IN THE NAME OF ALLAH, THE BENEFICENT, THE MERCIFUL

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

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 HP @ 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…

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…

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

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…

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

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…

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

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…

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…

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…

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…

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…

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

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

Questions??

4th STAGE EXTRACTION LINE ANTI-CHATTERING VALVE

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

DPT of accessory coupling spacer gear teeth being carried out