1. IN THE NAME OF ALLAH, THE BENEFICENT, THE MERCIFUL

2. Presented by; MUHAMMAD HAMMAD
FFBL
Construction and Control System of Gas Turbine KGT-306A (Driver for Synthesis Gas Compressor Train A)
Presented by; MUHAMMAD HAMMAD

3. FFBL Overview Features; Single-shaft, simple-cycle
Contents
Overview
Single-shaft, simple-cycle
Two bearing assemblies
Steam turbine for startup
16-stage axial flow compressor
Reverse flow combustion system
Two-stage impulse turbine
Power rating – 15,300 4,860 rpm
Originally K-model, partially up-rated to LA-model
Waste heat boiler (capable of producing 90 tonnes of steam per hour).
Features
Schematic Gas Flow Diagram
Working
Lube oil / Control oil
System
Components
Schematic Diagram
Cooling / Sealing and Control air system
Description
Control Air System
Schematic diagram
Turbine Control System
Description
Fuel Control System
Exhaust Temperature Control System
Protection System
Schematic Diagram
jobs during ta-09
CONTD…

4. FFBL Overview Schematic Gas Flow Diagram; CONTD… Contents
Features
Schematic Gas Flow Diagram
BOILER FEED WATER
Working
Lube oil / Control oil
System
COMPRESSOR
TURBINE
COMBUSTION
CHAMBER
WASTE HEAT
BOIILER
STEAM
Components
AMBIENT AIR
Schematic Diagram
TURBINE EXHAUST GAS
Cooling / Sealing and Control air system
EXHAUST
Description
Control Air System
Schematic diagram
Turbine Control System
Description
Fuel Control System
Exhaust Temperature Control System
Protection System
Schematic Diagram
jobs during ta-09
COMPRESSED AIR
HOT COMBUSTION
GASES
FUEL
CONTD…

5. FFBL Overview Working; Compressor Section; Combustion section;
Contents
Overview
Compressor Section;
Design inlet conditions: 970F and 14.7 psi
Air compression ratio is 6:1
Extraction of air at 4th, 10th and 16th stage
Combustion section;
Reverse-flow combustion system consisting of 10 combustion cans
Spark plugs / Flame detectors for initiating / monitoring combustion
Turbine section;
Two-stage impulse turbine
Design exhaust conditions: 8700F and 14.7 psi
Features
Schematic Gas Flow Diagram
Working
Lube oil / Control oil
System
Components
Schematic Diagram
Cooling / Sealing and Control air system
Description
Control Air System
Schematic diagram
Turbine Control System
Description
Fuel Control System
Exhaust Temperature Control System
Protection System
Schematic Diagram
jobs during ta-09

6. LUBE OIL / control oil SYSTEM
FFBL
Components;
Contents
Overview
Main lube oil tank (1700 gallons)
Lube oil pumps
Main Lube oil pump – driven by accessory gear (65 psi, 225 GPM)
Auxiliary pump – driven by AC motor (65 psi, 195 GPM)
Emergency pump – driven by steam turbine (20 psi, 120 GPM)
Oil cooler
Oil filters
Valves
Miscellaneous control and preventive devices
Features
Schematic Gas Flow Diagram
Working
Lube oil / Control oil
System
Components
Schematic Diagram
Cooling / Sealing and Control air system
Description
Control Air System
Schematic diagram
Turbine Control System
Description
Fuel Control System
Exhaust Temperature Control System
Protection System
Schematic Diagram
jobs during ta-09
CONTD…

7. FFBL LUBE OIL / control oil SYSTEM Schematic Diagram; Contents
Overview
Features
TO STARTING TURBINE BEARINGS
(5.5 GPM)
Schematic Gas Flow Diagram T
Working
TO CONTROL OIL SYSTEM
TO STARTING TURBINE GOVERNOR
(2.5 GPM)
Lube oil / Control oil
System
0 ~ 100
ACCESSORY
GEAR
(21 GPM)
FUEL REGULATOR
(6 GPM)
LOADED THRUST BEARING
(33 GPM)
UN-LOADED THRUST BRG.
(10 GPM)
JOURNAL
BRG. # 1
(17 GPM)
0 ~ 100
JOURNAL
BRG. # 2
(17 GPM)
LOADED THRUST BEARING
(33 GPM)
UN-LOADED THRUST BRG.
(10 GPM)
JOURNAL
BRG. # 1
(17 GPM)
JOURNAL
BRG. # 2
(17 GPM)
Components
LUBE OIL FILTERS
T-303A / B
CONTROL OIL FILTERS
T-304A / B
LOAD
GEAR
LPC
IPC
HPC
Schematic Diagram
ASSECCORY
COUPLING
COUPLING
LOAD
(5 GPM)
Cooling / Sealing and Control air system
0 ~ 100
MAIN LUBE OIL PUMP
G-315 S
COMPRESSOR
K-306A
Description
Control Air System S
Schematic diagram
LUBE OIL COOLERS
E-341A / B
Lube Oil Filters
Lube Oil Coolers
Drive Machines For Lube Oil Pumps
Control Oil Filters
Turbine Control System
Description
Fuel Control System
Exhaust Temperature Control System
0 ~ 100
low
alarm
High
alarm
eMPTY
Full
0 ~ 60
0 ~ 100
Protection System
Schematic Diagram
jobs during ta-09
10”
12”
16”
17”
25.29”
G-317
G-316 2”
Lube Oil
Control Oil T S
Pressure GAUGE
CHECK VALVE
SIGHT GLASS
Thermometer

8. COOLING / SEALING AND CONTROL AIR SYSTEM
FFBL
Contents
Overview
Description;
Features
Schematic Gas Flow Diagram
Working
Provision for extraction of air from 4th, 10th and 16th stage of compressor section
4th stage air – cools turbine shell and 2nd stage turbine wheel
10th stage air – cools 1st stage turbine wheel and also used as sealing air
4th and 10th stage extraction lines are connected by bypass valves
These valves are open during startup and are closed as the compressor discharge pressure rises to about 60 psia
16th stage air – helps to maintain normal operating temperatures by heating the turbine wheels during startup and cooling them during normal operation
Once the turbine reaches sufficient speed, the compressor discharge air is used as control air
Lube oil / Control oil
System
Components
Schematic Diagram
Cooling / Sealing and Control air system
Description
Control Air System
Schematic diagram
Turbine Control System
Description
Fuel Control System
Exhaust Temperature Control System
Protection System
Schematic Diagram
jobs during ta-09
CONTD…

9. FFBL CONTROL AIR SYSTEM Schematic Diagram; Contents
Overview
TO FUEL
REGULATOR
Features
TURBINE
EXHAUST DUCT
Schematic Gas Flow Diagram
TEMPERATURE
TRANSMITTERS
SENSORS
Control AIR TO DEVICES
VARIABLE PRESSURE
Control Air
Electric Signal
CONTROL
AIR PANEL
Working
ELECTRO-
PNEUMATIC
TRANSDUCER
Lube oil / Control oil
System
0 ~ 30
Components
Schematic Diagram
Cooling / Sealing and Control air system
Description
Control Air System
Schematic diagram
Turbine Control System
STARTING
CLUTCH
Description
Fuel Control System
POROUS
FILTER
Exhaust Temperature Control System
EXTERNAL CONTROL
AIR SUPPLY
Protection System
Schematic Diagram
jobs during ta-09
TURBINE CONTROL PANEL
0 ~ 160
POROUS
FILTER
COMPRESSOR SECTION
DISCHARGE AIR
0 ~ 160

10. Turbine Control System
FFBL
Description;
Contents
Overview
Mechanical, pneumatic, hydraulic type of system
Regulates the firing temperature and speed of the Gas Turbine according to the load requirements and ambient conditions
Control components are divided into 3 categories:
Fuel Control System – controls the amount of fuel to the combustion chambers as a function of starting requirements, turbine speed, and exhaust temperature limit
Exhaust Temperature Control System – operates, when necessary, to limit the firing temperature
Protection System – protects the Gas Turbine in case the normal devices do not maintain proper operating control specifications
Features
Schematic Gas Flow Diagram
Working
Lube oil / Control oil
System
Components
Schematic Diagram
Cooling / Sealing and Control air system
Description
Control Air System
Schematic diagram
Turbine Control System
Description
Fuel Control System
Exhaust Temperature Control System
Protection System
Schematic Diagram
jobs during ta-09
CONTD…

11. Turbine Control System
FFBL
Fuel Control System;
Contents
Overview
Features
Schematic Gas Flow Diagram
Governor
Generator
Exhaust Temperature
Control System
Working
Lube oil / Control oil
System
Components
Schematic Diagram
Cooling / Sealing and Control air system
Turbine Speed
Signal
Turbine Exhaust
Temperature Signal
Description
Control Air System
Schematic diagram
Turbine Control System
Description
Fuel Control System
Fuel
Regulator
Exhaust Temperature Control System
Speed / Load
Setting
Protection System
Schematic Diagram
jobs during ta-09
Variable Control
Oil (VCO) Pressure
Gas Control Valves
(Fuel System)
CONTD…

12. Turbine Exhaust Temperature Turbine Exhaust Temperature
Turbine Control System
FFBL
Exhaust Temperature Control System;
Contents
Overview
Maximum allowable temperature should not be exceeded in order to operate within design stress limitations of components
Thus, the temperature control signal overrides the speed / load control signal
Features
Schematic Gas Flow Diagram
Working
Lube oil / Control oil
System
Components
Schematic Diagram
Cooling / Sealing and Control air system
Description
Control Air System
Schematic diagram
Thermocouples
(Turbine Exhaust)
Turbine Control System
Description
Fuel Control System
Exhaust Temperature Control System
Protection System
Turbine Exhaust Temperature
Signal (millivolts)
Schematic Diagram
jobs during ta-09
Amplifier
Turbine Exhaust Temperature
Signal (amplified)
Electro-pneumatic
Transducer
Pneumatic Pressure representing
Turbine Exhaust Temperature
CONTD…

13. Turbine Control System
FFBL
Protection System;
Contents
Overview
Trips the Turbine in case the control devices do not maintain the proper operating conditions
Tripping occurs when oil pressure from the trip oil circuit is dumped (directly or through the electrical circuit of the solenoid operated trip valve 20HD)
The tripping mechanisms provided are:
Overspeed Trip – operated by overspeed bolt (can also be actuated manually), mechanically dumps oil in the hydraulic trip circuit
Overtemperature Trip – two temperature transmitters sense the turbine exhaust temperature and convert the temperature measurement into a proportional pneumatic output pressure signal. The Turbine is tripped in case the temperature rises above allowable limits
Features
Schematic Gas Flow Diagram
Working
Lube oil / Control oil
System
Components
Schematic Diagram
Cooling / Sealing and Control air system
Description
Control Air System
Schematic diagram
Turbine Control System
Description
Fuel Control System
Exhaust Temperature Control System
Protection System
Schematic Diagram
jobs during ta-09
CONTD…

14. Turbine Control System
FFBL
Protection System;
Contents
Overview
Vibration Equipment – two vibration sensors are mounted on the equipment; one on Bearing # 1 housing and one on the Bearing # 2 housing. The signals from these sensors trip the turbine by de-energizing the master relay if any of the sensor indicates abnormal conditions
Manual Emergency Trip – two-way manually-operated valve installed in the hydraulic trip circuit piping to manually shutdown the turbine in event of an emergency.
Electric Trip Circuit – the remaining trip devices de-energize the master control relay, causing the trip valve 20HD to open and dump trip circuit oil
Features
Schematic Gas Flow Diagram
Working
Lube oil / Control oil
System
Components
Schematic Diagram
Cooling / Sealing and Control air system
Description
Control Air System
Schematic diagram
Turbine Control System
Description
Fuel Control System
Exhaust Temperature Control System
Protection System
Schematic Diagram
jobs during ta-09
CONTD…

15. GAS CONTROL VALVE CYLINDER HYD. POSITION SERVO FOR GAS CONTROL VALVE
Turbine Control System
FFBL
Schematic Diagram;
Contents
Overview
Features
Schematic Gas Flow Diagram
Working
0 ~ 400
Lube oil / Control oil
System
FUEL REGULATOR
Components
Schematic Diagram
GAS FUEL SYSTEM
Cooling / Sealing and Control air system
0 ~ 300
GAS CONTROL VALVE CYLINDER
HYD. POSITION SERVO FOR GAS CONTROL VALVE
Description
Control Air System
Schematic diagram
RUN
Turbine Control System
Description
Fuel Control System
Exhaust Temperature Control System
FUEL GAS STOP VALVE
Protection System
Schematic Diagram
0.187” DIA ORIFICE
jobs during ta-09
TRIP
0 ~ 100
20HD
OVERSPEED TRIP
12T
63HD
Variable Control Air
Trip Circuit Oil
Lube Oil
Regulated Control Oil (CCO)
Variable Control Oil (VCO)
MANUAL EMERGENCY TRIP LEVER

16. JOBS DURING TURNAROUND-09
FFBL
Oil Leakage Rectification from Turbine Bearing # 2;
Oil leakage observed after fire incident on March 29, 2008
No sealant found between the mating faces of bearing casing (South end)
Contact between mating faces was checked and found OK
Even layer of sealant (Permatex®) applied between mating faces
Combustion Chamber Inspection;
All combustion cans disassembled
Power brush cleaning of combustion cans and DPT of can covers, fuel nozzles, combustion liners, crossfire tubes and crossfire tube retainers carried out – all parts found in good condition
Reassembled after replacement of all gaskets between flange joints
Accessory Coupling Inspection;
DPT of gear teeth of accessory coupling spacer carried out – found OK
Coupling reassembled after replacement of O-rings
Contents
Overview
Features
Schematic Gas Flow Diagram
Working
Lube oil / Control oil
System
Components
Schematic Diagram
Cooling / Sealing and Control air system
NO SEALANT FOUND HERE
Description
Control Air System
Schematic diagram
Turbine Control System
Description
Fuel Control System
Exhaust Temperature Control System
Protection System
Schematic Diagram
jobs during ta-09

17. Questions??

18. 4th STAGE EXTRACTION LINE
ANTI-CHATTERING
VALVE

19. DPT of crossfire tubes being carried out
Crossfire tube connecting Can # 2 and 3
Sealant being applied after replacement of combustion can cover gasket
Gaskets between can-to-can flanges being replaced with use of hydraulic jack
Cover of combustion can # 6 after DPT showing minor SURFACE IRREGULARITIES
CAN # 1
CAN # 2
CAN # 3
CAN # 4
CAN # 5
CAN # 6
CAN # 7
CAN # 8
CAN # 10
CAN # 9
All ten fuel nozzles after being removed from combustion cans
DPT of combustion liners being carried out
DPT of fuel nozzles being carried out

20. DPT of accessory coupling spacer gear teeth being carried out