KALLPA INDEPENDENT POWER - COMBUSTION TURBINE FAMILIARIZATION

ECONOPAC OVERVIEW
FUNCTION The function of the combustion turbine-generator unit is to convert the chemical energy in fossil fuels to electrical energy. Each unit may operate independently, simultaneously with other units, or as a component of a combined cycle arrangement to generate electric power. Each unit is shipped with factory assembled support modules. When erected, the complete package called an EconoPac (Economical Package) is a self-contained electrical generating system. Figure 1 shows the layout of the major components of a typical EconoPac facility. DESIGN BASIS The design of the EconoPac has evolved from over 50-years experience in combustion turbine technology. Performance gains have been obtained from improvements in component efficiency, careful matching of components and conservation of cooling air. The engine and plant have been designed for maximum application flexibility and maintainability. Designed for both simple cycle and heat recovery applications, the current engine has achieved additional performance gains over earlier models by increasing the number of compressor diaphragm seal points and by use of coated diaphragms with improved surface finish to retard degradation from ingested contaminants. Turbine stator cooling air is extracted from several compressor bleed points in order to use air at the lowest suitable pressure available. Improvements in detail design have reduced internal cooling flow leakage. Other features provide improved reliability and availability due to improved part life and easier maintenance and inspection. The high efficiency of the combustion turbine makes it ideally suited for heat recovery applications including co-generation, combined cycle, and repowering.

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KALLPA INDEPENDENT POWER - COMBUSTION TURBINE FAMILIARIZATION

Figure 1. ECONOPAC Plant Layout The combustion turbine is designed and built for ease of maintenance and inspection. It is located in a roomy enclosure with a walkway on both sides and laydown space on one side. Maintenance and inspections that do not require engine cover removal are conducted inside
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KALLPA INDEPENDENT POWER - COMBUSTION TURBINE FAMILIARIZATION

and without disruption of the weather-protected enclosure. The engine cover consists of several independently removable sections for easy engine access. The enclosure roof is sectionalized. When an engine cover section must be removed, only that portion of the enclosure roof immediately above it need be removed. The design maximizes the number of maintenance and inspection operations that can be made without engine cover removal. For example, a visual examination of the compressor and turbine blading is now provided to a large extent with covers in place. Borescope ports are located at key positions in both the compressor and turbine housings. Access openings are provided in the exhaust and inlet areas that permit viewing the blade path components from either end of the engine. In addition, personnel can gain access to the combustor section of the engine to examine the discharge end of the compressor and the inlet end of the turbine. Openings are provided in the cylinder casing for access to the combustor section. Combustor baskets and transitions are easily removed and replaced through these openings. The first-stage turbine single vane segments can be replaced through the same openings. When covers must be removed, every consideration has been given to reducing down time. Turbine and compressor blading can be removed and replaced without rotor removal and without disturbing other blading. The diaphragms carrying the turbine vanes are rolled in and out to service turbine stationary parts downstream of the row 1 vanes. The journal and thrust bearings can also be removed without rotor removal. The two-bearing rotor construction makes the journal bearing easily removable at either end of the engine using a specially designed trolley assembly. The compressor end journal bearing and the thrust bearing can be removed without lifting a cylinder cover. The exhaust end journal bearing can be removed by lifting the upper half of the exhaust manifold and the associated roof panels. However, this bearing can be inspected without exhaust manifold removal.

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KALLPA INDEPENDENT POWER - COMBUSTION TURBINE FAMILIARIZATION

The EconoPac is designed and engineered to provide the user with a complete electrical generating system. All components and subsystems are carefully selected and optimized to form a compact plant, housed within enclosures, and designed to comply with environmental requirements as well as being aesthetically pleasing. The EconoPac features modular construction to facilitate shipment and assembly. It is preassembled, to the extent permitted by shipping limitations. Subsystems are grouped and installed in auxiliary packages that are assembled and wired at the factory and require only field interconnections at the site. Pipe rack assemblies are supplied to eliminate the need for extensive piping fabrication during construction.

SUMMARY DESCRIPTIONS Provided on the following pages are summary descriptions of the major systems included in the Kallpa Independent Power Project EconoPac installation. Your attention is invited to the SIEMENS drawing of the Combustion Turbine Equipment Arrangement. Heating, Ventilation & Air Conditioning System Certain EconoPac enclosures contain atmospheric control equipment to maintain an internal environment suitable for personnel entry and equipment operation. The electrical package temperature and humidity are maintained within required limits by the use of heat pump type air conditioning units.

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KALLPA INDEPENDENT POWER - COMBUSTION TURBINE FAMILIARIZATION

The mechanical package utilizes a forced air circulation fan and an electric heater to maintain the proper environment. The combustion turbine enclosure is also ventilated with forced air fans to maintain required temperatures. Fire Protection System FM-200 is used for fire protection within the EconoPacs electrical package, mechanical package, and turbine enclosure. An automatically actuated dry chemical system is used to protect the exhaust bearing tunnel area of the combustion turbine. Each zone has detectors installed, which will activate visual and audible alarms, shut down ventilation systems, activate extinguishing agents, and trip the turbine in case of a fire. The fire detection and protection system utilizes a centralized fire protection control panel, temperature sensing devices, ionization particle detectors, spray nozzles, and extinguishing agents to provide full protection to personnel and equipment. Electrical Distribution System The EconoPac electrical distribution system supplies power necessary for the operation of the combustion turbine and associated auxiliary equipment. This system includes high voltage (16.5 kV), medium voltage (4160V, supplied by customer), and low voltage (480V) alternating current (AC) for the normal operation of plant systems and 125VDC (direct current) for the safe shutdown of the plant in case of an AC power loss. The electrical package contains the combustion turbine motor control centers as well as voltage regulation and generator protection equipment.

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KALLPA INDEPENDENT POWER - COMBUSTION TURBINE FAMILIARIZATION

Lubricating Oil System Most of the components of the lubricating oil system, including its oil reservoir, are housed within the mechanical package. The lubricating oil cooler is located on top of the mechanical package. The capacity of the lubricating oil reservoir is designed to provide sufficient residence time for oil deaeration. One of the two identical AC motor driven lube oil pumps normally supplies the required lubricating oil flow. An emergency DC motor driven lube oil pump is provided to supply lubricating oil for a safe shutdown of the combustion turbine upon a loss of AC power. In addition, a portion of this system provides lift oil to the generator bearing. The lift oil or jacking oil system supplies oil at a slightly higher pressure to maintain the generator journal floating on a thin film of oil thus preventing any metal contact between the bearing material and the shaft during startup. Fuel Gas System Vaporized natural gas is the primary fuel for the combustion turbine. The control components of the fuel gas system are located on a wall within the combustion turbine enclosure. A gauge panel is provided with instrumentation for local and remote monitoring of the gas system. Compressor Water Wash System The compressor water wash system is provided for both on-line and off-line combustion turbine compressor cleaning. The compressor wash skid contains the pump, detergent tank, eductor for detergent injection, and the control valves to place the system in and out of operation. The skid is located between the electrical package and the starting package.

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KALLPA INDEPENDENT POWER - COMBUSTION TURBINE FAMILIARIZATION

Electrical Starting System The electric starting system is a self-contained package, pre-mounted on a bedplate within a weatherproof enclosure. The package contains the turning gear that provides breakaway torque for initial rotation of the turbine-generator shaft, the starting motor with a torque converter necessary for acceleration to self-sustaining speed, and a system to allow for an automatic disengagement of the starting device once the unit reaches self-sustaining speed. During cool-down periods, a turning gear provides the means to slowly roll the turbinegenerator shaft to prevent distortions. The starting motor can also be used for rotation of the combustion turbine without ignition by utilizing the spin hold feature. Turbine Air Systems The turbine air systems are made up of several separate but interrelated systems. These systems include; the inlet air system, the turbine cooling air system, the compressor bleed air system, and the instrument air system. The inlet air system provides clean, cool atmospheric air to the combustion turbine compressor. The system protects the compressor from foreign object damage, reduces turbulence and creates a laminar airflow, and attenuates the compressor air noise level. The major components of the inlet air system are the weather hoods, air filters, an inlet silencer, ducting, and variable inlet guide vanes. The turbine cooling air system provides direct cooling to the combustion turbine internal components and provides for environmental control along the turbine hot gas path through the use of compressor bleed air and cooled compressor discharge air.

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A portion of the compressed air is removed from the combustion turbine, cooled, and redirected to the turbine rotor area for cooling of the turbines internal components. Air is also extracted from various stages of the compressor and utilized to cool the stationary members within the turbine section. The compressor bleed air system provides volumetric control of the airflow in the compressor section through the use of variable inlet guide vanes and compressor stage bleed valves. The instrument air system provides clean, dry, compressor discharge air to all pneumatically controlled valves and processes. An auxiliary air compressor is provided for startup operation when compressor air is not available from the combustion turbine. SGT6-5000F Combustion Turbine Engine. The combustion turbine engine assembly consists of three basic elements: a 16-stage axial-flow compressor, a combustion system with 16 individual can-annular combustors, and a 4-stage reaction type power turbine. These three elements are combined into a single assembly that ships complete with rotor in place, thereby facilitating field erection. Incorporated into the design are such features as a horizontally split and sectionalized casing, two-bearing rotor support, turbine air cooling system, compensating alignment system, and axial-flow exhaust. Generator The Totally Enclosed Water-Air-Cooled (TEWAC) generator is equipped with rack-mounted lubrication oil piping and necessary instrumentation. The design uses two rotor-mounted axial blowers for the intercooling circulation of air through the generator and the coolers. The excitation and voltage regulator components function to control the AC output of the generator by regulating the direct excitation of the generator field.

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T-3000 Control System The T-3000 control system provides integrated modulating process control, general-purpose computation, and man/machine interface for control of the combustion turbine, generator, and auxiliary equipment.

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