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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION

Please read these OPERATING AND MAINTENANCE MANUAL carefully before installation and
starting.

This type of compressor has been manufactured in accordance with the relevant safety standards.
It is essential to let users and operators have this information in order to avoid any risk of accident.
The safety instructions or warnings contained in this book must be strictly observed.

Modifications may only be made with the manufacturer's permission, otherwise the guarantee
expires.
The developer should conform to the regulation current concerning devices under pressure

1 SYSTEM DESIGN

1.1 - PURPOSE

The role of the self-cleaning air filter GDX system, designed for GT frame 6FA+E, is to remove the
contaminants of the ambient air sucked by the G.T. compressor, in order to protect the mechanical
components such as compressor and turbine blades against erosion, corrosion and fouling.
Self cleaning is accomplished by intermittently injecting compressed through the blowpipes. Each
pulse of air from the blowpipe into the filter cartridge provides a shock wave inside the filter
cartridge and a momentary reverse flow.
The power plant includes 2 Gas Turbine of 6FA+E type. The gas turbine is supplied by an outdoor
Air Processing Unit, located close the GT and is designed to supply compressed air to the GT’s
self cleaning air filter and instrument air for the plant.

The equipment are designed for neutral air compressed free of aggressive elements.
A stainless steel roof is mounted for outdoor location to protect the air compressed skid
components against sun, direct rain, dust or sand wind.

The Air Processing Unit includes:

- One auxiliary screw compressor CMP 301, 30 kW to supply compressed air to self-
cleaning air filter and instrument air.
- One motorized air cooler CLR 201 for the purpose of cooling the compressed air
coming from GT to +5°C above ambient.
- One refrigeration air dryer DRY 401.
- One compressed air tank TK 601 500 liters for storing the compressed air for self-
cleaning air filter and instrument air.
- Necessary filters, drain and instrumentation

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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION

The air processing unit has been designed according the following design data:

- Temperature mini /maxi .................................................. +3°C /+50°C (outdoor location)

- Temperature design ....................................................... +25°C
- Design relative humidity : ............................................... 60% max
- Wind design .................................................................... 126 km/h max
- Max. working pressure: .................................................. 20 bar
- Max temperature air outlet: ............................................. +55°C
- Required air outlet flow ................................................... 162+5 Nm3/h

1.2 – DESCRIPTION

1.2.1 - Screw compressor RAFALE 30 kW CMP 301

ERVOR screw type rotary compressors, RAFALE Range, have decisive advantages in terms of
performance, reliability, long life and accessibility. That is why they are particularly recommended
for continuous heavy duty applications.
The screw compressor is able to supply 162 Nm3/h required at self cleaning GT air filter and 5
Nm3/h for instrument air. The compressor outlet working pressure is from 8 to 10 bar.

- Type................................................................................ RAF40-3 SP
- Working pressure ........................................................... 8 / 10 bar
- Max. working pressure: .................................................. 12 bar
- Nominal flow ................................................................... 180 Nm3/h
- Compressor revolution speed ......................................... 3300 rpm
- Coupling ......................................................................... 5 Belts XPA 1180
- Installed power ............................................................... 30 kW
- Revolution speed ............................................................ 2960 rpm
- Protection class .............................................................. IP55
- Isolation class ................................................................. F
- Temperature class .......................................................... B
- Supply voltage / frequency ............................................. 400 V / 50 Hz
- Heating element ............................................................. yes
- Wiring ............................................................................. Star/Delta start-up
- Working temperature ...................................................... 0°C to +55°C
- Air outlet connection ....................................................... 1”1/2

1.2.2 – Compressed air tank 500L TK 601

The 500 litre air tank will store air coming from the GT for self cleaning air filter and
instrument air.
It's designed following PED CE / ASME VIII, hot dip galvanised.

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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION

- Capacity .......................................................................... 500 L

- Fluid ................................................................................ Compressed air
- Type................................................................................ vertical
- Design pressure ............................................................. 10.6 bar
- Maximum allowable temperature .................................... +100 °C
- Minimum design metal temperature ............................... -15°C
- Hydrostatic test pressure ................................................ 15.9 bar
- Joint Efficiency................................................................ 0.7 (longitudinal) / 0.65 (circular)
- Construction ................................................................... Directive 97/23 CE
- Design ............................................................................ ASME VIII div 1
- Protection ....................................................................... Int./Ext. galvanized
- Weight of vessel ............................................................. 150 kg approx.
.

The air receiver is equipped with:

- One pressure safety valve 10.5 bar PSV651

- One pressure indicator PI652 with instrumentation valve HV652
- One regulation pressure switch PSLH651 with instrumentation valve HV651
- An automatic drain system composed by:
- A solenoid drain valve FY653 with Y filter FLT 601
- An isolation valve ½" HV603
- A by-passed valve ½" HV604

Self cleaning air filter outlet S1:

- One isolating self cleaning outlet valve HV601

- One outlet check valve NV601
- One automatic valve FSV661 controlled by:
- One pressure switch low PSL661 with instrumentation valve HV661
- A solenoid valve FY661
- Pressure regulator PCV661

Instrument air outlet S2:

- One pressure control valve PCV665 to reduce to 7 bar instrument and service air
- One pressure safety valve PSV666 for instrument air 8 bar
- One air outlet check valve NV611
- One air tank outlet isolating valve HV621
- One air outlet isolating valve HV611

1.2.3 – Air cooler ARO203HT CLR 201

An air forced air cooler cool air coming from gas turbine to be used by compressed air network.
This air cooler is designed to decrease temperature for air coming from gas turbines compressors
from 400°C to +5°C above ambient.

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OPERATION AND MAINTENANCE MANUAL
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- Air flow capacity .............................................................. 203 Nm3/h

- Air inlet temperature ....................................................... 400 °C
- Air outlet temperature ..................................................... +5°C above ambient
- Maximum working pressure ............................................ 20 bar
- Connections.................................................................... 1” 1/2 G M
- Motor fan power .............................................................. 0.55 kW
- Voltage ........................................................................... 400V/3ph/50Hz

The air cooler is composed by :

- Cooler CLR 201
- Fan FAN 201
- Motor fan MO 201

The air cooler is equipped with :

- Manual isolating inlet valve HV201
- Pneumatic isolation valve TSV252 controlled by :
- A solenoid valve FY252
- Pressure regulator PCV252
- Temperature switch high TSH252

- An inlet temperature indicator TI251

- An outlet temperature indicator TI253
- An outlet pressure control valve PCV261 (setting: 10 bar)
- A pressure safety valve PSV281 (setting: 10.5 bar)
- An outlet isolating valve HV202 with check valve NV201

1.2.4 – Water separator filter SEP 302

Located downstream air compressor, the water separator is designed to separate water due to
temperature decrease in the air forced cooler.

- Type................................................................................ Centrifugal condensate separator

- Air flow capacity .............................................................. 330 Nm3/h
- Maximum working pressure ............................................ 16 bar
- Nominal pressure drop ................................................... 0.07 bar
- Connections.................................................................... 1” G F

The water separator filter is equipped with:

- An automatic drain system composed by:

- A solenoid drain valve FY351 with Y filter FLT 301
- An isolating valve 1/2" HV303
- A by-passed valve 1/2" HV304

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OPERATION AND MAINTENANCE MANUAL
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1.2.5 – Water separator filter SEP201

Located downstream air cooler, the water separator is designed to separate water due to
temperature decrease in the air forced cooler.

- Type................................................................................ Centrifugal condensate separator

- Air flow capacity .............................................................. 330 Nm3/h
- Maximum working pressure ............................................ 16 bar
- Nominal pressure drop ................................................... 0.07 bar
- Connections.................................................................... 1” G F

The water separator filter is equipped with:

- An automatic drain system composed by:

- A solenoid drain valve FY253 with Y filter FLT201
- An isolating valve 1/2" HV203
- A by-passed valve 1/2" HV204

1.2.6 - Refrigeration air dryer SFR360 DRY401

The refrigeration air dryer is located on instrument air line, downstream air tank and is able to dry
185 Nm3/h flow rate necessary for self cleaning air filter and instrument air network.

- Air flow capacity (*) ......................................................... 311 Nm3/h

(*) working pressure 8 bar - air inlet temperature 40°C
- Type................................................................................ SFR360
- Maximum working pressure ............................................ 14 bar
- Working temperature ...................................................... 0°C to 50°C
- Dew point ........................................................................ +3 °C
- Nominal pressure drop ................................................... 0.2 bar
- Connections.................................................................... 1”1/2 G
- Supply voltage ................................................................ 230V – 50Hz
- Nominal power ................................................................ 0.95 kW
- Refrigerant ...................................................................... R407c
- Weight ............................................................................ 68 kg

The air dryer is equipped with:

- Two isolation valves HV401, HV402
- One bypass by isolation valve HV405
- One moist indicator MI401
- An automatic drain system composed by:
- A solenoid drain valve FY453 with Y filter FLT451
- An isolation valve 1/2" HV413
- A by-passed valve 1/2" HV414

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- One cyclone pre-filter FLT401 to remove liquid particles. The efficiency is 99.5% for particles
above 1Micron.

- Air flow capacity .............................................................. 300 Nm3/h

- Type................................................................................ G11Z
- Maximum working pressure ............................................ 16 bar
- Maximum cartridge pressure drop .................................. 0.5 bar
- Working temperature ...................................................... 1.5°C to 55°C
- Connections.................................................................... 1”G
- Filtration .......................................................................... 1 µ

The pre filter is equipped with

- An automatic drain system composed of:
- A solenoid drain valve FY433 with Y filter FLT431
- An isolation valve HV403
- A by-passed valve HV404
- A local clogging indicator PDI401.

- One final oil filter FLT402 to remove oil particles. The efficiency is 99.5% for particles above
0.01Micron.

- Air flow capacity .............................................................. 300 Nm3/h

- Type................................................................................ G11X
- Maximum working pressure ............................................ 16 bar
- Maximum cartridge pressure drop .................................. 0.5 bar
- Working temperature ...................................................... 1.5°C to 55°C
- Connections.................................................................... 1”G
- Filtration .......................................................................... 0.01 µ

The final filter is equipped with

- An automatic drain system composed of:
- A manual drain valve HV433
- A local clogging indicator PDI402.

1.2.7 –Isolating valves

24 isolating valves ball type are installed on compressed air lines

See valves list n° D07001207-VL

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1.2.8 - Check valves

4 check valves are installed on compressed air circuit:

- At air outlet S1 1"½ NV601

- At air outlet S2 ½” NV611
- At air cooler outlet 1”½ NV201
- At auxiliary air compressor outlet 1”½ NV301

1.2.9 - Piping and fitting

The compressed air piping for interconnection are made of galvanized steel, linked with threaded
cast iron galvanized coupling. The air tightness of threads joints is made by means of Teflon tape.

1.2.10 - Drain collecting system

One drain evacuation D1 pipe collect filters, dryers and compressed air tank drains.

1.2.11 - Instrumentation

See measurement list n° D07001207-ML

1.2.12 - Frame

Air compressor, air tank, air dryer, air cooler, air filters and the electrical cubicle are mounted
on a common frame assembled by welding.
The frame is fitted with 4 lifting rings and is equipped with 4 ground connections according to
the GE standard document
A stainless steel roof is mounted for outdoor location to protect the air compressed skid
components against sun, direct rain, dust or sand wind.

1.2.13 - Local electrical cubicle CAB001

An electrical cubicle mounted on the compressed air container collects instrumentation signals
and include the common electrical junction for compressor, air cooler, solenoids and air dryer.

- Following command are possible from local cubicle:

- General circuit breaker IG

- Compressor CMP301 Auto/Off selector SA1
- Compressor CMP301 Fault Reset SB1
- Air cooler CLR201 Auto/Off selector SA2
- Air turbine line valve FY252 Open/Close selector SA3
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- Air dryer DRY401 On/Off selector SA4

- Emergency stop button AU1
- Lamp test SB2

- Following information are available on the local cubicle:

- Power On HL1
- Compressor CMP301 power supply signal lamp HL2
- Compressor CMP301 fault signal lamp HL3
- Air cooler CLR201 power supply signal lamp HL4
- Air cooler CLR201 fault signal lamp HL5
- Air dryer DRY401 power supply signal lamp HL6
- Air dryer DRY401 fault signal lamp HL7
- Air compressor CMP301 high pressure PSH301 fault HL8
- GT air line TSV252 open HL9
- Air processing unit high temperatureTSH252 fault HL10
- Low pressure PSL661 fault HL11
- Hour counter compressor CMP301 CH1

- Following information are available on the remote of local cubicle

- Air processing unit common fault for

- Air compressor CMP301 fault
- Air cooler CLR201 fault
- Air dryer DRY401 fault,
- High temperature TSH252
- High pressure PSH301 fault
- Low pressure PSL661 fault

1.3 – FUNCTIONS

1.3.1 – Normal functioning

In normal functioning, compressed air is supply by Gas Turbine air compressor bleed for
the self-cleaning air filter, and is available when the GT is running.
Compressed air is supply at 421 °C and 18.6 bar from Gas Turbine compressor outlet. It’s
cooled in air forced air cooler CLR201 down to +5°C above ambient. After passing
through the refrigeration dryer DRY401, compressed air is stored in air tank TK601 for self
cleaning filter and instrument air for the plant. Then compressed air is available for
distribution network.
An automatic Open/Close system for GT line control is installed, composed of a
pneumatic valve TSV252 controlled by a pilot solenoid valve FY252 and pressure control
valve PCV252 (setting: 5 bar)
In case of air cooler fault, temperature will increase at air cooler outlet. Temperature
switch high TSH252 will send high temperature signal to local cubicle (setting high 55°C)
and signal "air processing fault" will be given to Speedtronic. Then local cubicle will de-

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energise solenoid valve FY252 and close the pneumatic valve TSV252. After a few
minutes (depending on timer KA6 setting), air cooler is stopped.
When temperature decreases under temperature switch TSH252 low setting (50°C), air
cooler switch on and, pneumatic valve TSV252 re-open.

IN CASE OF AIR PROCESSING UNIT HIGH TEMPERATURE ALARM,

ALWAYS CLOSE THE INLET VALVE HV201 AND CHECK THE
FUNCTIONING OF THE AIR COOLER AND THE TEMPERATURE AIR
INLET BEFORE RE-OPENING THE GAS TURBINE LINE TO PROTECT AIR
DRYER.

In case of compressed air low pressure PSL661 in the tank TK601, the priority is
maintaining instrument air pressure to 7 bar and FSV661 is closing the self cleaning
compressed air flow. When the compressed air pressure is going up to 8 bar, FSV661 will
be re-opened automatically.

1.3.2 – Compressor CMP301 functioning

If the GT is shutdown, in case of air consumption, pressure will drop under the low setting
of the pressure switch regulation PSLH651. Then compressed air is supplied
automatically from auxiliary air compressor CMP301. After passing through the dryer
DRY401 compressed air is stored in air tank TK601 for self cleaning air filter and
instrument air for the plant.
Then compressed air is available for distribution network.

In case of screw compressor CMP301 fault, a signal "screw compressor fault" is given on
local electrical cubicle, and signal "air processing unit fault" will be given to Speedtronic.

Compressor start and stop is controlled by the low/high pressure switch PSLH651
installed on air tank TK601.
Compressor starts when its pressure switch detects a pressure under 8 bar.
Compressor stops when its pressure switch detects a pressure above 10 bar.
A high pressure switch alarm PSH301 is installed to stop compressor if an isolating valve
is closed between compressor and air tank.

NEVERTHELESS, NEVER ISOLATE THE RUNNING COMPRESSOR

CMP301 FROM HIS REGULATION PRESSURE SWITCH PSLH651.
THIS WILL STOP COMPRESSOR AT HIGH PRESSURE FAULT

1.3.3 - Air dryer DRY401 functioning

Dryer operation is fully automatic; the unit has been set at the factory to guarantee
a dew point of 3°C (ISO 7183 Part 2) and no calibration is required.
It‘s controlled by the switch SA4 on electrical cubicle

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1.4 - DESCRIPTION OF THE INSTRUMENTATION AND CONTROLS

PSLH651: Pressure switch located on air tank TK601. Its aim is to control screw
compressor CMP301 start and stop according to self cleaning consumption.
Setting low: 8 bar: starting of screw compressor CMP301
Setting high: 10 bar: stop of screw compressor CMP301

PSH301: Pressure switch located on air compressor CMP301. Its aim is to stop screw
compressor in high pressure fault.
Setting low: 11.5 bar: starting of screw compressor CMP301
Setting high: 9.5 bar: stop of screw compressor CMP301

PSL661: Pressure switch located on air tank TK601. Its aim is to control solenoid valve
FY661 to close the pneumatic FSV661 in case of low pressure.
Setting low: 7 bar: Pneumatic valve FSV661 closed (FY661 de-energized)
Setting high: 8 bar: Pneumatic valve FSV661 open (FY661 energized)

PI301: Oil pressure indicator located on compressor CMP301.

Range: 0-16 bar

PI302: Air outlet pressure indicator located on compressor CMP301

Range: 0-16 bar

TSH301: Temperature switch indicator located on compressor CMP301

Setting: 110°C: stop of screw compressor CMP301

PDI401: Differential pressure indicator located on pre filter FLT401 to indicate air filter
clogging

PDI402: Differential pressure indicator located on final filter FLT402 to indicate air filter
clogging

PI652: Pressure indicator located on compressed air tank TK601 to indicate air pressure
for self cleaning air filter
Range: 0-16 bar

TI251: Temperature indicator located upstream air cooler CLR201 to indicate air
temperature coming from turbine gas.
Range: 0-400°C

TI253: Temperature indicator located downstream air cooler CLR201 to indicate air
cooler outlet temperature.
Range: 0-200°C

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TSH252: Temperature switch high located downstream air cooler CLR201 to send high
temperature signal to local cubicle in case of air cooler fault. Then pneumatic
valve TSV252 will be closed.
Setting low: 50°C : Pneumatic valve TSV252 open (FY252 energized)
Setting high: 55°C : Pneumatic valve TSV252 close (FY252 de-energized)

PSV651: Pressure safety valve, located on air tank TK601.

Setting: 10.5 bar.

PSV666: Pressure safety valve, located on instrument air outlet.

Setting: 8 bar.

PCV252: Pressure control valve located on air pilot line for pneumatic valve TSV252.
Setting: 5 bar. (max: 8 bar)

PCV661: Pressure control valve located on air pilot line for pneumatic valve FSV661.
Setting: 5 bar. (max: 8 bar)

PCV665: Pressure control valve, located on instrument air outlet.

Setting: 7 bar.

MI401: Moist indicator located on air dryer DRY401.

SA1: Air compressor CMP301 Auto/Off selector located on electrical cubicle CAB001.

SA2: Air cooler CLR201 Auto/Off selector located on electrical cubicle CAB001.

SA3: GT air line valve TSV252 Open/Close selector located on electrical cubicle CAB001.

SA4: Air dryer DRY401 On/Off selector located on electrical cubicle CAB001.

IG: General circuit breaker located on electrical cubicle CAB001.

AU1: Emergency stop button located on electrical cubicle CAB001.

SB1: Reset compressor fault located on electrical cubicle CAB001.

SB2: Lamp test located on electrical cubicle CAB001

HL1: Power On signal lamp located on electrical cubicle CAB001.

HL2: Compressor CMP301 On signal lamp located on electrical cubicle CAB001.

HL3: Compressor CMP301 Fault signal lamp located on electrical cubicle CAB001.

HL4: Air cooler CLR201 On signal lamp located on electrical cubicle CAB001.

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HL5: Air cooler CLR201 Fault signal lamp located on electrical cubicle CAB001.

HL6: Air dryer DRY401 On signal lamp located on electrical cubicle CAB001.

HL7: Air dryer DRY401 fault signal lamp located on electrical cubicle CAB001.

HL8: Compressor CMP301 high pressure PSH301 fault signal lamp located on electrical
cubicle CAB001

HL9: GT air line valve TSV252 Open signal lamp located on electrical cubicle CAB001

HL10: Air processing unit high temperature TSH252 signal lamp located on electrical
cubicle CAB001.

HL11: Low pressure PSL661 fault signal lamp located on electrical cubicle CAB001

CH1: Hour counter compressor CMP301

1.5 - ANALYSIS OF FAILURE IN SERVICE

See wiring diagram E0463

1.5.1 – Compressor CMP301 Fault

- Overload defect thermal magnetic breaker motor QF1

- Overload defect thermal magnetic breaker fan motor QF2
- Oil temperature too high (outlet screw air end) TSH301
- High pressure outlet PSH301
- Revolution sense CP1
- Micro cut-off
- Voltage shutdown
- Phase cut-off

1.5.2 – Air dryer DRY401 Fault

- Overload defect thermal magnetic breaker QF6

1.5.3 – Air cooler CLR201 Fault

- Overload defect thermal magnetic breaker QF3

- Air cooler outlet too high TSH252

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1.5.4 – High temperature TSH252 Fault

- Air cooler default

- Air inlet too high

1.6 - INTERFACE OF SYSTEMS

See wiring diagram E0463

Compressed air system sends to SPEEDTRONIC following information:

- Air processing unit common fault for

- Air compressor CMP301 fault
- Air cooler CLR201 fault
- Air dryer DRY401 fault,
- High temperature TSH252 fault
- High pressure PSH301 fault
- Low pressure PSL661 fault

1.7 - HEALTH AND SAFETY

AIR COMPRESSOR ONLY

NOT RESPIRABLE AIR

THE RECYCLING OF USED LUBRIFIANTS MUST BE IN ACCORDANCE WITH THE

LEGISLATION

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1.8 - APPENDICES OF DOCUMENTS

Equipment list N° D07001207-EL

Valves list N° D07001207-VL

Measurement list N° D07001207-ML

Electrical consumers N° D07001207-EC

Connections limits N° D07001207-CL

Detailed piping and instrumentation diagram N° U2335

Piping and instrumentation diagram GE Energy Products – Europe N° 218D2303

Design manual GE Energy Products – Europe N° 91-465031

Wiring diagram E0463

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D07001207-01 Rev: A Date: 01/10/07
GE Power Systems

General Electric Company

One River Road, Schenectady, NY 12345
518 • 385 • 2211 TX: 145354
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