accelerometer Proximity Proximity Gearbox Case 1Y each Input and Output Shaft Radial Bearing 1X and 1Y each Input and Output Shaft Radial Bearing

Compressors
As Required X and Y proximity probes, keyphasors, and bearing temperature sensors

Gas Turbine Thrust Bearing Temperature Monitoring (Optional Not available on Centaur 40)
The gas turbine thrust bearing temperature monitoring system provides temperature indication and protection through preset warning indication and shutdown initiation in the event of unacceptable gas turbine thrust bearing temperature. The system monitors RTDs at both the gas generator and power turbine thrust bearings. Temperature level, alarm and shutdown indications are displayed on the control system video display terminal.

Lube Oil Drain Temperature Monitoring (Optional)

Lube oil drain temperature monitoring system options are available to provide temperature indication and preset warning in the event of unacceptable lube oil drain temperature. Options are available for monitoring RTDs located in the gas turbine, gearbox, and compressor lube oil drain lines. Temperature level and alarm indications are displayed on the control system video display terminal.

Gas Turbine Performance Map Display (Optional)

The gas turbine performance map displays realtime gas turbine performance corrected to standard conditions. The performance map is essentially

15

for reference and is used to monitor trends in gas turbine performance, not to verify absolute gas turbine performance levels. The system includes instrumentation to measure flow of the fuel to the gas turbine and requires certain static and dynamic inputs from the driven equipment. (See Gas Compressor Performance Map Display.) For gas fuel flow measurement, an orificed metering run is provided for offskid field installation. The metering run includes an upstream pressure transmitter, an orifice delta P transmitter and thermowell with RTD. For liquid fuel flow measurement, an onskid rotary transducer is provided.

predetermined alarm and shutdown level at a defined future time.

Printer/Logger (Optional)
The data logging and print system provides event logger, standard report form and screen print functions. The system consists of the control software and a table-top 80/160-column dot-matrix printer, available in 120 or 240 Vac, single phase, 50/60 Hz and a 7.6-m (25-ft) interconnect cable. For multiple unit applications, the control software can be configured for a dedicated printer for each unit or one printer for several units. The following functions are provided: Status Print current value of analog and status of discrete variables. Menu selectable and automatically generated on shutdown event followed by first-out alarm print. Alarm Logging prints alarm with time and date stamp. Daily Log last 24 hours of elapsed time data. Print Screen prints current screen. Historical Files prints data from all historical files.

Historical Displays (Optional)

The following maintenance and diagnostic programs are available to assist in routine monitoring of the gas turbine condition, as well as to make informed predictions of the future health of the unit. The historical display option includes running time display, elapsed time display and predictive trend monitoring as described below: Running Time Display. The running time display feature provides a four-channel strip chart recorder format displayed on the video display terminal. It provides simultaneous plots of multiple, operatorselected analog variables in real time of four selectable variables at selected time scales. Each plot is scaled for the selected variable and displays the numerical value of the raw data for each variable for actual running time only. Data are compressed after a period of time by averaging groups of data points so successively longer-term data are stored. Data are stored only while the gas turbine is running so that trends relate to only operational data. Any four parameters may be displayed at one time. Data to be plotted are chosen from an array of gas turbine and compressor parameters, including lube temperature, gas turbine temperature, gas turbine pressures, gas turbine vibration, air inlet system, and gas compressor data. Elapsed Time Display. The elapsed time display feature is used for plotting and determining trends in gas turbine or gas compressor data. Selected analog variables are stored on disk whether or not the unit is in operation, providing a continuous data file of all stored analog parameters. Data are saved at predetermined intervals and can be retrieved for analysis. Typically, data are stored at hourly intervals with approximately one month of data per disk. Predictive Trend Monitoring. The predictive trend monitoring feature analyzes the running time historical data base and approximates the future analog signal trends. Deteriorating trends result in a display that has the trend line intersecting a

Predictive Emissions Monitoring System (Optional)

The predictive emissions monitoring system (PEMS) predicts NOx (oxides of nitrogen) emissions concentration and flow in the gas turbine exhaust. The system does not measure or predict CO (carbon monoxide) or UHC (unburned hydrocarbons) emissions. The predictions are based on gas turbine measured T1 and T5 temperature and gas turbine inlet air pressure and relative humidity. The calculations are done once per minute. The concentration predictions are averaged to provide hourly averages. The flow predictions are totalized to provide hourly, daily, monthly and annual totals. The results are displayed on the video display terminal. A daily report is logged on a printer, listing the average concentration and flow for each of the 24 hours of the previous day. (The printer/logger option must be provided with this option.) The system absolute pressure transducer is mounted on the turbomachinery package. The system printer and humidity transmitter are shipped loose for installation by the purchaser.

Supervisory Interface Serial Link (Optional)

The following serial interface options provide a set of analog and discrete data from the Turbotronic control system. Includes definition of the PLC com-

16

munication interface data structure to facilitate user development of the supervisory side of the interface. The user may: 1. Request the standard message from the PLC 2. Read specific memory locations 3. Send supervisory control signals The standard message provides the same data used by the display system, including all input analogs, a number of computed values, status indications and all active alarms and shutdowns. Typical data include: Gas compressor status Gas generator turbine speed Power turbine speed Turbine T5 temperature Lube oil header pressure Lube oil temperature Ambient temperature All alarms and shutdowns All panel light status Supervisory control signals include: Start Stop Acknowledge/Reset Remote Speed/Load Set Point

terminal unit (RTU) version of the Modbus protocol. The module acts as a Modbus slave device to communicate with the users Modbus master device. The module is connected to the users device through an RS232C serial link for applications within 15 m (50 ft) and an RS422 for applications within 1219 m (4000 ft). Distances greater than this may require boosters, converters, telemetry or common carrier approaches.

Spare Inputs and Outputs (Optional)

Options are available for an additional 10%, 15% or 20% spare input/output analog/discrete channels for customer use. Does not include any signal conditioning or programming.

External Process Malfunction Override (Optional)

This system provides a temporary bypass of specified user and package-related shutdowns. Shutdowns related to the protection of the gas turbine, gearbox if applicable, and gas compressor are excluded. Up to 24 preselected shutdown malfunctions can be bypassed for a limited time for the purpose of testing the functionality of the sensing equipment. The bypass is activated by the operator at a specific user interface screen.

PLC Field Programming (Optional)

This feature allows the user, through predefined security access, to change the programming of control sequence, logic and values within the microprocessor. Includes programming software, interface card, and instruction manual. A laptop computer for interface to the microprocessor may also be provided.

The available options are: Remote RS232C/422 (DF1). (Optional) A table-topmounted interface module is provided which connects to the control system via the Data Highway Plus network. The module can be located up to 3048 m (10,000 ft) from the control system. The serial link uses the DF1 protocol. The module is connected to the users device through an RS232C serial port for applications located within 15 m (50 ft) or an RS422 serial port for applications located within 1219 m (4000 ft). The module requires a 120-Vac, 50/60-Hz power supply. Local RS232C (DF1). (Optional) A console PLC rackmounted interface module is provided which connects to the control system via the Data Highway Plus network. The serial link uses the DF1 protocol. The module is connected to the users device through an RS232C serial port for applications located within 15 m (50 ft). Local RS232C, Modbus. (Optional) A console PLC rack-mounted interface module is provided which connects to the control system through the PLC backplane. The serial link uses a subset of the remote

Heat Recovery Application Interface and/or Control (Optional)

This option provides the gas turbine control system modifications necessary to provide an interface between the gas turbine control system and the heat recovery control system. The modifications can include provisions to receive a start permissive signal from the heat recovery controls, to have an extended start cycle designed to purge the exhaust bypass, to have a gas turbine flameout protection system, to receive a malfunction shutdown signal from the heat recovery controls, and to send a malfunction shutdown signal to the heat recovery control in the event of a gas turbine shutdown. In addition, the heat recovery control may use the gas turbine Ready to Load signals as an indicator to begin operation. Also available is an expanded control scope to provide control of the diverter valve only or to provide the entire heat recovery device controls. The controls

17

interface is limited to heat recovery applications where the gas or dual fuel gas turbine package is operating in conjunction with one heat recovery system with a diverter valve and without supplemental duct burning. The complete heat recovery control option may accommodate more complex heat recovery systems.

Typical system scope includes the following: Engineering to determine the optimum control algorithms PLC software programmed and tested for the selected gas compressor staging Engineering to specify the antisurge control valve and accessories, including valve performance evaluation over the gas compressor performance map at varying valve positions Engineering to specify the flow meter type and size Evaluation of user piping and instrumentation diagram Documentation, including all surge control calculations and program constants Gas compressor flow versus differential pressure control with suction pressure and temperature compensation Automatic override of manual control mode Speed set-point decoupling Surge detection with step valve opening On-screen, real-time graphic displays On-screen, real-time control parameter setting All surge control parameters are available for remote monitoring via serial link. Suction flow transmitter shipped separately for installation by purchaser Suction pressure transmitter shipped separately for installation by purchaser Discharge pressure transmitter shipped separately for installation by purchaser The following components and information are required from the purchaser in order to facilitate the surge control system design and onsite operation: Expected gas compressor operating condition range for suction pressure (P1), suction temperature (T1), discharge pressure (P2), flow and gas specific gravity Flow meter specification sheet Purchaser piping and instrumentation diagram including suction and recycle pipe size and schedule Antisurge control (recycle) valve and specification sheet, unless included in Solars scope Suction gas temperature signal (100-ohm platinum RTD preferred)

GAS COMPRESSOR CONTROLS AND MONITORING Process Control (Optional)

The process control options provide for unit control based on the gas compressor suction pressure, discharge pressure, flow or combinations of these parameters. Local and remote set-point adjustment is included. An on-screen mimic diagram of the process can also be provided. The necessary transmitters are provided by Solar.

Discharge and Suction Pressure Shutdown Switch (Optional)

The basic package may be supplied with gas compressor suction and discharge pressure transmitters and associated control system logic to provide for indication, warning alarm, and unit shutdown when the discharge pressure exceeds a preset value. This option is to provide a pressure switch for the shutdown function in lieu of the transmitter signal. The transmitter is still used for warning alarm and indication, but the shutdown function is controlled by the independent pressure switch.

Gas Compressor Antisurge Control System (Optional)

Surge at a given gas compressor speed is caused by excessive head across the gas compressor (isentropic head) for a given suction flow rate. Therefore, surge in the gas compressor may be controlled by decreasing the head across the gas compressor and/ or by increasing the flow rate of the gas to the suction side of the gas compressor. The antisurge control system prevents surge by modulating a surge control (bypass) valve to lower head and increase suction flow. A typical system consists of pressure and temperature transmitters on the gas compressor suction and discharge lines, a flow differential pressure transmitter across the suction flow meter, an algorithm in the control system, and a surge control valve with corresponding accessories to keep the gas compressor from going into surge.

18

Gas Compressor Surge Detection System (Optional)

For applications without an antisurge control system supplied by Solar, a gas compressor surge detection system is recommended. The system detects gas compressor discharge pressure pulsations and initiates a gas turbine shutdown if pulsations exceed a preset value within a predetermined time period.

indications are displayed on the control system video display terminal.

Gas Compressor Performance Map Display (Optional)

This feature provides for the display of a real-time gas compressor nominal head-versus-cfm performance map and shows the position of the actual operating point. The primary sensing elements are not included. The accuracy of the map is commensurate with the accuracy of the sensing instrumentation. Gas compressor performance checkpoint data must be submitted to Solar in a specific format. Gas compressor maps are limited to one gas composition. Side streams, changing gas composition or other factors which can change gas compressor performance characteristics must be reviewed to confirm compatibility with the software program. The gas turbine performance map display option, described previously, requires this feature.

Antisurge Recycle Valve (Optional)

A wide variety of antisurge valves are available to facilitate the antisurge control system operation. Valves are available in 51, 76, 102, 152, 203, 254, and 305 mm (2, 3, 4, 6, 8, 10 and 12 in.) sizes from two different valve manufacturers.

High Discharge Temperature Shutdown Switch (Optional)

The basic package may be supplied with a gas compressor discharge temperature RTD and associated control system logic to provide for indication, warning alarm, and unit shutdown when the discharge temperature exceeds a preset value. This option is to provide a temperature switch for the shutdown function in lieu of the RTD signal. The RTD is still used for warning alarm and indication, but the shutdown function is controlled by the independent temperature switch.

CONTROL SYSTEM ACCESSORIES Control Battery/Charger System (Optional)

The control battery/charger system supplies the necessary 24-Vdc power for the operation of the gas turbine control system. The 135-ampere-hour lead acid, 150-ampere-hour lead calcium, or 102-amperehour nickel cadmium batteries and integrated 50ampere charger are mounted in a nonhazardous, freestanding, weatherproof National Electrical Manufacturers Association (NEMA) 3R cabinet. The charger is available with 240/480-Vac, 208/220/230-Vac and 120/240-Vac, 50 or 60-Hz, single-phase inputs.

Gas Compressor Journal Bearing Temperature Monitoring (Optional)

The gas compressor journal bearing temperature monitoring system provides temperature indication and protection through preset warning indication and shutdown initiation in the event of unacceptable journal bearing temperature. The system monitors either thermocouples or RTDs, depending on the type of signal provided by the gas compressor, with as many channels as required by the gas compressor configuration. Temperature level, alarm and shutdown indications are displayed on the control system video display terminal.

787 mm (2' 7") BATTERY CHARGER BAFFLE CONTROL PANEL (inside door) DOOR BATTERY COMPARTMENT WITH RACKS 673 mm (2' 2-1/2")

1003 mm (3' 3-1/2")

Gas Compressor Thrust Bearing Temperature Monitoring (Optional)

The gas compressor thrust bearing temperature monitoring system provides temperature indication and protection through preset warning indication and shutdown initiation in the event of unacceptable thrust bearing temperature. The system monitors either thermocouples or RTDs, depending on the type of signal provided by the gas compressor, with as many channels as required by the gas compressor configuration. Temperature level, alarm and shutdown

927 mm (3' 1/2") FRONT AND REAR KICKPLATE FOR WIRING CONNECTIONS
PA98026M

Typical Battery and Charger Cabinet

19

1219 mm (4')

Lead acid batteries are shipped dry; the electrolyte is not included.

Control and DC Lube Pump Battery/ Charger System (Optional)

This battery/charger system supplies the necessary 24-Vdc power for the operation of the gas turbine

control system and dc postlube backup pump. The 250-ampere-hour lead calcium or 184-ampere-hour nickel cadmium batteries and integrated 50-ampere charger are mounted in a nonhazardous, freestanding, weatherproof NEMA 3R cabinet. The charger is available with 240/480-Vac, 208/220/230-Vac and 120/240-Vac, 50 or 60-Hz, single-phase inputs.

20

Start Systems
PNEUMATIC START SYSTEM
The pneumatic start system is especially suited for gas turbine starting requirements and can use either gas or compressed air as a power source. Components of the standard system included with the package are a strainer, shutoff valve, starter motors, and associated stainless steel piping and manifolds. The turbine starter motors are mounted on the forward side of the accessory gear housing and transmit starting power to the gas turbine via a common overrunning clutch and shaft. When the gas generator reaches starter dropout speed, the starter motors shut down and the clutch overruns. the gas turbine via the accessory drive gearbox and overrunning clutch and shaft assembly. The VFD requires a supply of three-phase, 380to-575 volt, 50/60-Hz ac power. The VFD regulates the voltage and frequency to the start motor as required to initiate gas turbine rotation, accelerate to purge speed, and then accelerate to ignition and starter dropout speed as commanded by the Turbotronic control system. The VFD cabinet is shipped separately for installation in an appropriate nonhazardous location and provides for direct across-the-line starting control of the motor. The typical maximum symmetrical fault current capacity of the VFD is 25,000 amps. Feeder circuits exceeding this limit require the use of an isolation transformer, line reactor or other means of adding similar impedance to limit fault current. Electric disconnects and overcurrent protection devices are normally provided by others. The power cable run from the VFD to the start motor should not exceed 183 m (600 ft).

DIRECT-DRIVE AC START SYSTEM

The direct-drive ac (DAC) start system consists of a squirrel cage, three-phase, ac induction motor with a solid-state variable frequency drive (VFD). The start motor is mounted directly on the gas turbine accessory drive gearbox. Starting power is transmitted to

LEGEND G Air/Gas V Vent PILOT AIR / GAS SUPPLY

STARTER MOTOR

TO TURBINE

AIR/GAS SUPPLY

STRAINER G SKID EDGE SHUTOFF VALVE G

STARTER MOTOR

TO TURBINE

PA98027M

Typical Pneumatic Start System

21

CUSTOMER AC INPUT

VARIABLE FREQUENCY DRIVE

AC MOTOR

ADAPTER HUB COUPLING/ CLUTCH ASSEMBLY

GAS TURBINE

SKID EDGE

PA98029M

Typical Direct-Drive AC Start System

880 mm (2' 10-5/8")

421 mm (1' 4-1/2") Depth - 322 mm (1' 5/8") Weight - 70 kg (154 lb)

PA98030M

Typical Variable Frequency Drive Cabinet

22

Fuel System
NATURAL GAS FUEL SYSTEM
The fuel system, in conjunction with the electric control system, includes all necessary components to control fuel at the proper schedule during start and to modulate fuel flow during operation. The system also provides temperature topping control of fuel flow during start-up, acceleration and operation. The system requires a natural gas supply that conforms to Solars specification ES 9-98. The gas should have a lower heating value (LHV) of 31 496 to 39 370 kJ/nm3 (800 to 1000 Btu/scf) and should be free of sulfur, contaminants, entrained water, and liquid hydrocarbons. The natural gas fuel system includes: Pilot-operated primary fuel shutoff valve Pilot-operated secondary fuel shutoff valve Natural gas electric fuel control valve 10-micron pilot gas filter Gas fuel pressure gauge Fuel injector assemblies Valve check pressure switch High gas fuel pressure shutdown switch Gas strainer (loose shipped for field installation) Torch ignitor Drain valves Vent valve During the unit start sequence, prior to ignition, the primary and secondary fuel shutoff valves are both operated to verify proper operation. This fuel valve check sequence is verified by the valve-check pressure switch located between the two valves. Solar has developed an electric fuel control valve which replaces the pressure regulator/gas loader, throttle valve, and associated electrohydraulic actuator. This system has improved light-off reliability and enhanced performance flexibility to meet the demanding requirements of SoLoNOx gas turbine configurations and has allowed easier adjustments of fuel flow schedules for steady-state and transient conditions. The electrically controlled valve is composed of a balanced poppet valve actuated by a proportional solenoid-operated device mounted directly on the valve. All components, including the electronics, are packaged in a compact, lightweight housing constructed of either aluminum or stainless steel. Internal metering components are stainless steel. The valve assembly can operate in ambient and gas temperatures of 93C (200F). Control and actuation power required is 24 Vdc and less than 65 watts. The valve position is controlled by a 4-to-20 mA signal and the valve provides a 4-to-20 mA feedback signal via an integrated linear variable differential transformer (LVDT). The valve is certified to Canadian Standards Association (CSA) and NFPA/NEC Class I, Group D, Division 1, as well as IEC Zone 1. A differential pressure transmitter is included to measure the differential pressure across the injectors in order to properly schedule fuel flow during gas turbine light-off and acceleration. The fuel is distributed to the combustor via a fuel gas manifold and fuel injectors.

Component Operation
Fuel gas supply pressure required at the unit skid must meet minimum pressure requirements or the low pressure switch disables unit operation. The primary fuel shutoff valve is a pneumatically operated, spring-closed ball valve. Pilot gas pressure is admitted and exhausted from the operator via an integral solenoid valve. Removal of pilot gas or electric power will allow the springs to close the main valve. The secondary (backup) fuel shutoff valve is pilot gas operated by dual three-way solenoid valves. When energized, these solenoid valves admit pilot pressure to the valve-opening operator and exhaust pressure from the valve-closing operator, causing the main spool to shift to the open position. When deenergized, these solenoid valves vent the opening operator and supply pilot pressure in the closing direction to close the secondary shutoff valve.

SOLONOx COMBUSTION
SoLoNOx combustion systems use special fuel injectors, each with main and pilot fuel ports. The ratio of fuel injected through these ports is controlled during starting and operation to maintain a stable combustor flame while minimizing the formation of NOx and CO emissions. Combustion airflows, which affect the emissions levels, are also regulated within allowable limits using variable guide vanes and a bleed valve on the axial air compressor.

23

PRESSURE TRANSMITTER E GAS FUEL SUPPLY

BLOCK AND BLEED VALVE

GAS FUEL PRESSURE GAUGE

GAS VENT VALVE

VENT

BLOCK AND BLEED VALVE

PRESSURE TRANSMITTER

COMPRESSOR DISCHARGE PRESSURE GAUGE

VALVE CHECK PRESSURE SWITCH

PRESSURE SWITCH

PRESSURE CONTROL VALVE

STRAINER SKID EDGE FILTER PILOT PRIMARY SHUTOFF VALVE

PRIMARY SHUTOFF SECONDARY VALVE SHUTOFF VALVE

ELECTRIC CONTROL SIGNAL FROM PROCESS CONTROL SYSTEM GAS FUEL CONTROL VALVE/ACTUATOR

PILOT SECONDARY SHUTOFF VALVE ORIFICE PILOT GAS RELIEF VALVE PILOT GAS SUPPLY TO PNEUMATIC START SYSTEM AND PRE/POST LUBE PUMP GAS MANIFOLD AIR INTAKE BLEED VALVE CHECK VALVE

PRESSURE CONTROL VALVE

INJECTORS

EXHAUST

COMBUSTOR LEGEND: = Main Fuel Path A D E G O V = Air = Drain = Electrical = Gas Fuel = Oil = Vent GUIDE VANE ACTUATOR COMBUSTOR DRAIN VALVES PACKAGE DRAIN CONNECTION
PA98031M/S

VARIABLE GUIDE VANES

COMPRESSOR TORCH TORCH SHUTOFF VALVE

Typical Natural Gas Fuel System

24

Lubrication System
BASIC LUBRICATION SYSTEM
The lube oil system is a complete system suitable for operation with lube oil conforming to Solars specification ES 9-224. The system, which circulates oil under pressure to the various working parts of the gas turbine and driven equipment, is supplied from the lube oil tank located in the steel base frame. Proper oil temperatures are maintained by thermostatic oil control valves and an optional oil cooler. The lubrication system incorporates the following components: Oil tank Gas turbine-driven primary pump Motor-driven pre/post pumps Duplex oil filters with replaceable five-micron elements Offskid oil cooler (optional) Oil level, pressure and temperature gauges Oil pressure transducers Pressure and temperature regulators Strainers The filters are supplied with a six-way transfer valve, a differential pressure gauge, and differential pressure alarm. The system includes all piping and manifolds internal to the skid. The interconnect piping between the skid edge and the remote mounted oil cooler (optional) is not supplied as part of this system unless the cooler is provided as part of an enclosure roofmounted ancillary skid (optional). When unit start-up is initiated, oil is delivered to the gas turbine bearings by the pre/post lube oil pump for a predetermined period of time. As the gas turbine accelerates, the pre/post oil pump is shut down and all lube oil is supplied by the gas turbine-driven main pump. When the unit starts during cold ambient conditions, oil bypasses the cooler through a temperature control valve in the system control module. Pre/Post Lube Oil System. A pre/post lube oil pump supplies oil prior to package start-up and postlube cooling after shutdown. The pump is a rotary, positivedisplacement-type driven by an ac electric motor or by a pneumatic motor. The pneumatic motor requires an air or gas supply. Postlube Backup Oil System. A 24-Vdc or pneumatic motor-driven lube oil pump, filter and relief valve are available to supply the necessary oil pressure for postlube cooling of the gas turbine bearings in the event the postlube oil system is inoperable on shutdown. Lube Oil Tank Heater System. (Optional) A thermostatically controlled 10-kW lube oil tank heater is available to maintain lube oil temperature above 10C (50F). This heater requires ac electric power. Lube Oil Cooler. (Optional) A wide variety of air-to-oil type coolers is available to facilitate the oil cooling needs of the gas turbine, gearbox (if applicable), and the driven equipment. The standard cooler options are available with either ac motors or hydraulic motordriven fan and are sized for a range of heat loads and ambient temperatures. The cooler is loose shipped for offskid installation by others. Both simplex and duplex water-to-oil cooler systems are also available. Lube Oil Vent Separator. (Optional) An offskid mechanical coalescer element is provided to remove oil from the lube oil tank vent. The oil is allowed to drain back to the lube oil tank while the remaining oil vapor is exhausted to the atmosphere. A lube oil tank overpressure alarm and shutdown is included. The separator is approximately 1727 mm (68 in.) high by 610 mm (24 in.) in diameter and weighs 227 kg (500 lb) dry. Lube Oil Vent Flame Trap. (Optional) A lube oil vent flame trap can be provided to prevent an ignition source from entering the lube oil tank. Provided for installation by others, it must be installed vertically within 4.6 m (15 ft) of the end of the lube tank vent piping. Lube Oil Tank Level Control. (Optional) This system consists of a slow flow meter and a level controller which is used to maintain proper oil level in the tank during operation. It requires a user-provided, external oil supply and includes a high lube oil tank level alarm. Stainless Steel Lube Oil Tank and Filters. (Optional) Lube oil tank, covers and filters are normally carbon steel, but can be provided in 316L stainless steel if required.

25

TEMPERATURE CONTROL VALVE OIL COOLER

ALARM SWITCH INST VALVE

P GAUGE
E

PRESSURE GAUGE BLOCK AND BLEED VALVE TEMPERATURE GAUGE

O

INST VALVE

PRESSURE TRANSMITTER

FILTER TRANSFER VALVE

O

TRANSFER VALVE FILTER CHECK VALVE

O

RTD

CHECK VALVE

COOLER BYPASS VALVE

CHECK VALVE

PRESSURE CONTROL VALVE RELIEF VALVE CHECK VALVE

STRAINER

GEARBOX

FLAME ARRESTOR (optional) VENT SEPARATOR (optional) SIGHT GLASS

DRIVEN EQUIPMENT
O

*
O

FILTER MAIN LUBE PUMP PRE/ POST LUBE PUMP

RELIEF VALVE

STRAINER

SIGHT GAUGES POST LUBE BACKUP PUMP RTDS (optional) STRAINERS

TANK VENT AL/SD PRESSURE SWITCH (optional)

HEATER (optional)

Optional High Level Alarm Low Level Alarm Low Level Shutdown

Liters (gal.) 2362 (624) 1756 (464) 1514 (400)

mm (in.) 495 (19.5) 368 (14.5) 317 (12.5)

from tank bottom

and fuel * *To guide vane, bleed valve40 only. actuator - Centaur 50 and Taurus 60 only To fuel actuator - Centaur

PA98033M

Typical Lube Oil System

26

Seal Systems
SEAL OIL SYSTEM (Optional/As Available)
Compressor shaft end seals and their attendant system prevent the escape of process gas along the compressor shaft. The seal oil system delivers the oil and buffer gas required for operation of the compressor floating ring oil seals. The seal assembly typically consists of two carbon ring oil seals, separating spacer and housing. Seal oil is introduced between the two seals at a pressure slightly above compressor suction pressure. Oil leakage is controlled by the clearance established between the seals inside diameter and the shafts outside diameter. A small portion of the oil leaks across the inner seal toward the process gas, creating the seal. This oil is returned to the lube oil tank via a high pressure trap and degassing system upstream of the oil tank. The balance of the inlet oil flows across the outer seal and returns directly to the oil tank. Solar compressor packages normally use a combined lube and seal oil system with internally supplied buffer gas. The buffer gas can be taken from compressor discharge when the gas composition, temperature, and contamination are within acceptable limits. Although clean (sweet) buffer gas is preferred, the system may tolerate sour buffer gas, depending on the process conditions, gas composition and required seal oil flow. The buffer gas is taken from the compressor discharge and supplied to the bearing and seal capsules to buffer the compressor case from the seal oil. Seal oil at a pressure slightly higher than buffer gas is injected between the two liquid-film carbon seals to prevent the buffer gas from escaping into the lube system. The mixture of seal oil and buffer gas is separated in the seal oil trap where the buffer gas is returned to the compressor suction and the oil is returned to the oil tank. The standard seal oil system includes the following primary components: Turbine-driven main seal oil pump Auxiliary and backup seal oil pump Seal oil filter with differential pressure switch and gauge Seal oil differential pressure regulation system Seal oil flow control valve Buffer gas differential pressure regulation system Dual traps, one for each compressor seal Degassing flue 27 Flame arrestor for field installation on degassing flue vent Sight glasses, strainers and relief valves Pressure and differential pressure gauges and switches A system compliant with National Association of Corrosion Engineers (NACE) MR0175 is also available as an option.

DRY GAS SEAL SYSTEM (Optional)

The dry gas seal system is composed of two closely interrelated systems: the seal gas system and the buffer air system. The seal gas system maintains a barrier between the process gas in the compressor from the compressor bearings. The buffer air system maintains separation of the compressor bearing lube oil from the dry gas seals.

Seal Gas System

Solars gas compressor tandem dry seal system for each shaft end consists of a primary and secondary gas face seal to prevent the escape of process gas. The primary dry seal takes the full pressure drop. It is used to provide the main sealing function. The secondary or backup seal acts as an emergency barrier between the process gas and the atmosphere and operates at zero pressure differential. The dry gas seal system uses either clean and dry process gas or an independent clean and dry gas source as seal gas. A second buffer gas source of either air or nitrogen is required to isolate the lube oil from the seal gas. This buffer air must be available at all times during lube oil pump operation. Typical seal gas supply flow is 1.34 to 3.35 nm3/ min (50 to 125 scfm) at 690 kPa (100 psi) above maximum suction pressure, depending on compressor model and suction pressure. The seal gas flow rates are metered by maintaining a constant pressure drop across a flow-limiting orifice in each seal gas supply line to each compressor seal capsule. Differential pressure switches provide low flow alarm and shutdown functions. The seal gas supply flow is higher than the primary seal leakage. Most of the seal gas flow travels by the compressor shaft labyrinth seals and into the compressor case. This ensures that the dry seal cavity is flushed with clean dry gas and that the dry seal operates in a clean environment. The seal gas may be supplied from the discharge of the compressor, preferably from downstream of the gas cooler, if the process gas is clean and dry.

P GAUGE

COMPRESSOR SUCTION PRESSURE GAUGE

TO LUBE OIL TANK

O

E PRESSURE CONTROL VALVE E

LOW P SHUTDOWN SWITCH LOW P ALARM SWITCH

E LOW SUCTION PRESSURE SHUTDOWN PRESSURE TRANSMITTER COMPRESSOR CASE PRESSURIZATION SWITCH

P GAUGE BUFFER GAS P REGULATOR

GAUGE SEAL OIL P REGULATOR

O G

BUFFER GAS
O O G G G

SIGHT GLASS P GAUGE HIGH P ALARM SWITCH FILTER

O G

E HIGH DISCHARGE GAS TEMPERATURE SHUTDOWN SWITCH (RTD on Microprocessor Controller Units)

HIGH DISCHARGE PRESSURE SHUTDOWN PRESSURE TRANSMITTER

G

SUCTION LUBE OIL IN

DISCHARGE

COMPRESSOR DISCHARGE PRESSURE GAUGE LUBE OIL IN

CHECK VALVE FLOW CONTROL VALVE

CHECK VALVE

CHECK VALVE

G O

BUFFER GAS

G SUCTION DISCHARGE

PNEU MOTOR PUMP DISCHARGE PRESSURE PRIMING ORIFICE PRIMING ORIFICE

PUMP SEQUENCE SWITCH E

TO LUBE OIL TANK PRIMING ORIFICE SIGHT GLASS

G

COMPRESSOR

TO LUBE OIL TANK SIGHT GLASS ORIFICE

TO LUBE OIL TANK

TO LUBE OIL TANK

TO LUBE OIL TANK

STRAINER ORIFICE TRAP SIGHT GLASS

RELIEF VALVE PNEU BACKUP SEAL OIL PUMP (optional)

O

RELIEF VALVE MAIN SEAL OIL PUMP

RELIEF VALVE AUXILIARY SEAL OIL PUMP TRAP

SHUTTLE VALVE SIGHT GLASS SIGHT GLASS STRAINER

FLAME ARRESTOR
G

FROM LUBE OIL TANK

FROM LUBE OIL HEADER

FROM LUBE OIL TANK Legend = Main Line E = Electrical G = Buffer Gas O = Seal Oil

SIGHT GLASS
O

TO LUBE OIL TANK

O

DEGASSING FLUE

PA98035M

Typical Compressor Seal Oil and Buffer Gas System

28

The onskid duplex seal gas coalescing filters are designed for typical clean transmission pipeline conditions. If larger particle or liquid loads are expected, a larger offskid filtration with a high pressure external seal gas supply is recommended. When the seal gas is supplied from the compressor discharge but the compressor is not operating at a pressure ratio (i.e., start-up, shutdown, or pressurized hold), there is no flow of seal gas through the filters. During these times, the gas leakage across the dry seals is raw process gas from inside the compressor case. This is normally not a problem on clean transmission pipeline applications; however, it may be on new pipelines until the new line cleans up, or on pipelines handling wet and/ or dirty gas. Under these conditions, an external high pressure seal gas supply is recommended. Leakage past the primary dry seals is measured by monitoring the pressure drop across an orifice run. High flow alarm and shutdown functions are provided by pressure switches. Primary and secondary seal vent lines must be vented by the customer to a safe location. Vent pressure must not exceed 35 kPa gauge (5 psig).

Buffer Air System

A circumferential buffer air or nitrogen circumferential seal, manufactured by Kaydon, provides for buffering of lube oil and dry seal and is the outboard most component of the complete seal assembly. The buffer air or nitrogen circumferential seal is a segmented, split-ring type seal and functions to separate the seal from the lubricating oil. It is the outboard most component of the complete seal assembly.

Buffer air or nitrogen at 517 to 1724 kPa gauge (75 to 250 psig) at a flow of 0.13 nm3/min (5 scfm) is required from a customers source during all periods of compressor pressurization or lube oil pump operation. Maximum supply temperature is 93C (200F). Buffer air is injected between a pair of seal rings at a regulated pressure of approximately 172 to 207 kPa (25 to 30 psi) above the secondary seal gas/buffer air vent pressure. Air flows between the seal rings and the compressor stub shaft. Buffer air flowing pass the outboard seal mixes with lubricating oil and drains to the lube oil reservoir. Air flowing past the inboard seal is vented through the secondary seal gas/buffer air vent. The buffer air source may be clean dry shop air, instrument air, or nitrogen. The system includes a hand valve for maintenance, a coalescing filter, a differential pressure regulator, and pressure switches and gauges to monitor the buffer air differential pressure. The system forms a positive separation between the lube oil and the dry seal. Flame arrestors are supplied for the primary and secondary vents. Typical primary seal leakage rates per compressor for dynamic operating conditions are as follows, depending on the type of compressor, seal condition, speed, and suction pressure: Dry gas face seal: 0.0536 to 0.268 nm3/min (2 to 10 scfm) Air or nitrogen circumferential seal: 0.0027 to 0.080 nm3/min (0.1 to 3 scfm) This leakage seal gas and buffer air must be piped away by the customer to selected safe areas.

JOURNAL BEARING ASSEMBLY

BUFFER AIR OR N2 SEAL ASSEMBLY

SECONDARY SEAL VENT BUFFER AIR OR N2

SECONDARY SEAL

PRIMARY SEAL VENT

PRIMARY SEAL SEAL GAS IN

LABYRINTH SEAL

LUBE OIL/BUFFER AIR TO DRAIN

BUFFER AIR SEALS

DRIVE SHAFT

DRY GAS SEAL ASSEMBLY

Stationary Rotating
PA98036M

Typical Dry Gas Seal Assembly

29

FLAME ARRESTOR
G G

FLAME ARRESTOR FLOW SWITCH

G

FILTER
G G

FILTER P GAUGE

COMPRESSOR SUCTION PRESSURE GAUGE

FLOW P GAUGE

EXTERNAL SEAL GAS SUPPLY

G

ORIFICE E FILTER LOW SUCTION PRESSURE SHUTDOWN SWITCH ALARM SWITCH FLOW P GAUGE E ALARM SWITCH SEAL GAS P REGULATOR SEAL GAS P GAUGE SHUTDOWN SWITCH

RELIEF VALVE

ALARM SWITCH

ORIFICE

RELIEF VALVE

SHUTDOWN SWITCH
G

ALARM SWITCH

ORIFICE
G

HIGH DISCHARGE PRESSURE SHUTDOWN SWITCH

G

LIQUID DROP-OUT LEVEL GLASS

E SHUTDOWN SWITCH
G

ORIFICE HIGH DISCHARGE GAS TEMPERATURE SWITCH BUFFER AIR P GAUGE

COMPRESSOR DISCHARGE PRESSURE GAUGE

G

LOW P ALARM SWITCH

LIQUID DROP-OUT LEVEL GLASS

E SUCTION E LUBE OIL IN

O G

DISCHARGE

BUFFER AIR FILTER P GAUGE

LOW P SHUTDOWN SWITCH

LUBE OIL IN
O

CHECK VALVE
O

SUCTION

DISCHARGE

BUFFER AIR/N2 SUPPLY LEGEND: E G O

FILTER BUFFER AIR P REGULATOR

G

COMPRESSOR

= Electrical = Gas = Oil

PA98037M

Typical Dry Gas Seal System

30

1 4 7

2 5

3 6 8

DRY SEAL PANEL 1. 2. 3. 4. 5. Compressor Suction Compressor Discharge Seal Gas Differential Pressure Buffer Air Differential Pressure Primary Seal Leakage Flow Differential Pressure Suction 6. Primary Seal Leakage Flow Differential Pressure Discharge 7. Seal Gas Filter Differential Pressure 8. Buffer Air Filter Differential Pressure WET SEAL PANEL 1. 2. 3. 4. 5. 6. Compressor Suction Compressor Discharge Buffer Gas Differential Pressure Seal Oil Differential Pressure Seal Oil Filter Differential Pressure Seal Oil Differential Pressure

1 4

2 5

3 6

PA98038M

Typical Dry and Wet Gas Seal Panels

31

Ancillary Equipment
ENCLOSURE
The all-steel enclosure housing is a completely selfcontained, weatherproof, insulated, and soundattenuated structure assembled on the gas turbine package skid base. It can be provided in several configurations to house the gas turbine only, the gas turbine and driven equipment, or the gas turbine, gearbox and driven equipment. The enclosure sides and roof include panels and access doors supported on a heavy-duty frame. The panels are treated with fiberglass material for noise attenuation and thermal insulation, and weather stripping is installed on all panels for sealing and sound attenuation. The enclosure is constructed to support a specified roof load and to withstand a wind load of 161 km/h (100 mph). The panels and doors provided for access, inspection, and maintenance are easily removed for component removal by fork lift or overhead crane. Additional access doors can be provided when necessary. The gas turbine gauge panel is visible through a glass window in the enclosure wall. ing to standard commercial wiring practices and as necessary to meet the requirements for equipment installed in hazardous areas. Ventilation. All enclosures are ventilated using an ac motor-driven fan to provide the airflow required to ensure that internal temperatures remain within acceptable limits. Fan motor wiring is terminated at the motor junction box. Suitable openings are provided so that adequate free flow of ventilation is circulated through the enclosure. Ventilation openings may be equipped with elbow or straight-through type vent silencers. Enclosure High Temperature Alarm. A heat sensor, which is completely separate from the fire system thermal detectors, is mounted in the enclosure. The sensor is set to activate an alarm if enclosure temperature is abnormally high.

Optional Features
Lights. (Optional) Internal, explosionproof, incandescent or fluorescent lights are available to illuminate the gas turbine and driven equipment areas inside the enclosure, with an on/off switch located at an enclosure door. Backup dc lighting is also available with power supplied from the control battery system. Fire Detection/Suppression System. (Optional) An automatic, electronically controlled fire detection/ fire suppression system is installed in the enclosure. The system provides detection, suppression and supervision of input and output circuits for fault or loss of integrity. Design is in accordance with the U.S. National Fire Protection Association codes.

Standard Features
Sound Attenuation. The sound attenuated enclosure is intended for use with suitable gas turbine air inlet and exhaust silencing systems in environments where low noise levels are required. In addition, the enclosure ventilation openings are equipped with silencers to achieve maximum sound attenuation. The actual achievable noise reduction is a function of the noise source, installation considerations, other equipment in close proximity, and the acoustical characteristics of existing buildings and barriers. The intent of the enclosure design is to comply with U.S. Occupational Safety and Health Administration (OSHA) standards for eight-hour employee exposure. Transmission loss of the panels in decibels is available upon request, and further information is available in Solars publication SPNG, Noise Prediction Guidelines for Industrial Gas Turbines. Exterior Connections. Connections for oil vent line, fire and gas suppression systems, and gas turbine air inlet and exhaust are terminated outside the enclosure. Wiring. Electrically operated and controlled devices incorporated in the enclosure are wired accord-

Detection. The primary fire detection system uses ultraviolet (UV) detectors. The system includes the automatic optical integrity feature, which provides a continuous check of the optical surfaces, detector sensitivity and electronic circuitry of the detectorcontroller system. Also included is an automatic fault identification which provides a digital display of system status. The secondary detection system consists of thermal detectors. The thermal detectors are designed with rate compensation. Suppression. The enclosure is equipped with a CO2 fire suppression system consisting of a primary total flooding distribution system and a secondary metered

32

 HORN FIRE SYSTEM CONTROLS EMERGENCY STOP BUTTON

TURBINE GAUGE PANEL (inside door) STROBE LIGHTS (2) (fire system discharge) TURBINE AIR INLET

TURBINE EXHAUST

COMPRESSOR GAUGE PANEL (inside door)

ENCLOSURE VENTILATION INLET Forward End Forward End Left Side

ENCLOSURE VENTILATION EXHAUST Aft End DOORS GAS COMPRESSOR SUCTION/DISCHARGE CONNECTION DOOR

BASIC ENCLOSURE LUBE OIL TANK VENT FLAME TRAP (optional) LUBE OIL TANK VENT SEPARATOR (optional) TURBINE AIR INLET STROBE LIGHTS (2) (fire system discharge) TURBINE GAUGE PANEL (inside door) ENCLOSURE VENTILATION INLET Forward End Forward End Left Side DOORS

TURBINE EXHAUST

HORN FIRE SYSTEM CONTROLS EMERGENCY STOP BUTTON

ANCILLARY SUPPORT FRAME

COMPRESSOR GAUGE PANEL (inside door)

ENCLOSURE VENTILATION EXHAUST Aft End GAS COMPRESSOR SUCTION/DISCHARGE CONNECTION DOOR

TYPICAL ENCLOSURE WITH ANCILLARY EQUIPMENT

SPCUCS-020M

Typical Enclosure Configurations

distribution system. If a fire is sensed, the detectors transmit an electric signal via the fire system controller and the fire system supervisory panel to activate the fire suppression system. Upon receiving this signal, the explosionproof control heads activate the discharge valves on the primary and extended CO2 cylinders, releasing the CO2 into the enclosure and pressurizing the trips which close all vent openings. The primary suppression system is designed to provide the proper concentration of CO2 to extinguish the fire. A secondary metered distribution system is

used to extend the design concentration of 34% CO2 for 20 minutes. Other fire suppression systems are available. Fire Cylinder Cabinet. (Optional) A weatherproof fire cylinder cabinet is available to house the CO2 extinguishant cylinders and is equipped with doors for servicing. The manual pull levers are routed by cable to the exterior wall of the cabinet. Fire Detection System Test Equipment. (Optional) A portable UV light source complete with built-in

33

charger is available for testing the system. The light activates the UV detector which, in turn, activates the suppression system. Combustible Gas Monitoring System. (Optional) A single- or dual-channel system is available to continuously monitor for the presence of combustible gases within the enclosure. The PLC monitors the smart gas sensor(s) and the start signal is interlocked with the combustible gas monitoring system to ensure the atmosphere is clear prior to initiating gas turbine start. An alarm is initiated if the gas detector fails. Gas Monitoring System Test Equipment. (Optional) A portable purge calibration cylinder containing methane is available complete with the regulator, gauge, valve and extension tube used to periodically calibrate the gas detector. Fire and Gas System Test Kit. (Optional) The combustible gas calibration equipment and UV test light are available as a combined kit in a specially designed carrying case. Dust Protection System. (Optional) Enclosure inlet vents are equipped with cleanable, barrier-type, inertial separator-type, or self-cleaning barrier-type filters to remove dust and sand. The exhaust vents are equipped with back-draft dampers to prevent the entry of dust when the unit is not running. Pressurization System. (Optional) A pressurization system can be furnished to provide positive or negative pressure inside the enclosure compartment(s) to prevent entry of hazardous atmospheres through enclosure seams in hazardous areas. The system consists of the pressurizing fan, manually adjustable dampers, differential pressure gauge and switch, differential pressure alarm, and purging prior to start and after shutdown. Ancillary Support Frame. (Optional) A single-lift ancillary skid can be provided to roof-mount the gas turbine air inlet system and lube oil cooler. This skid is shipped complete with all ancillary equipment mounted, preassembled, and ready for installation, including gaskets, mounting hardware, and illustrated assembly drawings. Maintenance Platform and Access Ladder. (Optional) A maintenance platform and ladder can be provided to allow servicing of the ancillary skidmounted gas turbine air inlet filter. The platform and ladder are supplied with necessary hardware and instructions for assembly at the site by others. Gas Turbine Handling Equipment. (Optional) A gas turbine handling kit can be provided which consists of the following:

Internal maintenance frame trolley rail 3048-mm (10-ft) external extension to the maintenance frame trolley rail installed within the enclosure. Single-point lift tool Rail hugger chain-fall hoist and trolley The single-point lift tool, which has an adjustable center of gravity, attaches to the gas turbine flanges and provides a single-point attachment for the chain fall, allowing complete removal of the gas turbine or selected gas turbine components. The trolley beam extension allows gas turbine removal through the side of the enclosure. One end of the beam extension attaches to the inside trolley rail; the other end is floor-standing. The gas turbine can be removed through the enclosure side and placed on a truck bed or cart. Gas Turbine Cleaning System Cart. (Optional) A water-wash and solvent-cleaning cart is available which contains a stainless steel mixing tank and systems capable of supplying 7 to 15 L/min (2 to 4 gpm) at 138 to 276 kPa gauge (20 to 40 psig) to the gas turbine water-wash manifold. Approximately 0.08 nm3/ min (3 scfm) of shop-quality air is required at 586 to 689 kPa gauge (85 to 100 psi). Package Lifting Kit. (Optional) Also available is a lifting kit (shipped separately) containing slings, spreader bars, and assorted hardware to facilitate lifting the enclosed gas turbine package.

WASH FLUID OUTLET

PRESSURE GAUGE 0-1379 kPa (0-200 psi)

RELIEF VALVE TANK

GAUGE, FLUID LEVEL 0-60 LITERS (0-16 GALLONS)

Approx 863 mm (2' 10")

406 mm (1' 4")

DRAIN

1320 mm (4' 4")

381 mm (1' 3")

660 mm (2' 4")

PA98039M

Typical Water-Wash Cart

34

AIR INLET SYSTEM

The air intake system for the gas turbine package normally consists of an air inlet filter, air inlet silencer, and connecting ducts. Solar can recommend and supply suitable filtration, silencers, and duct work for any installation. Evaporative cooling is available and can be used where humidity is sufficiently low to give significant temperature reduction. Effectiveness of the cooler is typically 92% of the wet-bulb/dry-bulb differential. If the water supply is limited, a recirculating cooler may be used, but with provision for regular blow-down of the water system to dispose of accumulated salts and impurities.

EXHAUST HEAT RECOVERY

High thermal efficiencies can be obtained by using the gas turbine exhaust heat energy. There are several methods for using the exhaust heat and attaining greater than 70% thermal efficiency. The method used and efficiency achieved are primarily dependent on the type of application. The most common uses are: (1) producing steam with a heat recovery steam generator (HRSG) or heating a process fluid with a heat recovery fluid heater; (2) using the gas turbine exhaust as a source of preheated combustion air in a boiler or furnace (the gas turbine exhaust contains 15-to-18% oxygen); and (3) using the gas turbine exhaust directly for a drying or heating process in which high temperature air is necessary. A mixture of gas turbine exhaust and fresh air can be used in a reduced air temperature process. An air-to-air heat exchanger is required when the process involves any products in the human food chain. The exhaust heat recovery system must be designed to minimize the back pressure imposed on the gas turbine exhaust and provide for smooth flow transition into the exhaust heat recovery device. The recommended nominal system back pressure on the gas turbine is 203 mm (8 in.) water column, but higher back pressures can be accommodated. The exhaust back pressure should be less than 25.4 mm (1 in.) water column during gas turbine starting. Several manufacturers meet Solars design requirements for gas turbine exhaust heat recovery equipment. Solar can design and provide a complete exhaust heat recovery system to meet specific application requirements.

GAS TURBINE EXHAUST SYSTEM

When heat recovery equipment or silencers are used, the ducting must be adequately supported and expansion joints should be used to avoid exceeding the allowable loading of the gas turbine exhaust flange. Typically, the gas turbine exhaust system will consist of the following: Exhaust Silencer. The exhaust silencer is designed to provide attenuation consistent with the overall package noise emissions. Special silencers can be provided to meet special criteria when needed. Sound attenuating data and dimensional details are available upon request. Gas Turbine Exhaust Connection. As a standard, the gas turbine package is provided with an exhaust bellows, which allows a limited amount of compression for installations between the gas turbine exhaust collector and the external ducting. The bellows terminates in a lightweight flange.

35

Installation Requirements
SITE REQUIREMENTS
The gas turbine package is a compact, lightweight, vibration-free, unitized package requiring minimum facility support preparation. Since the package is generally supplied with completely self-contained operating systems for fuel, lube oil, and controls, it requires a minimum of piping and wiring connections to complete the installation. General installation requirements and typical use of standard ancillary equipment are described in this section. hoods, that are necessary to supply a clean, smooth flow of air to the gas turbine. Recommended maximum pressure drop is 76-mm (3-in.) water column. The air intake should be located so that entry of gas turbine exhaust, oil tank vent vapor, or other contaminants is minimized. The air inlet duct must be free of accumulated water prior to starting the gas turbine. Loads exceeding 91 kg (200 lb) should not be applied in any direction on the air inlet duct connection. Proper gas turbine inlet air filtration is critical to gas turbine life. Careful consideration should be given in selecting the appropriate filter for the specific application. Units to be installed in a salt-laden atmosphere or in an extremely dusty environment should incorporate an on-crank cleaning system to facilitate gas turbine compressor cleaning. An on-line cleaning system is also available as an option. This system can be used in addition to the on-crank system to increase the time between oncrank cleaning. Gas Turbine Exhaust System. The importance of having an exhaust system properly designed and installed cannot be overemphasized. A poorly designed or installed system can cause loss of power capability and impose severe mechanical strains on the gas turbine. The system should consist of all components downstream of the gas turbine exhaust flexible section, including silencers and ducting, that are necessary to supply a smooth flow of exhaust gas from the gas turbine. The exhaust duct system must be terminated in a manner that precludes recirculation of exhaust products through the gas turbine air inlet or oil cooler. Exhaust requirements include consideration of the relative height of the exhaust duct above the air inlet, building roof design, direction of prevailing winds, and the proximity of adjacent structures. Exhaust systems should be designed to meet the following requirements: Total system pressure loss should not be excessive. Recommended maximum is 203-mm (8-in.) water column. Duct design must be adequately sized for exhaust flow and temperature of 538C (1000F). The gas turbine must not be started against an excessive exhaust back pressure. Recommended maximum is 25.4-mm (1-in.) water column. 36

MECHANICAL INSTALLATION REQUIREMENTS

Mounting. Correct mounting of the gas turbine package is vital to the success of the installation and requires adequate preparation by the user. The site pad thickness is governed by soil condition and weight of the gas turbine package, air inlet system, and exhaust system. Mounting pad locations and package weights will differ with each package depending on options selected and will be clearly shown on the installation drawings. The equipment layout should provide adequate floor space for major components with sufficient access space around the set for routine maintenance. Space between units in multiple-unit installations should be a minimum of 2.4 m (8 ft). Cooling. Normally, the lube oil coolers are not integral with the package and must be located and installed separately. The following installation requirements apply: Top of the coolers should not be more than 9.1 m (30 ft) above the bottom of the package frame. Total oil volume of the outgoing and return lines should be limited to 132 L (35 gal.). This is to prevent oil tank flooding in the event of drain back. Maximum total design pressure drop of the combined outgoing and return lines and cooler should not exceed 345 kPa gauge (50 psig). Gas Turbine Air Inlet System. Inlet air is required for operation of the gas turbine. Total pressure drop across the inlet system should be kept to a minimum. The system should consist of all components upstream of the gas turbine inlet collector, including silencers, ducting, evaporative coolers, heat recovery equipment, air cleaners, insect screens and weather

LUBE OIL FILTERS TURBINE GAUGE PANEL

TURBINE AIR INLET

TURBINE EXHAUST GAS TURBINE

Forward End

Forward End

Left Side

Aft End

COMPRESSOR GAUGE PANEL

TURBINE EXHAUST

GAS TURBINE

TURBINE AIR INLET

TURBINE GAUGE PANEL

Aft End

Aft End

Aft End

Right Side

Forward End

DRIVEN SKID Left Side: 1. Gas Compressor Discharge Gas Pressure 2. Gas Compressor Suction Gas Pressure 3. Driven Equipment J-Box I.S. 4. Driven Equipment J-Box Non I.S., DC 5. Ground, Package Frame (2 places) Right Side: 1. Degassing Flue, Sparging Air Inlet 2. Pneumatic Supply, Auxiliary Seal Oil Backup 3. Pneumatic Supply, Auxiliary Seal Oil 4. Oil Drain from Drip Pan 5. Buffer Gas Filter Drain 6. Buffer Gas Inlet 7. Seal Gas Inlet - Dry Seals 8. Buffer Air Inlet - Dry Seals 9. Primary Seal Vent - Dry Seals 10. Secondary Seal Vent - Dry Seals 11. 2 Grounds, Package Frame 12. Auxilary Seal Oil Pump Motor, AC ENCLOSURE: 1. Turbine Air Inlet Flange 2. Turbine Exhaust Flange 3. Lube Oil Tank Vent 4. Pneumatic Start Vent 5. Degassing Tank Vent 6. Compressor Suction Flange (hp) 7. Compressor Discharge Flange (hp) 8. Pneumatic Postlube Backup Vent 9. Pneumatic Vent, Auxiliary Seal Oil Backup 10. Pneumatic Vent, Auxiiary Seal Oil 11. Pneumatic Pre/Post Lube Vent 12. Enclosure Vent Fan, AC

DRIVER SKID Left Side: 1. Turbine Exhaust Collector and Combustor Drain 2. Natural Gas Fuel Inlet 3. Water-Wash Inlet 4. Turbine Air Inlet Duct Drain 5. Pneumatic Start Inlet 6. Pilot Valves, Air/Gas Vent 7. Pneumatic Pilot Valve Air Inlet 8. Liquid Fuel Inlet 9. Liquid Fuel Atomizing Air Inlet 10. Liquid Fuel Return to Fuel Tank 11. Liquid Fuel Drain 12. Compressor Air for Self-Cleaning Filters 13. Water Injection Inlet 14. On-Line Cleaning Fluid Inlet 15. Oil Drain from Drip Pan 16. Liquid Fuel Primary Pump Motor, AC 17. Customer Service Box (2 places), DC 18. Driver J-Box I.S., DC 19. Ground, Package Frame (2 places) 20. Water Injection Motor, AC 21. Air-Assist Pump Motor, AC

Right Side: 1. Lube Oil Cooler Vent 2. To Lube Oil Cooler Hydraulic Fan Motor 3. Lube Oil Tank Drain 4. Lube Oil to Cooler 5. Lube Oil from Cooler 6. Pneumatic Pre/Post Lube Inlet 7. Lube Oil Tank Level Control Inlet 8. Lube Oil Filter Drain 9. Pneumatic Postlube Backup Supply 10. Enclosure Fire Ext Medium Inlet (Main) 11. Enclosure Fire Ext Medium Inlet (Extended) 12. Oil Drain from Drip Pan 13. Lube Oil Tank Heater, AC 14. Pre/Post Lube Oil Pump Motor, AC 15. Ground, Package Frame (2 places) 16. Backup Lube Oil Pump Motor, DC 17. Enclosure Lighting, AC 18. Enclosure Lighting, DC

SPCUCS-022M

Typical Service Connections

37

 Where two or more units exhaust into a common header, such as used for heat recovery equipment, provision must be made to prevent hot gas from flowing into the nonoperating unit. (Common exhaust ducting is not recommended.) Final termination of the ducting must not allow exhaust gas to be drawn into the gas turbine inlet. Provide the capability to purge the complete exhaust system prior to gas turbine light-off. For short, simple exhaust systems, purging capability should be designed to accomplish three air volume changes. For large, complex exhaust systems, purging capability should be designed to accomplish five air volume changes. Loads exceeding 91 kg (200 lb) should not be applied in any direction on the exhaust connection. When exhaust silencing is required, provisions must be made to adequately mount and support the equipment and limit the exhaust silencer pressure loss. Silencers and expansion joints can be provided by Solar. For long or complex exhaust systems, adequate provisions must be made to ensure proper purging capabilities either through gas turbine cranking or supplementary exhaust blowers.

standard options selected. Complete interconnect wiring diagrams are provided for each unit.

OPERATION AND MAINTENANCE MANUALS

Four copies of an operation and maintenance manual are supplied for each type of equipment on each order. The manuals can be provided on CD-ROM if requested. In addition to operating instructions, the manual contains recommended maintenance procedures for field level onsite maintenance and troubleshooting, an illustrated parts list for the entire gas turbine and accessories, and detailed system descriptions.

DRAWINGS
Three sets of prints and one reproducible of the following drawings are provided: Electrical Schematic Wiring Diagram Electrical Interconnect/Interface Software Documentation (on diskette) Mechanical Installation Drawing Start System Schematic Fuel System Schematic Lube Oil System Schematic Surge Control (when applicable)

ELECTRICAL INSTALLATION REQUIREMENTS

Onsite electrical interconnection requirements vary widely according to basic unit configuration and

38

OPTIONAL CUSTOMER CONNECTIONS

OIL COOLER FAN MOTOR STARTER

OIL COOLER FAN

24 VDC
CO2 FIRE DISCHARGE SOLENOID

CONTROLBATTERY SYSTEM

AIR FILTER MOTOR STARTER AC PRE/POST LUBE PUMP MOTOR STARTER AC START VARIABLE FREQUENCY DRIVE ENCLOSURE VENT FAN MOTOR STARTER LUBE TANK HEATER CONTACTOR
110 V, 50 or 60 Hz 220 V, 50 or 60 Hz

INERTIAL AIR FILTER LEADS AIR FILTER

MAIN PACKAGE J-BOX

AC PRE/POSTLUBE PUMP LEADS

AC START LEADS

AC ENCLOSURE FAN LEADS

AC LUBE TANK HEATER

ENCLOSURE LIGHTS AC

POWER MODULE

3 ac motors and lube oil tank heaters may be 460 V, 60 Hz; 575 V, 60 Hz; 380 V, 50 Hz; 400 V, 50 Hz; or 415 V, 50 Hz. Motor starters are customer supplied and must have a 24 -Vdc coil.

PA98066M

Typical Electrical Connections

39

Testing and Quality Assurance

Factory testing is in accordance with Solars specifications and as generally outlined below. The purchaser or purchasers designated representative is provided access to Solars Production Test facilities to observe factory production tests scheduled in accordance with production and testing schedules. Unavailability of the purchaser or purchasers representative will not be cause for delay in the performance of the production tests. equivalent of the design speed, and the head-versuscapacity characteristics of the machine are determined. Surge points are determined at various speed points to validate the surge flow estimate for the entire operating range of speed. Extensive instrumentation validates mechanical and aerodynamic performance. The gas compressor dry gas and seal oil systems are tested statically by pressurizing with nitrogen. The gas turbine-to-gas compressor alignment is adjusted to the manufacturing tolerances for bore plus face runout at the output drive bearing housing after installation of the gas compressor on the package. Package Acceptance Tests. Package acceptance testing is divided into two phases. In the first test phase of static electrical checkout, all sensing device actuations are manually simulated by closing various switches installed in parallel with the actual sensors. The control system outputs are then indicated by lights installed in parallel with the driven devices, and all modes of operation and malfunction protection are demonstrated in accordance with a rigorous test agenda. The second test phase involves prestart flushing of lube and seal oil supply lines, calibration of instruments and controls, and actual operation of the package up to gas generator idle speed. These tests are performed to satisfy a predetermined test agenda, confirming that the unit is ready for delivery. The basic package assembly, including the gas turbine, gearbox (if provided), and package-mounted accessories, together with the control console, is tested to ensure proper integration and function of the total package in accordance with Solars test specifications. Results are recorded and maintained by Solar. The package acceptance testing is run at gas generator idle speed and generally includes the following: Starting and combustion cycles Lubricating oil system flow, temperature and pressure measurements Vibration measurement Turbine temperature measurements Items excluded from standard package testing are contract inlet and exhaust system ancillary equipment, such as filters, silencers and ducting, battery systems, oil coolers, package enclosure, ancillary skid, and any customer-furnished hardware.

TEST FACILITIES
The computer-controlled test system includes a realtime data acquisition system which collects raw digital and analog data from the gas turbine package and displays or prints out results in customary engineering forms and units. The control and display units provide the capability of monitoring and controlling the power and test inputs to operate the unit under test and to measure and evaluate its performance. The system is used to establish specified test conditions by keying in calibration coefficients, constants and operating limits. Test data are displayed by a video terminal as instructed by the test agenda, selecting various parameters for display, checking values and limits, and generating hard-copy records as needed. When performance levels have been achieved, the test technician initiates a command to capture all instrumented points, which initiates automatic performance computations and prints the results for review for a permanent test record.

TESTING
Gas Turbine Acceptance Test. Each gas turbine is subject to a run-in and calibration test in accordance with Solars specifications. A test run at incremental loads up to and including full speed and power ensures functional and structural integrity and high performance standards. Gas turbine power is absorbed by a high speed dynamometer, enabling all aspects of gas turbine performance to be measured accurately. Gas Compressor Test. Prior to assembly of the internal components, all compressor casings are subjected to hydrostatic testing per API 617. Then, following a procedure similar to the gas turbine run-in test, the gas compressor is tested. For the aerodynamic test, the gas compressor is driven by a slave turbine or electric motor at the air

40

PERFORMANCE REVIEW
Acceptance Test Data. Acceptance test data are furnished approximately four weeks after completion of acceptance testing. The report provides test results and compares the results to Solars acceptance test specification requirements by means of calculations, graphs, strip charts and descriptions. Data are provided for each gas turbine compressor set. The acceptance test data include measurement and verification of heat rate and power. Fuel consumption, output power, and gas temperature are correlated and corrected to standard conditions of turbine match temperature, sea level, and zero duct losses. Test data are taken at rated speed and full load.

subassemblies and are responsible for functional testing of incoming components. The same rigid standards applied to parts manufactured by Solar are applied to all supplier parts received by Solar. Prior to commencement of testing, an inspection and test plan (ITP) is generated. The ITP documents quality assurance, inspection and testing requirements and defines the level of customer or thirdparty involvement in the inspection process. The ITP is the controlling Quality Assurance document for a project. Solar is an ISO 9000-certified company. The certification is a tool for continuous quality improvement.

PRODUCT IMPROVEMENT PROGRAM

The continuing design activity in Solars Product Improvement Program utilizes new technologies, processes and equipment to upgrade and improve all of Solars products. These activities cover a broad scope and are aimed at improving reliability and useful life of equipment manufactured by Solar. Special effort is made to maintain interchangeability with previous designs so that the improvements can be retrofitted economically into existing units.

QUALITY ASSURANCE
All testing operations are conducted under the direct control of Solars Quality Assurance activity and in accordance with Solars ISO 9000 Operation Practices. This activity ensures absolute compliance with the test procedures specified. In addition to final in-plant testing of the finished package, Quality Control engineers maintain surveillance over the manufacture of all purchased parts and

41

Support Services
CONSTRUCTION SERVICES
Solars Construction Services organization offers a comprehensive range of equipment and services to assist you in successfully meeting your complete power system expectations. Our experience takes us to many parts of the world, onshore and offshore, managing various types of power configurations. Our services, based on years of experience and expertise in power system engineering and complete project management, include: Feasibility studies Proposal preparation Design and engineering Material procurement Fabrication Onsite construction Quality control Scheduling Budget control Shipping Installation, testing, and commissioning Material procurement, for example, can include prime movers, driven equipment, associated mechanical process equipment, and electric power generation equipment. Construction Services is uniquely qualified worldwide to give you complete compression and/or power generation systems, with single-source responsibility, engineering expertise, optimal economic designs, and real attention to quality and safety to ensure you are satisfied with your complete power system. Solars Customer Services organization is wellknown for its excellent service and support. No other gas turbine service company can compare in: Product knowledge and experience with more than 10,000 units in more than 86 nations In-depth technical support via Solars global Customer Information Network Factory-qualified repair and overhaul procedures Genuine Solar Certified Parts Worldwide field service personnel and service facilities Around-the-clock response Exchange engine program to minimize your downtime Solar Turbines stands behind each of our customers with uncompromising commitment to the success of their turbomachinery installations throughout a projects life cycle.

CONTRACT POWER AND LEASING SERVICES

Solars Contract Power organization is dedicated to providing numerous financing options. All or part of a project can be financed, offered under a lease agreement, or installed on a service tariff with a performance contract. Financing or leasing terms can extend from shortterm rentals to long-term leases of 10 years or more. Financing can be structured as full-payout financing instruments that lead to ownership or as off-balance sheet operating leases that can allow for the return of the equipment at the end of the lease. Under a performance contract, Solar may supply, install, operate, maintain, and own the equipment, as well as auxiliary components required to provide the service, such as electric power, steam, or compressed gas. The tariff charged by Solar is based on the amount of service delivered. The Contract Power organization is fully qualified with worldwide experience and expertise in financing and power contracts to assist you in determining the best financial option to optimize your economic return.

CUSTOMER SERVICES
Solars Customer Services organization is dedicated to the support of Solars equipment worldwide. Customer Services support includes technical training, field service personnel, service parts, overhaul and repair services, and customized operation and maintenance programs. Customer Services also offers gas turbine uprates and updates, retrofit conversions to low emission SoLoNOx turbine configurations, and complete package refurbishments, all of which provide cost-effective life-cycle solutions.

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15 14 13 3 47 10 5 6 9 19 22 18 23 17 12 8

24 26 25 29 27

1 11 21

32

36

30

28

O R

20 UNITED STATES 1 R 2 P 3 4 O 5 6 7 BC R 8 P BC 9 10 11 P 12 13 Anaheim Anchorage Chicago DeSoto Houston Lafayette Mabank Miami New Orleans Odessa Ontario Upper Saddle River Salt Lake City San Diego

BC

16

R P

34 Headquarters 35 Representatives 33 Overhaul Center 31 Repair Center Boost Compressor O/R Center Service Parts Administrator Exchange Turbines Refurbishment Center 38 Service Parts Center 37

CANADA 14 O R 15
R P

BC

Calgary Edmonton

EUROPE/AFRICA 24 R 25 26 R 27 O R BC
P

Aberdeen Dublin Esbjerg Gosselies Lagos London

LATIN AMERICA 16 17 18 19 20 21 R 22 O R BC O R 23

Buenos Aires Caracas Cd. Del Carmen Mexico City Rio de Janeiro Tijuana Veracruz Villahermosa

28 29

PACIFIC 31 O R 32 33 O 34 35 36

BC

R BC P

Bandung Beijing Jakarta Kuala Lumpur Singapore Tokyo

MIDDLE EAST 30

AUSTRALIA O R 37 Dubai 38
R P BC

Melbourne Perth

PA95141MS

Solars Customer Services Facilities

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FOR MORE INFORMATION Telephone: (+1) 619-544-5352 Telefax: (+1) 619-544-2633 Telex: 695045 Internet: www.solarturbines.com

Solar Turbines Incorporated P.O. Box 85376 San Diego, CA 92186-5376

SPCUCS/998/12M