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CAT Titan 250 User's Manual

1. E S Ty F 7 TERR Be FS Rei D EE Jis i j F ce F B j NITROGEN WATER WATER WATER Fd I 5 B ga Fg H H du cf l Fd I Gi cit E THSH E q Il l Fd i DU 1 5 E i i Fd l l R i i i Fd i 3 s Fd l L jJ IT Figure 24 Typical Water Mist Fire Suppression Cylinders and Cabinet 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 49 Turbomachinery Package Specification Table 9 Enclosure Specifications Titan 250 Generator Set Enclosure Optional Ventilation Fan Motor Voltage Ratings 380 VAC 400 VAC and 415 VAC 50 Hz 460 VAC 60 Hz Primary Enclosure Lighting Voltage 220 VAC 50 Hz or 110 VAC 60 Hz Standby Enclosure Lighting Voltage 120 VDC Sound Pressure Level See Note a Enclosure Roof Load 244 kg m 50 Ib ft Enclosure Wind Load 193 kph 120 mph Approximate Measurements Height 4 m 13 ft Does Not Include Ventilation Ducting Width 7 m 23 ft With Enclosure Doors Open and Engine Removal Hoist Attached Length 15 m 49 ft Approximate Weights Gas Turbine Enclosure 8618 kg 19 000 Ib Generator Enclosure 5670 kg 12 500 Ib Fire
2. ES 9 56 Fusion Welding ES 9 58 Standard Paint Program Turbomachinery ES 1593 Guidelines for NEC Compliance of Solar s Product Lines Class Group D Division 1 and Division 2 ES 1762 Standards and Practices for Electrical Systems for Gas Turbine Packages Installed In Hazardous Areas CENELEC IEC Standards European ATEX Directive 94 9 EC ES 2201 Auxiliary Air ES 2231 Standards and Practices for The Design and Installation of Cable Channels and TC Rated Cables Installed In Class 1 Division 2 Hazardous Areas Solar s Applicable Product Information Letters PIL 127 Product Certification Notes a All package piping is fabricated from 316L stainless steel with the exception of lube oil vent lines and any piping welded directly to a carbon steel lube oil tank or tank cover 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary Turbomachinery Package Specification Titan 250 Generator Set 3 Titan 250 Gas Turbine 3 1 16 STAGE COMPRESSOR General Description The two shaft Titan 250 gas turbine Figure 3 is a completely integrated and self contained prime mover The Titan 250 gas turbine combines high performance operation with rugged industrial construction This design philosophy allows for high efficiency low maintenance and a long service life The Titan 250 gas turbine is designed for a high degree of compliance with American Petroleum Institute API requ
3. STROBES HORN Turbotronic 4 FIRE Back up SUPPRESSION Shutdown SYSTEM System OPERATOR PANEL AUTO INHIBIT MIR Multi spectrum IR Flame Detector DISCHARGED TD Thermal Detector AUTO INHIBIT IR IR Gas Detector LON Local Operating Network MANUAL RELEASE Figure 22 Typical Fire and Gas System 11 3 9 CO Fire Suppression System The enclosure can be equipped with a CO fire suppression system consisting of a primary total flooding distribution system and a secondary metered distribution system to extend the design concentration of 3796 CO for 20 minutes On fire detection by the optional fire and gas detection system the detectors transmit an electrical signal via the fire control panel to activate the fire suppression system release solenoids located in the CO fire suppression cylinder cabinets Figure 23 On receipt of this signal the solenoid actuated control heads activate the CO cylinders releasing CO into the enclosure CO pressure actuates the pressure trip operated dampers that close all vent openings CO release control heads are also provided with manual release levers 11 3 10 Water Mist Fire Suppression System The enclosure can be equipped with a water mist fine water spray fire suppression system consisting of a high pressure distribution system to provide approximately 10 minutes continuous water discharge The typical water mist fire suppression cylinder cabinet Figure 24 consist
4. MAIN LEAD LAMINATIONS GROUND ROTOR FAN LEAD STATOR FRAME ROTOR ROTOR FAN AIR DEFLECTOR AIR DEFLECTOR PERMANENT MAGNET X EXCITER ASSEMBLY i X SLEEVE BEARINGS SLEEVE BEARINGS SEAL SEAL d INPUT SHAFT 2 S NOUS o 8 BEARING DRAIN BEARING DRAIN SIGHT GLASSES SIGHT GLASSES MOUNTING FEET MOUNTING FEET Figure 6 Typical Open Drip Proof Generator with Permanent Magnet Exciter System 5 2 Functional Description During generator operation three phase AC power generated by the exciter armature is converted to DC power by a rectifier The DC output from the rectifier is applied as field excitation current to the generator rotor windings to create magnetic flux The generator voltage output is controlled by the generator field current and the generator field current is controlled by a brushless exciter The amount of DC current applied to the exciter field determines the exciter output voltage A potential transformer senses the bus potential and provides a signal to the combined generator control module CGCM for excitation control 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 14 Turbomachinery Package Specification Titan 250 Generator Set Any variations in bus potential will also be sensed and corrected by this circuit After voltage builds the generator accelerates to 100 speed and excitation and voltage control is assumed by the CGCM A crosscurrent compensating transformer
5. 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 46 Turbomachinery Package Specification Titan 250 Generator Set 11 3 3 11 3 4 11 3 5 11 3 6 11 3 7 11 3 8 an AC source independent from the package power system This independent power source is not provided by Solar Dust Protection System The enclosure ventilation inlets are equipped with a single stage disposable barrier type filter unit equipped with a differential pressure alarm switch The ventilation exhaust openings are equipped with back draft dampers to prevent the entry of dust when the unit is not running Dust and Moisture Protection System The enclosure ventilation inlet can be equipped with a two stage filter unit consisting of a first stage vane separator and a second stage filter The moisture eliminator section is hinged for filter access The unit is equipped with a differential pressure alarm switch and gauge The ventilation exhaust opening is equipped with back draft dampers to prevent the entry of dust and water when the unit is not running Standby Lighting Standby lights provide emergency automatic and backup lighting inside the enclosure in the event of an AC power loss Power is supplied from the package battery system To avoid battery system drainage the circuitry includes a shutoff timer Marinization Increased stiffening of enclosure structural components and additional flexibility of enclosu
6. Air Quality See Note a Minimum Maximum Regulated Pressure Range 552 to 758 kPag 80 to 100 psig Intermittent Flow Rate 0 5 nm min 18 scfm Pressure Drop Clean 25 mm 1 0 in water Marine Type Air Filter Pressure Drop Clean 53 mm 2 1 in water Construction Materials Prefilter Barrier Carbon Steel Standard 316L Stainless Steel Optional Insect Screen Carbon Steel Standard 316L Stainless Steel Optional Self Cleaning Barriers Carbon Steel Standard 316L Stainless Steel Optional Marine Type Air Filter 316L Stainless Steel Standard Air Inlet Silencer Carbon Steel Standard 316L Stainless Steel Optional Air Inlet Ducting Carbon Steel Standard 316L Stainless Steel Optional Air Inlet Support Structure Carbon Steel Standard Applicable Product Information Letters Solar s Product Information Letter PIL 054 OSHA Noise Requirements Solar s Product Information Letter PIL 178 Salt Ingress Protection for Gas Turbines Notes a The particle size in the air stream should not exceed 10um Since it is impractical to remove 100 of all particles larger than 10um this is defined as 310 gt 100 or 99 efficient Oil or hydrocarbon content should not exceed 1 ppm The dew point at line pressure shall be at least 6 C 10 F below the minimum temperature to which any part of the air system is exposed o
7. Approximate Measurements Lead Acid Batteries Height 1 78 m 5 8 ft Width 3 05 m 10 0 ft Depth 0 76 m 2 5 ft Approximate Measurements NiCd Batteries Height 1 65 m 5 4 ft Width 4 83 m 15 8 ft Depth 1 02 m 3 3 ft Turbine Cleaning System Water Solvent Supply Pressure 85 to 100 psig 586 to 689 kPag Water Solvent Supply Min Temperature Ambient Except In Extreme Cold On Line Water Solvent Flow Rate 2 3 4 5 Limin 0 6 1 2 gpm On Line Propulsion Air Flow Rate 0 026 nm min 0 98 SCFM Package On Line Triple Stage Strainer 300 200 100 Micron On Crank Water Solvent Flow Rate 9 1 12 9 L min 2 4 3 4 gpm On Crank Propulsion Air Flow Rate 0 080 nm min 3 0 SCFM Package On Crank Triple Stage Strainer 300 200 100 Micron External Air Supply Clean Filtered Air Air Supply Pressure 586 to 690 kPag 85 to 100 psig Turbine Cleaning Cart Capacity 98 L 26 gal Tank Discharge Strainer 100 Micron External Air Supply Clean Filtered Air Air Supply Pressure 586 to 690 kPag 85 to 100 psig Approximate Measurements Height 102 cm 40 2 in Width 55 cm 21 7 in Length 121 6 cm 47 87 in Approximate Weight 86 kg 190 Ib Tank Material 316L Stainless Steel Certification American Society of Mechanical Engineers ASME or Pressure Equipment Directive PED Electri
8. Header Tank Header Tank Oil Tank Level Oil Filter Pre Post Lube Pump Cmd Backup Pump Cmd 29 Solar Turbines Rev 0 Strip Chart ttvw File View Window Languages Help Engine Fired Hours Engine Starts Enclosure Purge Exhaust Purge Turbine Cooldown Post Lube Slow Roll Time Gas Fuel Viv Cmd Guide Vane Cmd Bleed Valve Cmd Pilot Valve Cmd Liq Fuel Viv Cmd Min Fuel Fuel Supply Prs Boost Pressure Gas Selected Gas Active Local Control Voltage Figure 15 Typical TT4000 Operation Summary Display Screen Actual Avg LL V Avg Current PF Frequency On Load Ready Running Light Off ES Summaries E Alarms Events Ei Tools EE Constants B Strip Chart i Maintenance RI Historical Analyzer T fas Reports LZ co documentation Solar Turbines Tag Ty Tag Name GB Reatime AN Exo V Bl Reatime AN Hop B Reattime AN T5 Average Temperature Figure 16 Typical TT4000 Strip Chart Display 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 35 Turbomachinery Package Specification Titan 250 Generator Set Engine Summary NGP 100 0 m OPER MODE CONTROL MODE oF On Load TS Average TS Setpoint TI T Average Fuel Supply Prs Air Inlet DP PCD Gas Fuel VIv Cmd Lube Header Temp Lube Header Prs System Voltage 1200 1200 61 0 1000 386 EM 380 86 0 128 38 0 24 0 SYSTEM CONTROL Local
9. The exhaust backpressure should be less than 25 4 mm 1 in water column during gas turbine starting 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 56 Turbomachinery Package Specification Titan 250 Generator Set 14 14 1 Accessory Equipment DC Power Supply and Battery Charger System This system provides 120 VDC power for the following devices e The electric actuators that drive the fuel valves bleed valve and variable guide vanes e The 120 to 24 volt DC to DC converter in the control system that provides the 24 VDC control power e The DC backup lube oil pump and DC back up engine turning gear motors e The DC backup lube oil scavenging pump motor when applicable for offshore installations The system includes a 3 phase charger Figure 26 and a set of batteries configured for 120VDC output mounted on a freestanding rack The batteries are sized to provide sufficient power to allow the package to shut down and cool down in an orderly manner in the event of loss of external AC power The system is designed for indoor installation in a nonhazardous area The batteries are shipped fully charged and ready for use Two battery types are available e Valve regulated sealed gas recombination lead acid e Nickel Cadmium UM AX Figure 26 Typical Battery Charger 14 2 Turbine Cleaning System The optional turbine compressor cleaning system Figure 27 facilita
10. c Longer cable runs may require an onskid marshalling box and or output line reactor 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 20 Turbomachinery Package Specification Titan 250 Generator Set 7 Fuel System 7 1 General Description The fuel system Figure 10 in conjunction with the control system includes all necessary components to control ignition and fuel flow during all modes of operation LEGEND PILOT FUEL PILOT FUEL gt TO FUEL TP MANIFOLD INJECTORS RT VS PRESSURE TRANSMITTER CONTROL RTD TEMPERATURE VALVE VALVE SOLENOID 4 GAS VENT Dei MAIN V VENT gt deae r1 b s Bai VALVES d VALVE VALVE 1 A m E MAIN MAIN FUEL p TO FUEL MANIFOLD INJECTORS 1 V PRIMARY SECONDARY E SHUT OFF gt SHUT OFF gt gt FUEL pe MAIN FUEL p TO FUEL p CONTROL MANIFOLD INJECTORS VALVE i VALVE VALVE 2 2 V A A A TORG Q Y i Y REGULATOR i V TORCH SHUT TORCH Jas OFF VALVE gt REGULATOR Be TOsTORCH Figure 10 Typical Fuel System Schematic 7 1 1 SoLoNOx Combustion System The SoLoNOx combustion system uses special fuel injectors with main and pilot fuel ports The fuel injected through these ports is controlled during starting and steady state operation to maintain stable combustion and minimize the formation of nitrous oxides NOx carbon monoxide CO and unburned hydrocarbon UHC emissions To further regulate emi
11. on the skid facilitate component alignment The gearbox is bolted directly to the engine and coupled by means of a splined interconnecting drive shaft that eliminates the need for field alignment The gearbox and generator are connected by means of a flexible dry disk shear type coupling enclosed in a coupling guard Jacking points are provided to facilitate alignment of the generator to the gearbox 2 3 Major Components and Systems Major components and systems of the gas turbine generator set typically include e Gas turbine e Reduction drive gearbox e Generator e Start system 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary Turbomachinery Package Specification Titan 250 Generator Set e Fuel system e Lubricating oil system e Turbotronic 4 Control System e Onskid electrical wiring e Skid with drip pans e Piping and manifolds e Ancillary air inlet system e Ancillary exhaust system e Package enclosure if specified with Ventilation system Fire detection and suppression system Combustible gas detection system 2 3 4 Package Electrical System The onskid package electrical system can be furnished to meet the following certification requirements e National Electrical Code NEC e Canadian Electrical Code CEC e Conformit Europ enne CE Mark e European Committee for Electrotechnical Standardization CENELEC When supplied the offskid control console variable frequency dri
12. so data storage is limited It displays data but without the graphics features of the full TT4000 version 9 5 1 TT4000 Display Screens A menu bar at the left of each screen allows navigation to any other screen A status bar at the top of every screen displays up to four alarm conditions Standard display screens include e Operation Summary complete package data Figure 15 e Generator Summary generator operating data e Temperature Summary all monitored temperature values e Vibration Summary all monitored vibration values e Alarm Summary e Discrete Event Log e Strip Chart Display real time data Figure 16 e Historical Data Display strip chart format e Program Constants Optional Display Screens e Gas Turbine Performance Customized screens can be provided to display other product specific information 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 34 Turbomachinery Package Specification CA Solar Turbines Rev 0 Operation ttvw Titan 250 Generator Set E summaries WI Temperature GT Fuel System fax Lube System ES vibration aa Generator Generator Control GC Engine Performance tmi Alarms Events E3 res Ld Reports Ld CD Documentation T5 Average Active T5 TCs T7 Average Active T7 TCs PCD Air Inlet DP T5 Setpoint Temperature Exhaust Gas Sensor Inlet Gas Sensor Exhaust Gas Sensor Inlet Gas Sensor Fan1 Fan 2
13. temperature The particle size in the air stream should not exceed 10u Since it is impractical to remove 100 of all particles larger than 10u this is defined as R10 gt 100 or 99 efficient Oil or hydrocarbon content should not exceed 1 ppm The dew point at line pressure shall be at least 6 C 10 F below the minimum temperature to which any part of the air system is exposed or between 29 C and 93 C 20 F and 200 F Air should be free of all corrosive contaminants hazardous gases flammables and toxics 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 23 Turbomachinery Package Specification Titan 250 Generator Set 8 Lubrication System 8 1 General Description The lubrication system Figure 11 circulates oil under pressure to the gas turbine and driven equipment Lube oil is supplied from the lube oil tank located in the driver frame Oil temperature is maintained at optimal levels by a thermostatic control valve oil tank heater and optional oil cooler The lubrication system incorporates the following components e Oil tank e Oil tank heater e Lube oil customer furnished e Gas turbine driven main lube oil pump e AC Motor driven pre post lube oil pump e DC Motor driven backup lube oil pump e Duplex lube oil filter system with replaceable elements e Oil level pressure and temperature indications e Pressure and temperature regulators e Strainers e Oil tank vent separator
14. 0 24VDC Thermocouples Type N Resistance Temperature Devices RTDs 100 ohm Platinum Proximiters 3300XL Solar s Applicable Engineering Specifications ES 9 56 Fusion Welding ES 1593 Guidelines for NEC Compliance of Solar Product Lines Class Group D Division 1 and Division 2 ES 2231 Standards and Practices for The Design and Installation of Cable Channels and TC Rated Cables Installed In Class 1 Division 2 Hazardous Areas 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 39 Turbomachinery Package Specification 10 Generator Control and Monitoring Titan 250 Generator Set 10 1 General Description For generator control and monitoring the Turbotronic 4 control system incorporates a Rockwell Automation Allen Bradley combination generator control module CGCM The CGCM provides generator control protection and monitoring Three excitation control modes are available Automatic voltage regulation AVR A constant generator output voltage is maintained Power factor PF control A constant power factor is maintained when operating in parallel with a large power source Reactive power control A constant reactive load is maintained when operating in parallel with a large power source The following excitation control features are available Protection features for the driver and driven equipment include Under frequency limiting Over and under excitation l
15. 16 2 6 Source Inspection As an option Solar can conduct a final product inspection at the supplier facility for the following contract specific items e Inlet system filter e Inlet system silencer e Exhaust system silencer e Lube oil cooler e Generator including rotor balancing and standard generator testing 16 2 7 Customer Participation As an option the customer may witness specified tests on a noninterference basis and or hold point basis 16 2 8 Weld Radiography As an option radiographic welding inspections can be performed on a percentage of the gas fuel and or lube oil system piping and manifolds 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 65 Turbomachinery Package Specification Titan 250 Generator Set 17 Preservation Installation and Documentation 17 1 General Description This chapter describes preservation general installation requirements and project documentation 17 2 Preservation Long term and short term preservation can be provided for the engine and package The type of preservation required dependents upon the following e Type of transportation sea air or truck e Climatic conditions during transport and storage e Storage period e Storage facilities e Static and dynamic loads imposed during shipment Long term preservation is required if e Equipment will be stored in an unimproved storage area for greater than 90 days before installation e Transport
16. 61 16 QUALITY ASSURANCE AND TESTING eeeseseeee es ieeeee essen nnne ennt n nennt rns nnns 63 16 1 Quality Assurance etri Eee Rr eee ree Lett ede ehe tire esent cab needs 63 ee EE 63 17 PRESERVATION INSTALLATION AND DOCUMENTATION eere 66 17 1 General Description oser enie eet ote ee ola tte ede rh t Latera RE Eee ates HERE SER eg AER 66 Ke e cene ce tis te eer cda ee RH e ER ud Aare 66 17 3 Site Requirements o eto erect rere eae ra Pee e oa bd andre ve eade aue ee eR eee 66 17 4 Mechanical Installation Requirements snnsensseeseennrenssesertnnrtnssesttrrrrnnntesttnnnnnnsreereenn 66 17 5 RL tun Le EE 67 ies ule um 70 18 1 General Description siisii eet et eL eei eben ded e ee dn sage cede enna a 70 18 2 National Electrical Code 70 18 3 Canadian Electrical Code eene nnne 70 18 4 Conformit Europ enne Mark eren nnne 71 18 5 International Electrotechnical Commission Safety Aesesement 72 18 6 Offshore Marine Applications eene nennen 72 OFEN 73 Ue del aptid id ecl E 74 19 1 Construction Servicesin a t eer e EE Re a REOR Ea Pea eR ee paran 74 19 2 Customer SERVICES iu emt m ege RR EUR e Da re tee ru ba exce Rer ta ea DR RO He eg reda 74 19 3 Contract Power and Leasing Gervices nemen 75 19 4 Solars Worldwide Lorcatons emere nennen 75 CONVERSION CHART EAR a ac renes Ue Deae va nuuc vut acra avra c Dres 76 LIST OF ABBREVIATIO
17. Figure 17 Typical TT4000S Engine Summary Screen GENERATOR Avg LL V 6600 Avq Current 120 Actual 12000 Apparent Pwr 140 Reactive Pwr 386 PF EI Frequency 60 1 GENERATOR EXCITER Excitation 6 0 Excitation 48 Vdc Field Ripple 1 0 GENERATOR WINDING Phase A Wdg 120 Phase B Wdg 120 Phase C Wdg 120 Vac A kw kVA kVAR Hz A C C C 100 0 CONTROL MODES Operation Mode Isoc Load Share Disabled GENERATOR Gen Arr Inlet Gen Air Outlet POWER METERS 1000 kWh 860 kVA h 1200 KVARh Figure 18 Typical TT4000S Generator Summary Screen 9 5 2 TT4000S Display Screens The TT4000S displays a comparable set of screens to the full TT4000 except that the data are in numerical form and graphics are limited Figures 17 and 18 9 5 3 TT4000 Data Collection and Display The Discrete Event Log records changes in status for all defined discrete inputs including operator commands alarms and shutdown annunciations and key sequencing and status signals Up to 5000 events are stored and can be viewed and sorted by heading Analog Data are collected and saved to disk The standard data files are Hourly Log data are read at hourly intervals for 2 years Each year s data are stored in a separate file Data is recorded whether or not the equipment is operating 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 36 Turbomachinery Package Specification Titan 250 Gener
18. Inc UL when certifying to Canadian standards 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 70 Turbomachinery Package Specification Titan 250 Generator Set 18 4 Conformit Europ enne Mark For installations that require Conformit Europ enne CE Mark certification Solar complies with the CE Mark codes and standards adopted by local authorities and government entities Sources for these codes and standards include the following European Union EU directives e Explosive Atmospheres ATEX Directive 94 9 EC e Pressure Equipment Directive 97 23 EC e Machinery Safety Directive 98 37 EC e Electromagnetic Compatibility Directive 89 336 EEC e Low Voltage Directive 73 23 EEC 18 4 1 Methods of Establishing Conformity To ensure compliance with applicable directives Det Norske Veritas DNV an approved Notified Body supports Solar s efforts to comply with directives by providing consultation and where applicable certification Solar has received from DNV type certification for standard turbomachinery packages for ATEX and PED directives As a result Solar self certifies for CE Mark requirements on standard packages This self certification process includes the following e The package is designed and manufactured to European Committee for Electrotechnical Standardization CENELEC and European Committee for Standardization CEN standards e A hazard analysis is performed to def
19. Loading The Start command initiates the sequence Prior to rotation the lube oil pump undergoes a test cycle the enclosure fans if applicable are started and the fuel valves undergo a test cycle with fuel pressure verification The starter then rotates the gas turbine and the compressor develops airflow to purge any accumulated gas in the gas turbine air inlet and exhaust duct The purge cycle is tailored to the exhaust duct volume When the engine has reached the required speed and temperature a small amount of fuel is introduced into the combustor from the gas torch and ignited by the ignitor plug 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 32 Turbomachinery Package Specification Titan 250 Generator Set 9 4 2 9 4 3 The fuel control valve gradually opens and admits fuel into the combustor through the injectors The inlet guide vanes open and the bleed valve gradually closes Fuel flow engine temperature and turbine speed all increase Once starter dropout speed is exceeded the starter freewheels and is de energized The engine continues to accelerate under its own power The generator is loaded by closing the generator circuit breaker The circuit breaker can be closed to a dead de energized or a hot energized bus If a dead bus is detected the circuit breaker may be closed without synchronization If a hot bus is detected the system must synchronize the generator output to
20. Signals 4to 20 mA Maximum Operating Pressure 4137 kPag 600 psig Maximum Operating Temperature 93 C 200 F Response Time Less Than 100 msec From 10 to 90 Stroke Valve Body Aluminum Standard Stainless Steel Optional Gas Fuel Filter Conventional Units Only 10 Micron Offskid Coalescing Filter Module SoLONOx Units Only Maximum Operating Pressure 3447 kPag 500 psig Maximum Flow 122 m min 4300 ft min Minimum Maximum Operating Temperatures 29 to 100 C 20 to 212 F Filtration Efficiency B0 3 gt 200 per ISO 4572 2008 Solar Turbines Incorporated All rights reserved 22 TPS250GS 908 Preliminary Turbomachinery Package Specification Titan 250 Generator Set Customer Furnished Pilot Air System Fluid Clean Dry Air Air Quality See Note d Minimum Maximum Regulated Pressure Range 689 to 1379 kPag 100 to 200 psig Pilot Air Filter 10 micron Construction Materials Piping Manifolds and Tubing 316L Stainless Steel Applicable Engineering Specifications Solar s Engineering Specification ES 9 98 Fuel Air and Water or Steam for Solar Gas Turbine Engines Solar s Engineering Specification ES 1593 Guidelines for NEC Compliance of Solar Product Lines Class Group D Division 1 and Division 2 Solar s Engineering Specification ES 1762 Standards and Practices for Electrical Systems for Ga
21. Space Heater Voltage 120 220 230 or 240 VAC Frequency 50 or 60 Hz Phase 1 Phase Vibration Monitoring Generator Bearing Driven End Displacement Probes X and Y axis Generator Bearing Exciter End Displacement Probes X and Y axis Notes a Other voltages can be provided to meet specific customer requirements b A 80 C 144 F temperature rise is based on the generator nameplate rating at 40 C 104 F and a power factor of 0 8 for continuous duty service 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary Turbomachinery Package Specification Titan 250 Generator Set 6 Start System 6 1 6 2 6 2 1 General Description The start system includes a direct drive AC starter motor driven by a solid state variable frequency drive VFD The start system provides torque to initiate engine rotation and to assist the engine in reaching a self sustaining speed The starter motor is mounted directly on the gas turbine accessory drive gearbox The VFD regulates voltage and frequency to the starter motor for engine rotation as commanded by the Turbotronic 4 control system Functional Description To begin gas turbine rotation the VFD initially provides low frequency AC power to the starter motor The VFD gradually increases the speed of the starter motor until the gas turbine reaches purging speed When purging is completed the control system activates
22. Suppression System Compliance CO Fire Suppression System U S National Fire Protection Association NFPA 12 United States Coast Guard USCG CFR 46 Water Mist Fire Suppression System U S NFPA Code 750 USCG CFR 46 Water Mist Fire Suppression System Minimum Operating Temperature 4 C 40 F Optional Heater Available CO Fire Cylinder Cabinets Fire Cylinder Cabinet Main Height 198 cm 78 in Width 214 cm 84 in Depth 46 cm 18 in Approximate Cabinet Weight 429 kg 946 Ib Without Cylinders Approximate Cylinder Weight 45 kg 100 Ib Fire Cylinder Cabinet Extended Release Height 198 cm 78 in Width 122 cm 48 in Depth 46 cm 18 in Approximate Cabinet Weight 269 kg 592 Ib Without Cylinders Approximate Cylinder Weight 45 kg 100 Ib Water Mist Fire Cylinder Cabinet Fire Cylinder Cabinet Height 226 cm 89 in Width 165 cm 65 in Depth 91 cm 36 in Approximate Cabinet Weight 1297 kg 2859 Ib Without Cylinders Approximate Cylinder Weight 1697 kg 3741 Ib Construction Materials Enclosure Housing Carbon Steel Enclosure Door Hardware 316L Stainless Steel Fire Cylinder Cabinets Carbon Steel 316L Stainless Steel Optional Dust and Moisture Protection System Carbon Steel 316L Stainless Steel Optional 2008 Solar Turbines Incorporated All right
23. Using the gas turbine exhaust directly for a drying or heating process in which high temperature air is necessary A mixture of gas turbine exhaust and fresh air can be used in a reduced air temperature process An air to air heat exchanger is required when the process involves any products in the human food chain Solar can design and provide a complete exhaust heat recovery system to meet specific application requirements The system must be designed to minimize the backpressure imposed on the gas turbine exhaust and provide a smooth flow transition into the exhaust heat recovery device 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 55 Turbomachinery Package Specification Table 11 Exhaust System Specifications Titan 250 Generator Set Exhaust System Temperature Class T2 Total System Pressure Loss Should Not Exceed 152 mm 6 In of Water Exhaust Temperature 465 C 865 F Nominal System Back Pressure 203 mm 8 in of water See Note a Construction Materials Exhaust Silencers Carbon Steel 316L Stainless Steel Optional Exhaust Ducting Carbon Steel 316L Stainless Steel Optional Exhaust Bellows Expansion Joint Carbon Steel 316L Stainless Steel Optional Solar s Applicable Engineering Specifications ES 1632 Exhaust Silencers for Solar Turbine Engines Notes a Higher backpressures can be accommodated
24. environment e All volumes of the manual set on one CD ROM e Search feature including full text search for supplier data 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 68 Turbomachinery Package Specification Titan 250 Generator Set e Graphics in a separate window for simultaneous viewing of text with associated illustration e PDF version for printing 17 5 5 Service Parts List Identifies operational service parts and tooling Once engineering has been finalized and manufacturing bills are available Solar s Service Parts department creates a detailed listing of service parts from the actual equipment manufacturing bills of material Table 14 Preservation Installation and Documentation Specifications Mechanical Installation Requirements Mounting Space Between Units In Multiple Unit A Minimum of 2 5 m 8 ft Installations Lube Oil Cooler s Top of The Lube Oil Cooler s Not Be More Than 9 m 30 ft Above The Bottom of The Package Frame See Note a Total oil volume of Outgoing and Return 1282 L 340 gal Lines Total Combined Pressure Drop of The Should Not Exceed 345 kPag 50 psig Supply and Return Lines and Lube Oil Cooler s Start Fuel Lube Air Drain System Schematics Compliance American National Standards Institute ANSI Y32 10 Solar s Applicable Engineering Specifications ES 9 4 Interpretation of Drawing Requirements ES 9 76 Traceability R
25. include the relative height of the exhaust duct above the air inlet building roof design direction of prevailing winds and the proximity of adjacent structures When exhaust silencing is required provisions must be made to adequately mount and support the equipment and limit the exhaust silencer pressure loss Documentation Four copies of the Operation and Maintenance Instruction OMI manuals and Quality Control QC data books are provided on CD ROM Additional copies and alternative formats can be ordered at additional cost Project specific drawings are provided in electronic format and include e Electrical schematic e Wiring diagram e Electrical interface Interconnect diagram e Turbotronic software documentation e Cause and effect drawing e Mechanical interface drawing e Start Fuel Lube Air Drain and Enclosure system schematics Solar s Product Information Letter 184 Documentation for New Equipment provides a complete list of all the documentation supplied on a typical project Quality Control Data Book The QC data book typically includes the following e Inspection and test plan ITP Describes the quality assurance requirements for each product on a project basis Lists the primary controlling and verifying documents codes and standards used to define the quality requirements and identifies inspection points e Package certified test report 2008 Solar Turbines Incorporated All rights re
26. relatively low to ensure a long service life FUEL AIR Y COMPRESSOR Figure 4 Typical Combustion Process 3 1 2 SoLoNOx Combustion System COMBUSTOR TURBINE EXHAUST GEARBOX OPTIONAL DRIV EN EQUIPMENT The Titan 250 incorporates Solars proprietary SoLoNOx dry emissions system that reduces pollution by limiting the formation of nitrous oxides NOx carbon monoxide CO and unburned hydrocarbons UHC This system uses lean premix combustion to lower the maximum flame temperature and reduce pollution formation Solar s engineering staff will work with the customer to meet local permitting emission requirements Table 1 Titan 250 Gas Turbine Specifications Compressor Type Axial Flow Number of Stages 16 Compression Ratio 24 1 Flow Nominal 67 3 kg sec 148 Ib sec Speed Maximum 10 500 rpm Combustion Chamber Type Annular Ignition Torch Number of Fuel Injectors 14 SoLoNOx Low Emissions Gas Generator Type Axial Number of Stages 3 Power Turbine Type Axial Number of Stages 2 Speed 7000 rpm Bearings Radial 5 Tilt Pad with Proximity Probes Thrust 2 Tilt Pad with Resistance Temperature Device Probes 2008 Solar Turbines Incorporated All rights reserved 11 TPS250GS 908 Preliminary Turbomachinery Package Specification Titan 250 Generator Set Construction Materials Compressor Case Forwar
27. 0 to 60 C 40 to 140 F Space Heater Voltage 115 VAC 60 Hz Approximate Measurements Length 66 cm 26 in Diameter 45 7 cm 18 in Approximate Weight AC Starter Motor Assembly 450 kg 990 Ib Power Wiring VFD to Starter Motors Power Cable Length 38 m 123 ft See Note c Turning Gear Motor Motor Type Squirrel cage Induction Motor Voltage Rating 240 VDC Power 3 73 kW 5 hp Operating Speed 2500 rpm Turbine Rotation Speed 300 rpm 2008 Solar Turbines Incorporated All rights reserved 19 TPS250GS 908 Preliminary Turbomachinery Package Specification Titan 250 Generator Set Applicable Engineering Specifications Solar s Engineering Specification ES 1593 Guidelines for NEC Compliance of Solar Product Lines Class Group D Division 1 and Division 2 Solar s Engineering Specification ES 1762 Standards and Practices for Electrical Systems For Gas Turbine Packages Installed in Hazardous Areas CENELEC Standards Applicable Product Information Letters Solar s Product Information Letter PIL 149 Direct drive AC Start Systems Notes a If the customer furnished input voltage is greater than 600 VAC 5 a step down transformer is recommended b Feeder circuits exceeding this limit require the use of an isolation transformer line reactor or other means of adding similar impedance to limit fault current
28. 2 TITAN 250 GAS TURBINE GENERATOR SET essere ee eeenee eene nunne nunne nnn nnn 6 2 1 General Description e et 6 2 2 Package Description nite e cr ee Et e eL Ede lad e ce e eene d 6 2 3 Major Components and Gvstems eene nnne 6 3 TITAN 250 GAS TURBINE uoi eege Ee 10 3 1 General D scriptlOri creo croci te t te ok D erede e gee aes 10 4 REDUCTION DRIVE GEARBOX e eeeeeee eee eeeeen nennen nennen nannten nnn nn mnane nnmnnn nnmnnn na 13 4 4 General Description 5 ecrire te i aee repa se dee cde nean ree de nean age 13 5 GENERATOR AND ASSOCIATED EQUIPMENT eeeeeeeeeeeee eene 14 5 1 General Description e vert E ren i eder are p a Har d eet eee rud 14 5 2 Eunctiorial Description x ro err eode deer oed REDE REPE EE eR ran 14 6 START SYSTEM uius eer ENEE 17 6 1 General Description 17 6 2 Functional Descr pi OM aa aaa aa a a a aa eene 17 6 3 Backup Slow Rotation Gvstem eene ene 18 T VFUEL SYSTEM basics Stik eae eat Salant Anaad ce ait ea eas 21 T A General Description aie ett elt ie D Eed 21 8 LUBRICATION SYSTEM cree neir eren cen enne trc n rie aree Fn e oce un nnnc e Fn iuc xa enn are Eegen 24 8 1 General Description 24 9 TURBOTRONIC A CONTROL SYSTEM eere eeseeeee eene en nnne n nennen nn nn nnn nnn 29 MERI NC LEE 29 9 2 System Architecture ein cap ete ted ea en eee 29 9 3 Compo
29. 7 Bearing Lubrication System The generator is supplied with a force fed bearing lubrication system consisting of onskid piping and a filter strainer Oil is supplied from the package lube oil system Table 3 Generator and Associated Equipment Specifications Approximate Weight Generator Typical Open Drip Proof 45 000 kg 99 200 Ib Construction Types Open Drip Proof OPD Air Cooled Standard Closed Air Circuit Water to Air Cooled CACW Optional Closed Air Circuit Air Cooled CACA Optional Totally Enclosed Air to Air Cooled TEAAC Optional Totally Enclosed Water Air Cooled TEWAC Optional Generator Optional Voltage Ratings See Note a 11 000 12 470 or 13 800 VAC Frequency Ratings 50 or 60 Hz Number of Poles 4 Number of Leads 6 Connection Wye Stator Windings Form Wound Insulation National Electrical Manufacturers Association NEMA Class F Temperature Rise See Note b NEMA Class B Overload Capacity 15096 Rated Current for One Minute 110 Rated Current for Two Hours Overload Compliance NEMA Short Circuit Capability 30096 For 10 seconds Rotor Balance To 125 of Rated Speed Maximum Wave Form Deviation 1096 Maximum Harmonic Content 3 Telephone Influence Factor TIF Balanced 100 Residual 75 Efficiency The combined generator exciter and regulator efficiency at full load is nominally 97
30. CONTROL CENTER TT4000 VARIABLE FREQUENCY DRIVES TURBINE CONTROL PANEL PRIMARY CONTROL SYSTEM COMPONENTS ONSKID OPERATOR INTERFACE SERIAL LINK TO CONTROLLOGIX CONTOUR SUPERVISORY CONTROL TT4000S CONTROLNET OPERATOR PANEL DL d GENERATOR CONTROL MODULE BACKUP SHUTDOWN SYSTEM FIRE amp GAS SYSTEM VIBRATION MONITOR VO MODULES CONNECTIONS TO PACKAGE AND FIELD INSTRUMENTATION Figure 14 Turbotronic 4 System Architecture 9 3 Component Descriptions 9 3 1 Controller The ControlLogix controller running RSLogix 5000 software provides primary control Project specific programs are created in a Windows based system and uploaded to the controller The RSLogix 5000 software supports ladder and function block programming and complies with the International Electrical Code IEC 61131 3 standard for programmable controllers 9 3 2 ControlNet 1 5 Operating at 5 Mbps the network is repeatable and deterministic Cabling is redundant with two separate channels carrying the same information The maximum total length of the network is 1000 meters without the use of repeaters However this length decreases based on the number of nodes on the network A practical design limit is 800 meters 9 3 3 Input Output Modules Flex I O modules provide an interface between the package instrumentation and the processor Specific modules handle discre
31. Demand Rate 4 67 nm min 165 scfm Main Lube Oil Duplex Filters Type Self Supporting Pedestal Duplex Filters 10 Micron Certification ASME Section VIII Division 1 Backup Lube Oil Pump Filter Type Bowl Filter Minimum Maximum Operating Temperatures 54 to 135 C 65 to 275 F Simplex Filter p X gt 75 Micron Lube Oil Vent Coalescer Type Air Oil Mist Eliminator Maximum Working Temperature 93 C 200 F Orientation Vertical Performance 100 removal of all droplets greater than 3 microns and 99 5 removal of all droplets less than 3 microns Certification ASME Division 1 Approximate Dimensions Height x Diameter 198 1cm x 121 9 cm 77 9 in x 48 in Approximate Weight 1093 kg 2 410 Ib Lube Oil Vent Flame Arrestor Orientation Vertical See Note f Approximate Dimensions Height x Width x Diameter 32 cm x 23 cm x 22 cm 13 in x 9 in x 9 in Approximate Weight 11 kg 25 Ib Strainers Tank Fill 20 mesh Gearbox Breather Vent If Applicable 40 mesh Gas Producer Start Up Strainer 70 Micron See Note g Gearbox Start Up Strainer If Applicable 70 Micron See Note g Compressor Driven End Start Up Strainer 70 Micron See Note g Compressor Exciter End Start Up Strainer 70 Micron See Note g Lube Oil Viscosity Grade ISO VG 32 C32 Use When Ambient Temperature is
32. NS 5 iicet ecc cedo Eggs AE dee 77 LIST OF SOLAR S ENGINEERING SPECIFICATIONS c cecceeseeeeeeeseceeeseseeeeeeseseenenseeeeees 80 LIST OF SOLAR S PRODUCT INFORMATION LETTERS eese errem 80 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary Turbomachinery Package Specification Titan 250 Generator Set Table of Figures Figure 1 Typical Titan 250 Gas Turbine Generator Get 6 Figure 2 Typical Titan 250 Generator Set Service Connections Driver Skid 8 Figure 3 Titan 250 Two Shaft Gas Turbine Cutaway eme 10 Figure 4 Typical Combustion Process 11 Figure 5 Typical Reduction Gearbox for the Titan 250 Generator Get 13 Figure 6 Typical Open Drip Proof Generator with Permanent Magnet Exciter System 14 Figure 7 Direct Drive AC Starter Motor and VFD Cabinet 17 Figure 8 Typical Direct Drive AC Start Gvstem 18 Figure 9 Turning Gear Assembly usss rassaa d pt rei pt er a e ee 18 Figure 10 Typical Fuel System Schematic sssssssseee emen 21 Figure 11 Typical Lube Oil System 26 Figure 12 Typical Onskid Control Gvstem ener 30 Figure 13 Typical Offskid Control Gvsiem emere 30 Figure 14 Turbotronic 4 System Architecture emen 31 Figure 15 Typical TT4000 Operation Summary Display Screen ssseeeeseeeesseerreseersreerresrenn 35 Figure 16 Typical TT4000 Strip Chart Display emen 35 Figure 17 Typ
33. Occupational Safety and Health Administration OSHA e National Fire Protection Association NFPA e Underwriters Laboratories Incorporated UL e American Society of Mechanical Engineers ASME e National Association of Corrosion Engineers NACE The following OSHA approved Nationally Recognized Testing Laboratories NRTLs provide approval for codes and standards e Underwriters Laboratories Incorporated UL e Factory Mutual FM e Canadian Standards Association CSA when certifying to U S standards e Entela Incorporated ENTELA CSA and UL also develop and promulgate standards The NEC establishes classification of hazardous sites in terms of Classes Divisions Zones and material Groups Class covers locations where flammable gases may be present in quantities sufficient to ignite Division 1 covers situations where flammable gases may be present as part of a process while Division 2 covers locations where flammable gas is less likely to be present Generator packages are designed for use in Class Division 2 hazardous locations 18 3 Canadian Electrical Code For installations that require Canadian Electrical Code CEC certification Solar complies with the CEC codes and standards adopted by local authorities and government entities Sources for these codes and standards include e Canadian Standards Association CSA electrical requirements only e Entela Inc ENTELA when certifying to Canadian standards e Underwriters Laboratories
34. POST PUMP PUMP LEGEND DPT DIFFERENTIAL PRESSURE TRANSMITTER FG FLOW GAUGE SIGHT GLASS LT LEVEL TRANSMITTER RT TEMPERATURE DEVICE RTD PT PRESSURE TRANSMITTER FILTER 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 25 Turbomachinery Package Specification Titan 250 Generator Set Figure 11 Typical Lube Oil System 8 1 7 Lube Oil Vent Flame Arrestor The lube oil vent flame arrestor prevents an ignition source from entering the lube oil tank The flame arrestor is loose shipped for offskid installation by others 8 1 8 Lube Oil System Options Lube Oil Cooler An air to oil type cooler is available to provide oil cooling for the gas turbine and the driven equipment The cooler is sized for specified heat loads and ambient temperatures and is designed for a 4 4 C 40 F approach temperature The cooler is loose shipped for offskid installation by others Lube Oil Immersion Tank Heater The lube oil tank immersion heater ensures the lube oil tank temperature is adequate for starting in cold conditions The tank heater also facilitates a short lube oil temperature warm up period after a cold start Electrical supply contactors are not included Table 6 Lubrication System Specifications Main Lube Oil Pump Pump Type Engine Driven Rotary Screw Flow 1999 Ipm 528 gpm Discharge Pressure 690 kPag 100 psig See Note a Pre Post Lube Oil Pump Pump Type AC Motor Driven Cent
35. ROL MODULE Es 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 41 Turbomachinery Package Specification Titan 250 Generator Set 10 2 2 10 2 3 10 2 4 10 2 5 During initial turbine generator acceleration the excitation power is switched off At approximately 80 speed the PMG output is connected to the excitation power contacts and voltage begins to build The CGCM then provides controlled exciter field current at a level to maintain the generator terminal voltage at a predetermined value established by the operator A potential transformer usually supplied with the switchgear provides a voltage level signal to the CGCM By sensing the generator output voltage and controlling the power to the brushless exciter the CGCM automatically maintains the generator output voltage at a constant level at all load conditions Since the PMG output power is independent of the main generator line voltage and current levels there is no need for additional auxiliary equipment to provide power to the CGCM during transient conditions The PMG provides sufficient generator terminal voltage during conditions of high generator line current to allow for selective tripping during a short circuit condition Current potential and cross current transformers required for input to the CGCM are not included A cross current compensating circuit is included to accommodate reactive load sharing between multiple turbine ge
36. Solar s Quality department and approved by DNV at the beginning of a project To eliminate redundant inspections Solar has established a manufacturing survey arrangement MSA with DNV for a specific group of products This MSA is based on a DNV audit of Solar s Quality System The MSA authorizes Solar to carry out a specific level of inspections and tests without the presence of a DNV representative American Bureau of Shipping The American Bureau of Shipping ABS performs design appraisals and inspections Typically ABS certification is performed according to ABS Guide for Building and Classing Facilities on Offshore Installations 1991 ABS certification of Solar s gas turbines is based on compliance with the American Petroleum Institute API Standard 616 with standard exceptions Lloyd s Register of Shipping Typically Lloyd s Register LR of Shipping performs design appraisals and manufacturing surveys LR recognizes engine type approvals provided by DNV LR s test and inspection witness points are defined in the project Inspection and Test Plan ITP Bureau Veritas Bureau Veritas BV performs design appraisals and manufacturing surveys Typically BV certification is performed according to BV publication Floating Production Storage and Offloading Units Ch 10 NR456 April 1998 Certification of Solar s gas turbines is based on compliance with the American Petroleum Institute API Standard 616 with specified ex
37. Solar Turbines TITAN 250 A Caterpillar Company Turbomachinery Package Specification Oil amp Gas and Power Generation Applications Generator Set Solar Turbines A Caterpillar Company TURBOMACHINERY PACKAGE SPECIFICATION Titan 250 Generator Set Solar Turbines Incorporated P O Box 85376 San Diego CA 92186 5376 Caterpillar is a trademark of Caterpillar Inc Solar Titan SoLoNOx and Turbotronic are trademarks of Solar Turbines Incorporated All other trademarks service marks or registered trademarks appearing in this specification are the intellectual property of their respective companies Specifications are subject to change without notice Direct customers of Solar Turbines Incorporated that receive this Turbomachinery Package Specification directly from Solar Turbines Incorporated may make limited copies of parts of this specification for use in the creation of their own specification documents However such customers shall not distribute any part of this Turbomachinery Package Specification outside their own organizations for any other purpose Any other use without the permission of Solar Turbines Incorporated is strictly prohibited 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary Turbomachinery Package Specification Titan 250 Generator Set Table of Contents 1 INTRODUCTION erc 5 1 1 EE IR RE dee 5 1 2 OVeEVIOW Rc Dette tr Deest enden fes euis testi Meroe s 5
38. Turning Gear Assembly 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 18 Turbomachinery Package Specification Table 4 Start System Specifications Titan 250 Generator Set Variable Frequency Drive Optional Voltage Input Ranges See Note a 380 to 460 VAC 48 to 62 Hz 500 to 600 VAC 48 to 62 Hz Minimum Input Current 380 to 460 VAC Input 525 amps 500 to 600 VAC Input 342 amps Voltage Output Range 0 to 460 VAC 0 to 240 Hz Maximum Line Distribution Capacity 1000 kVa Maximum Fault Current Capacity See Note b 30 000 amps Maximum Breakaway Amperage 383 amps Maximum Breakaway Torque 918 N m 677 ft Ib Power Factor 0 96 Efficiency 98 Minimum Maximum Operating Temperature 10 to 40 C 14 to 104 F Heat Rejection 380 to 460 VAC Input 7350 watts 500 to 600 VAC Input 9485 watts Input Fuse Rating 600 amp Approximate Measurements Height 220 cm 87 in Width 69 cm 24 in Depth 60 cm 28 in Approximate Weight 28 831 kg 850 Ib Length 73 cm 29 in Diameter 46 cm 18 in Starter Motor Motor Type Squirrel cage Induction Motor Voltage Rating 380 AC 0 to 133 Hz Power 93 kW 125 hp Operating Speed 0 to 7000 rpm Maximum Breakaway Amperage 659 amps Maximum Breakaway Torque 488 N m 360 ft lb Minimum Maximum Operating Temperature 4
39. Weight Gearbox 7300 kg 16 100 Ib Output Speed 50 Hz Service 1500 rpm 60 Hz Service 1800 rpm Inspection and Overhaul Intervals Major Inspection Interval 30 000 hours Overhaul Interval 100 000 hours Compliance American Petroleum Institute API 613 Compliant With Exceptions Refer to Solar s Standard List of Exceptions Ratings American Gear Manufacturers Association In Excess of 1 10 for Generator Applications AGMA Vibration Monitoring Gearbox Acceleration Probe 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 13 Turbomachinery Package Specification Titan 250 Generator Set 5 Generator and Associated Equipment 5 1 General Description For maximum flexibility the gas turbine package can be provided with several different generator types and voltage outputs to accommodate a broad range of application requirements The generator exciter and control system are integrated to provide optimal performance The standard generator type supplied is open drip proof ODP Figure 6 However the following other enclosure types are available to meet a variety of environmental conditions and cooling requirements e Closed air circuit air cooled CACA e Closed air circuit water to air cooled CACW e Totally enclosed air to air cooled TEAAC e Totally enclosed water to air cooled TEWAC GENERATOR STATOR WINDINGS
40. at 15 C 59 F Sea Level No Inlet Exhaust Losses Relative Humidity at 60 LHV 31 5 to 43 3 MJ nm 800 to 1 100 Btu scf 2008 Solar Turbines Incorporated All rights reserved 12 TPS250GS 908 Preliminary Turbomachinery Package Specification Titan 250 Generator Set 4 Reduction Drive Gearbox 4 1 General Description The reduction drive gearbox Figure 5 is an industrial epicyclic star gear design selected specifically for generator set applications The gearbox uses few moving parts which provides high reliability and ease of assembly and disassembly The reduction gearbox is designed for continuous duty operation and reduces the output speed of the turbine to the required operating speed of the generator The gearbox is coupled to the gas turbine through a balanced high speed shaft splined at both ends The output shaft is coupled to the generator through a flexible disk type dry coupling enclosed in a coupling guard The design of the gearbox facilitates straight through shafting avoiding offset problems and permitting engine gear and generator alignment from a common base Gear lubrication is provided by the package lube oil system The gearbox is designed to provide 99 reliability between major inspections and overhauls Figure 5 Typical Reduction Gearbox for the Titan 250 Generator Set Table 2 Reduction Drive Gearbox Specifications Approximate
41. ation is by ship e Transportation includes transshipment package will go from truck to barge to truck etc e g rigorous loads will be encountered during shipment e Package will be exposed to severe weather conditions during transport Short term preservation is required if e Equipment will be stored in an improved storage area for less than 90 days before installation e Transportation is not by ship e Transportation does not include transshipment package will not go from truck to barge to truck etc e g rigorous loads will not be encountered during shipment e Package will not be exposed to severe weather conditions during transport 17 3 Site Requirements Solar s gas turbine generator sets require minimal site preparation The Titan 250 generator set is supplied with self contained systems for starting fuel lube oil and control minimum piping and wiring connections are required for installation All service connections are conveniently located on the outer edge of the skid 17 4 Mechanical Installation Requirements 17 4 1 Mounting Correct mounting of the gas turbine package is vital to successful package installation and requires adequate preparation by the user The site pad thickness is governed by soil condition and the weight of the gas turbine package air inlet system and exhaust system Mounting pad locations and weights will differ with each package depending upon selected options and will be clearly shown on the installation dr
42. ation of ducting must not allow exhaust gas to be drawn into the gas turbine inlet e Capability to purge the complete exhaust system prior to gas turbine lightoff For short simple exhaust systems purging should be designed to accomplish three air volume changes For large complex exhaust systems purging should be designed to accomplish five air volume changes either through gas turbine cranking or supplementary exhaust blowers When exhaust silencing is required provisions must be made to adequately mount and support the equipment and limit the exhaust silencer pressure loss Exhaust Silencer Solar can provide a silencer with support structure and ducting suitable for connection to the radial exhaust of the Titan 250 generator set Brackets are available for mounting the silencer in a vertical or horizontal position Turbine Exhaust Heat Recovery System High thermal efficiencies can be obtained by using the gas turbine exhaust heat energy There are several methods for using the exhaust heat and attaining greater than 8096 fuel utilization The methods used and the efficiencies achieved are primarily dependent on the type of application The most common uses are 1 Producing steam with a heat recovery steam generator HRSG or heating a process fluid with a heat recovery fluid heater 2 Using the gas turbine exhaust as a source of preheated combustion air in a boiler or furnace the gas turbine exhaust contains 15 18 oxygen 3
43. ator Set 9 5 4 9 5 5 9 5 6 9 5 7 Minute Log data are read and stored at one minute intervals for the previous 62 days one file for each day 10 Second Log data are read at 10 second intervals for the previous 31 days one file for each day Trigger Log data are read at one second intervals for 6 minutes before a trigger event that is defined in the software The standard trigger is a shutdown Six minutes before the trigger of data are written to a file Up to 50 trigger logs files can be stored TT4000 Display Language In addition to English dual language screens are available with English and Spanish Latin America Portuguese Brazil French German or Chinese simplified Other languages can be provided as custom features TT4000 Operating Modes There are two operating modes for the TT4000 software Design Time and Run Time Design Time is used to create or modify a project s working files Run Time uses those files in the normal equipment operation Supervisory Control Interfaces The Turbotronic 4 control system can transmit data to and receive control instructions from a supervisory control system All analog data and the status of all discrete values are available for transmittal Interface modules mount in the controller rack and connect through the rack s backplane Available connections are e ControlLogix 1 5 e Ethernet e Data Highway Plus e Modbus System Programmability The Turb
44. ator set is in parallel with a large power source When kW import control is enabled the control system monitors the load imported from the utility and adjusts the turbine generator set fuel flow to maintain a preset amount of imported power When it is not desirable to export power to the utility KW import control is normally selected While in parallel with a 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 42 Turbomachinery Package Specification 10 2 6 2008 Solar Turbines Incorporated All rights reserved Titan 250 Generator Set large power source protection against excessive kW load is provided by turbine T5 temperature control Generator Metering Panel Optional Mounted on the front of an optional control console the generator metering panel Figure 20 provides meters to monitor generator output and switches to manually adjust generator voltage and to synchronize the generator breaker to the bus The metering panel typically includes the following analog meters lights and switches AC ammeter Frequency meter KW kVAr meter AC voltmeter Power factor meter Synchroscope Exciter field ammeter Exciter field voltmeter Manual synchronizing lights Manual synchronizing switch Generator breaker Open Close switch Generator breaker Open Close status lights Automatic synchronization switch optional Automatic synchronization fail light optional Generator line to line voltm
45. awings The equipment layout should provide adequate floor space for major components with sufficient room around the package for routine maintenance access 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 66 Turbomachinery Package Specification Titan 250 Generator Set 17 4 2 17 4 3 17 4 4 17 4 5 17 5 17 5 1 Alignment Tooling As an option alignment tooling can be provided to align the reduction gearbox output shaft hub to the generator input shaft hub The alignment tooling includes a dial indicator kit gearbox to generator alignment tool axial distance gauge and custom storage container Lube Oil Cooler s The lube oil cooler s is are not integral with the package and must be located and installed separately Gas Turbine Air Inlet System The gas turbine air inlet should be located so that entry of gas turbine exhaust oil tank vent vapor or other contaminants is minimized The air inlet duct must be free of accumulated water prior to starting the gas turbine Gas Turbine Exhaust System The importance of having an exhaust system properly installed cannot be overemphasized A poorly installed exhaust system can cause a loss of power and impose severe mechanical strains on the gas turbine The exhaust duct system must be terminated in a manner that precludes recirculation of exhaust products through the gas turbine air inlet or oil cooler Exhaust installation considerations
46. bine combustion process requires a steady and consistent flow of clean air Proper gas turbine inlet air filtration is critical to gas turbine life Careful consideration should be given to selecting the appropriate air filtration system Solar offers several air filtration systems that conform to a broad range of operating requirements For unenclosed packages the turbine air inlet can be mounted on the right hand or left hand side of the package in a vertical or 45 degree angle to vertical position For enclosed packages the air inlet must be in the vertical position Figure 25 shows typical Titan 250 air inlet and exhaust systems Figure 25 Typical Titan 250 Turbine Air Inlet and Exhaust Systems 12 1 1 Prefilter and Barrier Inlet Air Filter The prefilter and barrier inlet air filter system is suitable for moderate environments This system features vertical moisture eliminators direct contact prefilter elements and high efficiency barrier filter elements Access doors are provided in the filter housing for servicing A weather hood and insect screens are available as options 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 52 Turbomachinery Package Specification Titan 250 Generator Set 12 1 2 12 1 3 12 1 4 12 1 5 12 1 6 Insect Screens Optional insect screens can be installed on each side of the air inlet filters except for self cleaning filters This option is used with the ai
47. c flux produced by the stationary field The stationary field is wound on salient poles supported by the stator core or frame The PMG consists of permanent magnets on the generator rotor and a stationary armature also supported by the generator frame The rotating rectifier assembly rectifies the exciter armature AC output to DC In turn the DC power is applied to the main generator rotating field windings The complete exciter is enclosed and protected by a removable cover When the rotor operates at synchronous speed the PMG provides power to the CGCM The CGCM provides the appropriate exciter field current to control the exciter armature output which is rectified to provide DC power to the main generator rotating field winding GENERATOR CIRCUIT GENERATOR BREAKER GENERATOR ARMATURE Stationary GENERATOR FIELD RECTIFIER ASSEMBLY EXCITER ARMATURE BEE EES PERMANT MAGNET GENERATOR ROTATING PORTION EXCITATION OUTPUT LOAD SHARE LINES To Turbotronic 4 Control Processor Figure 19 Typical Generator Exciter and Generator Control Module Arrangement EXCITER FIELD Stationary GENERATOR GENERATOR CROSS CURRENT BUS POTENTIAL CURRENT COMPENSATION POTENTIAL TRANSFORMERS TRANSFORMERS TRANSFORMER TRANSFORMERS EXCITATION POWER To other Combined Generator Control CONTROLNET Module or Load Share Module COMBINED GENERATOR CONT
48. cal Certifications CSA LR 77954 Solar s Applicable Engineering Specifications ES 9 62 Ingestive Cleaning Solar Gas Turbine Engines ES 2416 DC Supply Systems 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary Turbomachinery Package Specification Titan 250 Generator Set 15 Marinization 15 1 General Description The Titan 250 generator sets may be operated in offshore oil and gas applications Depending upon operating conditions and movement of the underlying support structure optional package modifications may be required Solar turbomachinery packages operate successfully on the following types of offshore installations e Fixed platform FP e Tension leg platform TLP e Compliant tower CT e Spar platform SP e Semi submersible platform SSP e Floating production systems FPS e Floating production storage and offloading FPSO e Mini tension leg platform Mini TLP Applications are evaluated based on the expected motion severity and the degree of package mounting surface flexing Solar offers the following package modifications to achieve successful long term operation 15 1 1 Package Sub base As a standard the Titan 250 package is suitable for three point mounting In severe cases a substructure may be required to provide additional package rigidity to protect equipment and to maintain proper alignment of the driver and driven equipment 15 1 2 Gimba
49. cal support via Solar s global Customer Information Network e Factory qualified repair and overhaul procedures e Genuine Solar Certified Parts e Worldwide field service personnel and service facilities e Around the clock response e Exchange engine program to minimize your downtime Solar stands behind each of our customers with uncompromising commitment to the success of their turbomachinery installations throughout the equipment s life cycle 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 74 Turbomachinery Package Specification Titan 250 Generator Set 19 3 19 4 Contract Power and Leasing Services Solar offers numerous financing options All or part of a project can be financed offered under a lease agreement or installed on a service tariff with a performance contract Financing or leasing terms can extend from short term rentals to long term leases of 10 years or more Financing can be structured as full payout financing instruments that lead to ownership or as off balance sheet operating leases that can allow for the return of the equipment at the end of the lease Under a performance contract Solar may supply install operate maintain and own the equipment as well as auxiliary components required to provide the service such as electric power steam or compressed gas The tariff charged by Solar is based on the amount of service delivered Solar has extensive worldwide background in financi
50. ceptions 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 72 Turbomachinery Package Specification Titan 250 Generator Set 18 7 Summary Solar has a continuing program to support customers in ensuring that Solar s products conform to applicable codes and regulations Solar also has the resources to provide customer guidance and assistance in this process Table 16 Certification Specifications Solar s Applicable Engineering Specifications ES 1593 Guidelines for NEC Compliance of Solar Product Lines Class Group D Division 1 and Division 2 ES 2231 Standards and Practices for The Design and Installation of Cable Channels and TC Rated Cables Installed In Class 1 Division 2 Hazardous Areas Solar s Applicable Product Information Letters PIL 127 Product Certification 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 73 Turbomachinery Package Specification Titan 250 Generator Set 19 Support Services 19 1 Construction Services Solar s Construction Services organization offers a comprehensive range of equipment and services to successfully meet power system expectations and needs Our experience takes us to many parts of the world onshore and offshore managing various types of power configurations Our services are based on years of experience and expertise in power system engineering and complete project management that inc
51. condition such as a 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 24 Turbomachinery Package Specification Titan 250 Generator Set fire control system failure emergency stop or if a turbine over speed is detected by the backup system 8 1 5 Duplex Lube Oil Filter System The duplex lube oil filter system is supplied with a filter transfer valve and filter differential pressure indication with alarm The transfer valve allows a filter transfer to be performed while the gas turbine is running The lube oil filter system is contained completely within the skid The interconnect piping between the skid edge and the offskid oil cooler if applicable is not provided 8 1 6 Lube Oil Vent Coalescer An offskid lube oil vent coalescer is provided to remove oil vapor from the lube oil tank vent airflow The coalescer drains trapped oil vapor back to the lube oil tank and allows the remaining vent airflow to exhaust to the atmosphere A tank overpressure alarm and shutdown are also included The lube oil vent coalescer is loose shipped for offskid installation by others Oo CO NENNEN THRUST BEARING KE J fe GENERATOR 8 COUPLING GEARBOX 0 DUPLEX Y LUBE OIL x FILTER SCAVENGE LUBE OIL PUMP SYSTEM MARINE APPLICATIONS i E FLAME ARRESTER VENT e DEMISTER COOLER CONTROL VALVE LUBE OIL COOLER MAIN LUBE OIL PUMP BACKUP PRE
52. d Section Nodular Iron Aft Section WCE6 Alloy Steel Combustor Case 410 Stainless Steel Exhaust Diffuser Nodular Iron Accessory Gear Housing Ductile Iron Protective Coatings Compressor Rotor and Stator Blades Inorganic Aluminum Nozzles First and Second Stage Precious Metal Diffusion Aluminide Blades First and Second Stage Precious Metal Diffusion Aluminide Approximate Weight Gas Turbine Assembly 19 050 kg 42 000 Ib Performance Output Power Note a 22 370 kW 30 000 hp Heat Rate 9000 kJ kW hr 6360 Btu kW hr Exhaust Flow 245 660 kg hr 541 590 Ib hr Exhaust Temperature 465 C 865 F Temperature Monitoring Turbine T5 12 Thermocouples Vibration Monitoring Turbine Bearing 1 Displacement Probes X and Y axis Turbine Bearing 2 Displacement Probes X and Y axis Turbine Bearing 3 Displacement Probes X and Y axis Turbine Bearing 4 Displacement Probes X and Y axis Turbine Bearing 5 Displacement Probes X and Y axis Gas Producer Rotor Shaft Displacement Probe Axial Position Power Turbine Rotor Shaft Displacement Probe Axial Position Gas Producer Rotor Shaft Keyphasor Power Turbine Rotor Shaft Keyphasor Accessory Gearbox Velocity Pickup Notes b Performance is calculated under the following conditions Nominal Rating ISO
53. d are located on the package skid for the onskid controls configuration or in an auxiliary console for the offskid configuration 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 29 Turbomachinery Package Specification Titan 250 Generator Set AUXILIARY CONSOLE METERING PANEL TURBINE CONTROL PANEL TT4000 PACKAGE SKID TT4000S REMOTE DESKTOP L OPERATOR PANEL COMPUTER o S S et CONTROLNET ETHERNET TT4000 CONTROL PROCESSOR UO MODULES BACKUP SHUTDOWN SYSTEM FIRE amp GAS SYSTEM VIBRATION MONITOR AUXILIARY DESKTOP COMPUTER GENERATOR CONTROL MODULE TT4000 Figure 12 Typical Onskid Control System AUXILIARY CONSOLE METERING PANEL TURBINE CONTROL PANEL TT4000 PACKAGE SKID REMOTE DESKTOP COMPUTER CONTROLNET ETHERNET TT4000 TT4000S OPERATOR PANEL CONTROL PROCESSOR e UO MODULES BACKUP SHUTDOWN SYSTEM FIRE amp GAS SYSTEM VIBRATION MONITOR GENERATOR CONTROL MODULE Figure 13 Typical Offskid Control System 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 30 Turbomachinery Package Specification Titan 250 Generator Set SAFE AREA OPERATOR INTERFACE MOTOR
54. dges 3 37 m 11 ft 1 in Width including lifting bollards 3 60 m 11 ft 10 in Length Engine Skid 10 29 m 33 ft 9 in Length Generator Skid Approximate Package Weights AC Start Motor Assembly 450 kg 990 Ib Gas Turbine Assembly 19 050 kg 42 000 Ib Total Driver unenclosed package without oil 49 900 kg 110 000 Ib Total Driver enclosed package without oil 57 600 kg 127 000 Ib Generator unenclosed Piping and Tubing Thickness Piping 76 2 mm 3 in Nominal Pipe Size NPS Schedule 40 Unless Otherwise Specified Piping lt 50 8 mm 2 in NPS Schedule 80 Unless Otherwise Specified Tubing 3 175 mm 0 125 in Nominal Tubing Size NTS 0 889 mm 0 035 in Minimum Wall Thickness Tubing 6 35 mm 0 25 in NTS 1 245 mm 0 049 in Minimum Wall Thickness Tubing 12 7 mm 0 50 in NTS 1 651 mm 0 065 in Minimum Wall Thickness Tubing 19 05 mm 0 75 in NTS 1 651 mm 0 065 in Minimum Wall Thickness Tubing 25 40 mm 1 00 in NTS 2 108 mm 0 083 in Minimum Wall Thickness Tubing 31 75 mm 1 25 in NTS 2 768 mm 0 109 in Minimum Wall Thickness 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary N DRIVEN 7 V EQUIPMENT Turbomachinery Package Specification Titan 250 Generator Set Construction Materials Piping Manifolds and Tubing lt 10 2 cm 4 in Note a 316L Stainless Steel Unle
55. e Oil tank vent flame trap Optional features include e Offskid oil cooler e Stainless steel oil tank and tank covers e Stainless steel filter system 8 1 1 Lube Oil Lube oil is customer furnished Petroleum base or synthetic oil with a viscosity grade of C32 or C46 may be used Synthesized hydrocarbon oils are recommended due to lower pour point higher viscosity index better heat transfer and lower oxidation rate Lube oil must conform to Solar s Engineering Specification ES 9 224 8 1 2 Gas Turbine Driven Main Lube Oil Pump The main lube oil pump is mounted on an integral accessory drive gearbox This positive displacement pump provides lube oil pressure for normal operation 8 1 3 AC Motor Driven Pre Post Lube Oil Pump The pre post lube oil pump provides lube oil pressure during package starting and for post lube cooling of the gas turbine and driven equipment bearings The pre post lube oil pump provides lube oil pressure during a gas turbine roll down in the event the main lube oil pump has failed 8 1 4 DC Motor Driven Backup Lube Oil Pump The backup lube oil pump provides lube oil pressure for post lube cooling of the gas turbine and driven equipment bearings in the event the pre post lube oil pump fails The backup lube oil pump provides lube oil pressure during a gas turbine roll down in the event the main lube oil pump and pre post lube oil pump have both failed The backup lube oil pump also provides lube oil pressure during an emergency
56. e Third stage high efficiency bag filters e Fourth stage marine vane separator moisture eliminator Access doors are provided in the first stage marine vane separator moisture eliminator for filter removal Standard features include e High performance drainage system e Transition outlet flange e Lifting lugs e Instrumentation panel e Differential pressure gauge e Electrical connections prewired to a common junction box e High differential pressure alarm and shutdown switches Air Inlet Silencer Optional air inlet silencers can be incorporated into the air inlet ducting to reduce noise levels Typical installations include one air inlet silencer Air Inlet Ducting and Support An optional support structure and ducting can be provided for offskid support of the air inlet filter and silencer assembly Attaching hardware and a tube of sealant are provided for one flange per duct 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 53 Turbomachinery Package Specification Table 10 Air Inlet System Specifications Titan 250 Generator Set Air Inlet System Pressure Drop Less Than 102 mm 4 in H2O with a Clean Air Filter Ducting Loads Should Not Be Applied In Any Direction Prefilter and Barrier Inlet Air Filter Pressure Drop Clean 44 mm 1 75 in water Fouled 127 mm 5 in water Self Cleaning Barrier Type Air Filter Fluid Clean Dry Air
57. e Veritas ENTELA Entela Incorporated ES Engineering Specification EU European Union FM Factory Mutual FP Fixed Platform fos Feet Per Second FPS Floating Production Systems FPSO Floating Production Storage and Offloading ft lb Foot Pound ft IbzIb Foot Pound Force Pound Mass ft s Feet Second F Degrees Fahrenheit gal Gallon hp Horsepower 2008 Solar Turbines Incorporated All rights reserved 77 TPS250GS 908 Preliminary Turbomachinery Package Specification Titan 250 Generator Set Abbreviations Cont HRSG Heat Recovery Steam Generator IEC International Electrotechnical Commission IEEE Institute of Electrical and Electronic Engineers in Inch in Hg Inches of Mercury in H20 Inches of Water IP Ingress Protections IR Infrared IS Intrinsically Safe ISO International Standards Organization Isoch Isochronous ITP Inspection and Test Plan kcal Kilocalorie kg Kilogram kJ Kilojoule kPa Kilopascal ksi 1000 pounds square inch kw Kilowatt L Liter LR Lloyd s Register m Meter mm Millimeter MMSCFD Millions of Standard Cubic Feet Day MPa Mega Pascal Mph Miles per Hour MRP Manufacturing Resource Planning MSA Manufacturing Survey Arrangement m Square Meter m Cubic Meter m min Cubic Meters Minute N Newton N m Pascal NACE National Association of Corrosion Engineers NEC National Electrical Code NEMA National Electrical Manufacturers Association NFPA U S National Fire Protection Agency Ng
58. eal time data acquisition system that collects digital and analog data from the engine during acceptance testing to facilitate a comprehensive test report Test Phases Solar s production test facilities provide a three phase test program The first phase uses simulation equipment to perform static testing of the control console and package Systems to verify electrical and fluid system continuity and calibration The second phase consists of interconnecting the package and control console if applicable to undergo additional simulated systems testing of the total package In the final phase the package is controlled and monitored by its own control console and the computerized test facility Generator Package Acceptance Testing The basic package assembly which includes the gas turbine reduction drive gearbox generator package mounted accessories and control console are tested as a complete System to ensure proper integration and function in accordance with Solar s package test specifications Results are recorded and maintained by Solar The acceptance test generally includes the following e Starting and combustion cycles e Lubricating oil system temperature and pressure measurements 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 63 Turbomachinery Package Specification Titan 250 Generator Set e Vibration measurements e Power and heat rate measurements at partial and full load under ambien
59. equirements Critical Parts Engine and Related Systems ES 2231 Standards and Practices for The Design and Installation of Cable Channels and TC Rated Cables Installed In Class 1 Division 2 Hazardous Areas Solar s Applicable Product Information Letters PIL 184 Documentation for New Equipment PIL 097 Package Preservation and Preparation for Shipment Notes a This is to prevent oil tank flooding in the event of a drain back 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 69 Turbomachinery Package Specification Titan 250 Generator Set 18 Certification 18 1 General Description Solar s leadership in the gas turbine industry is supported by its ability to comply with regulations codes and standards required by industry and or regional authorities around the world Solar continually evaluates compliance requirements to ensure conformance to the following standards e National Electrical Code NEC e Canadian Electrical Code CEC e Conformit Europ enne CE Mark e International Electrotechnical Commission IEC Safety Assessment e Australian New Zealand Standard AS NZS 3000 Wiring Rules e Offshore Marine Applications 18 2 National Electrical Code For installations that require National Electrical Code NEC certification Solar complies with the NEC codes and standards adopted by local authorities and government entities Sources for these codes and standards include e
60. erved TPS250GS 908 Preliminary 45 Turbomachinery Package Specification Titan 250 Generator Set 11 2 11 2 1 11 2 2 11 2 3 11 2 4 11 2 5 11 2 6 11 3 11 3 1 11 3 2 Standard Features Inlet and Exhaust Ventilation Silencers The enclosure ventilation openings are equipped with silencers with weather louvers Single Fan Ventilation A single high efficiency motor driven fan provides enclosure ventilation The ventilation fan provides airflow to ensure the enclosure internal air temperature remains within acceptable limits Fan size can vary depending on the ventilation system filtration configuration Fan motor wiring is terminated at the motor junction box Enclosure ventilation openings are provided to facilitate airflow circulation For additional ventilation or certification requirements a dual fan ventilation system may be selected as an option Enclosure High Temperature Alarm A heat sensor completely separate from the fire system thermal detectors is mounted in the enclosure The sensor is set to activate an alarm if enclosure temperature is abnormally high Pressurization System The ventilation airflow through the enclosure can be controlled to provide either positive or negative pressure relative to the outside pressure Hazardous area classifications and the applicable codes and regulations will determine the pressurization requirements for specific projects Lighting Fluorescent lighting is pr
61. eter select switch Kilowatt KW and kilovolt amp reactive KVAr power meter select switch Generator phase current ammeter select switch All data indicated by the metering panel is also indicated on the video display terminal 7 RK MOM SS AS d Q BS s A s y Oy 4767 07 07 Q n t 7 E di Pd TPS250GS 908 Preliminary 43 Turbomachinery Package Specification Titan 250 Generator Set Figure 20 Typical Generator Metering Panel 10 2 7 10 2 8 Generator Vibration and Temperature Monitoring X and Y proximity probes are mounted in the generator exciter and driven end bearings These probes are monitored continuously by the control system Alarm and shutdown levels are set to protect the generator from excessive vibration levels Resistance temperature devices RTDs are mounted in the generator exciter and driven end bearings Two RTDs are also imbedded in each of the three stator winding phases One RTD is connected to the control system and the other is provided as a spare Alarm and shutdown levels are set to protect the generator from excessive temperature levels Redundant Combined Generator Control Module Optional A second CGCM can be provided to function as a hot backup to the primary CGCM The system is configured for automatic transfer to the second CGCM in the event the primary CGCM fails All control protection and
62. ging and Sagging 0 3833 mm m 0 0046 in ft Deck Twist 0 0198 m 0 006 ft Angular Displacement and Acceleration Limits Moderate Severe Duty Sac DUY Duty Parallel Perpendicular Maximum Permissible Angular Displacements Dynamic Pitch Period 2 13 sec 7 5 9 sec 10 9 sec 7 5 9 sec Roll Period 2 13 sec 7 5 13 sec 22 5 13 sec 10 13 sec Static Trim 2 5 5 5 List 2 5 15 5 Maximum Permissible Accelerations Operating t0 1g 0 5 9 1 0g 1 0g Survival 0 5g 1 0g 1 5g 1 5g 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 62 Turbomachinery Package Specification Titan 250 Generator Set 16 16 1 16 2 16 2 1 16 2 2 Quality Assurance and Testing Quality Assurance Solar is an International Organization for Standards ISO 9000 company with ISO 9001 2000 and 9002 certification Several Solar gas turbine models and manufacturing processes have been type certified In recognition of Solars commitment to quality Solar has received Manufacturing Resource Planning MRP II Class A certification and the Malcolm Baldrige National Quality Award Solar has developed a comprehensive set of specifications to address areas such as engineering requirements manufacturing and assembly standards and test procedures and acceptance criteria Upon request Solar will evaluate customer required standards to assess Solar s ability to comply Project inspection te
63. gs from thermal damage If the shutdown is the result of fire being detected the turbine is brought to a complete stop and the start of the post lube cycle is delayed for 10 minutes unless an operator intervenes 9 4 4 Vibration and Temperature Monitoring In addition to the T5 thermocouples the system provides continuous monitoring of temperature and vibration levels at key package locations Refer to the Specification Table for details 9 5 TTA4000 Display and Monitoring System The TT4000 display and monitoring system provides extensive data collection and display capabilities On a typical project two standard versions of the product are used TT4000 is the fully featured version with extensive data collection and display capability It is installed in a high performance industrial grade personal computer PC in either a desktop or a console panel mounted version It runs on the Windows 2000 operating system The hardware is not rated for hazardous areas and must be installed in a non hazardous area typically a control room Note this full TT4000 version is required for the engine performance map option TT4000S is a reduced version of the product specifically designed for the onskid interface It is installed in a special industrial grade PC that is approved for use in both NEC Division 2 and CENELEC ATEX Zone 2 areas It runs on the embedded Windows XP operating system Due to the environment it uses no moving media such as disk drives
64. iary systems required for operation In addition to the standard package features a wide array of optional equipment is available to meet the customer s installation and operation requirements Designed specifically for industrial service Solars gas turbine generator sets are compact lightweight and require minimal floor space for installation Proven packaging designs greatly reduce installation costs time materials and labor The package features a radial exhaust resulting in a short overall package length that conserves valuable mounting space TURBINE TURBINE AIR INLET EXHAUST GENERATOR GEARBOX i e Ian 82808 Figure 1 Typical Titan 250 Gas Turbine Generator Set 2 2 Package Description The gas turbine generator set consists of an axial flow gas turbine engine generator and reduction drive gearbox These components are installed in line on a two piece heavy steel base frame referred to as the skid The skid is a structural steel assembly with beam sections and cross members welded together The two sections of the skid can be separated to facilitate handling and shipment but when bolted together they form a rigid structure suitable for three point mounting Drip pans are included to collect any potential liquid leakage Package connection points for fuel lube oil air and water are located on the outer edge of the skid Electrical connections are made in onskid junction boxes Machined mounting surfaces
65. ical TT4000S Engine Summary Screen enne 36 Figure 18 Typical TT4000S Generator Summary Screen sss 36 Figure 19 Typical Generator Exciter and Generator Control Module Arrangement 41 Figure 20 Typical Generator Metering Panel 44 Figure 21 Typical Complete Package Enclosure sene 45 Figure 22 Typical Fire and Gas Gwvstem eene 48 Figure 23 Typical COsFire Suppression Cylinders and Cabinets AAA 49 Figure 24 Typical Water Mist Fire Suppression Cylinders and Cabinet A 49 Figure 25 Typical Titan 250 Turbine Air Inlet and Exhaust Gvsiems 52 Figure 26 Typical Battery Charger sssesssseee enn emm nemen ener 57 Figure 27 Turbine Cleaning System essen enne emnes 58 Figure 28 Turbine Cleaning Cart enne enne 58 Figure 29 Separation of Engine Sections eee emnes 59 Figure 30 Rails and Fixtures for Axial Separation of Engine Sections eeeceeeeeeeeereeeee 59 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary Turbomachinery Package Specification Titan 250 Generator Set 1 Introduction 1 1 1 2 General Description Solar Turbines Incorporated is a worldwide leader in the design manufacture and installation of industrial gas turbines Solar s 40 years of experience integrating high technology with fluid compression liquid pumping power generation and cogeneration applications has resulted in more than 12 500 gas turb
66. ides descriptive and instructional data for operating and servicing the turbomachinery package General functional and component descriptions of the turbine engine and associated package systems with supporting illustrations are included in four volumes e Systems Operator s Guide Intended for the equipment operator the systems operator s guide provides familiarization with controls and indicators operating procedures and safety precautions to ensure safe equipment operation e Maintenance Instructions Intended for maintenance and field service personnel the maintenance instructions include preventive and corrective procedures including periodic inspection requirements alignment procedures cleaning procedures removal and installation procedures adjustment procedures and tolerances e Supplementary Data Provided in the form of supplier manuals and data sheets the supplementary data provides descriptions of components and assemblies not covered or fully discussed in the Maintenance Instructions volume Due to copyright restrictions supplementary data from suppliers is available in English only e Illustrated Parts List Provides part numbers part names quantities reference designators and illustrations for locating and ordering parts e Language The OMI is provided in English Other languages are available as an option The OMI manual typically includes the following features e Electronic viewing of data in a Windows
67. imiting Reactive droop compensation Cross current compensation Line drop compensation Field current limit Generator overcurrent Generator overvoltage Generator undervoltage Loss of excitation current Loss of operating power Loss of sensing Over excitation voltage Overfrequency Underfrequency Phase rotation error Reverse power Reverse volt amp reactive VAR Exciter rotating diode monitor The protection features provided typically do not meet the requirements of power utility companies for the general protection of power distribution systems This can only be done through the use of appropriately certified protective relay components with settings approved by qualified personnel based on a comprehensive analysis of the complete system 2008 Solar Turbines Incorporated All rights reserved 40 TPS250GS 908 Preliminary Turbomachinery Package Specification Titan 250 Generator Set 10 2 Generator Control 10 2 1 Functional Description The Turbotronic 4 control system working in conjunction with the generator s excitation system provides control monitoring and protection of the generator and its output The key components are e Permanent magnet generator PMG e Rotating armature type AC exciter e Full wave rectifier assembly e CGCM Figure 19 provides a simplified layout of these components The exciter armature is mounted on the main generator rotor and generates an AC voltage as it revolves in the magneti
68. ine any and all conceivable hazards e Tests are performed to verify proper operation and functionality of components and systems e Operation and Maintenance Instruction OMI manuals package labels and control system display screens are produced in the operator s native language e Prior to application of the Conformit Europ enne CE Mark the Test Facilities Production Quality and a Compliance Engineer perform an audit of the completed package e A Declaration of Conformity is then issued for each CE Marked package 18 4 2 Solar Compliance International Electrotechnical Commission IEC Electrotechnical Standardization CENELEC 60079 10 categorizes hazardous areas in terms of Zones shown in Table 15 Table 15 Zone Classifications Zone Definition 0 Explosive atmosphere continuously present 1 Explosive atmosphere often present 2 Explosive atmosphere may be present under fault conditions While electrical systems can be provided to meet Zone 1 or Zone 2 under ATEX generator sets can only be certified for Zone 2 due to the hot surface temperature of the gas turbine 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 71 Turbomachinery Package Specification Titan 250 Generator Set 18 5 18 6 18 6 1 18 6 2 18 6 3 18 6 4 International Electrotechnical Commission Safety Assessment International Electrotechnical Commission IEC 61508 is an in
69. ine installations in 92 countries around the world Solar gas turbine packages have logged more than 1 3 billion operating hours around the world in a wide range of applications Solar gas turbine packages are complete operational systems that require a minimum of site preparation prior to installation The Titan 250 generator sets represent years of intensive engineering and manufacturing design Solar gas turbines are manufactured to rigid industrial standards and are thoroughly tested in modern facilities Solar s operations are certified by Det Norske Veritas DNV to conform to International Standardization Organization ISO 9001 2000 Standard for Quality Management Systems Overview This document describes product features and provides product specification information for the Titan 250 generator sets Included are basic package configurations ancillary descriptions installation requirements and a list of customer support services available at the time of publication Please note that changes in equipment service descriptions and specifications may occur without prior notice 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary Turbomachinery Package Specification Titan 250 Generator Set 2 Titan 250 Gas Turbine Generator Set 2 1 General Description The Titan 250 gas turbine generator set Figure 1 is a completely integrated and fully operational package equipped with all accessories and auxil
70. ircuit breaker and closure of the fuel valves without a cooldown period In the event of a hazardous condition or equipment malfunction the control system will shut the package down automatically These shutdowns are divided into four categories e Cooldown stop nonlockout CN e Cooldown stop lockout CL e Fast stop nonlockout FN e Fast stop lockout FL Cooldown and fast stops correspond to the manual normal and emergency stops respectively Lockout stops inhibit operation of the control system and prevent restarting until the malfunction is reset Lockout stops result from serious malfunctions that require corrective action before the system can be restarted Nonlockout stops result from an operational disruption or abnormal condition and can be reset when conditions return to normal To protect the rotor from deformation and to enable a prompt restart of the package the turbine does not come to a complete stop unless the shutdown is the result of fire being detected The starter motor or the DC backup turning gear mechanism in the case of loss of AC power engages the turbine at low speed and maintains rotation until the cooldown cycle is complete At the same time the control system initiates and supervises 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 33 Turbomachinery Package Specification Titan 250 Generator Set a post lube cycle to protect the gas turbine and driven equipment bearin
71. irements EXHAUST COLLECTOR Deg d 3 STAGE POWER OUTPUT DRIVE TURBINE E SHAFT 2 STAGE GAS GENERATOR COMBUSTOR HOUSING ASSEMBLY EXHAUST DIFFUSER FUEL INJECTORS VARIABLE INLET GUIDE VANES AIR INLET Figure 3 Titan 250 Two Shaft Gas Turbine Cutaway 3 1 1 Principles of Operation During the typical combustion process Figure 4 air is drawn into the gas turbine air inlet and is compressed by the multi stage axial flow engine compressor The compressed air is directed into the annular combustion chamber at a steady flow Fuel is injected and mixed with the compressed air and ignited during the start cycle Continuous combustion will be maintained as long as there is an adequate flow of pressurized air and fuel Hot pressurized gas from the combustor expands through and drives the turbine dropping in pressure and temperature as it exits the turbine This combustion cycle converts the energy in the fuel into kinetic rotating power at the turbine output shaft 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 10 Turbomachinery Package Specification Titan 250 Generator Set For combustion the gas turbine requires approximately one fourth of the total air it compresses The excess air is mixed with the combustion products to reduce the gas temperature at the turbine first stage inlet The cooling air also keeps metal temperatures in the combustor and turbine assembly
72. is equipped with an innovative system to remove the gas turbine as a complete entity or in sections Figure 29 The compressor combustor gas producer turbine and the power turbine can be separated axially using fixtures that attach to longitudinal rails Figure 30 The rails are an integral part of the package frame When service is scheduled the fixtures are mounted on the rails and attached to the turbine A screw thread mechanism is then used to separate the sections This arrangement allows easy access to the different sections of the engine for in situ service It also allows the individual sections or the entire engine to be removed laterally using a separate external rail based handling system GAS PRODUCER TURBINE 5 b COMBUSTOR POWER TURBINE Figure 29 Separation of Engine Sections A Figure 30 Rails and Fixtures for Axial Separation of Engine Sections 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 59 Turbomachinery Package Specification Table 12 Accessory Equipment Specifications Titan 250 Generator Set 120 VDC Battery and Charger System Charger Type Floor Mount Supply Voltage 380 400 or 415 VAC 50 Hz 3 phase 460 VAC 60 Hz 3 phase Operating Temperature 10 to 50 C 14 to 122 F Approximate Measurements Charger Height 1 21 m 47 5 in Width 0 98 m 38 5 in Depth 0 65 m 25 5 in
73. l protection The Eagle Quantum Premier system from Det Tronics detects gas and or fire inside the enclosure based on inputs from gas thermal and optical flame detectors If fire is detected the system releases an extinguishing agent into the enclosure If a fire or an unacceptable gas level is detected the system instructs the Turbotronic control processor to initiate a package shutdown The system is also wired directly to the backup shutdown system See Enclosure Section 11 for a more complete description Combination Generator Control Module The combination generator control module CGCM provides voltage regulation automatic breaker synchronization excitation control power metering load sharing and protective relay functions For a more detailed description of the CGCM capabilities refer to Section 10 Generator Control and Monitoring Control System Power Supplies The control system operates on 24 VDC power The standard battery charge system provides 120 VDC power to the control system The control system includes a 120 to 24 volt DC to DC converter to supply 24 VDC power to the control system For a more detailed description of the battery charger system refer to Section 14 Accessory Equipment System Monitoring and Control Functions The control system provides sequencing control during gas turbine startup steady state operation and shutdown Protective functions are provided during all stages of operation Starting and
74. ls Gimbals provide protection against G forces generated by vessel pitch and roll movements and against deflection twisting and thermal growth of the mounting deck Gimbals may be used for three point package mounting 15 1 3 Anti Vibration Mounts Anti vibration mounts AVMs are used to isolate the mounting surface from package generated vibrations AVMs do not provide the same level of motion protection as gimbals AVMs may be used for three point package mounting 15 1 4 Internal Package Modifications Moderate or severe package motion can potentially interfere with lube oil system operation To prevent interference modifications may be made to the lube oil system to ensure proper lube oil circulation 15 1 5 Inclinometers For moderate and severe duty applications an inclinometer is furnished to provide alarm annunciation and equipment shutdown inputs when maximum allowable angular displacements are exceeded Alarm levels are typically set 2 degrees below shutdown levels 15 1 6 Flexible Ducting Flexible ducting can be provided for the turbine air inlet duct turbine exhaust duct and enclosure ventilation duct 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 61 Turbomachinery Package Specification Titan 250 Generator Set 15 1 7 15 1 8 15 1 9 Certification Certification is typically required to demonstrate offshore turbomachinery compliance with applicable rules for a fixed or mobile offsho
75. lt 110 F Viscosity Grade ISO VG 46 C46 Use When Ambient Temperature is gt 110 F Pour Point Must Be At Least 6 C 11 F Below The Lowest Ambient Temperature Lube Oil Tank Capacity 11 450 L 3025 gal See Note h Weight 1995 kg 4 400 Ib Construction Materials Piping Manifolds and Tubing 316L Stainless Steel Lube Oil Tank and Tank Covers Carbon Steel Standard 316L Stainless Steel Optional Construction Materials Cont d Main Lube Oil Duplex Filter Housing and Transfer Valve Carbon Steel Standard 316L Stainless Steel Optional Backup Lube Oil Pump Filter Housing Carbon Steel Standard 316L Stainless Steel Optional Lube Oil Vent Coalescer Carbon Steel Standard 316L Stainless Steel Optional Lube Oil Vent Flame Arrestor Aluminum 2008 Solar Turbines Incorporated All rights reserved 27 TPS250GS 908 Preliminary Turbomachinery Package Specification Titan 250 Generator Set Applicable Engineering Specifications Solar s Engineering Specification ES 9 224 Fuel Air and Water or Steam for Solar Gas Turbine Engines Solar s Engineering Specification ES 1593 Guidelines for NEC Compliance of Solar Product Lines Class Group D Division 1 and Division 2 Solar s Engineering Specification ES 1762 Standards and Practices for Electrical Systems for Gas Turbine Packages Installed In Hazardous Area
76. lude e Feasibility studies e Proposal preparation e Design and engineering e Material procurement e Fabrication e Onsite construction e Quality control e Scheduling e Budget control e Shipping e Installation testing and commissioning Material procurement for example can include prime movers driven equipment associated mechanical process equipment and electric power generation equipment Construction Services is uniquely qualified worldwide to provide complete fluid compression liquid pumping and power generation systems with single source responsibility engineering expertise optimal economic designs and real attention to quality and safety to ensure complete power system satisfaction 19 2 Customer Services Solar s Customer Services organization is dedicated to the support of Solar s equipment worldwide Customer Services support includes technical training field service personnel service parts overhaul and repair services and customized operation and maintenance programs Customer Services also offers gas turbine uprates and updates retrofit conversions to low emission SoLoNOx turbine configurations and complete package refurbishments all of which provide cost effective life cycle solutions Solar s Customer Services organization is known for its excellent service and support that no other gas turbine service company can compare in e Product knowledge and experience with more than 11 500 units in 90 nations e In depth techni
77. min 0 0268 Nm h 1 61 sq in mm 645 16 cm 6 4516 sq ft m 0 0929 m 0 0929 yd m 0 914 m 0 914 To Convert From Old Metric To S I Metric Multiply By Atm kPa 101 325 Bar kPa 100 0 cm mm 10 cm Hg kPa 1 3332 cm Ha kPa 0 09807 kcal h W 1 16279 kg cm kPa 98 0665 Nm h Nm min 0 0167 2008 Solar Turbines Incorporated All rights reserved 76 TPS250GS 908 Preliminary Turbomachinery Package Specification List of Abbreviations Titan 250 Generator Set Abbreviations ABS American Bureau of Shipping ABS Absolute AGMA American Gear Manufacturers Association API American Petroleum Institute AS NZS Australian New Zealand Standard ASME American Society of Mechanical Engineers Ata Atmosphere Absolute ATEX Atmosphere Explosive AVM Anti Vibration Mount AVR Automatic Voltage Regulation Btu British Thermal Unit Btu h British Thermal Units Hour BV Bureau Veritas CACA Closed Air Circuit Air Cooled CACW Closed Air Circuit Water To Air Cooled CE Conformit Europ ene CEC Canadian Electrical Code CEN European Committee for Standardization CENELEC Comit Europ en de Normalisation Electrotechnique cfm Cubic Feet Minute CGCM Combination Generator Control Module cm Centimeter cm Square Centimeter cm Cubic Centimeter CO Carbon Monoxide CO2 Carbon Dioxide CSA Canadian Standards Association CT Compliant Tower Cu ft Cubic Feet C Degrees Celsius dBA Decibels Acoustic DNV Det Norsk
78. monitoring features of the primary CGCM are duplicated in the second CGCM Control can also be manually transferred between the CGCMs Table 8 Generator Specifications Voltage Regulation Voltage Regulator Solid State Phase Sensing Three Phase Standard Single Phase Sensing Optional Voltage Adjustment Range 10 With a Voltage Resolution of 0 1 Steady State Voltage Regulation 0 25 From No Load to Rated kVA Reactive Load Sharing Within 5 of Nameplate Rating Cross Current Compensation Optional Voltage Drift See Note a Generator Breaker Synchronization Generator Voltage To Close Breaker Generator Voltage Must be Within 1 0 Percent of Bus Voltage Generator Phase To Close Breaker Generator Phase Must be Within 10 Degrees of Bus Phase Generator Frequency To Close Breaker Generator Frequency Must Be Within 0 01 Hz of bus frequency Generator Ready to Load Twenty seconds after generator set attains 90 percent speed Notes a The change in voltage will not exceed 1 0 over a 30 minute period when the generator is operating at rated voltage power factor of 0 8 to 1 0 and with a constant load between no load and full rated load 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 44 Turbomachinery Package Specification Titan 250 Generator Set 11 Enclosure General Description A driver only or complete package encl
79. nd Preparation for Shipment PIL 127 Product Certification PIL 148 LPG and NGL Fuels PIL 149 Direct drive AC Start Systems PIL 150 Direct drive AC Start Systems PIL 161 Lube Oil System Cleanliness PIL 162 Recommendations for the Sourcing Handling Storage and Treatment of Fuels for Solar Gas Turbines PIL 176 Siloxanes in Gas Fuel PIL 178 Salt Ingress Protection for Gas Turbines 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 80
80. nent D scriptlons tee de ERE De PE eee de PUES de e Re e terse 31 9 4 System Monitoring and Control Functions sss em 32 9 5 TT4000 Display and Monitoring System mem 34 10 GENERATOR CONTROL AND MONITORING 1 eeeeeee essere esee en nennen nnns nnns 40 10 1 General Description 40 10 2 Generator Control 41 T1 ENGLOSURE 5 1 ERG rais ee ciccccc ie ioco ree sont cuen soa cenae dad eae sene coUe qoab RRE ANEA 45 1121 General DeScriptlOn eiit tate etae tete uM tude ebq See ka B esee bla edd 45 11 2 Standard Features 2 t e et te uere etur teet be iB aaaea 46 11 3 Optional TTT 46 12 AIR INLET SYSTEM eerte uoo nnno nnno tnn ENNEN EENEG ged 52 12 1 General Description 52 13 EXHAUST KENNEN 55 13 1 General Description nhe P ertt eh Pen terti t rte e te Da AEN 55 13 2 Turbine Exhaust Heat Recovery System sss eene 55 14 ACCESSORY EQUIPMENT 2 errrecce erroe ck nunne cca nn nn aD a anna nd Dk nnmnnn a anna mnanaa nnna 57 14 1 DC Power Supply and Battery Charger System e 57 14 2 Turbine Cleaning System cin enti e terae Ee dE 57 14 3 Package Lifting EE 59 14 4 Engine Removal Equipment nennen enne 59 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary Turbomachinery Package Specification Titan 250 Generator Set 15 IMARINIZATION e 61 15 1 GeneraliBescriptioi 2 1 re eerie re ee De d m OO n ede ret ides
81. nerators operating in parallel Instrumentation transformers are usually supplied with the switchgear Control Modes In addition to voltage regulation the following generator control modes are also available e Speed Load Control sochronous Isoch Speed Control Droop Speed Control Kilowatt Import Control e Reactive Compensation Droop Voltage Control e Power Factor Control e Reactive Load Volt Amp Reactive Control Differential Cross Current Control Breaker Synchronization The control system provides automatic generator breaker synchronization control when paralleling to the bus Automatic synchronization can be initiated by the operator or by a remote signal received from a supervisory control system If manual synchronization is required an optional generator metering panel must be included Synchronization control is provided by the CGCM Auto Start and Synchronizing System When the generator set is in standby mode the control system will automatically start the generator set accelerate the engine to loading speed and synchronize the generator breaker to the bus upon receipt of a supervisory command If the control system detects a hot bus it will synchronize the generator to the bus and close the breaker If the control System detects a dead bus it will close the generator breaker without synchronization Kilowatt Import Control The kW import control system controls the real load KW when the gener
82. ng Gas Turbine Refer to Section 3 Gearbox Refer to Section 4 Generator Refer to Section 5 Offskid Control Console Dimensions One Bay Control Console Height 2286 mm 90 in Width 914 mm 36 in Depth 800 mm 31 5 in Approximate Weight 570 kg 1250 Ib Two Bay Control Console Height 2286 mm 90 in Width 1448 mm 57 in Depth 800 mm 31 5 in Approximate Weight 680 kg 1500 Ib Supervisory Interface Modules ControlNet 1 5 Cables RG 6U Coaxial Maximum Cable Length 1000 m 3300 ft Transmission Protocol Common Industrial Protocol CIP Transmission Speed 5 Mbps Ethernet Cables 10BaseT Network Length 100 m 330 ft To Nearest Hub Transmission Protocol CIP Protocol with TCP IP Transmission Speed 10 Mbps Data Highway Plus Cables DH Twisted Pair Maximum Cable Length 3000 m 10 000 ft Transmission Protocol CIP or DF1 Protocol Transmission Speed 57 6 bps Modbus Cables RS232C RS422 or RS485 Cable Length RS232C 15 m 50 ft RS422 and RS485 1200 m 4000 ft Transmission Protocol Subset of Modbus RTU Protocol 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary Turbomachinery Package Specification Titan 250 Generator Set Package End Devices Transmitters 4 20 mA Switches
83. ng and in providing power contracts to assist you in determining the best financial option to optimize your economic return from the turbomachinery project Solar s Worldwide Locations Solar maintains sales and service facilities throughout the world For a list of the current locations please visit Solar on the internet at www solarturbines com 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary T5 Turbomachinery Package Specification Conversion Chart Titan 250 Generator Set Conversion Factors To Convert From To Convert To English To S I Metric Multiply By Old Metric Multiply By Btu kJ 1 0551 kcal 0 252 Btu h W 0 2931 kcal h 0 252 Btu scf kJ nm 39 3694 kcal nm 9 382 cfm m min 0 028317 m min 0 028317 cfm m s 0 00047195 m s 0 00047195 cu ft m 0 028317 m 0 028317 F S F 32 5 9 C F 32 5 9 F Interval C Interval 5 9 C Interval 5 9 ft m 0 3048 m 0 3048 ft lb lbm mJ kg 0 0029891 kJ kg 0 002989 fts m s 0 3048 m s 0 3048 gal U S L 3 7854 L 3 7854 hp kW 0 7457 kW 0 7457 in mm 25 400 cm 2 540 in Hg kPa 3 3769 cm Hg 2 540 in H2O kPa 0 2488 cm Ha 2 540 kcal kJ 4 1868 Ib kg 0 4536 kg 0 4536 Ib cu ft kg m 16 0185 kg m 16 0185 Ibr in Nm 0 1129848 MMSCFD Nm min 18 62 Nm h 1117 mph km h 1 6093 km h 1 6093 psi kPa 6 8948 kg cm 0 070 psia kPa a 6 8948 bars Abs 0 068948 psig KPa g 6 8948 Ata 0 070 scfm Nm
84. nk vent piping Start up strainers must be inspected after 100 hours of operation An additional 246 L 65 gal is required for package filters and piping Additional oil will also be required to fill any offskid oil piping and vessels if applicable 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 28 Turbomachinery Package Specification Titan 250 Generator Set 9 Turbotronic 4 Control System 9 1 Overview The Turbotronic 4 control system controls and monitors the turbomachinery package including the gas turbine and driven equipment The system scope can be expanded to include monitoring and or control of balance of plant equipment that is directly package related The system architecture is based on a Rockwell Automation Allen Bradley hardware and software platform and includes fully integrated generator vibration and when required fire and gas monitoring and control subsystems In the standard onskid configuration Figure 12 the primary control system components are mounted on the package skid with a local operator interface An auxiliary display and monitoring system is available mounted either in an optional console or desktop computer and connected to the package by redundant network cables In the standard offskid configuration the entire control system is mounted in an offskid console with a full set of hardwired cables connecting to the package as illustrated in Figure 13 An independen
85. oltage and frequency to the starter motor to control engine speed from standstill to starter dropout speed The system is capable of performing up to six start attempts per hour as well as extended purge cycles for heat recovery unit applications and engine wash cycles The VFD cabinet is designed for installation in a non hazardous location Electrical disconnects and overcurrent protection devices are not provided 6 2 3 Power Wiring The start system Figure 8 requires customer furnished three phase AC input Additional three phase AC power wiring is required to connect the VFD to the starter motors A start contactor is not required for VFD operation A customer furnished fused disconnect at the VFD input is recommended Optional motor space heater wiring is available RADIO VARIABLE INTERFERENCE FREQUENCY AC FILTER LINE REACTOR DRIVE GAS TURBINE AC POWER CONNECTION CLUTCH ASSEMBLY Figure 8 Typical Direct Drive AC Start System 6 3 Backup Slow Rotation System The Titan 250 package is equipped with a DC powered turning gear system Figure 9 to ensure low speed rotation of the turbine as backup for the DAC starter motor in the event of loss of AC power to the package The system engages the decelerating turbine at low speed and maintains rotation for a specified time Ww Y 2 VAL LARA F js p v V SE al Game dat E ALSO o EK SS LASS Y iu s TURNING GEAR AY ASSEMBLY Figure 9
86. osure can be provided as required The enclosure housing Figure 21 is a completely self contained weatherproof insulated and sound attenuated system The enclosure is mounted on the package skid and supported by a heavy duty frame The enclosure sides include removable panels and or doors to allow access to major components for inspection and maintenance and to permit removal of components by forklift or overhead crane The engine area is furnished with bi fold type doors to facilitate engine removal from either side of the package All enclosure doors include a three point heavy duty door locking mechanism handles hinges latching mechanism internal lock override release restraining device and attaching hardware The enclosure panels are treated with fiberglass material for sound attenuation and thermal insulation Weather stripping is installed between all panels for sealing and sound attenuation The enclosure is normally factory assembled on the package skid prior to shipment but can be drop shipped pre assembled for site installation or shipped as a kit for site assembly and installation The following standard features are included with the basic enclosure e Inlet and exhaust ventilation silencers e Single fan ventilation system e Pressurization system e AC lighting e Equipment handling system e Stainless steel door hardware Figure 21 Typical Complete Package Enclosure 2008 Solar Turbines Incorporated All rights res
87. otronic 4 system is fully programmable in the field Programming requires a licensed copy of Rockwell Automation s RSLogix 5000 software installed on a suitable computer with the corresponding interface card installed Solar offers two standard options Software instruction manual interface card and connecting cable Fully configured portable computer with the software instruction manual interface card and connecting cable 9 5 8 Engineering Units The following engineering unit options are available for the screen displays Metric 1 Metric 2 Metric 3 English Pressure kPa bar kg cm psig Temperature C C C F 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary of Turbomachinery Package Specification Titan 250 Generator Set Table 7 Turbotronic 4 Control System Specifications Control System Components Control Processor Allen Bradley ControlLogix controller Input Output Modules Allen Bradley Flex I O modules Generator Control Allen Bradley Basler Electric Combination Generator Control Module Vibration Monitoring System Bently Nevada 1701 FieldMonitor Internal Control System Network ControlNet 1 5 Human Machine Interface HMI Solar s TT4000 Display amp Monitoring System Fire amp Gas Monitoring System Enclosed Packages Det Tronics Eagle Quantum Premier System Temperature amp Vibration Monitori
88. out load Cleaning solution activation can be initiated from the control console or turbine control junction box This system is intended to supplement the on crank system by increasing the time intervals between periodic on crank cleaning 14 2 3 Turbine Cleaning Cart A portable offskid cleaning tank Figure 28 can be provided to supply cleaning fluid to the skid edge cleaning system connection The cleaning tank can be used to mix hold and pressurize the turbine cleaning solution The tank comes with wheels that are removable for stationary installation PRESSURE AUXILIARY REGULATION FILLPORT can VALVE SERT E PRESSURE GAGE HOSE RACK G STRAINER LEVEL GAGE B E OPERATING INSTRUCTION PLAQUE TT Li m DRAIN VALVE aT SWIVEL CASTER A WITH FOOT BREAK Oy 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 58 TEAL Figure 28 Turbine Cleaning Cart Turbomachinery Package Specification Titan 250 Generator Set 14 3 14 4 Package Lifting Kit A package lifting kit can be shipped separately that contains slings spreader bars and assorted hardware to facilitate separate lifting of the driver and driven equipment modules with or without an export crate Engine Removal Equipment The Titan 250 package
89. ovided to illuminate the enclosure interior Lighting on off switches are provided on the enclosure exterior Sound Attenuation The sound attenuated enclosure is intended for use with suitable gas turbine air inlet and exhaust silencing systems in environments where low noise levels are required Enclosure ventilation openings are equipped with silencers to achieve maximum sound attenuation The actual achievable noise reduction is a function of the noise source installation considerations other equipment in close proximity and the acoustical characteristics of existing buildings and barriers The intent of the enclosure design is to comply with U S Occupational Safety and Health Administration OSHA standards for eight hour employee exposure Transmission loss of the panels in decibels is available upon request Further information is available in Solar s publication SPNP Noise Prediction Guidelines for Industrial Gas Turbines Optional Features Enclosure Configuration An enclosure can be selected to house both the gas turbine and generator or only the gas turbine Dual Fan Ventilation The enclosure can be ventilated with a dual AC motor driven fan system The fan motor wiring is terminated at the motor junction box Openings are provided to ensure adequate airflow is circulated through the enclosure For Conformit Europ enne CE Mark certification the second or backup ventilation fan is mandatory and must be powered by
90. p Speed Gas Producer Nm h Normal Cubic Meters Hour Npt Speed Power Turbine NOx Nitrogen Oxides NRTL Nationally Recognized Testing Laboratory ODP Open Drip Proof OMI Operation and Maintenance Instruction OSHA U S Occupational Safety and Health Administration QA Quality Assurance QC Quality Control Pcd Pressure Compressor Discharge PED Pressure Equipment Directive 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 78 Turbomachinery Package Specification Titan 250 Generator Set Abbreviations Cont d PF Power Factor PIL Product Information Letter PMG Permanent Magnet Generator psi Pounds Square Inch psia Pounds Square Inch Absolute psig Pounds Square Inch Gauge rom Revolutions Per Minute RTD Resistance Temperature Device scf Standard Cubic Foot scfd Standard Cubic Feet Day scfm Standard Cubic Feet Minute sm h Standard Cubic Meters Hour SoLoNOx Solar Proprietary Low Emissions System SP Spar Platform sq Square TEAAC Totally Enclosed Air To Air Cooled TEWAC Totally Enclosed Water To Air Cooled TLP Tension Leg Platform UHC Unburned Hydrocarbon UL Underwriters Laboratories Incorporated UPS Uninterruptible Power Supply USCG United States Coast Guard UV Ultraviolet VAC Voltage Alternating Current VAR Volt Amp Reactive VDC Voltage Direct Current VFD Variable Frequency Drive VPI Vacuum Pressure Impregnated Standard 60 F 14 7 psia a Normal O C 1 01325
91. powered by integrated DC motor driven actuators Integrated actuator electronics provide precise closed loop valve control based on position command inputs versus position feedback outputs The three valves are fast acting and provide fuel metering for light off acceleration full load and load transient conditions Fail safe operation ensures both valves will close in case the command signal or control power is lost During the start sequence prior to ignition the control system will verify gas pressure and perform a gas valve check to verify proper operation of all gas fuel valves Table 5 Fuel System Specifications Gas Fuel System Acceptable Gas Fuels See Note a Natural Gas Propane Butane Fuel Quality Refer to Solar s Engineering Specification ES 9 98 Compliance National Association of Corrosion Engineers NACE Compliant Minimum Maximum Gas Fuel Supply Pressure 2240 to 3447 kPag 325 to 500 psig See Note b Minimum Flow Rate 3513 to 5480 kg hr 7746 to 12086 Ibm hr See Note b Minimum Maximum Fuel Supply Temperature 40 to 93 C 40 to 200 F See Note c Primary Gas Fuel Shutoff Valve Pneumatically Actuated Spring Closed Ball Valve Secondary Gas Fuel Shutoff Valve Pneumatically Actuated Vane Type Valve Gas Fuel Control Valve and SoLoNOx Fuel Pilot Control Valve Actuator Valve Actuator Voltage 120 VDC Valve Discrete Signals 0 to 24 VDC Valve Analog
92. precision punched and individually insulated Windings are typically form wound and treated with thermosetting synthetic varnish or vacuum pressure impregnated VPI epoxy for maximum moisture resistance high dielectric strength and high bonding qualities The windings are braced to withstand shock loads such as motor starting and short circuits Space heaters can be supplied to minimize condensation during shutdowns 5 2 4 Shaft The shaft diameter provides the necessary stiffness to avoid torsional vibration The turbine driven generator set is given a complete torsional analysis 5 2 5 Frame The frame is heavy duty steel and is fabricated with deep welds and internal reinforcing for extra rigidity and strength The frame also includes lifting lugs 5 2 6 Exciter Excitation current for the generator field coils is provided by a brushless rotating exciter with a PMG pilot exciter The exciter is mounted directly on the generator rotor shaft The exciter consists of two basic parts a small three phase AC generator with rotating 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 15 Turbomachinery Package Specification Titan 250 Generator Set armature and a three phase full wave diode type bridge rectifier that rotates with the armature The pilot exciter is a PMG that rotates with the main generator rotor shaft It feeds the exciter field windings with excitation current and is controlled by the CGCM 5 2
93. provides the signal to the CGCM for reactive loadsharing between multiple paralleled units It should be noted that the generator rotor windings rotate and the generator armature is stationary The exciter field coils are also stationary and the exciter armature rotates with the main generator rotor shaft As a result a single rotating assembly consisting of the exciter armature exciter rectifier and the generator rotor windings is formed This single rotating assembly greatly simplifies all electrical connections within the generator 5 2 4 Standard Features Generators include the following standard features e Sleeve bearings with pressure fed sumps e Terminal box e Form wound stator windings e Amortisseur windings e Rotor balance to 125 rated speed e Anti condensation space heaters e Permanent magnet generator PMG e Rotating armature type VAC exciter e Full wave rectifier assembly Special order generators are available to meet unique customer requirements including non U S specifications 5 2 2 Rotor The salient four pole forged rotor is dynamically balanced to minimize vibration Motor fans move cooling air through the generator and around the rotor The rotors have layer wound field windings cemented with a high strength resin and are baked to cure the resin The rotor is in electrical and mechanical balance at all speeds up to 125 of rated speed 5 2 3 Stator The stator is built with high grade silicon steel laminations that are
94. r between 1 6 C and 60 C 35 F and 140 F Air should be free of all corrosive contaminants hazardous gases flammables and toxics 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 54 Turbomachinery Package Specification Titan 250 Generator Set 13 Exhaust System 13 1 13 1 1 13 2 General Description The exhaust system Figure 25 typically consists of all components installed downstream of the engine exhaust bellows expansion joint including silencers and ducting that are necessary to ensure a smooth flow of exhaust gas from the engine The exhaust duct system must be terminated in a manner that precludes recirculation of exhaust products through the engine air inlet or oil cooler Exhaust considerations include the relative height of the exhaust duct above the air inlet building roof design direction of prevailing winds and the proximity of adjacent structures The importance of having an exhaust system properly designed cannot be overemphasized A poorly designed exhaust system can cause loss of power capability and impose severe mechanical strains on the gas turbine Exhaust systems should be designed to meet the following requirements e Where two or more units exhaust into a common header such as used for heat recovery equipment provisions must be made to prevent hot gas from flowing into the non operating unit common exhaust ducting is not recommended e Final termin
95. r filter when large numbers of insects are present The insect screen design reduces the velocity of the air stream sufficiently to allow most insects to fly away Use of the screen helps to avoid clogging and premature filter replacement During cold weather operation the insect screens should be removed and stored due to a potential for ice or snow to clog the screens Self Cleaning Barrier Type Air Filter Updraft Type The self cleaning barrier type air filter system is suitable for extreme environments where dust loading or cold weather operation is a concern This system requires a suitable supply of cleaning air Cleaning air can be provided by the customer or supplied using turbine compressor discharge pressure Pcd bleed air If bleed air is used an air heat exchanger is provided for mounting in the air inlet ducting between the air inlet filter and the turbine air inlet Access to change filter elements from below must be provided Standard features include e Support leg kit e Dual differential pressure alarm and shutdown switch e Filter elements e Differential pressure gauge e Electrical connections prewired to a common junction box Marine Type The marine type air filter system is suitable for use in coastal offshore and tropical locations This system provides high efficiency removal of salt water and particulates This system consists of e First stage marine vane separator moisture eliminator e Second stage prefilter
96. r to submittal to the customer With this review and approval cycle the test data are furnished approximately four weeks after completion of acceptance testing The test data includes test result comparisons to Solar s acceptance test specifications using calculations graphs strip charts and descriptions Data are provided for each turbine generator set The acceptance test data generally includes the following e Turbine fuel consumption rates a comparison of measured fuel consumption versus specified fuel consumption that shows a correlation between fuel consumption power output and turbine gas temperature at full load e Voltage and frequency transients strip chart traces are provided that show voltage and frequency deviations during load transitions e Operating values a chart that includes the following operating parameters at each step load from no load to full load Lubricating oil pressure temperature and flow Package temperatures Generator power Generator voltage amperage and frequency Engine compressor discharge pressure Package vibration levels 16 2 5 Additional Testing As an option additional testing can include a four hour full load test using gas and or liquid fuel factory emissions testing and field performance testing 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 64 Turbomachinery Package Specification Titan 250 Generator Set
97. re and flexible joints between the gas turbine and enclosure can be provided Door Open Alarm The enclosure doors can be equipped with a door position switch that will initiate an alarm when any enclosure door is not closed securely Fire and Gas System Enclosed packages must include a fire and gas control system The typical fire and gas system shown in Figure 22 provides gas monitoring fire detection and extinguishing agent release using an advanced distributed architecture to monitor gas heat and optical flame detectors The system communicates with the Turbotronic 4 control system to initiate a shutdown if a fire or a high gas level is detected On the package exterior indicator lights strobe lights and an alarm horn provide system status A keyswitch is provided to inhibit the system and a push button switch is provided to manually release the fire extinguishing agent The primary fire detection system uses multi spectrum IR MIR flame detectors The system includes an automatic optical integrity feature to provide a continuous check of the optical surfaces detector sensitivity electronic circuitry of the detector controller system and automatic fault identification with digital display of system status in numerical code The secondary detection system consists of rate compensated thermal detectors The two detection systems act independently in detecting and reporting a fire The number of detectors may vary depending on the enclo
98. re installation Solar can provide the necessary certification or assist the customer in obtaining certification Involvement of one of the following certifying authorities is usually required e Det Norske Veritas DNV e Bureau Veritas BV e Lloyd s Register LR e American Bureau of Shipping ABS Deck Deflection Limits The package supporting deck structure must have sufficient stiffness to maintain alignment of the turbine and driven equipment under dynamic vessel motion Table 13 lists the maximum allowable deflections measured between the furthest mounting points With analysis these limits may be extended through the use of gimbals or AVMs Angular Displacement and Acceleration Table 15 Marinization Specifications lists the maximum allowable angular displacement and acceleration limits for marine applications The Basic Duty category is met by the standard package without any additional modification Moderate Duty and Severe Duty categories require modification 15 1 10 Main and Auxiliary Service The information provided in this section does not apply to equipment used in Main and Auxiliary Service If equipment is intended for this type of service please contact Solar Turbines Incorporated for guidance to ensure the correct application and certification requirements are met Table 13 Marinization Specifications Supporting Deck Deflection Limits Hog
99. rifugal Optional Motor Voltage Ratings 380 VAC 400 VAC and 415 VAC 50 Hz 460 VAC and 575 VAC 60 Hz Motor Power 7 45 kW 10 hp Backup Lube Oil Pump Pump Type DC Motor Driven Centrifugal Motor Voltage Rating 120 VDC Motor Power 7 45 kW 10 hp Lube Oil Cooler Lube Cooler Oil Volume Per Cooler Project Specific Design Heat Load Per Cooler Project Specific Design Oil Flow Rate Per Cooler Project Specific Air Flow Rate Project Specific See Note b Maximum Ambient Temperature 43 C 110 F Maximum Design Lube Oil Cooler Outlet Temperature 66 C 150 F Maximum Lube Oil Cooler Design Pressure Drop 173 kPag 25 psig See Note c Minimum Lube Oil Cooler Design Pressure 1 035 kPag 150 psig Optional Motor Voltage Ratings 380 VAC 400 VAC and 415 VAC 50 Hz 460 VAC and 575 AC 60 Hz Optional Motor Power 7 5 kW 10 hp 15 kW 20 hp or 2 x 15 kW 20 hp Lube Oil Tank Immersion Heater See Notes d and e Optional Voltage Ratings 380 VAC 400 VAC and 415 VAC 50 Hz 460 VAC and 575 VAC 60 Hz Power 3 Phase VAC 40 kW Minimum Maximum Regulated Supply Pressure 100 to 225 psig 689 to 1551 kPag 2008 Solar Turbines Incorporated All rights reserved 26 TPS250GS 908 Preliminary Turbomachinery Package Specification Titan 250 Generator Set Maximum Flow
100. s CENELEC IEC Standards European ATEX Directive 94 9 EC Applicable Product Information Letters Solar s Product Information Letter PIL 058 Package Sound Levels Solar s Product Information Letter PIL 161 Lube Oil System Cleanliness Notes a A pressure control valve regulates main lube oil supply pressure to 241 kPag 35 psig when b c d e f 9 h unit is at normal operating temperature Prevailing winds must be considered to prevent the lube oil cooler from exhausting into the engine air inlet system or to take air in from the engine exhaust system No airflow backpressure is allowed at the lube oil cooler face The maximum total design pressure drop of the off skid oil cooler loop including supply and return lines shall not exceed 50 psid 345 kpad at the design flow rate and an oil viscosity of 60 ssu 10 5 centistokes No check valves are allowed in the oil cooler loop This is recommended for all applications but mandatory for units in cold climates oil cooler supply return and optional vent lines must slope from the oil cooler to the turbine package to facilitate draining when the unit is not operating The heater is mandatory if unit ambient temperature is less than 10 C 50 F The lube oil tank immersion heater ensures the lube oil tank temperature remains above 10 C 50 F for starting in cold temperatures The flame arrestor must be installed vertically at the end of the lube ta
101. s Turbine Packages Installed In Hazardous Areas CENELEC IEC Standards European ATEX Directive 94 9 EC Applicable Product Information Letters Solar s Product Information Letter PIL 148 LPG and NGL Fuels Solar s Product Information Letter PIL 162 Recommendations for the Sourcing Handling Storage and Treatment of Fuels for Solar Gas Turbines Solar s Product Information Letter PIL 176 Siloxanes in Gas Fuel Notes a The gas fuel system is designed to operate with fuels that comply with Solar s Engineering b c d Specification ES 9 98 Most commercially available natural gas fuels comply with ES 9 98 The gas fuel system can be modified to operate with fuels that do not comply with ES 9 98 Solar gas turbines can operate on low Btu fuels Please contact Solar Turbines for assistance in evaluating fuel characteristics and gas turbine requirements Fuel pressure and flow requirements can be affected by several factors such as fuel temperature fuel lower heating value air inlet temperature fuel composition fuel specific gravity engine injector type inlet duct loss relative humidity site elevation and piping length and diameter Based on site conditions minimum fuel pressure and flow requirements may be less than stated values Please contact Solar Turbines for site specific fuel pressure and flow requirements Fuel must have a differential temperature AT of at least 27 C 50 F above fuel dew point
102. s of two high pressure nitrogen cylinders used as a propellant and five water bottles 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 48 Turbomachinery Package Specification Titan 250 Generator Set On detection of a fire by the optional fire and gas detection system the fire control panel activates the fire suppression system release solenoids located on the water mist suppression skid On receipt of this signal the solenoid actuated control heads activate the discharge valves on the water cylinders releasing a water mist into the enclosure A pressure switch in the water mist discharge piping transmits an electrical signal to the fire control panel to activate a release solenoid to close pressure operated dampers on all vent openings The water mist nitrogen actuator valve is also provided with a manual release lever 11 3 11 Fire Cylinder Cabinets When installed outdoors weatherproof fire cylinder cabinets are available to house the extinguishing agent The cabinets are equipped with service doors The manual pull levers are routed by cable to the exterior wall of the cabinet SEE ei ji DP SE e Di i ES i EXTENDED EXTENDED EXTENDED MAIN MAIN MAIN RELEASE RELEASE RELEASE t RESERVE RESERVE RESERVE El E A El ERU ca Eur ii T F e ET Lp J Ee Wa D
103. s reserved TPS250GS 908 Preliminary 50 Turbomachinery Package Specification Titan 250 Generator Set Solar s Applicable Engineering Specifications ES 1593 Guidelines for NEC Compliance of Solar Product Lines Class Group D Division 1 and Division 2 ES 1762 Standards and Practices for Electrical Systems for Gas Turbine Packages Installed In Hazardous Areas CENELEC IEC Standards European ATEX Directive 94 9 EC Solar s Applicable Product Information Letters PIL 054 OSHA Noise Requirements PIL 058 Package Sound Levels PIL 150 Fire and Gas Detection and Control System Notes a The estimated A weighted sound pressure level is 85 dBA at a distance of 1 m 3 ft from the enclosure wall and a height of 1 5 m 5 ft This value is based on an average of multiple readings taken around the perimeter of the package This level applies only to the enclosed equipment and is exclusive of sound generated by piping unenclosed driven equipment if applicable other equipment reflected sound or contributing site conditions Sound levels at a specific site will depend on existing walls barriers equipment in close proximity multiple units and other installation considerations 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 51 Turbomachinery Package Specification Titan 250 Generator Set 12 Air Inlet System 12 1 General Description The gas tur
104. served TPS250GS 908 Preliminary 67 Turbomachinery Package Specification Titan 250 Generator Set e Generator acceptance test report e American Society of Mechanical Engineers ASME data reports as applicable e Solar s Certificate of Compliance If specified on the final project ITP the QC data book may also include the following documents at additional cost and increased delivery time e Engine rotor balance record e Engine casing leak test record e Documentation from suppliers of major package components such as oil coolers oil filters gearboxes and driven equipment e Optional electrical device list when applicable e Third Party Certificates and Declarations of Conformity when applicable 17 5 2 Torsional Analysis Report Optional A torsional analysis can be performed on the entire drive train to determine if there are any significant torsional resonance conditions within 10 of the operating speed range If a resonance condition interference is found then a fatigue analysis is performed to confirm the resonance will not cause fatigue failure in the shafting 17 5 3 Lateral Analysis Report Optional A lateral forced response analysis of the driven equipment can be performed to confirm that any lateral critical speeds aren t close enough to the operating speed range to cause lateral vibration problems 17 5 4 Operation and Maintenance Instruction Manual The Operation and Maintenance Instruction Manual OMI prov
105. ss Otherwise Specified Piping Manifolds and Tubing gt 10 2 cm 4 in Note a Carbon Steel Unless Otherwise Specified Piping Interface Connections 316L Stainless Steel Unless Otherwise Specified Flange Assembly Hardware 316L Stainless Steel Pipe Support Brackets Carbon Steel Standard 316L Stainless Steel Optional Pipe Flexible Couplings Carbon Steel Standard 316L Stainless Steel Optional Tubing Dual Ferrule Compression Fittings 316L Stainless Steel Sliding Lube Oil Drain Couplings and Plates Carbon Steel Standard 316L Stainless Steel Optional Lube Oil Vent Flame Arrestor Aluminum Electrical System Certifications NEC Class 1 Group D Division 1 or 2 CENELEC Zone 1 or 2 Group II CE ATEX Zone 2 Group II Three Phase Package Motors Optional Motor Voltage Ratings 380 400 or 415 VAC 50 Hz 460 VAC 60 Hz Single Phase Battery Charger Optional Battery Charger Voltage Ratings 220 230 240 380 400 415 440 460 or 480 VAC 50 Hz or 60 Hz Single Phase Lighting and Space Heater Voltage Optional Package Lighting and Space Heater Voltage Ratings 120 220 230 or 240 VAC 50 Hz or 60 Hz Ingress Protection IP Ratings Onskid Junction Boxes IP56 to IP66 Control Console IP50 Battery Charger NEC IP22 Battery Charger CE IP31 Solar s Applicable Engineering Specifications
106. ssion levels combustion airflow is regulated using a bleed valve mounted on the combustor case The SoLoNOx combustion system also includes an additional inlet gas filter coalescer for mounting offskid 7 1 2 Fuel System The SoLoNOx fuel system includes e Supply pressure transmitter e Pilot air operated primary gas fuel shutoff valve e Pilot air operated secondary gas fuel shutoff valve e Pilot air operated gas vent valve e Electrically operated fuel control valves 2 e Torch with shutoff valve and pressure regulators e Main fuel manifold e Fuel injectors 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 21 Turbomachinery Package Specification Titan 250 Generator Set e Fuel pilot control valve e Fuel pilot manifold e Inlet gas filter coalescer loose shipped for field installation Component Operation The gas fuel pressure supplied to the turbine skid must meet minimum and maximum pressure and flow requirements If the gas fuel pressure is too high or too low the control system will prevent turbine operation Pneumatically actuated primary and secondary gas fuel shutoff valves are controlled using pilot air pressure For each valve pilot air pressure is admitted to and exhausted from a pneumatic actuator through a solenoid valve Fail safe operation ensures both valves will close in case pilot air pressure is lost The gas fuel control valves and the SoLoNOx fuel pilot control valve are
107. sting and quality assurance QA documentation along with customer or third party involvement in the QA process is defined in the inspection and test plan ITP The ITP is the controlling quality assurance document for a project Since advance procurement is involved in Solar s production process special inspection and documentation milestones may be missed if these requirements are not defined at the project outset All testing operations are conducted under the direct control of Solar s QA department which ensures compliance with specified test procedures In addition to in plant testing of the finished package quality control engineers survey the manufacture of all purchased parts and subassemblies and are responsible for functional testing of incoming components The same rigid standards apply to parts manufactured both in and outside of Solar Testing Factory testing is in accordance with Solar s engine test specifications and as outlined below The customer or customer s designated representative can observe factory production tests listed in the production and testing schedules However production tests will not be delayed due to the unavailability of the customer or customer s representative The production test facilities provide a comprehensive test program using simulators to perform static testing of package systems to verify control system operation and component calibration Calibrated engine test cells feature a computerized r
108. sure configuration The fire system control panel provides system supervision for open circuit ground fault or loss of integrity initiates alarm and release of fire suppression agent and visual display of system status The suppression system agent release is activated automatically with release solenoids located on the fire suppression skid The optional CO or water mist suppression system can also be activated manually by switches mounted on the gas turbine enclosure or at the suppression skid If a fire is detected the fire detectors transmit an electrical signal to the fire system control panel to activate the fire alarm and suppression system 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 47 Turbomachinery Package Specification Titan 250 Generator Set The enclosure is also equipped with two gas detectors one at the gas turbine enclosure ventilation air inlet and the other at the ventilation exhaust to provide continuous monitoring of combustible gases The detectors consist of IR hydrocarbon sensors that provide input to the logical operating network LON module The gas turbine start signal is interlocked with the combustible gas monitoring system to ensure the atmosphere is safe prior to initiating a turbine engine start An alarm is initiated if the gas monitor fails Turbomachinery Package To From Customer Supervisory System ControlNet Turbotronic 4 Control Processor
109. t conditions with a unity power factor of 1 0 e Turbine and generator temperature measurement e Variable guide vane adjustment e Generator and engine tuning e Fuel transfers for dual fuel units e Load speed transient testing e Malfunction and safety devices testing e AC metering and control circuitry testing if AC metering is supplied calibration of AC metering circuits is performed by bench testing The package is usually tested with the generator When this is not practical due to schedule availability or test cell limitations the package may be tested with a slave generator Prior to shipment the contract generator will be mounted and aligned on the package Items excluded from standard package testing are inlet and exhaust systems ancillary equipment such as filters silencers ducting battery systems oil coolers ancillary skid switchgear and any customer furnished hardware 16 2 3 Generator Testing The generator is tested in accordance with the Institute of Electrical and Electronic Engineers IEEE standard specifications and Solar s specifications at the manufacturer s plant These tests satisfy both Solar and National Electrical Manufacturers Association NEMA requirements Supplier testing is performed under periodic quality control review by Solar to ensure conformity 16 2 4 Acceptance Test Data Acceptance test data are reviewed and approved by Test Engineering Quality Engineering and the project manager prio
110. t backup shutdown system provides additional protection This shuts the package down in a safe and orderly manner in the event of malfunction of the primary control system 9 2 System Architecture Key system components include e ControlLogix controller Allen Bradley e RSLogix 5000 programming software Rockwell Automation e 1794 Flex I O input output modules Allen Bradley e Combination generator control module Allen Bradley Basler Electric e 1701 FieldMonitor vibration monitoring system Bently Nevada e ControlNet network ControlNet International e TT4000 offskid display and monitoring system Solar Turbines e Offskid operator control panel Solar Turbines e TT4000S onskid local operator interface Solar Turbines e Onskid operator control panel Solar Turbines e Fire and gas monitoring and control system Det tronics e Independent backup shutdown system Solar Turbines Figure 14 provides an overview of the principle control system elements The ControlNet network provides primary communications between components Hardwire backup is provided for critical circuits The TT4000S and onskid operator panel are located on the package skid The TT4000 and offskid operator panel are located in a non hazardous area such as a control room The variable speed frequency drive VFD for the starter motor is typically located in a motor control center All other components are rated NEC Class 1 Division 2 or CENELEC Zone 2 for hazardous area duty an
111. te inputs analog inputs temperature inputs speed inputs discrete outputs and analog outputs 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 31 Turbomachinery Package Specification Titan 250 Generator Set 9 3 4 9 3 5 9 3 6 9 3 7 9 3 8 9 4 9 4 1 Vibration Monitoring System The system uses 1701 FieldMonitors and associated sensing devices from Bently Nevada The capacity of each monitor is eight vibration channels plus a keyphasor input The system is configurable from the control processor It detects preprogrammed alarm and shutdown levels See the specification tables for a list of monitored channels Backup Shutdown System The backup shutdown system shuts the package down in a safe and orderly manner without damage to the equipment in the event of a failure in the primary system The control processor is monitored by both an internal watchdog circuit and by an external watchdog device If either circuit detects a processor failure the backup system takes control It opens the generator circuit breaker closes the fuel valves and initiates a post lube cycle to protect the turbine bearings Once a backup shutdown is initiated operation can only be restored manually from the control panel after all faults have been cleared The emergency stop push button switches are wired to both the primary and backup systems Fire and Gas System Enclosed packages require fire and gas contro
112. ternational standard that describes a standardized approach to Asses the functional safety of electric electronic and programmable electronic safety related systems This standard is based on a life cycle evaluation of system reliability and safety level determination Safety integrity levels are categorized as SIL1 SIL2 SIL3 and SIL4 Levels are established by assessing the potential for personnel injury equipment damage and environmental damage The installation site design and operating requirements will determine the applicable SIL level Solar can provide reliability data on its equipment to assist customers in their overall safety assessments Offshore Marine Applications For installations that require offshore marine certification Solar conforms to the rules and standards established by certification authorities and or customer specifications Certification can be performed by one of the following authorities e Det Norske Veritas DNV e American Bureau of Shipping ABS e Lloyd s Register LR of Shipping e Bureau Veritas BV Solar can provide certification or provide supporting information to permit certification by another party Det Norske Veritas Certification Det Norske Veritas DNV certification includes design verification and a manufacturing survey DNV witnesses the fabrication and testing of engines and packages Operations witnessed by DNV are defined in the inspection and test plan ITP that is prepared by
113. tes periodic cleaning of the turbine compressor The cleaning system is designed for use in salt laden or dusty environments or where compressor contamination from hydrocarbon vapors is possible The turbine compressor cleaning system is composed of the following systems e On crank cleaning system e On line cleaning system Both cleaning systems are independent of each other and include a separate distribution manifold with pressure atomizing spray nozzles in the engine air inlet collector onskid piping strainer and solenoid shutoff valves to deliver water or approved cleaning fluid to the manifold Both systems require an external source of clean filtered air to pressurize the cleaning solutions 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 57 Turbomachinery Package Specification Titan 250 Generator Set SPARY NOZZLES MANIFOLD ASSEMBLIES STRAINERS QUICK DISCONNECTS SELNOID VALVE SELNOID VALVE Figure 27 Turbine Cleaning System 14 2 1 On Crank Cleaning System The on crank cleaning system only operates at gas turbine cranking speed with the fuel system and ignition system deactivated The gas turbine cranking and cleaning solution activation can be initiated from the control console or turbine control junction box 14 2 2 On Line Cleaning System The on line cleaning system only operates when the gas turbine speed is between 90 and 100 gas producer speed and with or with
114. the bus before the circuit breaker is closed Typically synchronization and closing of the breaker are done automatically Manual synchronization is available as an option Steady State Control During steady state operation the control system keeps the equipment within specified operating conditions The maximum power limit is determined by engine temperature and speed Temperature control is based on the third stage nozzle temperature T5 A set of thermocouples arranged circumferentially around the turbine are used and the values averaged If one thermocouple has a value that deviates from the average by more than a preset amount an alarm is generated by the control system If two thermocouples deviate the package is shut down Special sensors continuously monitor the gas turbine speed and the control system makes adjustments to meet operating requirements and to keep the speed within specified limits A separate backup overspeed detection system provides additional protection by automatically shutting the engine down if a preset overspeed limit is reached Stopping The gas turbine may be shutdown either manually or automatically The Normal Stop command initiates a cooldown stop The generator circuit breaker is opened and the gas producer runs at idle speed for a preset time to allow the gas turbine and driven equipment to cool then the fuel valves close The Emergency Stop command results in the immediate opening of the generator c
115. the fuel system The speed of the starter motor is gradually increased until the gas turbine reaches starter dropout speed The VFD then deenergizes the starter motor and the motor clutch assembly is disengaged Starter Motor The starter motor Figure 7 provides high breakaway starting torque and acceleration from standstill to starter dropout speed The motor is standard frame size and is constructed to be explosion proof and flameproof The motor includes an integral over temperature protection thermostat connected to the Turbotronic 4 control system for hazardous area motor certification and protection Separate cable entry points are provided for power connections thermal protection wiring and the space heater wiring Starting power is transferred to the gas turbine via the reduction drive gearbox and over running clutch and shaft assembly After a shutdown the starter motor rotates the turbine at low speed to prevent deformation of the rotor during cool down STARTER MOTOR Figure 7 Direct Drive AC Starter Motor and VFD Cabinet 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary 17 Turbomachinery Package Specification Titan 250 Generator Set 6 2 2 Variable Frequency Drive The VFD Figure 7 is a motor speed controller that provides pulse width modulated power with variable frequency and voltage to the starter motor Controlled by the Turbotronic 4 control system the VFD regulates v
116. ves batteries and battery charger are not approved for hazardous duty areas and must be installed in a nonhazardous area Three Phase Motor Voltage All three phase motors and three phase electrical components have the same voltage rating Motor starters and contactors are not provided 2 3 2 Service Connections The Titan 250 generator set is supplied with self contained systems for starting fuel lube oil and control All service connections Figure 2 are conveniently located on the outer edges of the skid 2008 Solar Turbines Incorporated All rights reserved TPS250GS 908 Preliminary Turbomachinery Package Specification LUBE OIL TO COOLER LUBE OIL FROM COOLER OIL DRAIN FROM DRIP PAN LOW POINT DRAIN FROM LUBE OIL LUBE OIL FILTER DRAIN UNFILTERED LUBE OIL TANK FILL DRIVEN EQUIPMENT PACKAGE AIR SUPPLY NATURAL GAS FUEL INLET Titan 250 Generator Set LUBE OIL COOLER VENT ENGINE EXHAUST COLLECTOR AND COMBUSTOR DRAIN LUBE OIL TANK DRAIN OIL DRAIN FROM DRIP PAN ON LINE CLEANING FLUID INLET ON CRANK CLEANING FLUID INLET ENGINE AIR INLET DUCT DRAIN TANK VENT AC POWER INPUTS Figure 2 Typical Titan 250 Generator Set Service Connections Driver Skid Table 1 Package Specifications Dimensions Approximate Package Measurements Height Unenclosed 3 89 m 12 ft 9 in Height Enclosed 4 12 m 13 ft 6 in Width to skid e
117. x 10 Pascals Wee Standard 15 C 760 mm Hg 2008 Solar Turbines Incorporated All rights reserved 79 TPS250GS 908 Preliminary Turbomachinery Package Specification Titan 250 Generator Set List of Solar s Engineering Specifications Solar s Engineering Specifications ES 9 4 Interpretation of Drawing Requirements ES 9 56 Fusion Welding ES 9 62 Ingestive Cleaning Solar Gas Turbine Engines ES 9 76 Traceability Requirements Critical Parts Engine and Related Systems ES 9 98 Fuel Air and Water or Steam for Solar Gas Turbine Engines ES 9 224 Lubricating Oils for Use In Solar Gas Turbine Engines ES 1593 Guidelines for NEC Compliance of Solar Product Lines Class Group D Division 1 and Division 2 ES 1762 Standards and Practices for Electrical Systems For Gas Turbine Packages Installed in Hazardous Areas CENELEC Standards ES 2231 Standards and Practices for The Design and Installation of Cable Channels and TC Rated Cables Installed In Class 1 Division 2 Hazardous Areas ES 2416 DC Supply Systems Note Engineering specifications can be made available upon request in accordance with Caterpillar and Solar Turbines Incorporated confidentially guidelines List of Solar s Product Information Letters Solar s Product Information Letters PIL 012 OG Customer Drawings Oil and Gas PIL 054 OSHA Noise Requirements PIL 058 Package Sound Levels PIL 097 Package Preservation a

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