GT24/GT26 Electro Hydraulic Safety

Operation System

Training Lesson

ALSTOM (Switzerland) Ltd ABCD

 GT24/GT26 Electro Hydraulic Safety
ABCD Operation System

We reserve all rights in this document and in the information contained therein.
Reproduction, use or disclosure to third parties without express authority is strictly
forbidden.
Copyright© by ALSTOM (Switzerland) Ltd 2008

This is a training lesson. It provides overall information about the specific system
only.
To understand the operation concept in detail the project specific documents as
defined in the document reference section have to be included together with this
lesson.
All mentioned / attached values and settings are for information only. Typical
values are used to clarify particular subjects. Settings furthermore are subject to
change site specifically during commissioning.
For actual values please refer to the final plant specific
Operation & Maintenance Documentation.

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Table of Contents

Document Reference ........................................................................................................................... 5

Typical Documents ........................................................................................................................... 5
O&M Documentation ....................................................................................................................... 5
Lesson Objectives................................................................................................................................ 6
Overview ............................................................................................................................................ 7
System Function ............................................................................................................................... 8
Component Description.................................................................................................................. 13
Operation and Supervision ................................................................................................................ 20
General......................................................................................................................................... 20
Preparation Prior to Start-up ........................................................................................................... 20
Operating Methods ........................................................................................................................ 20
Normal Operation ......................................................................................................................... 21
Monitoring Equipment ....................................................................................................................... 26
Routine Operation Maintenance......................................................................................................... 27
General......................................................................................................................................... 27
Periodic Checks................................................................................................................................. 27
Exercises ........................................................................................................................................... 29
General......................................................................................................................................... 29
System Outline............................................................................................................................... 29
Component Name, KKS Designation & Function.............................................................................. 30
Exercises Operation & Routine Maintenance ....................................................................................... 31
Operation ..................................................................................................................................... 31
Test Questions for Verification of Learning Progress ............................................................................ 35
Questions: ..................................................................................................................................... 35
Lesson Test Questions Solution Key ................................................................................................. 38
Summary .......................................................................................................................................... 38
Electro Hydraulic Safety System .......................................................................................................... 39
Simplified Diagram ........................................................................................................................ 39
Designation of Parts ....................................................................................................................... 41

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Table of Figures

Figure 1: Operating Station Image of Gas Turbine Protection Safety System (Typical) ............................. 7
Figure 2: Hydraulic Trip Unit de-energized (Typical) ............................................................................. 9
Figure 3: Electro Hydraulic Safety System Block Diagram for GT24/GT26 Fuel Gas Fired only (Typical) 11
Figure 4: Hydraulic Trip Unit, Maintenance Manual Drawing (Typical)................................................. 13
Figure 5: Solenoid Valve de-energized / energized (Typical) ............................................................... 14
Figure 6: Hydraulic Trip Unit: Solenoid Trip Valve (Typical) ................................................................. 15
Figure 7: Hydraulic Trip Unit: Solenoid Staging, designed as impulse Valve (Typical) ........................... 16
Figure 8: Staging Valve: EHSS not activated / EHSS activated (Typical) ................................................ 16
Figure 9: Trip Shut-off Valve, Simplified P&ID (Typical) ....................................................................... 17
Figure 10: Blow-off Valve, Simplified P&ID (Typical) ........................................................................... 18
Figure 11: Simplified Flow Amplifier and Actuator of Shut-off Valve (Typical) ....................................... 19
Figure 12: Hydraulic Trip Unit de-energized (Typical) ......................................................................... 22
Figure 13: Trip Button (Typical) ......................................................................................................... 24
Figure 14: Position Monitoring at Solenoid Trip Valves (Typical) .......................................................... 26

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Document Reference
Typical Documents

Typical documents are used to clarify aspects described in this lesson. These typical
documents may not show project specific contents, deviations are possible. All
typical documents are clearly identified.

O&M Documentation

O&M Documents are plant specific and form an important part of each training
course. A selection of the most relevant O&M Documents has been made and
included in the training course material. These documents provide a basis for
exercises and personal notes, markings, etc. The most relevant documents for the
operation training are:
• P&ID with legend
• Gas turbine operating concept
• System description
• Maintenance manual

The O&M Documents are separated into:

• System specific documents
• Overall plant specific documents
The system specific documents are in principle not attached to each specific lesson,
whereas the overall plant specific documents can be found in separate sections at
the end of the training manual.

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Lesson Objectives

Upon completion of this lesson, the trainee is able to:

• State the purpose of the Electro Hydraulic Safety System (EHSS), and describe
how it works electrically and hydraulically.

• List by heart the main components of the safety system.

• Explain the function of the trip valves during normal operation.

• Explain the function of the staging valve during normal operation.

• List by heart the three possibilities to “activate” the EHSS that means to trip the
gas turbo set.

• Describe how the correct functioning of the EHSS is checked by EGATROL and
the frequency it is checked.

• Describe the difference of the safety oil MBX42 connected to the flow amplifiers
of the blow-off valves in comparison with the safety oil connected to the flow
amplifier of the fuel gas trip shut-off valves.

• Describe the protective actions performed by the proximity switches

MBX41 AA011/012/013L.

• Describe the actions performed by the pressure switch MBX42 CP001.

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Overview

Figure 1: Operating Station Image of Gas Turbine Protection Safety System (Typical)

The Electro Hydraulic Safety System (EHSS) is controlled by the GT protection

controllers.
The gas turbine is equipped with a test system that allows checking the function of
the hydraulic tripping unit including the related electrical circuits to the hydraulic trip
unit.

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System Function

Function In the case of an emergency situation for the gas turbo set detected either
• by the protection system of EGATROL or
• by the operator
immediately the fuel supply to the gas turbo set must be shut-off, the blow-off valves
must open and the generator must be disconnected from the high voltage line –
with other words the gas turbo set must be tripped.
An immediate and safe trip of the gas turbo set is performed by the hydraulic trip
unit which is the link between the protection system of EGATROL and the gas
turbine.
The gas turbine is tripped via the EHSS, either
• by the EGATROL’s protection system
• by following the programmed protection rules
(1 out of 1, 1 out of 2, 2 out of 3)
• by manually pushing one of the emergency push buttons
• by a loss of the electric power supply (power cut, blackout).

The hydraulic trip unit is connected to the power oil system. When controlled by
EGATROL in a way that:
• the three trip valves are energized and
• the staging valve controls the oil flow from port P to port B
then pressurized oil is available at point 1 and 2 of Figure 2. This oil is called safety
oil. When reaching the correspondent steps during a start-up sequence the opening
of the fuel trip shut-off valves and the closing of the blow-off valves is thus enabled.

Operating The EHSS is used to interrupt the fuel supply and to open the blow-off valves as fast
Summary as possible whenever an emergency situation for the gas turbine arises.

(Continued next page)

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System Function (continued)

Components The system consists of the following major components:

• Power oil system.
• Hydraulic trip unit with:
• Non-latching solenoid trip valve channel 1.
• Non-latching solenoid trip valve channel 2.
• Non-latching solenoid trip valve channel 3.
During operation of the gas turbine the three solenoid trip valves are
constantly energized.
• Latching (impulse/memory/bi-stable) solenoid staging valve.
• Safety oil system with:
• Exit flow amplifier for trip shut-off valve fuel gas EV premix
• Exit flow amplifier for trip shut-off valve fuel gas SEV
• Exit flow amplifier for trip shut-off valve fuel gas EV pilot
• Exit flow amplifier for trip shut-off valve fuel oil
• Exit flow amplifier for trip shut-off valve fuel oil NOX water
• Exit flow amplifier for compressor blow-off valves stage 1
• Exit flow amplifier for compressor blow-off valve stage 2
• Exit flow amplifier for compressor blow-off valve stage 3
• Piping and monitoring equipment.

MBX40
MBX42
1

DRAIN

MBX42
2

CSXA403596.cdr

Figure 2: Hydraulic Trip Unit de-energized (Typical)

(Continued next page)

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System Function (continued)

Emergency
push
buttons

Measure- Electronic controller

Electronic safety system (protection) +
ments
test unit
HP turbine

Solenoid Solenoid Solenoid Solenoid Speed

trip trip trip staging LP turbine Compressor probe
valve valve valve valve

Valve
position
LP HP
controller
combustor combustor
Valve
position Solenoid Servo
controller System SEV
valve motor fuel gas
feed orifice
Servo 3 pipes
EV pilot
motor
fuel gas
Flow Actuator, Actuator,
amplifier cylinder cylinder
3 pipes
Trip Fuel Blow-off valves stage 1
Power oil supply shut-off control EV premix Blow-off valve stage 2
Flow Actuator, valve valve fuel gas Blow-off valve stage 3
amplifier cylinder Power oil drain

Blow-off
valves Fuel gas supply
Power oil drain
CSXA403251.cdr

Figure 3: Electro Hydraulic Safety System Block Diagram for GT24/GT26 Fuel Gas Fired only (Typical)

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Component Description

Hydraulic The hydraulic trip unit consists of three solenoid trip valves and one staging valve.
Trip Unit The trip valves actuate in a 2 out of 3 safety principle. The three trip valves are
energized permanently during normal operation.

Connection block for

valves and piping

Staging valve

Trip valves

CSXA402611.cdr

Figure 4: Hydraulic Trip Unit, Maintenance Manual Drawing (Typical)

(Continued next page)

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Component Description (continued)

Solenoid Trip The three solenoid trip valves – designed as 4/2 type way valve - are actuated
Valves • by magnetic force after energisation of the solenoid or
• by the built-in pressure spring when de-energized.
This type of solenoid valve is called non-latching valve, i.e. in the de-energized
status the solenoid valve is always in a defined position.
In de-energized mode port P is connected to A, port B is connected to T. In
energized mode all four ports P, T, A and B are isolated (closed).
A proximity switch inserted in the casing monitors the position of the piston (spool)
of the solenoid trip valve.

T P Oil supply
De-energised:
spring load
pre-dominant
B A

Pp = 40bar

T P Oil supply
Energised:
magnetic force
pre-dominant
B A
CSXA402612.cdr

Figure 5: Solenoid Valve de-energized / energized (Typical)

(Continued next page)

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Component Description (continued)

Symbol for solenoid trip valves MBX41 AA011/012/013

T P
GSZA
MBX41 AA011L

B A

De-energised

Proximity switch

T A P B T L

Energized

T A P B T L CSXA403238.cdr

Figure 6: Hydraulic Trip Unit: Solenoid Trip Valve (Typical)

Solenoid The solenoid staging valve is designed as an impulse valve. Other names for this
Staging Valve type of solenoid valve are:
• Latching solenoid valve
• Bistable solenoid valve
• Memory solenoid valve
The solenoid staging valve is equipped with two solenoids – one at each side of the
casing. After energizing of one of the solenoids the piston inside the casing moves
accordingly. After de-energizing of the solenoid the piston remains in this position,
only after energizing of the opposite solenoid the piston changes its position. The
status of the solenoid staging valve can additionally be changed by manual
actuation.
The piston inside the solenoid staging valve is maintained in the actuated position
by spring-loaded balls and corresponding notches in the piston.

(Continued next page)

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Component Description (continued)

Symbol for staging valve MBX41 AA014

MBX41 AA014L

T P
GSZA

B A

Proximity switch

Diode, illumating when

solenoid energized

T A P B T

CSXA403239.cdr

Figure 7: Hydraulic Trip Unit: Solenoid Staging, designed as impulse Valve (Typical)

Staging valve shown when EHSS Staging valve shown when

is not activated (hydraulic trip unit EHSS is activated
de-energized)

T P T P

B A B A
Oil flow only as long as the trip shut-off
valves are not completely open CSXA403240.cdr

Figure 8: Staging Valve: EHSS not activated / EHSS activated (Typical)

(Continued next page)

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Component Description (continued)

Flow Amplifier The flow amplifiers are mounted on the actuators (cylinders) of the trip shut-off
valves. As soon as safety oil system is pressurized the flow amplifiers close the
connection between piston stem chamber of the trip shut-off valves and the drain
lines. Thereafter EGATROL controls the solenoid valve, therefore the trip
shut-off valve opens, actuated by power oil.
If during operation of the gas turbo set the pressure in the safety oil drops, the
pistons in the flow amplifiers are immediately changed to open position. This
means the pressurized power oil in the piston stem chamber is drained over the
flow amplifier, hollow stem, piston stem chamber and drain piping.
Actuated by the spring load inside the cylinder the shutoff valves close, interrupting
immediately the fuel/ NOX water supply, to the combustor.

Trip shut-off valve

MBX44 AA004

Power oil Fail safe

P A closed

T B

Fuel / NOx water

MBX42 AA004
Flow amplifier
Safety oil

CSXA402615.cdr

Figure 9: Trip Shut-off Valve, Simplified P&ID (Typical)

(Continued next page)

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Component Description (continued)

Compressor air Blow-off valve

Fail safe
open

B T

A P

MBX40
AA011

MBX42
AA011
Flow amplifier

Safety oil Power oil Tank

CSXA403241.cdr

Figure 10: Blow-off Valve, Simplified P&ID (Typical)

(Continued next page)

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Component Description (continued)

Flow Amplifier

Safety oil

Drain

Solenoid directional
valve
T P

B A

Power oil

Flow amplifier

Cylinder
(actuator) CSXA402941.cdr

Figure 11: Simplified Flow Amplifier and Actuator of Shut-off Valve (Typical)

(Continued next page)

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Operation and Supervision

General

The system must be operated in accordance to the operating instructions and the
operation concept. During plant commissioning these documents may be available
as “preliminary”. The final versions will be released and handed over after plant
commissioning.

Proper walk-down procedures are mandatory for a safe operation of the system.
During the walk-down check the systems and components using the appropriate
checklist.

Preparation Prior to Start-up

Operating Before any operation of the EHSS, may take place, the following conditions must be
Methods fulfilled:
• All maintenance is completed, all open work permits are cancelled.
• EGATROL without any protection signal active.
• Function group lube oil on.
• Power oil on.
• Mini Circuit Breaker (MCB) for all solenoid valves energized.

Operating Methods

The system may be operated using the following methods:

• Manual operation on the Operation Station (OS) and Function Group (FG)
controller.
• Automatic operation by the sequencer during start-up and shutdown.
• Initiated by EGATROL, a test cycle is commanded every 24h when the gas
turbine is in operation.
Normally the system will be operated under automatic control. However, during
system checks, routine or plant maintenance the system can be started manually.

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Normal Operation

Automatic During normal (idle or load) operation of the gas turbo set:
Operation • The power oil system is pressurized.
• The solenoids of trip valves are constantly energized, maintaining the trip valves
in operating position (all ports isolated from each other).
• Staging valve is in its operation position, i.e. P to B open, A to T connected.
• All exit flow amplifiers are closed by pressurized safety oil.
The pressures in the power oil and in the safety oil system are equal.
EGATROL checks the correct functioning of the hydraulic trip unit during start-up
operation. When the gas turbo set is operated for a longer period the function test
is repeated in intervals of 24 hours.

The power oil distribution system supplies the following items with pressurized oil:
• Trip shut-off valves for fuel gas, fuel oil and NOX water.
• Relief valves for fuel gas.
• Electro hydraulic servo motors for fuel gas, fuel oil and NOX water control.
• Electro hydraulic servo motors for Variable Inlet Guide Vanes (VIGV) control.
• Hydraulic trip unit.
• Actuator of blow-off valves.

The trip shut-off valves in the fuel gas, fuel oil and NOX water supply lines and the
blow-off valves are maintained in their operating position only when safety oil
system is pressurized.
Operating position for those valves means:
• Trip shut-off valves for fuel and NOX water supply: open
• Blow-off valves: closed

The trip shut-off valves and the blow-off valves are all equipped with an exit flow
amplifier. Only when the piston of the flow amplifier is actuated by safety oil,
• the trip shut-off valves can be opened
• the blow-off valves can be closed
by power oil. As long as the exit flow amplifiers are not actuated by safety oil, no
pressure of the power oil can build up in the cylinders; the power oil is immediately
drained via the open exit flow amplifiers. The closing force by the pressure spring
inside the trip shut valves; respectively the opening force by the pressure spring
inside the blow-off valves cannot be overcome.

(Continued next page)

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Normal Operation (continued)

If during operation of the gas turbo set the pressure in the safety oil system drops
the exit flow amplifiers are not longer actuated. In the trip shut-off valves and in the
blow-off valves the power oil is drained, the valves close/open immediately by the
built in spring load.

During normal operation the safety oil system:

• Is maintained pressurized.
• Does not flow.
• Small quantities of oil leaks are replaced.

The safety oil system has three modes:

• Pressure free during a standstill, shutdown or a trip of the gas turbine.
• Pressurized to the fuel / NOX trip shut-off valves and blow-off valves. The
staging valve must be controlled that port P is connected to port B.
• Pressurized to the blow-off valves only. The staging valve must be controlled that
port P is connected to port A, port is A plugged.

MBX40
MBX42
1

DRAIN

MBX42
2

CSXA403596.cdr

Figure 12: Hydraulic Trip Unit de-energized (Typical)

(Continued next page)

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Normal Operation (continued)

Hydraulic If during operation:

Trip Unit • The hydraulic trip unit is de-energized
• by a trip signal (protection intervention) or
• a loss of electric power, or
• Two trip valves of the hydraulic trip unit fail, or
• Two channels of EGATROL are disabled.
Then in all cases the safety oil pressure is lost; the gas turbo set is immediately
tripped.

The solenoid trip valves:

• Are permanently energized during normal operation, the ports are isolated from
each other (closed position).
• Are de-energized by a trip signal or loss of electric power, then connections P to
A and B to T are established (open position).

The staging valve is:

• Designed as an impulse valve. It is held in its last actuated position. The piston
(spool) is switched either by one of the solenoids or by manual actuation – there
is no internal spring load.
In case of a trip:
• If electric power is available: simultaneously the staging valve is switched into
the standstill position, P to A connected, B to T open.
• If no electric power is available the staging valve does not change its position.
P remains connected to B, A remains connected to T. The pressure of the safety
oil is relieved and drained over the open trip valves.

Stand Still During standstill of the gas turbo set:

• The trip valves are de-energized, P to A and B to T is open.
• The staging valve is in its standstill position, P to A connected, B to T open.
• The exit flow amplifiers of the trip shut-off valves and blow-off valves are in
open position.

(Continued next page)

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Normal Operation (continued)

GT Protection: EGATROL checks the correct functioning of the hydraulic trip unit during start-up
Function Test of operation. When the gas turbo set is operated for a longer period the function test
Hydraulic Trip is automatically repeated in intervals of 24 hours.
Unit The test of the hydraulic trip unit means a successive de-energisation of each of the
three trip valves. After de-energisation of one trip valve, the piston (spool)is pushed
by the spring load to open position. This is indicated by the built-in proximity switch.
After verification of this move, the solenoid is energized again, the piston moves
back to closed position, verified again by the proximity switch.
By the design of the hydraulic trip unit the pressure in the safety oil system will not
drop, when only one channel is de-energized or when one trip valve fails.
If one trip valve remains in open position the test procedure is stopped immediately.
If one valve remains in closed position, an alarm will be actuated but the test will
continue.
If two trip valves remain in closed position, a PLS will be initiated automatically.

GT Protection: Emergency push buttons – when pushing in an

Manually emergency – are interrupting the supply voltage to
actuated Trip the solenoids of the trip valves. This either by
(Emergency Push generating a trip signal on all three protection
Buttons) channels of EGATROL or a hardwired voltage
interruption.
Typical locations of emergency push buttons are:
• Outside of the thermal block’s enclosure.
• In the local control room.
• In the main control room. Figure 13: Trip Button (Typical)
In the remote control room (if available).

GT Protection: When a trip by the EGATROL is actuated, at least the voltage for 2 out of 3 selected
Trip actuated by solenoids of the trip valves is cut off. The trip valves go in the de-energized (open)
EGATROL position. Normal activation by EGATROL will de-energize all 3 solenoid trip valves.
The staging valve is switched to its standstill position (voltage is available).
The pressure in hydraulic safety system collapses, all exit amplifiers are switched
over, the power oil is drained, thus the pressure drops.
The gas turbo set is tripped.
• All trip shut-off valves are closing
• All blow-off valves are opening
• And all the relief valves are opening
(Continued next page)

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Normal Operation (continued)

GT Protection: A live over speed test is performed:

Live Over Speed • During plant commissioning, before first synchronization.
Test
• After a major inspection.
• According to customers and governmental safety rules.
For the live over speed test the gas turbo set must be in warm condition, meaning in
minimum two hours in idle operation. The generator must not be synchronized.
Before the actual over speed test first an “over speed simulation” has to be made to
test the function of the over speed device. The indication “test ok” must appear.
Now the “real over speed test” can be initiated.
When the command is accepted by EGATROL the set point speed is automatically
increase until the rotor speed reaches “real over speed limit”. First an alarm “GT
speed > 110 %” appears, thereafter the gas turbine is tripped by the over speed
protection device.
Thereafter the three over speed channels must be reset manually.

For execution of a live over speed trip test please follow strictly the description of the
operation guideline.

Compressor During compressor off-line washing the power oil system MBX21 is in operation.
Off-line Washing The solenoid trip valves MBX41 AA011/012/013 are energized, the pressure of the
safety oil system MBX42 is – as described below – maintained in the line to the exit
flow amplifiers of the blow-off valves.
The staging valve MBX41 is controlled in such a way that port P is connected to A.
That means no safety oil flows to the flow amplifiers of the trip shut-off valves
because A is plugged. B is connected to T, oil in the related flow amplifiers is
drained.
Because there is no pressure downstream of the staging valve no actuation of the
trip shut-off valves is possible. This measure provides additional safety to avoid any
fuel entry into the combustor(s).
Safety oil pressure exists upstream of the staging valve. Therefore the blow-off
valves MBA81 AA011/012/021/031 can be operated to the required closed
position during the compressor off-line washing.

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Monitoring Equipment

Position Proximity switches monitor the closed position of solenoid trip valves
Monitoring • if a valve piston returns to the open position during operation, (P to A and B to T
open) an alarm is issued.

Proximity Switch

CSXA402619.cdr

Figure 14: Position Monitoring at Solenoid Trip Valves (Typical)

Proximity switch monitors the position of the piston in the staging valve.

Pressure Pressure switch checks safety oil pressure and enables continuation of the start-up
Measurement sequence.
• If the pressure does not reach the pre-set level, the opening of the motorized
main shutoff valve in the fuel system and NOX water system is interrupted. The
start-up sequencing cycle will not continue.

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Routine Operation Maintenance

General

General Remark When the automatic control and protection systems are working properly, any
particular attendance is not needed. Abnormalities will be alarmed and signalized.
However, in order to prevent unprepared shutdowns by any safety device, regular
routine maintenance is recommended.

Logbook A logbook with all readings of measurements as well as any observation regarding
operation, starting and shutdown times should be kept. Overhauls and adjustments
carried out should be recorded. The variation of values provides a picture of the
system performance and allows quick and accurate identification of any
abnormality.

Documents In detail the necessary actions are defined in the gas turbo set
Operation & Maintenance Manual.

Periodic Checks

Check the corresponding screen picture “Protection Test” (see Figure 1) on the
operation station before and during start up.

During operation of the gas turbo set, walk down the plant – at least once per shift
– to check the following:
• Leaks from the components and piping.
• Position of the trip solenoid valves’ piston (LED indication).
• Unrestricted heat removal from the solenoid surfaces.

(Continued next page)

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Periodic Checks (continued)

Periodic checks of the hydraulic unit:

• An automatic test of the trip unit is performed during start-up.
• An automatically initiated check of the hydraulic trip unit is released every 24
hours of operation of the gas turbo set.
• During operation the hydraulic trip unit can be tested. To start the test:
select the OS-screen “GT-Protection” and initiate
“FG Protection Testing → deactivate → ON” and observe the step by step
action.
In the case of disturbances EGATROL follows the following rules:
• If one valve remains in open position after re-energisation the test is
immediately shut down.
• If one valve remains in closed position, an alarm will be activated but the test
will continue.
• If two trip valves remain in closed position, a PLS will be initiated automatically.

The manual trip with emergency push buttons can not be tested during operation:
• It is only tested according to the check list during inspections or stand still.
The live over speed test can not be tested during load operation.
• It is only tested according to the check list during inspections or national
regulations.

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 GT24/GT26 Electro Hydraulic Safety
ABCD Operation System

Exercises
General

To be able to understand the exercises the relevant chapters of the following project
specific documents must be studied carefully:
• Process & Instrumentation Diagram (P&ID)
• Legend to P&ID
• Operation concept

System Outline

Exercise Task Mark (with color pens according to the color code for gas turbines) all media lines
which belong to the EHSS system in your P&ID as follows:
• Power oil supply from oil tank to hydraulic trip unit and trip shut-off valves.
• Safety oil from hydraulic trip unit to trip shut-off valves.
• Safety oil from hydraulic trip unit to blow-off valve control block.

Exercise Aids • Plant specific P&ID, legend to P&ID and color code

Group, • Each trainee for himself

Time Frame, • 10 minutes
Presentation
• discussion in classroom

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ABCD Operation System

Component Name, KKS Designation & Function

Exercise Task Fill-in the table below with the following information according to the example
given in the first line:
• Component name
• KKS number
• Short functional description

Exercise Aids • Plant specific P&ID and legend to P&ID

• Safety System Block Diagram

Group • Each trainee for himself

Time Frame • 10 minutes
Presentation
• Discussion in classroom

Component Name KKS - Number Component Function

Hydraulic trip unit

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ABCD Operation System

Exercises Operation & Routine Maintenance

Operation

Exercise Task Mark with colors the pressurized and pressure free piping for the given 7 situations.

Exercise Aids • Plant specific P&ID

• Operating concept of gas turbine
• Training lesson Electro Hydraulic Safety System

Group • Group work with max. 4 trainees per group

Time Frame • 15 minutes
Presentation
• Group presentation in front of class.

Situation 1:
• Power oil is pressurized
• Trip valves de-energized
• Staging valve connected P to A

MBX40
MBX42
1

DRAIN
POINT M
MBX42
POINT M: 2
NO PRESSURE !

BECAUSE THIS PIPE IS CONNECTED TO DRAIN (PORT B TO T)

NO PRESSURE CAN EXIST AT POINT M CSXA403591.cdr

(Continued next page)

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 GT24/GT26 Electro Hydraulic Safety
ABCD Operation System

Operation (continued)

Situation 2:
• Power oil is pressurized
• Trip valves energized
• Staging valve connected P to A

MBX40
MBX42
1

DRAIN
POINT M
MBX42
POINT M: 2
NO PRESSURE !

CSXA403589.cdr

Situation 3:
• Power oil is pressurized
• Trip valves energized
• Staging valve connected P to B
MBX40
MBX42

DRAIN
POINT M
MBX42
2
AT POINT M PRESSURIZED
OIL AVAILABLE, THE
SAME VALUE AS THE
POWER OIL PRESSURE
CSXA403590.cdr

(Continued next page)

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 GT24/GT26 Electro Hydraulic Safety
ABCD Operation System

Operation (continued)

Situation 4:
• Power oil pressurized
• One channel/solenoid valve de-energized
• Staging valve connected P to B

MBX40
MBX42
1

DRAIN
POINT M
MBX42
2
AT POINT M PRESSURIZED
OIL AVAILABLE, THE
SAME VALUE AS THE
POWER OIL PRESSURE
CSXA403590.cdr

Situation 5:
• Power oil pressurized
• Two channels/solenoid valves de-energized
• Staging valve connected P to B
MBX40
MBX42

DRAIN
POINT M
MBX42
POINT M: 2
NO PRESSURE !

CSXA403589.cdr

(Continued next page)

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 GT24/GT26 Electro Hydraulic Safety
ABCD Operation System

Operation (continued)

Situation 6:
• All three trip valves de-energized either by
• Protection system
• Loss AC (in this case power oil pressure collapses as well)

MBX40
MBX42
1

DRAIN
POINT M
MBX42
POINT M: 2
NO PRESSURE !

CSXA403589.cdr

Situation 7:
• Power oil pressurized
• Trip valves energized
• Staging valve connected P to A
• For compressor off-line washing MBX40
MBX42

DRAIN
POINT M
MBX42
2
POINT M:
NO PRESSURE BUT
THE BLOW-OFF VALVES
CAN BE CLOSED

CSXA403595.cdr

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 GT24/GT26 Electro Hydraulic Safety
ABCD Operation System

Test Questions for Verification of Learning Progress

General The following points are important and shall be taken into account:
• The training manual may be used (open book);
• Mark the box in front of each correct statement with a diagonal cross;
• One or more or all statements may be correct.
Use this section to verify your learning progress! Review subjects, which are not
clearly understood.

Questions:

Question 01: The electro hydraulic trip unit is located in the

A † Auxiliaries block

B † Thermal block

C † Control valve block

D † Air intake manifold

E † Local control module

Question 02: The main components of the electro hydraulic trip unit are

A † Solenoid trip valve MBX41 AA011

B † Solenoid pilot valve MBX44 AA002

C † Solenoid trip valve MBX41 AA012

D † Solenoid trip valve MBX41 AA013

E † Solenoid pilot valve MBX44 AA004

F † Solenoid staging valve MBX41 AA014

G † Solenoid pilot valve MBX44 AA003

(Continued next page)

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ABCD Operation System

Questions (continued):

Question 03: During normal operation of the electro hydraulic trip unit

A † Solenoid trip valve MBX41 AA011 is energized

B † Solenoid trip valve MBX41 AA011 is not energized

C † Solenoid trip valve MBX41 AA012 is not energized

D † Solenoid trip valve MBX41 AA012 is energized

E † Solenoid trip valve MBX41 AA013 is energized

F † Solenoid trip valve MBX41 AA013 is not energized

G † Solenoid staging valve MBX41 AA014 is energized

H † Solenoid staging valve MBX41 AA014 is not energized

Question 04: The electro hydraulic trip unit is activated to trip the GT by

A † Emergency trip button at control valve block

B † During each start up sequence of the GT

C † AC loss

D † Emergency trip button in local control room

E † Emergency trip button in main control room

F † By the local control panel for compressor off line washing

G † By a 2 out 3 logic protection signal from the EGATROL

(Continued next page)

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Questions (continued):

The positions of pistons inside the solenoid valves and staging valve
Question 05:
are monitored

A † By micro switches

B † By proximity switches

C † By a 4-20 mA feedback signal

D † Not monitored

Question 06: The pressure of the electro hydraulic safety system MBX42 is

A † The same as the power oil system pressure

B † Decreased by the electro hydraulic trip unit

C † Increased by the electro hydraulic trip unit

D † 40 barg

E † Is monitored by the pressure switch MBX42 CP001

F † Is monitored by the pressure transmitter MBX42 CP010

The piston in the flow amplifier blocks the connection from the piston
Question 07:
stem chamber of the trip shut-off valve to the drain, if

Power oil pressurized, all three solenoid trip valves energized, staging
A † valve position enabling oil flow from port P to port B
Power oil pressurized, two solenoid trip valves energized, staging valve
B † position enabling oil flow from port p to port A

C † Power oil pressurized, fuel control valves open, rotor speed > 1 rpm

Power oil pressurized, one solenoid trip valve energized, staging valve
D † position enabling oil flow from port P to port B
Jacking oil pressurized, power oil system OFF, all three solenoid trip
E † valves energized, staging valve position enabling oil flow from port P to
port B

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ABCD Operation System

Lesson Test Questions Solution Key

The correct answers for each question are as follows:

01: C
02: A, C, D, F
03: A, D, E, H
04: A, C, D, E, G
05: B
06: A, D, E
07: A

Summary

Objectives Carefully review the objectives stated on page 6 of this lesson together with the Test
Review Questions for Verification of Learning Progress.
Note that this lesson is not complete without the system specific and overall plant
Operation & Maintenance Documentation.

Summary The purpose of the electro hydraulic safety system is to ensure a safe and quick shut
down of the turbo set under all operating conditions.
This module describes the main components and how the system functions and its
operation.

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 GT24/GT26 Electro Hydraulic Safety
ABCD Operation System

Electro Hydraulic Safety System

Simplified Diagram

MBX40
MBP42
AA002

MBA81 MBA81 MBA81 MBA81 MBX44

MBA81 MBA81 MBA81 MBA81 AA014
AA031 AA021 AA012 AA011

MBP42
MBX40 MBX40 MBX42
MBX40 AA012 MBX40
AA031 AA021 AA011 AA014

MBP52
Fuel Gas AA001

MBP32 MBP42
MBX42 MBX42 MBX42 MBX42 AA001
AA031 AA021 AA012 AA011

MBX44

MBP41
AA004

MBX42

MBX40

MBX42

MBX40

MBX42

MBX40
MBX42

MBX40

MBX71

MBX71

MBX71
MBX71

MBX40 MBX42
AA004
MBP41

MBP52
AA002

MBX42

MBX71
MBP41
MBX71 MBX71 Fuel Gas AA001
MBX42

MBP31
MBX42
MBX40 MBP51
AA001 MBP51
MBP31

MBX40

MBP43
MBX21
MBX42
MBX40

GSZA GSZA GSZA

MBX41 AA011L MBX41 AA012L MBX41 AA013L
MBX41 MBP43

MBP51
Hydraulic AA002
trip-unit
MBP43
MBX41 MBX41 MBX41 MBX41 AA003
AA011 AA012 AA013 AA014

P A P A P A P A MBX42
AA013

MBX71
T B T B T B T B
MBP53
AA001 MBP53
GSA
MBX41 AA014L

MBX41
BP001

PS
MBX42 CP001 MBX44
MBX42 AA007
MBX40

MBX40
MBV70

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 GT24/GT26 Electro Hydraulic Safety
ABCD Operation System

Simplified Diagram (continued)

1. Stand still, trip 2. Off-line Washing 3. Normal Operation
MBX42

MBX42

MBX42
GSZA GSZA GSZA GSZA GSZA GSZA GSZA GSZA GSZA
MBX41 AA011L MBX41 AA012L MBX41 AA013L MBX41 AA011L MBX41 AA012L MBX41 AA013L MBX41 AA011L MBX41 AA012L MBX41 AA013L

HYDRAULIC TRIP UNIT HYDRAULIC TRIP UNIT HYDRAULIC TRIP UNIT

MBX41 MBX41 MBX41 MBX41 MBX41 MBX41 MBX41 MBX41 MBX41 MBX41 MBX41 MBX41
AA011 AA012 AA013 AA014 AA011 AA012 AA013 AA014 AA011 AA012 AA013 AA014

P A P A P A P A P A P A P A P A P A P A P A P A

MBX71

MBX71

MBX71
T B T B T B T B T B T B T B T B T B T B T B T B

MBX41 MBX41 MBX41

BP001 BP001 BP001
MBX40

MBX40

MBX40
PS PS PS
MBX42 CP001 MBX42 CP001 MBX42 CP001
MBX42 MBX42 MBX42

MBX40 GSA MBX40 GSA MBX40 GSA

MBX41 AA014L MBX41 AA014L MBX41 AA014L

4. Trip, 2-channel 5. 1-channel without power 6. Staging valve trip

MBX42

MBX42

MBX42
GSZA GSZA GSA
GSZA GSZA GSZA GSZA GSZA GSZA GSZA
MBX41 AA011L MBX41 AA012L MBX41
MBX41AA013L
AA013L MBX41 AA011L MBX41 AA012L MBX41 AA013L MBX41 AA011L MBX41 AA012L MBX41 AA013L

HYDRAULIC TRIP UNIT HYDRAULIC TRIP UNIT HYDRAULIC TRIP UNIT

MBX41 MBX41 MBX41 MBX41 MBX41 MBX41 MBX41 MBX41 MBX41 MBX41 MBX41 MBX41
AA011 AA012 AA013 AA014 AA011 AA012 AA013 AA014 AA011 AA012 AA013 AA014

P A P A P A P A P A P A P A P A P A P A P A P A
MBX71

MBX71

MBX71
T B T B T B T B T B T B T B T B T B T B T B T B

MBX41 MBX41 MBX41

BP001 BP001 BP001
MBX40

MBX40

MBX40
PS PS PS
MBX42 CP001 MBX42 CP001 MBX42 CP001
MBX42 MBX42 MBX42

MBX40 GSA MBX40 GSA MBX40 GSA

MBX41 AA014L MBX41 AA014L MBX41 AA014L

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 GT24/GT26 Electro Hydraulic Safety
ABCD Operation System

Designation of Parts

KKS-No. Designation
MBA81 Compressor blow-off system
MBA81 AA011 Blow-off valve, pressure stage 1
MBA81 AA012 Blow-off valve, pressure stage 1
MBA81 AA031 Blow-off valve, pressure stage 2
MBA81 AA021 Blow-off valve, pressure stage 3
MBP31 Fuel gas supply before MBP41 AA001 (EV combustor)
MBP32 Fuel gas supply before MBP42 AA001 (SEV combustor)
MBP41 Fuel gas control (EV combustor)
MBP41 AA001 Trip shut-off valve
MBP41 AA002 Control valve
MBP42 Fuel gas control (SEV combustor)
MBP42 AA001 Trip shut-off valve
MBP42 AA002 Control valve
MBP43 Fuel gas control (EV combustor, pilot)
MBP43 AA002 Control valve
MBP51 Fuel gas relief (EV combustor)
MBP51 AA001 Gas relief valve
MBP52 Fuel gas relief (SEV combustor)
MBP52 AA001 Gas relief valve
MBV70 Lube oil return system
MBX21 Power oil forwarding system
MBX40 Power oil distribution system
MBX40 AA011 Solenoid pilot valve
MBX40 AA012 Solenoid pilot valve
MBX40 AA021 Solenoid pilot valve
MBX40 AA031 Solenoid pilot valve
MBX41 Hydraulic trip unit
MBX41 AA011 Solenoid trip valve channel 1
MBX41 AA011-S01 Limit switch "Closed"
MBX41 AA012 Solenoid trip valve channel 2
MBX41 AA012-S01 Limit switch "Closed"
MBX41 AA013 Solenoid trip valve channel 3
MBX41 AA013-S01 Limit switch "Closed"
MBX41 AA014 Solenoid staging valve
MBX41 AA014-S01 Limit switch "Closed"
MBX41 BP001 Orifice
MBX42 Hydraulic safety system
MBX42 AA004 Exit flow amplifier, fuel gas
MBX42 AA011 Exit flow amplifier, stage 1
MBX42 AA012 Exit flow amplifier, stage 1
MBX42 AA013 Exit flow amplifier, fuel gas
MBX42 AA014 Exit flow amplifier, fuel gas
MBX42 AA021 Exit flow amplifier, stage 3

(Continued next page)

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 GT24/GT26 Electro Hydraulic Safety
ABCD Operation System

Designation of Parts (continued)

KKS-No. Designation
MBX42 AA031 Exit flow amplifier, stage 2
MBX42 CP001 Measurement of safety oil pressure
MBX44 Power oil to fuel gas control
MBX44 AA004 Solenoid pilot valve to trip valve for fuel gas
MBX44 AA007 Solenoid pilot valve to trip valve for fuel gas
MBX44 AA014 Solenoid pilot valve to trip valve for fuel gas
MBX71 Power oil return system

Designation of Connections
(A) Solenoid trip valves:
Power oil outlet to the following connected valve
(A) Solenoid staging valve:
Outlet permanently closed
(B) Solenoid trip valves and staging valve:
Inlet to power oil return system
(P) Solenoid trip valves:
Power oil inlet (passage closed during normal operation)
(P) Staging valve:
Power oil inlet to hydraulic safety system during normal operation
(T) Solenoid trip valves and staging valve:
Outlet to power oil return system (drain)

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