Kawasaki GPB30 Gas Turbine Generator Operation and Troubleshooting Guide

KAWASAKI GPB30
This document is the property of Kawasaki

Gas Turbine Asia (KGA) . It has been
prepared exclusively for PPGJ GTG internal
use only. It contains confidential and
proprietary information of KGA and is not to
be disclosed to any person outside of PPGJ.
The reproduction of this document in any
manner or medium is strictly prohibited
without written authorization from KGA. Any
use made of this document, in whole or in
part, other than for evaluation purposes is
strictly prohibited without the express prior
written consent of KGA.
Warning: The purpose of this training is to provide basic information and principles of
Gas Turbine Generator (GTG) and its components. Under no circumstances, this
note is to be used as a reference during GTG maintenance or operation.
CONTENT
SYSTEM:
a.
GTG in General
b.
Enclosure and Inlet/Exhaust System
c.
Fuel System
d.
Lube Oil System
e.
Instrument Air System
f.
Electrical System
g.
Control System
OPERATING INSTRUCTION
a.
Pre-operation Check
b.
Starting Procedure
c.
Load Transfer Procedure
d.
Stopping Procedure
e.
Cranking
f.
Log and Operating Condition
TROUBLESHOOTING
GTG IN GENERAL AND SPECIFICATION

GPB30 Engine Arrangement and Specification
Engine Assembly: consists of 2 power sections, main reduction

gearbox and 2 accessory gearboxes.
Package Assembly: consists of engine assembly and generator.
POWER SECTION
Called Gas Turbine or GT
Consists of:- Two stages of CENTRIFUGAL Compressors
- Three stages of AXIAL Turbine
- Single CAN type combustor
- Double end supported BEARINGS
Speed: 21870 rpm
Weight: 1.19 ton
MAIN REDUCTION GEARBOX AND

ACCESSORY GEARBOX
Main Reduction Gearbox:- Type: Parallel
- Output Speed: 1,500 rpm (50Hz)
- Reduction Gear Ratio: 14.58
Accessory Gearbox
- Mounted to main reduction gearbox
GENERATOR
Type: Synchronous AC generator type
Capacity: 2812.5 kVA
Voltage: 6.6 kV
Frequency: 50 Hz
Number of poles: 4 poles
Enclosure and Inlet/Exhaust System

Enclosure Cooling Air
Turbine Inlet Air
Exhaust Air
FUEL SYSTEM
Engine Gas Fuel System
PT, FT, TE
Temperatur/Presure
compensation
PA
To Gas Exhaust
KHI/PLC
KHI/PLC
PT
FT
Gas fuel filter

differensial
presure high
EOV
PGV
TE
SSV1
SSV2
MGV
Gas Control
Valve
Gas Filter
SGV
FUEL SYSTEM
Engine Diesel Fuel System
PASSING
Pressurizing
Valve
Supply Fuel
Shutoff
Valve
Start Fuel
Pump
Main Fuel
Pump
Start Fuel
Valve
Fuel Control
Valve
Bypass Fuel
Valve
Main Fuel
Valve
Return to
service tank
DIESEL FUEL
LEAK
LUBE OIL SYSTEM

Engine Lube Oil System
LO Cooler
Oil mist separator
Vent
Manifold
Gas Turbine
Generator
Gearbox
LO Tank
160L
Main LO Pump
M
Pre Post
Pump
INSTRUMENT AIR SYSTEM

Engine Instrument Air System
Pressure for air starting: 0.9 1.0 MPa
Pressure for instrument: 0.6 MPa
P
G
P
G
P
G
Pressure
Control
Valve
Air for Starting
Pressure
Control
Valve
M
Instrumen
t Air Tank
Instrumen
t Air Tank
Fuel Line Purge

Air
Dryer
SSV-1 & SSV-2

Regulating
Valve
EOV
Intake Filter
JB Pressurizing
Gas Pressure Regulating
Valve
ELECTRICAL SYSTEM
Engine Electrical System
1. Ignition System
2. EGT Hardness
3. Speed Pick Up (Pulse)
4. Turning Motor
1. Ignition System
Ignition system is required to ignite the mixture of fuel and air inside the combustor during start up.
Ignition Plug:
Manufacturer: NGK Spark Plug Co.Ltd.
Ignition Exciter:
Manufacturer: Yamamoto Electric Works Co. Ltd.
Input voltage: DC24V
Discharge cycle: 3.5 sparks per seconds
Discharge specification: 1 Joule per spark
2. Exhaust Gas Temperature

(EGT) Hardness
EGT Hardness is required to measure result of the combustion of fuel before discharge into the atmosphere.
It is also used to compare and monitor the performance of the gas turbine.
Thermocouple type : K type, T1 bias
3. Speed Pickup Pulse

Speed Pickup Pulse is required to detect the rotation speed of the power section and gearbox by magnetic
pulse.
Speed Pickup Pulse for power section:
Type: Magnetic detection
Voltage: 4.5 V p-p (output)
Speed Pickup Pulse for gearbox:
Type: Magnetic detection
Voltage: 85-120 V p-p (output)
4. Turning Motor
Turning motor is required to rotate the turbine shaft slowly after shutdown to allow uniform cooling to
the turbine shaft.
The turning duration is controlled automatically by the gas turbine control panel.
Manufacturer: Sawamura Denki Kogyo Co.

Type
: DC Electrical motor
Rating
: 24 VDC, 0.5A
CONTROL SYSTEM
Engine Control System
1. Timing Schedule (Gas)
2. Timing Schedule (Diesel)
3. Alarm and Interlock
4. Operation Display Panel
TIMING CHART
Start
com
Gas Pressure
Established
Voltage
establish
Loading
completed
CB
close
95%
Stop
com
Stop
CB
open
95%
GTG cooling 5 min
55%
Fuel Changing
Unloading
4%
Loading
22%
3 min
Synchronizing
2 sec
Pre-excite
Fuel Changing
Pre Purge
Pre Purge
On
Off
55%
22%
4%
Starter Motor
Aux Machine
cooling 30 min
Ignition Exciter
Oil Cooler Fan
Encl Vent Fan
Turning Motor
Liquid Fuel Cooler Fan
Turning 10 hours
Pre Post LO Pump

Safety Shutoff Valve 1 (SSV1)
Main Gas Valve (MGV)
1 sec
Start Gas Valve (SGV)

E. Open Valve Close (EOV)
Main Fuel Valve (MFV)
1 sec
1 sec
Start Fuel Valve (SFV)

Bypass Fuel Valve (BFV)
Purge Gas Valve (PGV)
Assist Air Valve (AAV)
30 sec
10 sec
TIMING CHART
Start
com
Gas Pressure
Established
Voltage
establish
Loading
completed
CB
close
95%
Stop
com
Stop
CB
open
95%
GTG cooling 5 min
55%
Fuel Changing
Unloading
Loading
22%
3 min
Synchronizing
4%
2 sec
Pre-excite
Fuel Changing
Pre Purge
Pre Purge
On
Off
55%
22%
4%
Starter Motor
Aux Machine
cooling 30 min
Ignition Exciter
Oil Cooler Fan
Encl Vent Fan
Turning Motor
Turning 10 hours
Pre Post LO Pump

1 sec

1 sec
1 sec

30 sec

10 sec
TIMING CHART (DIESEL)

Start
com
Voltage
establish
Loading
completed
CB
close
95%
Stop
com
Stop
CB
open
95%
GTG cooling 5 min
55%
55%
Unloading
22%
Loading
5%
Pre-excite
22%
Synchronizing
2 sec
4%
Starter Motor
Ignition Exciter
Aux Machine
cooling 30 min
Oil Cooler Fan

Encl Vent Fan
Turning Motor
Turning 10 hours
Pre Post LO Pump

30 sec
TIMING CHART (DIESEL)

Start
com
Voltage
establish
Loading
completed
CB
close
95%
Stop
com
Stop
CB
open
95%
GTG cooling 5 min
55%
55%
Unloading
22%
Loading
5%
Pre-excite
22%
Synchronizing
2 sec
4%
Starter Motor
Ignition Exciter
Aux Machine
cooling 30 min
Oil Cooler Fan

Encl Vent Fan
Turning Motor
Turning 10 hours
Pre Post LO Pump

30 sec
ALARM AND INTERLOCK

Failure Description
Set Point
Major Fault
1.1
Start Failure 0-55%
352 seconds
1.2
Start Failure 55-95%
202 seconds
1.3
Over Speed
110+0, -2%
1.4
Under Speed 55-95%
54+0, -4%
1.5
Under Speed 95%~
94+0, -4%
1.6
LO Supply Temperature HH
905C
1.7
LO Supply Pressure LL (starting)
0.1+0.05, -0 MPa
1.8
LO Supply Pressure LL (running)
0.2+0.05, -0 MPa
1.9
Exhaust Gas Temperature HH (starting)
700+0, -40C
1.10
Exhaust Gas Temperature HH (running)
58010C
1.11
Emergency Shutdown
Push Button
1.12
Main Shaft Vibration HH
2D3m
1.13
Gearbox Vibration HH
2D0.5 mm/s
1.14
Flame Out
20010C
1.15
Miss Fire
1.16
GTG Package Gas Leak HH
10000 ppm
1.17
Generator Stator Winding Temperature HH
1502C
1.18
Generator Bearing Temperature HH
952C
1.19
Under Voltage (27G)
85V, 2 seconds
1.20
Over Voltage (59G)
130V, 2 seconds
1.21
Loss of Excitation (40G)
2 seconds
1.22
Generator Differential Protection (87G)
0.4A, 10%, instant
ALARM AND INTERLOCK

Failure Description
Set Point
1.23
Revolving Rectifier Failure (71G)
1.24
GTG Package Fire
1.25
Emergency Opening Valve Open
1.26
Pre-Post LO Supply Pressure L
1.27
Fuel Gas Valve Leak
1.28
PLC Major Fault
1.29
Control Power Fault
1.30
Supply Fuel Shutoff Valve Abnormal
1.31
Strainer Differential Pressure HH
1.32
Package Inlet Air Damper Close
1.33
Package Ventilation Air Damper Close
Middle Fault
2.1
Over Current (51G)
111%, M:1
2.2
Reverse Power (67PG)
10%, 10 seconds
2.3
Negative Sequence Current (46G)
M:10, 30%
2.4
Over Frequency (95HG)
54 Hz, 0.1 second
2.5
Under Frequency (95LG)
47.5 Hz, 0.1 second
2.6
Ground Over Current (51N)
2.7
AVR Failure
0.0150.0013 MPa
0.35 MPa
ALARM AND INTERLOCK

Failure Description
Set Point
Light Fault
3.1
Main Shaft Vibration H
1.5D3 m
3.2
Gearbox Vibration H
1.5D0.5 mm/s
3.3
GTG Package Gas Leak H
2500 ppm
3.4
Exhaust Gas Temperature H
56010C
3.5
LO Supply Temperature H
805C
3.6
LO Tank Level L
12010 L
3.7
LO Filter Differential Pressure H
0.240.04 MPa
3.8
LO Supply Pressure L
0.260.02 MPa
3.9
Sensor Failure
3.10
Turning Motor Power Failure
3.11
Pulse Filter Differential Pressure H
3.12
Intake Air Filter Differential Pressure H
3.13
Gas Fuel Control Valve Failure
3.14
GTG Oil Leak
3.15
Fuel Gas Pressure L (for fuel change)
3.16
Generator Stator Winding Temperature H
1352C
3.17
Generator Bearing temperature H
852C
3.18
Auxiliary Machine Failure
3.19
Fail to Syncoro
3.20
PLC Minor Fault
3.21
Display Failure
3.22
Starting Air Pressure L
0.7 kPa
2 minutes
ALARM AND INTERLOCK

Failure Description
Set Point
3.23
Strainer Differential Pressure L
0.3 MPa
3.24
Gas Fuel Filter Differential Pressure L
3.25
Liquid Fuel Filter Differential Pressure H
3.26
UPS Panel Failure
3.27
DC Battery Failure
3.28
Fire Extinguish Panel Failure
3.29
Ground Over Current (51N)
3.30
Fuel Gas Pressure LL
3.31
Supply Fuel Shutoff Valve Abnormal
3.32
Junction Box Air Pressure L
0.24 MPa
0.880.025 MPa
500 Pa
OPERATION INSTRUCTION
a.
b.
c.
d.
e.
f.
Pre-operation Check
Starting Procedure
Load Transfer Procedure
Stopping Procedure
Cranking
Log and Operating Condition
a. PRE OPERATION CHECKS

Following checks to be carried out prior to start GTG by Diesel Fuel Mode
NO
DESCRIPTION
CRITERIA
Intake Air Filter
Ensure security & no obstruction
GTG
Area
Ensure clear and no abnormality
GTG Ventilation Inlet Filter
Diesel Fuel System
Service Tank Outlet Supply Valve
Open
GTG Inlet Supply Valve
Open
GTG Outlet Return Valve
Open
FO Cooler Inlet Return Valve
Open
Service Tank Inlet Return Valve
Open
Service Tank Level
Confirm Full
Instrument Air
Supply
Confirm Supply Available
Open
Lubrication Oil (GTG)
Oil Tank Level
Confirm >120
Visual Inspection
No Leak
Oil Mist Vent
Confirm no obstruction
Power Supply
AC120V supply to TCP
confirm energize
DC24V supply to TCP
confirm all energize
JUDGEMENT
a. PRE OPERATION CHECKS

Following checks to be carried out prior to start GTG by Gas Fuel Mode
NO
DESCRIPTION
CRITERIA
Intake Air Filter
GTG
a
Area
Ensure clear and no abnormality
GTG Ventilation Inlet Filter
Lean Gas Fuel System

a
Lean Gas Fuel Valve
Open
Lean Gas Supply Pressure
> 1.323 MPa
Confirm Gas Filter Select
Valve Open
Diesel Fuel System

a
Service Tank Outlet Supply Valve
Open
Open
GTG Outlet Return Valve
Open
FO Cooler Inlet Return Valve
Open
Service Tank Inlet Return Valve
Open
Instrument Air
A
Supply
Confirm Supply Available
Open
Lubrication Oil (GTG)

A
Oil Tank Level
Confirm >120
Visual Inspection
No Leak
Oil Mist Vent
Confirm no obstruction
Power Supply
a
AC120V supply to TCP
confirm energize
DC24V supply to TCP
confirm all energize
JUDGEMENT
b. STARTING PROCEDURE
Starting and Loading in Manual Mode
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
On Operation page, select MANUAL mode and execute

If GTG starting in Diesel Mode, confirm following
On Operation page, select DIESEL and execute
If GTG starting in Gas Mode, confirm following
On Operation page, select GAS and execute
On Menu Bar, select READY
Confirm followings:
GTG Speed <5%
No Heavy Fault (GTG Trip Signal)
CB no Trip Signal
Generator CB Open
Starter Motor Ready to Start
On Operation page, select GAS TURBINE START and execute
Confirm Voltage Establish after GTG in RUNNING mode
On Operation page, select the SYNC DEVICE ON and execute
Manually adjust the voltage and GT speed
Manually CLOSE the generator CB when GTG frequency and voltage meet the criteria of
differential
Starting and Loading in Semi Auto Mode
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
On Operation page, select SEMI AUTO mode and execute

Confirm followings:
GTG Speed <5%
CB no Trip Signal
Generator CB Open
Confirm Voltage Establish after GTG in RUNNING mode
On Operation page, select the AUTO SYNCRO and execute
GTG will auto raise/reduce speed and voltage to meet the differential criteria
GTG will auto command to close the generator CB when frequency and voltage meet the
criteria of differential
Starting and Loading in Auto Mode
1.
2.
3.
4.
5.
6.
7.
8.
9.
On Operation page, select AUTO mode and execute

Confirm followings:
GTG Speed <5%
CB no Trip Signal
Generator CB Open
GTG will AUTO SYNC after voltage established
GTG will auto raise/reduce the speed and voltage to meet the differential criteria
GTG will auto close the generator CB when frequency and voltage meet the criteria of
differential
c. LOAD TRANSFER PROCEDURE

Load Transfer in Manual Mode
1.
2.
3.
4.
5.
6.
On Operation page, select MANUAL mode and execute

Start another GTG according to starting procedure
Synchronize another GTG to existing on load GTG for PARALLEL OPERATION
Manually raise another GTG speed and lower existing GTG speed
Observe the load (kW) is transferring to another GTG
Manually OPEN/TRIP the generator CB when load reduced to <80kW
c. LOAD TRANSFER PROCEDURE

Load Transfer in Semi Auto or Auto Mode
1.
2.
3.
4.
5.
6.
On Operation page, select SEMI AUTO or AUTO mode and execute

Start another GTG according to starting procedure
Synchronize another GTG to existing on load GTG for PARALLEL OPERATION
On Operation page of existing GTG, select AUTO UNLOAD and execute
Observe the load (kW) is transferring to another GTG
The generator CB will automatically OPEN/TRIP when load reduced to <80kW
d. GTG STOPPING PROCEDURE

Stopping in Manual Mode:
On Operation page, select MANUAL mode and execute.
Unload GTG according to manual unload manual.
Wait for 5 minutes for GTG cooling.
Carry out fuel change to DIESEL mode
After GTG cooling sequence completed, select the STOP on the Operation page and execute.
After GTG completely stopped, carry out inspection and verify for pre-post pump and turning motor operation.
Stopping in Semi Auto Mode:
On Operation page, select SEMI AUTO mode and execute.
Unload GTG according to semi auto unload manual.
GTG will auto fuel change to DIESEL mode after 3 minutes of cooling and resume another 2 minutes cooling
on DIESEL mode.
After GTG cooling sequence completed, select the STOP on the Operation page and execute.
Stopping in Auto Mode:
On Operation page, select AUTO mode and execute.
Then select STOP on the Operation page and execute.
GTG will unload, cooling, fuel change and stop automatically.
e. GTG MANUAL PURGING

(CRANKING)
On the Operation page, select PURGE,
push and hold the execute button.
Verify that GTG speed will rise up.
Cranking will stop if:
GTG speed > 25%
Release the execute button.
f. LOG AND OPERATION CONDITION

Description
Unit
Criteria
#1 Engine Speed
95~108
#2 Engine Speed
95~108
Gearbox Speed
95~108
#1 Intake Air Temp
#2 Intake Air Temp
#1 Exhaust Gas Temp (1)
<560
<560
<560
<560
#1 LO Supply Temp
<80
#2 LO Supply Temp
<80
#1 Main Shaft Vibration
<1.5D
#2 Main Shaft Vibration
<1.5D
Gearbox Vibration
mm/s
<1.5D
#1 Comp Discharge Press
MPa
#2 Comp Discharge Press
MPa
#1 LO Filter Inlet Press
MPa
#2 LO Filter Inlet Press
MPa
#1 LO Filter Outlet Press
MPa
#2 LO Filter Outlet Press
MPa
Time
Time
Time
Time
Time

Description
Unit
Criteria
#1 LO Supply Press (PP)
MPa
>0.015
#2 LO Supply Press (PP)
MPa
>0.015
Starting Air Pressure
MPa
Intake Air Filter Diff Press
kPa
<0.7
Fired Start Counter

Total Running Hour
Hr
#1 LO Outlet Temp (1)
#1 LO Supply Pressure
MPa
>0.26
#2 LO Supply Pressure
MPa
>0.26
#1 Strainer Inlet Pressure
MPa
#1 Strainer Outlet Pressure
MPa
#1 Strainer Diff Pressure
MPa
#2 Strainer Inlet Pressure
MPa
#2 Strainer Outlet Pressure
MPa
#2 Strainer Diff Pressure
MPa
<0.3
<0.3
Time
Time
Time
Time
Time

Description
Unit
Criteria
Generator Voltage (U-V)
400
Generator Voltage (V-W)
400
Generator Voltage (W-U)
400
Generator Current (U)
Generator Current (V)
Generator Current (W)
Generator Power Factor

Generator Frequency
Hz
50
Generator kWh
kWh
Generator kW
kW
Generator kVar
kVar
Excitation Voltage
Excitation Current
Gen Winding Temp (U)
<135
Gen Winding Temp (V)
<135
Gen Winding Temp (W)
<135
Gen Bearing Temp (DE)
<85
Gen Bearing Temp (NDE)
<85
Gas Governor Output
Liquid Governor Output
Time
Time
Time
Time
Time

Description
Unit
Gas Governor Actuator
Bus Voltage
400
Bus Frequency
Hz
50
Gas Fuel Flow
Nm3/h
Gas Fuel Pressure
MPa
Gas Fuel Temperature
Gas Fuel Flow (Pulse)
Nm3
Combustor Inlet Gas Fuel

Pressure
MPa
Accumulator Gas Fuel

Pressure
MPa
Gas Fuel Flow
MMSC
FD
Remarks
Criteria
Time
Time
Time
Time
Time
TROUBLESHOOTING
1.
2.
3.
4.
5.
6.
Large Vibration
High Exhaust Gas Temperature
Overspeed
Startup Failure
Low Lubrication Oil Pressure
High Lubrication Oil Temperature
1. Large Vibration
Vibration of gas turbine shaft is monitored to
detect Large Vibration. Specific alarm
value and trip value has been set in the
PLC.
1. Large Vibration
Possible causes of this problem are as
follows:
1. Defect of gas turbine itself: Abnormal
bearing or rotary part, etc.
2. External factor: Rubbing with foreign
matters entering through intake port.
3. Defect of control system: Abnormal
vibration system, etc.
1. Large Vibration
1.1 Simplified Inspection of Equipment
Gas Turbine
Inspection item 1
Visually check that engine (output shaft) is rotating smoothly as driven by turning motor
Objective
To confirm that rotor system is not on contact with stationary part and that foreign matter has not been
caught. If there is such abnormality, engine rotation is not smooth and generating friction sound.
Inspection item 2
Manually rotate engine by hand to check for abnormal rotation or abnormal rotating sound
Objective
This method is to be conducted if above inspection item 1 cannot be done by turning motor.
Inspection item 3
Study of data before occurrence of problem
Change in gas turbine shaft vibration value or reduction gear vibration value
Generator output
Lubrication oil temperature and pressure
Change in temperature for No.1, No.2 lube oil drain.
Objective
To obtain data useful to determine whether vibration increase is sudden or gradual as the result of
aged deterioration or false meter indication
To confirm that load is normal
To confirm that bearings are lubricated properly.
1. Large Vibration
1.2 Inspection of Individual Control Devices
Vibration System
Inspection item 1
Check monitor cable connection for looseness. If connection is loose or disconnect then connect cable
properly.
Objective
To confirm that signal is input properly to monitor
Inspection item 2
Check sensor wiring connection for looseness
Objective
To confirm that signal is output properly from sensor
Inspection item 3
Disconnect wire from sensor and measure DC resistance. Normal value is between 2.5-3.0 ohm
Objective
To confirm that wire is not broken
2. High Exhaust Gas Temperature

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

Possible causes of this problem are as follows:
1. Defect of gas turbine itself: Deteriorated
performance of turbine, deteriorated
performance of compressor due to soil, etc.
2. External factor: Clogged intake/exhaust line,
overload, etc.
3. Defect of control system: Abnormal load
control, abnormal exhaust gas temperature
thermocouple, etc.

Gas Turbine
Inspection item 1
Visually check that engine (output shaft) is rotating smoothly as driven by turning motor.
Objective
To confirm that gas turbine itself and reduction gear are normal.
Inspection item 2
Objective
Inspection item 3
Gas turbine shaft vibration
Gas turbine intake air temperature and ambient temperature
Generator output
Compressor discharge pressure
Lubricating oil temperature
Operation mode: island or parallel with another GTG or Diesel Gen Set.
Objective
To confirm that gas turbine itself is normal
To confirm that air intake line is normal
To confirm that gas turbine is not operated under overload
To confirm that compressor is not soiled (check pressure data for the last one week or more)
To confirm that bearing is lubricated
To see if gas turbine is operated in island or parallel with other machines.

Instrumentation Devices
Inspection item 1
Inspection of exhaust gas temperature thermocouple for broken wire
Measure insulation resistance. Normal value is 1.5 ohm or higher as measured with a 500-V
megohmmeter at ordinary temperature
Objective
To confirm that thermocouple is not damaged
Inspection item 2
Heat up temperature sensing elements sequentially while checking if output voltage increases
Objective
To confirm that exhaust gas temperature is detected.
Inspection item 3
Inspection of rotation pickup for looseness
Objective
To confirm that connector or pickup is not loose
Inspection item 4
Disconnect cable from pickup and measure resistance. Normal value is 30050 ohm at 25 degC
Objective
To confirm that wire is not broken
Miscount during operation as interconnected with commercial power system can cause high exhaust
gas temperature.
3. Overspeed
Rotation of gas turbine power section is
monitored to detect Overspeed. Specific
trip value has been set in the sensor.
3. Overspeed
follows:
1. Defect of gas turbine itself: Broken
coupling of output shaft of power section
rotor system, etc.
2. External factor: Sticking fuel control
valve, etc.
3. Defect of control system: Abnormal
rotation pickup, etc.
3. Overspeed
Gas Turbine
Inspection item 1
Objective
To confirm that gas turbine itself and reduction gear are normal
Inspection item 2
Objective
Inspection item 3
Gas turbine shaft vibration
Gas turbine speed
Whether any problem occurred at startup or during operation
If problem occurred during operation, check generator output for change
Operation mode: island or parallel with other GTG or Diesel Gen set.
Objective
To confirm that gas turbine itself is normal
To clarify the time of problem occurrence
3. Overspeed
Inspection item 1
Inspection of rotation pickup connector for looseness
Objective
To confirm the connector or pickup is not loose
Inspection item 2
Measure resistance for rotation pickup. Normal value is 30050 ohm at 25 degC
Objective
To confirm that sensor is normal
4. Startup Failure
Rotation and exhaust gas temperature of
gas turbine are monitored to detect
Startup Failure. Alarm signal is output
when specified conditions are not met.
4. Startup Failure
follows:
1. Defect of gas turbine itself: Defective fuel
nozzle, etc.
2. External factor: Abnormal starter
equipment, abnormal ignition system,
etc.
3. Defect of control system: Defective
rotation pickup, defective controller, etc.
4. Startup Failure
Gas Turbine
Inspection item 1
Visual check that engine (output shaft) is rotating smoothly as driven by turning motor.
Objective
To confirm that gas turbine itself and reduction gear are normal.
Inspection item 2
Objective
Inspection item 3
Study of data before occurrence of problemIncrease in turbine speed
Increase in exhaust gas
Instrument air pressure 0.45MPa or higher
Fuel filter differential pressure indication
Objective
To confirm that fuel system is normal
To confirm that shutoff valve opening air pressure is normal
4. Startup Failure
Inspection item 1
Inspection of solenoid valve operation of starter valve unit
Objection
To confirm the integrity of starter air supply equipment
Inspection item 2
Inspection of exciter and ignition plug. Visual check for damage
Objective
To confirm that ignition system is normal
Inspection item 3
Inspection of exhaust gas temperature thermocouple for broken wire. Measure insulation resistance. Normal value is
1.5Mohm or higher as measured with a 500V megohmmeter at ordinary temperature
Objective
To confirm that thermocouple is not damaged
Inspection item 4
Inspection of rotation pickup for looseness. Disconnect cable from pickup and measure resistance. Normal value is
30050 ohm at 25 degC.
Objective
To confirm that pickup is not loose and wire is not broken.
5. Low Lubrication Oil Pressure

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

follows:
lubrication oil pump, clogged filter
caused by abnormal bearing, etc.
2. External factor: Drop of lubrication oil
level, etc.
3. Defect of control system: Defective oil
pressure switch, etc.
Gas Turbine
Inspection item 1
Objective
Inspection item 2
Objective
Inspection item 3
Check piping for any lubrication oil leakage.
Objective
To confirm that there is no oil leakage which can cause low oil pressure
Inspection item 4
Check oil level of lubrication oil tank.
Objective
To confirm that there is no oil level drop which can cause low oil pressure
Inspection item 5
Lubrication oil temperature at bearing outlet.
Interval between alarm and trip.
Indication of clogged lubrication oil filter
Objective
To confirm that bearing are normal
To confirm that filter is free of foreign matters

Inspection item 1
Inspection of lubrication oil pressure transmitter for looseness. Visual check for damage.
Objective
To confirm that the lubrication oil pressure transmitter is normal.
6. High Lubricating Oil

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

Temperature
follows:
bearing, etc.
2. External factor: Deteriorated oil cooler
performance, etc.
3. Defect of control system: Defective oil
temperature sensor, etc.

Temperature
Gas Turbine
Inspection item 1
Objective
Inspection item 2
Objective
Inspection item 3
Lubricating oil temperature
Lubricating oil at bearing outlet
Objective
To confirm that bearing are normal

Temperature
Inspection item1
Inspection of lubrication oil temperature sensor (Pt 100-ohm resistance bulb). Measure resistance
value.
Objective
To confirm that sensor is normal.

Kawasaki GPB30 Gas Turbine Generator Operation and Troubleshooting Guide

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Kawasaki GPB30 Gas Turbine Generator Operation and Troubleshooting Guide

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KAWASAKI GPB30

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GTG IN GENERAL AND SPECIFICATION

Engine Assembly: consists of 2 power sections, main reduction

MAIN REDUCTION GEARBOX AND

Enclosure and Inlet/Exhaust System

Gas fuel filter

LUBE OIL SYSTEM

Oil mist separator

INSTRUMENT AIR SYSTEM

Fuel Line Purge

SSV-1 & SSV-2

Manufacturer: NGK Spark Plug Co.Ltd.

Manufacturer: Yamamoto Electric Works Co. Ltd.

Input voltage: DC24V

Discharge cycle: 3.5 sparks per seconds

Discharge specification: 1 Joule per spark

2. Exhaust Gas Temperature

Thermocouple type : K type, T1 bias

3. Speed Pickup Pulse

Manufacturer: Yamamoto Electric Works Co. Ltd.

Type: Magnetic detection

Voltage: 4.5 V p-p (output)

Speed Pickup Pulse for gearbox:

Manufacturer: Yamamoto Electric Works Co. Ltd.

Type: Magnetic detection

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

Manufacturer: Sawamura Denki Kogyo Co.

Pre Post LO Pump

Start Gas Valve (SGV)

Start Fuel Valve (SFV)

Pre Post LO Pump

Start Gas Valve (SGV)

Start Fuel Valve (SFV)

Purge Gas Valve (PGV)

TIMING CHART (DIESEL)

Oil Cooler Fan

Pre Post LO Pump

TIMING CHART (DIESEL)

Oil Cooler Fan

Pre Post LO Pump

ALARM AND INTERLOCK

Start Failure 0-55%

Start Failure 55-95%

Under Speed 55-95%

Under Speed 95%~

LO Supply Pressure LL (starting)

LO Supply Pressure LL (running)

Exhaust Gas Temperature HH (starting)

Exhaust Gas Temperature HH (running)

Main Shaft Vibration HH

GTG Package Gas Leak HH

Generator Stator Winding Temperature HH

Generator Bearing Temperature HH

Under Voltage (27G)

Over Voltage (59G)

Loss of Excitation (40G)

Generator Differential Protection (87G)

0.4A, 10%, instant

ALARM AND INTERLOCK

Revolving Rectifier Failure (71G)

GTG Package Fire

Emergency Opening Valve Open