GE Frame 7 Gas Turbines

Elliott Compressors
ABB Helper motor
Operator Familiarization

14-January-2004
Barney Ong
Rotating Equipment Engineering Advisor
 Discussion Topics
• Refrigeration Strings
– Mixed Refrigerant
– Propane
• GE Frame 7 Driver
– Design Performance Specification
– Site Performance
• String Starting Challenge and Methodology
• Supplementary Power
– What provides Supplementary Power ?
– When is Supplementary power required ?
– When is Supplementary power activated ?
– When and how do you activate Supplementary power ?
 Sea Water
Sea Water Cooling
Circuit

FCW
Fresh Cooling Water
Cooling Circuit

PR

MR
Propane
Refrigeration
Circuit

Mixed Refrigerant LNG

Refrigeration
Circuit
Feed Gas
 Difference in Train Designs
• T1&2
– 3.3 MMT/A
– One (1) Propane and Two (2) Mixed Refrigerant Compressors
– 8 MW VFD motor for Starting Only (Rated 10 minutes continuous operation – Air
Cooled)
– Speedtronic Mk.V + <I> Computers (ArcNet)
• T3&4
– 4.7 MMT/a
– One (1) Propane and Three (3) Mixed Refrigerant Compressors
– 12 MW VFD motor for Starting and Supplementary Power (Rated Continuous Duty
– Water Cooled)
– Speedtronic Mk.VI + (HMI> Computers (Ethernet)
 Refrigeration String
• Propane Compressor
– Elliott 88M8-5 36-K004
– Three Sections – First Stage Suction and Three side loads
• Mixed Refrigerant Compressor
– Three Compressors
• Elliott 88M4 36-K001
– Low Pressure Compressor
• Elliott 60M4 36-K002
– Medium Pressure compressor
• Elliott 56MB5 36-K003
– High Pressure compressor
 T1& T2 Refrigeration String

Elliott Elliott
GE Frame 7EA 88M4 8MW Starter
60MB6
Gas Turbine LP MR Motor
HP MR

GE Frame 7EA Elliott 88M7 8MW Starter

Gas Turbine Propane Motor
 T3 & T4 Refrigeration String

Elliott 88M4 Elliott 60M4

GE Frame 7EA LPMR MP MR 12 MW
Gas Turbine 36-K001 36-K002 Starter/Helper ABB
36-KT001 Motor 36-KM001

Elliott 88M8-5 Elliott 56MB5

GE Frame 7EA PR HP MR 12MW
Gas Turbine 36-K003 36-K003 Starter/Helper ABB
36-KT004 Motor 36-KM004
 Frame 7 Driver
Typical Design Performance Specifications

• MS 7121EA Model
– Designed as a 60 Hz Power Generator Driver
– 82.7 MW ISO
– Single Shaft
– Design Speed 3600 RPM
• Output & Firing Temperature
– Power Ranges from ISO 64.9 MW To 89 MW
– Firing Temperature ranges from 1985 Deg.F to 2055 Deg.F
• Turbine Starting
– Need to accelerate to 92% before bleed valves are closed
– Conventionally a 1250 kW motor
 Frame 7 Driver
Typical Design Operating Characteristics

• Initially started by 1250 kW starter

• Turbine accelerates to about 25% TNH for purging
• Turbine decelerate to 14.5 %
• Combustors are ignited
• Turbine starter motor re-accelerates to full speed no load (FSNL)
– Bleed Valves closes at 92% TNH
• Turbine becomes power producer at approximately 60% TNH
 Frame 7 Driver
Typical Design Operating Characteristics

GAS TURBINE SPEED / TORQUE - FIRED

12000

10000

8000

6000
FT-LB

4000

2000

-2000
0 10 20 30 40 50 60 70 80 90 100

% DESIGN SPEED
 Frame 7 Driver
Performance Characteristics at Various Ambient Conditions

140 100000

95000
120

90000

100
Ambient temperature in Deg.F

85000

80

Power in KW
80000

75000
60

70000
40

65000

20
60000
64.9 MW at 120 F (49 C)

0 55000
One Year
 Frame 7 Driver
Site Performance Characteristics

• Weather
– Altitude : Sea Level
– Humidity Range : 20~100%
– Ambient Temperature Range : 8 ~ 49 Deg.C
• Site Power
– Model : MS7121EA
• 82.7 MW ISO
• 2032 Deg.F Firing Temperature
• String Starting
– 1250 kW Turbine Starter motor not capable of providing adequate torque to
accelerate refrigeration string safely to “sustaining” speeds
– Supplementary Starting power is required
• Typically Generator at unloaded state presents only generator rotor inertia
• Refrigeration compressor cannot be completed unloaded
 Supplementary Power

• Provided by 12 MW Variable Frequency Motor

– ABB
• When is Supplementary Power needed ?
– Starting the Refrigeration String
– When load is beyond Turbine output
• During high rates
• During High Ambient
• How do you activate Supplementary Power (after FSNL) ?
– DCS Panel
 String Starting Methodology
Power Challenges during start-up

Following requirements needs to be met by Starting system:

• System Inertia
• Windage Load of Gas Turbine
• Process Compressor Gas Loading during start. This is a function of:
– Compressor Speed
– Flow throughput
– Density of Gas
• Acceleration rate for safe control of turbine temperatures
 String Starting Methodology
Power Challenges during start-up …. continued

Sources of string driving torque during start-up

• Turbine Starter Motor

– 1250 kW
– 9,000 ft-lb torque
• Helper Motor (12 MW)
– Variable Frequency Synchronous
– 12 MW
– 15,500 ft-lb maximum torque capability
• Gas Turbine after reaching approximately 2250 RPM
– Gas Turbine makes positive contribution to string driving torque after 60% TNH
– Gas Turbine is able to absorb full design load after bleed valves are closed at 92%
 String Starting Methodology
Starting Torques required by Process required

Propane Compressor String - SPEED/TORQUE

10

0
FT. # F x 1000

3rd Section

-5
2nd Section

-10
1st Section

-15

-20
0 500 1000 1500 2000 2500 3000 3500 4000

RPM
 String Starting Methodology
Site Starting Philosophy

• Reduce Process Compressor Starting Loads by Starting in “Stonewall”

– Near Choked conditions
– Reduced pressure ratio thereby reducing power requirement
• Process Compressor pressure rise keep to minimum during start-up by:
– sizing anti-surge valves large enough to allow higher flows than design
– Closing all process compressor isolation valves and vent

• Supplement Turbine Starting Motor torque through the use of a directly

coupled Helper Motor
– Turbine Starting motor provides torque for the purge cycle
– Helper Motor starts contributing torque at 1000 rpm
– Both motors cut off is ramped down after the turbine bleed valves are closed (92%)
 String Starting Methodology
Site Starting Sequence

• Close all Process Compressor isolation valves and open all anti-surge valves
• Vent process gas in process compressor
• Start rotating String with Turbine Starting Motor
• Accelerate String to 1000 rpm to complete purge cycle
• Decelerate to 400 RPM when Ignition occurs
• Accelerate String beyond 400 rpm
• Helper Motor kicks in at 1008 rpm (28% TNH)
• Accelerate String to FSNL with turbine making positive driving torque beyond
2250 rpm
• Ramp down Helper Motor and Turbine Starting Motor when turbine bleed
valves are closed (92% TNH 3312 RPM)
 String Starting Methodology
Torque developed by Turbine Starter Motor (1250kW)

Turbine Starter Motor Torque - Speed / Torque

12000

10000

8000
FT-LB

6000

4000

2000

0
0 20 40 60 80 100 120

% DESIGN SPEED
 String Starting Methodology
Torque developed by Helper Motor (12 MW)

MR Compressor String - Helper Motor Speed/Torque Curve

12

10

8
FT-LB F (x1000)

0
0 500 1000 1500 2000 2500 3000 3500 4000

% DESIGN SPEED
 String Starting Methodology
Torque developed and Load Torque

Propane Compressor String - SPEED/TORQUE

40

30

Turbine Starter
Auxiliary StarterMotor (1250 KW) Main Motor
Helper Motor (8 MW)
20
FT. # F x 1000

10

0
3rd Section

2nd Section
-10
Gas Turbine 1st Section

Ignition End of Purge Cycle Turbine starts making power

-20
0 500 1000 1500 2000 2500 3000 3500 4000

RPM
 Plan for Start up
• Complete Start-up Checks
• Put all Strings on RACHET at least 24 Hrs prior to Start-up
• Gas Fuel In
– False Fire
– Start up to FSNL
• Defrost …………. For few days
– All Recycle Valve fully open … or ..
– CCC on manual
• Shut down
– Remove Strainers
– Introduce MR and PR refrigerant into compressors
– Restore MR & PR curve on CCC Surge Control
• Refrigerate and Manufacture LNG
– Surge Test
– Set final control surge lines