GAS TURBINE

 2nd & 1st GRADE

INTERNAL
COMBUSTION
ENGINE DRIVER
 PART 1
INTRODUCTION TO GAS
TURBINE
Why Gas Turbine?
 Lower weight per unit of
power output
 Smaller size compared to
diesel engine
 Less vibration (rotating
machine)
 Less pollution
Can you tell the familiar &
difference?
GAS-TURBINE THEORY
A simple gas turbine is comprised of three main sections
a compressor, a combustor, and a turbine. The gas-
turbine operates on the principle of the Brayton cycle,
where compressed air is mixed with fuel, and burned
under constant pressure conditions. The resulting hot
gas is allowed to expand through a turbine to perform
work. approximately two / thirds of this work is spent
compressing the air, the rest is available for other work
ie.( mechanical drive, electrical generation)
Brayton Cycle
Newton’s third law of motion
which states that,
 ’for every force acting on a body there is
an opposite and equal reaction’.

A jet engine produces thrust, more thrust

Types of Gas Turbines
• There are two basic types of gas
turbines
– Aero derivative units are aircraft jet engines
modified to drive electrical generators
– Industrial gas turbines units robust
construction, are suitable for base load
operation
Aero derivative (Aero Trent)
Industrial Gas Turbines
Gas Turbine with Regeneration

One variation of this basic cycle is the addition of a

regenerator. A gas-turbine with a regenerator
(heat exchanger) recaptures some of the energy
in the exhaust gas, pre-heating the air entering
the combustor. This cycle is typically used on
low pressure ratio turbines.
Gas Turbine with Regeneration
Horse power
 The term horsepower
was invented by the
engineer James Watt.
Watt lived from 1736 to
1819 and is most famous
for his work on improving
the performance of steam
engines. We are also
reminded of him every
day when we talk about
60-watt light bulbs.
Horse power
 What horsepower means is this: In
Watt's judgement, one horse can
do 33,000 foot-pounds of work
every minute. So, imagine a horse
raising coal out of a coal mine as
shown above. A horse exerting 1
horsepower can raise 330 pounds
of coal 100 feet in a minute, or 33
pounds of coal 1,000 feet in one
minute, or 1,000 pounds 33 feet in
one minute. You can make up
whatever combination of feet and
pounds you like. As long as the
product is 33,000 foot-pounds in
one minute, you have a
horsepower
HORSE POWER

A unit of power equals to 33,000 ft-lb/min or

550 ft-lb/sec or 2,545 Btu/hr.
1hp = 746 watts
COMPRESSOR SURGE

Pulsating of compressor discharge pressure

due to chokage as a result of too much of air to
be handled
How does gas turbine work?
Ground rule for
Watching movie
Type of Gas Turbine
 There are two type of gas turbine
 Single Shaft
 Split Shaft
Single Shaft Gas Turbine
 The single shaft gas turbine was develop
primarily for the electric power industry
and uses a compressor and a power
turbine integrated on a common shaft. As
the unit is used continuously at single
rotational speed.
Single- spool compressor
Twin spool compressor
Twin spool compressor
Typical triple spool compressor
Split Shaft Gas Turbine
 The split shaft gas turbine was develop
primarily for mechanical drive application
like pump and compressor, where the
output power and speed might be
expected to be variable.
Quiz
 Gas Turbine operated on what cycle?
 What it mean by surging?
 How to prevent surging?
 When surging occur?
 How many type do gas turbine have?
 Single Shaft is suitable for what condition?
 Split Shaft is suitable for what condition?
 What is the capacity of your gas turbine?
 The difference
 PART 2
MAJOR COMPONENTS AND
FUNCTION
Main component
1. Gas Generator (GG) which consist of
• Compressor
• Combustion chamber
• High Power Turbine (HPT)
3. Power Turbine (PT)
• Casing for compressor and turbine
• Accessory (L.O, Sealing & etc)
Main component
Air Intake System
 a screen is fitted at the entrance to the
intake system to keep out large foreign
objects such as tools, clothing, birds, etc.
Enclosure
Air Filter
Compressor
The compressor is
driven by the turbine via
a connecting shaft and
has the job of drawing
external air into the
engine, pressurizing it,
and passing it along to
the combustion
chamber.
Compressor Rotor
Stator
Type of Compressor
 There are two type of compressor
 Centrifugal Compressor
 Axial Flow Compressor
1. Centrifugal compressor
 This compressor uses a spinning
impeller to draw in intake air
and accelerates it outward by
means of centrifugal force into
a diffuser.
 It is used in small gas
turbines and is best suited
for low pressure ratios
where the overall engine
diameter is not important.
Two- stage centrifugal
2. Axial flow compressor
Consists of rotating blades and
stationary vanes. Air is
compressed as it flows axially
along the shaft. This allows
greater efficiency and higher
pressure ratios by multi-stage
construction. A stage of
compression consists of one row
of rotating blades followed by a
row of stationary vanes. This is
the most common type of
compressor used in marine gas
turbine engines.
Inlet Guide Vane (IGV)
Blow Off Valve (BOV)

Prevention against compressor

surge during start up
/ shut down and acceleration
(The valve reduce back
pressure by venting air to atm
through BOV line to
exhaust duct) and compressor
began surging when
front stages of compressor
would be highly loaded
(mid Span)
A hydraulically operated bleed valve and inlet guide vane
airflow control system.
A pneumatically operated bleed valve system.
IGV Opening
Diffuser
 Compress air from
the Compressor enter
the diffuser section
where the moving gas
will have a static
pressure and to
prevent flame in the
burner section from
being extinguished.
(divergent)
Divergent and convergent
Compressor Diffuser Assembly(Mars)
Diffuser & Combustor
Combustor section
Function :
• Provide proper mixing of fuel and air for
efficient combustion
Combustor
• fuel and air are mixed and combust.
burner system
• disperse/atomize the fuel
ignition system
• ignite the main flame
Combustor section continue
 The combustion process is first initiated by
igniter plugs, which are then isolated after
ignition has been accomplished.
 The combustion of the fuel and air mixture is
continuous and remains so until the fuel
supply is removed.
Combustion temperature
 Fuel sprayed from the fuel
injector nozzles, mixes with
high-pressure air entering
the combustion chamber
through its perforations
from the compressor.
 This mixture of compressed
air and fuel then burns at
temperatures approaching
2000oC , in order to
maximize the heat energy
obtained
Exhaust temperature profile
Thermocouple

Inter-turbine duct

Gas temperature
contours

17 thermocouples
Combustion Process
Flame pattern
Combustor Flame Pattern
Normal Condition

104-019
Combustor Flame Pattern
Condition with Clogged Fuel Injectors

104-030
Turbine showing outboard flame traverse
Fuel gas flow

Gas

Gas
Flame
Temperature
Flame traverse on gas with
Liquid hydrocarbons

Blade Height

Flame Temperature
1st-Stage Nozzle Damage

104-020
Condensate in Fuel Gas
combustor
• Combustion chamber configuration
1.Single Silo
compressor is mixed with fuel and ignited in this
chamber
3.Twin silo (each consist of multiple burners)
4.Can annular (ez maintenance & better
balance)
5.Annular ring (popular for >200MW)
Silo combustor
Silo combustion chamber in
its simplest form
consist of single burner or
multiple burner.
Compressed air from the
The hot gas is then lead to
the turbine section
Silo combustor
 Disadvantage
influence the size of the
turbine house.
 Advantage
furnace inspection can be
done easily because of it big
size.
Silo combustor
Can Annular combustor
1. Individual burner cans are mounted around the
periphery of the engine. Each can is an
individual combustor and liner receiving its own
fuel supply.

Advantage: Easy replacement

Disadvantages - Inefficient, structurally weaker

Annular combustor
 One large combustor within the engine case.
Multiple fuel nozzles form a solid "ring of fire".
This type is used on the LM2500
 Advantage
 Most efficient, strongest, frame member of engine
 Disadvantage
 A repair or replacement requires complete engine
disassembly.
Combustor
High Power Turbine & Power
Turbine
Function
To convert high pressure and temperature
combustion gases into mechanical energy and
drive the compressor and generator.

turbine blades
converts the kinetic energy into mechanical
energy
High Power Turbine
Internal air cooling
- High thermal efficiency is
dependent upon high turbine
entry temperature, which is
limited by the turbine blade and
nozzle guide vane materials.
- Continuous cooling of these
components allows their
environmental operating
temperature to exceed the
material’s melting point without
affecting the blade
and vane integrity.
Internal air cooling continue
Cooling blade
Power turbine
Power turbine continue
Pure Impulse turbine and an impulse/reaction turbine.
system

when the gas is expanded by the combustion

process, it forces its way into the discharge
nozzles of the turbine where, because of their
convergent shape, it is accelerated to about the
speed of sound. At the same time the
gas flow is given a ’spin’ or ’whirl’ in the direction of
rotation of the turbine blades by the nozzle guide
vanes. On impact with the blades and during the
subsequent reaction through the blades, energy is
absorbed, causing the turbine to rotate at high speed
and so provide the power for driving the turbine shaft
and compressor.
Quiz
 Name two type of the compressor?
 What Type of Combustor do your Gas
Turbine used?
 How much air using for combustion and
cooling?
 PART 3
GAS TURBINE SUPPORT
SYSTEM
Starting Systems
 Gas Turbine are not self starting.
 Starter are used to provide the rotational
drive necessary to accelerate the turbine
engine up to 20% turbine speed (light off)
and remain until 60 to 66% starter will
automatically uncoupled and allow the
turbine to accelerate to 100% speed on its
own.
Type of Starter
 1. Electric Starter
 A/C motor
 DC motor
 2. Pneumatic starter
 Compressed air, nitrogen or gas
 3. Hydraulic starter
 Hydraulic oil
 4. Diesel engine start
 Diesel engine for starting only
 5.Gas expansion motor
 Gas is bled from the main fuel supply to drive expansion motor
Fuel and Start Gas
 With control panel switches in proper position for
a unit start, the logic circuits cause the following
events to occur.
 Once purge cycle is complete, upstream
fuel gas valve is energised to open. Vent
valve is energised closed and the igniters
are switched on. Starting gas flow control
valve PCV is ramped fully open to bring
starter up to high speed to crank the gas
generator for startup.
 Fuel gas block valve is energised open. Fuel is
ignited in the combustion chambers of the gas
generator and speed ramps up to idle.
 Once at idle the igniters are switched off.
Starting gas flow control valve PCV is de-
energised closed. Starting gas upstream shutoff
valve is de-energised closed and the starter is
shutdown.
Fuel and starter gas
LM2500
GAS GENERATOR POWER TURBINE
gas
manifold

ACC VENT
GEARBOX TO SAFE
LOCATION

STARTER

1183
XV
EXHAUST
1192
PV

XV
FMV XV XV
1184 1181
1191
HP FUEL GAS
STARTER GAS PT
1182
Fuel and starter gas continue
Fuel Gas Starter
Hydraulic Starter
GG lube oil
 Synthetic oil is used for the gas generator.
The console is mounted outside of the
turbine enclosure.
 Hydraulic oil after filtration is routed to the
fuel metering valve actuator. Hydraulic oil
exiting the fuel metering valve actuator is
returned to the reservoir.
 Lube oil after filtration is routed to the
accessory gearbox and bearing sumps.
The lube oil is removed from the
accessory gearbox and bearing sumps by
scavenge pump. The oil passes through
filter.
 Magnetic chip detectors are installed in
the drain lines from the accessory gearbox
and each gas generator bearing sump
ahead of the scavenging pumps. An
additional magnetic chip detector is
installed in the common drain header.
Metal carried by the drain oil will
accumulate on the detectors and signal an
alarm.
 Scavenge oil after filtration flows to
Cooler. A temperature valve regulates oil
flow through or around the cooler to
maintain oil temperature at 60°C.
GG lube oil
36bar

Gas Generator
FMV

Scavenge oil cooler

Acc
Hydraulic oil filter Lube Oil Sump
Gear
box
Hydraulic
Oil pump

Scavenge oil pump

7bar
Lube oil Lube oil
pump Scavenge oil Filter
Filter
Magnetic Chip Detector
Gear pumps
Gear pumps continue
Air oil separator
GG lube oil sump
Power Turbine and Compressor Lube Oil

 Mineral oil is used for the power turbine and

compressor lubrication. The console is
mounted outside of the turbine enclosure.
 Two pumps are used for normal operation.
One pump is driven by an electric motor and
is used for start-up and standby. The
remaining pump is driven from the power
turbine accessory gearbox and supplies all of
the lube oil to the power turbine and
compressor once the unit is in operation.
 Oil from the pumps flows to a separately
mounted fin fan cooler, Temperature
control valve TCV regulates oil flow
through or around the cooler to maintain
oil temperature at 49°C.
 Lube oil from the power turbine and
compressor bearings is returned to the
reservoir.
 A third oil pump, Post Pump is included in
the lube oil console to provide cooling oil
to the power turbine after shutdown. Unit
control panel logic will start pump after
main unit shutdown has commenced.
Lube Oil System (PT)
Check valve

Filter

Gas Turbine
compressor

Cooler

Emergency
pump
Aux LO
Pump
LO Reservoir Main Pump
 Safety precautions
The following safety precautions must be
observed when adding lubricant (top up):

1. Avoid touching moving parts of the machine

2. Keep loose clothing well away from moving
parts
3. Avoid spilling lubricant onto hot surface
4. Clear up spillage immediately
5. Do not remove safety protection from the machine
A good quality of lube oil

 Continuous check of physical oil

characteristics during operation will predict
warrant of machinery life spent,
maintenance cost and time saving.
 The oil shall be oxidation, foam inhibited
and have good demulsibility for rapid
separation of water.
 Operating precautions

1. Avoid mixing different grades of oil

2. Avoid mixing different grades of grease
3. Avoid mixing with water or other liquids
4. Avoid contamination with dust or dirt
5. Check that oil cans are free of all foreign
materials before filling
6. Avoid overfilling equipment
Routine Checks
1. During the shift, routine checks must be carried out
on a regular basis.
2. The operator must carry out routine checks
immediately upon taking over the shift to ascertain
the operating conditions of the unit and/or equipment.
3. Just prior to the end of the shift, the operator must
again check the unit and/or equipment to ensure that
his handover to the next operator is accurate and
gives a true reflection of the situation at that time.
4. Operating troubles that may have been experienced
on the unit and/or equipment should be recorded in
the log book and verbally
The following check shall be carried out .

1. Check oil level.

2. Check oil temperature
3. Check oil pressure
4. Check and drain water.(Investigate
reason for water in the bearing.).
5. Take samples for laboratory analysis
when requested
Lesson learn
 On 30/09/2006, 37drums of PT Lube oil lost due to PT
Auxiliary pump auto run when a maintenance work ( hot
section replacement, 25K) on going. Cause it to
splashing on the PT exhaust insulation.

 PT Auxiliary pump run cause by compressor casing

pressure built up (set at 0.5bar) due to shut off valve
passing
Lesson learn continue
 23/10/2006, 12.00pm prepare to start up after 25k
completed. Starting with manual crank.
 12:19pm running with idle speeds, CO2 inhibit for DR
vendor to do inspection check and found fire on the PT
side.
 12:29pm manually shutdown the compressor. Using dry
power to put out the fire but fail
 12:36 close all the enclosure door and manually activate
the CO2 discharge.
 13:00 electrical isolation the package
Lesson learn continue
Over Oiling
Caution!
Enclosure ventilation system
 The enclosure surrounding the gas generator
and power turbine is provided with a ventilation
system.
 Air is pulled from the inlet air filter through a
silencer by an electric driven fan
 Three fans are used for the ventilation system.
 Two fans are to be used during normal
operation and the third fan is for emergency
use.
 The ventilation air passes through fire shutters
before entering the enclosure.
 The shutter actuator is activated by the fire
suppression system.
 The differential pressure within the enclosure is
monitored by a differential pressure switch 505-
PDS-1207
 alarm and start the emergency ventilation fan

at 2.54 mm H2O decreasing

 shutdown after 60 second delay if the

differential pressure does not increase above

the alarm setting
Fire and Gas Suppression Systems
 Gas detectors are located in the intake
plenum and turbine enclosure
 The gas sensors monitor gas levels within
the plenum and enclosure. An alarm is
sounded if gas levels reach 20%.
Shutdown occurs if gas levels reach 60%.
FIRE DETECTION SYSTEM
 All access doors to the air filter enclosure, intake
plenum and turbine enclosure are fitted with limit
switches which will sound an alarm if any door is
left open.
 Fire detectors are placed in the turbine
enclosure. The fire detectors are of the optical
type, and response to ultraviolet and infrared
radiation which is emitted by flame. The
detectors have a 120° field of view.
 When the detector senses UV or IR radiation, it signals
the control panel module. The module issues signals to
trigger release of CO2, and closes the fire damper doors
to isolate the fire in the enclosure. Two dump nozzles are
provided. The 559 nozzles dump the CO2 into the
enclosure at a fast rate. The 560 nozzle dumps the CO2
at a slow rate. The CO2 bottles are stored in a cabinet
which is adjacent to the unit. Two CO2 tanks are
provided for the main system (fast dump) and one CO2
tank is provided for the extended system (slow dump). A
duplicate set of reserve tanks are also included in the
system.
Warning!
 WARNING
 PERSONNEL SHOULD NOT BE EXPOSED TO
HIGH CONCENTRATIONS OF FOR
PROLONGED PERIODS TO CO2 DISCHARGE.
 CO2 MAY CAUSE SUFFOCATION AND
REDUCED VISIBILITY DURING AND AFTER A
DISCHARGE PERIOD.
 Fast Discharge
Slow Discharge

CO2

CO2
Gas Turbine Enclosure Temperature
Alarm 71deg C
S/down 80deg C

Fire Detector (Optical) Gas

Detector
Response to ultraviolet and
Alarm 20%
infrared
S/Down 60%
Fire Detector(Optical type)
Dump Nozzle
Gas Detector
Periodic Maintenance

Every 4000 Running hours

detergent wash with boroscope

25,000 Running hours

Replacement of the Hot Section

Note; Depend on vender recommendation

 EXHAUST SYSTEM
Function:- Convey hot exhaust gases to either
atmosphere or waste heat boiler

- exhaust casing
- provides exhaust gases flow path

- exhaust ducting and silencer

- routes the exhaust gases to chimney or waste
heat boiler with a reduction in noise
Quiz
 What is the safety protection device
installed in your gas turbine?
 What do you check on your lube oil
system and why is it important to do so?
 What we periodic maintenance are
necessary and why?
 New high tech safety protection system
 PART 4
START-UP AND SHUTDOWN
PROCEDURE
UNIT START-UP
 Types of start-up
 1. Start-up after maintenance.
 2. Start-up after temporary shut-down.
 3. Start-up after emergency shut-down.
Start-up after Maintenance
 Summary
 Following a planned shutdown for
maintenance and inspection, the equipment
are handed back to operations department for
start up.
1. Pressure tests must be made to ensure that all
disturbed flanges, valves and pipe work are leak
free
2. The whole system must be thoroughly
purged of air by using nitrogen
3. AII accessories and equipment related to the
operation of the main equipment must be
checked out correctly.
4. Check that all the platforms and immediate
external areas are clean and unwanted
material removed.
 Operating precautions

Fuel and Start System

 WARNING
 INSTRUMENT BLOCK VALVES IN SENSING LINES TO
Fuel Gas, Start-up Gas, Starter Exhaust AND
Instrument Air supply MUST BE IN THE OPENED
POSITION WHEN UNIT IS OPERATIONAL. UNIT
OPERATION WITH BLOCK VALVES CLOSED COULD
DISABLE THE SHUTDOWN SIGNAL FROM THE
SWITCHES, WHICH MAY CAUSE EQUIPMENT
DAMAGE AND OR PERSONNEL INJURY.
 CAUTION
 WATER WASH VALVE IS OPENED ONLY
WHEN USING A WATER WASH CART.
 OPEN EXHAUST CASING DRAIN VALVE
AFTER WATER WASH CART HAS BEEN USED
TO CLEAN THE UNIT OR TO REMOVE LIQUID
WHICH HAS ACCUMULATED DURING UNIT
OPERATION.
 Gas Generator Lube Oil System
 The pressure and temperature checks can
only be made after the gas generator is in
operation.
Normal Start Sequence
 A Normal Start Sequence can only be
initiated locally from the Local Control
Panel (LCP).
 When the mode select switch on the LCP
is in Local, a Normal Start is initiated by
depressing the Start push button on the
face of the LCP.
 "Permissive To Start."

 Gas Generator Oil Reservoir Level is OK

 Power Turbine / Compressor Oil Reservoir Level is OK
 Fuel Metering Valve is at Minimum Position
 Fuel Shutoff Valves are closed
 Start Gas Shutoff Vent Valves are closed
 AC Power "OK"
 Vibration Monitor is "OK"
 Turbine Enclosure Doors are closed
 Unit Process Valves are in Shutdown (Prestart) Position
 Gas Generator Coastdown Timer Time out
 Gas Generator Speed Ramp is at Minimum
 Power Turbine Speed Ramp is at Minimum
 LCP Run Local Mode is Selected
 All Fire and Gas System Alarms are Cleared
 All Trip to Idle/Recycle Alarms are Cleared
 Unit Shutdown is Cleared
 Buffer Gas Supply is greater than the Low Alarm
 Fuel Control Summary Shutdown is Cleared
 NOTE
 If the Permissive To Start pilot light is not
illuminated on the face of the LCP, select the
Start Permissive Screen on the Operator
Interface CRT the status for each of the above
conditions will be displayed.
 The corrective action for each point should be
taken in order to achieve a Unit Start Permissive.
Immediately after the Start push button is
depressed

 The Turbine Enclosure Fan selected as Main will be

started
 The PT Seal Air Supply valve is opened
 The Compressor Separation (Buffer) Gas Supply
valve is opened
 Upon establishing of the Compressor Seal Gas
Separation Pressure, the PT Post Cooling Oil Pump
is started for test purposes
 The Standby Lube Oil Pump is started and a
Standby Lube Oil Pump test is initiated
Auxiliary Sequences
 Stand-by Lube Oil Pump Test
 Power Turbine/Compressor Lube Oil Pressure
 Lube Oil Pump Sequence
 Enclosure fan Sequence
 Seal Gas System
 After the Auxiliary Sequence has been
completed, the Purge and Pressurising
Sequence for the Compressor will be initiate
Pressurising Sequence
 The Suction Bypass Valve is opened.
 When the Differential Pressure across the
Suction Valve is reduced to less than 1.0
Bar the Suction Valve will open
 After the Suction Valve is fully open, the
Suction Bypass Valve closes and the
Discharge Valve will open
Gas Turbine Start Sequence
 The Gas Starter Control Solenoids are
energised
 The Starter Speed Control Output will be
ramped up until the Gas Generator Speed
has achieved 1250 RPM
 If the Gas Generator fails to reach 1200 RPM within
thirty (30) seconds, a Fail To Crank Shutdown will be
initiated; thus the Unit Start/Run Sequence will be
aborted.
 GG Speed will be controlled between 1250 and 1350
RPM to purge the Plenum, GG, PT/Exhaust Duct and
the GG Purge Timer will begin to time out.
 When the GG Purge Timer has timed out, the Starter
Speed Control Card High Speed command will be
enabled and the Starter Speed Control Output will ramp
up to maximum.
 The Gas Generator will begin to accelerate. and. The
Ignitors (A or B) are alternated on successive starts of
the Gas Generator.

 The Fuel Gas Vent solenoid (XY-1183) will be energised

to close.
 The Ignitor Relay (A or B) (IGN-1261 or 1262) is
energised
 The Fuel Gas Secondary Shutoff Valve Solenoid (505-
XY-1184) is energised to open 505-XV-1184
 Light Off (greater than 204°C) must be
verified within 10 seconds after the
Secondary Shutoff is opened or a "Fail to
Light Off Shutdown " is initiated. This will
then initiate a High Speed Purge of the
Gas Generator at greater than 2000 RPM
to rid it of any residual fuel.
 Once Light Off has been verified, the Gas
Generator will continue to accelerate until the
GG Speed has achieved 4500 RPM. When the
GG Speed is greater than 4500 RPM, the
Starter Control Signal is disabled and both the
Gas Starter Supply and Shutoff Solenoids are
de-energised. Simultaneously, the Ignition is
also disabled. The Gas Generator continues
accelerating to Idle.
 Once the Gas Generator has reached Idle
Speed (5000 RPM), the Unit Warmup Timer will
begin to time out. When the warmup Timer has
time out, the Unit is ready to load.
 When the Unit Load Sequence is initiated, the
GG will accelerate until the Power Turbine
minimum speed (3250 RPM) is achieved. The
Unit will now be operated in Power Turbine
Speed Control Mode.
 Normal operation & routine
checks
 During the shift, routine checks must be carried out on a
regular basis.
 The operator must carry out routine checks immediately
upon taking over the shift to ascertain the operating
conditions of the unit and/or equipment.
 Just prior to the end of the shift, the operator must again
check the unit and/or equipment to ensure that his
handover to the next operator is accurate and gives a
true reflection of the situation at that time.
 Operating troubles that may have been
experienced on the unit and/or equipment
should be recorded in the log book and
verbally communicated to the incoming
operator.
 Operating aspects to be monitored in order to keep the
performance of the unit under control and to identify
proper corrective actions are:
 Compressor and Turbine vibrations
 Compressor and Turbine axial displacement
 Temperature and pressure of the lube oil systems.
 Differential pressure across the Lube Oil Filters.
 Differential pressure across the Hydraulic Oil Filters.
 Status of the Lube Oil Stand-by Pumps.
 Differential pressure across Seal Gas Filters.
 Differential pressure across Nitrogen Buffer Gas Filters.
 Differential pressure across Instrumental air Filters.
 Gas Generator speed.
 Power Turbine/Compressor speed.
 Types of shut down

1. Shut down for maintenance

2. Temporary shut-down.
3. Emergency shut-down.
Scheduled shut-down
 Scheduled shut-downs occur at infrequent
intervals and are carefully planned. This
enables preventive maintenance work to be
carried out e.g. internal inspection of an
equipment.
 All maintenance work which cannot be
handled whilst the Equipment is in operation
is carried out at this time. A Previously
prepared shut-down procedure and work list
must be strictly adhered to. This will ensure a
safe, controlled shut-down and a minimum
loss of time in completing maintenance work.
Operating precautions

 Close co-ordination between the Panel

Operator and Field Operator is essential for
good control.
 Safe operating procedures and safety
regulations must be followed at all times.
 Coordinate with other Units and warn the
other departments, especially the Fire
Department.
Temporary shut down

 A temporary shut-down is unscheduled and may

only last for a few hours. The shut-down follows
the same procedure as for a scheduled shut-
down except that the pressure should be
maintained ready for immediate start up.
 A temporary shut-down is usually due to
operational requirements, or, a unit upset of
short duration. Every effort must be made to
return to normal operations as soon as possible.
Emergency shut-down
 An emergency shut-down can be caused by
equipment failures related to the plant
operation or utility failures, e.g. loss of
instrument air.
 In the event of an emergency shut-down being
necessary the unit must be taken out of
service as quickly and safely as possible.
 The prevailing conditions at the time must be
taken into consideration when shutting down
the unit.
 WARNING
 Safety of personnel and the prevention of
damage to equipment are the primary
considerations. All operations personnel
must be thoroughly conversant with the
procedures to be taken for an emergency
shut-down.
 The exact procedure to follow must be
decided in the light of individual
circumstances at the time. Frequent
checking of equipment can normally give
adequate warning of impending trouble
and allow a normal shut-down to be
effected.
 A thorough knowledge of all the
equipment related to unit operation is
essential.
 The main causes of unit emergencies are:
power failure, instrument air failure, fuel
gas failure.
Unit Vented Shutdown Sequence
 Unit Vented Shutdown requires
depressurising the Compressor.
 When a Vented Shutdown is initiated,
Fuel Gas is immediately cut off, the
Turbine begins coasting to a stop and
Compressor Vent Valve is opened.
 The following conditions will initiate a Vented
Shutdown:
 CO2 Release Shutdown
 Common Fire Shutdown
 Inlet Plenum Gas Shutdown
 Turbine Enclosure Gas Shutdown
 Compressor Vibrations Shutdown
 Compressor Thrust Shutdown
 Gas Seal Vent Leakage Primary High Shutdown or
Signal Fail
 PT/Compressor Lube Oil Supply Pressure
Low Shutdown or Signal Fail
 Compressor Rupture Disc Failure Shutdown
 Process Shutdown – Vented
 Unit ESD
 2 of 3 CPU’s Failure Shutdown
Quiz
 Explain briefly start up and shut down
procedure of your gas turbine?
 What is Normal operation & routine
checks?
 Start-up after Maintenance, What is very
important to check?
 PART 5
OPERATING PROBLEMS AND
SOLUTION
Operating problems
 Divided into three group
 Mechanical failure
 Temperature related problems (thermal
shock)
 Combustion (explosion)
1.Mechanical Failure
(a) Overspeed
 As the rotor speed increase significantly, the
centrifugal force on the components become
greater that the rotor will eventually burst.
This not only destroys the turbine but also
may cause damage to nearby equipment
and even to personal injury.
Solution
 Overspeed protection System
 There are two type of Overspeed protection
system
 Electronic Overspeed protection system
 Mechanical Overspeed protection system
Electronic Overspeed protection system

 The turbine speed signal is received from

the sensor and is compared to the
overspeed reference set-point, usually
about 10% over normal speed.if the speed
exceeds this set-point, a trip signal is
transmitted to the master protection circuit
to shut-down the turbine.

Most turbine are fitted both mechanical and electronic.

Electronic Overspeed Protection System

Generator shaft

comparator
Trip
Circuit
Set point

sensor
 Mechanical Overspeed Protection System

Trip device Trip device Shaft

Shaft rotation

rotation

Normal Position Trip Position

(b) Bearing Problems
 Journal bearing- Serve to support and
accurately position the shaft.
 Thrust bearing- locate the rotor in the
longitudinal direction, and so maintains axial
clearance between rotating and stationary
components.
Result of Failure
 Misalignment and
possible contact,
resulting in serious
internal damage to
the turbine.
Symptom of bearing problem?
 High temperature of housing
 Thermocouples are installed to measure oil
temperature, and to trigger an alarm when
condition become abnormal.
Vibration problem
 Factors that cause
vibration problem,
 Mechanical unbalance
of the rotor.
 Deposits on the
turbine blade.
 Thermal unbalance.
Vibration and Temperature
monitoring
2.Thermal Unbalance
 This will bring difference expansion and
may cause;
1. Distortion- this may result of failure, such as;
1. Internal cooling
2. Turbine casing
2. Misalignment
3. Mechanical stress
4. Damage to the labyrinth seal
3. Combustion Hazard
 The biggest danger to the smooth operation of
the combustion process are;
1. Loss of ignition- by sudden loss of fuel gas pressure
and supply of fuel enter with no ignition resulting
explosion due to high temperature surface.
2. Overheating- Caused by
1. Excessive ambient temperature
2. Poor air circulation due to improper ventilation.
3. Low lube oil supply
4. Worn bearing
Quiz
 Explain Overspeed protection device?
 What cause combustion hazard?
 What cause thermal unbalance?
 What cause vibration?
 PART 6
MAINTENANCE OF GAS
TURBINE
Compressor Cleaning
 To remove deposits from the compressor
blade to restore engine performance and
to avoid compressor surge.
Water wash system

A.Purpose: Used to remove dirt and salt buildup on the

compressor blades.

B.Components: Consists of a 40 gallon tank and permanently

installed piping to direct water wash solution into the inlet of the
compressor.

C.Procedure: Compressor must be washed to maintain

efficiency and prevent compressor stalls.
Methods of Cleaning
1. Water Washing
1. Engine has operate at dusty atmosphere.
2. Detergent Washing
1. If the blade are contaminated with oil and
adhesive.
3. Abrasive Cleaning
1. deposit cannot be removed by water or
detergent wash
Water and detergent wash
Periodic Maintenance

Every 4000 Running hours

detergent wash with boroscope

25,000 Running hours

Replacement of the Hot Section

Note; Depend on vender recommendation

Chance Notice
Mid Span
Change Of Design
 Reducing the capacity
of the gas turbine
(16MW to 12MW) will
increase the speed of
the Gas turbine thus
reduce wear at the
mid span
Engine troubleshooting
 Troubleshooting is a systematic analysis
of symptoms that indicate equipment
malfunction. These symptoms usually
appear as deviations from normal values
of observed equipment parameters.
 Before concluding that an engine fault
does exist, the troubleshooter must assure
that his knowledge of suspected trouble
area is adequate, that the instruments
used are calibrated and working properly,
and that they have been accurately read
and interpreted.
NOTE
 If troubleshooting procedures do not
isolate and eliminate the fault, secure
assistance from vendor service
representative through your customer
service manager.
GG Fails to reach maximum
motoring speed
 If engine is hot, allow it to cool for 30minutes
and then attempt motoring.
 Check starter supply pressure. If pressure is
below minimum limit, check pressure source.
 Check instrumentation. Replace indicator if
defective.
 Replace starter.if the rotation is still low,perform
borescope inspection of compressor and HPT.
Check scavenge oil screens for sump problems.
GG Fails to Light Off
 Check to make sure GG will motor to
2000-2500 rpm on the starter.
 Check supply pressure to fuel control and
fuel manifold
 If fuel supply pressure are within the limits,
troubleshoot ignition system.
CAUTION
 ALWAYS PURGE FUEL FROM GAS
GENERATOR BY MOTORING THE GAS
GENERATOR AFTER ANY FALSE START
WARNING
 NO FUEL AIR MIXTURE MAY BE
PRESENT DURING THIS TEST.HIGH
VOLTAGE EXISTS AT THE IGNITERS,
THEY MUST NOT BE TOUCHED WHILE
ENERGIZED.
High Vibration in Gas Generator
 Check that vibration instrument and its wiring
are operating properly
 Check that vibration pickup is securely mounted.
 Inspect oil scavenge and magnetic plugs in lube
scavenge pump.
 Water wash compressor if inspection reveals
dirty blades and vanes.
High Vibration in Power Turbine
 Check that vibration instrument and its
wiring are operating properly
 Check that vibration pickup is securely
mounted.
 Inspect oil scavenge and magnetic plugs
in lube scavenge pump.
Low Lube Oil Pressure
 Oil pressure is a function of gas generator
speed and supply temperature.
 If oil supply pressure is low,check supply
oil filters for cleanliness and supply line for
leaks. If low pressure persists, replace
lube/scavenge pump.
Essential Fitting for Gas Turbine
 Following accessories are normally fitted to a gas
turbine unit to prevent damage and serious injury
1. Overspeed device
2. Bearing temperature monitor
3. Flame detector
4. Surge monitor
5. Exhaust temperature monitor
6. Fuel master trip valve
7. Blow – off valves
8. Emergency lubrication oil pump
Operation and Maintenance
 Good Equipment Strategy
 Daily Operator Surveillance
 Maintenance Walkabout
 Condition Monitoring
 Optimum Preventive Maintenance
 Sparing Philosophy
 Overhaul Plan
 Improvement Plan