LM6000 60 Hz Grey Book 2008 Rev 2
LM6000-50/60 HZ
Gas Turbine Generator Set
Product Specification
GE Energy
1333 West Loop South
Houston, TX 77027
Telephone: 713-803-0900
THIS PRODUCT MANUAL IS SUBMITTED WITH THE UNDERSTANDING THAT THE INFORMATION CONTAINED HEREIN WILL BE KEPT
CONFIDENTIAL AND NOT DISCLOSED TO OTHERS OR DUPLCIATED WITHOUT THE PRIOR CONSENT OF GE ENERGY DATA AND SPECIFICATIONS
MAY BE UPDATED FROM TIME TO TIME WITHOUT NOTICE. DATE OF ISSUE-6/2008
Table of Contents
Tab
Introduction
LM6000 Introduction
1
Data Sheet
2
Codes and Standards
3
Typical Performance Specifications
4
Typical Performance Curves
5
Technical Data
Performance
Description of Equipment
Major Equipment
6
System Descriptions – Major Equipment
7
Optional Equipment
8
Mechanical Outlines
9
Generator, Exciter and Voltage Regulator
10
One-Line Diagram
11
Control System Description
12
Equipment and Services by Buyer
13
Reference Specifications
14
Maintenance, Special Tools and Spare Parts
15
LM6000 - 60Hz Classic 6/2008
TABLE OF CONTENTS
Index I
Tab
Services
Customer Drawings
16
Extended Scope Equipment and Services
17
Training
18
Aftermarket Services
19
LM6000 - 60 Hz Classic 6/2008
Page 2 of 156
1.
1.1
LM6000 Introduction
Equipment Capabilities
GE is pleased to offer the LM6000 Aeroderivative Package. With the ability to deliver over
49 MW on a gross electrical basis, the LM6000 maintains the proven reliable technology with
modern design enhancements to improve maintainability and reliability. Additional benefits
of the LM60000 Package are the lower overall installed cost, shorten installation time,
reduced customer interfaces and enhanced safety.
The Package features the GE LM6000 gas turbine and a matching electric generator. It is
designed for simple-cycle, combined-cycle, and cogeneration installations. The LM6000 is
built with rugged components for base-load utility service. It can also start and stop easily for
“peaking” or “dispatched” applications. Additionally, quick dispatchability is available in
simple-cycle applications with the 10-minute fast start feature.
Package Type (60 Hz)
LM6000 PC SPRINT® – Natural Gas
and Water Injection
LM6000 PC – Natural Gas and Water
Injection
LM6000 PC – Natural Gas and Steam
Injection
kW
Btu/kWh
KJ/kWh
50,337
8457
8923
43,882
8,511
8,980
43,854
7,879
8,312
Conditions: Power at generator terminals
NOx = 25 ppm (SAC-Water)
59º F / 15 ºC, 60% RH
13.8kV, 0.85 pf
Losses: 0”/0” H2O Inlet/Exhaust
Fuel: Spec Gas (19,000 Btu / Lb, LHr) at 77º / 25ºC
VIGV option included
1.1.2 Engine Heritage
The LM6000 gas turbine is derived from the GE commercial CF6-80C2 aircraft engine. This
engine first entered aircraft service in 1985 and is used extensively in wide-body commercial
airliners. More than 2000 “80C2” engines are either on order or in use today.
1.1.3 Simple Design
The LM6000 package is offered in a 50 Hz and 60 Hz design. This document covers the 60
Hz design.
The LM6000 is a 2-shaft gas turbine engine equipped with a low-pressure compressor, highpressure compressor, combustor, high-pressure turbine, and low-pressure turbine.
LM6000 - 60 Hz Classic 6/2008
Page 3 of 156
1.1.4 Emissions Control
The table below shows the emission levels for each configuration at 15% O2 dry.
Fuel
Combustor
Diluent
Power
Augmentation
NOx Level
LM6000 SAC, 60 Hz
Gas, Liquid or
Dual Fuel
Single Annular
(SAC)
Water
None
25 ppm gas/
42 ppm liquid
LM6000 DLE, 60 Hz
Gas
Dry Low Emissions
(DLE)
None
None
15 ppm
Product Offerings
LM6000 Emissions Abatement Configurations
1.1.5 Output Enhancements
Various options are available to improve the typical OUTPUT-MW profile of the LM6000
gas turbine. To improve high ambient temperature performance, either evaporative cooling or
coils for mechanical chilling are available.= GE Energy will work with the customer to
determine the applicability of of these enhancements to their particular case.
1.1.6 High Availability and Reliability
The LM6000 gas turbine generator set has a proven record of high availability and reliability.
With more than 700 units installed since 1992, the LM6000 gas turbine generator set leads the
industry in reliability greater than 99.7%* and availability above 98.6%*. Each gas turbine is
factory tested to full speed and full load for performance and mechanical integrity. Every
package is static tested to check each system of the package. Refer to section 1.2.1 for static
testing summary.
Leveraging aircraft experience and design, the aeroderivative design approach incorporates
features such as split castings, modular construction, individual replacement of internal and
external parts, and GE’s “lease pool” engine program. The extensive use of high quality
components common with its parent aircraft engine validates engine reliability and offers
reduced parts cost.
Various inspections and hot section repairs can be performed on the gas turbine at site within
the turbine enclosure. The “Hot Section”,HPT and combustor, can be removed/replaced in the
field within seventy-two hours allowing for greater availability during planned maintenance.
Greater availability is achieved by the on-condition maintenance program, which inspects and
repairs only as necessary to desired operational condition.
* 50th percentile of 233 units reporting into ORAP® as of July 2007.
LM6000 - 60 Hz Classic 6/2008
Page 4 of 156
1.1.7 Simple Cycle
Simple cycle aeroderivative gas turbines are typically used to support the grid by providing
quick start (10 minutes to full power) and load following capability. High part-power
efficiency, as shown in Figure 1.1, enhances load following and improves system-operating
economics.
39%
Efficiency, %
37%
35%
33%
31%
SAC-Dry
29%
SAC-Water
DLE
27%
25%
50%
55%
60%
65%
70%
75%
80%
85%
90%
95%
100%
% of Baseload
Basis of Performance: Amb 59ºF RH of 60% with 0” H20 inlet/exhaust losses at 0 ft. ASL, Fuel natural Gas (19,000 Btu / Lb),
60Hz, 13.8 kV, 0.85pf. Not for guarantee.
NOx Water, Steam and DLE are to 25 PPMVD Nox at 15% 02
Figure 1.1: Part Power Efficiency
1.2
Factory and Service Capabilities
A full range of services are available for the LM6000:
1.2.1 Factory Static Testing
The standard factory test for the package is a 400-point static test to confirm:
• Temperature element output and wiring
• Transmitter range, output and wiring
• Solenoid operation
• Control valve torque motor, excitation and return signal
• Fire system continuity and device actuation
LM6000 - 60 Hz Classic 6/2008
Page 5 of 156
•
•
System cleanliness
Control system software loading and validation
1.2.2 Factory String Testing
Available as a factory option. Reference section 8.2.28 for more details on String Testing.
1.2.3 Drawings and Service Manuals
Drawings are supplied which allow a buyer to design foundations for the package and offbase auxiliary modules, make station layouts, order long lead buyer-supplied equipment and
prepare an installation bid package or plan. The Operation and Maintenance Manuals are
provided in CD form in the English language, using standard (U.S.) customary engineering
units. The manuals include basic concepts in operating the power generating equipment,
guides to troubleshooting, equipment schematics, and general arrangement and flow and
instrument diagrams.
The copies of the Installation and Commissioning (I&C) manuals will also be provided.
1.2.4 Recommended Spare Parts
Supplied with the Operation and Maintenance Manual are lists of the recommended spare
parts for the turbine, generator, exciter, unit controls and off-base accessories. Additionally,
specialists are available to assist you with your parts planning and ordering activities.
1.2.5 Installation and Start-Up Services
Field service consultation for installation and startup is available as an option with the basic
unit. This extended service can be supplemented with the full range of in-house product
support services available with various GE divisions and GE Energy in Houston, including
supervisory services for field assembly of the major equipment components, commissioning
and initial operation. Refer to Section 17 for details. (do a find and replace where appropriate
for “See Section” to Refer to)
1.2.6 Operation and Maintenance Training
The basic scope includes a Gas Turbine Familiarization Course in Cincinnati, Ohio and an
Operator’s Training Course at the GE Energy Jacintoport facility. These courses include
basic concepts of an aeroderivative gas turbine generator set plus the normal operating
guidelines and maintenance practices. Additional training courses are available (i.e., for
controls) at other GE Training Centers.
The training material is also available for purchase in CD format for reference.
LM6000 - 60 Hz Classic 6/2008
Page 6 of 156
1.2.7 Field Verification of Performance
GE Energy will assist with field performance testing to demonstrate that the generator
electrical output and heat rate achieve guaranteed levels.
1.2.8 Summary
In summary, the LM6000 is unique to the power generation industry. As the most trusted and
reliable gas turbines in the world, we recommend the LM6000 as a standard 40-50 MW
building block for utility and industrial applications.
LM6000 - 60 Hz Classic 6/2008
Page 7 of 156
2.
Data Sheets
This section provides additional data for a typical LM6000 gas turbine generator package (60
Hz), including: auxiliary power loads, optional auxiliary power loads, and shipping
dimensions and weights.
2.1
LM6000 Auxiliary Power Loads (60 Hz)
Normal Operating Load
Standard Electric Loads
Turbine Vent Fans
Generator Vent Fans
Hydraulic Start Pump
Generator Aux. L.O. Pump
Generator Jacking Oil Pump
Gas Turbine Lube Oil Heater
Generator L.O. Heater
Hyd. Starter L.O. Heater
Generator Space Heater
Turbine Air/Oil Separator
Lighting & Low Voltage
Distribution System
Water Wash Supply Pump
Hydraulic Starter Oil Heat
Exchanger Fan
Turbine Water Wash Tank
Heaters
Total (kW)
LM6000 - 60 Hz Classic 6/2008
Required for Black Start
Qty
2
2
1
1
1
1
2
1
1
1
Aux
Rating
125 hp
100 hp
200 hp
7.5 hp
15 hp
3 kW
4 kW
3 kW
4 kW
1 hp
Total Qty
1
1
0
1
0
0
0
0
0
1
KW
93
75
0
5.6
0
0
0
0
0
0.75
Total Qty
1
1
1
1
1
1
2
1
1
1
kW
93
75
149
5.6
11.2
3
8
3
4
0.75
1
1
45 kVA
2 hp
1
1
45
1.5
1
0
45
0
1
3 hp
1
2.2
1
2.2
2
9 kW
2
0
222
2
0
397
Page 8 of 156
2.2
Optional LM6000 Auxiliary Power Loads
Optional Electrical Loads
Auxiliary Skid Vent Fans
Liquid Fuel Pump
Water Inj. Pump - Gas Fuel
Water Inj. Pump - Liquid
Fuel
Evap Cooler Recirc. Pumps
Auxiliary Skid Heater
Fuel Pump Skid Vent Fans
Gen. Vent Fans - TEWAC
Control House A/C
Sprint Skid Pump
Liquid Fuel Pump Skid
Heater
Turbine Enclosure Heaters
Turbine Enclosure Heaters
Generator Enclosure Heaters
Generator Enclosure Heaters
LM6000 - 60 Hz Classic 6/2008
Qty
2
2
2
hp
1
100
75
2
2
1
2
2
2
1
125
5
3 kW
1
25
4.1 kW
10
1
2
2
2
2
3 kW
5 kW
10 kW
5 kW
10 kW
Normal Operating Load
Total Qty
kW
2
1.5
1
74.6
1
55.9
1
2
Required for Black Start
Total Qty
kW
2
1.5
1
74.6
0
0
2
1
1
1
93.2
7.46
3
1.5
18.6
4.1
7.5
1
2
1
2
1
2
1
93.2
7.46
3
1.5
18.6
8.2
7.5
1
0
0
0
0
3
5
5
10
10
1
2
2
2
2
3
5
5
10
10
Page 9 of 156
2.3
Preliminary Shipping Dimensions and Weights
for One (1) LM6000 Gas Turbine Generator Unit
GROSS WEIGHT LENGTH
Description
lbs
kg
in
cm
Turbine Base 120,000 54,432.0 371.00 942.3
Shear Lugs
1,020
462.7
45.00 114.3
H-Frame
2,085
945.8
174.00 442.0
Ruffneck
heaters
1,050
476.3
67.00 170.2
CDP Purge
1,185
537.5
80.00 203.2
VBV
Expansion
Joint
695
315.3
90.00 228.6
Exhaust
Flashing
725
328.9
62.00 157.5
Mechanical
Shiploose
2,785 1,263.3 170.00 431.8
Alignment
Tool
530
240.4
104.00 264.2
Turbine Lift
Fixture
1,410
639.6
128.00 325.1
LM6000
Generator
Base
68,000 30,844.8 337.00 856.0
Brush
Generator
176,000 79,833.6 301.00 764.5
Generator
Lube Oil
Piping
1,420
644.1
212.00 538.5
Run down
tanks
1,455
660.0
106.00 269.2
Generator
transition
throat
1,800
816.5
125.00 317.5
Generator
exhaust hood 9,070 4,114.2 174.00 442.0
Electrical
Shiploose
1,105
501.2
96.00 243.8
Lucas
Coupling
1,445
655.5
120.00 304.8
Roof Skid
Transition
44,000 19,958.4 470.00 1193.8
Raincap
1,320
598.8
82.00 208.3
Raincap
1,320
598.8
82.00 208.3
Ventilation
Silencer
3,100 1,406.2 80.00 203.2
LM6000 - 60 Hz Classic 6/2008
WIDTH
in
cm
171.00 434.3
25.00
63.5
35.00
88.9
HEIGHT
in
cm
178.00 452.12
17.00
43.18
36.00
91.44
VOLUME
ft3
m3
6535.0 185.03
11.1
0.31
126.9
3.59
36.00
48.00
91.4
121.9
67.00
24.00
170.18
60.96
93.5
53.3
2.65
1.51
32.00
81.3
24.00
60.96
40.0
1.13
62.00
157.5
17.00
43.18
37.8
1.07
48.00
121.9
43.00
109.22
203.1
5.75
30.00
76.2
32.00
81.28
57.8
1.64
76.00
193.0
17.00
43.18
95.7
2.71
171.00
434.3
178.00
452.12
5936.1
168.08
159.00
403.9
130.00
330.20
3600.5
101.94
32.00
81.3
21.00
53.34
82.4
2.33
46.00
116.8
30.00
76.20
84.7
2.40
125.00
317.5
39.00
99.06
352.6
9.98
150.00
381.0
87.00
220.98
1314.1
37.21
48.00
121.9
38.00
96.52
101.3
2.87
32.00
81.3
40.00
101.60
88.9
2.52
172.00
82.00
82.00
436.9
208.3
208.3
149.00
54.00
54.00
378.46
137.16
137.16
6970.6
210.1
210.1
197.36
5.95
5.95
80.00
203.2
131.00
332.74
485.2
13.74
Page 10 of 156
2.3
Preliminary Shipping Dimensions and Weights
for One (1) LM6000 Gas Turbine Generator Unit (Cont.)
Description
Ventilation
Silencer
VBV Duct
VBV Silencer
VBV Hood
Roof Skid
Transition
Generator
Fan Exp Jpint
Demister
Plenum
LH Coil
Module
RH Coil
Module
Walkways &
Handrails
Coil Module
Parts
Support
Structure &
Ladder
Pre-Filter
Doors (16)
Pre-Filter
Doors (16)
Nuts & Bolts
Shiploose
Paint (1-5
gal)
Flex Hoses
Auxiliary
Module
Lineside
Cubicle
Neutral
Cubicle
Acid
CO2 Cover &
Rack
CO2 Bottles
BUS Relay
station
GROSS WEIGHT
lbs
kg
LENGTH
in
cm
WIDTH
in
cm
HEIGHT
in
cm
VOLUME
ft3
m3
3,100
15,600
19,800
6,460
1,406.2
7,076.2
8,981.3
2,930.3
80.00
158.00
172.00
140.00
203.2
401.3
436.9
355.6
80.00
150.00
146.00
102.00
203.2
381.0
370.8
259.1
131.00
102.00
82.00
108.00
332.74
259.08
208.28
274.32
485.2
1399.0
1191.7
892.5
13.74
39.61
33.74
25.27
1,710
775.7
148.00
375.9
73.00
185.4
34.00
86.36
212.6
6.02
450
204.1
51.00 129.5 51.00
720
326.6
36.00
91.4
36.00
24,400 11,067.8 394.00 1000.8 146.00
129.5
91.4
370.8
24.00
74.00
149.00
60.96
187.96
378.46
36.1
55.5
4960.1
1.02
1.57
140.44
43,500 19,731.6 400.00 1016.0 153.00
388.6
149.00
378.46
5277.1
149.42
43,500 19,731.6 400.00 1016.0 153.00
388.6
149.00
378.46
5277.1
149.42
3,640
1,651.1
152.00
386.1
60.00
152.4
44.00
111.76
232.2
6.58
1,225
555.7
44.00
111.8
44.00
111.8
38.00
96.52
42.6
1.21
5,620
2,549.2
312.00
792.5
81.00
205.7
62.00
157.48
906.8
25.67
2,010
911.7
129.00
327.7
56.00
142.2
52.00
132.08
217.4
6.16
1,940
880.0
129.00
327.7
56.00
142.2
52.00
132.08
217.4
6.16
1,750
793.8
48.00
121.9
48.00
121.9
36.00
91.44
48.0
1.36
130
260
59.0
117.9
24.00
64.00
61.0
162.6
18.00
19.00
45.7
48.3
23.00
14.00
58.42
35.56
5.8
9.9
0.16
0.28
85,000 38,556.0 564.00 1432.6 168.00
426.7
168.00
426.72
9212.0
260.83
2,800
1,270.1
68.00
172.7
68.00
172.7
124.00
314.96
331.8
9.40
4,400
650
1,995.8
294.8
96.00
47.00
243.8
119.4
68.00
19.00
172.7
48.3
120.00
33.00
304.80
83.82
453.3
17.1
12.84
0.48
3,180
3,885
1,442.4
1,762.2
110.00
47.00
279.4
119.4
45.00
37.00
114.3
94.0
115.00
72.00
292.10
182.88
329.4
72.5
9.33
2.05
6,500
2,948.4
72.00
182.9
36.00
91.4
36.00
91.44
54.0
1.53
LM6000 - 60 Hz Classic 6/2008
Page 11 of 156
2.3
Preliminary Shipping Dimensions and Weights
for One (1) LM6000 Gas Turbine Generator Unit (Cont.)
GROSS WEIGHT LENGTH
Description
lbs
kg
in
cm
Lift pins
7,260 3,293.1 114.00 289.6
Air Filter
spreader bar
4,650 2,109.2 440.00 1117.6
Main Unit
Spreader bar 1,800
816.5
211.00 535.9
Generator
spreader bar
1,400
635.0
133.00 337.8
Slings &
Shackles
10,000 4,536.0 139.00 353.1
Additional
Cable (3
rolls)
3,000 1,360.8 72.00 182.9
Vent(Anti
icing system) 15,600 7,076.2 158.00 401.3
Vent(Anti
icing system) 15,600 7,076.2 158.00 401.3
Ladders
1,250
567.0
339.00 861.1
Platforms
8,325 3,776.2 202.00 513.1
Nuts & Bolts
Shiploose
670
303.9
61.00 154.9
High Pressure
Demin Water
Filter
460
208.7
27.00
68.6
Fire
700
317.5
36.00
91.4
Misc Parts for
water system
50
22.7
48.00 121.9
Relay Panels 900.00
408.2
72.00 182.9
Switch Board 750.00
340.2
72.00 182.9
Switch Gear 5,000.0 2,268.0 77.00 195.6
Switch Gear 18360.0 8,328.1 181.00 459.7
Switchgear
Accessories 1,250.0 567.0
88.00 223.5
Switchgear
Accessories 1,350.0 612.4
110.00 279.4
Switchgear
Accessories 850.00
385.6
94.00 238.8
Switchgear
Accessories 290.00
131.5
60.00 152.4
LM6000 - 60 Hz Classic 6/2008
WIDTH
in
cm
78.00 198.1
HEIGHT
in
cm
30.00
76.20
VOLUME
ft3
m3
154.4
4.37
33.00
83.8
12.00
30.48
100.8
2.85
26.00
66.0
12.00
30.48
38.1
1.08
26.00
66.0
12.00
30.48
24.0
0.68
96.00
243.8
42.00
106.68
324.3
9.18
36.00
91.4
36.00
91.44
54.0
1.53
150.00
381.0
102.00
259.08
1399.0
39.61
150.00
59.00
102.00
381.0
149.9
259.1
102.00
48.00
59.00
259.08
121.92
149.86
1399.0
555.6
703.5
39.61
15.73
19.92
43.00
109.2
42.00
106.68
63.8
1.81
27.00
36.00
68.6
91.4
48.00
72.00
121.92
182.88
20.3
54.0
0.57
1.53
24.00
48.00
36.00
106.00
106.00
61.0
121.9
91.4
269.2
269.2
55.00
72.0
72.0
116.0
116.0
139.70
182.88
182.88
294.64
294.64
36.7
144.0
108.0
547.9
1287.9
1.04
4.08
3.06
15.51
36.47
48.00
121.9
48.0
121.92
117.3
3.32
39.00
99.1
29.0
73.66
72.0
2.04
46.00
116.8
20.0
50.80
50.0
1.42
31.00
78.7
17.0
43.18
18.3
0.52
Page 12 of 156
2.3
Preliminary Shipping Dimensions and Weights
for One (1) LM6000 Gas Turbine Generator Unit (Cont.)
GROSS WEIGHT LENGTH
Description
lbs
kg
in
cm
Switchgear
Accessories 475.00
215.5
96.00 243.8
Switchgear
Accessories 1,600.0 725.8
125.00 317.5
Switchgear
Accessories
90.00
40.8
25.00
63.5
WIDTH
in
cm
HEIGHT
in
cm
VOLUME
ft3
m3
50.00
127.0
50.0
127.00
138.9
3.93
95.00
241.3
60.0
152.40
412.3
11.67
15.00
38.1
15.0
38.10
3.3
0.09
Note: Some equipment listed in this table may not be applicable to specific projects.
.
LM6000 - 60 Hz Classic 6/2008
Page 13 of 156
3.
3.1
Codes and Standards
Codes and Standards for Gas Turbine Generators
GE Energy considers the applicable sections of the following US and ISO Codes and
Standards to be the most relevant standards for gas turbine equipment. Our designs and
procedures are generally compliant with applicable sections of the following:
ANSI A58.1
Minimum Design Loads for Buildings and Other Structures
ANSI B1.1
Unified Inch Screw Threads
ANSI B1.20.1
Pipe Threads
ANSI B16.5
Steel Pipe Flanges and Flanged Fittings
ANSI B16.9
Factory-Made Wrought Steel Butt Welding Fittings
ANSI B16.21
Non-Metallic Flat Gaskets for Pipe Flanges. (Spiral-wound gaskets
per API 601 may be used, particularly in turbine compartment
piping)
ANSI B31.1
Pressure Piping and Gas Turbine Piping Systems Comply
ANSI B133.2
Basic Gas Turbine
ANSI B133.3
Gas Turbine Auxiliary Equipment.
ANSI B133.4
Gas Turbine Controls and Protection Systems
ANSI B133.5
Gas Turbine Electrical Equipment
ANSI B133.8
Gas Turbine Installation Sound Emissions
ANSI/NAFPA 12
Carbon Dioxide Extinguishing Systems
ANSI/NFPA 70
National Electrical Code
ANSI C31.1
Relays Associated with Electric Power Apparatus
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3.1
Codes and Standards for Gas Turbine Generators (Cont)
ANSI IEEE C37.2
Electrical Power System Device Function Numbers
ANSI C37.90a/
IEEE-472
ANSI C50.10
Guide for Surge Withstand Capability (SWC) Tests
General Requirements for Synchronous Machines
ANSI C50.14
Requirements for Combustion Gas Turbine Driven Cylindrical
Rotor Synchronous Generators
ANSI C57.94
American Standard, Guide for Installation and Maintenance of Dry
Type Transformers
ANSI C83.16
Relays
ANSI/IEEE 100
IEEE Standard Dictionary of Electrical and Electronic Terms
ANSI/NEMA MG1
Motors and Generators
ANSI/NEMA MG2
Safety Standard for Construction and Guide for Selection,
Installation and Use of Electric Motor and Generators
ANSI S1.2
Method for the Physical Measurement of Sound
ANSI S1.4
Specification for Sound Level Meters
ANSI S1.13
Method for the Measurement of Sound Pressure Levels
ANSI S6.1/
SAE/J184A
Qualifying a Sound Data Acquisition System
AGMA 421
Standard Practice for High Speed Helical and Herringbone Gear
Units
IBC 2000
International Building Code
IEEE Std 421
IEEE Standard Criteria and Definitions for Excitation Systems for
Synchronous Machines
EIA RS-232
Interface between Data Terminal Equipment and Data
Communication Equipment Employing Serial Binary Interchange
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Note: ATEX and CE Codes and Standards are applied when required.
EN 61010-1 Safety Requirements for Electrical Equipment for Measurement, Control, and
Laboratory Use, Part 1: General Requirements
CAN/CSA 22.2 No. 1010.1-92 Safety Requirements for Electrical Equipment for
Measurement, Control, and Laboratory Use, Part 1: General Requirements
ANSI/ISA S82.02.01 1999 Safety Standard for Electrical and Electronic Test, Measuring,
Controlling, and Related Equipment – General Requirements
UL 796 Printed Circuit Boards
ANSI IPC Guidelines
ANSI IPC/EIA Guidelines
EN 55081-2 General Emission Standard
EN 50082-2 Generic Immunity Industrial Environment
EN 55011 Radiated and Conducted Emissions
IEC 61000-4-2 Electrostatic Discharge Susceptibility
IEC 61000-4-3 Radiated RF Immunity
IEC 61000-4-4 Electrical Fast Transit Susceptibility
IEC 61000-4-5 Surge Immunity
IEC 61000-4-6 Conducted RF Immunity
IEC61000-4-11Voltage Variation, Dips & Interruptions
ANSI/IEEE C37.90.1 Surge
EN 61010-1 Safety Requirements for Electrical Equipment for Measurement, Control, and
Laboratory Use, Part 1: General Requirements
EN 50021 Electrical Apparatus for Potentially Explosive Atmospheres
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The GE Gas Turbine Drafting Standards are based on the following Standards as appropriate
to the gas turbine. Please note that in several instances, symbols, etc. have been devised for
GE’s special needs (such as flow dividers and manifolds:
ANSI B46.1
Surface Texture
ANSI Y14.15
Electrical and Electronics Diagrams (On base
gas turbine and accessory base equipment)
ANSI Y14.17
Fluid Power Diagrams
ANSI Y14.36
Surface Texture Symbols
ANSI Y32.2/CSA
Graphic Symbols for Electrical and
Electronics
299/IEEE 315
Diagrams
ANSI Y32.10
Graphical Symbols for Fluid Power Diagram
ANSI Y32.11
Graphical Symbols for Process Flow Diagram
ANSI Z32.2.3
Graphical Symbols for Pipe Fittings, Valves
& Piping
AWS A2.0-68
Welding Symbols
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4.
4.1
Typical Performance Specifications
LM6000 ISO Performance Data
Simple Cycle Gas Turbine 60 Hz Applications
(Natural Gas)
Engine
Fuel Configuration
Single Annular Combustor
Single Annular Combustor
Natural Gas
Natural Gas and Water
Injection
Natural Gas and Steam
Injection
Natural Gas
Single Annular Combustor
Dry Low Emissions
Power
kW
43,284
43,882
Heat Rate LHV
BTU/kW-hr
KJ/kW-hr
8,133
8,581
8,511
8,980
43,854
7,879
8,312
42,300
8,315
8,773
Conditions:
Power at Generator Terminals
NOx = 51 mg / Nm³ (SAC-Water, SAC-Steam, and DLE)
15°C, 60% RH
11.5 kV,PF: 0.85
Losses: 0/0mm H2O Inlet/Exhaust
Fuel: Spec Gas (44,194 kJ/kg, LHV) at 25ºC
VIGV Included
Simple Cycle Gas Turbine 60 Hz Applications
(Liquid Fuel)
Engine
Fuel Configuration
Single Annular Combustor
Single Annular Combustor
Liquid
Liquid and Water
Injection
Liquid
Dry Low Emissions
Power
kW
41,784
43,053
40,179
Heat Rate LHV
BTU/kW-hr
KJ/kW-hr
8,253
8,708
8,631
9,106
8,421
8,885
Conditions:
Power at Generator Terminals
NOx = 86 mg / Nm³ (SAC-Water)
15ºC, 60% RH
11.5 kV, PF: 0.85
Losses: 0/0mm H²O Inlet/Exhaust
Fuel: Spec (42,798 kJ/kg) Liquid with ≤ 0.1% Sulfur
VIGV Included
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Simple Cycle Gas Turbine 60 Hz Applications
(Natural Gas with SPRINT®)
Engine
Fuel Configuration
Single Annular Combustor
Single Annular Combustor
Natural Gas
Natural Gas and Water
Injection
Natural Gas and Steam
Injection
Natural Gas
Single Annular Combustor
Dry Low Emissions
Power
KW
46,673
50,337
Heat Rate LHV
BTU/kW-hr
KJ/kW-hr
8,142
8,591
8,
8,980
50,500
7,895
8,329
46,903
8,272
8.727
Conditions:
Power at Generator Terminals
NOx = 25PPM (SAC-Water, SAC-Steam, and DLE)
15ºC, 60% RH
13.8 kV, 0.85 pf
Losses: 0/0mm H²O Inlet/Exhaust
Fuel: Spec Gas (44,194 kj/kg), LHV) at 25 ºC
VIGV included
Simple Cycle Gas Turbine 60 Hz Applications
(Liquid with SPRINT®)
Engine
Fuel Configuration
Single Annular Combustor
Single Annular Combustor
Liquid
Liquid and Water
Power
KW
41,769
43,811
Heat Rate LHV
BTU/kW-hr
KJ/kW-hr
8,291
8,748
8,311
8,769
Conditions:
Power at Generator Terminals
NOx = 86 mg / Nm³ (SAC-Water)
15ºC, 60% RH
11.5 kV, 0.85 pf
Losses: 0/0mm H²O Inlet/Exhaust
Fuel: Spec (42,798 kj/kg) Liquid with ≤ 0.1% Sulfur
VIGV Included
4.2
Performance Data and Curves
Performance curves are included in Performance Curves Section 5. From these curves it is
possible to determine performance at ambient temperatures, altitudes, and conditions differing
from those listed in the performance specifications.
4.3
Guarantee Basis
Performance guarantees for power and efficiency are based on the condition and cleanliness
of the gas turbine. If more than 200 fired hours have elapsed before conducting a
LM6000 - 60 Hz Classic 6/2008
Page 19 of 156
performance test, a GE Energy representative has the right to inspect the unit to ensure
condition and cleanliness standards have been met. The guarantees are also based on a site
test conducted in accordance with GE Energy’s standard practices and protocols as described
in the Test Specifications. GE Energy reserves the right to have a representative present
during the performance test.
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5.
5.1
Performance Curves
Turbine Performance Curves
5.1.1 Turbine Curves –at 60 Hz/ 13.8 kV*
• LM6000 performance at various ambient temperatures
• LM6000 with SPRINT performance at various ambient temperatures
• LM6000 heat rate at various ambient temperatures
• LM6000 with SPRINT® heat rate at various ambient temperatures
• LM6000 part power heat rate
• LM6000 with SPRINT® performance at various altitudes
• LM6000 part power heat rate (LHV)
• LM6000 with SPRINT part power heat rate (LHV)
• LM6000 part power efficiency
• LM6000 with SPRINT™ part power efficiency
• LM6000 10-minute start cycle
Figure 5-1
Figure 5-2
Figure 5-3
Figure 5-4
Figure 5-5
Figure 5-6
Figure 5-7
Figure 5-8
Figure 5-9
Figure 5-10
Figure 5-11
* Note - The performance curves may change slightly upon finalization of the product design
and/or generator manufacturer selection.
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Power at Generator Terminal, kW
55000
50000
45000
40000
35000
SAC DRY
30000
Water
DLE
25000
-20
-10
0
10
Temperature,
20
O
30
40
C
Figure 5- 1: LM6000 performance at various ambient temperatures
Basis of Performance: RH of 60% with 0 mm H20 inlet exhaust losses at 0m ASL, Fuel: Natural Gas (44,194 kJ/kg), 50Hz,
11.5kV, 0.85pf. Not for guarantee.
Nox Water and DLE are to 51 mg / Nm³.
Power at Generator Terminal, kW
55000
50000
45000
40000
35000
SAC DRY
30000
Water
DLE
25000
-20
-10
0
10
Temperature,
20
O
30
40
C
Figure 5- 2: LM6000 with SPRINT performance at various ambient temperatures
Basis of Performance: RH of 60% with 0 mm H20 inlet exhaust losses at 0m ASL, Fuel: Natural Gas (44,194 kJ/kg), 60Hz,
11.5kV, 0.85pf. Not for guarantee.
Nox Water and DLE are to 51 mg / Nm³.
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10400
Heat Rate, kJ/kW-hr, LHV
9900
9400
8900
8400
SAC DRY
7900
Water
DLE
7400
-20
-10
0
10
20
30
40
O
Temperature, C
Figure 5- 4: LM6000 heat rate at various ambient temperatures
Basis of Performance: RH of 60% with 0 mm H20 inlet exhaust losses at 0m ASL, Fuel: Natural Gas (44,194
J/kg), 60Hz, 11.5kV, 0.85pf. Not for guarantee.
Nox Water and DLE are to 51 mg / Nm³.
9900
Heat Rate, kJ/kW-hr, LHV
9400
8900
8400
7900
SAC DRY
W ater
DLE
7400
-20
-10
0
10
Temperature,
20
O
30
40
C
Figure 5- 3: LM6000 with SPRINT heat rate at various ambient temperatures
Basis of Performance: RH of 60% with 0 mm H20 inlet exhaust losses at 0m ASL, Fuel: Natural Gas (44,194
J/kg), 60Hz, 11.5kV, 0.85pf. Not for guarantee.
Nox Water and DLE are to 51 mg / Nm³.
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140%
Heat Rate, % of Baseload
135%
130%
125%
120%
115%
SAC DRY
110%
SAC W ater
DLE
105%
100%
50
60
70
80
90
100
% of Baseload
Figure 5- 6: LM6000 60Hz with SPRINT performance at various altitudes
Basis of Performance: RH of 60% with 0 mm H20 inlet exhaust losses at 0m ASL, Fuel: Natural Gas (44,194
J/kg), 60Hz, 11.5kV, 0.85pf. Not for guarantee.
Nox Water and DLE are to 51 mg / Nm³.
52000
Power at Generator Terminal, kW
50000
48000
46000
44000
42000
40000
SAC DRY
38000
W ater
DLE
36000
34000
0
200
400
600
800
1000
1200
1400
1600
Altitude, M eters above sea level
Figure 5- 5: LM6000 part power heat reate
Basis of Performance: RH of 60% with 0 mm H20 inlet exhaust losses at 0m ASL, Fuel: Natural Gas (44,194 J/kg),
60Hz, 11.5kV, 0.85pf. Not for guarantee. Nox Water and DLE are to 51 mg / Nm³.
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140%
Heat Rate, % of Baseload
135%
130%
125%
120%
115%
SAC DRY
110%
S A C W a te r
D LE
105%
100%
50
60
70
80
90
100
% o f B a s e lo a d
Figure 5- 7: LM6000 60Hz with SPRINT part power heat rate (LHV)
Basis of Performance: RH of 60% with 0 mm H20 inlet exhaust losses at 0m ASL, Fuel: Natural Gas (44,194 J/kg),
60Hz, 11.5kV, 0.85pf. Not for guarantee.
Nox Water and DLE are to 51 mg / Nm³.
140%
Heat Rate, % of Baseload
135%
130%
125%
120%
115%
110%
SAC DRY
SAC Water
105%
DLE
100%
50
60
70
80
90
100
% of Baseload
Figure 5- 8: LM6000 60Hz part power heat rate (LHV)
Basis of Performance: RH of 60% with 0 mm H20 inlet exhaust losses at 0m ASL, Fuel: Natural Gas (44,194 J/kg),
60Hz, 11.5kV, 0.85pf. Not for guarantee.
Nox Water and DLE are to 51 mg / Nm³.
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50%
Efficiency, %
45%
40%
35%
30%
SAC DRY
25%
SAC WATER
DLE
20%
50
55
60
65
70
75
80
85
90
95
100
% of Baseload
Figure 5- 10: LM6000 60Hz part power efficiency
Basis of Performance: RH of 60% with 0 mm H20 inlet exhaust losses at 0m ASL, Fuel: Natural Gas (44,194
J/kg), 60Hz, 11.5kV, 0.85pf. Not for guarantee.
Nox Water and DLE are to 51 mg / Nm³.
50%
Efficiency, %
45%
40%
35%
30%
SAC DRY
25%
SAC W ATER
DLE
20%
50
55
60
65
70
75
80
85
90
95
100
% of Baseload
Figure 5- 9: LM6000 60Hz with SPRINT part power heat rate (LHV)
Basis of Performance: RH of 60% with 0 mm H20 inlet exhaust losses at 0m ASL, Fuel: Natural Gas (44,194
J/kg), 60Hz, 11.5kV, 0.85pf. Not for guarantee.
Nox Water and DLE are to 51 mg / Nm³.
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10-Minute Simple Cycle Start Cycle for LM6000 with SPRINT®
Figure 5- 11: LM6000 10-minutes start cycle
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6.
6.1
Major Equipment
LM6000 PC Gas Turbine
Base-mounted, simple cycle, two (2) spool gas turbine in a fully enclosed turbine
compartment:
•
•
•
•
•
•
•
•
•
•
•
Two-shaft configuration with direct drive output at (50 Hz) 3600 rpm… match apps for
PC & PD
Radial inlet
Five stage low pressure compressor (LPC)
Fourteen stage high pressure compressor (HPC) with horizontal split casing
Combustor
Thirty fuel nozzles and dual igniters (DLE is option)
Two stage high pressure turbine (HPT)
Five stage low pressure turbine (LPT)
Borescope ports for diagnostic inspection
Accessory drive gearbox for starter, lube & scavenge pumps
Flexible dry type main load coupling and guard
6.1.1 Fuel Systems
•
•
•
Natural gas fuel system
Water Injection for NOx
Liquid/Dual Fuel
6.1.2 Starting System
The hydraulic start system mounted on the auxiliary skid will include:
•
•
•
•
•
40 gallon / 151 l Reservoir tank (should the dimensions be included in the Greybook or
contract)
Hydraulic pump assembly
LP return filter
Case drain filter
Heat exchanger
6.1.3 Inlet Air System
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•
•
•
High efficiency inlet filter system
Silencing system
Support structure, ladders, and platforms
6.1.4 Exhaust System
•
•
Axial exhaust collector system
Connection flange at the wall of the turbine enclosure
6.1.5 Lube Oil Systems
The synthetic lube oil system for the turbine will include:
• 304 stainless steel tank (150 gallons / 568 l) and piping mounted on turbine skid
• Valves with stainless steel trim
• Duplex filters (supply) mounted on turbine skid
• Duplex filters (scavenge) mounted on auxiliary module
• Duplex shell and tube coolers mounted on the auxiliary module
• Shaft-driven positive displacement supply
• Scavenge pump
6.1.6 Turbine Engine Compartment
•
For weatherproofing, acoustics, ventilation and fire system
6.1.7 Fire Protection System – CO2
•
•
•
Gas detectors, optical flame detectors and thermal detectors
Primary and secondary high pressure CO2 cylinders
Automatic vent fan shutdown and damper closure
6.1.8 Compressor Cleaning and Water Washing
•
•
•
•
On-line water wash system
Off-line water wash system
100 gallon / 379 l - 304 stainless steel reservoir mounted on the auxiliary skid
Motor-driven pressurizing pump
6.1.9 Base Scope Auxiliary Equipment Module
Base auxiliary equipment module is provided with the unit to integrate several functions.
Auxiliary components and fuel system components can be equipped with optional enclosures.
The following is included:
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Auxiliary equipment
• Synthetic lube oil reservoir, duplex scavenge oil filter and duplex shell/tube oil-to-water
heat exchangers
• Electro-hydraulic start system
• CO2 cylinders
• On-line/off-line water wash system (including instrument air filter)
Note: In the base configuration the TCP and 24 VDC battery systems are shipped separately
to be installed by others.
6.2
Generator & Excitation
6.2.1
•
•
•
•
•
•
•
•
•
•
-
Totally Enclosed, Open – Ventilated, Brushless Excitation
Stator winding with Class F insulation and Class B temperature rises
Cylindrical forged steel rotor with Class F insulation and Class B temperature rises
Open ventilated air cooling with unit mounted filters
Strip heaters (to prevent condensation during periods of shutdown)
Resistance temperature detectors (RTD)
embedded in the stator windings
in the air stream
Displacement probes with internal proximeters for vibration monitoring
Bearing metal and drain RTDs for temperature monitoring
Rotating rectifier excitation system including:
Three-phase rotating armature
Three-phase rotating rectifier
Exciter field
GE EX2100 automatic digital voltage regulator located in the turbine control panel (TCP).
Provisions for a key phasor (add to options)
Permanent magnet generator (PMG) for the excitation system
6.2.3 Generator Auxiliaries
•
-
As viewed when looking at generator non-drive end:
Instrument and control termination box (MGTB), right side
Lineside termination cubicle (containing lightning arrestors and surge capacitors) left side
(very this is standard)
Neutral cubicle containing CTs and a HI Z (impedance) grounding system, right side
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6.3
Unit Controls
6.3.1 Turbine Control Panel
•
•
•
•
•
•
•
•
•
•
•
Free standing, for indoor location: 9 ft – 6 inch W x 2 ft – 6 inch D x 7 ft -6 inch H /
289.6 cm W x 76.2 cm D x 228.6 cm H
Woodward Micronet Plus
Sequencing, control, protection, monitoring
Desktop display and keyboard for operator I/O
Metering readouts shown digitally on the display
Plant ethernet port to user’s DCS
Protective relaying and metering
Rack-mounted electronic voltage regulator
Vibration monitoring system
Fire monitoring system
Generator controls
6.3.2 24V Control Battery and Redundant Charger
•
•
•
Battery: 19 cells, 24 VDC, Ni-CAD type
Charger: 230 V (service voltage), 150 amps
323 AH
6.3.3 24V Fire and Gas Battery and Charger
•
•
•
Battery: 19 cells, 24 VDC, Ni-CAD type
Charger: 120 V (service voltage), 25 amps
138 AH
6.3.4 125 V Battery and Charger (SAC)
•
•
•
Battery: 45 cell blocks, 125 VDC, Ni-CAD type
Charger: 230 V (service voltage), 3-ph, 50 amps
84 AH
6.3.5 125 V Battery and Charger (DLE)
•
•
•
Battery: 45 cell blocks, 125 VDC, Ni-CAD type
Charger: 230 V (service voltage), 3-ph, 50 amps
112 AH
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6.4
Drawings, Documentation and Training
In addition to the supply of the equipment, for each unit GE Energy will:
•
Coordinate engineering, manufacturing, and shipping schedules to meet contractual
requirements
For the site, Services include:
•
Provide Buyer’s drawings and six (6) copies of the Operation and Maintenance Manuals
in CD form
•
Provide Installation and Commissioning Manual
•
•
Provide field technical direction for performance tests per GE standard test procedures.
Conduct a Gas Turbine Package Familiarization and Operator’s Training Course for
customer personnel at the GE Energy Jacintoport facility. See Section 18 for further
details.
6.5
Testing and Transportation
In addition to the supply of the equipment, for each unit GE Energy will:
•
Conduct standard factory tests of the equipment and conform to carefully established
quality assurance practices
•
Static test the LM6000 gas turbine package before shipment from Houston utilizing
contract unit controls
•
Prepare the equipment for domestic shipment
•
Deliver the equipment, ex-works factory Houston, Texas
Note: A recommended installation schedule will be prepared by GE, which will define the
manpower loading, and classification of the supervisors provided, as well as the schedule of
events. (BD to verify)
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7. Mechanical Descriptions - Major Equipment
7.1
Turbine Engine
The LM6000 is a 2-shaft gas turbine engine derived from the core of the CF6-80C2, GE's
high thrust, high efficiency aircraft engine. More than eighteen hundred CF6-80C2s are in
service and 2,000 or more are on order or option. The CF6-80C2 has logged more than
30,000,000 flight hours in the Boeing 747 and other wide-body aircraft, with a 99.88%
dispatch reliability and commercial aviation's lowest shop visit rate. GE used this 30 million
hour flight experience to create the LM6000. Both engines have a common design and share
most major parts. The Low Pressure Turbine, High Pressure Compressor, High Pressure
Turbine, and Combustor are virtually identical. This use of flight-proven parts, produced in
high volume, contributes to the low initial cost and high operating efficiency of the LM6000.
LM6000 Turbine Engine
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7.1
Turbine Engine (Cont)
Major Engine Components:
•
•
•
•
•
•
5-stage low-pressure compressor (LPC)
14-stage variable geometry high pressure compressor (HPC)
Annular combustor
2-stage air-cooled high pressure turbine (HPT)
5-stage low pressure turbine (LPT)
Accessory Gear Box
The LM6000 has two concentric rotor shafts: The LPC and LPT are assembled on one shaft,
forming the Low Pressure Rotor. The HPC and HPT are assembled on the other shaft,
forming the High Pressure Rotor.
The LM6000 uses the Low Pressure Turbine (LPT) to power the output shaft. By eliminating
the separate power turbine found in many other gas turbines, the LM6000 design simplifies
the engine, improves fuel efficiency and permits direct-coupling to 3600 rpm generators for
60 Hz power generation. The LM6000 gas turbine drives the generator via a flexible dry type
coupling connected to the front, or “cold,” end of the LPC shaft.
7.1.1 Turbine Cycle
•
•
•
•
•
•
•
•
•
•
•
Filtered air enters the bellmouth and flows through guide vanes to the LPC
LPC compresses air by 2.4:1 ratio
Air flows from LPC through the front frame & bypass air collector to HPC
Air enters HPC through Inlet Guide Vanes
The HPC compresses air by 12:1 ratio
30 Fuel (SAC) nozzles or 75 fuel (DLE) nozzles mix air and fuel
Air-Fuel mixture is ignited in Annular Combustor
Hot combustion gases expand through HPT driving the HPC
Hot combustion gasses expand further through LPT driving the LPC and load
Flanged end of the LPC shaft drives the electric generator load.
Exhaust gasses exit engine/package at the exhaust flange
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7.1.2 Inlet and IGV Section
The turbine inlet straightens the air stream and directs it into the Low Pressure Compressor
(LPC).
7.1.3 Low Pressure Compressor
The Low Pressure Compressor (LPC) is a 5-stage axial flow compressor with a 2.4:1 pressure
ratio. It is derived from the CF6-50 flight engine. A horizontally split casing provides access
to blades and vanes. Borescope ports permit flow path inspection.
7.1.4 Bypass Air Collector
The LM6000 matches the airflow between the Low Pressure (LP) and High Pressure
Compressor (HPC) with 12 hydraulically actuated variable bypass valves mounted in the
turbine front frame. During start-up and part-load operation these valves open partially and
vent excess air to the bypass air collector. The bypass air collector also supports the
accessory gearbox.
7.1.5 High Pressure Compressor
The LM6000 High Pressure Compressor (HPC) is a 14-stage unit. Variable stators in stages
1-5 ensure high efficiency throughout the starting and operating range. The stator geometry
of stages 6 through 14 is fixed horizontally. This allows ready access to the stator vanes and
rotor blades for inspection or replacement.
7.1.6 Combustion Section
7.1.6.1 Singular Annular Combustor (SAC)
Thirty nozzles feed fuel into the LM6000 annular combustor, providing a uniform heat profile
to the High Pressure Turbine (HPT). This produces maximum output with low thermal stress.
The swirler-cup dome design produces a lean thoroughly mixed, mixture in the primary zone
of the combustor. This provides cleaner combustion and reduces NOX. Available nozzle
designs allow natural gas, distillate or dual-fuel operation. The nozzles also permit NOX
reduction with water injection (natural gas and distillate fuels) and steam injection (natural
gas fuel only). The annular combustor design provides low pressure loss, low exit
temperature and extended operating life. A Hastelloy X inner liner resists corrosion and
extends combustor life.
7.1.6.1.1
Dry Low Emissions (DLE) Combustor
LM6000 - 60 Hz Classic 6/2008
Page 35 of 156
The DLE system controls NOx emissions without the use of water or steam. GE Energy
installs special combustors, manifolds, nozzles and metering to control flame temperature and
reduce emissions of NOx, CO and unburned hydrocarbons. This DLE system reduces
emissions over the entire power range, not just at high power settings.
The fuel system hardware supplied with the DLE gas turbine includes a base mounted gas
manifold, hoses, staging valves, and a set of thirty fuel premixers. The LM6000 DLE gas
turbine utilizes a lean premix combustion system designed for operation on natural gas fuel as
well as dual fuel. Gas fuel is introduced into the combustor via 75 air/gas premixers packaged
in 30 externally removable and replaceable modules. The premixers produce a very uniformly
mixed, lean fuel/air mixture. The triple annular configuration enables the combustor to
operate in premix mode across the entire power range, minimizing nitrogen oxide (NOx)
emissions even at low power.
The head end or dome of the combustor supports 75 segmented heat shields that form the
three annular burning zones in the combustor, known as the outer or A-dome, the pilot or Bdome, and the inner or C-dome. In addition to forming the three annular domes, the heat
shields isolate the structural dome plate from the hot combustion gases. The heat shields are
an investment-cast superalloy and are impingement and convection cooled. The combustion
liners are front mounted with thermal barrier coating (TBC) and no film cooling.
Fuel to the gas turbine will be controlled based on control mode, fuel schedules, and the load
condition. For normal start sequence (13 minutes), gradual load changes are preferred with at
least 5-minute ramp from idle to maximum power. If a fast start (10 minutes) is required, the
load may be ramped from idle to full load in 4 minutes as part of the start sequence provided
in Operation. Normal load reduction transients should be no faster than 2-3 minutes from
maximum power to synchronous idle.
7.1.7 High Pressure Turbine
The High Pressure Turbine (HPT) is a 2-stage, air-cooled turbine rotated by the hot gasses
exiting the combustor. The HPT powers the High Pressure Compressor (HPC) to supply highpressure air to the combustor. Turbine disks, blades and stator are air-cooled for efficiency.
Blades are coated to resist erosion and corrosion.
7.1.8 Low Pressure Turbine
The 5-stage Low Pressure Turbine (LPT) receives the outlet flow from the HPT. The LPT
drives the Low Pressure Compressor and the driven load (generator, compressor, etc.) through
a shaft concentric to the HPT shaft.
7.1.9 Gas Turbine Support Structures
LM6000 - 60 Hz Classic 6/2008
Page 36 of 156
The LM6000 gas turbine uses three frames to support the LP and HP rotors, the front frame,
compressor rear frame and the turbine rear frame. This configuration produces excellent rotor
stability and closely controlled blade tip clearance.
7.1.9.1
Front Frame
The LM6000 front frame is a major engine structure that provides sup-port for the LPC shaft
and the forward end of the HPC shaft. The frame also forms an airflow path between the
outlet of the LPC and the inlet of the HPC. The front engine mounts attach to the front frame.
The front frame contains the engine “A” sump that incorporates the thrust and radial bearings
to support the LPC rotor and a radial bearing which supports the forward end of the HPC
rotor. Lubrication oil supply and scavenge lines for the “A” sump are routed inside the front
frame struts. The accessory gearbox drive shaft is located in the “A” sump and extends out
through the strut located at the six o’clock position.
Pads are contained on the frame outer case for mounting of the two High Pressure
Compressor inlet temperature sensors.
7.1.9.2
Compressor Rear Frame
The compressor rear frame consists of an outer case, 10 struts and the “B-C” sump housing.
The outer case supports the combustor and 30 fuel nozzles. The hub supports both the thrust
bearing, the radial bearing and in turn, the mid-section of the HP rotor system.
7.1.9.3
Turbine Rear Frame
The turbine rear frame supports the rear engine mount and contains the D-E sump. The 14strut rear frame guides and straightens the exhaust flow for lower pressure drop and greater
efficiency.
7.1.10 Accessory Drive System
The hydraulic starter, lube and scavenge pump, variable geometry hydraulic pump, and other
accessories are mounted on and driven by the accessory gearbox. The accessory gearbox is
located below the front HPC casing at the six o'clock position on the LPC bleed air collector
and is driven by the transfer gearbox through a short horizontal shaft. The transfer gearbox is
driven by the high-pressure rotor system. The gearbox is supported from the LPC bleed air
collector.
LM6000 - 60 Hz Classic 6/2008
Page 37 of 156
7.2
Auxiliary Equipment Module
The base auxiliary equipment module is provided with the unit and integrates several
functions. The auxiliary and fuel systems can be equipped with optional separate enclosures.
The following is included as part of the standard auxiliary equipment module:
Auxiliary Module
•
•
•
Synthetic lube oil system components including: reservoir, duplex oil filter and duplex
shell/tube oil-to-coolant heat exchangers
Electro-hydraulic start system components, including: electric starting motor, variable
displacement hydraulic pump, reservoir, air/oil cooler, low pressure return filter, and case
drain return filter
On-line/off-line water wash system, including: reservoir, supply valves, solenoid valves,
pump, electric tank heater, in-line water filter, and instrument air filter
7.3
Fire Protection CO2 cylinders
•
Optional sun shield
•
Optional heated enclosure
7.4
Inlet Air System Multi-Stage Design
The GE Energy air inlet system is designed to protect the gas turbine, generator and
equipment compartments from effects of air-borne dirt, contamination and foreign objects. It
also provides a pre-engineered, modular design to minimize field assembly and eliminate field
welding.
LM6000 - 60 Hz Classic 6/2008
Page 38 of 156
COIL OPTIO N
I
TE PDI
4084 4105
I
TO ATM
AIR
COIL SECTION
DRIFT ELIMINATOR
GUARD FILTER
AIR
COMPOSITE FILTER
CANISTERS
COMBUSTION
AIR
COMPOSITE FILTER
CANISTERS
COIL SECTION
DRIFT ELIMINATOR
GUARD FILTER
AIR
LH
SECTION
"A"
RH
SECTION
"B"
TE MT
4082B 4000B
AIR
VENTIL ATION
AIR
I
I
TO ATM
I
TO ATM
PDT
4005A
I
PDI TE
4104 4083
ALARM: IF ICING
CONDITION EXIST
TE MT
4082A 4000A
PDT
4005B
TO
ATM
COIL OPTIO N
I
I
REL HUMIDITY
SENSOR
REL HUMIDITY
SENSOR
TE PDI
4086 4107
PDI TE
4106 4085
TO ATM
I
PDT
4004
I
I
TO ATM
~105000 SCFM [2973 SCMM]
~45000 SCFM [1247 SCMM]
~60000 SCFM [1699 SCMM]
TO ATM
I
TE TE TE TE
4101A 4101B 4101C4101D
I
TE TE TE TE TE TE TE TE TE TE TE TE
4026 4026 4025 4025 4024 4024 4023 4023 4022 4022 4021 4021
A1 A2 A1 A2 A1 A2 A1 A2 A1 A2 A1 A2
~45000 SCFM [1274 SCMM]
AIR
I
MOT
4103A
MOT
4103B
I
LO
TE
4102A1
TE
4102A2
A
~60000 SCFM [1699 SCMM]
PDT
4007
LO
I
~45000 SCFM [1274 SCMM]
I
B
~60000 SCFM [1699 SCMM]
TE TE
4030 4030 ATM
A1
A2
HI
PDT
4014
TURBINE ROOM EXHAUST
HI
CO2 ACTU ATOR RESE T
PDT PDT
4011A 4011B
I
I
I
MOT
4017A
I
A
B
MOT
4017B
TE
4001A1
TE
4001A2
GENER ATOR
ROOM
TE
4031A1
TE
4031A2
I
I
GENER ATOR EXHAUS T
ATM
INLET
AIR
VOLUTE
TE
4054A1
TE
4054A2
STATOR TEMP SENSORS
MGTB
I
I
I
HE
4051
INLET VOLUTE DRAI N
TE
4091
I
MTTB
TURBINE ROOM
VBV DRAIN
TE TE
MOT MOT MOT MOT 4090A14090A2
4019 4120 4121 4122
I
TE TE TE
4129 4128 4127
STATOR
SPARES
HE
4050
I
TE
4093
TC HE
4053 4053
I
I
I
I
I
G-255-05
I
Simplified Schematic – Ventilation and Combustion Air System
LM6000 - 60 Hz Classic 6/2008
Page 39 of 156
7.4.1 Filtration Specification
The LM6000 static barrier filter removes more than 99.9% of all particles 5.0 micron and
larger by utilizing a three-stage design.
Engine Combustion Air
230,000 scfm / 6,514 m3/min
Turbine Ventilation Air
60,000 scfm / 1,699 m3/min.
Generator Ventilation Air
45,000 scfm / 1,274 m3/min.
Total Typical Air Flow
355,000 scfm / 9,487 m3/min.
7.4.2 General Arrangement
The three-section inlet air filter mounts directly above the turbine enclosure, conserving space
and providing compact, low-pressure loss ducting to the turbine inlet.
The filtered air is partitioned within the filter house assembly, providing combustion air for
the gas turbine and ventilation air for the turbine and generator compartments.
The filter is designed for easy maintenance. A ladder and platform provides access to service
doors on each filter section. Lighted internal walkways provide generous working room for
replacement and maintenance of the filter elements.
LM6000 - 60 Hz Classic 6/2008
Page 40 of 156
AIR FILTER
Air Inlet Filter Assembly
7.4.3 Filter House Materials
The filter housing is constructed of 3/16 inch / 76 mm (verify units) steel plate. Protective
paint is applied to the exterior and interior carbon steel surfaces.
Floors and drain pans downstream of the optional evaporative cooler media or optional inlet
air chiller coils are stainless steel to resist corrosion.
7.4.4 Inlet Screens/Weatherhood
The weather hood provides a deflecting surface to prevent driving rain and snow from
entering the filter house. In addition paper, leaves and wind-blown trash are blocked by the
inlet screen. This structural component makes up the exterior face of the filter house and is
manufactured from carbon steel.
LM6000 - 60 Hz Classic 6/2008
Page 41 of 156
7.4.5 Barrier Filter
The high-efficiency cylindrical barrier filter elements are mounted to the filter face of the inlet
plenum and extend into the clean air plenum. The elements have extended surface area, large
dirt holding capacity and low-pressure drop. Air flows through the elements from inside to
outside keeping dirt safely trapped inside the element. The filter elements are designed
specifically for gas turbine protection, and are particularly effective in filtering particles 5
microns or larger.
7.4.6 Clean Air Plenum
Air passes through the barrier filters and enters the clean air plenum. This fabricated structure
is the center section of the inlet filter assembly and separates ventilation air from combustion
air.
7.4.7 Transition Ducts
Combustion air flows through a transition duct from the clean air plenum to the combustion
air inlet silencer. Ventilation air flows through transition ducts to the turbine and generator
compartment.
7.4.8 Inlet Silencer
The inlet silencer is a low-pressure-drop device located in the combustion air stream before
the inlet volute. The silencer attenuates noise from the turbine and helps maintain the unit's
low noise level.
7.4.9 Inlet Volute
The inlet volute is stainless steel weldment that directs the combustion air flowing down from
the filter and turns it 90° to flow axially into the turbine inlet. Vanes within the volute smooth
the airflow and present a balanced air stream to the turbine bellmouth.
LM6000 - 60 Hz Classic 6/2008
Page 42 of 156
7.5
Package Enclosures
The package is equipped with a generator and a turbine enclosures plus an optional auxiliary
module enclosure is available. The unit enclosures are designed for outdoor installation with
wind loads up to 150 mph / 240 km/h and to reduce the average near field noise to 85 dB (A)
at 3 ft. / 1.0 m from the enclosure and 5 ft. / 1.5m above grade. Each compartment is provided
with access doors and AC lighting.
The turbine compartment contains an integral overhead bridge crane to facilitate engine
removal.
Enclosure walls are a “sandwich” construction filled with insulation blankets of high
temperature, sound attenuating material. The inner wall panel is fabricated from perforated
1.21 mm / 18-gauge stainless steel. The outer wall panel is 1.9 mm / 14-gauge cold rolled
carbon steel, painted with abrasion resistant, exterior quality epoxy paint.
The turbine and generator compartment walls are supported by a structural steel framework
that can withstand external wind loading and the internal pressure developed by the fire
extinguishing system. External door hinges, latches and mounting hardware are stainless steel
or chrome plated.
7.5.1 Enclosure Lighting
AC lighting for the interior of the gas turbine and generator compartments is provided.
7.5.2 Enclosure Ventilation System
The ventilation system removes heat from the turbine and generator compartments and
removes combustible gases in the event of a fuel system failure. Both the turbine
compartment and generator compartment are fully ventilated by redundant fans to improve
reliability. Ventilation air is filtered to the same quality levels as the gas turbine combustion
air.
LM6000 - 60 Hz Classic 6/2008
Page 43 of 156
Gas Turbine Generator Package Airflow
LM6000 - 60 Hz Classic 6/2008
Page 44 of 156
7.5.2.1
Turbine Compartment Ventilation
Ventilation air enters the turbine compartment around the inlet collector. Dual 125 hp / 93 kW
exhaust fans (1 running / 1 standby) create an induced-draft airflow of approximately 60,000
scfm / 1,699 m3.
7.5.2.2
Generator Compartment Ventilation
Filtered air is forced into the generator compartment by dual 100 hp / 75 kW forced draft fans
(1 running / 1 stand-by) through ducts from the inlet air filter. The 45,000 scfm / 1,270
m3/min. airflow cools the generator and the generator compartment.
The ventilation fans produce a positive pressure in the generator compartment, providing
additional isolation from the turbine compartment for gas leak protection purposes. This
contributes to classification of the generator compartment as a non-hazardous area.
7.5.3 Noise Control
The LM6000 enclosure and air inlet silencer reduce the average near field noise to 85 dB (A)
at 3 ft. / 1.0 m from the enclosure and 5 ft / 1.5 m above grade.
Lower noise limits can be provided with optional silencing equipment. Noise control will
depend on the scope of the equipment supplied, the site plan, and project specific
requirements.
7.5.4 Turbine Exhaust
The LM6000 exhausts air is extracted axially through a flange located at the end of the
turbine enclosure. This provides low restrictions and a direct path into optional, or customersupplied silencing or heat recovery equipment.
7.6
Baseplate
LM6000 generator sets are mounted on rugged I-beam baseplates to simplify shipping and
installation.
The basic equipment is supplied with the support structures consisting of a two-piece skid
assembly, which is sectioned between the gas turbine and the generator. The full depth, bolted
section is designed to provide the full structural properties of the wide flange I-beams. Full
depth crossmembers are utilized to provide a rigid design that meets the requirements of IBC
2006 and is therefore suitable for installation in earthquake areas. The baseplate support
system is enhanced by the installation of a heavy-duty, welded superstructure which utilizes 6
inch x 6 inch x 3/8 inch wall structural tubing for wall columns and roof beams.
LM6000 - 60 Hz Classic 6/2008
Page 45 of 156
Tapered pins between the baseplates simplify field alignment and lifting spools are built into
the baseplates providing a convenient structure for transportation.
7.7
Fuel System
The LM6000 gas turbine can be configured for gas, liquid or dual fuel operation. The basic
gas fuel system is described below. Other configurations are available as options.
7.7.1 Gas Fuel System
The gas fuel system contains the following major components. They are mounted in the
turbine compartment, adjacent to the engine.
•
•
•
•
•
•
•
•
Fuel gas strainer
Fuel gas flow meter
Instrumentation
Primary shutoff valve
Fuel metering valve
Secondary shutoff valve
Fuel gas manifold
Shipped loose manual shut-off valve
7.7.1.1
Gas Fuel Flow
Gas fuel must be supplied to the package baseplate connection at 675 +30/-20 psig / 4,053 –
4,962 kPag. Please see Section 14 for applicable fuel specification. Lower fuel supply
pressure requirements for base load operation may be possible in certain circumstances.
A customer supplied pressure regulator, pressure relief valve and GE supplied manually
operated shut-off valve should be installed in the customer fuel supply system outside of main
unit.
LM6000 - 60 Hz Classic 6/2008
Page 46 of 156
11
I
I
24
EDGE OF MAIN SKID
PT
2027B
GAS FUEL
VENT TO SAFE ARE A
FROM CDP
PURGE SYSTEM
LC
EE
PT
2027A
GAS FUEL
VENT TO SAFE ARE A
I
I
I
I
FSV
2006
SOV
2008
S
FO
I
EDGE OF
MAIN SKID
FCV
2001
PT
2028
FSV
2004
E
M
FC
SET:
40 PSI
SOV
2004
S
FT
2000
IN
CYL
IN
CYL
EXH
FO
EXH
FO
AA
TE
2032A2
I
TE
2032A1
GAS FUE L PURG E
I
I
G-249-05
30 FUE L NOZZLE S
TOTAL
S
DD
SET:
40 PSI
FC
I
GAS MANIFOLD
I
FE
2000
10
GAS FUEL
INLET
FC
SOV
2006
SECONDA RY FUEL SUPP LY
LO
Simplified Schematic – Gas Fuel System
7.7.1.2
Pressure and Temperature Monitoring
Pressure transmitters monitor the fuel supply pressure up stream and downstream of the fuel
metering valve and forward the data to the fuel control and sequencer system. A platinum,
dual element temperature RTD monitors fuel supply temperature and forwards the data to the
fuel control and sequencer system.
7.7.1.3
Fuel Shutoff Valves and Safety Venting
Fuel shutoff valves manage gas flow to the combustor. Solenoid piloted fuel shutoff valves
are quick-closure valve assemblies located upstream and downstream of the gas fuel metering
valve. These fail-close valves are either fully open to allow fuel flow or fully closed to
prevent fuel flow.
During startup, the shutoff valves are opened and fuel flow to the gas manifold is metered by
the gas fuel metering valve. During shutdown, when the shutoff valves are closed, a solenoidoperated vent valve opens to vent the fuel supply line between shutoff valves to a safe area.
A gas fuel drain valve opens during certain shutdown conditions to purge the gas manifold
and the engine.
LM6000 - 60 Hz Classic 6/2008
Page 47 of 156
7.7.1.4
Fuel-Metering Valve
The electronically controlled fuel valve provides accurate, non-pulsating fuel flow to the
turbine during starting, steady-state operation and dynamic load changes.
Low fuel gas pressure starting is possible, using the electrical output of the LM6000 to power
a fuel gas compressor. The LM6000 can start on a minimum 200 psig / 1,380 kPag fuel gas
pressure. At this pressure the LM6000 produces enough electrical power to start a fuel gas
compressor. The compressor then builds the fuel gas pressure up for full power output.
This “bootstrap” starting simplifies gas utility requirements and eliminates high electrical
“demand charges” for starting the gas compressor motors. Contact GE for your specific
application.
7.8
Independent Lube Oil Systems
The LM6000 gas turbine is lubricated with synthetic lube oil (SLO) while a separate mineral
lube oil (MLO) system lubricates the generator.
Dual shell and tube coolers with valves for on-line changeover are used to cool both turbine
and generator lube oil. The SLO & MLO coolers are mounted on the auxiliary module.
Lube oil piping, fittings and reservoirs are Type 304 stainless steel and valves have stainless
steel trim.
7.8.1 Gas Turbine Lube Oil System
The gas turbine lube oil system has two lube oil circuits:
Supply System - Provides filtered, cool oil to the turbine bearings.
Scavenge System - Recovers (scavenges) the lube oil from the bearing drain sumps. It also
filters and cools the oil and returns it to the reservoir.
These two circuits cool, lubricate and protect the turbine. The turbine supply system contains
the following major components:
•
•
•
SLO reservoir
Supply pump
Supply filter
The scavenge system contains the following major components:
LM6000 - 60 Hz Classic 6/2008
Page 48 of 156
•
LT
1002A
LT
1002B
TE TE
TE TE TE TE TE TE TE TE TE TE TE TE
1023 1023 1029 1029 1025 1025 1026 1026 1027 1027 1030 1030 1028 1028
A1 A2 A1 A2 A1
A2
A1 A2 A1 A2 A1
A2 A1
A2
I
I
A23
A24
A10
A9
TURBINE LUBE
LG
OIL RESERVOIR
1000
CAPACITY: 150 GALLONS [568 L ]
LO
TE
1013A1
19
DRAIN
I
I
TE
1013A2
TE
1037
21
COOLING WATER RETURN
LC
COOLER #1
TO
ATM
PSV
1056
TE
1036
FI
1086
D3
D4 D6
FI
FI
1087 1088
NC PCV
1091
FI
1089
NC
MAIN SKID SUMP
229
LC
25
HEAT EXCHANGER ASSEMB LY
C MOUNTED ON AUXILIA RY SKID
A
TCV B
1001
228
57
57A
VENT TO SAFE AREA
PDT
1007
NC
MANUAL
SHUTTLE
VALVE
PSV
1003
I
I
TO
ATM
PSV
1057
MAIN SKID
TURBINE AREA
I
PDT
1006
COOLER #2
I
A51B A51A
D1 D2
6
COOLING WATER
20 SUPPLY
26
71A
SOV
1085
I
L4 L5 L8 L9
DISCHARGE
LC
L2
L3
SCAVENGE
HE
1004
TC
1004
L6
PUMP SUCTIO N
I
I
A28
L1
71
SUPPLY
DISCHARGE
LSL
1002
A25
GG
VENT TO
ATMOSPHERE
LL
DEMISTER/FLAME
ARRESTOR
FUEL SYSTE M
FI
1005
LC
78A
I
AIR/OIL SEPARATOR
DRAINS
FROM WATER WASH
PURGE AIR
Scavenge filter/5-element scavenge pump
• Duplex shell and tube water / oil or fin fan air/oil heat
exchanger (optional)
• Air/oil separator system
TE
1035
SUPP LY FILTER
NC
MANUAL
SHUTTLE
VALVE
SCAVENGE FILTER
G-258-05
Simplified Schematic – Turbine Lube Oil System
LM6000 - 60 Hz Classic 6/2008
Page 49 of 156
7.8.1.1
Turbine Lube Oil Supply Description
Approximately 130 U.S. gallons / 492 l of synthetic lube oil are stored in the 150 U.S. gallon
/ 568 l capacity stainless steel reservoir mounted on the auxiliary module. The reservoir is
fitted with a low-level alarm switch, a level gauge, a level transmitter, a filler connection, and
a demister/flame arrestor. The reservoir also includes a thermostatically controlled heater and
a lube oil temperature transmitter.
A positive displacement lube oil pump, mounted on the gas turbine accessory drive gearbox,
takes suction from the lube oil reservoir. The pump discharge is filtered by a duplex, 6
micron (absolute), full-flow filter located on the auxiliary module. Filter elements can be
changed while the turbine is running.
The lube oil supply passes through an anti-siphon check valve and is distributed to the bearing
chambers, where oil is sprayed onto each engine bearing.
Pressure transmitters and temperature RTDs monitor lube oil supply with readout, alarm and
shutdown at the turbine control panel. Chip detectors in the A and B sumps and in the
common scavenge return provide alarms if metal chips are detected in the lube oil. A
differential pressure transmitter senses filter differential pressure and warns the operator of
dirty filter conditions.
7.8.1.2
Turbine Lube Oil Scavenge Description
Oil flows through the turbine bearings and accumulates in the bearing sumps. A 5-element
scavenge pump is connected to a low point drain in each sump. Whenever the engine is
turning the scavenge pump is working to remove oil from the sump drains.
The scavenge pump discharge flows through a 6 micron (absolute) duplex filter, then is
cooled by a shell and tube cooler, (1 running / 1 standby) and then returns the oil to the
reservoir.
A temperature RTD on each scavenge line measures temperature, with readout, alarm and
shutdown at the turbine control panel. A check valve on the pump discharge prevents
siphoning of oil back into the engine during shutdown.
Each bearing sump is vented by the air/oil separator system, consisting of a pre-separator, airto-oil cooler, and a final separator. Recovered oil drains back to the reservoir to reduce
emissions and oil consumption.
A shell and tube cooler (1 running / 1 standby) rejects 600,000 Btu/hr / 633,100 kJ/hr from the
turbine lube oil circuit. A thermostatic valve regulates the amount of hot oil that bypasses the
cooler.
LM6000 - 60 Hz Classic 6/2008
Page 50 of 156
7.8.2 Generator Lube Oil System
The generator lubrication system provides approximately 46 gpm / 174 lpm of cooled and
filtered mineral oil to the generator bearings. The generator lube oil reservoir, pumps and
duplex filters and coolers are located near the rear of the generator and lube oil filters may be
changed while the unit is operating. Filters have stainless steel plates. Valves are carbon
steel bodies with stainless steel trim.
The generator lube oil system has two lube oil circuits:
Supply System – Provides cool, filtered oil to the generator bearings. The supply system
contains the following major components:
•
•
•
•
•
•
MLO reservoir
AC pump
Generator driven mechanical pump
Four-element jacking oil pump
Duplex shell and tube heat exchanger
Duplex filter
Return System - Recovers the lube oil from the bearing drain sumps and returns it to the
reservoir.
These two circuits cool, lubricate and protect the generator.
LM6000 - 60 Hz Classic 6/2008
Page 51 of 156
Simplified Schematic – Generator Lube Oil System (Supply Flow)
7.8.2.1
Generator Lube Oil Supply Description
The 60 Hz generator lubrication system provides approximately 174 Lpm/46 gpm of cooled
and filtered oil to the generator bearings
The generator/gearbox lube oil reservoir, pumps and filters are located on a separate lube oil
module. The lube oil filters may be changed while the unit is operating.
The simplex shell & tube coolers serving the generator lube oil system are also located on the
lube oil module. Filters have stainless steel plates. Valves have stainless steel trim.
The stainless steel reservoir includes a sight level gauge, fill connection and drain valve. A
switch provides a low-level alarm at the unit control panel. An immersion heater turns on at
32ºC falling temperature keeping the oil heated to prevent condensation when the unit is
stopped.
The 60 Hz lube system has three pumps mounted on the reservoir:
o Main Pump – 1,250 Lpm/330 gpm with a 37.3 kW AC motor
LM6000 - 60 Hz Classic 6/2008
Page 52 of 156
o Stand By Pump – 1,250 Lpm/330 gpm, with a 37.3 kW AC motor
o Emergency Pump – 550 Lpm/145 gpm with a 12 kW DC motor
o
The reservoir assembly includes:
o Duplex 100% filters
o Duplex shell and tube heat exchangers sized to reject 2,943.8 MJ/hr
o Oil-mist heat exchanger and motor-driven oil demister
Rundown tanks provide additional protection if the AC lube pumps should fail, or if AC
power is lost. A DC pump provides coastdown protection.
The oil flows through the orifice and into the bearings and forms a film that cools and
lubricates the journal. Pressure switches at the bearing supply header provide low pressure
alarm and shutdown signals to the unit control panel.
If the supply pressure drops, a low lube oil pressure switch automatically starts the auxiliary
lube oil pump. An annunciator alarm indicates that the auxiliary pump is running. If the lube
oil pressure falls to a lower level, the turbine generator set shuts down.
The primary and auxiliary lube oil pumps can each supply 100% of the generator lube oil
requirements. Each pump is equipped with a pressure relief valve piped to the reservoir.
Lube oil pressure at the supply header is controlled by a pressure-regulating valve, which
bypasses excessive oil flow to the reservoir. Duplex coolers are provided to reject 198.1
MJ/hr from the generator lube oil circuit. The amount of hot oil that bypasses the cooler is
regulated by a thermostatic valve.
The duplex generator / gearbox lube oil filters (6 micron absolute) are mounted on the lube oil
module. Filters may be replaced during operation by switching the manual transfer valve. A
pressure switch senses high filter differential pressure and provides alarm at 20 psid/138 kPa.
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(LUBE OI L SUPP LY)
I
PSV
0097
(JACKING OI L RELIEF LINE )
PSV
0096
I
I
LT
LT
0041B
RUNDOWN
TANK
I
RUNDOWN
TANK
PT
0049
PT
I
TE
I
PT
I
I
I
LT
LT
RUNDOWN
TANK
TE
RUNDOWN
TANK
LO
(JACKING OI L RELIEF LINE )
PSV
0094
TE
I
TE
TE
PI
0091
I
I
(J.O. RELIEF LINE)
MOT
0085
PI
0092
I
(J.O. RELIEF LINE)
I
PSV
0095
TE
0022
TE
JOURNAL BEARING
THRUST BEARING
I
GENER ATOR
DRIVE END
EXCITER END
TE
0057
I
TE
I
I
TE
TE
PI
0093
I
I
PI
0090
TE
FI
0067
FI
0068
G-252-05
Simplified Schematic – Generator Lube Oil System (Bearing Lubrication)
7.8.2.2
Generator Lube Oil Return Description
Each bearing has a gravity drain and sight glass to visually verify oil flow. A dual element
RTD is embedded in each generator bearing to measure the actual metal temperature. These
RTDs are continuously monitored at the unit control panel and provide alarm and trip signals
at 183°F/91.6°C and 194°F/95ºC, respectively. The gearbox has a turning gear to rotate the
shaft. The gearbox bearing RTDs alarm and trip at 225°F/107ºC and 241°F/116ºC
respectively.
For starting and water wash cycles, we lift the generator rotor off the bearing seats with a film
of high-pressure oil from a small “jacking oil” pump. The oil film reduces bearing friction
and helps the rotor “break away” and begin turning.
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7.8.3 Customer Cooling Water Requirements
Customer provides continuous water to the lube oil cooler flange connections. Approximate
cooling water requirements are 190 gpm at 95 °F / 719 lpm at 35 °C. Maximum water
pressure is 100 psig / 689 kPag. Total heat rejection for turbine and generator is 787,800
Btu/hr / 831,200 kJ/hr.
7.9
Starting System
The LM6000 turbine is started by an electro-hydraulic system, including an electric motor, a
pump, a hydraulic starter motor, and other equipment described below. The starter rotates the
LM6000 high-pressure compressor shaft for purging, cool down, engine starting and water
wash sequences.
The hydraulic start system consists of a hydraulic starting motor / clutch mounted on the
turbine accessory gearbox, the following equipment mounted on the auxiliary module:
•
•
•
•
•
200 HP / 150 kW electric starting pump motor
Variable displacement hydraulic pump
40 gal. / 151 l hydraulic reservoir
Air/oil cooler
Low pressure return filter and case drain return filter
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Simplified Schematic – Hydraulic Start System
7.9.1 Hydraulic Start System Flow
The hydraulic circuit is a closed loop design with a 40-gallon / 151 L reservoir. The system
requires an initial fill of approximately 35 gallons / 132 l of ISO VG 46 premium, anti-wear
petroleum-based hydraulic fluid.
During each start cycle a charge-pump portion of the main pump draws fluid from the
reservoir to prime the system and supply control oil. Controls modulate the main pump flow
from zero to approximately 55 gpm / 208 Lpm during the starting cycle. This permits accurate
control of gas generator speed for purging, ignition and acceleration. The starter pump
increases the hydraulic fluid pressure and delivers the pressurized fluid to the hydraulic starter
motor. A portion of the return fluid from the starter motor is routed back to the starter pump.
Before reaching the main hydraulic pump on the auxiliary skid, the oil is filtered through a
low-pressure, return filter.
Low-pressure hydraulic fluid from the starter motor case is routed off the main skid to the
auxiliary skid. On the auxiliary skid, the hydraulic fluid flows through a case drain return
filter and a air to oil heat exchanger before returning to the reservoir.
7.9.2 Starting System Operation
To start the gas turbine, the hydraulic motor must:
•
•
•
Rotate the gas generator to purge the engine
Accelerate the gas generator to ignition speed
Continue acceleration to self-sustaining speed
The starter accelerates the gas generator to 2,300 rpm and cranks for two minutes in typical
simple cycle applications. This forces purging air through the gas turbine and exhaust stack
to remove hydrocarbons that may have accumulated during the prior shutdown.
Air-flow during the purge cycle is approximately 7842 scfm / 12,600 Nm3/h / 10 lbs/sec.
After the purge cycle, the gas generator is slowed to 1700 rpm for light off. Fuel is initiated,
igniters are actuated, and the turbine starts. Then the starter and the combustion accelerate the
gas generator to 4500 rpm where the starter disengages automatically.
The gas generator continues to accelerate until it reaches idle speed. The turbine is now selfsustaining.
Overall start time varies with stack height; also units with heat recovery steam generators will
require a longer purge cycle, typically 15 to 30 minutes.
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However, the typical LM6000 in simple cycle application can reach full power from a cold
start in 10 minutes. See Section 5 for 10-minute start cycle curve.
7.10 Water Wash System
All gas turbines demonstrate lower levels of performance if the airfoils are not in a clean
condition. An integral soak wash system is provided for on/offline cleaning. See Section 14
for compressor cleaning water/detergent specifications. GE Energy LM6000 units include a
unit mounted on-line cleaning system to remove deposits from the compressor airfoils. The
off-line or “crank-soak” water wash system is for thorough removal of built-up deposits. This
system requires the turbine to be off-line for a short time. The on-line cleaning system is used
to remove deposits while the turbine is running. This system extends the intervals between
crank-soak cleanings and reduces downtime.
Simplified Schematic – Water Wash System
7.10.1
Water Wash Equipment
Both on-line and off-line spray nozzles are mounted on the Inlet Air Volute on the main
baseplate. The remaining water wash equipment below is mounted on the auxiliary module:
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• 100 gallon / 379 l stainless steel reservoir
• Manual water and chemical supply valves
• Solenoid valves to sequence water wash and purging
• Motor-driven pressurizing pump
• Electric heater in tank
In-line water filter
7.10.2
Cleaning Solution Specifications
Cleaning agents conforming to GE Specification MID-TD-0000-5 are recommended for
washing the gas generator section of the engine. The solvents are mixed within the reservoir
and sprayed into the turbine inlet. Water is then sprayed in the inlet to rinse the turbine.
A water/anti-freeze mixture must be used for dilution and rinsing in ambient temperatures of
50 °F / 10 °C, or below.
7.10.3
Water Quality Standards
Please see GE Specification MID-TD-0000-4 for water wash criteria.
7.10.4
Interface Requirements
Customer supplies a source of hot water and instrument/compressed air to purge lines at GE
Energy flange connections on auxiliary module. Interconnecting piping and hoses to the
permanently mounted turbine spray manifold is provided.
7.11
Fire Protection System
The LM6000 turbine generator set includes controls and sensors to detect fire, unsafe
temperatures or explosive atmospheres in the equipment enclosure. The system releases CO2
if fire is detected.
The package enclosure is designed to reduce the hazard of fire and explosion. A wall
separates the turbine and generator compartments to provide isolation. Ventilation systems,
with redundant fans, create a positive pressure in the generator compartment and a negative
pressure in the turbine compartment. This maintains separation and forces hydrocarbons
away from the generator. The enclosure is protected by gas detectors, thermal detectors,
optical flame detectors and a CO2 extinguishing system conforming to NFPA 12.
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Fire and Gas Protection System
7.11.1
Gas Detectors
Four hydrocarbon gas detectors and two infrared gas detectors are provided. Two
hydrocarbon gas detectors are located in the turbine compartment. One hydrocarbon gas
detector is located below the turbine. A fourth detector is located in the front of the generator
compartment. Two infrared gas detectors are located in the turbine enclosure near the
ventilation exhaust duct. If the gas detectors in the turbine or generator compartments sense a
gas concentration of 15% LEL, a warning is initiated. If a sensor detects a gas concentration
of 25% lower explosion limit, an emergency shutdown is initiated. If an infrared sensor
senses a gas concentration of 5% LEL, a warning is initiated. If a sensor detects a gas
concentration of 10% LEL, an emergency shutdown is initiated.
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7.11.2
Optical Flame Detectors
There are three IR/Optical flame detectors mounted in the turbine enclosure and three
mounted in the generator enclosure. A flame indication by a turbine enclosure sensor causes
an emergency shutdown and release of CO2.
7.11.3
Thermal Detectors
The turbine enclosure temperature is monitored by two thermal spot detectors, initiating a
shutdown at 450 °F / 232.2 °C. The generator enclosure temperature is monitored by two
thermal spot detectors, initiating a shutdown at 225 °F / 107.2 °C.
In addition to alarm and shutdown functions, the thermal spot detectors provide enclosure
temperature signals for the turbine control panel HMI. The spot temperature detectors are bimetallic and respond to both temperature and rate-of-rise. They cause a unit shutdown and
release of the CO2 when tripped.
7.11.4
Manual System Trip
Three manual trip stations are located on the main enclosure; one on each side near the center
of the package, and the third at the exciter end of the generator.
7.11.5
CO2 Extinguishing System
The system components include:
•
•
•
Main CO2 storage cylinders
Reserve CO2 storage cylinders
Valves, piping and wiring
The pressurized CO2 bottles are stored on a rack that includes manifolds, controls, valves and
a weigh scale. The reserve cylinders are an “automatic backup,” and are released, if the
detectors still indicate a hazard, 90 seconds after release of the main cylinders.
GE Energy provides piping within the main enclosure from the pressure connection to the
nozzles in the turbine and generator compartment. Release of the CO2 is controlled by the fire
system control panel or by a manual valve at the unit.
Signals from the equipment-mounted sensors are monitored by solid-state modules in the
control panel. The panel-mounted unit includes logic, memory and output functions.
7.11.6
Dedicated Power Supply
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GE Energy furnishes a dedicated 24 VDC battery system with charger, to power the fire and
gas protection and control system. This battery system conforms to NFPA 12 requirements.
7.11.7
Control System
A solid-state monitor mounted in the Turbine Control Panel compares the signal from each
sensor to alarm and shutdown setpoints. Meters provide a read out of each gas detector signal.
Any alarm signal sounds an alarm at the control panel and in the turbine enclosure.
Any shutdown signal from a gas detector, optical detector, thermal detector, or manual station
closes a contact and causes an emergency shutdown of the unit.
7.11.8
Defective Sensor Protection
Each sensor is connected with closed loop circuitry to verify its readiness. Should the sensor
or its wiring become defective, a "fault" condition is indicated on the control panel.
7.11.9
CO2 Release Logic
When a shutdown signal is received the control system turns off the ventilation fans and
sounds an alarm horn at the panel and both inside and outside of the turbine enclosure. After
a time delay, CO2 is released into the generator and turbine compartments.
A CO2 concentration sufficient to extinguish flames is reached in approximately 30 seconds.
If the primary cylinders should fail to discharge within four seconds, the reserve cylinders are
discharged.
If flames are still detected 90 seconds after the primary CO2 cylinders have been discharged,
the reserve cylinders are discharged.
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8. Optional Equipment
8.1
Optional Equipment List
The equipment and services listed in Section 6 and described in Section 7 are included with
the LM6000 Gas Turbine Package basic price. Design variations are available as options to
the basic package. Below is a list of design variations and services available followed by
detailed descriptions.
1.
2.
Synchronous condenser clutch
Totally Enclosed Water-to-Air Cooled (TEWAC) generator (in lieu of an open
ventilated generator)
3.
Power system stabilizer
4.
Left-hand piping connections / right-hand piping connections
5.
Left-hand cubicles / right-hand cubicles
6.
Liquid fuel system
7.
Dual fuel system
8.
Water injection system
9.
SPRINT® power boost system
10. Evaporative cooling
11. Inlet air chiller coil
12. Inlet air anti-ice coil – exhaust heat recovery unit
13. Inlet air anti-ice coil
14. Inlet air anti-ice coil – ventilation recirculation (legged housing)
15. Pulse filter (legged housing)
16. Static excitation
17. Air-oil cooler
18. Winterization
19. Medium voltage switchgear and generator bus duct
20. Unit motor control center
21. Remote work station
22. Lifting gear
23. Control module options (ACM and PCM)
24. 80 dB (A)(near field)
25. Remote monitoring and diagnostics services
26. Full load string test
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27.
Fuel filter / separator
8.2
Optional Equipment Descriptions
8.2.1 Synchronous Condenser
The LM6000 generator set, with optional modifications, can operate as a synchronous
condenser when an electrical grid needs VARs to improve the Power Factor (PF).
For this option, GE adds a synchronous clutch, in an enclosure, between the gas turbine and
generator. Modifications are also added to the protective relay system and the voltage
regulator. These additions allow the unit to operate as follows:
•
The gas turbine is started and brought up to speed
•
The generator is synchronized to the grid
•
The operator selects Synchronous Condenser operation with a switch on the Turbine
Control Panel
•
The gas turbine begins a normal shutdown
•
As the turbine slows down, the Synchronous Clutch disengages
•
The generator remains running, and is now operating as a motor, powered by the grid.
•
The operator can now export or import VARs by raising or lowering the voltage set point
on the Voltage Regulator (within limits designed to protect the equipment).
8.2.2
Totally Enclosed Water-Cooled Generator
GE Energy furnishes a Totally Enclosed Water-to-Air Cooled (TEWAC) generator for
customers who prefer water-cooling. Customer must supply approximately 571 gpm / 2161
lpm of treated water at 85ºF / 29ºC, or cooler, at 100 psig / 690 kPa. If water is to be
recycled, customer must supply a cooling loop to reject approximately 2 million BTU/hr /
2110 MJ/hr.
8.2.3
Power System Stabilizer
The GE EX2100 digital power system stabilizer integrates supplementary control signals to
the generator’s voltage regulator to control power fluctuations and to help improve the
stability of the power system.
8.2.4
Left-Hand Piping Connections
In the standard LM6000 configuration, the customer’s piping connections are on the right
side, as viewed from the exciter. As an option, the unit can be built with the piping
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connections on the left side. The turbine removal area is located on the side opposite of the
piping connections.
8.2.5
Left-Hand Cubicles / Right Hand Cubicles
In the standard LM6000 configuration the generator line side cubicle is on the right side as
viewed from the exciter. The neutral cubicle is on the left side. As an option the unit can be
configured with the line side cubicle on the left side and the neutral cubicle on the right side.
8.2.6
Liquid Fuel System
The LM6000 can be equipped to operate using liquid fuel instead of natural gas. Typical
liquid fuels include DF1, DF2, JP4 or kerosene. Customer must supply liquid fuel at 20-50
psig /138-345 kPag and at least 20ºF / 11ºC above the “wax point” temperature (normally
35ºF / 1.6ºC). Maximum fuel temperature is 150ºF / 65ºC. Customer supplied fuel must be
clean, filtered and meet required fuel specifications. See Section 14.
8.2.7
Dual Fuel System
Complete fuel systems for two different fuels, including piping, valves and controls. Fuels
can be:
•
•
Natural gas with liquid fuel
Two gaseous fuels
• Two liquid fuels
Manual or automatic transfer to backup fuel requires a reduction in power. However, if full
load fuel transfer is required, an optional cooler is provided to cool the air stream used to
purge the fuel nozzles during transfer. This cooler requires a continuous water flow of 20gpm
/ 76 lpm at 65psi / 448 kPag, 95 °F / 35 °C max.
8.2.8 Water Injection System
The water injection system contains the following major components. They are mounted on
the water filter skid, water injection pump skid and main skid.
•
•
•
•
Duplex low pressure filter
Water injection pumps (primary and standby)
Flow transmitter
Flow metering valve
To control the amount of oxides of nitrogen (NOx) emitted by the gas turbine engine during
normal operation, demineralized water is injected into the combustor section of the gas
turbine through the water injection manifold. Demineralized water from a customer source is
pressurized by the selected water injection pump and plumbed into the main skid.
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8.2.8.1
Water Filter and Water Injection Pump Equipment
Demineralized water supplied to the auxiliary skid must meet GE quality requirements MIDTD-0000-3 – See Section 14. Demineralized water flows through the duplex water injection
filter, where water is filtered to 10 microns before being pressurized by the centrifugal water
injection pump. Downstream of the filter, demineralized water flow branches to provide
water to either water injection pump. Two identical water injection pumps are provided in the
system (primary and standby). If there is a pump failure, the operator, after investigating the
cause of the failure to verify the problem is not related to water supply or piping problems,
can then select the standby pump from the human machine interface (HMI) screen. The
standby pump becomes the primary pump and the operator can enable the water injection
system. Necessary pressure and temperature instrumentation allow remote monitoring of the
water injection system on the auxiliary skid.
8.2.8.2
Main Skid
Water flow enters the main skid piping at an operating pressure of 800-950 psig / 5,517 –
6,550 kPag for gas fuel operation an 1200-1320 psig / 8274-9101 kPag for liquid fuel. An
electrically actuated water injection flow-metering valve modulates de-mineralized water flow
to the engine manifold and to the water return in response to data received and processed by
the control system. Downstream of the metering valve, de-mineralized water flows through a
solenoid shutoff valve which opens when the control system commands the water injection
system active and closes when the GTG set is stopped or the water injection system is
commanded off. A flow transmitter sends a 4–20 mA proportional signal to the digital
control system providing flow data used to totalize water use and calculate the water-to-fuel
ratio.
While the system is not in operation, any water in the manifold piping drains from the system
through a manifold drain solenoid valve. Pressure in the downstream piping blows any
residual water out of the system. The gas fuel purge flow from the engine manifold assists in
clearing residual water from the system piping.
Necessary pressure and temperature instrumentation allow remote monitoring of the water
injection system on the main skid. All piping is stainless steel, and the valves are trimmed
with stainless steel.
8.2.9
SPRINT® Power Boost System
SPRINT® Is A Spray Intercooling System That:
•
Reduces combustion air temperature
•
Boosts turbine output power
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•
Increases exhaust energy by injecting fine water droplets into the inlet and interstage air
stream
The SPRINT power performance curves are provided in chapter 5.
Customer supplies demineralized water at 30 gpm / 114 lpm, and 275 psig / 1896 kPag and
150 ºF / 66 ºC nominal. Consult GE Energy for details.
8.2.10
Evaporative Cooling
Evaporative cooling lowers inlet temperature to the gas turbine for added power. This option
is recommended when high dry bulb temperatures are common, with low/medium ambient
humidity.
This system is designed for recirculation of evaporative cooling water from a sump in the
bottom of the inlet air filter. This option includes recirculation pump, conductivity probe,
blowdown and make-up valves, piping and wiring. Customer must supply filtered, potable
water to a flanged connection on the filter house and must dispose of waste water from the
blowdown valve. Flow rates will vary based on blowdown.
8.2.11
Inlet Air Chiller Coil
To increase the output of the LM6000 during hot weather, GE Energy installs a chiller coil
upstream of the static filter. A water/glycol mixture is circulated through the coil to lower
inlet air temperature and improve turbine performance. The chiller system includes the
following:
•
High performance cooling coils
•
Can be offered separately or in conjunction with a mechanical chiller module with pumps,
motors and controls for water/glycol circulation of 3,300 gpm / 12,493 lpm.
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8.2.12
Inlet Air Anti-Ice Coil – Exhaust Heat Recovery Unit
(Primary Option)
GE Energy recommends an anti-ice system for safe operating during icing conditions and
provides several anti-ice options. With this option, exhaust heat is utilized to provide anti-ice
heating of the inlet air and can be used with the included anti-ice coils or with chilling coils
provided separately. The three major components of this system are as follows:
Waste Heat Skid
The waste heat skid utilizes gas turbine exhaust gas to fluid heat exchanger. Exhaust gas from
the gas turbine stack is extracted and flows through the plate fin and tube, all stainless steel
heat exchanger. Exhaust gases then flow through a blower which boosts the exhaust gas
pressure and returns the exhaust gas back to the stack. A flow control damper is provided at
the blower discharge to control the air temperature rise across the inlet air going to the gas
turbine. A water- glycol mixture is heated in the gas-to-fluid heat exchanger with a design
duty of 4 mm BTU/hr.
At ambient conditions when the anti-ice system is not required, dampers at the inlet to the
waste heat recovery unit (WHRU) and outlet of the blower are closed. A purge blower is
activated to inject air to prevent overheating the fluid. A temperature alarm set at 200° F / 93°
C is also provided to start the fluid pump if the purge blower is inoperative or cannot provide
sufficient purge air to prevent overheating.
Fluid Pump Skid
The heated fluid is pumped through an anti-ice coil located upstream of the static filter to heat
the inlet air 15º F / 8.3º C. The pump skid is designed to circulate 300 gpm / 1136 lpm of
fluid using duplex (2 x 100%) 7.5 kW / 10 hp pumps. The closed system includes a
pressurized expansion tank and the entire anti-ice system contains approximately 350 gallons
of fluid. Under normal conditions no make-up or discharge is required. A low flow switch is
provided to shut down the pump and blower skid if flow disruption is detected and an alarm
on the Turbine Control Panel alerts the operator to this condition. Please consult GE Energy
sales for details.
Anti-Ice Heating Coils
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Anti-ice coils are provided and installed in the air filter assembly. Coils are piped to a
common manifold with customer connections on each side of the main skid. If chilling coils
are present they will be utilized for both chilling and anti-icing duty.
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8.2.13
Inlet Air Anti-Ice Coil
With this option, GE Energy installs an anti-ice coil upstream of the static filter. The
customer circulates a heated water-glycol mixture through the coil to heat the inlet air 15 ºF /
8.3 ºC. Check with GE Energy for details.
8.2.14
Inlet Air Anti-Icing - Ventilation Recirculation
With this option, GE Energy recirculates warm turbine room ventilation air back to the inlet
air filter in order to keep ice from forming on the filter. Check with GE Energy for details.
8.2.15
Pulse Filter (Self Cleaning)
GE Energy uses a pre-engineered, self-cleaning filter option for job sites with special needs
such as dust, pulp and paper fiber and snow. Self-cleaning filter elements are provided for
combustion and ventilation air paths.
The filter house mounts above the turbine enclosure and is supported with legs. Downward
air-flow provides filtered air for combustion and ventilation. This compact filter design is
easily installed in the field, and it eliminates customer supplied ducting. The filter system
includes a stainless steel inlet silencer and a ladder and platform for inspection and servicing
of the filter.
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8.2.16
Static Excitation
The supplied static excitation system is based on a GE EX2100 Potential Fed Excitation
System. This excitation system is GE’s latest state-of-the-art control offering for both new
and retrofit steam, gas, or hydro generation. The EX2100 incorporates a powerful diagnostic
system and a control simulator to support fast installation, tuning of control constants, and
training. Easy to use graphics are used for operating, troubleshooting and maintaining
optimum generator performance. The architecture is a single control rack, one power supply
rack, control power input module and the power module. The power module consists of a
bridge interface sub-system, power bridge, ac and dc filter networks, and ac and/or dc
isolation devices. The EX2100 will directly communicate to the Turbine Control Panel
through Ethernet connection also has hand control switches on front of GT Turbine Control
Panel for control
8.2.17
Air-Oil Cooler
The air-oil cooler replaces standard shell and tube coolers for customers who prefer aircooling of lube oil. The air-oil cooler includes dual stainless steel tube bundles (one for
synthetic oil; one for mineral oil) and two electric motor-driven fans (one running and one
backup).
8.2.18
Winterization
For equipment operating outdoors in cold climates, -20 - 40º F / -29 - 4.4º C, GE Energy
recommends a winterization option. This option can include any and all of the following
modifications:
•
•
•
•
Inlet air anti-icing
Heat tracing and insulation of applicable unit-mounted piping
Enclosing and heating exposed instrumentation and equipment, as specified by GE Energy
Enclosing the auxiliary equipment module.
When enclosing the auxiliary module equipment for ambient temperatures below -20 ºF / -29
ºC, the above modifications plus additional special provisions will be required. Consult GE
Energy for details.
8.2.19
Medium Voltage Switchgear and Generator Bus Duct
Medium Voltage Switchgear
Outdoor NEMA 3R, non-walk in 15 kV, 3000 A three section line up to include 3000 A
generator circuit breaker, 1200 A auxiliary circuit breaker, and 1200 A spare cell. Each
circuit breaker is rated at 1000 MVA with an optional 1500 MVA rating available. Lineup
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includes current transformers, draw out potential transformers, protective relaying and
metering are also included.
Generator Bus Duct
Outdoor, totally enclosed, non-ventilated, non-segregated, epoxy insulated bus duct rated at
15 kV, 3000 A, 3 phase with ground. Includes a heating system with thermostat. Standard
length is ten feet from generator line side cubicle to medium voltage switchgear. The
generator bus duct also includes all necessary supports.
8.2.20
Unit Motor Control Center
Free-standing lineup of motor controls for motors in GE Energy equipment. The MCC is
suitable for indoor installation in optional modular control room or other non-hazardous area.
Customer supplies feeder breaker to energize the MCC and interconnecting wiring to motors
on main enclosure.
8.2.21
Remote Work Station
GE Energy offers a remote workstation consisting of a desktop Pentium® computer, HMI,
keyboard and mouse. This station is linked to the main control and mimics the HMI located
in the turbine control panel in monitoring and control features.
8.2.22
Lifting Gear
Three Options
•
•
•
Option 1: Receive all applicable drawings – customer is free to choose supplier.
Option 2: Purchase lifting gear equipment – customer purchases equipment directly from
GE Energy.
Option 3: Rent lifting gear equipment - Cost is $55,000.00 per set of gear required. If the
equipment is returned pre-paid within 45 days of shipment (domestic) and 90 days
(foreign) then GE will credit 50% of the original rental cost per set.
8.2.23
Control Module Options
8.2.23.1
Auxiliary Control Module (ACM)
The optional ACM comes complete with a basic auxiliary equipment module as described in
Section 7 as well as an integral 15 ft / 4.6 m control room. The TCP and battery system are
installed (wiring included) in the control room. The motor control center (MCC) is not
included with this option.
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8.2.23.2
Power Control Module (PCM)
The optional PCM comes complete with a basic auxiliary equipment module as described in
section 7 as well as an integral 25 ft / 7.6 m control room. The PCM control room houses the
following GE provided equipment: TCP, battery system, and motor control center (MCC). In
addition, GE will provide interconnect wiring between the MCC and the motors on the
package and auxiliary skid, pre-wired before shipment.
The MCC is a freestanding lineup of motor controls for all motors furnished by GE Energy.
The MCC is provided installed and fully wired within the modular control room in
accordance with GE Energy Industrial Motor Control Specifications.
This option also includes providing and installing power cables for the following:
-Hydraulic start motor
-Water wash motor
-Generator and turbine compartment ventilation fan motors
-Lighting auxiliary transformer
8.2.23.2
Power Control Module (PCM) (Continued)
-Water injection motors (optional)
-SPRINT® motor (optional)
-Liquid fuel boost pump motors (optional)
-Other auxiliary motors
-Provide the auxiliary skid base penetrations thru ROX transition frames and will install
cables to the respective motor termination boxes.
8.2.24
80 dB (A) (near field)
Additional silencing, enclosure, lagging etc. is added to reduce the average near field noise to
80 dB (A) at 3 ft / 1.0 m from the enclosure and 5 ft / 1.5 m above grade. Extent of scope will
depend on the scope of equipment, Site Plan and Project Special Requirement. Start-up and
Shutdown modes may exceed these levels.
8.2.25
Remote Monitoring and Diagnostics Service
Monitoring and Diagnostics Service helps aeroderivative turbine plant operators improve
availability, reliability, operating performance, and maintenance effectiveness. Monitoring of
key parameters by engine experts may lead to early warning of equipment problems and
avoidance of expensive secondary damage. Diagnostic programs seek out emerging trends,
prompting proactive intervention to avoid forced outages and extended downtime. The ability
for GE engineers to view real-time operation accelerates troubleshooting and sometimes
removes the need for service personnel to visit the plant.
8.2.25.1
System Overview
LM6000 - 60 Hz Classic 6/2008
Page 72 of 156
GE Energy developed the Monitoring and Diagnostics System (M&D) to complete its
comprehensive world-class service and support network.
System Functionality
•
GE’s Monitoring and Diagnostics System includes on-site hardware and software, which
retrieves operating data from each plant’s control system and makes it available for
transmission to GE’s centralized M&D offices.
•
Operating data is transmitted from the site over a standard telephone line, either on a
continuous basis via a private Internet network, or in a periodic downloading session.
8.2.25.1
System Overview (Cont)
•
The central office archives the operating data, conducts diagnostics on
key parameters, and provides all data necessary for displaying or trending.
Site Requirements
•
A dedicated phone line or Internet connection must be available to access the Monitoring
and Diagnostics System. If cellular data service is adequate at the site, GE may be able to
provide a cellular modem.
•
The plant control system must be configured to send data to a serial or Ethernet port.
•
Mounting space and available power must also be supplied for the onsite M&D System
equipment.
8.2.25.2
Product Features
The Monitoring and Diagnostics System enables aeroderivative gas turbine operators to
access real-time remote monitoring, early problem identification, and proactive diagnostics.
Key features include:
On-Line Monitoring
•
On-line, real-time monitoring allows GE specialists to be on-line to support maintenance
and operations personnel.
•
On-line monitoring enables quick-response troubleshooting by factory experts, which may
result in faster detection and corrective action to avoid potential forced outages.
Accelerated Troubleshooting Support from Factory Experts
•
Internet access to the database and on-line monitoring by GE service network enables
remote assistance to the customer’s site.
•
Certain faults can be diagnosed and corrected without a site visit by GE service
representatives and engineers.
LM6000 - 60 Hz Classic 6/2008
Page 73 of 156
•
Experienced LM monitoring analysts incorporate factory knowledge and enhanced service
for diagnostics, parametric trending, and maintenance planning.
Customer Notification Report
•
Customer Notification Reports (CNR) are issued to document anomalies and submit
recommended actions for correction.
Product Features (Cont)
Customer Notification Report
•
Selected conditions will trigger early warning alerts to M&D Center monitors; the center
analysts will then escalate the issue to the Customer Satisfaction Manager or directly to
the site, along with CNR that documents the observations and recommended corrective
action.
Vibration Monitoring System
•
The Vibration Monitoring System complements the standard monitoring service by
providing early and accurate detection of excessive vibration in the gas turbine.
•
The optional Vibration Monitoring System is designed to detect and filter discrete
frequencies and display vibration magnitudes directly related to specific problems.
•
The system can be custom-designed to filter for any type of problem frequency, ensuring a
more sensitive vibration signal for evaluating long-term degradation.
Access to M&D Data
•
The M&D Website provides customers secure access to their plant’s data via the Internet.
8.2.25.3
Service Benefits
Performance capabilities provided by GE’s Monitoring and Diagnostics Service include:
Early Warning of Changing Conditions
•
Active monitoring by factory engineers may provide early warning of changing operating
conditions, thus prompting appropriate on-site action and allowing proactive maintenance
scheduling.
•
The Anomaly Alert and Escalation Process documents automated early warning alerts,
trend shifts, and instrumentation faults in order to help avoid outages and equipment
failure.
Proactive Recommendations for Action
•
Diagnostic programs seek out emerging trends and alert monitoring personnel; this
enables proactive intervention against potential outages and extended downtime.
LM6000 - 60 Hz Classic 6/2008
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•
Daily trending of key parameters by factory experts may lead to early warning of
equipment problems and avoidance of expensive secondary damage.
•
Factory assistance to on-site personnel speeds DLE gas turbine control mapping process.
•
When trips and failed starts are detected, GE support organizations are notified, alerting
them to the possible need for assistance or outage cause investigations.
Reduced Downtime
•
The Monitoring and Diagnostics Service may reduce plant downtime and costs by
supporting investigations of systems such as the gas fuel system, purge valves, and
sensory devices.
•
LM monitoring provides advanced knowledge, quicker resolutions, and optimal
performance, which have resulted in an average down-time reduction of three days per gas
turbine each year.
Optional Features
The following features are available as options to the standard M&D service:
•
Independent vibration monitoring system.
•
Wireless or landline communications management from site for data transmission.
•
Control system setup for M&D service.
8.2.25.4
Pricing
Annual pricing is dependent upon number of run hours per year, level of service and features
desired as well as your plant operating profile. Standard service is offered on an annual fee
basis, which includes on-site equipment. Some options may require upfront setup charges
and/or annual fees. Contact your GE service sales representative for a customized proposal.
8.2.25.5
Contracts
Monitoring and Diagnostics Service is available under annually renewable or multi-year
contracts, and may be included in Contractual Service Agreements or as independent service.
M&D service is offered with the limitation that GE assumes no greater or lesser liability than
it has under the terms of any other contracts as a result of the application of the on-site
monitoring equipment and M&D System or use of data retrieval software to the monitored
units. Also, GE shall not be responsible for failing to monitor the OSM or failing to notify the
unit’s owner of abnormalities.
8.2.26
Full Load String Test
LM6000 - 60 Hz Classic 6/2008
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A full load string test of the turbine package and control system, including flushing, and
verification of safety alarm and shutdown setpoints is available in place of the standard nonfired test. The full load test includes starting the gas turbine and running to full power.
8.2.27
Fuel Filter/Separator
An optional gas fuel filter/separator removes moisture from the gas fuel and provides
filtration to 3 microns absolute.
LM6000 - 60 Hz Classic 6/2008
Page 76 of 156
9.
9.1
Mechanical Outlines
Contents
9.1.1
9.1.2
9.1.3
Turbine Generator
Left Side
Figure 9-1
Right Side
Figure 9-2
Exhaust End
Figure 9-3
Generator End
Figure 9-4
Exhaust Flange Detail
Figure 9-5
Auxiliary Control Module Option (ACM)
Left Side
Figure 9-6
End View
Figure 9-7
Power Control Module Option (PCM)
Left Side
Figure 9-8
End View
Figure 9-9
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9.1.1 Turbine Generator
49'- 11 7/8 "
[15237]
VBV
DUCT
WEATHER
HOOD
42'-3"
[12877]
46'-10 3/4"
[14294]
AIR FLOW
VBV
DUCT
SILENCER
GEN.
VEN T.
AIR
INLET
TURBINE ENCLOSURE
EXHAUST FAN
VBV
DUCT
TURBINE
COMBUSTION &
VENTIL ATIO N
AIR INLET
GENERATOR
AIR/OIL
SEPARATOR
GENER ATOR
VENT AIR
EXHAUST
AIR FLOW
LINESIDE
CUBICLE
TOP OF
ENCLOSURE
DAMPER
14'-5 3/8" [4405]
C
L
C
L
GENER ATOR /
TURBINE
TURBINE
ENCLOSURE
9'-8 7/8"
[2970]
"0" D ATUM
AL L ELE VATIO N
DIMENSIONS ARE TAKE N
FROM BOT TOM
OF SKID
7'-3"
[2210]
4'-7 1/8"
[1400]
49'- 11 3/4 "
[15235]
55'-0 5/8"
[16778]
GROUNDING LUG
56'-6"
[17221]
END OF SKID
34'-9 7/8"
[10615]
25'-9 3/8" [7857]
GENER ATOR ENCL .
ACCESS DOOR
2'-8 3/4" X 6'-10"
[832 X 2083]
31'-1 1/2"
[9487]
INLET ACCESS H ATCH
5'-10 3/8" X 3'-8"
[1708] X [ 1118 ]
8'-6 5/8"
[2608]
13'-0 5/8"
[3980]
1'-2" [356]
GROUNDING
LUG
"0" D ATUM
ALL TAI L
DIMENSIONS
ARE TAKEN
FROM
GENER ATOR
END OF SKID
38'-7 1/8"
[11764 ]
TURBINE ENCL.
ACCESS DOOR
2'-8 3/4" X 6'-10"
[832 X 2083]
Figure 9- 1 Turbine generator - left side
LM6000 - 60 Hz Classic 6/2008
Page 78 of 156
9.1.1 Turbine Generator (Cont)
VBV
DUCT
AIR FLOWWE ATHER HOO D
VBV
DUCT
AIR FLOW
2'-1" [635]
SE RVIC E
CLEARANCE
FILTER
REMO VAL
HEIGHT
8'-0"
[2438]
GENER ATOR
AIR/OIL
SE PAR ATOR
GENER ATOR
VENT AIR
EXHAUST
GEN.
VEN T.
AIR
INLET
AIR FLOW
TOP OF
ENCLOSURE
TURBINE
COMBUSTION &
VENTIL ATIO N
AIR INLET
25'-2 1/2"
[7685]
VBV
DUCT
DAMPER
14'-5 3/8"
[4405]
NEUTRAL
CUBICLE
GENER ATOR
ENCLOSURE
TURBINE
ENCLOSURE
C
L
TURBINE /
GENER ATOR
7'-3"
[2210]
"0" D ATU M
AL L TAI L
DIMENSIONS
ARE TAKEN
FROM
GENER ATOR
END OF SKID
8'-6 5/8"
[2608]
13'-0 5/8"
[3980]
25'-9 3/8"
[7857]
GENER ATOR ENCL .
ACCESS DOOR
2'-8 3/4" X 6’-10”
[832 X 220831]
45'-8 5/8"
[13934]
55'-0 5/8"
[16778]
GROUNDING LUG
56'- 6"
[17221]
END OF SKID
27'-7 3/8"
[8415]
SPLIT LINE
31'-1 1/2"
[9488]
INLET ASS H ATCH
ACCESS DOOR
5'-10 3/8" X 3’-8”
[17881 X 1118 ]
36'-1 7/8"
[11019 ]
TURBINE ENCL.
ACCESS DOOR
2'- 0 3/4" X 6’-10”
[832 X 2083]
Figure 9- 2: Turbine genertor - right side
LM6000 - 60 Hz Classic 6/2008
Page 79 of 156
9.1.1 Turbine Generator (With PCM Option) (Cont)
PCM
SWITCHGEAR
13'-0 5/8"
[3978]
9'-0"
[2743]
3'-5"
[1040]
21'-11 7/8"
[6703]
13'-6"
[4115]
9'-0 7/8"
[2766]
8'-7"
[2616]
UEXHAUST END VIEW
Figure 9- 3: Turbine generator - exhaust end
LM6000 - 60 Hz Classic 6/2008
Page 80 of 156
9.1.1 Turbine Generator (With PCM Switchgear Option) (Cont)
Figure 9- 4: Turbine generator - generator end
LM6000 - 60 Hz Classic 6/2008
Page 81 of 156
9.1.1 Turbine Generator (Cont)
Figure 9- 5: Turbine generator - exhaust flange detail
LM6000 - 60 Hz Classic 6/2008
Page 82 of 156
9.1.2 Auxiliary Control Module (ACM)
Left Side
Figure 9- 6: Auxiliary control module - left side
LM6000 - 60 Hz Classic 6/2008
Page 83 of 156
Figure 9- 7: Auxiliary control module - end view
LM6000 - 60 Hz Classic 6/2008
Page 84 of 156
9.1.4 Power Control Module Option (PCM)
15'-0 7/8"
[4596]
13'-1 1/8"
LIQUID
[3990]
FUEL
12'-8 5/8"
[3875]
12'-11 1/2"
[3950]
FAN
LIQUID
FUEL
ENCL.
8'-3 3/4"
[2534]
1'-7 1/4"
[489]
0"
21'-1 5/8"
[6442]
1'-0"
[305]
GROUNDING
LUG
38'-5 1/8"
[11712]
41'-7 1/4"
[12680]
46'-3"
[14096]
48'-6"
[14783]
49'-6"
[15088]
Figure 9- 8: Power control module option - left side
Figure 9- 9: Power control module option - end
LM6000 - 60 Hz Classic 6/2008
Page 85 of 156
10. Generator, Exciter and Voltage Regulator
10.1 Generator Design
The generator is a synchronous, two-pole, cylindrical rotor machine. It
has open-air cooling and a brushless excitation system with permanent
magnet generator. The rotor is supported by two (2) split sleeve
bearings lubricated by a pressurized mineral oil system.
The generator has a design life of 30 years. The weatherproof acoustic
enclosure reduces average noise levels to 85 dB(A) at three feet (1.0m)
from unit and five feet (1.5m) above grade.
The generator is conservatively sized, with capacity to spare. The
stator, rotor and exciter have Class F insulation, and the generator can
absorb all of the turbine's output power without exceeding Class B
temperature rises.
The generator can also supply the following overload or fault currents
without measurable loss of life:
•
•
•
LM6000 - 60 Hz Classic 6/2008
110% of normal current for 2 hours out of every 24 hours
130% of normal current for one minute
300% of normal current into a 3-phase fault for 10 seconds
Page 86 of 156
10.2 Generator Codes And Standards
The generator is designed to meet codes and standards applicable to
most areas of the world. The primary standards include ANSI C50.14
for 60 Hz. Other ANSI, IEE, IEC and NEMA standards also apply.
10.3 Stator Design
10.3.1
Stator Frame
The stator frame is fabricated from mild steel plate to form a rigid structure. The stator is equipped
with substantial mounting pads with boltholes to secure the generator to the I-beam baseplate.
10.3.2 Stator Core
The core is made of segmental laminations of low-loss, high permeability,
high silicon content electrical steel, carefully deburred and coated with
insulating varnish.
To ensure uniformity, the core is hydraulically pressed at pre-determined
stages during the building operation, and the finished core is clamped
between heavy steel end plates. The core is subjected to a magnetizing
test of the windings to check for the soundness of inter-laminar insulation
and adequate tightness.
10.3.3 Stator Winding
The stator is made of pre-insulated half-coils assembled into a two
layer diamond array. Eddy current losses are minimized by dividing
each conductor into smaller laminations. The laminations are insulated
from each other by a resin-impregnated woven glass braid and are
transposed to minimize circulating currents.
10.3.4 Insulation System
The insulation system is based on a resin-rich mica glass tape that
produces a high performance insulation system capable of continuous
operation at temperatures up to 311°F / 155°C (Class F).
LM6000 - 60 Hz Classic 6/2008
Page 87 of 156
The insulation possesses high dielectric strength, low internal loss and
meets all current specifications. The resin system is thermo-setting, so
that the resulting insulated coil sides are dimensionally stable. This
resin insulation is highly resistant to most common electrical machine
contaminants, such as hydrocarbons, acids, alkalis and tropical molds.
10.3.5 Coil Manufacture
The insulated copper laminations are cut to length, stacked together and
the coil ends are formed into shape on a fixture. The laminations are
then clamped tightly together, taped with an initial layer of tape and hot
pressed to consolidate the conductor stack.
Following this, the main insulation is applied and pressed to size. The
amount of the compression is carefully controlled to ensure correct
resin flow and produce consistent void-free insulation.
Each finished half-coil is subjected to dimensional checks to ensure a
correct fit in the stator slot, and special tapes are added to the inner and
outer coil surfaces to prevent corona discharge.
10.3.6 Coil Winding and Connections
The half-coils are placed in the stator slots in two layers and wedged
securely in position by synthetic resin bonded wedges prior to
connection of the endwinding.
In order to withstand the forces resulting from an accidental short
circuit, the endwinding is securely braced to insulated brackets
mounted on the stator frame.
Spacer blocks are fitted between adjacent coil sides to produce a strong,
resilient, composite structure. Finally, the completed stator is "baked"
in an oven to fully cure the insulation. Resistance Temperature
Detectors (RTD) are embedded in the windings at selected points, and
anti-condensation heaters are fitted into the stator frame.
To ensure electrical performance, the individual coils and the
completed windings are given high-voltage tests.
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10.4 Cylindrical Rotor
The cylindrical rotor is manufactured from an integral forging of
vacuum poured nickel-chromium-molybdenum alloy steel. The
resulting forging is thermally stable, uniform in composition, and has
excellent tensile and mechanical properties. As assembly proceeds,
slots are machined in the rotor surface, and insulated coils of highconductivity silver-copper strip are pressed into the slots. Then damper
windings and wedges are added.
Finally, end caps of non-magnetic manganese chromium steel are
shrink-fitted to the ends of the rotor body.
The rotor is then balanced dynamically and tested at 120% of normal
speed for two minutes. Following high speed testing, the rotor is given
a series of high voltage tests to prove the integrity of the insulation
system.
10.5 Bearings
The main bearings are conventional, white metal lined, hydrodynamic
cylindrical bearings, split on the horizontal centerline for ease of
inspection and removal. The two halves are bolted and dowelled
together.
Oil is supplied under pressure to the bearings with flow controlled by
an orifice in the supply line. Drain oil collects in the bottom of the
bearing housing and returns to the generator lube oil reservoir by
gravity flow.
The generator bearings are end frame mounted on specially stiffened
and reinforced stator frames. A detachable solid ribbed steel plate, split
on the bearing horizontal centerline, supports the lower half bearing
housing. Pressurized air from the downstream side of the generator fans
is used to seal the lubricating oil in the bearings. RTDs in the bearing
metal and in the oil drain lines provide bearing temperature sensing.
LM6000 - 60 Hz Classic 6/2008
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10.6Ventilation Systems
Internal Air Circuit
The generator is cooled by air forced through ducts in the stator and
rotor by two axial fans mounted on the rotor shaft. The cooling air is
supplied to the generator from the inlet air filter.
10.7Brushless Excitation System
The generator is equipped with a low maintenance brushless excitation
system consisting of:
•
•
•
•
•
•
Three phase rotating armature
Three phase rotating rectifier
Rotating permanent magnet generator (PMG)
Exciter field
GE EX2100 automatic digital voltage regulator located in the
turbine control panel
Provisions for a optional Key Phasor
The shaft-mounted PMG powers the voltage regulator and excitation system.
10.8Voltage Regulator
The generator is furnished with a GE EX2100 microprocessor
controlled voltage regulator system. The voltage regulator is rackmounted in the turbine control panel and maintains generator output
voltage within ±0.5% under steady state operating conditions.
The voltage regulator utilizes single phase sensing circuitry and
includes:
•
•
•
•
•
•
•
LM6000 - 60 Hz Classic 6/2008
Diode failure alarm
Flux limiter
Over-excitation limiter
Under excitation limiter
Auto follower & null balance
Auto transfer to manual control
Volts per Hz control
Page 90 of 156
The voltage regulator can be adjusted manually or by remote signals to:
•
•
Raise/lower voltage
Raise/lower VARs or power factor (manual only)
10.9Generator Accessories
10.9.1
Stator Temperature Detectors
Six duplex temperature detectors (two per phase) are embedded in the
stator windings. The detectors are 100 ohm at 0°C platinum type RTDs.
10.9.2
Space Heaters
Space heaters are located inside the generator to prevent condensation
of moisture when the generator is not operating. The space heaters are
suitable for operation on three-phase, 480 VAC power, 60 Hz.
Automatic ON/OFF control for the space heater is provided by the unit
control panel that controls a contactor in the motor control center.
10.9.3
Vibration Detectors
Two vibration detectors are mounted 90° apart at each radial bearing
(Total 4). The proximeters and cables are wired to the Main Generator
Terminal Box (MGTB) in the generator compartment. Monitoring
equipment is provided in the unit control panel.
10.9.4
Ground Fault Monitoring
This control system provides continuous electronic monitoring of the generator rotor winding and its
connections. Indication of a ground fault is shown on the unit control panel.
LM6000 - 60 Hz Classic 6/2008
Page 91 of 156
11. One Line Diagram
11.1 Contents
9.1.4
60 Hz One Line Diagram
Typical Schematic
LM6000 - 60 Hz Classic 6/2008
Figure 11-1
Page 92 of 156
Figure 11- 1: LM6000 60 Hz typical one-line schematic
LM6000 - 60 Hz Classic 6/2008
Page 93 of 156
12. Control System Description
12.1 Control System Overview
Vibration
Monitor
Fire & Gas
Monitor
HMI
(Human Machine
Interface)
Hardwired
I/O
Generator
Controls
Generator
Protection
Distributive
I/O System
Modbus
Hardwired
LinkNet LAN
Generator
Monitoring
Sequencer/
Fuel Control
Distributive
I/O
System
To DCS
Turbine Control Panel
Equipment Package
The overall control systems for the LM6000 GTG set include all individual turbine-generator
system monitoring and operating indicators, controls, and transmitters as well as central
electronic control system.
LM6000 - 60 Hz Classic 6/2008
Page 94 of 156
The turbine control panel (TCP) houses a majority of the control system equipment. From the
TCP, an operator can initiate the turbine-generator’s electronic control system to perform
automatic startup, fuel management, load assumption, and system operation. Critical
parameters are constantly monitored and alarms or shutdowns are initiated automatically, as
appropriate, for out-of-tolerance conditions.
Automatic fuel control and turbine sequencing are controlled by the logic control system
software and hardware. Also, an operator or anyone on site can initiate, as necessary, a
manual emergency shutdown at any time.
12.1.1
Human Machine Interface (HMI)
The HMI displays turbine operation data and mimic screens. It includes operator input and
function pushbuttons.
12.1.2
Vibration Monitoring
The Bently Nevada 3500 vibration monitoring system monitors the vibration levels at critical
points along the turbine generator package.
12.1.3
Generator Monitoring
The Satec SA296 simplifies the monitoring and management of generator electrical conditions
and output. In addition to displaying generator output conditions, control and alarm relays are
programmed to activate alarms for measured output values, i.e. high or low current and voltage
conditions.
12.1.4
Fire and Gas Monitoring
The fire and gas detection system is comprised of plug-in modules that link to flame,
temperature, and gas detection sensors inside the turbine enclosure. The fire and gas
detection system interfaces with the turbine control system to provide the necessary engine
shutdown, ventilation fan on/off signals, and other operator messages.
12.1.5
Generator Controls
The GE AVR, EX2100 Brushless Regulator System is designed to control the excitation of a
brushless generator.
LM6000 - 60 Hz Classic 6/2008
Page 95 of 156
12.1.6
Generator Protection
The Beckwith 3425 integrated generator protection system (IGPS®) for generators is a
microprocessor-based digital relay system that provides protection, control, and monitoring of
the generator. Necessary drainage, including sumps and drain piping
LM6000 - 60 Hz Classic 6/2008
Page 96 of 156
12.1.7
Digital Control and Monitoring System
Item
Control/Indicator
Abbreviation
1
2
3
5
6
7
8
9
10
11
12
Horn
Lamp, Synchronizing
Lamp, Synchronizing
Meter, Digital Multifunction
Switch, Synchronize
Ammeter, Null Balance
Relay, Lockout (Generator)
Blower, Control Cubicle
Blower, Termination Cubicle
Switch, Circuit Breaker Control and Status “52G”
Switch, PF/VAR Adjust
SL2
SL1
DMMF
SS
NBA
86G
BLR1
BLR2
CBCS1
PFAS
LM6000 - 60 Hz Classic 6/2008
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12.1.7
Digital Control and Monitoring System (Cont)
Item
Control/Indicator
Abbreviation
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Switch, Voltage/PF/VAR Control Enable/
Switch, Manual Voltage Adjust
Switch, Voltage Regulator “On/Off “(Inside Panel)
Switch, Excitation Mode
Switch, Automatic Voltage Regulator Adjust
Regulator, Auto/Manual Voltage
Human Machine Interface
Switch, Emergency Stop “TCP”
Switch, Local/Remote Selector
Switch, Speed Adjust
Integrated Generator Protection System
Hole, Spare
Panel, Fire & Gas Protection
Monitor, Vibration
Door, Access
Switch Block, Test, Bus Voltage
Switch Block, Test, Generator Voltage
Switch Block, Test, Generator Current (Metering)
Switch Block, Test, Bus Current (Protection)
Switch Block, Test, Generator Current (Protection)
Switch Block, Test, Spare
Switch Block, Test, Spare
Switch Block, Test, Generator Lockout Relay (86G)
Digital Synchronizer Module
Filter, Control Cubicle
Filter, Termination Cubicle
Nameplate
HMI Keyboard
Laptop Shelf
Switch, Turbine Start-Stop
VCES
MVAS
ES
EMS
AVAS
AVR
HMI
ES3
LRS
SAS
IGPS
LM6000 - 60 Hz Classic 6/2008
FPP
VIB
TSB1
TSB2
TSB3
TSB4
TSB5
TSB6
TSB7
TSB8
DSM
FLTR1
FLTR2
TSS
Page 98 of 156
13.Equipment and Services by Buyer
13.1 Civil
In order to provide a complete operational installation, additional equipment and services, not
included in the basic unit scope, must be provided by the buyer or the installer. These
include, but are not limited to, the following:
•
•
•
Foundations – Design and construction with all embedments including sole plates, anchor
bolts, and conduit
Grounding grid and connections
Necessary drainage, including sumps and drain piping
13.2 Mechanical
•
•
•
•
•
•
•
•
•
•
Natural Gas: Provide 50 °F / 28 °C of heating above the dew-point. In addition, a gas
shutoff valve located remotely from the unit must be provided to shut off the gas supply to
the turbine when the unit is not in operation. GE fuel specifications are included in
Section 14.
#2 Distillate Oil: Provide storage tanks and piping to the fuel forwarding skid inlets, and
from the forwarding skid outlets to the base auxiliary equipment module connections, and
for treatment devices (centrifuge and duplex filters.)
Demineralized water for the water injection system at required pressure
Water injection pump skid (NOx control only)
Compressed instrument air to pressurize off-base water washing tanks, pulse clean air
filters as required
Heated fluid for the inlet air heating system if required
Fluid for inlet air chilling or evaporative cooling, if required
Heated fluid for anti-icing system, if required
Ventilation ducting, if required
Exhaust expansion joint, ducting, elbow(s) and stack, if required
LM6000 - 60 Hz Classic 6/2008
Page 99 of 156
13.3 Electrical
•
Air conditioned control room for turbine/generator panels and other “indoor type” control
equipment
• 480V AC electrical power for gas turbine starting and accessories
• Electrical power connections (power cable or duct) from the generator lineside cubicle to
the buyer’s electrical systems
• Electrical control connections from the on-base terminal points to the turbine control
panel, to the generator control panel, and to the Buyer’s systems
• Motor control centers (MCC) and auxiliary power transformers as necessary for station
services such as:
- Fuel gas compressors
- Distillate fuel forwarding skids
• The following cables:
- Control cables between the turbine/generator panels and the MCC, fuel gas compressor,
fuel forwarding skid, and other controlled and off-base devices
- Power cables from the Buyer’s electrical system to the MCCs, and from the MCCs to their
load devices.
- Power cables to and from the 125 VDC battery and charger systems
See the Typical One-Line for further definition.
13.4 Miscellaneous
•
•
•
Transport, unload, place on the foundation and install the equipment
Construction services including electric power, lighting, temporary heaters, test
equipment, compressed air, crane(s) and all required standard tools
Storage and security for equipment received.
13.5 Balance of Plant Equipment, if necessary
•
•
•
•
•
•
•
•
•
•
Exhaust system equipment
Heat recovery boiler and by-pass stack
Plant fuel gas scrubbers, filtration, separation or regulation
De-aeration and chemical injection equipment
Steam turbines and condensers
Boiler feed pumps and auto level control assemblies
Automatic blowdown controls
Non-standard inlet filter house support structures
De-superheater equipment
Cooling tower and circulating water system
LM6000 - 60 Hz Classic 6/2008
Page 100 of 156
•
•
Power plant calibration tools
Spare parts and consumables
13.6 Limits of Scope of Supply
Listed below are the limits of GE Energy BaseScope of Supply. All piping, wiring, cables,
duct, etc. connecting to these points will be furnished by the Customer (unless modified by
specific agreement).
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
All piping, including fuel gas, fuel oil, steam, cooling water, heating water, demineralized
water, lube oil, compressed air, instrument air, hydraulic start oil
Inlet air-to-filter
Turbine cooling air exhaust and generator cooling air exhaust
Turbine exhaust
Power and control terminations at package skid edge
Wiring from Turbine Control Panel
High voltage connections
Generator ground connection
Bus bar in GE Energy lineside cubicle
GE Energy neutral cubicle
Terminal box on individual motor
Ladders and platforms for inlet air filter maintenance only
Battery terminals to baseplates (if supplied loose)
Electric motors
Ladders and platforms for air filter
24 VDC batteries and chargers* for control system and fire/gas system
125 VDC batteries and chargers* for optional DLE operation and medium voltage
switchgear
Flanged or threaded connection on GE Energy baseplates
Atmosphere (non-standard duct by others)
Exhaust flange on main baseplate
Terminal box on baseplate
* GE Energy will include installation of the TCP and batteries with the ACM option and installation of the TCP, batteries and
MCC with the PCM option.
13.6.1
•
•
•
Additional Materials and Labor Furnished by Others
Civil engineering design of any kind
Building and civil works
Site facilities
LM6000 - 60 Hz Classic 6/2008
Page 101 of 156
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Support steelworks and hangers for the gas turbine ducting, silencing and pipework
All inlet, exhaust and ventilation ducting other than included in the scope of supply
Drains and/or vent piping from the gas turbine package to a remote point
Fuel storage, treatment and forwarding system
Site grounding
Lightning protection
Power systems study
Sensing and metering voltage transformers
Machine power transformers, and associated protection
Grid failure detection equipment
Off-loading, at site transportation and storage
Training except as described in Section 18
Off-skid cabling, and design of off-skid cable routing
Balance of plant and energy optimization controls
Anchor bolts, embedments, and grouting
Distributed plant control
Customer’s remote control (quoted separately)
Field supervision
High voltage transformer(s), cables, and associated equipment
Interconnect piping, conduit, and wiring between equipment modules
Plant utilities, including compressed air supply and off-skid piping
Battery containment
Lube oil measurement other than that defined in the scope of supply
Additional lube oil breather ducting other than that defined in the scope of supply
Fuel transfer pump
Fuel for gas turbine
Off-skid fuel block and vent valves
Fuel supply pipework beyond the scope of supply
Generator controls other than that defined in the scope of supply
Load sharing control
Balance-of-plant control
Site labor
Ladders, stairs, and platforms (except those for inlet air filter)
Lifting Gear (also an option)
Site performance testing (GE Energy provides Power/HR test correction procedure and
technical direction during test)
13.7 Start-Up/Test Materials and Labor Furnished by Others
•
•
Operating personnel for starting, preliminary runs and tests
Lubricating fluid, greases, and supplies for starting, preliminary runs, tests and normal
operation thereafter
LM6000 - 60 Hz Classic 6/2008
Page 102 of 156
•
Fuel and load for tests.
•
All field performance tests. Such tests to measure quoted guarantees shall be in
accordance with General Electric recommended test procedures.
Note: Various types of contracts are available from GE, thus the above may not reflect the
contracted scope. In case of conflict, the agreed upon contract with GE prevails.
LM6000 - 60 Hz Classic 6/2008
Page 103 of 156
14. Reference Specifications
14.1Contents
Natural Gas Fuel for GE Aircraft Derivative Gas Turbines
MID-TD-0000-1
Liquid Fuel for GE Aircraft Derivative Gas Turbines
MID-TD-0000-2
NOx Suppression Water Purity Specification
MID-TD-0000-3
Compressor Cleaning Water Purity Specification
MID-TD-0000-4
Liquid Detergent for Compressor Cleaning
MID-TD-0000-5
Lubricating Fluid Recommendations for
GE Aircraft Derivative Gas Turbine
MID-TD-0000-6
Water Supply Requirement for Gas Turbine Inlet Air Evaporative Coolers
GEK-107158A
LM6000 - 60 Hz Classic 6/2008
Page 104 of 156
15. Maintenance, Special Tools and Spare Parts
15.1 LM6000 Maintenance Advantages
Down time is costly and in addition to labor and material for repairs, the owner loses profits
while the turbine is down for maintenance. In most instances, the lost profit during down time
exceeds the cost of repairs.
The LM6000’s simplified design helps reduce these field costs. The entire LM6000 package
is designed for easy maintenance. Enclosures are large and provide ample working space.
Components are accessible and easily adjusted or repaired, and an internal bridge-crane
speeds engine removal for major repairs.
The result is more “up-time” and less “down-time.” The LM6000 fleet of generator sets
operated by GE Energy has an average reliability of 99.5%, exceeding the industry average by
almost a full percentage point. The LM6000’s simple package design and easy replacement of
turbine modules contributes to this fine result.
15.2 LM6000 Repairs
To speed repairs, members of GE’s engine lease pool can have stock replacement engines
dispatched to the job site for either planned repairs or an unscheduled overhaul.
The owner of an LM6000 package can easily remove the entire turbine engine in the event of
serious failure. A replacement engine can be installed and on-line within 48 hours, and the
customer's operations can return to normal while the engine is being repaired off-site.
15.3 Engine Compartment Design
The GE Energy engine compartment includes a shock isolation mounting system that permits
the LM6000 turbine to ship in the package. This eliminates field reassembly. The turbine
arrives tested, wired and fully piped.
The engine compartment includes built-in lighting, walkways and comfortable working space.
The overhead bridge crane can easily lift and turn the engine for removal through the side
doors.
15.4 “On Condition” Maintenance
Maintenance on many gas turbines is scheduled on a “clock-hour” basis. Parts are replaced
after a set number of operating hours. This can lead to unnecessary costs and maintenance.
LM6000 - 60 Hz Classic 6/2008
Page 105 of 156
The LM6000 is designed for “On-Condition” maintenance. Every six months the engine is
given a thorough borescope inspection. Twenty-one borescope ports permit close inspection
of all major internal parts.
15.5 Preventative Maintenance Inspection
This inspection reveals wear and mechanical problems. Maintenance is scheduled only when
inspection shows a specific need, rather than replacing parts on an arbitrary schedule.
GE Energy literature and training stress preventative maintenance and operator awareness.
We teach the customer's operators to perform preventative measures, including:
•
Condition monitoring of critical parameters
•
Trend analysis of performance
•
Visual inspection of auxiliary systems and external wiring
•
Borescope inspection
•
Water wash
•
Filter changes and inspections
• Lube oil sampling
In addition, GE Energy teaches operators to perform routine " condition monitoring, "
including:
•
Gas generator speed
•
Power turbine speed
•
Gas generator exhaust gas temperature
•
Gas generator discharge pressure
•
Vibration
•
Oil pressure
•
Oil temperature
Condition monitoring, in conjunction with borescope inspections, can provide an essential
history of engine condition-versus-operating time. This allows maintenance to be predicted
and scheduled for an appropriate time.
15.6 Maintenance Levels
Downtime for maintenance is reduced by the LM6000's modular design. Routine maintenance
tasks are done on-site, while major engine repairs are performed at specialized off-site
LM6000 - 60 Hz Classic 6/2008
Page 106 of 156
facilities, saving the customer the expense of tooling and equipment. On-site and off-site
maintenance tasks are divided into categories, or “levels,” described below.
15.7 On-Site Maintenance
15.7.1
Level 1
On-site external maintenance and module replacement includes protective and corrective
tasks such as:
•
Adjusting or replacing externally accessible components
•
Engine replacement
15.7.2
Level 2
On-site internal maintenance requiring partial disassembly of the engine and replacement of
components includes:
•
Compressor blade/vane replacement
•
Hot section component replacement
•
HPT blade replacement
•
Gearbox replacement
15.8 Off-Site Maintenance
15.8.1
Level 3
Off-site internal maintenance. Includes all Level 2 capabilities, plus complete teardown and
rebuilding of engine. Includes replacement of major subassemblies with spare subassemblies.
15.8.2
Level 4
Off-site overhaul. Includes Level 3 capabilities plus complete disassembly of the major
subassemblies of the gas turbine and rebuilding subassemblies with replacement parts. A
permanent shop and a test cell are required for a Level 4 overhaul facility.
GE Energy has full Level 4 maintenance capabilities for customer’s needs. We feature fullload testing of the repaired engine to ensure maximum field performance.
15.9 Owner’s Maintenance
LM6000 - 60 Hz Classic 6/2008
Page 107 of 156
In most cases, the Owner prefers to have his operators trained to perform Level 1 maintenance
to the gas turbine, and Levels 2-4 maintenance tasks handled by outside contract. However,
GE Energy can train operators for Level 2 maintenance tasks, if desired.
15.10 Special Tools
Special tools are required to perform Level 1 and Level 2 maintenance activities. These tools
are listed on the following pages and are priced separately for customers intending to perform
maintenance themselves.
GE Energy includes a lift fixture for the LM6000 turbine engine in the basic scope of supply.
This fixture and the built-in crane are used during engine removal and replacement.
LM6000 - 60 Hz Classic 6/2008
Page 108 of 156
15.11 LM6000 Level 1 and On-Site Maintenance Tooling for New
Equipment (Minimum Recommandations)
P/N
1C3569G3
1C6361G01
1C8182G02
1C8208G02
1C9353G02
1C9359G02
1C9393G01
1C9400G01
1C9428G01
2C6352G07
2C6613G01
2C6647G01
2C6925G02
2C8102G02
RC3501
RC3503
9448M18G01
Description
Hydraulic Actuator Unit:
Actuates Hydraulic System for checking VBV, VIGV, and VSV System
Tool Set-Radial Drive Shaft:
Necessary to remove and reinstall Radial Drive Shaft
Fixture Set-Removal, Mating Seal:
Used to remove and reinstall Transfer Gearbox Carbon Seal, Mating
Ring and O Rings
Drive Adapter, Borescope Motoring Fixture:
Adapts between Ace. Gearbox and Ratchet for Manual Rotation in
Borescope Inspection
Tool Set-Rigging, VBV Doors:
Used to position the Variable Air Bleed By-pass Valve and Linkage
Rigging Set – VIGV:
To check travel of Actuator Ring in Relation to Outer Vane Case
Requires use of 1C3569G3
Adapt. Set, Pressure Test/Rigging-VIGV, VBV, VSV System:
Necessary to pressure test VBV, VIGV, and VSV System Requires use
of 1C3596G3
Fixture, Raise & Hinge - Upper Compressor Case:
Necessary to raise, hinge, and prop open the Compr. Stator Case for
Rotor Blade Maint.
Adpt. Torque Breaking CSV Actuating Arm Retaining Nut:
Used to break the torque of the Compressor Stator Vane Actuation Arm
Retaining Nuts
Wrench Set, Spanner - Airtube Nuts:
Necessary to torque Circular Nuts on Air Tubes
Gage, Immersion Depth –Igniter:
Checks Igniter Plug immersion depth
Wrench, Spanner-Compressor Stator Vane Spacer:
Holds Spacer during Assembly and Disassembly of Compressor Stator
Vanes
Gage, Set -VSV Clevis Assemblies:
Sets and Measures Variable Stator Vane Clevis Assemblies to proper
length
Fixture, Torque Measuring - VSV Assembly:
Used to Measure Torque required to actuate Half Rings and Vanes
Borescope Kit - Rigid Type:
Used for visual inspection of internal components of engine
Fiberscope 6mm:
Necessary to inspect areas inaccessible to rigid borescope kit
Hand Tool Kit (Snap-On):
Contains Hand Tools necessary for General Maintenance
LM6000 - 60 Hz Classic 6/2008
WP (GEK)
WP1112
WP2810
WP2813
WP4015
WP1312
WP1113
WP1112
WP2411
WP2412
MULT
WP1516
WP1411
WP4015
WP4015
Page 109 of 156
15.12 LM6000 Tools - Optional
P/N
1C6119G01
1C9408G01
2C 14699G02
2C6018G01
RC2000-LM
FG145
Description
Guide - Expandable Bushing:
Necessary top install expandable bushing into Transfer Gearbox
Fixture Set, Torque Measuring - Compressor VSV:
Required for setting proper torque of VSV Assembly (low boss vanes)
Fixture, Lift-Compressor Stator Vane Spacer:
Used to remove and handle Compr. Stator Upper Half with Engine in the
Horiz. Position
Tool Set, Holding –VSV:
Holds individual Variable Stator Vanes for Removal and Installation
Fixture Drive Electronic Turning Tool - Borescope Inspection:
Used to electronically rotate engine core for borescope inspection
Borescope Camera With Coupler:
Still camera attaches to borescope
WP (GEK)
WP2811
WP2412
WP2411
WP2412
WP4015
WP4015
15.13 Transportation/Maintenance Dolly Assembly - Optional
P/N
1C9371G01
1C9372G05
1C9373G01
1C9375G01
1C9376G01
1C9377G01
1C9378G02
Description
WP (GEK)
Ring Assy - Support IGV Stator Case:
WP3012
Provides support for EGV Case Forward Flange required for 1C9372G05
WP3012
Maintenance Dolly-External Engine:
Provides frame Assy for use with multiple adapters for Horiz. Engine
Maint. /Transportation
WP3012
Adapter Set - Pedestal Turbine, Rear Frame:
Adapter from Mount Side TRF to Horiz. Engine Maint. /Trans Dolly
required for 1C9372G05
WP3012
Adapter Set - Support Air Manifold:
Provides support at Air Collector Forward Side required for 1C9372G05
WP3012
Jack Assembly, Support Compressor Rear Frame:
Supports Aft Flange of HPC Stator Case for Horiz. Eng. Support
required for 1C9372G05
WP3012
Adapter Set Assembly - Support LPC Forward:
Supports Fwd Flange of LPC Case if VIGV is removed required for
1C9372G05
WP3012
Adapter Assembly - Maintenance Dolly:
Adapter Assy's for Horizontal Engine Maint. /Transportation Dolly
required for 1C9372G05
LM6000 - 60 Hz Classic 6/2008
Page 110 of 156
15.14 LM6000 Level II Tools (Optional)
P/N
8200
1C6804G04
IC6892GOI
1C9116G01
IC9150G02
IC9302G02
1C9316G02
1C9317G01
1C9327G03
1C9336G01
1C9338G02
1C9354G03
1C9358G02
1C9362G02
1C9385G01
1C9390G01
1C9397G01
1C9608G01
1C9609G01
IC9610GOI
1C9613G01
1C9616G01
IC9617GOI
1V9618G01
1C9619G01
IC9620GOI
IC9622GOI
IC9626GOI
1C9627G01
2C 14025G05
2C 14038G02
2C 14049G01
2C 14094G06
2C14131G02
2C 14199G09
2C14222G01
2C14664G01
2C 14672G02
2C14679P01
2C 14684G02
2CI4688G04
2C 14689G01
2C14691G01
Description
Torque Multiplier (Sweeney)
Tool Set, Jack Screw-Disassemble Flanges
Push Bolt - CFF/TGV Bracket
Fixture, Lift LP Rotor and Stator Fwd.
Tool Set, Jack Screws
Tool Set, Assembly, Install -Balance Piston Seals
Adapter, Sleeve LPT Rotor Shaft
Adapter, Support / Lift LPC
Puller, LPT Module - Mid Shaft
Fixture, Assembly, Install / Remove - Aft Drive Shaft Nut
Fixture, Fwd Restraint - LPT RTR to STTR
Dolly Assembly, LM600 Engine Changeout
Fixture, Lift, HPT, Horizontal
Adapter, Lift, Combustor & HPT Nozzle Stg 1&2
Fixture, Support-LPC Rotor/Stator
Fixture Assembly, Lift & Turn VIGV
Holder, Shim
Pusher/Puller HPT (used with 2C 14199G09)
Adapter Assembly Drive Rear
Pilot, LP Mid Shaft, Aft
Fixture, Lift and Turn LPT Horizontal (Strongback)
Fixture, Seating Check LPTR
Wrench, LPTS Coupling Nut
Tool, Install/Remove LPT Snap Ring
Fixture, Torque LPT Coupling Nut
Gage Inspection, Fan Shaft to HPC Case
Collar Center
Wrench HPT Coupling Nut
Fixture, Lift and Turn LPT Horizontal
Pusher Set - Races / Seals HPTR Stg 1
Fixture, Lift - HPTR Aft
Truck, HP Turbine Rotor Horizontal
Fixture, Seal Check No. 4 Bearing and Seal
Fixture, Seating Check
Pusher/Puller HPTR
Remove and Replace HPTR Seals
Wrench Set, No. 5R Bearing Inner Race Nut
Fixture, Lift - HP Turbine Assembly Forward
Sleeve Retaining, No. 4 Bearing Stackup
Tool Set, Remove / Install - HPC Sttr Vane Spacer
Puller, Races and Seals HPTR Stg 1
Adapter, Lift - Combustor
Fixture, Inst/Remove Combustor
LM6000 - 60 Hz Classic 6/2008
Page 111 of 156
15.15 LM6000 Level II Tools (Optional) (Cont)
P/N
2C 14693G01
2C14695G01
2C14703G01
2C14785G02
2C6348P02
2C6967G06
2C6968G02
8112B
Description
Tool Set, Install / Remove - LPT Module - Core Module
Fixture, Lift-Stage 1 HPT Nozzle Assembly
Adapter, Lift-Stage 2 HPT Nozzle
Fixture, Removal HPT Aft Air Seals
Pin, Guide - Fan Rotor Installation
Tool, Install, S-2, HPC Blade Retainer Lock Pin
Tool, Removal, S-2, HPC Blade Retainer Lock Pin
Torque Multiplier (Sweeney)
15.16 LM6000 Start-up and Commissioning Spares
P/N
Description
5VX1000
Belt, Generator, Supply Fan
5VS1250
Belt, Turbine, Exhaust Fan
HC9600FKN13Z Filter Element, Turbine
CONNTECT
Waterwash (55 Gal Drum)
5000
HC9606FKS8Z
Filter Element, HP Hydraulic
AL1335
50 MA Fuses
AL1328
2 Amp Fuses
AL1310
0.1 Amp Fuse
AL1269
4 Amp Fuse
AL1308
31 MA Fuse
P13-2582
3 Amp Fuse
P13-5712
¼ Amp Fuse
226166-001
Calibration, Gas Cylinder
CGI-3L
Gasket, Flg.4”-300#
CGI-3p
Gasket, Flg.6”-300#
CGI-3Q
Gasket, Flg.8”-300#
CGI-6D
Gasket, Flg 1”-600#
CGI-6G
Gasket, Flg.2”-600#
CGI-6J
Gasket, Flg.3”-600#
CGI-6L
Gasket, Flg.4”-600#
HC9600FKD13Z Fuel Filter (Liquid)
ACB2442440Y1 Filter Element, Turbine Hyd
P16-5659
Filter Element, Hyd Start
HUOO157956
Filter Element, Charge Pump
LM6000 - 60 Hz Classic 6/2008
Qty
4
6
4
1
2
5
5
5
5
5
5
5
1
5
5
5
5
5
5
5
2
1
2
1
Page 112 of 156
15.17 Recommended Spares
Listed are the typical “minimum” recommended spare parts for a typical LM6000 gas turbine
generator set. Special configuration specific lists can be prepared upon request.
15.18.1
P/N
1304M52G03
9392M95P04
L21131P02
L28490P05
L31967P01
L31967P06
L35166P01
L43563P01
RD34485
RD34489
RD35234
L44500P02
15.18.2
P/N
L44684P01
L44736P01
L44745P01
L44745P02
15.18.3
P/N
9504M33P01
L31476P53
L31476P54
L45816P04
L45881P05
L45882P05
L45921P01
L45970G01
L45972G01
LM6000 Critical Spares (All Configurations)
Description
Plug, HPT Stage 2 Borescope
Plug, Igniter
Sensor, Speed XN25
Sensor, Flame
Accelerometer
Accelerometer
Detector, Resistance
Detector, Chip
Screen
Screen
Screen
Lube Oil Scavenge Pump
Qty
1
1
1
1
1
1
1
1
1
1
1
1
LM6000 Critical Spares (PC Configuration)
Description
Sensor, LP Speed
Harness, T48 Upper
Sensor, T2/P2
Sensor, T25/P25
Qty
1
1
1
1
LM6000 Critical Spares (Dual Fuel with Water Injection)
Description
Sensor, Temperature
Nozzle, Fuel
Nozzle, Dual
Hose, Fuel
Hose, Fuel – Primary
Hose, Fuel – Secondary
Gasket
Tube, Fuel
Tube, Fuel
LM6000 - 60 Hz Classic 6/2008
Qty
1
6
1
6
1
1
2
2
2
Page 113 of 156
15.18.4
Two-Year Spare Parts Recommendation
P/N
5VX1000
5VX1250
95-117
ACB2442440Y1
HC9600FKN13Z
132P46C6B
78R25N00A025T3
4E5
PG3000-01M-4812-21-XX-93
1151GP9E22B2D3
8915-877
HC9600FKD13Z
1151AP6E22B2D3
330100-50-01
330130-045-01-00
330130-085-01-00
86517-01-01-01-01
EJA310-DAS4B92NC/HAC
PA3000-01M-4813-21-XX-93
PA3000-200-4813-21-XX-93
PA3000-500-4813-21-XX-93
100P44C6R
180P44C6R
273800
HU00157956
P16-5659
HC9606FKS8Z
Description
Qty
Ventilation and Combustion
Belt, Generator Supply Fan
Belt, Turbine Exhaust Fan
Turbine Lube Oil
Element, Filter-Lube Oil Tank Demister
Element, Filter-VGV Pump
Element, Filter-Lube Oil
Gas Fuel System
Switch, Pressure-Fuel Gas
Sensor, Temperature-Fuel Gas
1
1
Transmitter, Pressure, Fuel Supply
1
4
6
1
2
4
Liquid Fuel System
Transmitter, Pressure, Liquid Fuel
Valve, Liquid Fuel
Element, Filter
Auxiliary Systems
Transmitter, Pressure – HP Compressor
Proximeter
Cable, 4.5 Meter
Cable, 8.5 Meter
Module – Accelerometer Interface
Transmitter, Pressure-Inlet Static
1
1
1
1
1
1
Transmitter, Pressure – Turbine HP
1
Transmitter, Pressure-LP Turbine Inlet
1
Transmitter, Pressure-Thrust Balance
1
Hydraulic Start System
Switch, Pressure-Hydraulic Pump
Switch, Vacuum-Charge Pump
Overrunning Clutch
Element – Charge Pump
Element, Filter – Charge Pump
Turbine Hydraulic System
Element, Filter High Pressure
LM6000 - 60 Hz Classic 6/2008
1
1
2
1
1
1
1
4
2
Page 114 of 156
15.18.4
Two-Year Spare Parts Recommendation (Cont)
P/N
132P4S129
132P4S185
655R-EDR-2”
78R25N00A025T3
4E5
HC9600FKN13Z
L-471-02-SG1
P16-7185
7J30D1/30501BH-D-6-C-007.5
C327335
C327345
C327405
1151GP6E22B2D3
86160R1W039A-1
132P49C6B
160P4S36
3051CG5A02A1A
S5M5
3051TG3A2A214
B4E5
V6-EPB-S-S-3-S
10319HE
1530-X1061
Description
Qty
Generator Lube Oil System
Switch, Pressure – Lube Oil
Switch, Pressure Switch – Lube Oil
Valve, Control – Generator/Pressure
Sensor, Temperature – Lube Oil Supply
1
1
1
1
Element, Filter – Lube Oil
Switch, Level – Rundown Tank
Element, Filter – Jacking Oil Pump
Purge System (Dual Fuel Only)
Sensor, Purge Temperature
2
1
2
1
Control, Purge Flow (VB)
Control, Purge Flow Vent (VV1)
Control, Purge Flow (VA)
Liquid Fuel Boost
Transmitter, Pressure Supply
Pump, Liquid Fuel
SPRINT™ System
Switch, Pressure
Switch, Pressure
Transmitter, Pressure
1
1
1
Transmitter, Pressure
1
Switch, Flow
Switch, Temperature
Valve, Solenoid
1
1
1
1
1
1
1
1
LM6000 Consumables
1337M46P03
1538M42P01
619E223P52
635E901P02
9009M74P01
9011M60P01
9013M28P02
9013M29P02
9013M30P02
9014M45P64
9016M30P02
9048M33P05
9057M50P01
9107M23P01
9107M55P01
Gasket
Gasket
Fitting Reducer
Nut Self Locking
Gasket, Round
Gasket
Gasket
Gasket
Gasket
Clamp
Seal, Ring
Bearing
Seal
Gasket
Shim
LM6000 - 60 Hz Classic 6/2008
2
5
1
5
1
2
1
1
1
1
30
3
1
5
2
Page 115 of 156
15.18.4
Two-Year Spare Parts Recommendation (Cont)
P/N
Description
Qty
9365M41P117
9365M41P122
9371M19P04
9371M19P06
9371M19P08
9371M19P10
9371M19P12
9378M31P01
9379M93P01
9397M22P02
9608M12P02
9609M13P02
9610M50P29
9629M48P02
9629M48P04
9629M48P06
9629M48P10
9649M39P04
AC-B244F-2440
AN960C10
AN960C10L
AN960C416L
AN960C516
AN960C616L
An960C616L
J1092P04
J1092P05
J219P02
J219P03
J219P04
J219P07
J221P216
J221P222
J221P224
J221P260
J221P904
J221P905
J221P906
J221P908
J221P910
J221P912
LM6000 Consumables (Cont)
Packing
Packing
Seal
Seal
Seal
Seal
Seal
Fitting
Gasket
Lock Washer
Gasket
Guide
Nut
Nut
Nut
Nut
Nut
Clamp
Filter Element
Flat Washer
Flat Washer
Flat Washer
Washer
Washing
Flat Washer
Nut
Nut
Gasket
Seal Gasket
Seal Gasket
Gasket Seal
Packing, Preformed
Packing, Preformed
Packing, Preformed
Packing, Preformed
Packing, Preformed
Packing
Packing
Packing
Packing
Packing, Preformed
10
10
2
2
1
4
3
10
8
2
5
5
25
25
25
25
25
1
1
100
100
100
100
100
100
5
5
1
2
4
1
25
25
5
1
25
25
25
25
25
25
LM6000 - 60 Hz Classic 6/2008
Page 116 of 156
15.18.4
Two-Year Spare Parts Recommendation (Cont)
P/N
Description
Qty
J221P916
J415P123A
J515P04
J522P57
J534P06
J534P08
J534P10
J534P12
J628P06D
J643P04B
J643P12A
J644P06D
J644P07D
J644P08D
J644P09D
J645P30A
L22281P02
L34976P069
M83248/1-121
M83248/1-243
M83248/1-904
M83248/1-905
M83248/1-910
M83248/1-912
MS21083C4
MS21083C5
MS9193-04
MS9193-12
MS9202-042
MS9315-04
MS9315-12
MS9321-10
MS9404-04
MS9557-07
MS9557-10
MS9557-22
MS9567-14
NAS1291C8M
R1316P007
R287P04
R287P06
R287P08
R287P10
LM6000 Consumables (Cont)
Packing, Preformed
Bolt
Elbow
Nipple
Tube Nipple
Nipple
Tube Nipple
Tube Nipple
Nut
Machine Bolt
Machine Bolt
Machine Bolt
Bolt
Machine Bolt
Bolt
Bolt
Gasket
Bolt
Packing
Packing
Packing
Packing
Packing
Packing
Nut Self Locking
Nut
Connector
Connector
Gasket
Tube Cap
Cap Assy
Washing Flat
Plug
Machine Bolt
Machine Bolt
Machine Bolt
Bolt
Nut
Packing
Nipple
Nipple, Tube
Nipple
Nipple
25
6
1
1
1
1
2
2
5
25
10
5
10
90
5
10
1
5
1
1
1
1
1
3
5
5
5
1
2
25
5
100
5
5
5
5
5
1
1
4
1
2
2
LM6000 - 60 Hz Classic 6/2008
Page 117 of 156
15.18.4
Two-Year Spare Parts Recommendation (Cont)
P/N
Description
1704M61P03
1704M62P04
1704M62P05
1704M63G07
1704M63G08
1704M63G09
1704M63G10
1704M63G11
1704M63G12
1774M59P01
705B276P5
9009M32P01
9108M27P03
9365M41P229
9397M20P02
9609M43P02
9628M16P02
9699M66P01
AN316C4R
J1220G05
J1221G03
J1221G04
J1221G07
J1221G08
J1221G10
J201P04
J221P028
J221P138
J221P163
J221P219
J221P240
J221P903
J414P034A
J511P106
J511P108
J511P110
J511P112
J644P10A
J644P12A
J816P072C
L43073P01
L43616P01
L47372P01
Sleeve
Spacer
Spacer
Arm
Arm
Arm
Arm
Arm
Arm
Seal
Ring
Washer
Bolt
Seal
Bushing
Washer
Bolt
Bolt
Nut
Clamp
Clamp
Clamp
Clamp
Clamp
Clamp
Nut
Packing
Packing
Packing
Packing
Packing
Packing
Bolt
Nipple
Nipple
Nipple
Nipple
Bolt
Bolt
Bolt
Gasket
Bolt
Packing
Qty
LM6000 Consumables - PC
LM6000 - 60 Hz Classic 6/2008
5
5
5
5
1
5
1
5
1
2
2
5
5
5
1
25
5
5
25
5
5
5
5
5
5
5
5
5
5
5
5
5
5
1
1
1
1
5
5
2
5
1
25
Page 118 of 156
15.18.4
Two-Year Spare Parts Recommendation (Cont)
P/N
Description
L47372P02
MS35842-15
MS9201-04
MS9371-15
MS9489-07
MS9556-06
MS9556-10
MS9557-06
MS9557-09
MS9557-14
MS9557-38
MS9565-05
MS9566-12
MS9902-03
MS9902-04
MS9902-06
MS9902-08
MS9902-10
Packing
Clamp
Nut
Gasket
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Plug
Plug
Plug
Plug
Plug
Qty
LM6000 Consumables
LM6000 - 60 Hz Classic 6/2008
25
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
Page 119 of 156
P/N
Description
Qty
00176-198
1174392/01
1327747/04
18711-115
25281-528
25711-012
25711-249
25711-425
25711-428
25715-005
25715-006
25715-010
25771-148
25771-163
25771-167
26632-032
26661-014
28239-088
28239-089
28278-218
28428-187
29812-761
3116456/52
3116682/01
312916/01
3127195/01
3128497/01
3130399/19
3130399/27
3135217/01
3135356/01
3140899/01
3142638/01
9602933/00
9602943/00
9602947/00
9607087/00
9608488/00
9611592/00
9615175/00
Generator Spares
Seal Kit (L.O. Pump) (New)
Brush Holder
Fuse SF21
Gasket Cmpnd (HYLOMAR) 100
Heater Finned 650W
Fuse 4F21
Fuse 20ET
Fuse 315SBMT (3127032/01)
Fuse 450SBMT (3132472/01)
Fuse 250mA, Size 0
Fuse 500mA, Size 0
Fuse 2A, Size 0
Relay VP/2 26V
Relay 24VDC 3P
Relay COMAT 125VDC
POT 500R + 500R
POT Drive Unit
Diode (6W12030VO)
Diode (6W02030VO)
Diode Bridge 36MB80
Thyristor N018R/H08
RTD Temp Detector
Insulated Washer Set (20/set)
Earthing Brush
Exciter Heater
RTD Air Temp Detector
Seal Ring Spring
Insulated Tube Set (20/set)
Insulated Tube Set (20/set)
Duplex RTD Bearing Metal
Gasket F/Bearing
L.O. Pump ACG045N5
L.O. Pump Coupling
Assy Auto Power Card
Assy PF Control Card
Assy Volts Monitor Card
Assy EHC CD, Aux Rack
Assy Exciter Monitor Card
MAVR Control Card, Type B
Assy Exciter Lmtr CD, Type B
1
2
2
6
24
5
5
12
12
5
5
5
2
2
2
1
1
6
6
2
2
2
2
10
2
2
10
2
2
2
2
1
1
1
1
1
1
1
1
1
LM6000 - 60 Hz Classic 6/2008
Page 120 of 156
16. Customer Drawings
16.1 General
GE Energy prepares a comprehensive drawing package for each gas turbine generator set.
The package includes:
•
Proposal Drawings
Drawings furnished with the proposal to assist customer evaluation of the product.
•
Approval Drawings
Drawings requiring specific customer approval.
•
Information Drawings
Drawings of standard manufactured items in the turbine package, furnished for customer
information.
GE Energy provides all engineering drawings on-line at a secure server (www.projectnet.com). Each customer can enter this database and view, print or annotate his own project
drawings. ProjectNet provides the customer with immediate access to the latest revisions of
his drawings. ProjectNet speeds job completion and saves weeks of time mailing drawings
back and forth.
16.1.1
Proposal Drawings - Typical
GE Energy prepares Proposal drawings to show:
• General Arrangement of the Gas Turbine Generator Package
• Electrical “One-Line” information.
These drawings are “Preliminary” in nature. They help define the product for evaluation, and
they form the basis for an Engineering “ODM” or Order Design Meeting after contract award.
16.1.2
Approval Drawings
After the ODM meeting, which defines the project details, GE Energy updates the general
arrangement and one-line drawings and submits them for customer approval.
16.1.2.1
General Arrangement Drawings
These drawings define the orientation of the major GE Energy modules.
A general arrangement drawing with Plan and Elevation views is prepared for each of the
following major components:
LM6000 - 60 Hz Classic 6/2008
Page 121 of 156
•
•
Turbine generator set and associated skids
Turbine Control Panel
•
Auxiliary control module
The general arrangement drawings include the following information:
•
•
•
•
•
Overall dimensions of the equipment
Access space required for removal or maintenance of major components
Foundation loads, foundation bolt hole locations and sizes, plus any special requirements
Lifting lug locations
Customer piping connections with appropriate dimensions
16.1.2.2
One -Line Electrical Drawings
This drawing is an electrical schematic of the power system from the generator terminals to
the purchaser's high voltage bus connections and ground, including the generator excitation
and synchronizing systems. Also indicated are the protective relays, potential transformers,
circuit breaker and auxiliary and main transformers, some of which may be furnished by
others. In cases where the GE Energy equipment will be interfaced with an existing facility or
with customer supplied devices, the customer's one-line drawing must be furnished to GE
Energy for preparation of the GE Energy one-line electrical diagram.
16.1.2.3
Revisions to Approval Drawings
Customer should mark any requested revisions on one copy of the Approval Drawings and
return them to GE Energy within two weeks. GE Energy will then reissue drawings showing
mutually agreeable corrections.
16.1.2.4
Certified Drawings
GE Energy certifies only drawings showing anchor bolt locations, foundation loading and
Customer's piping connection locations.
16.1.3
Information Drawings
The following drawings cover standard manufacturing items. They provide a reference for
construction, maintenance and operations. The drawings are submitted for “information only”
and are not subject to approval.
16.1.3.1
Electrical System Interconnection Plan
This drawing shows recommended sizes for interconnecting cables and corresponding
minimum cable lengths between GE Energy supplied modules and the customer’s control
room. The Interconnection Plan assists the customer in purchasing wire and cable for
LM6000 - 60 Hz Classic 6/2008
Page 122 of 156
interconnection and helps in planning the site layout.
Point-to-point interconnection wiring diagrams are also provided. These drawings are
completed after other system drawings have been finalized.
16.1.3.2
Flow and Instrument Diagrams (F&ID)
F&IDs are issued for each of the fluid systems in the GE Energy scope of supply. This
typically includes the following:
•
•
Fuel system
Water injection system (optional)
•
•
•
Steam injection system (optional)
Water wash system
Hydraulic starting system
•
•
•
•
Gas turbine lube oil system
Electric generator lube oil system
Fire protection system
Evaporative cooling system (optional)
•
•
•
•
Combustion air chilling system (optional)
Air inlet and ventilation system
Turbine auxiliary instrumentation
Anti-icing system (optional)
Each F&ID drawing depicts the equipment components, piping, valves and instruments in the
system, complete with line sizes. The part number of items on the F&ID are shown on a Bill
of Material, which is part of each F&ID drawing.
The F&IDs also show the pressure, temperature and volume limita-tions of the system,
including set points for alarms and shutdowns. Each working fluid in the system is identified,
and initial fill quantities for fluid reservoirs are shown.
For clarity, the F&ID drawings are schematic in nature. Pipe elbows, fittings and similar
details are omitted.
LM6000 - 60 Hz Classic 6/2008
Page 123 of 156
16.1.3.3
Digital Control and Monitoring System
This drawing provides installation details for operator information. The drawing shows the
front of the turbine control panel as viewed by the operator, including HMI screen, meters,
indicator lights and switches. Overall dimensions and installation footprint are shown on this
drawing.
16.1.3.4
Drawings with Manuals
In addition to the above drawings, a complete set of system wiring diagrams is included in the
operation and maintenance manuals to serve as a reference for field check-out and
troubleshooting.
16.2 Documentation
GE Energy provides extensive documentation to help install, commission, operate and
maintain the gas turbine generator package. Information includes:
16.2.1
Installation Manual
The Installation Manual provides detailed instructions on:
•
•
Receiving and Inspecting the Equipment
Assembly of the Components
•
Scheduling, manpower and tooling
16.2.2
Commissioning Manual
The Commissioning Manual provides detailed instructions on:
• Mechanical and electrical precommisioning activities complete with checklists
• Commissioning activities including prestart testing, rotation test, initial fired start, and
auxiliary systems
•
Scheduling, manpower, and tooling
The Installation Manual and Commissioning Manual are each one- volume publications. Two
copies of each are shipped to the job site approximately 1 month before shipment of the gas
turbine generator.
LM6000 - 60 Hz Classic 6/2008
Page 124 of 156
16.2.3
Operation and Maintenance Manuals
This multi-volume manual is prepared by a team of engineers, writers, illustrators and editors.
It is specifically edited for each project, including project specific drawings and details.
The O&M manual is designed as a reference for the operators and technicians in the field. It
provides system descriptions, specifications, and procedures for field operation and
maintenance.
Included are project details and illustrations for the following:
•
Product description
•
Turbine and generator specifications
•
Unit operating procedures
•
Turbine operating sequences
•
Generator operating data
•
•
Gearbox operating data (if applicable)
Control system components and operations
•
Fire & gas system
•
Electrical and Mechanical drawings (as listed in 16.2.4)
In addition to the above information, GE Energy includes vendor’s operation and maintenance
data on all major systems and components.
Six copies of the O&M manuals in CD form are shipped about 30 days after shipment of the
Gas Turbine Generator. This provides GE Energy time to include the latest engineering
drawings. The manuals are also available on a secure internet website.
LM6000 - 60 Hz Classic 6/2008
Page 125 of 156
16.2.4
Typical Drawing List for GTG Package
Some drawings listed in this table may not be applicable to specific projects. Approval
drawings are submitted to the customer for approval. Information drawings are provided for
customer information only and are not subject to approval.
Title
Submittal Time (Weeks)
Approval Drawings
General Arrangement, Main Unit
One Line Diagram
8
8
Information Drawings:
Electrical
Electrical Symbols, Abbreviations and Reference Data
Interconnect Plan, Electrical
Interconnect Wiring Diagram, customer
Interconnect Cable Schedule
Plan & Elevation, Turbine Control Panel
Plan & Elevation, 24 VDC Battery System
Plan & Elevation, 125 VDC Battery System
Plan & Elevation, 240 VDC Battery System
Plan & Elevation, Lineside Cubicle
Plan & Elevation, Neutral Cubicle
Three Line Diagram, Generator Metering
Schedule, Motor Control Center
Schematic Diagram, Motor Control Center
Schematic Diagram, Circuit Breaker ControlDiscrete Control
Schematic Diagram, Analog Control
Schematic Diagram, Circuit Breaker Control
System Schematic, Generator Excitation
System Schematic, Lighting & Distribution
System Schematic, Critical Path Emergency Stop, DC Power
System Schematic, Communication
Instrument Loop Diagram, Hydraulic Start System
Instrument Loop Diagram, Ventilation & Combustion Air System
Instrument Loop Diagram, Synthetic Lube Oil System
Instrument Loop Diagram, Mineral Lube Oil System
Instrument Loop Diagram, Turbine Hydraulic System
Instrument Loop Diagram, Fire & Gas Protection System
Instrument Loop Diagram, Gas Fuel System
Instrument Loop Diagram, Liquid Fuel System
Instrument Loop Diagram, CDP Purge System
Instrument Loop Diagram, NOx Water Injection System
Instrument Loop Diagram, NOx Steam Injection System
Instrument Loop Diagram, Power Augmentation Steam Injection System
Instrument Loop Diagram, Water Wash System
Instrument Loop Diagram, SPRINT™ System
8
10
16
12
12
8
8
8
8
8
12
8
12
16
16
12
12
12
12
12
16
16
16
16
16
16
16
16
16
16
16
16
16
16
LM6000 - 60 Hz Classic 6/2008
Page 126 of 156
16.2.4
Typical Drawing List for GTG Package (Cont)
Title
Submittal Time (Weeks)
Electrical (Cont)
Instrument Loop Diagram, Vibration System
Instrument Loop Diagram, Auxiliary System
Generator Protective Relay Settings
Mechanical
General Arrangement, Air Filter
General Arrangement, Water Injection Skid
General Arrangement, Steam Skid
General Arrangement, Liquid Fuel Pump Skid (Boost)
General Arrangement, Auxiliary Skid
Anchor Bolt & Shear Lug Detail (Main Unit)
Installation Footprint (Main Unit)
Lift Arrangement
Shipping Data
Flow and Equipment Symbols, Mechanical
F&ID, Hydraulic Start System
F&ID, Nozzle Steam Injection System
F&ID, Ventilation and Combustion Air System
F&ID, Turbine Lube Oil System
F&ID, Gas Fuel System (DLE)
F&ID, Turbine Hydraulic System
F&ID, Fire Protection System (CO2)
F&ID, Water Wash System
F&ID, Liquid Fuel Pump (Boost)
F&ID, Water Injection Pump
F&ID, SPRINT™ System
Instrument Skid, Auxiliary Systems
Reference Drawings
Wiring Diagram, Turbine Control Panel, Control Cubicle
Wiring Diagram, Turbine Control Panel, Termination Cubicle
Wiring Diagram, Turbine Skid
Wiring Diagram, Auxiliary Skid
Wiring Diagram, Air Inlet Filter
Wiring Diagram, Generator Skid
Wiring Diagram, Lineside Cubicle
Wiring Diagram, Neutral Cubicle
Wiring Diagram, Fire & Gas Protection System
Nameplate List, Engraving Schedule, & Switch Development
Fuel Control Layout
Worksheet, Fuel Control
Sequencer Layout
Worksheet, Distributed I/O Configuration
LM6000 - 60 Hz Classic 6/2008
16
16
16
8
8
8
8
8
8
8
16
16
10
10
10
10
10
10
10
10
10
10
10
10
10
Included w/O&M
Included w/O&M
Included w/O&M
Included w/O&M
Included w/O&M
Included w/O&M
Included w/O&M
Included w/O&M
Included w/O&M
Included w/O&M
Included w/O&M
Included w/O&M
Included w/O&M
Included w/O&M
Page 127 of 156
Digital MultiFunction Settings
Digital Synchronizer Settings
Area Settings
Area Classification Drawings
Area Classification Report
16.2.4
16
16
16
12
12
Typical Drawing List for GTG Package (Cont)
Notes:
1) Submittal time is for standard equipment and is shown in weeks after receipt of a mutually
agreed upon purchase order, a fully conformed design specification, and the post award
Order Definition Meeting (ODM).
2) Drawing dates for Standard equipment only. Custom designed features for specific
project requirements may require additional submittal times.
3) Some of the above drawings may not be required on specific jobs.
4) A drawing is considered submitted when uploaded to the www.projectnet.com site
Drawing Quantities and Format
GE Energy places customers’ drawings on ProjectNet, a secure internet site, (www.projectnet.com). On this site the drawings can be viewed, printed and annotated by the customer.
GE Energy provides all manuals in CD format for convient access and distribution. In
addition, by using web-based technology GE Energy provides today’s customers instant and
secure access to their unit’s operation and maintenance documentation with easy updates and
“real time” information.
LM6000 - 60 Hz Classic 6/2008
Page 128 of 156
17. Extended Scope Equipment and Services
Overview
GE Energy has the capability to provide everything from individual pieces of balance of plant
equipment to the complete power plant supplied on a “turn-Key” basis. GE Energy has a
dedicated team of engineers who specialize in the design, procurement and construction of
power plants and has successfully demonstrated the ability to do so for the following types of
facilities:
•
•
•
•
•
Simple Cycle Power Generation
Cogeneration Power Plants
Combined-Cycle Power Plants
Turbine-Compressor Plants
Compression Modules
GE Energy designs power plants with a focus on reliability and availability.
Turn-Key Services
Engineering
GE Energy can provide complete power plant design services, including civil, mechanical and
electrical design. The plants we design are reliable and intended to maximize the owner’s
profitability and minimize the total installation and construction duration. In order to achieve
this, we utilize pre-engineered designs for plant applications wherever possible. These designs
are proven and are ready for use today, saving engineering costs and project time, allowing
for the lowest installed cost basis. To meet unique project requirements, we work with the
Owner to adapt GE Energy’s standard plant designs to accommodate their particular needs.
Most of our designs are for shop built modules or systems, reducing the complexities of field
installation. This process saves weeks of time and hundreds of engineering man-hours.
Our field experience simplifies the job by bringing the knowledge and engineering skill gained from
previous power plant projects to each new project.
Most of our simple-cycle engineering is done “in-house” to provide tight coordination for our
customers. On large projects we call in experienced third-party engineering companies to
LM6000 - 60 Hz Classic 6/2008
Page 129 of 156
work under our supervision. This approach helps us put units “on-the-line” quickly to meet
owner’s deadlines.
Procurement
The GE Energy Extended Scope engineering team can provide procurement services for the
entire power plant. We use the experience of the GE Energy organization to help us find the
best balance of plant equipment vendors in the business. We utilize GE components to the
extent possible to minimize cost, ensure highest quality, and maximize standardization
between balance of plant components and the turbine package. We demand quality,
dependability, and experience from each of our vendors while keeping an eye on minimizing
installed costs. Most pieces of major equipment are purchased from vendors who have served
us for years, with hundreds of successful applications.
Construction Services and Start-Up Services
The GE Energy project execution team can provide full construction and start-up services for
the power plant. We place an experienced Construction Manager on each site. The
Construction Manager and specialists from our Houston office select from a group of prequalified construction sub-contractors to provide skilled craftsmen for the job. The
Construction Manager schedules and coordinates the work of the subcontractors. This
individual verifies the quality and completeness of each element of the job, and ensures that
the work progresses properly, with order and safety.
A team of start-up specialists from GE Energy and from major equipment vendors arrives at
the job when construction is nearing completion. These technicians check each plant system
carefully. Then, in parallel with the combustion turbine Technical Advisory team and plant
operations team, they commission the plant.
After thorough operating checks, these specialists prepare the plant for performance testing
and eventual turnover to plant operators.
Extended Scope Services
Combustion Turbine Package Installation and Commissioning Supervision
Services
GE Energy can provide technical advisory supervision services for the installation and
commissioning of the combustion turbine package. Installation services include supervising
the installation of the combustion turbine package by the Owner’s or by GE Energy’s
construction contractor. Commissioning services include flushing supervision, checkout, and
commissioning supervision of gas turbine mechanical systems, electrical systems, and control
system. GE Energy provides all general hand tools required for the commissioning of the
unit. Flushing and calibration kits can also be provided at GE Energy’s standard published
rates.
LM6000 - 60 Hz Classic 6/2008
Page 130 of 156
Engineering Studies
GE Energy can provide other engineering support services including complex or new product
design, troubleshooting, problem solving, and power plant conceptual layouts. Quite often,
GE Energy will coordinate with third party expertise to meet the project requirements.
Exhaust Emissions Testing
GE Energy can provide complete and comprehensive gas turbine exhaust emissions mapping testing
services for the project if required. For these services, GE provides a testing specialist at the jobsite to
conduct the typical exhaust emissions testing services including:
•Oxygen (O2), nitrogen oxides (NOx), unburned hydrocarbons and carbon monoxide (CO)
monitoring
•Preliminary O2 traverse, if required
A formal site data test report will be provided once the testing is completed.
Training
In conjunction with the training provided by the gas turbine instructors, GE Energy can
provide specialized operator training on each of the balance of plant systems as well as
provide total plant maintenance training.
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Balance of Plant Equipment
As options, GE Energy can supply almost all of the extended scope equipment required to
complete the power plant installation.
Simple Cycle Exhaust Stack
GE Energy can provide an exhaust stack and silencer assembly capable of reducing the
exhaust noise of the combustion turbine. Typical scope of supply for the exhaust stack and
silencer assembly is as follows:
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•
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•
•
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•
•
Expansion joint
Transition duct
Access door to stack base
Silencer
Stack
Emission ports
Ladders and platforms
All bolting hardware, gaskets, and field insulation
The design characteristics of the standard exhaust stack / silencer assembly is as follows:
Description
Stack Height
at 1m / 3 ft 1.5 m / – 5 ft Above Grade
Far Field Silencing – at 122 m / 400
ft
Exterior Casing Material
Interior Liner Material
Insulation Material
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Specification
Project Specific
85 dB(A)
65 dB (A)
ASTM A36 Carbon Steel
409 Stainless Steel
High Temperature Ceramic Fiber
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SCR / COR Assembly
GE Energy can provide a Selective Catalytic Reduction (SCR) / Carbon Monoxide Reduction
(COR) assembly to reduce the gas turbine emissions to the levels dictated by local permitting
agencies. The scope of supply for the SCR / COR assembly typically includes an expansion
joint, ductwork, CO oxidation catalyst, NOx reduction catalyst, ammonia injection grid,
ammonia injection skid, integral stack / silencer assembly, and the necessary ladders and
platforms. The SCR is controlled by a PLC based control system installed in a NEMA
enclosure on the ammonia injection skid. The assembly is designed and manufactured in a
modular fashion in order to minimize site assembly costs and duration.
If required, GE Energy can provide the following equipment associated with a SCR system:
•
•
•
Tempering air or purge air fans
Stainless steel ammonia storage tank (with unloading facility)
Ammonia forwarding systems
Continuous Emissions Monitoring System
GE Energy can provide a Continuous Emissions Monitoring (CEM)/Data Acquisition
Historical Storage (DAHS) system for the gas turbine package. The system utilized will be an
extractive sampling system that is capable of monitoring of NOX, CO, CO2, O2, and NH3.
The system is provided in a walk-in shelter with a wall-mounted air conditioning unit. The
system also consists of the necessary stack probes and sample lines.
GE Energy can provide the following equipment and services, as an option, if required for the
project:
•
•
•
•
•
•
Uninterrupted Power Supply (UPS) for PLC and analyzers
Inlet NOX for SCR system / performance measurement
Opacity monitoring system
Installation and commissioning supervision
Training
Certification testing by a third party tester
Air Inlet Chilling System
GE Energy can provide a packaged, modularized chilled water system, containing the
equipment necessary to condition or chill the inlet air to the gas turbine and maintain the
desired power output during hot day conditions. The chiller package consists of one “duplex”
centrifugal chiller mounted on a heavy structural steel skid with packaged piping, cooling
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tower, valves, pumps, medium voltage (MV) and low voltage (LV) motor control centers
MCC and controls installed and pre-wired. The chiller system will be prefabricated to the
maximum extent possible such that field installation consists of setting chiller skids on the
owner provided foundations, connecting utility services and control interfaces, and
interconnecting chilled water and cooling water piping between modules, cooling towers, and
cooling coils.
The package is designed to require a single MV power feeder and a single LV power feeder. All MV and
LV MCC’s, bus connections, and step-down transformers to utility and control voltages are included and
pre-wired on the chiller package to minimize field wiring required at the site. Package comes complete
with an insulated, weatherproof enclosure for the chillers, pumps and electrical systems. The enclosure
provides weather protection and acoustical attenuation as well as thermal insulation.
A central control system is provided for controlling the entire inlet air chiller system. The
system proposed monitors and controls chiller and all chiller related auxiliary equipment.
Operation and monitoring of the system is provided, locally, through full color graphical
touch screen HMI interface mounted in the package enclosure.
Gas Fuel Booster Compressor
GE Energy can provide a gas compressor if the gas-supply pressure at the facility is not of
sufficient pressure to meet the needs of the gas turbine generator. The compressor will be
skid mounted, and utilizes a compressor directly coupled to a horizontal induction electric
motor. The system includes a suction scrubber, discharge coalescer, air-to-gas inter-stage /
after cooler (if suction pressure requires), and control panel utilizing a GE 90-30 PLC.
The design characteristics of the standard gas fuel booster compressor assembly is as follows:
Description
Installation Type
Hazardous Area Classification
Rated Discharge Pressure
Rated Capacity
Specification
Suitable For Outdoor Installation
Class I, Group D, Div 2
700 psig
11 MMSCFD
An acoustical enclosure or sound barrier walls can be provided for jobsites with strict
acoustical requirements, if necessary.
Liquid Fuel Treatment Module
GE Energy can provide a liquid fuel treatment module to remove water-based contaminants in the Owner
supplied fuel system. This system treats fuel from the Owner supplied storage tank and forward to the
Owner-supplied day tank.
The standard system includes the following components:
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Duplex strainer with differential pressure gauge and switch
Fuel oil feed pumps with AC motors
Self-cleaning centrifuge with AC motor
Sludge pump with AC motor
Associated valves and instrumentation
Skid interconnect piping and conduit wiring
Skid-mounted, combined control panel with motor control centers
Self-supporting structural steel skid with sludge tank
Liquid Fuel Forwarding Skid
GE Energy can provide a single skid consisting of two (2) 100% plant capacity liquid fuel
forwarding pumps. The skid comes complete with centrifugal pumps, motors, motor starters,
and all necessary instrumentation. This skid is designed to be located between the Owner
supplied liquid fuel storage/day tank and liquid fuel filter skid.
Demineralized Water Treatment System
GE Energy can provide a modularized demineralized water treatment system (when provided with a raw
water quality analysis). Each system incorporates any or all required facilities (i.e., multi-media
filtration; anti-scalant; a reverse osmosis system including "clean-in-place" capability; and electrodeionization polishing system, etc.) to produce demineralized water at the quality, flow, and pressure in
accordance with the GE requirements for NOx control and/or SPRINT power augmentation. A raw
water analysis (provided by the owner) is necessary to specify a final design for the treatment system.
Included with the water treatment equipment system is a complete set of instrumentation and
automatic valves (where required). This enables automated operation of the water treatment
system via the control system, consisting of a single comprehensive programmable logic
controller (PLC) with an operator interface. This system is provided, installed, pre-piped and
pre-wired, in a modular building designed to house the equipment, to minimize overall field
installation requirements. The normal operation of the treatment units is fully automatic
through a PLC based control system. The plant is normally operated at full load to maintain
the site required demineralized tank level.
The following equipment is part of the standard demineralized water treatment system:
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•
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•
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Two (2) sets of multimedia filters
One (1) backwash pump
Two (2) cartridge filters
One (1) sodium sulphite chemical dosing tank and pump
One (1) reverse osmosis pump
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•
•
•
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One (1) reverse osmosis unit
One (1) reverse osmosis permeate storage tank
One (1) EDI pump
One (1) EDI unit
Raw Water Forwarding Skid
GE Energy can provide a single skid consisting of two (2) 100% plant capacity raw water
forwarding pumps. The skid is supplied complete with centrifugal pumps, motors, motor
starters and all necessary instrumentation. This skid is designed to be located between the
Owner supplied raw water storage tank and GE Energy or Owner supplied water treatment
system.
Demineralized Water Forwarding Skid
GE Energy can provide a single skid consisting of two (2) 100% plant capacity demineralized
water forwarding pumps. The skid is supplied complete with centrifugal pumps, motors,
motor starters and all necessary instrumentation. This skid is designed to be located between
the Owner supplied demineralized water storage tank and GE Energy supplied water injection
boost skid. Piping construction will be stainless steel.
Instrument Air Compressor
GE Energy can provide a skid-mounted air compressor sufficiently sized for the air
requirements of the gas turbine package and the auxiliary equipment. The air compressor
system is self-contained and includes a control and indicator panel, air dryer, coalescing prefilters, particulate after-filters, and air receivers.
The design characteristics of the standard instrument air compressor system are as follows:
Description
Compressor Type
Rated Flow
Rated Pressure
Specification
Rotary Screw Design
150 SCFM
8.62 bar / 125 psig
GE Energy can provide the following equipment associated with the instrument air
compressor system if required for the project:
•
•
•
•
Acoustic enclosure or sun shade
Water cooled system in lieu of air cooled
Service air line and air receiver
•
A larger air compressor skid can be provided to accommodate other power plant air
requirements, if necessary.
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Initial Fill Lubricants
GE can provide first fill of lubricants to which includes the turbine lube oil, generator lube
oil, hydraulic start system oil and chemical water wash.
Oil Type
Turbine Lube Oil – Synthetic
Generator Lube Oil – Mineral
Hydraulic Lube Oil – Mineral
Water Wash Chemical
Specification
MIL-TD-0000-6
ISO-VG46
MIL-H-17672
MID-TD-0000-5
Combustion Turbine Package Anchor Bolts
GE Energy can design and procure equipment foundation anchoring systems for the gas
turbine generator package only. The scope of supply will include anchor bolts complete with
nuts, embedded plates, washers and sleeves. The Owner is responsible for placing the
embedments in the foundations per GE Energy specifications.
Generator Step-Up Transformer
GE Energy can provide the generator step-up (GSU) transformer rated with design characteristics as
noted in the below table with off-load taps and CT’s. The GSU is sized to export power from the
generator under all ambient conditions. Lightning arrestors will be provided and connected to the
transformer high voltage bushing terminals.
The design characteristics of the standard generator step-up transformer are as follows:
Description
Primary Voltage Rating
Secondary Voltage Rating
Size
Cooling Class
Maximum Temperature Rise
Impedance
Primary Voltage Connection Type
Secondary Voltage Connection Type
LM6000 - 60 Hz Classic 6/2008
Specification
Project Specific
13.8 kV
45/60/75 MVA
ONAN / ONAF / ONAF
65 °C / 149 °F
Job specific
Wye (with de-energized tap
changer)
Delta
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Medium Voltage Switchgear
GE Energy can provide 4,160V switchgear as required to provide auxiliary power for plant
operation.
Auxiliary Transformer – Low Voltage
GE Energy can provide pad mounted auxiliary transformers for the various plant loads as
required. The size of the transformers are dictated by the plant design.
Balance of Plant Motor Control Center
GE Energy can provide motor control centers for the various balance of plant motor starters as
required. The MCC line-ups can be provided in an appropriate NEMA enclosure suitable for
either indoor or outdoor installation.
Electrical Equipment Module
GE Energy can provide a walk-in, pre-fabricated electrical equipment module designed for
the installation of the various balance of plant electrical control equipment. Several preengineered designs and sizes are available to accommodate the project specific requirements.
The module comes complete with an emergency lighting system, interior cable tray (if
applicable), and lighting and convenience receptacles.
Black Start Generator
GE Energy can provide a diesel engine driven generator package to provide gas turbine
generator start-up capability in the event of a loss of connection to the grid. For black starts,
the diesel generator provides AC power for the gas turbine generator hydraulic starter motor,
package ventilation fans, and various accessories. In addition to the diesel engine and
generator, the black start system includes a breaker cubicle, distribution/ control panel, and
fuel tank
Supervisory Control System
GE Energy can supply a Supervisory Control System (SCS) to provide a common operator
interface that integrates the controls for the GE Energy supplied Balance of Plant equipment
with the gas turbine generator. By using either a Mark VIe platform or a PLC based platform
a completely integrated control system can be achieved, eliminating the multiple hardware
and software interfaces typically encountered in most power plants. Each GE Energy supplied
component and/or skid, including the gas turbine generator, supplied with local
instrumentation and/or control systems will interface with the SCS for monitoring and
supervisory control.
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Interface between each component and the SCS is established using a combination of hardwired instrument I/O, high-speed redundant Ethernet communications, and/or serial link
connections. The instrumentation and controls provided will ensure the safe and efficient
operation of the process over the complete range of operating conditions.
A unified operator control interface is provided for operation from the Power Control Module
(PCM) or owner supplied control room via CRT-based Human Machine Interfaces (HMIs).
A graphical interface is created for both the turbine and plant controls using Cimplicity HMI
software. Each HMI is powered by a Pentium class workstation PC.
The SCS components are assembled in a control cabinet to be installed in the Power and
Control Module (PCM) or Owner provided control room. Components installed in the SCS
cabinet typically include the following:
•
•
•
•
•
•
MarkVI BOP control hardware
Analog and Digital I/O termination boards
Ethernet Network Switch
Uninterrupted Power Supply (UPS) (for SCS only)
Power Distribution Components and wiring
Lighting
GE Energy can provide additional optional equipment and services for the SCS as follows:
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Control room DCS furniture
Plant historian for both BOP and turbine data
Additional local HMI servers/viewers
Remote control room HMI servers/viewers
Automatic Generator Control (AGC)
Sequence of Events (SOE) Recording
One Button Start
Operator Training for Plant Controls
LCDs in lieu of CRTs
Interfacing with Owner supplied components
Onsite commissioning services
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18. Training
18.1 Gas Turbine Familiarization
18.1.1
Objective
The Gas Turbine Familiarization course is designed to train operators and supervisory
personnel to safely operate a gas turbine generator unit.
Emphasis is placed on the operator’s responsibilities with regard to the auxiliary systems,
operational data logging, and data evaluation. Operators are also instructed in how to
interpret fault annunciation and how to determine if the annunciated fault can be remedied by
operator action or by the assistance of instrumentation and/or maintenance personnel.
The course, located in Houston, Texas, focuses on starting, loading, and specific operator
checks of the various turbine support and auxiliary systems to ensure safe and reliable
operation of the turbine unit.
18.1.2
Content
The typical Gas Turbine Familiarization course covers the following areas:
•
•
•
•
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Unit Arrangement
Gas Turbine, Generator
General Description
Gas Turbine and Generator Major Components
Support Systems
Lube Oil
Hydraulic and Control
Cooling Water
Cooling and Sealing Air
Fuel(s)
Starting
Heating and Ventilation
Fire Protection
Generator Systems
Control System
Basic Control Functions and Operating Sequences
Basic Protection Functions
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•
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•
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Turbine Generator Operation
Startup
Operating Parameters
Emergency Procedures
Operator Responsibilities
Data Logging and Evaluation
Operating Limits and Required Operator Action on Various Annunciator Indications
Unit Documentation
Duration: Five (5) consecutive days in length, six (6) hours per day, exclusive of
weekends and holidays.
Textbook: Student textbooks will be supplied for fifteen (15) students and will be retained
by the customer.
Field Trips: Equipment walk around and panel familiarization will be dependent on
equipment availability.
Classroom: The customer is responsible for providing a classroom facility suitable for
instructing fifteen (15) students.
Language: English
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19.Aftermarket Services
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19.1 Services
19.1.1
Overview
From jet engines to power generation, financial services to plastics, and medical imaging to
news and information, GE people worldwide are dedicated to turning imaginative ideas into
leading products and services that help solve some of the world's toughest problems. As a
major division of the GE Company, GE Energy provides reliable, efficient products, services
and financing for the energy industry. We help businesses and authorities that generate,
transmit or use electricity. We work in all areas of the energy industry including coal, oil,
natural gas and nuclear energy, as well as renewable resources such as water and wind energy.
GE Energy has a full portfolio of offerings to help its customers focus on their core business
activities while we do the rest. Our LM6000 Services include:
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Gas Turbine Parts
Package Parts
Power Turbine Parts
Balance of Plant Parts and Services
Tooling/Support Equipment
Overhaul and Repair Services
Conversions, Modifications, and Upgrades
Rotable Exchange Programs
New and Used Engine Sales and Exchanges
Lease Pool Programs
Field Services
Engineering Services
Remote Monitoring and Diagnostics
Contractual Service Agreements
Operation and Maintenance Agreements
Training Programs and Video Tapes
Technical Manuals
Extended Warranty
19.2 Gas Turbine Parts
19.2.1
Overview
GE Energy Global Parts supports our customer needs for LM6000 Gas Turbine Parts via a
worldwide parts network with a primary warehouse in Cincinnati, Ohio. Our Customer
Account Managers are supported by engineering, configuration, planning and forecasting
experts who are all committed to getting you the right part, to the right place, at the right time.
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Orders and Inquiries
Office Hours: 8:00 AM - 5:00 PM EST
Monday through Friday
ph: 513-552-2000
fax: 513-552-5008
After-Hour Emergencies
ph: 513-552-3272
ph: 877-432-3272 (Toll Free)
All purchase orders and inquiries are to be directed to our spare parts sales organizations at:
GE Aircraft Engines – Gas Turbine Spare Parts
One Neumann Way, MD S133
Cincinnati, OH 45215-1988 U.S.A..
Attention: GE Energy Global Parts Sales
19.2.2
Parts Support
GE Energy Global Parts is committed to providing our customers with a total parts support
package for every LM product line. With GE parts, you get more than just a part. You get the
backing of our in-depth engineering design, operational, and total part-to-system experience.
The underlying value is that each and every part is designed and supplied by GE with the goal
to provide you, the customer, with optimal operating system performance.
We are also upgrading our material solution offerings. Customer specific
modifications/upgrades and improving our support are all examples of how GE Energy
Global Parts is striving to be your source for the highest quality parts with the best delivery
and service.
19.3 Package Parts
19.3.1
Overview
GE Energy Global Parts provides service to all aeroderivative package equipment owners and
operators. Materials required for the operation of the Package are available through GE
Energy Global Parts.
•
Maintain specifications for all GE units produced.
•
Quotations for budgetary lists for new units are available through the sales group using
your unit’s configuration. This is all done via a web based quotation program.
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•
In-house engineering resources to insure the material we supply is the correct material for
your unit and application.
•
Exchange components to provide quick turnaround are available on a limited basis.
•
Requests for emergency material can be handled on a 7-day, 24-hour basis. (pager: 281267-9768)
Orders or quote requests can be sent direct to us at the numbers listed below or log onto the
Internet at GEPartsEdge.com
19.3.2
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Package Components Supported
LM6000 Gas Turbine Spare Parts
Generator Spares
Control Systems
Fire Equipment
Vibration Systems
GE Drive Systems
Metal Scan Monitoring Systems
Air, Fuel and Oil Hoses
Air, Fuel and Oil Filters
Overhaul and Field Maintenance Tools
Fittings and Tubing
Pumps for Fuel and Oil
Valves – Solenoid and Manual
Cables – RTD and Thermocouple
Gauges – Pressure and Temperature
Consumables
19.4 Power Turbine Parts
19.4.1
Overview
GE Energy Global Parts is a provider of spare parts in the power turbine industry. Our facility
located in Houston, TX house the repair, refurbishment, and overhaul services. We work
together as a team to provide your entire Power Turbine needs. Our global parts organization
is prepared to assist you with all your spare part requirements. Please call your Customer
Account Manager who will be available during our normal working hours of 8:00 am to 5:00
pm Monday through Friday, Central Standard Time. Service is our priority and we are
dedicated to supporting your entire Power Turbine spare part needs.
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19.5 Tooling/Support Equipment
19.5.1
Overview
GE Structured Services, LP has supported engine products around the world for a quarter of a century.
Our vision is “To be our customers One-Stop Shopping source, providing business solutions for a
complete line of engines”. We support all tooling applications for aeroderivative engines, including
industrial, power generation, marine and military.
19.5.2
Product Offerings
GE Structured Services offers a wide array of products used in the maintenance and operation
of your GE gas turbine. Applications: Levels 1 and 2 are available for end users. Levels 3, 4,
and 5 are available to authorized repair shops.
19.5.3
Products
Shipping containers, Maintenance tooling, Inspection and test equipment, Hand tools,
Upgrade kits. In addition, by choosing GE Structured Services for your support equipment
and tooling needs, you will receive the current OEM design. Our quality equipment allows for
optimal safety conditions. Inquiries for support equipment and tooling should be directed to
GE Structured Services, LP, or your GE Energy Services Team.
19.6 Overhaul and Repair Services
19.6.1
Overview
Overhaul and repair services are performed at our Service Center in Houston, Texas.
19.6.2
Parts
By choosing GE Energy as the overhaul provider the user is guaranteed that, when required,
new original engine manufacturer parts are used. If a part can be repaired, the users can rest
assured that the procedure used for the repair has been approved by GE Energy engineering.
Many of the repairs were developed for use in the aviation industry and have been adapted for
use in the industrial engine.
19.6.3
Service Bulletins
While the gas turbine is in the Service Center all pertinent service bulletins should be complied with.
Compliance with service bulletins ensures the user that the latest technology available is being used.
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By taking advantage of the latest technology the user may be able to reduce the overall maintenance
cost of operating a GE LM6000 product.
19.6.4
Cycle Reduction Initiative
GE Energy, through its Six Sigma quality program, is continually measuring both the internal and
external processes that drive turn time. These processes include parts availability, repair technology,
and customer reporting. The reduction in turn time can reduce then user’s cost of maintenance by
reducing lease engine cost or downtime.
19.6.5
Testing
State of the art full power testing is available through the Service Center. Testing ensures the
user that the overhaul or repair performed meets the GEK requirements and will meet or
exceed all performance standards when put into service at the user’s site. The test is
conducted in accordance with specifications of new production engines.
19.6.6
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•
•
•
•
•
•
•
•
Service Center Capabilities
Chemical and mechanical cleaning
Non-destructive testing
High speed rotor tip grind
Coating and surface finishing
Rotor build, balance and grind
Weld shop and heat treat
Machine shop and services
Coordinate measuring center
On-site test capability
Gearbox shop, fuel systems, pneumatics shop
Full inventory support
Rotable support
19.7 Conversions, Modifications, and Upgrades
19.7.1
Overview
A conversion, modification or upgrade CM&U, is anything that improves the reliability,
availability, maintainability, performance, efficiency, safety, or affects the configuration of
the equipment. A CM&U can include the gas turbine engine, the package, and the balance-ofplant equipment. CM&U’s are available from GE Energy Services for GE and many non-GE
aeroderivative gas turbine packages. The following list contains descriptions of many of our
typical CM&U offerings, although new and customized upgrades are also available to suit
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individual needs. Please feel free to contact your GE Energy Services Sales Manager if you
would like to discuss a potential CM&U for your operation.
19.7.2
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•
•
•
•
•
•
•
•
•
•
•
•
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Offerings
Liquid fuel treatment systems
Reduced emissions (Wet)
Water wash systems
Anti-Icing systems (steam, electric, or gas fired water/glycol systems, or bleed air)
Fire protection panel and halon to CO2 fire system upgrades
HMI upgrades
Fuel system upgrades
Sensor upgrades
Enhanced flow and speed upgrade
STIG conversion
Vibration system upgrades
Inlet Filtration Systems
Remote Monitoring and Diagnostics
Lube Oil Chip Detectors
MetalSCAN On-Line Oil Monitoring System
Fuel Heating Systems
Inlet Cooling/Heating Systems
Dry Low Emissions (DLE) Upgrades
Package Frequency Conversions
Synchronous Condensors
Control System Upgrade
19.8 Rotable Exchange Programs
19.8.1
Hot Section Exchange
GE Energy offers a package of hardware, tooling and labor to remove and install your
LM6000 gas turbine engine and replace the Hot Section (HPT Rotor, Stage 1 and 2 Nozzle
Assemblies) at a predetermined fixed price. Two GE field service representatives per shift
will be provided for this work. This procedure can normally be accomplished in 1-3 days, thus
eliminating the need for a lease engine, and sending the engine into the shop for repair. With
the Aero Energy Hot Section Exchange, you get a fully balanced HPT rotor with factory
established blade to shroud clearances to optimize performance. As with all of the Aero
Energy Rotable EMUs, the Hot Section hardware carries a one year warranty. All returned
EMUs are overhauled per GE specifications.
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The LM6000 Aeroderivative gas turbine is designed so that it is easy to replace major engine
assemblies (also referred to as Engine Maintenance Units or EMUs) quickly to maximize gas
turbine availability. GE Energy has developed a program that takes advantage of this
engineering concept. In many cases, a Rotable EMU can be installed at the customer’s site
eliminating the need to send the engine to a Service Center. The User benefits by on-site
replacement of the EMU by eliminating the cost of using a lease engine and the second engine
change-out if the damaged engine is sent to a Service Center for repair. GE Energy also has
EMUs that are available to be used to shorten the time an engine is at a Service Center for
repair. This reduces the cost of operating a lease engine (if installed) or can help expedite the
return of the engine back to the site to meet a critical operating period. Removed EMUs
(including Hot Sections) become the property of GE.
19.9 New and Used Engine Sales and Exchanges
19.9.1
Overview
GE Energy can offer both new and used LM6000 gas generators and gas turbines to
customers that own or operate LM6000 gas turbine equipment. The new units are provided
with a factory performance guarantee and carry a 1-year operation warranty. The used
LM6000 gas generators or gas turbines offered have normally undergone a complete overhaul
per GE specifications prior to availability for sale. These units also may carry a 1-year
operational warranty. New and used units can be purchased outright, or purchased with the
return of an existing LM6000 unit. GE Energy refers to this as our Engine Exchange Program.
Through this program, a customer may trade the current unit in for the same model
configuration or upgraded equipment for improvements in power and heat rate.
19.9.2
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•
•
•
Customer Benefits
An estimated one-to-three day plant shutdown to complete the equivalent of an gas turbine
overhaul program
Elimination of spare gas engine lease usage fees
One-time gas turbine change-out fees
One-year new-gas turbine warranty
New-engine output and heat rate factory performance guarantees
New GE gas turbine technology
Compliance with current service bulletins
Fixed-cost transaction
May reduce fuel and maintenance costs
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19.10 Lease Pool Programs
19.10.1
Overview
The GE Lease Program is designed to help customers minimize or reduce their overall life
cycle costs and offers a low cost way for customers to maintain availability of their gas
turbines. Customers can maximize site availability by leasing equipment from GE when their
own equipment is at a Service Center for repair or when it cannot be repaired on site within a
reasonable amount of time. Lease customers can continue operations to serve their customers
and meet their business objectives. Lease assets are provided under either of two lease
agreement concepts: Member or Non-member.
GE has made the capital investment in these gas turbines and incurs costs for every operating
and non-operating hour. Member and non-member rates and options are structured to reflect
this.
19.10.2
Lease Engine Membership
A member agreement is a contract of six-year duration. It provides a guarantee of availability
if the customer should need a lease gas turbine. The customer pays an annual membership fee
and a weekly usage fee whenever a lease asset is installed at the customer site. Weekly fees
are subject to Special Applications adjustments for liquid fuel operation, STIG, and
SPRINT™ water injection applications.
19.10.3
Lease Engine Usage by Non-Members
A customer who has not opted for the six-year membership agreement may use a GE lease
asset on a single event basis under the terms of a Non-member agreement. No guarantee of
availability exists for non-member usage. An installation fee and a higher weekly charge
apply to non-members. Non-member lease rates are calculated from the rates in the member
tables. The weekly non-member rate is 3.5 times the weekly member rate, after any Special
Applications adjustments. An installation charge applies to each usage plus actual
transportation costs each way.
Note: New customers who request a lease gas turbine within 45 days of executing a member
lease agreement will be charged at non-member rates for that lease usage event.
19.11
Field Services
19.11.1
Overview
GE Energy Field Service is a world-class service and support network designed to anticipate
and respond to our customers needs throughout the product life of GE LM6000 gas turbine
and packages. The worldwide team supplies the highest quality parts, tools and support. This
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results in higher availability and lower costs for you, the customer. Please contact any one of
our 10 regionally located offices around the world for any of your service needs, 24 hours a
day, 7 days a week.
19.11.2
Offerings
GE Energy Field Service is dedicated to responding to your needs in an expedient manner.
Aero Energy Field Service helps to minimize your downtime and provide a lower cost
operation of by providing full technical coverage for your gas turbine and package. Our
services include but are not limited to: Periodic Inspections of the gas turbine and package,
Hot Sections, Generator Test and Inspection, Trim Balances, Vibration Surveys, Performance
Testing, Controls Calibration, and all Level 1 and 2 Maintenance. In response to our
customers’ requests for flexibility in commercial offerings, Aero Energy Field Services now
provides the option for Firm Fixed pricing.
19.12
Engineering Services
19.12.1
Overview
Aero Energy Service Engineering provides engineering support to GE and non-GE industrial
aeroderivative turbine products. A comprehensive Product Service Engineering and
Conversion, Modification and Upgrades Engineering organization delivers field investigative
support and product design, as well as engineered modifications to gas turbine, package and
balance of plant equipment. In addition a New Product Introduction team develops engineered
solutions for future upgrades. The combined service engineering groups of GE Energy
support the product from factory shipment, through the course of service agreements and
throughout the product life cycle.
19.12.2
Product Service Engineering
Full engineering services are available for owners and operators of GE and certain non-GE
aeroderivative engines and packages. Services include operational reviews, data analysis,
maintenance practices, fleet optimization, failure root cause analysis and other studies. GE
Energy also provides a variety of field investigation services for industrial and marine
products. Formal engineering studies are available.
19.12.3
Conversions, Modifications and Upgrades (CM&U)
Engineering
A range of standard upgrades and modifications are available (see Upgrade Services section)
through the CM&U Engineering organization. Specialized engineering services are also
offered to customers interested in package conversions. Upgrade kits covering a variety of gas
turbine systems are available for each of the LM series of engines and certain non-GE
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aeroderivative engines and packages. In addition engineering services are available to support
limited specialized upgrades. Contact Project Engineering to request an evaluation and
quotation for required modifications.
19.12.4
Engineering Services
•
Hourly service support
•
Reliability, availability and maintainability improvement services
•
Unscheduled trips/outages reduction evaluation
•
Evaluation of gas turbine, package and BOP operational costs with the objective of
improving site profitability
•
Hourly engineering service packages with CSA, RMD or CM&U/NPI
•
Engineering evaluation of gas turbine hardware service life with the objective of
improving time between removals
•
On-site engineering specialty training for customer personnel
•
Detailed engineering failure investigation report to identify root cause
•
Engineering specialist for DLE operability, vibration, performance or emissions
•
Pre-start Operational Readiness Review (PSOR) of existing installations to identify
operational problems
•
Analysis service of fuel, water, oil and emissions samples
19.13
Monitoring and Diagnostics Service
19.13.1
Overview
Monitoring and Diagnostics Service helps aeroderivative turbine plant operators improve
availability, reliability, operating performance, and maintenance effectiveness. Monitoring
key parameters by factory experts may lead to early warning of equipment problems and
avoidance of expensive secondary damage. Diagnostic programs seek out emerging trends,
prompting proactive intervention to avoid forced outages and extended downtime. The ability
for GE engineers to view real-time operation accelerates troubleshooting and sometimes
removes the need for service personnel to visit the plant.
19.13.2
•
•
Product Features
On-Line Monitoring
Accelerated Troubleshooting Support from Factory Experts
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•
•
•
Customer Notification Report
Vibration Monitoring System
Access to M&D Data
19.13.3
•
•
•
•
Service Benefits
Possible Early Warning of Changing Conditions
Proactive Recommendations for Action
May Reduce Downtime
Optional Features
19.14
Contractual Services Agreements
19.14.1
Overview
Utilities, independent power producers and oil and gas producers that own and operate gas turbines
now have an easy way to get a handle on maintenance costs. GE Contractual Services Agreements
(CSA’s) enable customers to get a full spectrum of maintenance options that takes the burden off of
them, and allows them to focus on their core businesses.
19.14.2
Benefits to Customers
The benefits of GE CSA’s are numerous. For instance, a GE CSA can help keep equipment running
properly, provide for reduced downtime, and lessen repair time. Also, depending on the type of CSA,
the cost of maintenance can be uniformly distributed and easier to predict for the customer. GE CSA’s
can be initiated at any time in the life of the equipment, but are most effective when started in
conjunction with:
•
•
•
•
•
New engine purchases
Upgrades
Unscheduled engine replacements
Engine exchanges
Hot section exchanges or major overhauls
19.15 Operating and Maintenance Agreements
19.15.1
Overview
GE Energy’s Global O&M Services group is one of the world’s largest 3rd party providers of
plant Operation and Maintenance services, currently with over 16,000 MW at 60 sites in 17
countries under O&M contract. Our global resources and experience base allow us to provide
comprehensive services across the turbine island and balance of plant for both GE and nonGE equipment.
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With continuously evolving new technology, expertise and process improvements, GE Global
O&M applies the latest cost-effective practices to ensure optimal economic performance.
19.15.2
Offerings
GE Global O&M offers a comprehensive suite of services to deliver maximum reliability,
availability, and economy including:
•
•
•
Daily operation and maintenance of the plant
•
Complete plant staffing
Planned and unplanned maintenance services, including parts
•
Local and remote monitoring and diagnostics
•
Comprehensive training
•
Environmental health and safety programs
•
Site documentation and procedure development
Site-specific computerized maintenance management software (CMMS)
•
Switchgear maintenance and management
•
Power delivery
•
Fuel management
GE Global O&M follows a rigorous environmental health and safety program that is
implemented at every plant where we provide O&M services. We are dedicated to
providing a safe and secure environment for all GE and plant personnel on site. All of
our O&M sites comply with local and government regulations as well as customer
requirements and are held to our stringent company-wide environmental standards.
Our ISO 9000-2000 Certified Quality Assurance Program combined with our Six Sigma
methodology, places a premium on developing technology that improves the quality of
our products and services while also meeting the expressed needs of the customer.
GE Energy’s Global O&M services team helps ensure optimum performance at existing
power plants as well as plants still in the planning stages.
From initial project support to mobilization, through actual operation and maintenance,
our highly trained specialists work with the customer to develop the ideal strategy for
their particular site.
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With our worldwide inventory, manufacturing facilities, and global service centers, GE
Energy has the expertise and ability to keep your plant running at peak performance.
19.16 Training Programs and Video Tapes
19.16.1
Overview
GE has developed comprehensive hands-on training classes to provide customers and authorized nonGE suppliers, Service Centers, and service providers the knowledge and ability to properly maintain
their LM6000 gas turbines and package to ensure maximum availability and reliability.
•
•
•
•
Classroom work with training manuals and video tapes
Related hands-on disassembly and assembly tasks on LM6000 engines
Led by experienced instructors
Small class size
For more information, contact us for a Course Catalog and Class Schedule.
19.17 Technical Manuals
19.17.1
Overview
GE Energy Services supplies a complete set of technical manuals for the operation and
maintenance of each aeroderivative gas turbine. Manuals are supplied with the gas turbine,
but additional copies can be purchased on request. These are available to customers and
authorized non-GE suppliers, Service Centers and service providers. Currently all manuals are
published in printed format and most are available on CD version. Eventually all manuals will
be published only in an electronic format.
19.18 Extended Warranty
19.18.1
Overview
The Extended Engine Warranty provides warranty coverage for months 13 through 24 from
the initial startup of your gas turbine.
•
Same thorough coverage as the standard New Engine Warranty
•
Provides for periodic inspection by GE Field Service representative
•
On-line support through Remote Monitoring and Diagnostics is available to customers
until the end of initial New Engine Warranty.
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19.18.2
•
•
•
•
Benefits
Protects your operation and investment
Enhanced support by engine specialists
Allows for early problem diagnosis
Reduced risk of unscheduled maintenance costs
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