Energy Services International Doc. Turbo.

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OJT for Premier Oil Natuna Sea Ltd Sec. 1
Anoa AGX Project Rev. 0

INTRODUCTION TO GAS TURBINES

Turbines & Origins

There are many different types of turbines in use in the world today. Some forms are old, like the Waterwheel
(hydraulic turbine) and Windmill. Others are of more recent origin, Steam Turbines date from the 19th century
while Gas Turbines date from the 20th century. Gas Turbines were originally conceived as a means of aircraft
propulsion and were not developed for industrial use until 1947. Since then they have undergone significant
changes in design to become more powerful and efficient and capable of operation in a wide variety of
environments and applications.

Operating Principles

All turbines are basically engines that convert the energy of a moving stream of fluid (liquid / water,
steam or gas) into mechanical energy. The essential element of all turbines is a shaft with blades or
buckets arranged radially around the shaft in such a fashion that the fluid stream imparts a force to
the blades or buckets to cause the shaft to rotate. The rotational torque imparted to the shaft is then
used to provide useable power;

Examples : Waterwheel mechanical drive (corn mill) ,hydro-electric generator.

Windmill mechanical drive (water pump), generator.
Steam Turbine numerous including mechanical drives and generators.
Turbo-charger compressor driver.

Note: The rotating shaft on a Turbo-jet (aircraft engine) drives a compressor and other auxiliary
drives and uses the exhaust gases to provide thrust to push the aircraft forward.

Why Gas Turbine?

There are numerous variants to the basic operating concept of an engine that converts the energy of a
moving fluid stream into mechanical energy. What is common to all Gas Turbines is the Driving fluid which
is Gas. An aircraft Turbo-jet may use liquid fuel, but it is still a Gas Turbine because it is driven by gas, just
as the Turbo-charger is driven by the exhaust gas of a reciprocating engine and an Expander / Compressor
is driven by the gas of the process it is operating on.

Solar Mars 100 under construction before transit to Anoa AGX

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Industrial Gas Turbine Principle of Operation

There are numerous designs and configurations of Industrial Gas Turbines, but they all operate in
essentially the same basic manner. They are heat engines and use the expanding gases of
combustion to drive the turbine shaft. They operate under what is called the Brayton Cycle. Unlike the
reciprocating Internal Combustion engine which also uses the expanding combustion gases to drive
its pistons and operates under the Otto Cycle; the Gas Turbine has continuous combustion to
provide continuous torque to the turbine shaft. They do not need a flywheel to dampen the intermittent
cylinder combustion of the Internal Combustion engine and do not develop the high internal pressures
encountered in the cylinders of a reciprocating engine.
The Brayton Cycle

Brayton Cycle In order to begin and then sustain

combustion, an oxidizer (oxygen) must be
combined with the fuel and ignited. Free air
contains nearly 21% oxygen and like the
internal combustion engine, this is used
by being drawn in and compressed,
(compression Brayton Cycle 1>2).

It is then mixed with the fuel and ignited and

combustion occurs, (Brayton Cycle 2>3).

The combustion gases expand rapidly,

(expansion, Brayton Cycle 3>7) and drive the
turbine shaft.

The expanding gases are then allowed to

exhaust to atmosphere (Brayton Cycle 7>1)
where the remainder of their heat energy is
dissipated (the temperature falls).

Note from diagram (A) that pressure only

increases from 1>2 where it is at a maximum
and is designed so that there is no increase
in pressure at combustion. The points in the
diagrams (1,2,3,7) are Engine Data Points
commonly used to indicate particular
locations throughout the engine gas path
(refer to diagram on page 1.3).

This is the basis on which all Industrial Gas

Turbines operate and will be more fully
explained in the modules that follow.
At this stage it is worth noting that although
only about of the air that is drawn into the
engine is used for combustion, the bulk of
the remainder is used for cooling and this
still contributes to expansion.
About 2/3 of the total power developed is
used to compress the air, the remainder is
used to drive loads.
Most machines are as described and are
referred to as Open Cycle units. However,
some using Recuperators, while others use
Waste Heat Recovery Units to extract

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heat from the exhaust to be used elsewhere,

for example to raise steam.

Principle to Practice

As the thermodynamic principle on which Gas Turbines operate has been mentioned, how this is
achieved in practice can now be considered. On Anoa AGX, Premier have Solar Saturn 20
Generator and Mars 100 Compressor sets. While other manufacturers use different arrangements
these two machines are typical of the most common internal mechanical arrangements generally
used.

The Saturn 20 is referred to as a Single Shaft while the Mars 100 configuration used on Anoa is
referred to as a Split or Two Shaft arrangement. The Single Shaft configuration is the least
complicated arrangement and will be considered first.
T5
P5
T3 T7
Data Points T1, etc P3 P7

T1 T2
P1 P2

Typical Single Shaft Cold End Drive Data Points

Typical Single Shaft (Cold End Drive)

The drawing above shows the engine internal arrangement and the Data Points in the gas path. Air
from the atmosphere is drawn in through the Air Inlet (T1, P1) by the Compressor Rotor Assembly,
which is mounted on a common shaft connected to the Turbine Rotor Assembly at the RH end and
the Engine Output Shaft at the LH end. As the Engine Output Shaft is at the cooler Air Inlet end and
not at the hotter Turbine Exhaust end it is referred to as Cold End Drive.

The compressed air leaves the compressor and enters the Diffuser (T2,P2) where its pressure(P2) is
greatest and the temperature (T2) has also increased about 260C [@ 500F] above T1. Fuel Gas from
the Fuel Gas Manifold is mixed with air from the Air Manifold and injected into the Combustion
Chamber through Fuel Injectors where it is burnt after having been initially ignited by the Igniter Torch
at the start. Combustion causes the temperature to increase to about 2800F and the volume to also
increase greatly. The Combustion Chamber is constructed to allow cooler air to enter and direct the
hot gases away from the Combustion Chamber liners (to minimise heat damage and to cool the hot
gas) and into the Turbine assembly without increasing the pressure. The temperature at the inlet of

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the Turbine (T3) sometimes referred to as TRIT (Turbine Rotor Inlet Temperature) is generally not
monitored, but the temperature at the inlet of the last stage (T5) invariably is and can be used as an
indication of the heat energy in the engine. After exiting the turbine section the gases are directed
away to atmosphere through the Turbine Exhaust (T7) and any external ducting.

Single v Split Shaft

In the single shaft arrangement the rotational speed of the output shaft (load) will always be directly
related to the speed of the turbine shaft, even if a gearbox is used to alter the ratio from 1:1. The
speed of the turbine shaft will largely determine how much air is compressed by the compressor,
(essentially the faster it rotates the more air mass it can compress) and consequently at what speed
and how much load the engine can tolerate before the driving gases become too hot for it to operate.

This fixed ratio is normally suitable where the speed is constant and the load varies, in generator
applications for instance. It can be a disadvantage in some applications, especially where the load is
required to operate over a wide speed range, for example Compressors and other Mechanical Drives.

To overcome this, the split shaft machine is designed so that on one shaft the turbine rotor and the
compressor are mounted (as per the single shaft arrangement) and on a second shaft which is
mechanically independent from the first, another turbine rotor is mounted and this shaft is connected
to the load . Both shafts are driven by the same expanding gas path imparting kinetic energy to their
rotors from the velocity energy of the gas. The diagram below shows the gas path and data points.

The first shaft which drives the compressor is known variously as the CT (Compressor Turbine),
GG (Gas Generator) or as Solar usually refer to it as GP (Gas Producer). The second shaft is
invariably known as the PT (Power Turbine) as it provides the useful power to drive the load.

Typical Split Shaft Hot End Drive

A split shaft machine operates in essentially the same way as a single shaft arrangement, but is
controlled such that the fuel and air input into the machine are regulated to produce enough gas to
firstly drive the GP (compressor) to provide Primary Air for combustion and Secondary Air for
cooling, etc, and also enough to rotate the PT and thus the load. As the 2 shafts are both driven
(rotated) by a common gas path produced by the same combustion system, the amount of gas
produced will determine how quickly they will each rotate.

FUEL EXHAUST
T5
P5
AIR
IN COMBUSTOR T7
T1 AIR P7
P1 OUT
T2
P2

AIR
COMPRESSOR
LOAD

T3
P3

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GAS
PRODUCER
DATA POINTS T1, etc
POWER
TYPICAL SPLIT SHAFT GAS FLOW WITH DATA POINTS
TURBINE

T2
P2
T1
P1

T7
P7

T3 T5
P3 P5

COMPRESSOR ROTOR

Typical Split Shaft Sectional Diagram with Data Points

DATA POINTS T1, etc

The drawing above shows the engine internal arrangement and the Data Points in the gas path. Air
from the atmosphere is drawn in through the Air Inlet (T1, P1) by the Compressor Rotor Assembly,
which is mounted on a shaft connected to the Gas Producer Turbine Rotor.

Compressed air leaves the compressor and enters the Diffuser (T2,P2) where its pressure(P2) is
greatest and the temperature (T2) has also increased about 260C [@ 500F] above T1. From the Fuel
Gas Manifold it is mixed with air from the Air Manifold and injected into the Combustion Chamber
through Fuel Injectors where it is burnt after having been initially ignited by the Igniter Torch at the
start. Combustion causes the temperature to increase to about 2800F and the gas volume increases
greatly. The Combustion Chamber is constructed to allow cooler air to enter and direct the hot gases
away from the Combustion Chamber liners (to minimise heat damage and to cool the hot gas) and into
the Turbine assembly without increasing the pressure. The temperature at the inlet of the Gas
Producer Turbine Rotor (T3) sometimes referred to as TRIT (Turbine Rotor Inlet Temperature) will
have decreased to @1900F and is generally not monitored, but the temperature at the inlet of the
Power Turbine Rotor (T5 @1300F) invariably is and can be used as an indication of the heat energy
in the engine. After exiting the turbine section the gases are directed away to atmosphere through the
Turbine Exhaust (T7) and any external ducting.

As mentioned earlier (Page 1.2) about 2/3 of the total power produced is used to drive the compressor
through the first shaft arrangement (Gas Producer = GP) and the remainder is available to drive the
connected load through the Power Turbine (PT).

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Ancillary Systems

In order to support the processes described in outline above, obviously several support systems have
to be available and integrated into an overall control scheme to allow the engine to function correctly
and for the load parameters to be controlled safely. For example the fuel and air to the engine are
critical and as these engines are High Speed Rotating Heat Engines lubricating oil will be required to
help lubricate and cool the bearings which support the shafts and the other rotating components. Also
the engine must initially be started to allow the power generation processes described above to be
self-sustaining. These topics will be examined in the sections that follow.

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INTRODUCTION TO PREMIER OIL ANOA SOLAR TURBO-MACHINERY

Premier Anoa Solar Turbo-Machinery

Premier currently have the following machine packages installed on Anoa AGX:-
GT 7300 Solar Saturn 20 Generator Natural Gas Fuel
GT 7400 Solar Saturn 20 Generator Natural Gas Fuel / Liquid Fuel
CT 2500 Solar Mars 100 Gas Compression 1 or 3 stages (Export / Boost modes)
CT 2600 Solar Mars 100 Gas Compression 1 stage Export

Note: GT 7400 has Liquid Fuel capability, but no supply is currently available.

CT 2500 can be configured as a single stage Export or triple stage Boost Compressor. Premiers
design intention at some future date is to re-configure CT 2500 to a 2 stage arrangement to be
capable of operating in parallel with CT 2600 which will then also be re-configured to a 2 stage
compression package.

These engines were mentioned earlier (Page 1.3) and will now be described in more detail, with
material
largely quoted from the Solar Manuals available on site.

SAFETY

Industrial Gas Turbines are high speed rotating heat engines which can present many
potential hazards and caution must be exercised at all times, not only when in the vicinity of
the Turbine package, but also when operating remotely. The following WARNING should be
understood and heeded at all times. Appendix A of these notes contains the Solar Operations
Manual Safety Guides which must be understood and should be used as a guide to the safe
operation and maintenance of the packages.
WARNING

1. Operation of the unit may be performed only when conditions indicate it is safe to
proceed. Dangerously explosive accumulations of natural gas, fuel fumes, oil tank vent
leakage, or solvent fumes must be avoided at all times. This is done by proper
ventilation, elimination of leaks, and by confining the use of solvents to appropriate
maintenance facilities.

2. Appropriate hearing and eye protection must be used by operating and maintenance
personnel in the vicinity of the operating machine.

3. Turn off electrical power. Tag control devices to prevent electrical shock and starting
of unit while unit is shut down.

4. Allow sufficient time for piping and system components to cool. Components can
become extremely hot and cause burns if touched with unprotected hands.

5. Do not allow fluids to come in contact with hot surfaces. Fluids discharged from lines
or fittings may be flammable and could cause a fire hazard.

6. Depressurize system before loosening line fittings or removing components. High

pressure lines or jetstreams can cause serious injury.

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TURBINE PACKAGE INSPECTION ON-LINE

YOU MUST HAVE A PERMIT TO WORK ON ANY PART OF THE TURBINE PACKAGE

Before Opening Package Doors

1. Contact control room operator for permission to enter and to disarm fire
system.
2. Disarm fire system. If fire system is not disarmed it may discharge
3. Take care when opening package doors. Inside package is pressurised
and doors will open hard and fast
4. Carry out inspection

Closing Package Doors

1. Take care. They are hard to close against the inside pressure and may
require help to close.
2. Relock doors.
3. Rearm fire system.
4. Contact control room operator and notify you have finished inspection,
fire system is re-armed and doors are locked.

NOTE - ORIENTATION
Directional references on the unit (right side, left side, forward, and aft) are
established by viewing the unit facing the engine exhaust (aft) end and looking
forward.

AFT Orientation Diagram

LEFT

RIGHT

FORWARD

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SATURN 20 GAS TURBINE-DRIVEN GENERATOR SET

General Package Description

The Saturn 20 Gas Turbine-Driven Generator Set consists of an axial-flow turbine engine, a
generator, and gear unit. These elements are installed in-line on a steel base frame, a structural
weldment with beam sections and cross members forming a rigid foundation. Machined mounting
surfaces on the base facilitate alignment of major components. The gear unit input shaft is connected
with the engine compressor rotor nose cone hub with a splined sleeve coupling. A mating flange
bolted to the engine air inlet housing attaches the assemblies.
The generator input shaft is aligned with the gear unit output shaft, and the shafts are connected with
a flexible shear coupling in a protective cover.

Components

The generator sets accessories include the start, fuel, electrical control, lube oil, pneumatically
controlled air systems, and a governor.

MAJOR COMPONENTS AND SYSTEM

Saturn 20 Gas Turbine Generator Set

Air Inlet
Gauge Panel Assembly
Generator

Coupling

Starter
Motor

Gear Unit
Exhaust
(hidden by
Assembly
Package Air Inlet
Turbine Assembly)
Base
Engine
Saturn 20 Gas Fuel Generator Set Frame

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Saturn 20 Dual Fuel Gas Turbine Engine

Compressor Compressor
Exhaust Diffuser Turbine Assembly Combustor Assembly Diffuser Assembly

T5 Thermocouples Gas Fuel Manifold Air Manifold Liquid Fuel Manifold Fuel Injectors

The turbine engine is the package power plant. Air is drawn into the compressor section through the
air inlet and is compressed. Fuel is added to the compressed air in the combustor and is ignited. After
combustion, hot gases expand through turbine nozzles and drive the turbine rotor. The turbine drives
the engine compressor, accessories, and generator. Air and combustion gases are discharged to the
atmosphere through the exhaust system. Major components include air inlet, engine compressor,
compressor diffuser, combustor, turbines, exhaust diffuser and exhaust collector.

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Generator
Drive End Non-Drive End
The genator, the driven equipment, transforms
Mechanical energy to electrical energy. The
Generator is bolted to the raised mounting pads on
The base, in alignment with thegear unit. The
Standard generator ste has a two-bearing, revolving
field-type, three-phase, ac generator, of dripproof
construction, with damper windings and a direct-
connected brushless exciter,controlled by an Electrical Generator
Automatic Voltage Regulator (AVR).

AVR

Coupling Guard

Coupling Guard

Main Lube
Oil Pump

Gear Unit

The two-stage, epicyclic gear unit transmits

power from turbine engine to the electrical
generator and also drives the main lube oil pump.
The unit will sustain momentary overloads of
up to approximately eight times normal operating
torque. The lube oil system lubricates bearings
and the gear train. The engine air system pressurizes
the bearing oil seals

Lube Oil Regulator Assembly

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Start System

The start system initiates rotation and assists the

engine to self-sustaining speed using a pneumatic Starter Motor Exhaust Transit Cap
starter motor. When engine reaches self-
sustaining speed, the starter shuts down (starter
shutoff valve closes), the starter clutch overruns,
and the engine accelerates under its own power to
loading speed.

Actuator

Gear Unit Starter Motor Coupling Guard

Fuel System

The fuel system regulates fuel flow. The dual fuel

Starter Motor systemis a combination gas fuel and liquid (diesel) fuel
Shutoff Valve system.Specially designed components, mechanical
linkages, solenoid-operated valves and other devices
Body combine the gas fuel system and the liquid fuel system
into a single intergrated system.

Gas Fuel Valves

Primary Gas Fuel Valve

Secondary Gas Fuel
Gas Fuel Control Valve
Control Valve

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Lube Oil System

Supplied from the base frame reservoir,

the lube oil system circulates
pressurized oil to to hydraulic
subsystems and to the turbine engine,
gear unit and starter motor to gear unit
drive connection. An oil cooler and a
thermostatic oil control valve maintain oil
temperature.

Air/Oil Cooler

Oil Reservoir Lube Oil Filters

Filter Selector

Filler Cap
Level Gauge Crossfeed Hand Valve

Electrical System

The 24 Vdc electrical control system monitors

the engine and generator and controls normal
and emergency (malfunction) shutdowns. In
Turbotronics Display
operation, the electrical control system
protects the engine and driven equipment
from damage from hazards such as
overspeed, high engine temperature and
vibration levels, low lube oil pressure,
excessive oil temperature and generator over
or undervoltages and high winding
temperature.

The control system wiring is routed via control

and monitoring junction boxes on the

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package skid to the Turbotronics panel located in the MCC. Display of engine and generator
operational conditions is available on theTurbotronics panel , along with indicator lights and
pushbutton and other switches to display and control operational status. A gauge panel is also
installed on the engine package to show some engine operating conditions.

MARS 100 GAS TURBINE DRIVEN COMPRESSOR SET

General Package Description

The Mars 100 gas turbine-driven compressor set consists of an axial-flow engine and the driven
compressor(s). Engine and compressor(s) are mounted on a heavy steel base frame in an in-line
arrangement. The base frame is a structural steel weldment, forming a rigid foundation. To facilitate
alignment of major package elements the steel base may include a machined mounting surface for
the driven equipment.The engine power turbine output shaft is aligned with the driven equipment input
shaft, and the shafts are connected with a splined interconnecting drive shaft enclosed in a cover.

Mars 100 Gas Fuel Gas Turbine Engine Package

Exhaust Assembly Air Inlet Assembly Lube Oil

Filters

Combustor Section Compressor Section Starter Motor

The turbine engine is the prime mover. Air is drawn into the compressor section through the air inlet
and is compressed. Fuel is added to the compressed air in the combustor and the mixture is ignited.
After combustion, hot gases expand through turbine nozzles and drive both the gas producer and
power turbine rotors. The two-stage gas producer turbine drives the engine compressor and
accessories. The two-stage power turbine powers driven equipment. Air and combustion gases are
discharged into the atmosphere through the exhaust system. Major components include air inlet,
multistage compressor, compressor diffuser, annular combustor, gas producer and power turbine
assemblies and an exhaust diffuser, and exhaust collector.

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Compressor Skid
Gear Unit
Gauge & Instrument Panel

Natural Gas Compressor

Construction transit bogey

Mounting Pad for 2nd Compressor

Base Frame

The Gear Unit

The gear unit, with drive shaft,

transmits operating speed from
turbine engine (through the Power
Turbine Drive Shaft) to driven
equipment.

Natural Gas Compressor

The centrifugal gas compressor is

for efficient gas boosting service
under a variety of field conditions.

Dry Gas Seals

The dry gas seal system consists of filters, regulators, pressure-sensitive devices, and valves to
supply regulated buffer air or nitrogen and seal gas to the gas compressor suction and discharge
seals. The system prevents contamination of process gas with bearing lubricating oil and prevents
process gas from entering the lubricating oil drain lines.

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Start System
Starter Motor
The start system includes starter and control
devices. The starter rotates the engine to self-
sustaining speed, where the starter shuts
down, the starter clutch overruns, and the
engine accelerates under its own power to
loading speed.

Fuel System
Fuel Valves Gas Fuel Loader Valve
The fuel system controls the fuel pressure
and flow to the engine.

Secondary Gas Fuel Valve

Gas Fuel Actuator

Lube Oil System

Backup Post Lube Oil Pump
The lubricating oil system circulates
pressurized oil to engine, gear unit,
and driven equipment bearings and
hydraulic subsystems. The system is
supplied from the lubricating oil
reservoir in the steel base frame.
Heater, cooler, and thermostatic oil
control valves maintain oil
temperature.

Lube Oil Pumps Pre/Post Lube Oil

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Electrical Control System

The electrical system controls start and
acceleration to operating speed,
monitoring engine and driven equipment
in operation. Automatic warning and
shutdown devices protect engine and Turbotronics Display
driven equipment from damage from
hazards such as an overspeed, high
engine temperature, low lubricating oil
pressure, and excessive oil temperature.
Other malfunction shutdown devices are
also provided.
The electrical control system is operated
from a control console. A turbine engine
control panel, with switches, pushbuttons,
and indicators for engine status, is on the
front of the control console.

Mars 100 Split Shaft Turbine Sectional View

2 Stage Gas Producer Turbine Output Drive Shaft

& Cover

Combustor
Assembly

Combustor

Compressor
Diffuser

Compressor
Air Inlet Muff

Exhaust Collector

Exhaust Diffuser

2 Stage Power Turbine

Fuel Injectors

Fuel Manifold
Compressor Case

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